Instructions For Repair: BW 211 D-40 / BW 212 D-40 BW 213 D-40

Instructions for repair
BW 211 D-40 / BW 212 D-40

BW 213 D-40
S/N 101 582 42.... S/N 101 582 43 ...
S/N 101 582 44 ....
Single drum roller
Catalogue number
008 910 32 11/2005
Table of Contents
General 5
1.1 Foreword 6
1.2 Safety regulations 7
1.3 General repair instructions 10
1.4 Tightening torques 13
1.5 Connection overview 14
1.6 Technische Daten 16
1.7 Table of fuels and lubricants 26
Tests and adjustments 27
2.1 Special tools, tests and adjustments 28
2.2 Adjusting the solenoid for engine speed control 31
2.3 Checking the rotation speeds 32
2.4 Checking / adjusting the neutral positions of the travel pump 34
2.5 Pressure tests in the travel circuit 36
2.6 Checking / adjusting the vibrator shaft speeds 38
2.7 Pressure measurements in the vibration circuit 39
2.8 Check the leakage rate of the vibration motor 40
2.9 Pressure test in steering circuit 41
Flushing and bleeding 43
3.1 Special tools for flushing 44
3.2 Flushing - general 48
3.3 Flushing schematic travel circuit (distribution travel pump) 50
3.4 Flushing the travel circuit (travel pump distribution) 52
3.5 Flushing schematic travel circuit (distribution axle motor) 58
3.6 Flushing the travel circuit (axle motor distribution) 63
3.7 Flushing schematic for vibration drive 68
3.8 Flushing the vibration circuit 70
3.9 Bleeding the travel circuit 74
3.10 Bleeding the vibration circuit 76
Technical Manual 79
4.1 Technical Manual / Basic Electrics 81
4.2 Techn.Manual/Service Training 133
4.3 Speedometer Module 249
4.4 Vibration module 253
Air conditioning system 257
5.1 Notes on safety for the air conditioning system 258
5.2 Notes on repair of the air conditioning system 259
5.3 Physical basics 261
5.4 Refrigerant R134a 263
5.5 Compressor oil / refrigeration oil 264
5.6 Working principle of the air conditioning system 265
5.7 Refrigeration diagram 266
5.8 Description of components 267
5.9 Checking the compressor oil level 273
5.10 Checking the magnetic clutch 274
5.11 Inspection and maintenance work 275
008 910 32 BOMAG 3

Table of Contents
5.12 Measuring the pressure in the refrigerant circuit 275

5.13 Checking, replacing the refrigerant compressor V-belt 276
5.14 Servicing the air conditioning 277
5.15 Drying and evacuation 279
5.16 Emptying in case of repair 280
5.17 Leak test 280
5.18 Filling instructions 281
5.19 Heating control / air conditioning control 285
Replacing the cab window panes 291
6.1 Assembly of window panes 292
6.2 Special tools 293
6.3 Auxiliary materials 294
6.4 Removing and installing the window pane 296
Drum 301
7.2 Repair overview for drum 304
7.3 Removing and installing the drum 312
7.4 Repairing the drum 317
7.5 Disassembling and assembling the change-over weight 350
7.6 Changing the rubber buffers and adjusting the pretension 353
Oscillating articulated joint 357
8.2 Repair overview oscillating articulated joint 360
8.3 Removing and installing the oscillating articulated joint 363
8.4 Dismantling the oscillating articulated joint 365
8.5 Assembling the oscillating articulated joint 370
Suppliers documentation 381
9.1 Travel pump series 90R 383
9.2 Travel drive series 51 473
9.3 Vibration pump 42R 041 555
9.4 Vibration motor A10FM 593
9.5 MS/MSE 02 to 18 617
9.6 Axle DANA 192 667
Circuit diagrams 791
10.1 Wiring diagram 793
10.2 Hydraulic diagram 829
4 BOMAG 008 910 32

1 General
008 910 32 BOMAG 5

1.1 Foreword
Introduction
1.1 For eword
These repair instructions contain all necessary infor-

mation for training and repair work.
Notes on maintenance, care and trouble shooting can
be found in the operating and maintenance instruc-
tions.
This instruction manual contains only assembly
groups needed for this type of machine.
The repair instructions describe the removal or dis-
mantling and assembly of components and assembly
groups.
The repair of disassembled assembly groups is de-
scribed 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.
! Danger
Danger of injury
Please observe strictly the safety regulations in
these operating instructions and the applicable
accident prevention regulations.
Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
You should only use genuine BOMAG spare parts.

These repair instructions are not subject of an updat-
ing service; for this reason we would like to draw
your attention to our additional "Technical Service
Bulletins".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this repair manual must
not be reproduced and distributed, nor must they be
used for the purpose of competition. All rights accord-
ing to the copyright law remain expressly reserved.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
6 BOMAG 008 910 32

Safety regulations 1.2
Important notes Tools, lifting gear, lifting tackle, supports and other
1.2 Safety regulations
l
auxiliary equipment must be fully functional and in

These safety regulations must be read and ap- safe condition.
plied by every person involved in the repair of this l
Use only safe and approved lifting gear of sifficient
machine. The applicable accident prevention in-
load bearing capacity to remove and install parts or
structions and the safety regulations in the oper-
components from and to the machine.
ating and maintenance instructions must be
additionally observed. l
Be careful with cleansing agents. Do not use easily
inflammable or harmful substances, such as gaso-
Repair work shall only performed by appropriately line or paint thinners for cleaning.
trained personnel or by the after sales service of
BOMAG.
l
Cleaning or repair work on the fuel tank is very dan-
gerous. Do not smoke or allow any ignitable sparks
These repair instructions contain headers like „Note“,
or open fire in the vicinity when cleaning or repairing
„Attention“, „Danger“ and „Environment“, which must
a tank. .
be strictly complied with in order to avoid dangers for
health and for the environment. l
When performing welding work strictly comply with
the respective welding instructions.
! Danger
Special safety regulations
Paragraphs marked like this highlight possible
dangers for persons. l
Use only genuine BOMAG spare parts for repair
purposes. Original parts and accessories have
been specially designed for this machine.
Caution
!
l
We wish to make explicitly clear that we have not
Paragraphs marked like this highlight possible
tested or approved any parts or accessories not
dangers for machines or parts of the machine.
supplied by us. The installation and/or use of such
products may therefore have an adverse effect on
i Note the specific characteristics of the machine and
Paragraphs marked like this contain technical infor- thereby impair the active and/or passive driving
mation for the optimal economical use of the machine. safety. The manufacturer explicitly excludes any li-
ability for damage caused by the use of non-original
parts or accessories.
Environment l
Unauthorized changes to the machine are prohibit-
Paragraphs marked like this point out practices ed for safety reasons.
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
l
If tests on the articulated joint need to be performed
with the engine running, do not stand in the articu-
Observe the regulations for the protection of the lation area of the machine, danger of injury!
environment.
l
Do not perform cleaning work while the engine is
running.
General
l
If tests must be performed with the engine running
l
Before starting repair work stand the machine on do not touch rotating parts of the engine, danger of
level and solid ground. injury.
l
Always secure the machine against unintended roll- l
Exhaust gases are highly dangerous. Always en-
ing. sure an adequate supply of fresh air when starting
l
Secure the engine reliably against unintentional the engine in closed rooms.
starting. l
Refuel only with the engine shut down. Ensure strict
l
Mark a machine that is defective or being repaired cleanliness and do not spill any fuel.
by attaching a clearly visible warning tag to the l
Keep used filters in a separate waste container and
steering wheel. dispose of environmentally.
l
On machines with articulated joint keep the articu- l
Dispose of oils and fuel environmentally when per-
lated joint locked during work. forming repair or maintenance work.
l
Use protective clothes like hard hat, safety boots l
Do not refuel in closed rooms.
and gloves.
l
Do not heat up oil higher than 160 °C because it
l
Keep unauthorized persons away from the machine may ignite.
during repair work.
l
Wipe off spilled oil and fuel.
008 910 32 BOMAG 7

1.2 Safety regulations
l
Do not smoke when refuelling or when checking the The lower the boiling point, the higher the pressure.
acid level in the battery. 2. The height of the temperature. The following ap-
plies: The higher the temperature, the higher the
l
Do not check the acid level of the battery with a na-
pressure.
ked flame, danger of explosion!
l
In a refrigerant container there must be a steam
l
Old batteries contain lead and must be properly dis-
space above the liquid space. The liquid expands
posed of.
with increasing temperature. The steam filled space
l
There is a danger of scalding when draining off en- becomes smaller. From a certain time on the con-
gine or hydraulic oil at operating temperature. tainer will be filled with just liquid. After this only a
l
on machines with rubber tires a tire may busr if in- minor temperature increase is enough to generate
correctly assembled. This can cause severe injury. very high pressures in the container, because the
liquid would like to expand, but there is no more
l
Do not exceed the specified highest permissible tire room. The related forces are high enough to cause
pressure. the container to burst. In order to avoid overfilling of
a container the pressure gas directive clearly spec-
Hydraulics ifies how many kilograms of refrigerant may be filled
into the container per litre volume.
l
Hydraulic oil escaping under pressure can pene-
trate the skin and cause severe injury. You should l
In case of occurring mechanical damage or corro-
therefore relieve the pressure in the system before sion on the refrigerant container, the container must
disconnecting any lines. be replaced, in order to prevent it from bursting and
causing further damage.
l
Before applying pressure to the system make sure
that all line connections and ports have been prop- l
Since the fluid container is pressurized, the manu-
erly tightened and are in perfect condition. facture and testing of these pressure vessels is gov-
l
Hydraulic oil leaking out of a small opening can erned by the pressure vessel directive. (New edition
hardly be noticed, therefore please use a piece of from April 1989). This directive classifies the pres-
cardboard or wood when checking for leaks. When sure vessels into the test groups in dependence on
being injured by hydraulic oil consult a physician im- their permissible operating pressure "p" in bar, its
mediately, as otherwise this may cause severe in- volume "l" in litres and the pressurized product p x
fections. l. On the basis of these prerequisites
the fluid containers must be classified as per testing
l
Do not step in front of or behind the drums/wheels group II. Paragraph 10 of the pressure vessel direc-
when performing adjustment work in the hydraulic tive demands that these pressure containers must
system while the engine is running. Block drums be periodically inspected and tested by a specialist,
and/or wheels with wedges. according to paragraph 32. . In this case
periodically recurring inspections consist of external
Reattach all guards and safety installations after
examinations, normally on containers in opera-
all work has been completed.
tion . The refrigerant container must be vis-
ually examined twice every year in connection with
Air conditioning system the inspection. Special attention must thereby
be paid to signs of corrosion and mechanical dam-
age. If the pressure vessel is in no good condi-
i Note
tion, it should be replaced for safety reasons, thus
In some countries the legislator demands minimum
to make sure that sufficient precautions have been
requirements concerning the qualification of the main-
applied to protect the operator and third par-
tenance personnel. In the Federal Republic of Germa-
ties. .
ny refrigeration and air conditioning equipment must
only be serviced by persons who are in the posses- l
Wear safety goggles! Put on your safety goggles.
sion of a so-called qualification certificate. This will protect your eyes against coming into con-
tact with refrigerant, which could cause severe
damage by freezing.
! Danger
l
Wear safety gloves and an apron! Refrigerant are
Do not open refrigerant containers which contain
excellent solvents for greases and oils. In contact
refrigerant!
with skin they will remove the protective grease film.
l
When opening refrigerant containers the contents However, degreased skin is very sensitive against
may escape in liquid or vaporous state. The higher cold temperatures and germs.
the pressure in the container, the fiercer this proc- l
Do not allow liquid refrigerants to come into contact
ess will take place. The height of the pressure de-
with skin! Refrigerant takes the heat required for
pends on two conditions. 1. Which type of
evaporation from the environment. Very low tem-
refrigerant is in the container. The following applies:
8 BOMAG 008 910 32

Safety regulations 1.2
peratures may be reached. The results may be local
frost injuries (boiling point of R134a -26.5°C at am-
bient pressure).
l
Do not inhale higher concentrations of refrigerant
vapours! Escaping refrigerant vapours will mix with
the ambient air and displace the oxygen required for
breathing.
l
Smoking is strictly prohibited! Refrigerants may be
decomposed by a glowing cigarette. The resulting
substances are highly toxic and must not be in-
haled.
l
Welding and soldering on refrigeration equipment!
Before starting welding or soldering work on vehi-
cles, (in the vicinity
of air conditioning components) all refrigerant must
be drawn out and the rests removed by blowing out
the system with nitrogen. The decomposition prod-
ucts created from the refrigerant under the influence
of heat not only are highly toxic, but also have a
strong corrosive effect, so that pipes and system
components may be attacked. The substance is
mainly fluorohydrogen.
l
Pungent smell! In case of a pungent smell the afore
mentioned decomposition products have already
been created. Extreme care must be exercised not
to inhale these substances, as otherwise the respi-
ratory system, the lungs and other organs may be
harmed.
l
When blowing out components with compressed air
and nitrogen the gas mixture escaping from the
components must be extracted via suitable exhaust
facilities (workshop exhaust systems).
008 910 32 BOMAG 9

1.3 General repair instructions
General Fill new hydraulic units with hydraulic oil before

1.3 General rep air instructions
l
starting operation.
l
Before removing or disassembling and parts, hoses
or components mark these parts for easier assem- l
After changing a component thoroughly flush and
bly. bleed the entire hydraulic system.
l
Before assembly oil or grease all parts, as far as this l
Perform measurements at operating temperature of
is necessary. the hydraulic oil (approx. 40 °C).
l
After changing a component perform a high and
Hydraulic system charge pressure test, if necessary check the speed
of the exciter shaft.
! Caution
l
The operating pressure of the exciter shaft to a
great extent depends on the base under the vibrat-
Do not open any hydraulic components if you
ing drum. If the soil is too hard place the drums on
have not been properly trained and without exact
old rubber tires. Do not activate the vibration on a
knowledge.
hard, concreted base, danger of bearing damage.
Please note l
After the completion of all tests perform a test run
Cleanliness is of utmost importance. Make sure that and then check all connections and fittings for leaks
no dirt or other contaminating substances can enter with the engine still stopped and the hydraulic sys-
into the system. tem depressurized.
l
Clean fittings, filler covers and the area around such Before commissioning
parts before disassembly to avoid entering of dirt.
l
After changing a component clean the hydraulic oil
l
Before disconnecting hoses, pipes or similar relieve tank thoroughly.
the system pressure with the engine shut down.
l
Fill the housings of hydraulic pumps and motors
l
During repair work keep all openings closed with with hydraulic oil.
clean plastic plugs and caps.
l
Use only hydraulic oils according to the specifica-
l
Do not run pumps and motors without oil. tion in the maintenance instructions.
l
When cleaning hydraulic components take care not l
After changing a component clean the hydraulic
to damage any fine machine surfaces. system as described in the flushing instructions in
l
Chemical and rubber soluble cleansing agents may order to prevent all other components from being
only be used to clean metal parts. Do not use such damaged by abrasion and metal chips remaining in
substances to clean seals and gaskets. the system.
l
Rinse of cleaned parts thoroughly, dry them with l
Change the hydraulic oil filter.
compressed air and apply anti-corrosion oil immedi-
Commissioning
ately. Do not install parts that show traces of corro-
sion. l
Bleed the hydraulic circuits.
l
Avoid the formation of rust on fine machined caused l
Start up the system without load.
by hand sweat. l
Check the hydraulic oil level in the tank, fill up oil if
l
Grease must not used as a sliding agent for assem- necessary.
bly work. Use hydraulic oil.
After commissioning
l
Do not start the engine after the hydraulic oil has l
Check system pressures and speeds.
been drained off.
l
Check fittings and flanges for leaks.
l
Use only the specified pressure gauges. Risk of
damaging the pressure gauges under too high pres- l
After each repair check all adjustment data, rota-
sure. tional speeds and nominal values in the hydraulic
system, adjust if necessary.
l
Clean ports and fittings before removal so that no
dirt can enter into the hydraulic system. l
Do not adjust pressure relief valves and control
valves to values above their specified values.
l
Check the hydraulic oil level before and after the
work.
Seals and gaskets
l
Use only clean oil according to specification.
l
Generally use new seals and gaskets when per-
l
Check the hydraulic system for leaks, find and rec-
forming assembly work. The required seal kits are
tify the cause.
available as spare parts.
10 BOMAG 008 910 32

General repair instructions 1.3
Air conditioning system l
All O-rings as well as pipe and hose fittings must be
oiled withcompressor oil / refrigeration oilibefore as-
sembly.
i Note
l
When replacing a heat exchanger, e.g. evaporator
In some countries the legislator demands minimum
or condenser, any compressor oil / refrigeration oil
requirements concerning the qualification of the main-
lost by exchanging the components, must be re-
tenance personnel. In the Federal Republic of Germa-
placed with fresh oil.
ny refrigeration and air conditioning equipment must
A too high compressor oil / refrigeration oil level ad-
sion of a so-called qualification certificate. versely affects the cooling performance and a too
low oil level has a negative effect on the lifetime of
l
In case of a repair on the refrigeration system you
the compressor.
should first evacuate the air conditioning system for
at least 45 minutes to remove any moisture from the l
If a air conditioning unit needs to be opened, the
system, before you start to refill. Moisture bonded in dryer must be replaced in any case.
the compressor oil / refrigeration oil (PAG oil) can l
Always use new O-rings when reassembling the
only be removed from the system by changing the unit.
oil.
l
Always use two spanners when connecting pipes or
l
During repair work on refrigerant lines and compo- hoses, to prevent the pipe end from being dam-
nents, these must be kept closed as far as possible, aged.
in order to prevent the invasion of air, moisture and
dirt, because the operational reliability of the system
l
Tighten screw fittings with the specified torque.
can only be assured if all components in the refrig- l
Check the connections of pipes, fittings or compo-
erant circuit are clean and dry from inside. nents thoroughly; do not use if damaged.
l
Make sure that no dirt or foreign parts can enter into l
Do not leave the refrigerant circuit unnecessarily
the compressor or the air conditioning system. The open to the atmosphere. Do not attempt to repair
area around the refrigerant hoses should be bent or burst pipes.
cleaned with a gasoline free solvent. l
Compressor valves must only be opened after the
l
All parts to be reused should be cleaned with a system has been properly sealed.
gasoline free solvent and blow-dried with clean l
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-
l
Before opening all components should have known and its effect on compressor oil and rubber
warmed up to ambient temperature, to avoid that elements is not predictable. The use of leak detec-
damp air is drawn into the component by the differ- tion colouring matter makes any warranty claims
ence in temperatures. null and void.
l
Damaged or leaking parts of the air conditioning l
Tools used on refrigeration circuits must be of ex-
must not be repaired by welding or soldering, but cellent condition, thus to avoid the damage of any
must generally be replaced. connections.
l
Do not fill up refrigerant, but extract existing refrig- l
The dryer is to be installed last, after all connections
erant and refill the system. in the refrigerant circuit have been tightened.
l
Different types of refrigerant must not be mixed. l
After completion of repair work screw locking caps
Only the refrigerant specified for the corresponding (with seals) on all connections with valves and on
air conditioning system must be used. the service connections. Start up of the air condi-
l
Refrigerant circuits with refrigerant type R134a tioning system. Observe the filling capacity.
must only be operated with the compressor oil / re- l
Before start up of the air conditioning system after a
frigeration oil approved for the compressor. new filling: - Turn the compressor approx. 10 revo-
l
Used compressor oil / refrigeration oil must be dis- lutions by hand using the clutch or V-belt pulley of
posed of as hazardous waste. the magnetic clutch. - Start the engine with the com-
pressor/control valve switched off. - Once the idle
l
Due to its chemical properties compressor oil / re- speed of the engine has stabilized switch on the
frigeration oil must never be disposed of together compressor and run it for at least 10 minutes at idle
with engine or transmission oil. speed and maximum cooling power.
l
Compressor oil / refrigeration oil is highly hydro- l
Never operate the compressor over longer periods
scopic. Oil cans must strictly be kept closed until of time with high engine speeds without a sufficient
use. Oil rests should not be used, if the can had amount of refrigerant in the system. This could
been opened over a longer period of time. probably cause overheating and internal damage.
008 910 32 BOMAG 11

1.3 General repair instructions
Electrics
l
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Electric signals must be checked at
the locations to which they are applied, i.e. on con-
trol unit or sensor technology. So, if the system had
been diagnosed without unplugging the control unit
and checking the wiring, one should be alerted.
l
Check for good cable and ground contacts, there-
fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
l
Perform trouble shooting in a systematic way. Do
not become confused by the high number and vari-
ety of electric cables, current can only flow in a
closed circuit. You should first become acquainted
with the function of the corresponding electric circuit
by following the correct wiring diagram. Detected
faults should be rectified immediately. If the system
still does not work correctly after this measure, trou-
ble shooting must be continued. Several faults very
rarely occur at the same time, but it is not impossi-
ble.
l
Surge voltages in the electric system must be strict-
ly avoided: For electric and inert gas welding all
electric components, battery and generator must be
electrically isolated. When performing welding work
always fasten the earth clamp of the welding unit in
the immediate vicinity of the welding location. Strict-
ly disconnect the cables from the generator before
starting work.
l
Do not disconnect or connect battery or generator
while the engine is running. Do not operate the main
battery switch under load. Do not use jump leads af-
ter the battery has been removed.
12 BOMAG 008 910 32

Tightening torques 1.4
Tightening torques
1.4 Tightening tor ques
l
Tighten fastening screws and nuts according to the table of tightening torques.
l
Tightening torques deviating from the ones in the table are specially mentioned in the repair instructions.
! Caution
Self-locking nuts must be generally renewed.
Tightening torques for screws with metric unified thread
Tightening torque Nm* (ft-lb)

Screw dimension
8.8 10.9 12.9
M4 3 (2) 5 (4) 5 (4)
M5 6 (4) 9 (7) 10 (7)
M6 10 (7) 15 (11) 18 (13)
M8 25 (18) 35 (26) 45 (33)
M10 50 (37) 75 (55) 83 (61)
M12 88 (65) 123 (91) 147 (108)
M14 137 (101) 196 (145) 235 (173)
M16 211 (156) 300 (221) 358 (264)
M18 290 (213) 412 (303) 490 (361)
M20 412 (304) 578 (426) 696 (513)
M22 560 (413) 785 (559) 942 (695)
M24 711 (524) 1000 (738) 1200 (885)
M27 1050 (774) 1480 (1092) 1774 (1308)
M30 1420 (1047) 2010 (1482) 2400 (1770)
Tightening torques for screws with metric fine thread
Tightening torques Nm * (ft-lb)

Screw dimension
8.8 10.9 12.9
M8 x 1 26 (19) 37 (27) 48 (35)
M10 x 1.25 52 (38) 76 (56) 88 (65)
M12 x 1.25 98 (72) 137 (101) 126 (119)
M12 x 1.5 93 (69) 127 (94) 152 (112)
M14 x 1.5 152 (112) 216 (159) 255 (188)
M16 x 1.5 225 (166) 318 (235) 383 (282)
M18 x 1.5 324 (239) 466 (344) 554 (409)
M20 x 1.5 461 (340) 628 (463) 775 (572)
M22 x 1.5 618 (456) 863 (636) 1058 (780)
M24 x 2 780 (575) 1098 (808) 1294 (1416)
M27 x2 1147 (846) 1578 (1164) 1920 (1416)
M30 x 2 1568 (1156) 2254 (1662) 2695 (1988)
* Strength classes for screws with untreated, non-lubricated surface.
The values result in a 90% utilization of the screw’s yield point at a coefficient of friction µ total = 0,14.
Compliance with the tightening torques is checked with torque wrenches.
Tightening torques deviating from the ones mentioned in the table are specially mentioned in these descriptions.
The values specified in the table apply for screws black, oiled and with surface protection A4C.
The quality designation of the screws is stamped on the screw heads.
008 910 32 BOMAG 13

1.5 Connection overview
Fig. 1 Travel pump
14 BOMAG 008 910 32

Connection overview 1.5
1 Control solenoid, high frequency 21 Connection D, charge pressure to filter
2 Control solenoid, low frequency 22 Multi function valve 345 bar (boost check and
3 Multi-function valve 400 bar (boost check and pressure relief valve), vibration drive high frequen-
pressure relief valve), travel system cy
4 Connection, charge pressure to brake solenoid 23 Connection S, suction line charge pump from hy-
valve, travel speed range selection and charge oil draulic oil tank
supply for vibration pump 24 Multi function valve 345 bar (boost check and
5 Multi-function valve 400 bar (boost check and pressure relief valve), vibration drive low frequen-
pressure relief valve), travel system cy
6 Setscrew, mechanical neutral position 25 Charge pressure relief valve, vibration pump
(blocked)
7 Connection L, leak oil connection to vibration
pump 26 Connection E, charge oil from travel pump
8 Lever, travel control 27 Connection L1, leak oil connection to travel pump
9 Pilot pressure test port 28 Pressure test port MB, high pressure reverse
10 High pressure port B, high pressure reverse 29 Charge oil from filter
11 Charge pressure relief valve, 26 bar 30 Pressure test port MA, high pressure forward
12 Adjustment screw, low frequency 31 High pressure port A, high pressure forward
13 Connection L2, leak oil to tank 32 Setscrew, mechanical neutral position, vibration
14 Pressure test port MB, high frequency 33 Leak oil connection D, leak oil from axle drive mo-
tor
15 High pressure test port MA, low frequency
34 Leak oil connection A, leak oil from travel pump
16 High pressure port A, low frequency
35 Leak oil connection G, leak oil from drum drive
17 High pressure port B, high frequency
motor
18 Charge pump, internal
36 Leak oil connection F, leak oil from vibration motor
19 Connection L2, to drum drive motor (flushing)
37 Radiator inlet
20 Adjustment screw, high frequency
008 910 32 BOMAG 15

1.6 Technische Daten
16 BOMAG 008 910 32

Technische Daten 1.6
008 910 32 BOMAG 17

1.6 Technische Daten
18 BOMAG 008 910 32

Maschinentyp BOMAG 19
Fig. 2
Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 211 D-40 2960 2250 1500 2268 2972 490 5840 60 60 25 2130
BW 211 PD-40 2960 2250 1480 2268 2972 490 5840 60 60 25 2130
*
BW 211 D-40 BW 211 PD-40
Weights
Operating weight (CECE) kg 9500 10500
with ROPS and cabin
Axle load, drum (CECE) kg 5750 6750
Rear axle load (CECE) kg 3750 3750
Static linear load kg/cm 27 -
Travel characteristics
Travel speed (1) km/h 0 ... 6 0 ... 6
Travel speed (2) km/h 0 ... 10 0 ... 10
Max. gradability (depend- % 45 49
ing on soil)
Engine
Engine manufacturer Deutz Deutz
Type BF4M 2012C BF4M 2012C
Cooling Water Water
Number of cylinders 4 4
Rated power DIN ISO kW 98 98
3046
Rated speed 1 rpm 2300 2300
Fuel Diesel Diesel
20 BOMAG Maschinentyp
* BW 211 D-40 BW 211 PD-40
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydr.-mech. hydr.-mech.
Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic
Vibration
Vibrating drum 1 1
Frequency Hz 30/36 30/36
Amplitude mm 1,8/0,9 1,64/0,82
Tires
Tire size 23.1-26/12 PR TL C7 23.1-26/12TL R1
Air pressure bar 1,4 1,4
Filling capacities
Engine Litres 10 10
Fuel Litres 250 250
Hydraulic oil Litres 60 60
Coolant Litres 16 16
* The right for technical modifications remains reserved
Fig. 3
mm
BW 212 D-40 2960 2250 1500 2268 2972 490 5840 60 60 25 2130
BW 212 PD-40 2960 2250 1480 2268 2972 490 5840 60 60 25 2130
*
BW 212 D-40 BW 212 PD-40
Weights
with ROPS and cabin
Static linear load kg/cm 33,6 -
Travel speed (1) km/h 0 ... 6 0 ... 6
Travel speed (2) km/h 0 ... 10 0 ... 10
ing on soil)
Engine
Cooling Water Water
3046
Fuel Diesel Diesel
* BW 212 D-40 BW 212 PD-40
Driven axles 2 2
Brakes
Steering
Vibration
Vibrating drum 1 1
Amplitude mm 1,8/0,9 1,64/0,82
Tires
Filling capacities
Engine Litres 10 10
Fuel Litres 250 250
Fig. 4
mm
BW 213 D-40 2960 2250 1500 2268 2972 490 5840 60 60 35 2130
BW 213 PD-40 2960 2250 1480 2268 2972 490 5840 60 60 25 2130
*
BW 213 D-40 BW 213 PD-40
Weights
with ROPS and cabin
Static linear load kg/cm 36,7 -
Travel speed (1) km/h 0 ... 6 0 ... 6
Travel speed (2) km/h 0 ... 10 0 ... 10
ing on soil)
Engine
Cooling Water Water
3046
Fuel Diesel Diesel
* BW 213 D-40 BW 213 PD-40
Driven axles 2 2
Brakes
Steering
Vibration
Vibrating drum 1 1
Amplitude mm 1,8/0,9 1,64/0,82
Tires
Filling capacities
Engine Litres 10 10
Fuel Litres 250 250
1.7 Table of fuels and lubri-
cants
Assembly Fuel or lubricant Quantity approx.
Summer Winter Attention

Observe the level marks
Engine Engine oil ACEA: E3-96/E5-02 or approx. 8,5 litres without

oil filter
API: CG-4/CH-4
SAE 10W/40
(-20 °C to +40 °C)
SAE 15W/40
(-15 °C to +40 °C)
Fuel
Diesel Winter diesel fuel approx. 150 litres
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres
46 mm2/s at 40 °C
Vibration bearings Engine oil SAE 15W/40 approx. 0,8 litres
Drive axle Gear oil SAE 90, API GL5 approx. 9,5 litres
Wheel hubs Gear oil SAE 90, API GL5 approx. 1,9 per side
Air conditioning system Refrigerant R134A approx. 1400 g
Tires (only BW 213) Water approx. 295 litres
Calcium chloride (CaCl2) or magnesium chloride approx. 100 kg

(MgCl2)
Engine cooling system Cooling system protection agent approx. 16 litres
2 Tests and adjustments
008 910 32 BOMAG 27

2.1 Special tools, tests and adjustments

1. Vibration reed frequency meter
BOMAG part-no.: 300 120 80
Fig. 1
2. RPM-meter for diesel engine
Fig. 2
3. Hydraulic test case, large
i Note
4 X 600 bar pressure gauges
4 X 60 bar pressure gauges
8 pressure test hoses
Fig. 3
4. Hydraulic test case, small
i Note
1X 25 bar pressure gauge
1X 150 bar pressure gauge
2X 400 bar pressure gauges
4 pressure test hoses
Fig. 4
28 BOMAG 008 910 32

Special tools, tests and adjustments 2.1
5. Pressure test hoses
1000 mm BOMAG part-no.: 079 930 02
2500 mm BOMAG part-no.: 079 930 03
Fig. 5
6. Pressure gauge
60 bar BOMAG part-no.: 059 721 07
600 bar BOMAG part-no.: 059 721 04
Fig. 6
7. Adapter for pressure test hose
Fig. 7
8. Gear pump testing device
Fig. 8
008 910 32 BOMAG 29

9. Vacuum pump for hydraulic oil tank
BOMAG part-no.: 007 610 04 (12 Volt)
BOMAG part-no.: 007 610 24 (24 Volt)
Fig. 9
10. Electric test case
Fig. 10
30 BOMAG 008 910 32

Adjusting the solenoid for engine speed control 2.2
2.2 Adjusting the solenoid for engine
speed control
11. Remove screw 3 (Fig. 1).
12. Switch on the ignition.
13. Switch on the solenoid (2) (move to full load posi-
tion).
i Note
When switched on, the plunger of the solenoid is
pulled in against the stop and the integrated limit
switch deactivates the pickup winding. The cur-
rent flow is reduced from approx. 70 A to approx.
3.5 A.
14. Push the throttle lever (1) to the right.
Fig. 1
i Note
There must be a gap of max. 0.5 mm between
stop screw (5) and throttle lever (1). Insert a dou-
ble folded piece of paper to check.
15. Keep adjusting the linkage (4), until the screw (3)
can be easily installed.
16. Retighten the screw (3).
008 910 32 BOMAG 31

2.3 Checking the rotation speeds
2.3 Checking the rotation speeds

Special tools
Vibration reed frequency meter, RPM-meter for
diesel engines.
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
2. Block the wheels with suitable chocks.
Fig. 1
Check the engine speed
i Note
If necessary, the engine speed may also be
checked with the vibration Reed frequency meter.
1. Connect the RPM-meter to the injection line (Fig.
2).
2. Run the engine with maximum speed.
3. Apply the brake.
4. Measure the rotation speeds.
Nominal value idle speed:

Low idle speed, see technical data.
High idle speed, see technical data.
5. Switch the vibration on .
Nominal value nominal speed:

Fig. 2
See technical data.
Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting for the engine.
32 BOMAG 008 910 32

Checking the rotation speeds 2.3
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, rest the
tester on your thumb (Fig. 3).
Nominal value:
See technical data.
Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting in the vibration circuit.
Fig. 3
008 910 32 BOMAG 33

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

tions of the travel pump
Special tools
Hydraulic test case
! Caution
1. Block drums and wheels with suitable chocks
(Fig. 1).
Fig. 1
2. Unhook the travel cable (Fig. 2) from the pump.
Fig. 2
3. Pull the plug (Fig. 3) off the brake solenoid valve
to close the brake.
Fig. 3
34 BOMAG 008 910 32

Checking / adjusting the neutral positions of the travel pump 2.4
4. Connect 600 bar pressure gauges to high pres-
sure test ports MA and MB (Fig. 4).
Fig. 4
5. Connect the control chamber ports X3 and X4
(Fig. 5) with a hose
Fig. 5
6. Start the engine and run it with maximum speed.
Nominal value
Both pressure gauges (Fig. 6) must show equal
pressure (charge pressure).
i Note
If necessary repeat the pressure test with 60 bar
pressure gauges, for more accurate readings.
Fig. 6
Evaluation of test
If pressure builds up on one side, adjust the me-

chanical neutral position (Fig. 7), until the pres-
sures on both pressure gauges are identical.
Fig. 7
008 910 32 BOMAG 35

2.5 Pressure tests in the travel circuit
2.5 Pressure tests in the travel circuit

Special tools
Hydraulic test case
! Caution
1. Block drums and wheels with suitable chocks
(Fig. 1).
Fig. 1
2. Pull the plug (Fig. 3) off the brake solenoid valve
to close the brake.
Fig. 2
3. Connect 600 bar pressure gauges to the high
pressure test ports for "forward travel" and "re-
verse travel" and a 60 bar pressure gauge to the
charge pressure test port (Fig. 2).
5. Read charge and high pressure gauges.
Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = charge pressure at high
Fig. 3 idle
Evaluation of test
If the nominal value is not reached, check the
steering/charge pump.
36 BOMAG 008 910 32

Pressure tests in the travel circuit 2.5
Measurement with quickly operated travel le-
ver
6. Move the travel lever (Fig. 4) quickly forward,
read the pressure gauge.
Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = pressure override
Evaluation of test
Fig. 4
If the specified high pressure is not reached,
check the travel pump.
If the charge pressure drops considerably during
the high pressure test, check the components in-
dividually.
008 910 32 BOMAG 37

2.6 Checking / adjusting the vibrator shaft speeds
2.6 Checking / adjusting the vibrator shaft

speeds
Special tools
Vibration reed frequency meter
! Caution
1. Drive the machine on an elastic base (rubber
buffers) (Fig. 1).
2. Apply the parking brake and block the wheels ad-
ditionally with suitable chocks.
4. Switch on vibration high frequency / low ampli-
tude or low frequency / high amplitude.
Fig. 1
5. Measure the speed (Fig. 2), rest the tester on
your thumb.
Nominal value
high amplitude/
low frequency = see technical data
low amplitude/
high frequency = see technical data
Evaluation of test
In case of deviations exceeding 10% determine
the cause, perform trouble shooting for engine /
vibration circuit and check vibration motor.
Fig. 2
6. Adjust the speed on the corresponding adjust-
ment screw (Fig. 2).
i Note
Turning the adjustment screw in reduces the
speed, turning the screw out increases the
speed.
Fig. 3
38 BOMAG 008 910 32

Pressure measurements in the vibration circuit 2.7
2.7 Pressure measurements in the vibra-
tion circuit
Special tools
Hydraulic test case
! Caution
1. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
2. Block the wheels with suitable chocks.
3. Apply the brake.
Fig. 1
4. Connect a 60 bar pressure gauge (Fig. 2) to the
charge pressure test port.
5. Connect a 600 bar pressure gauge each to the
high pressure test ports for "high amplitude" and
"low amplitude".
7. Switch on vibration with high or low frequency.
Nominal value
Charge pressure = charge pressure at high idle
(see technical data of travel pump).
Start-up pressure = vibration pump start-up pres-
Fig. 2 sure (see technical data of vibration pump).
Operating pressure = vibration pump operating
pressure (see technical data of vibration pump).
Evaluation of test
If the charge pressure drops, check the compo-
nents individually.
If the starting pressure is not reached, check the
vibration pump.
If the starting pressure is only reached for one fre-
quency, check the high pressure relief valves.
008 910 32 BOMAG 39

2.8 Check the leakage rate of the vibration motor
2.8 Check the leakage rate of the vibration

motor
! Caution
1. Drive the drum of the machine on an elastic base
(rubber buffers) (Fig. 1) and block the wheels ad-
ditionally with suitable chocks.
2. Apply the brake.
Fig. 1
3. Block the flushing valve (Fig. 2) with washers.
Fig. 2
4. Disconnect the leak oil hose (Fig. 3), connect a
measuring hose and hold it into a measuring
beaker.
6. Switch the vibration on and measure the running
out leak oil during one timed minute.
Nominal value
max. 1.5 litre/min
Evaluation of test
If the permissible leak oil rate is exceeded, re-
place the vibration motor.
Fig. 3
40 BOMAG 008 910 32

Pressure test in steering circuit 2.9
2.9 Pressure test in steering circuit
Special tools
Hydraulic test case, gear pump testing equipment
! Caution
ture of the hydraulic oil (approx. 50 °C).
Measurement 1
1. Connect a 600 bar pressure gauge to the steering
pressure test port (Fig. 1).
2. Start the engine and run it at idle speed.
! Danger
Danger of crushing, do not access the articu-
lation area of the machine!
3. Turn the steering against an end stop.
4. Read the pressure gauge.
Nominal value
Fig. 1
see technical data, max. steering pressure of
Evaluation of test 1
If the nominal value is reached, check the steer-
ing cylinder.
Measurement 2
5. Disconnect the hydraulic hoses from ports L and
R (Fig. 2) (machines with one steering cylinder)
on the steering cylinder and close them with
plugs.
Fig. 2
6. Disconnect the hydraulic hoses from ports L and
R (Fig. 3) (machines with two steering cylinder)
on the steering cylinders and close them with
plugs.
7. Start the engine and run it at idle speed.
8. Turn the steering wheel.
9. Read the pressure gauge.
Nominal value
see technical data for steering/charge pump.
Fig. 3
008 910 32 BOMAG 41

2.9 Pressure test in steering circuit
If the nominal value is reached, replace the steer-
ing cylinder.
If the nominal value is not reached, check the
10. Reconnect the hydraulic hoses to the steering
cylinders.
Measurement 3
11. Actuate the emergency stop switch.
Fig. 4
12. Close the pump outlet port (Fig. 5) with the gear
pump test equipment.
13. Crank the engine with the starter
Nominal value
see technical data for steering/charge pump.
If the nominal value is reached, replace the steer-
ing valve.
If the nominal value is not reached, replace the
Fig. 5
42 BOMAG 008 910 32

3 Flushing and bleeding
008 910 32 BOMAG 43

3.1 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
44 BOMAG 008 910 32

Special tools for flushing 3.1
13. Flanged plate 1“ - 25S

14. O-ring
BOMAG part-no. 062 202 22
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 32 BOMAG 45

18. Connecting socket 18L
Fig. 9
19. Connecting socket 16S
Fig. 10
20. Connecting fitting 20S
Fig. 11
21. Connecting fitting 25S
Fig. 12
46 BOMAG 008 910 32

Special tools for flushing 3.1
22. Angular fitting 18L
Fig. 13
23. Elbow 20S
Fig. 14
24. Elbow 25S
Fig. 15
008 910 32 BOMAG 47

3.2 Flushing - general
3.2 Flushing - general Clean the hydraulic tank
!Caution
Solid particles in the circuit will very quickly
cause damage to machine components.
Changing a component
Caution
!
Always flush the complete oil circuit after

you have replaced a component.
Fig. 2
Chips (abrasion) in the oil
l Open and clean all components in the oil ! Caution
circuit, replace if necessary.
Change the oil in case of excessive contam-
l Clean all high pressure hoses in the oil cir- ination, oil discoloration or if the oil change
cuit, replace if necessary. interval is almost due.
l If abrasion is found in the travel circuit you l Filter the tank content with the filling and fil-
should also flush the vibration circuit. tering unit and pump it into the oil bag.
l If abrasion is found in the vibration circuit

you should also flush the travel circuit.
Before flushing
Change the filter element
Fig. 3
l Mark all hoses and disconnect them from

the tank cover.
l Unscrew the fastening screws for the cover
and remove the cover.
Fig. 1
l Clean the hydraulic oil tank thoroughly from
l Change the hydraulic oil filter element (1). inside, reassemble cover and hoses.
l Fill the hydraulic oil tank again with the fill-
ing and filtering unit.
48 BOMAG 008 910 32

Flushing - general 3.2
Bleeding
Fig. 4
l Always bleed the closed hydraulic circuit if

lines had been removed or connected.
Servicing the flushing filter kit
Fig. 5
l Replace the filter element of the flushing fil-

ter when the red control pin of the contami-
nation indicator is pressed out during the
filtering process.
l Clean hoses and connections and store the
flushing kit in a clean and protected envi-
ronment.
008 910 32 BOMAG 49

3.3 Flushing schematic travel circuit (distribution travel pump)
3.3 Flushing schematic travel circuit (dis-

tribution travel pump)
50 BOMAG 008 910 32

Flushing schematic travel circuit (distribution travel pump) 3.3
1 Elbow union (tool) 13 High pressure hose (A, drum drive motor for-
ward)
2 Connecting union (tool)
14 High pressure hose (B, axle motor reverse)
3 Drum drive motor
15 High pressure hose (A, axle motor forward)
4 Axle motor
16 High pressure hose (B, axle motor reverse)
5 Screw socket R1 - 25S (tool)
17 High pressure port (B, drum drive motor reverse)
6 Flushing hose 25S - 20S (tool)
7 Flushing hose 25S - 20S (tool) 18 Flushing hose 25S - 20S (tool)
8 Flushing filter with filter element 1µ (tool)
9 Elbow union (tool)
10 Reducing fitting (tool)
11 Travel pump
12 High pressure hose (B, drum drive motor reverse)
008 910 32 BOMAG 51

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

pump distribution)
Flushing the drum drive

Replacing the hydraulic oil filter element
Cleaning the hydraulic oil tank
i Note
Observe the chapter "Flushing - General"
Installing the flushing filter
! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
The flushing filter must be installed in the low
pressure side in the return flow to the pump,
so that only cleaned oil will enter the travel
pump in forward travel.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
Fig. 1
1. Disconnect the high pressure hose 12 (see chap-
ter "Flushing schematic - travel circuit") from the
travel pump (high pressure port 17) and connect
it with the flushing hose (7) (flushing filter inlet
"IN").
2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port 17) on the travel
pump.
Disconnect the drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
cuit by joining the high pressure hoses (12 and
13) on the drum drive motor together.
Fig. 2
52 BOMAG 008 910 32

Flushing the travel circuit (travel pump distribution) 3.4
Bleeding the travel circuit
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 3
Flushing the hoses
4. Block drums and wheels with suitable chocks.
Fig. 4
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 5
! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
5. Start the engine and shift the travel lever to travel
direction forward.
6. Perform the flushing process at various engine
speeds for approx. 10 minutes.
7. Shut down the engine.
8. Reconnect the hydraulic hoses (12 and 13) to the
drum drive motor.
Fig. 6
008 910 32 BOMAG 53

Flushing the drum drive motor
! Danger
Danger of accident!
The drum must rotate freely.
9. Jack up the front of the machine, so that the drum
can rotate freely.
10. Secure the rear wheels with chocks.
11. Pre-select the slow speed range.
Fig. 7
i Note
flushing process.
Fig. 8
! Caution
12. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
13. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve forward travel.
Fig. 9 15. Remove the flushing filter and reconnect the high
pressure lines.
54 BOMAG 008 910 32

Flushing the axle drive
"IN").
17. Connect the flushing hose (19) (flushing filter out-
let "OUT") to the (high pressure port 16) on the
travel pump.
Fig. 10
Disconnecting the axle motor
18. Take the axle drive motor out of the hydraulic cir-
15) on the axle drive motor together.
Fig. 11
i Note
Fig. 12
008 910 32 BOMAG 55

Flushing the hoses

Fig. 13
i Note
flushing process.
Fig. 14
! Caution
direction forward.
axle drive motor.
Fig. 15
Flushing the axle motor
!Danger
Danger of accident!
Both wheels must be off the ground. The
wheels must be able to rotate freely.
24. Jack up the rear of the machine, so that the
wheels can rotate freely.
25. Secure the drum with wheel chocks.
Fig. 16
56 BOMAG 008 910 32

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

31. Bleed the travel circuit (see corresponding chap-
ter).
Keep circulating the tank content.

32. After completing the bleeding process circulate
the tank content with the filtering unit for another
15 minutes.
Function test
33. Check the hydraulic oil level in the tank, fill up if
necessary.
34. Check all connections for leaks with the engine
running (visual inspection).
35. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or starting
on a gradient.
36. Check all ports and connections for leak tightness
(visual inspection).
Fig. 19
008 910 32 BOMAG 57

3.5 Flushing schematic travel circuit (distribution axle motor)
3.5 Flushing schematic travel circuit (dis-

tribution axle motor)
58 BOMAG 008 910 32

Flushing schematic travel circuit (distribution axle motor) 3.5
008 910 32 BOMAG 59

60 BOMAG 008 910 32

Flushing schematic travel circuit (distribution axle motor) 3.5
008 910 32 BOMAG 61

1 Elbow union (tool) 13 High pressure hose (drum drive motor forward)
2 Connecting union (tool) 14 High pressure hose (B, axle motor reverse)
3 Drum drive motor 15 High pressure hose (A, axle motor forward)
4 Axle motor 16 High pressure hose (B, axle motor reverse)
5 Screw socket R1 - 25S (tool) 17 not used
6 not used 18 Flushing hose 25S - 20S (tool)
7 not used 19 Flushing hose 25S - 20S (tool)
8 Flushing filter with filter element 1µ (tool)
9 not used
10 Reducing fitting (tool)
11 Travel pump
12 High pressure hose (drum drive motor reverse)
62 BOMAG 008 910 32

Flushing the travel circuit (axle motor distribution) 3.6
3.6 Flushing the travel circuit (axle motor
distribution)
Flushing the drum drive

i Note
! Caution
so that only cleaned oil will enter the travel
pump in forward travel.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
Fig. 1
"IN").
2. Connect the flushing hose (18) (flushing filter out-
let "OUT") to the (high pressure port 16) on the
travel pump.
Disconnect the drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
13) on the drum drive motor together.
Fig. 2
008 910 32 BOMAG 63

3.6 Flushing the travel circuit (axle motor distribution)
i Note
Fig. 3
Flushing the hoses
i Note
flushing process.
Fig. 4
Fig. 5
! Caution
direction forward.
drum drive motor.
Fig. 6
64 BOMAG 008 910 32

Flushing the drum drive motor
! Danger
Danger of accident!
The drum must rotate freely.
9. Jack up the front of the machine, so that the drum
can rotate freely.
10. Secure the rear wheels with chocks.
Fig. 7
i Note
flushing process.
Fig. 8
! Caution
Fig. 9
008 910 32 BOMAG 65

3.6 Flushing the travel circuit (axle motor distribution)
Flushing the axle motor

!Danger
Danger of accident!
Both wheels must be off the ground. The
wheels must be able to rotate freely.
15. Jack up the rear of the machine, so that the
wheels can rotate freely.
16. Secure the drum with wheel chocks.
Fig. 10
i Note
flushing process.
Fig. 11
! Caution
pressure lines.

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

15 minutes.
66 BOMAG 008 910 32

Function test
necessary.
25. Check all connections for leaks with the engine
running (visual inspection).
26. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or starting
on a gradient.
Fig. 13
008 910 32 BOMAG 67

3.7 Flushing schematic for vibration drive
3.7 Flushing schematic for vibration drive
68 BOMAG 008 910 32

Flushing schematic for vibration drive 3.7
1 Elbow union (tool) 7 Flushing hose 25S - 20S (tool)
2 Connecting union (tool) 8 Flushing filter with filter element 1µ (tool)
3 Vibration motor 9 SAE flange (tool)
4 Vibration pump 10 High pressure hose (B, high frequency)
5 Screw socket R1 - 25S (tool) 11 High pressure hose (A, low frequency)
008 910 32 BOMAG 69

3.8 Flushing the vibration circuit

i Note
! Caution
so that only cleaned oil will enter the vibration
pump in high frequency.
For the connection schematic shown here the
vibration must always be filtered with "high
frequency / low amplitude".
Fig. 1
ter "Flushing schematic - vibration circuit") from
the vibration pump (4) and connect it with the
flushing hose (7) (flushing filter inlet "IN").
2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port A) on the vibra-
tion pump.
Disconnect the vibration motor
3. Take the vibration motor out of the hydraulic cir-
11) on the vibration motor together.
Fig. 2
70 BOMAG 008 910 32

Flushing the vibration circuit 3.8
Bleeding the vibration circuit
i Note
Bleeding the vibration circuit, see chapter "Bleed-
ing the vibration circuit".
Fig. 3
Flushing the hoses
Fig. 4
i Note
flushing process.
Fig. 5
! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
5. Switch on vibration with high frequency.
7. Flush the circuit for approx. 10 minutes, thereby
switch the vibration on and off at intervals of ap-
prox. 30 seconds.
Fig. 6 vibration motor.
008 910 32 BOMAG 71

Flushing the vibration motor

10. Unscrew the fastening screws for the vibration
motor and pull the motor out of the coupling.
Fig. 7
i Note
flushing process.
Fig. 8
! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
utes. Switch the vibration on and off at intervals of
approx. 30 seconds.
14. Remove the flushing filter and reinstall the vibra-
tion motor.
Fig. 9
Bleeding the vibration circuit
15. Bleed the vibration circuit (see corresponding
chapter).

15 minutes.
72 BOMAG 008 910 32

Flushing the vibration circuit 3.8
Function test
necessary.
18. Test drive.
Fig. 10
008 910 32 BOMAG 73

3.9 Bleeding the travel circuit
3.9 Bleeding the travel circuit
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
! 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
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Bleeding the travel circuit 3.9
8. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Pause for approx. 30 seconds and keep repeat-
ing this procedure, until the gauge shows a con-
stant charge pressure reading.
Fig. 4
! Caution
With the flushing filter installed shift the travel
lever only to travel direction forward, as oth-
erwise the flushing filter will be subjected to
oil flow from the wrong direction.
! Danger
Run the engine with idle speed.
10. Start the engine.
11. Shift the travel lever (Fig. 5) approx. 1/3 to for-
ward direction.
Fig. 5 12. After approx. 1 to 2 minutes shut down the engine
for a minute.
i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
008 910 32 BOMAG 75

3.10 Bleeding the vibration circuit
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
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
76 BOMAG 008 910 32

Bleeding the vibration circuit 3.10
8. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Wait for approx. 30 seconds and repeat the pro-
cedure, until the pressure gauge shows a con-
stant charge pressure.
Fig. 4
! Caution
With the flushing filter installed use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-
tion.
10. For bleeding switch on vibration with high fre-
quency (Fig. 5).
11. Start the engine.
12. After running the engine 1 to 2 minutes pause for
approx. one minute.
Fig. 5 i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
008 910 32 BOMAG 77

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4 Technical Manual
End of Import
4.1 Technical Manual / Basic Electrics
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Technical Manual / Basic Electrics 4.1
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4.2 Techn.Manual/Service Training
008 910 32 BOMAG 133

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Techn.Manual/Service Training 4.2
Service Training
Single Drum Rollers

BW 211 / 212 / 213 D- 40
with Deutz engine 2012 C
Part-No. 008 097 26 11/2005
008 910 32 BOMAG 135

Service Training
Table of contents
Foreword A1
Documentation A2
General A3
Novelties
Technical data and adjustment values B1
Maintenance C1
Maintenance chart C2
DEUTZ diesel engine D1

Operating side D2
Exhaust side D3
Lubrication oil circuit D4
Fuel circuit D5
Checking and adjusting the valve clearance D6
Assembly of plug-type injection pump D8
Test and adjustment points D16
Travel system E1
Travel pump E3
Control E6
Charge pressure relief valve E 11
High pressure relief valve E 12
Pressure override E 14
Axle drive motor E 16
Drum drive motor E 20
Test and adjustment points, travel system E 25
Trouble shooting in travel system E 29
BW 211 / 212 / 213 D-40
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Service Training
Vibration F1
Vibration pump F3
High pressure relief valves F6
Control F7
Charge pump F8
Vibration motor F9
Drum F 12
Test and adjustment points, vibration system F 14
Trouble shooting in vibration system F 16
Steering G1
Steering pump(s) G2
Steering valve G4
Articulated joint G6
Measuring and adjustment points G8
Trouble shooting steering system G9
Electrics H1
Wiring diagram
Hydraulic diagram
BW 211 / 212 / 213 D-40
008 910 32 BOMAG 137

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 211 / 212 / 213 D-40 -A1-
138 BOMAG 008 910 32

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 211 / 212 / 213 D-40 -A2-
008 910 32 BOMAG 139

Service Training
General
The new BOMAG single drum rollers D-40 are mainly further developments of their predecessors.
These machines have been successfully and reliably used for years on construction sites all over the
world, especially in earth construction and on sanitary landfill sites.
High compaction power and excellent traction are characteristics, which are of utmost importance for
this type of machine.
All components installed in these machines are manufactured in series production and are subjected to
stringent quality tests. This guarantees a high level of reliability and safety.
As with many other BOMAG products, and here especially with the large single drum rollers of the new
generation, we have decided to use the same successful drive concept with diesel engine (water cooled)
and hydrostatic drives also for these machines. The hydrostatic drives transfer the output power of the
engine directly to drum, drive wheels and steering.
The drive wheels are driven by fast rotating hydraulic motors and axle, whereas the drum is driven by
slow running radial piston motors.
On construction machines the work place of the operator is of utmost importance. Under such working
conditions the health and safety of the operator must be the greatest concern.
The cabin is very spacious and clearly arranged. The driver’s seat is very comfortable and can be
individually adjusted for every operator, even for his weight.
All control elements and gauges are within the reach and in the sight of the operator.
A monitoring display with light emitting diodes and clear pictograms informs the operator about any
operating faults. The operator is therefore always informed about the present condition of the machine.
The generously glazed cabin with windscreen wiper and washer systems for front and rear windscreens,
as well as a heated rear windscreen, offers clear vision to all sides.
BW 211 / 212 / 213 D-40 -A3-
140 BOMAG 008 910 32

Service Training
Important characteristics of the new generation of single drum rollers are
• strong ROPS/FOPS according to SAE-standard
• the multi-disc brake in the axle serves as parking and emergency brake
• high stability due to low centre of gravity and the use of an articulated joint
• operating safety due to the use of monitoring boards for all important system data
• automatic engine shut down under a too high engine temperature and too low engine oil pressure.
The machines of series D-40 are well designed down to the smallest detail, so that they can meet the
toughest demands on large scale construction sites all over the world.
BW 211 / 212 / 213 D-40 -A4-
008 910 32 BOMAG 141

Service Training
Novelties
The new instrument cluster shows important warnings and control data of
the machine.
BW 211 / 212 / 213 D-40 -A5-
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Service Training
Technical data and adjustment values
The following pages contain technical data valid at the date of printing (see front page of this manual).
Attention!
The currently valid technical data and adjustment values can be taken from the BOMAG Intranet
or Extranet (BOMAG Secured Area) in accordance with the serial number of the machine.
BW 211 / 212 / 213 D-40 -B1-
008 910 32 BOMAG 143

BOMAG Central Service Seite 1 von 2
BOMAG Central Service - Technical data and adjustment values
Status: 2005-11-23
Product type: BW 211 / 212 / 213 D-40

Type No.: 58242 / 58243 / 58244
Serial numbers from: 101 582 42/43/44 1001
Engine:
Type: BF4M2012C
Combustion principle: 4-stroke-Diesel
Cooling: Water
Number of cylinders: 4
Power acc. to ISO 9249: 98 kW
Power data at nominal speed of: 2300 1/min
Low idle speed: 900+/-200 1/min
High idle speed: 2430+/-50 1/min
Spec. fuel consumption: 225 g/kWh
Valve clearance, inlet: 0,3 mm
Valve clearance, outlet: 0,5 mm
Opening pressure, injection valves: 220 bar
Starter voltage: 12 V
Starter power: 3,1 kW
Travel pump:
Type: 90R 075
System: Axial piston-swash plate
Max. displacement: 75 cm3/U
Max. flow ratio: 172,9 l/min
High pressure limitation: 400 +26 bar
Charge pressure, high idle: 26 bar
Travel motor, rear:

Type: 51D110
System: Axial piston-bent axle
Max. displacement (stage 1): 110 cm3/U
Min. displacement (stage 2): 69 cm3/U
Perm. leak oil quantity: 2 l/min
Rinsing oil quantity: 16 l/min
Rinsing oil pressure limitation: 16 bar
Drum drive:
Type: MSE 18 1C
System: Radial piston
Displacement stage 1: 2800 cm3/U
Perm. leak oil quantity: 2 l/min
Vibration pump:
23.11.2005
144 BOMAG 008 910 32

BOMAG Central Service Seite 2 von 2
Type: 42R 041

Max. displacement: 41 cm3/U
Starting pressure: 345+26 bar
Operating pressure, soil dependent: ca.100 bar
Vibration motor:
Type: A10FM 45
Displacement: 45 cm3/U
Frequency: 30/35 Hz
Amplitude: 2 / 1 mm
Rinsing oil quantity: 6 l/min
Rinsing oil pressure limitation: 13 bar
Steering and charge pump:

Type: HY/ZFS11/16
System: Gear pump
Displacement: 16 cm3/U
Max. steering pressure: 175+26 bar
Steering valve:
Type: OSPC 500 ON
System: Rotary valve
Rear axle:
Type: CHC 192/51HD
Differential: No-Spin
Degree of locking: 100 %
Reduction ratio: 43,72
Filling capacities:
Engine coolant: 16 l (50% Water, 50% Anti-freeze agent on
Ethane-diol-basis)
Engine oil: 10 l (SAE 15W-40, API CG-4 (for details see
maintenance manual))
Hydraulic oil: 60 l (HVLP 46 VI 150)
Vibration bearing housing: 2x 0,8 l (SAE 15W-40, API SJ/CF)
Rear axle: 11 l (SAE 90 EP, API GL 5)
Rear axle wheel hubs: 2,9 l (SAE 90 EP, API GL 5)
AC refrigerant: 1300 g (R 134a)
Compressor oil (filling the system): 100 ml (PAG Öl)
23.11.2005
008 910 32 BOMAG 145

Service Training
Maintenance
Single drum rollers are heavy-duty construction machines for extremely difficult tasks in earth
construction. To be able to meet these demands the machines must always be ready to be loaded up
to their limits. Furthermore, all safety installations, protections and guards must always be in place and
fully functional.
Thorough maintenance of the machine is therefore mandatory. This not only guarantees a remarkably
higher functional safety, but also prolongs the lifetime of the machine and of important components.
The time required for thorough maintenance is only minor when being compared with the malfunctions
and faults that may occur if these instructions are not observed.
The maintenance intervals are given in operating hours. It is quite obvious that with each maintenance
interval all the work for shorter preceding intervals must also be performed. During the 2000 hours
interval you must also perform the work described for the service intervals after 50, 250 and 500 hours.
During maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and
lubricants (oils, fuels, grease etc.).
The designation specified under No: in the first column of the maintenance chart refers to the
corresponding number of the service work to be performed, as specified in the operating and
maintenance instructions. This also helps to find detailed information on the individual maintenance
tasks.
BW 211 / 212 / 213 D-40 -C1-
146 BOMAG 008 910 32

5.3 Table of fuels and lubri-

cants
Assembly Fuel or lubricant Quantity approx.
Summer Winter Attention

Observe the level marks
Engine Engine oil ACEA: E3-96/E5-02 or approx. 8,5 litres without

oil filter
API: CG-4/CH-4
SAE 10W/40
(-20 °C to +40 °C)
SAE 15W/40
(-15 °C to +40 °C)
Fuel
Diesel Winter diesel fuel approx. 150 litres
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres
2
46 mm /s at 40 °C
Vibration bearings Engine oil SAE 15W/40 approx. 0,8 litres
Drive axle Gear oil SAE 90, API GL5 approx. 9,5 litres
Wheel hubs Gear oil SAE 90, API GL5 approx. 1,9 per side
Air conditioning system Refrigerant R134A approx. 1400 g
Tires (only BW 213) Water approx. 295 litres
Calcium chloride (CaCl2) or magnesium chloride approx. 100 kg

(MgCl2)
Engine cooling system Cooling system protection agent approx. 16 litres
BW 211/212/213 D-40
008 910 32 BOMAG 147

5.4 Running-in instructions
The following maintenance work must be per-

formed when running in new machines or
overhauled engines:
Caution
Up to approx. 250 operating hours check the
engine oil level twice every day.
Depending on the load the engine is subjected
to, the oil consumption will drop to the normal
level after approx. 100 to 250 operating hours.
After a running-in time of 30 minutes

Retighten the V-belt
After 250 operating hours

Retighten bolted connections on intake and
exhaust tubes, oil sump and engine mounts.
Retighten the bolted connections on the ma-
chine.
Retighten all wheel fastening screws with the
specified tightening torque.
Changing engine oil and oil filter
1. Oil change vibration bearings
Oil change in drive axle
Oil change in wheel hubs
After 500 operating hours

2. Oil change vibration bearings
BW 211/212/213 D-40
148 BOMAG 008 910 32

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


after 250 operating hours
Running-in instructions
No. Maintenance work Remark
as required
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Check the coolant level Inspection glass X
5.11 Check the dust separator X
5.12 Check the tire pressure X
5.13 Clean the cooling fins on engine and hy- X
draulic oil cooler
5.14 Check the oil level in the drive axle X
5.15 Check the oil level in the wheel hubs X
5.16 Check the oil level in the vibration bear- X
ings
5.17 Change engine oil and oil filter car- min. 1x per year X X
tridge*
5.18 Drain the sludge from the fuel tank X
5.19 Service the battery Pole grease X
5.20 Check, replace the refrigerant compres- X
sor V-belt
5.21 Service the air conditioning X
5.22 Check, adjust the valve clearance Intake = 0,3 mm X
Exhaust = 0,5 mm
5.23 Check, replace the ribbed V-belt X
5.24 Change the fuel filter cartridge X
BW 211/212/213 D-40
008 910 32 BOMAG 149

every 10 operating hours, daily


after 250 operating hours
Running-in instructions
No. Maintenance work Remark
as required
5.25 Change the fuel pre-filter cartridge X
5.26 Check the engine mounts X X
5.27 Oil change in drive axle min. 1x per year X X
5.28 Oil change in wheel hubs min. 1x per year X X
5.29 Oil change vibration bearings** see foot note, min. X X
1 x per year
5.30 Retighten the fastening of the axle on X
the frame
5.31 Tighten the wheel nuts X X
5.32 Check the ROPS X
5.33 Clean the oil bath air filter min. 1x per year X
5.34 Change hydraulic oil and breather fil- at least every 2 X
ter*** years
5.35 Change the hydraulic oil filter*** at least every 2 X
years
5.36 Change the coolant at least every 2 X
years
5.37 Check the injection valves X
5.38 Service the combustion air filter min. 1x per year, X
safety cartridge at
least every 2 years
5.39 Adjusting the scrapers X
5.40 Adjust the parking brake X
5.41 Change the tires X
5.42 Change the fresh air filter in the cabin X
5.43 Tightening torques X
5.44 Engine conservation X
BW 211/212/213 D-40
150 BOMAG 008 910 32

* Oil change intervals depend on quality of oil and fuel (sulphur content)
** Oil change intervals after 50 h, after 500 h, after 1000 h, and then every 1000 h.
*** Also in case of repair in the hydraulic system.
BW 211/212/213 D-40
008 910 32 BOMAG 151

Service Training
Deutz diesel engine
Single drum rollers of series BW 211 / 212 / 213 D-40 are powered by a Deutz diesel engine of product
range BF4M 2012 C.
These engines are characterized by the following positive features:
• short and compact design,
• low noise level,
• almost vibration-free running,
• low fuel consumption,
• low exhaust emissions (EPA II),
• high power reserves and
• good access to all service points.
Crankcase and cylinders of this engine are made of alloyed cast iron. This provides strength and
ensures high wear resistance.
The forged steel conrods are fitted with compensation weights near the conrod bearing seats. These
weights compensate manufacturing tolerances with respect to weight and centre of gravity.
The pistons are made of an aluminium alloy. The combustion chamber recess is slightly offset from the
middle at its side walls are inclined for 10° towards the inside. All pistons are fitted with three piston rings
and a cast iron ring carrier for the first ring. The pistons are lubricated by an oil mist.
The forged crankshaft is equipped with integrated counterweights.
The block-type cylinder head is made of cast steel. Each cylinder is fitted with one intake and one
exhaust valve. The valve guides are shrunk into the cylinder head. The valve seat rings are made of
high-grade steel and are also shrink fitted.
BW 211 / 212 / 213 D-40 -D1-
152 BOMAG 008 910 32

Service Training
Service side
3 4
2
5
6
14
9 8
13 12 11 10
Fig. 1: Service side BFM 1013/2012
1 Oil filler neck 8 Fuel pump

2 Valve, boost fuel supply 9 Engine mounting
3 Engine solenoid 10 Fuel filter
4 Oil pressure switch 11 Lubrication oil filter
5 Cooling air blower 12 Oil sump
6 Coolant pump 13 Dipstick
7 V-belt pulley 14 Steering/charge pump
BW 211 / 212 / 213 D-40 -D2-
008 910 32 BOMAG 153

Service Training
Starter side
3
1
Fig. 2: Starter side
1 Flywheel
2 Ground cable
3 Starter
4 Turbo charger
5 Generator
6 Coolant temperature switch
BW 211 / 212 / 213 D-40 -D3-
154 BOMAG 008 910 32

Service Training
Lubrication oil circuit
3 4 5 6 7 8 9 10 11 12 13 14 15
2 1 22 21 20 19 18 17 16
Fig. 3: Lubrication oil circuit
1 Oil sump 12 Piston cooling nozzle

2 Return flow turbo charger to crankcase 13 Camshaft bearing
3 Turbo charger 14 Main oil channel
4 Oil line to turbo charger 15 Lubrication oil cooler
5 Line to mass balance wheel (2 x) 16 Lubrication oil pump
6 Oil pressure sensor 17 Pressure relief valve
7 Valve with pulse lubrication 18 Leak oil return line
8 Push rod, oil supply to rocker arms 19 Lubrication oil filter
9 Line to spray nozzles 20 Suction line
10 Rocker arm 21 Crankshaft bearing
11 Return flow to oil sump 22 Conrod bearing
BW 211 / 212 / 213 D-40 -D4-
008 910 32 BOMAG 155

Service Training
Lubrication oil circuit
3 1
5 4
Fig. 4: Lubrication oil circuit
1 Cooler
2 To cooler
3 From cooler
4 Coolant pump
5 Lubrication oil cooler
6 Cylinder cooling
7 Cylinder head cooling
8 Ventilation connection between cylinder head and heat exchanger
BW 211 / 212 / 213 D-40 -D5-
156 BOMAG 008 910 32

Service Training
FuelFuel system
7
1a
1b
1c
Fuel tank
1d
Fuel system
BW 211 / 212 / 213 D-40 -D6-
008 910 32 BOMAG 157

Service Training
Legend:
1a Fuel lift pump

1b Fuel pre-filter
1c Water separator
1d) Water proportion sensor
2 Feed to fuel lift pump
3 Fuel lift pump
4 Connecting line lift pump – main filter (fuel pre-pressure up to 10 bar)
5 Main fuel filter (pressure resistant)
6 Connecting line main filter – supply for injection pump
7 Single injection pump
8 High pressure line
9 Injection nozzle
10 Leakage line
11 Pressure retaining valve - 5 bar
12 Return flow to tank
BW 211 / 212 / 213 D-40 -D7-
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Service Training
Fuel pre-filter with water separator
1
2
Fig. 5: Fuel pre-filter with water separator
1) Lift pump
2) Vent valve
3 Filter element
4) Water and dirt collecting bowl
5 Drain valve
6 Electric connection for water level sensor
The fuel pre-filter / water separator consists mainly of:
• the dirt / water sediment bowl with water level warning sensor
• and the filter element
BW 211 / 212 / 213 D-40 -D8-
008 910 32 BOMAG 159

Service Training
Function:
The fuel lift pump draws the fuel through both filters.
The water resistant filter element retains remaining smaller dirt and water particles.
Once the water level reaches the height of the warning connections, the warning light in the dashboard
lights up.
Draining off water or fuel :
If the filter element is clogged before a service is due (indicated by e.g. a power drop), the filter may be
regenerated as follows to keep up operation of the engine:
• Open the bleeding screw (this applies atmospheric pressure to the filter element and releases bigger
dirt particles from the bottom side of the filter, which will then sink down.
• Open the drain valve and let approx. 0.5 l of fuel run out. The fuel above the filter element presses
through the filter element and cleans the underside of the filter element from dirt.
• Close the drain valve.
Draining off larger dirt particles or sludge:
• Unscrew the water separator housing
Bleed the system by operating the fuel lift pump and then tighten the bleeding screw.
Main fuel filter
Attention!
The main fuel filter is subjected to approx. 10 bar fuel pre-pressure from the fuel lift pump. This
pressure is considerably higher than on other engines. For this reason only original filter
elements must be used. Filter elements of similar design or with adequate dimensions are not
necessarily pressure resistant!
A filter element of insufficient pressure resistance will be damaged by the high pressure and will
disintegrate. This causes severe damage to the injection system!
BW 211 / 212 / 213 D-40 -D9-
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Service Training
Checking and adjusting the valve clearance
Excessive or insufficient valve clearance can cause failure of the engine as a result of mechanical and
thermal overloads. The valve clearance must therefore be checked and, if necessary, adjusted at the
intervals specified in the operating and maintenance instructions.
Note: The valve clearance must be checked and adjusted when the engine is cold.
Intake valve = 0.3 mm Exhaust valve= 0.5 mm
• Turn the crankshaft until both valves on cylinder 1 are overlapping (the exhaust valve is not yet
closed, the intake valve starts to open).
Flywheel
side
1 2 3 4
Fig. 6: Crankshaft position 1
• Check and adjust the valve clearance by following the black marking in the adjustment schematics.
For control purposes mark the respective rocker arm with chalk.
Flywheel
side
1 2 3 4
Fig. 7: Crankshaft position 2
Turn the crankshaft one full turn (360°) further.
Check and adjust the valve clearance by following the black marking in the adjustment schematics.
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Service Training
Explanation of pictograms
During the following work the following pictograms are used for the reason of simplicity:
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Service Training
plug-in injection pump
Deutz diesel engines of product range 2012/1013 are equipped with plug-in injection pumps of series
PF 33 from Bosch.
The concept of the plug-in fuel injection pumps enables the realization of high injection pressures in
connection with extremely short injection lines, which contributes to a high hydraulic stiffness of the
injection system. This in turn provides the prerequisite for low exhaust emission values (soot) in
combination with a low fuel consumption.
Plug-in fuel injection pumps have the following plunger dimensions:
• Stroke 12 mm
• Diameter 9 mm
Cavitation in the injection lines and injection overrun, which is normally associated with high pressures,
is prevented by a return flow nozzle arranged after the pressure valve
The constant volume relief is 50 mm³.
Assembling the plug-type injection pumps
The adjustment of the injection pump timing (FB) affects:
• the fuel consumption,
• the power
• the exhaust emission
of the engine.
On engines of series 2012/1013 the start of delivery is adjusted without tolerance. The start of delivery
is entered in degree of crank angle measured from the top dead centre of the piston and depends on
application, power and speed setting of the engine.
The plug-in injection pump is in position of start of delivery when the plunger just closes the fuel supply
bore in the plunger sleeve.
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Service Training
On engines with inline injection pumps the engine drive is turned to start of delivery position and closing
of the fuel supply bore is determined by means of a high pressure pump. Occurring tolerances are
compensated in the coupling of the injection pump drive, whereby the injection pump camshaft is turned
to start of delivery position against the fixed engine drive.
The injection pump cams on engines of series 2012/1013 are arranged on the camshaft of the engine.
For this reason the conventional adjustment method for the start of delivery cannot be used.
The start of delivery of the injection pump must be adjusted using the new method.
For this the conventional adjustment method is subdivided into length measurements of individual
engine parts and calculations.
The permissible manufacturing tolerances for the components
• cylinder crankcase,
• camshaft,
• plunger
• plug-in injection pump
are measured and eliminated by the adjustment of the start of delivery.
However, in cases of interest for BOMAG engineers the engine will not be overhauled completely, but
individual injection pumps will be replaced.
Crankcase, camshaft and plunger remain unchanged.
This results in a certain installation measurement for the engine drive, which is stamped on the engine
type plate.
In column „EP“ it is stamped as „CODE“ for each cylinder.
Note:
If an injection pump and/or nozzle is replaced, the respective high pressure line between pump and
nozzle must also be replaced..
1. Remove crankcase ventilation and cylinder

head cover.
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Fig. 8:
2. Remove the engine solenoid
Fig. 9:
3. Insert the pressing device, WILBÄR No. 100

830 carefully into the groove in the governor
rod and tighten.
Fig. 10:
4. Turn the knurled fastening screw to press the

governor rod to stop position.
Note:
Tighten the knurled fastening screw by hand.
Fig. 11:
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5. Set the cylinder of the injection pump to be
replaced to ignition top dead centre (valves
overlapping). Then turn the crankshaft
approx. 120° against the sense of rotation.
Note:
View on flywheel
Fig. 12:
6. Remove injection line and injection pump.
Fig. 13:
7. Take the compensation shim carefully out with

the rod magnet.
Fig. 14:
Determine the thickness of the new compensation shim:
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Determination of the compensation shim thickness when replacing plug-in fuel injection
pumps
On the engine type plate column - EP – contains a code for the plug-in fuel injection pump for each
cylinder.
295
Each line represents 1 cylinder

e.g. 1st line = cylinder 1
2. line = cylinder 2 etc.
Fig. 15: Injection pump code BFM 2012/1013
The EP-code is used to determine the installation measurement to be corrected „Ek“ from table 1.
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Service Training
EK EP EK EP EK EP EK EP
(mm) code (mm) code (mm) code (mm) code
119,250 230 119,850 254 120,450 278 121,050 302
119,275 231 119,875 255 120,475 279 121,075 303
119,300 232 119,900 256 120,500 280 121,100 304
119,325 233 119,925 257 120,525 281 121,125 305
119,350 234 119,950 258 120,550 282 121,150 306

119,375 235 119,975 259 120,575 283 121,175 307
119,400 236 120,000 260 120,600 284 121,200 308
119,425 237 120,025 261 120,625 285 121,225 309
119,450 238 120,050 262 120,650 286 121,250 310

119,475 239 121,075 263 120,675 287 121,275 311
119,500 240 120,100 264 120,700 288 121,300 312
119,525 241 120,125 265 120,725 289 121,325 313
119,550 242 120,150 266 120,750 290 121,350 314

119,575 243 120,175 267 120,775 291 121,375 315
119,600 244 120,200 268 120,800 292
119,625 245 120,225 269 120,825 293
119,650 246 120,250 270 120,850 294

119,675 247 120,275 271 120,875 295
119,700 248 120,300 272 120,900 296
119,725 249 120,325 273 120,925 297
119,750 250 120,350 274 120,950 298

119,775 251 120,375 275 120,975 299
119,800 252 120,400 276 121,000 300
119,825 253 120,425 277 121,025 301
Fig. 16: Injection pump code table BFM 2012
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EK EP EK EP EK EP EK EP
(mm) code (mm) code (mm) code (mm) code
145.7 349 146.3 373 146.9 397
145.725 350 146.325 374 146.925 398
145.75 351 146.35 375 146.95 399
145.775 352 146.375 376 146.975 400
145.8 353 146.4 377 147.0 401

145.825 354 146.425 378 147.025 402
145.85 355 146.45 379 147.05 403
145.875 356 146.475 380 147.075 404
145.9 357 146.5 381 147.1 405

145.925 358 146.525 382 147.125 406
145.35 335 145.95 359 146.55 383 147.15 407
145.375 336 145.975 360 146.575 384 147.175 408
145.4 337 146.0 361 146.6 385 147.2 409

145.425 338 146.025 362 146.625 386 147.225 410
145.45 339 146.05 363 146.65 387 147.25 411
145.475 340 146.075 364 146.675 388 147.275 412
145.5 341 146.1 365 146.7 389 147.3 413

145.525 342 146.125 366 146.725 390 147.325 414
145.55 343 146.15 367 146.75 391 147.35 415
145.575 344 146.175 368 146.775 392 147.375 416
145.6 345 146.2 369 146.8 393 147.4 417

145.625 346 146.225 370 146.825 394 147.425 418
145.65 347 146.25 371 146.85 395 147.45 419
145.675 348 146.275 372 146.875 396
Fig. 17: Injection pump code table BFM 1013
Ek (mm) = corrected injection pump measurement, determined by EP-code on type plate and from
table 1.
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Service Training
During the manufacture of the plug-in fuel injection pump the high pressure method is used to determine
the wear in the fuel supply bore. In this position – injection pump plunger in start of fuel delivery position
- the distance between pump contact face and plunger foot contact face is measured.
Measurement "A" in 1/100 mm has been written on the pump with an electric marker.
64
Fig. 18: Plunger code inscription
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A=XXX
Fig. 19: Individual injection pump
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Measurement "A" specifies by how many 1/100 mm the gap between contact area on cylinder
crankcase and plunger foot is longer than the hydraulic base measurement Lo.
Lo
A = XX
A/100
Fig. 20: Presentation of measurement „A“
• Lo = 117,5 mm - BFM 2012
• Lo = 143 mm - BFM 1013
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Ek Lo+A/100
Z
Ts
Fig. 21: Drive in start of delivery position after determination of „Ts“
The plug-in fuel injection pump is now positively connected with the drive, which has been set to start
of delivery by inserting a compensation shim "Z" of calibrated thickness..
The illustration explains that according to calculation:
(Ek) - (Lo + A/100)
there is a gap „Ts“ between injection pump plunger foot and roller plunger. This gap has to be
compensated with a compensation shim "Z" of appropriate (calculated) thickness.
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Service Training
Theoretical Compensation Theoretical Compensation

thickness shim thickness shim
„Ts“ thickness „Ss“ „Ts“ thickness „Ss“
(mm) (mm)
(mm) (mm)
0.95 - 1.049 1.0 2.45 - 2.549 2.5
1.05 - 1.149 1.1 2.55 - 2.649 2.6
1.15 - 1.249 1.2 2.65 - 2.749 2.7
1.25 - 1.349 1.3 2.75 - 2.849 2.8
1.35 - 1.449 1.4 2.85 - 2.949 2.9
1.45 - 1.549 1.5 2.95 - 3.049 3.0
1.55 - 1.649 1.6 3.05 - 3.149 3.1
1.65 - 1.749 1.7 3.15 - 3.249 3.2
1.75 - 1.849 1.8 3.25 - 3.349 3.3
1.85 - 1.949 1.9 3.35 - 3.449 3.4
1.95 - 2.049 2.0 3.45 - 3.549 3.5
2.05 - 2.149 2.1 3.55 - 3.649 3.6
2.15 - 2.249 2.2 3.65 - 3.749 3.7
2.25 - 2.349 2.3 3.75 - 3.850 3.8
2.35 - 2.449 2.4
Table 1: Compensation shims 2012/1013
For the determination of the theoretical shim thickness „Ts“ it is also necessary to determine
measurement Lo + A/100 of the new fuel injection pump, which must then be subtracted from the
corrected injection pump measurement Ek.
Ts = Ek - (Lo + A/100) [mm]
The real compensation shim thickness „Ss“ is determined with the help of table 2.
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Exemplary calculation for BFM 2012
EP-code read off engine type plate: 295
• see table 1
corrected injection pump measurement „Ek“: 120,875 mm
Lo = 117,5 mm (fixed measurement)
Value for A/100 read off new injection pump A/100 = 42
• Ts = Ek - (Lo + A/100)
Ts = 120,875 mm - (117,5 + 42/100 mm)
Ts = 2.955 mm
see also table 1
Ts = 3,0 mm
Exemplary calculation for BFM 1013
EP-code read off engine type plate: 397
• see table 1
corrected injection pump measurement „Ek“: 146.9 mm
Lo = 143 mm (fixed measurement)
Value for A/100 read off new injection pump A/100 = 133
• Ts = Ek - (Lo + A/100)
Ts = 146,9 mm - (143 + 133/100 mm)
Ts = 2.57 mm
• see also table 1
Ts = 2,6 mm
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Service Training
8. P?lace the new calculated compensation shim
on the roller plunger.
Fig. 22:
9. Turn the injection pump control lever to

approx. middle position.
Fig. 23:
10. Apply some oil to the locating bore in the

crankcase and the O-rings on the injection
pump. Carefully insert the injection pump
control lever into the governor rod.
Fig. 24:
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11. Attach the flange.
Note:
The chamfer must face towards the injection

pump body
Fig. 25:
12. Slightly oil the screws and tighten them

evenly with 5Nm.
Fig. 26:
13. Loosen the screws again for 60°.
Fig. 27:
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14. Carefully turn the injection pump with and
open end spanner in anti-clockwise direction
against the noticeable stop
Fig. 28:
15. Tighten the screws again for 60° and

continue in stages with tightening torques of
7 Nm, 10 Nm and 30 Nm.
Note:
Start with the outer screw, viewed from the

flywheel. (see arrow).
Fig. 29:
16. Back out the knurled screw of the pressing

device, remove the pressing device.
17. Reinstall the engine solenoid with a new O-

ring.
18. Reinstall the cylinder head cover. Tightening

torque: 9 +/-1 Nm.
Note:
If necessary replace the gasket.
Fig. 30:
19. Slightly oil the O-ring of the crankcase ventilation. Reassemble the crankcase ventilation. Tightening
torque 9 +/- 1Nm
Note: If necessary replace the gasket.
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Tools
The following tools can be ordered from the respective supplier (in brackets) under the stated part-
number.
For tools from Hazet and Bosch you should consult your nearest representative, orders to Wilbär should
be addressed to:
Co. Wilbär
P.O. box 140580
D - 42826 Remscheid
Fig. 31
• Pressing device for governor rod 100 830 (Wilbär)
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Service Training
Diesel engine, components and test points
Air filter
2
2
11
1
2
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values

diagram
1 Visual coolant level indicator
2 Visual air filter pressure differential
indicator
BW 211 / 212 / 213 D-40 - D 29 -
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Service Training
Fuel tank

diagram
1 Visual fuel level indicator
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008 910 32 BOMAG 181

Service Training
Flywheel end
1
2
3 4

diagram
1 Boost fuel valve Y 01 0/12 V
2 Coolant temperature switch with B 30 cold open,
warning light
3 Coolant temperature sensor B 113 approx. 2 Ω at
(Option) 20°C
4 Throttle lever
BW 211 / 212 / 213 D-40 - D 31 -
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Service Training
Auxiliary power take-off side
4 2 3
1 5
7
diagram
1 Engine oil pressure switch B 06 pressureless
closed,
2 Engine solenoid, speed control Y 120
3 Engine shut-down solenoid Y 58
4 Fuel pre-filter with hand pump
5 Fuel filter
6 Engine oil filter
Water separator sensor, fuel B 124
BW 211 / 212 / 213 D-40 - D 32 -
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Service Training
Diesel engine monitoring:
Warning and control lights are integrated in the instrument cluster
Display and shut-down functions
Control light Warning buzzer Shut down time Shut down time
10 s 2min
Water separator X X X
Fuel filter
Engine oil X X X
pressure
Coolant X X X
temperature
BW 211 / 212 / 213 D-40 - D 33 -
184 BOMAG 008 910 32

Travel circuit
008 910 32
from brake valve
M4 M5
from speed
ø 0.8
BW 211 / 212 / 213 D-40

range valve
M4 M3 L
2 A
ø 0.81
Techn.Manual/Service Training
ø 0.6
6
ø 0.6
8
4 T3
25 bar 9
BOMAG
3
1
M2
B
Charge pressure to vibration pump
Charge pressure from hydraulic oil filter
Fig. 1: Hydraulic diagram travel system BW 211 / 212 / 213 D-40
1 Travel pump Sauer 90 R 075 4 Multi function valve 7 Speed range valve
2 Servo control 5 Rear axle 8 Flushing valve
3 Charge pressure relief valve 6 Axle drive motor Sauer 51 D 110 9 Drum drive motor Poclain MSE 18 1C
Service Training
-E1-
185
4.2
Service Training
The travel system of the single drum rollers is a closed hydraulic circuit and consists mainly of:
• travel pump with control and safety elements,
• Drum drive motor without brake,
• axle drive motor,
• rear axle with brake,
• charge pump (also for vibration circuit),
• hydraulic oil filter (in charge circuit),
• hydraulic oil cooler with thermostat
• hydraulic lines.
Travel pump and vibration pump are connected to a tandem pump unit. The charge pump is an integral
part of the vibration pump.
The travel pump is the first pump section, flanged directly to the flywheel side of the diesel engine.
The pump delivers the hydraulic oil to the travel motors for drum and axle drives. The multi-function
valves in the pump limit the pressure in the closed circuit to (∆p = 400 bar between low and high
pressure sides).
A flushing valve in the axle drive motor (and in the Sauer drum drive motor 51 C 110) flushes a certain
oil quantity out of the closed circuit when the machine is driving (∆p between the two sides of the closed
circuit).
Leakage in the individual components of the circuit are replaced by the charge circuit through the boost
check valves in the travel pump.
The charge pumps draw hydraulic oil out of the tank and deliver it through the hydraulic oil filter and the
charge pressure relief valve to the boost check valves in travel and vibration pumps. The machine is
fitted with two charge pumps. One pump is integrated in the vibration pump and the other pump is driven
by the auxiliary output of the engine and serves primarily as steering pump.
The charge circuit provides the oil for the charge system and the control functions in the closed circuits
for travel and vibration drive, as well as to release the parking brakes and to change the travel speed
ranges.
The travel motor in the axle is desired with variable displacement. The operator can choose from two
different travel speed ranges.
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Service Training
Travel pump
The travel pump is a swash plate operated axial piston pump with variable displacement, most suitable
for applications in hydrostatic drives with closed circuit.
M4 M5
2
A from/to
Travel motor
25 bar 4
3
1
from/to
Travel motor
B
Charge pressure to vibration pump
Charge pressure from hydraulic oil filter
Fig. 2: Hydraulic diagram of travel pump
1 Pump drive 3 Charge pressure relief valve

2 Servo control 4 Multi-function valves
BW 211 / 212 / 213 D-40 -E3-
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Service Training
The travel pump delivers the hydraulic oil to the motors on rear axle and drum. The pump flow is
proportional to the pump speed (output speed of diesel engine) and the actual displacement (swashing
angle of swash plate) of the pump.
7 1
6
5
Fig. 3: Travel pump
1 Control lever 5 Cylinder block

2 Drive shaft 6 Valve plate
3 Swash plate bearing 7 Control piston
4 Pistons with slipper pads
With the servo control the swashing angle can be infinitely adjusted from neutral position (0) to both
maximum displacement positions.
When altering the swash plate position through the neutral position, the oil flow will be reversed and the
machine will drive to the opposite direction.
All valves as well as the safety and control elements needed for operation in a closed circuit, are
integrated in the pump.
Note:
These machines are equipped with two charge pumps.
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Service Training
Cross-sectional view of travel pump
2
4
5
1 3
9
10
8
11
Fig. 4: Cross-sectional view of travel pump
1 Retainer for swash plate 7 Swash plate bearing

2 Sliding block 8 Swash plate guide
3 Control piston 9 Swash plate
4 Servo arm 10 Swashing lever
5 Servo valve 11 Charge pump (only in vibration pump)
6 Feedback device
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Service Training
View of the rotating group
4 3
5
Fig. 5: Travel pump, view of the rotating group
1 Working pistons
2 Slipper pad
3 Pre-tensioning spring
4 Cylinder block
5 Drive shaft
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Service Training
Description of function
2 3 4 5 6
1
8 6 7
Fig. 6: Function of travel pump
1 Drive shaft 5 Cylinder block

2 Drive shaft bearing 6 Multi-function valves
3 Swash plate 7 Charge pump (only in vibration pump)
4 Pistons with slipper pads 8 Valve plate
The drive shaft (1) is directly driven by the diesel engine via an elastic coupling. the shaft turns the tightly
connected cylinder block (5).
With the rotation of the drive shaft (1) the cylinder block (5) moves the working pistons (4). The slipper
pads of the working pistons abut against the swash plate (3).
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Service Training
When moving the swash plate out of neutral position, the working pistons will perform a stroke
movement with every rotation of the cylinder block.
The slipper pads are hydrostatically balanced and are retained on the sliding face of the swashing cradle
by a retaining device.
During a full rotation of the cylinder block each working piston will move through the bottom and top dead
centre back to the initial position. During this movement each piston performs a complete stroke.
During the piston stroke each piston draws in a certain quantity of oil from the low pressure side of the
hydraulic circuit and presses it out into the high pressure side.
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Service Training
Tandem pump
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Tandem pump, connections and adjustment points
32
Thermostat
housing
Fig. 7: Connections and adjustment points
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1 Control solenoid, high frequency (vibration pump)
2 Control solenoid, low frequency (vibration pump)
3 Multi-function valve 400 bar (charging and pressure limitation), travel system
4 Charge pressure to solenoid valve for brakes and speed range selector, charging vibration
5 Multi-function valve 400 bar (charging and pressure limitation), travel system
6
7 Port L, leak oil to vibration pump
8 Travel lever
9 Pressure test port, pilot pressure
10 High pressure port B, high pressure reverse
11 Charge pressure relief valve, 26 bar
12 Adjustment screw, low frequency
13 Port L2, leak oil to tank
14 Pressure test port MB, high frequency
15 Pressure test port MA, low frequency
16 High pressure port A, low frequency
17 High pressure port B, high frequency
18 End plate with integrated charge pump (only in vibration pump)
19 Port L2
20 Adjustment screw, high frequency
21 Port D, charge pressure to filter
22 Multi-function valve 345 bar (charging and pressure limitation), vibration high frequency
23 Port S, suction line between hydraulic oil tank and charge pump
24 Multi-function valve 345 bar (charging and pressure limitation), vibration low frequency
25 Charge pressure relief valve, vibration pump (blocked)
26 Port E, charge oil from travel pump
27 Port L1, leak oil port to travel pump
28 Pressure test port MB, high pressure reverse
29 Charge oil from filter
30 Pressure test port MA, high pressure forward
31 High pressure port A, high pressure forward
32 Adjustment screw for mechanical neutral position, vibration
Thermostat housing: 33, 34, 35, 36 Leak oil port

37 cooler inlet
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Service Training
servo control
The servo control (mechanical – hydraulic displacement control) converts the mechanical input signal
of the pump control lever into a position controlling output signal. This position controlling signal
determines the swashing angle of the swash plate (the displacement of the pump), as well as the
swashing direction (flow direction of the pressure fluid).
The flow quantity delivered by the variable displacement pump is proportional to the value of the
mechanical input signal. A mechanical feedback device ensures the fixed correlation between the
mechanical input signal and the swashing angle of the swash plate (displacement of pump).
Servo cylinder
Control piston
Sliding block
Servo arm
Fig. 8: Control piston
A mechanical safety device (spring) makes sure that a too fast lever movement will not cause any
damage to the servo control.
The pump displacement can be adjusted by actuating the pump control lever via travel lever and travel
control cable. This requires only very little manual forces and only a slight movement of the lever.
Since the control is spring centred, the swash plate will automatically return to neutral position under the
following conditions, thereby interrupting the oil flow and braking the machine:
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• when shutting the engine down,
• if the external control cable comes loose,
• if the pressure in the charge circuit drops below a certain value.
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Service Training
Multi-function valves
High pressure limitation
Pumps of series 90 are equipped with so-called multi-function valves, which activate a pressure override
and a pressure relief valve, one after the other.
1 2
3
A
6 5
B
4
Fig. 9: Multi-function valves
1 to the control 6 Drive shaft

2 Multi-function valve 7 to the control piston
3 Charge pump 8 to the control piston
4 Charge pressure relief valve A Port A
5 Pilot pressure relief valve B Port B
If the adjusted pressure is reached, the pressure override will move the swash plate quickly back
towards neutral position, thereby limiting the system pressure. The average response time is less than
90 ms.
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In case of a very quick increase in pressure (pressure peaks) the system utilizes the function of the
pressure relief valves as a protection for the hydraulic systems. In such a case the pressure override
works as a pre-control unit for the control piston of the pressure relief valve. The pressure level of the
high pressure relief valve is higher than the pressure level of the pressure override. The high pressure
relief valves will only respond if the pressure override is not able to swash the pump back quick enough
in case of sudden pressure peaks.
2 3
4
5
1
6
9 7
8
10
11
Fig. 10: Multi-function valve, details
1 Reducing fitting 7 Check valve

2 Hydraulic by-pass piston 8 Pressure limitation
3 Spring plate 9 Spring
4 Spring 10 By-pass housing
5 High pressure relief valve 10 By-pass sleeve
6 Valve seat
Pressure override and high pressure relief valve are both parts of the multi-function valve, which is
screwed into the pump.
With its possibility to swash the swash plate inside the pump back within a period of 90 ms, the pressure
override makes sure that the high pressure relief valves will only respond in exceptional cases. This
protects the hydraulic circuit against overheating and reduces the load on the diesel engine.
Note:
The multi function valves must be tightened with a torque of 89 Nm!
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Service Training
Charge pressure relief valve
The machines are equipped with two charge pumps, one driven by the auxiliary output of the engine
(steering and charge pump) and the other pump is integrated in the vibration pump.
The pressures of both pumps are limited by a charge pressure relief valve.
The charge pressure relief valve is a direct acting valve with fixed adjustment and is part of the safety
elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted
value (26 bar).
The charge circuit compensates leaks and flushing quantities in the closed travel and vibration circuits
and provides the necessary pressure to control the travel and vibration pumps and to operate the multi-
disc brakes in the travel drives.
Since feeding of cool and filtered oil is only possible in the low pressure side of the closed circuit, the
pressure in the low pressure side is almost identical with the pressure in the charge circuit.
When parking the machine on level ground with the engine running, the pressures in both sides of the
closed circuit are identical (charge pressure).
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Service Training
Flushing valve
Fig. 11Cross-section of flushing valve
1 Flushing spool
2 Flushing pressure relief valve
The flushing valve is integrated in the axle drive motor. In case of a pressure increase in one of the two
sides of the closed circuit the flushing valves have the function to flush a certain quantity of oil out of the
low pressure side.
The valve is operated by the pressure difference between the two sides of the closed circuit (A and B).
If the pressure in one side is higher than in the other, this pressure will move the valve out of neutral
position against the neutral setting spring. Oil can now flow out of the low pressure side. This oil flows
through a thermostat valve back to the tank. The oil quantity flushed out of the closed circuit is
immediately replaced by oil entering from the charge circuit through the corresponding boost check
valve (part of the multi-function valve).
In this way the closed travel circuit is permanently supplied with cool and filtered oil and the temperature
household of the hydraulic system is maintained at a permissible level.
BW 211 / 212 / 213 D-40 - E 17 -
008 910 32 BOMAG 201

Service Training
Axle drive motor,
The axle drive motor is a swash plate controlled axial piston motor of series 51 D 110 with variable
displacement.
5 7 8
6
9
11
10
4
2
Fig. 12: Axle drive motor,
1 Control piston 7 Cylinder block

2 Flushing valve 8 Universal joint
3 Control 9 Output shaft
4 Spindle with ball 10 Output shaft bearing
5 Qmin-screw 11 Working piston
6 Valve plate
BW 211 / 212 / 213 D-40 - E 18 -
202 BOMAG 008 910 32

Service Training
The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle
between cylinder block and output shaft.
With a large angle position the motor works with maximum displacement, slow speed and high torque.
When changing the swash plate position to minimal angle the motor works with minimum displacement,
high speed and low torque.
The displacement is changed by a control piston, which is tightly connected with the valve segment.
Changing of the displacement is accomplished by pressurizing the corresponding control piston side
with pressure oil from the charge circuit via a 4/2-way solenoid valve.
Function
The motor is connected with the travel pump via the high pressure ports A and B. The hydraulic oil flows
under high pressure through the corresponding port to the back of the working pistons. Since the
working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a
stroke movement, thereby causing a rotation of the output shaft.
Once the respective piston has passed its dead centre (max. extended position), it will change to the
low pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is
thereby displaced out of the cylinder chamber through the low pressure side back to the pump.
The synchronizing shaft with roller surfaces ensures uniform rotation of output shaft and cylinder block.
The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the
connection between output shaft and pistons no other parts are required. The output shaft runs in two
tapered roller bearings.
BW 211 / 212 / 213 D-40 - E 19 -
008 910 32 BOMAG 203

Service Training
Rear axle
Releasing the axle drive brake manually (on both axle drive designs)
For manual releasing of the brakes on the rear axle you should proceed as follows:
Fig. 13: Manual releasing of rear axle brakes
• Slacken the counter nut (Fig. 14, Pos. 1) and back it off by approx. 8 mm.
• Turn the brake releasing screw (2) in against the stop.
• To release the brake tighten the screw for max. 1 complete turn.
Attention!
Turn the screws on both sides in uniformly (alternately by 1/4 of a turn)
• Repeat this procedure on the opposite side of the axle.
BW 211 / 212 / 213 D-40 - E 20 -
204 BOMAG 008 910 32

Service Training
Front drum drive motor: Radial piston motor MSE 18 2 CX
On single drum rollers of series D-40 the drum is driven by a hydraulic radial piston motor.
These drum drive motors consist of three housing parts, the flat distributor, the cylinder block with the
working pistons and the output shaft.
2 3
4
1
43090070
6 5 4 5
Fig. 14: Drum drive motor
1 Drive shaft with output flange

2 Piston with roller
3 Oil distributor
4 Cylinder block
5 Cam ring
6 Bearing plate
The housing consists of:
BW 211 / 212 / 213 D-40 - E 21 -
008 910 32 BOMAG 205

Service Training
• bearing section (drive shaft bearings),
• torque section (cam race) and
• oil distributor.
Pressure oil flows through the flat distributor to the working pistons in the cylinder block. This pressure
oil presses the working pistons with the rollers against the cam race of the torque section and forces the
rollers to roll along the cam race.
This transforms the axial movement of the pistons to a radial movement of the cylinder block. The
cylinder block transfers this rotation via a splined connection to the output shaft.
The output shaft runs in two tapered roller bearings. It transfers the rotary movement via the drive disc
and the rubber elements to the drum.
The function of the radial piston motor is described hereunder. The piston positions described in this
explanation can be seen in the related illustration.
The movement of a piston along the cam race must be examined in several phases during a full rotation:
2
3
Fig. 15: Function of the radial piston motor
BW 211 / 212 / 213 D-40 - E 22 -
206 BOMAG 008 910 32

Service Training
Piston position 1:
The oil enters into the oil distributor under pressure, flows through the distributor and presses against
the piston. The rotation starts at this point. The pressure applied to the back of the piston moves the
roller along the cam and causes a rotation of the cylinder block.
Piston position 2:
At this point the opening cross-section for the oil flow to the piston has reached its maximum size. The
piston continues his travel along the cam race towards the valley between two cams. As the movement
continues the opening cross-section for the oil supply decreases.
Piston position 3:
Once the piston has reached the bottom of the valley, the oil flow to the piston is interrupted. The piston
is no longer driven. It has reached its dead centre. Now another piston must be driven to move the first
piston out of the dead centre.
Piston position 4:
Other driven pistons now move the first piston out of the dead centre. The oil behind the piston is now
connected with the low pressure side and the reverse movement of the piston presses the oil back to
the pump.
Piston position 5:
The pumping movement of the motor back to the pump comes to an end, the connecting bore between
cylinder chamber and low pressure side closes again. The piston will now reach its second dead centre
position. This point is the start of a new working cycle.
Reversing the oil flow reverses also the rotation of the motor.
The output shaft runs in two tapered roller bearings. It transmits the rotary movement via the drive disc
and the rubber elements to the drum.
BW 211 / 212 / 213 D-40 - E 23 -
008 910 32 BOMAG 207

Service Training
Travel circuit: Drum drive with radial piston motor
1
4
6 1
n
ctio 1 Travel pump
i r e
ld 2 Vibration pump
e
av 3 Travel lever
Tr 4 Hydraulic oil filter
High pressure 5 Rear axle
Low pressure 6 Axle drive motor
7 Drum drive motor
Charge pressure
8 Hydraulic oil tank
Leak oil (case pressure)
Fig. 16: Single drum rollers D-40, travel circuit, hose installation
BW 211 / 212 / 213 D-40 - E 24 -
208 BOMAG 008 910 32

Service Training
Brake control: Travel motor in axle
Brake valve
Charge pressure
Brake releasing pressure
Leak oil
Fig. 17: Brake circuit
BW 211 / 212 / 213 D-40 - E 25 -
008 910 32 BOMAG 209

Service Training
Travel drive, components and test points
Travel pump:
2
2 1
1
diagram
1 Test port, forward 10, MD max. 426 bar
2 High pressure port, forward 10, A
3 Charge pressure port 7, MA 26 bar
BW 211 / 212 / 213 D-40 - E 26 -
210 BOMAG 008 910 32

Service Training
Travel pump: right hand side
2 3
1
diagram
1 Test port, reverse 10, MC max. 426 bar
2 High pressure port, reverse 10, B
3 Travel control (travel control cable)
BW 211 / 212 / 213 D-40 - E 27 -
008 910 32 BOMAG 211

Service Training
Front travel motor, without brake (radial piston motor)
2 1
2 1
45 3
4
6
3

diagram
1 High pressure port, forward 12, L
2 High pressure port, reverse 12, R
3 Cross-flushing of travel pump T1 12
4 Leak oil port 12, 1
BW 211 / 212 / 213 D-40 - E 28 -
212 BOMAG 008 910 32

Service Training
Rear travel motor: Axle motor
1
4
3 2
6
5
7

diagram
1 Solenoid for speed range selector Y31 14 Motor Qmax---
valve depressurized,
Motor Qmin---
26 bar
2 Flushing valve 14
3 High pressure port, drum drive 14, A
motor forward
4 High pressure port, drum drive 14, B
motor reverse
5 High pressure from travel pump 14, A
forward
6 High pressure from travel pump 14, B
reverse
7 Qmin- setscrew 14
BW 211 / 212 / 213 D-40 - E 29 -
008 910 32 BOMAG 213

Service Training
Brake valve
11

diagram
1 Brake valve Y 04 08, open, 12V closed,
de-energized
BW 211 / 212 / 213 D-40 - E 30 -
214 BOMAG 008 910 32

Service Training
Travel lever console
BW 211 / 212 / 213 D-40 - E 31 -
008 910 32 BOMAG 215

Service Training
Travel lever

diagram
1 Initiator for backup alarm B14 0 / 12V, normally
closed
2 Initiator for brake B13 Normally closed,
opened in braking
position
0/12V
BW 211 / 212 / 213 D-40 - E 32 -
216 BOMAG 008 910 32

Service Training
Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The numerical values specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
Machine travels with travel lever in 'Neutral'

Machine does not drive (forw. and reverse)
Machine drives to one direction only
Max. travel speed not reached

TROUBLE SHOOTING TRAVEL
Hydraulic oil overheating

SYSTEM
BW 211 / 212 / 213 D-40
SYMPTOMS
POSSIBLE CAUSES
Brake valve (electric/mechanical/hydraulic) 1
Brake in axle-drive motor (mechanical/hydraulic) 2 2 3
Travel speed range switch position /defective/wiring 1
Charge pump / charge pressure relief valve(s)
2 3
dirty/defective
Pump control (servo control) 2 1 2 3
Pressure override/ travel pump high pressure limitation
3 2 3 3
dirty/out of adjustment/defective
Adjustment of travel cable 1 2
Travel pump mechanical neutral 3 3
Travel pump(s) defective 3 3 2
Axle drive motor control valve (electric / mechanical / hydraulic) 1 2
Flushing valve axle drive motor seized 3
Travel motor(s) defective 3 3
Hydraulic oil cooler soiled (internally/externally) 1
Thermostat (hydraulics) soiled/jammed/defective 2
Clutch- Dieselmotor-Pumpe 2
Dieselmotor 1
BW 211 / 212 / 213 D-40
008 910 32 BOMAG 217

Service Training
Vibration system
The vibration system of the single drum rollers of generation D-40 works with two frequencies and two
amplitudes. This enables perfect adaptation of the machine to various types of soil and different
applications.
The vibration drive is a closed hydraulic circuit. The circuit consists of:
• the vibration pump,
• the vibration motor and
• the pressure resistant connecting hoses
from charge pump via to release the brake

Travel pump
Charge oil
D
Vibration pump
M3 E
L2 N
Block
M1
M2
S
B
2
1
M4
M5
Fig. 1: Vibration circuit
1 Vibration pump
2 Vibration motor
BW 211 / 212 / 213 D-40 -F1-
218 BOMAG 008 910 32

Service Training
Vibration pump and travel pump are joined together to a tandem pump unit. This tandem unit is directly
driven by the diesel engine.
When operating a 4/3-way solenoid valve on the pump control the pump is actuated out of neutral
position to one of the two possible displacement positions, pilot oil from the charge circuit is guided to
one of the two control piston sides. The swash plate inside the pump will swash to the corresponding
side and the pump will deliver oil to the vibration motor. The vibration motor starts and rotates the
vibrator shaft inside the drum.
When altering the position of the swash plate through the neutral position to the opposite side, the oil
flow will change its direction and the vibration motor will change its sense of rotation.
Since the end stops for the swash plate are set to different swashing angles to both directions, the angle
for the piston stroke is also different to both sides. This angle influences the length of the piston stroke
and thereby the actual displacement of the pump.
• Large angle = high displacement = high vibrator shaft speed (frequency)
• Small angle = low displacement = slow vibrator shaft speed (frequency)
The eccentric weights on the vibrator shaft are fitted with additional change-over weights. Depending
on the sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic
weights.
This results in the following constellations:
• Basic weight + change-over weight = high amplitude
• Basic weight - change-over weight = low amplitude
In order to achieve effective compaction results the vibration system is designed in such a way, that high
amplitude is coupled with low frequency and low amplitude with high frequency.
Fig. 2:
BW 211 / 212 / 213 D-40 -F2-
008 910 32 BOMAG 219

Service Training
Vibration pump
Similar to the travel pump the vibration pump is also a swash plate operated axial piston pump with
variable displacement for operation in a closed circuit.
The displacement of the pump is proportional to the engine speed and the chosen displacement.
When actuating the swash plate out of neutral position the flow quantity to the chosen direction will
increase from ”0” to the maximum value. When altering the position of the swash plate through the
neutral position to the opposite side, the oil flow will change its direction and the vibration motor will
change its sense of rotation. All valves and safety elements for operation in a closed circuit are
integrated in the pump.
from charge pump via Releasing the brake

Travel pump
Charge oil
Vibration pump
D M3 E
1 Vibration pump
L2 N 2 Charge pump
3 High pressure limitation
Block
4 4/3-way solenoid valve
A
M1
M2
S
B
M4
M5
Fig. 3: Hydraulic diagram vibration pump
BW 211 / 212 / 213 D-40 -F3-
220 BOMAG 008 910 32

Service Training
Function
1 2
5 4 3
Fig. 4Cross-section of vibration pump
1 Servo piston
2 Working pistons
3 Charge pump
4 Valve plate
5 Roller bearing
6 Swash plate
BW 211 / 212 / 213 D-40 -F4-
008 910 32 BOMAG 221

Service Training
1
2
5
4 3
Fig. 5 Cross-section of vibration pump
1 Control
2 Servo piston
3 Friction free swash plate bearing
4 Attachment plate
5 Spool valve
The engine drives the drive shaft with the cylinder block. The cylinder block carries the working pistons.
The slipper pads rest against the sliding surface of the swash plate and are at the same time held on
the sliding surface by a retaining device.
During each rotation the piston pass through their upper and lower dead centre back to their initial
position. Between both dead centres each piston performs a full working stroke. During this stroke
movement oil is drawn in from the low pressure side of the closed circuit and pressed out through the
slots in the valve plate into the high pressure side. The oil quantity depends on the piston area and the
length of the working stroke.
BW 211 / 212 / 213 D-40 -F5-
222 BOMAG 008 910 32

Service Training
During the suction stroke the oil is drawn into the piston chamber, i.e. the charge pressure forces it into
the piston chamber. On the opposite side the piston presses the oil out into the high pressure side of he
closed circuit.
Control
The electro-hydraulic displacement control (remote control) converts the electric input signal to a load
controlling output signal. Since the pump is not equipped with a proportional control, but a 12 Volt
solenoid valve, the pump is always actuated to one of the two end stop positions.
Charge pumps
These machines are equipped with two charge pumps.
One of the pumps is an external gear pump, which is directly driven by the auxiliary output of the engine
and serves also as steering pump.
The second pump is an internal gear pump and is located in the end cover of the vibration pump.
The oil flow generated by the charge pumps is joined together with the return flow from the steering
valve before the hydraulic oil filter and flows through the filter to the charge ports on travel pump and
vibration pump.
BW 211 / 212 / 213 D-40 -F6-
008 910 32 BOMAG 223

Service Training
High pressure relief valves
As a measure to protect the closed vibration circuit against to high pressures the vibration pump is fitted
with pressure relief valves.
Fig. 6Pressure relief valve
1 From the charge pump

2 Closed circuit
3 High pressure relief valve with
integrated boost check valve
Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the
vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this
phase. The high pressure relief valve reduces these pressure peaks to a value of max. 371 bar
(pressure difference between high and low pressure side = 345 bar + charge pressure = 26 bar).
The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the
closed vibration circuit. The function of these valves has already been described in the chapter "travel
system".
BW 211 / 212 / 213 D-40 -F7-
224 BOMAG 008 910 32

Service Training
Vibration motor
The vibration motor is a Bosch-Rexroth (Hydromatik) axial piston motor of series A10FM 45 with fixed
displacement in bent axle design. Since the motor can be subjected to pressure from both sides, it is
most suitable for the use in closed hydraulic circuits.
The output speed of the motor depends on the oil quantity supplied by the vibration pump.
2 3
4 5
1
8 7
10 9
Fig. 7Cross-section of vibration motor
1 Flushing valve block

2 Flushing valve
3 Working pistons with slipper pads
4 Roller bearing for output shaft
5 Radial seal
6 Output shaft
7 swash plate
8 Retaining plate
9 Pre-tensioning spring
BW 211 / 212 / 213 D-40 -F8-
008 910 32 BOMAG 225

Service Training
The output torque raises with increasing pressure difference between low and high pressure side in the
closed circuit.
Changing the flow direction of the oil will also change the sense of rotation of the vibration motor.
When switching the vibration on the motor must first start to move the resting vibration shaft. This
resistance causes a hydraulic starting pressure, which is limited to 345 bar by the corresponding high
pressure relief valve. Once the vibrator shaft has reached its final speed, the pressure will drop to a
value between 100 and 150 bar (operating pressure). The value of the operating pressure mainly
depends on the condition of the ground (degree of compaction, material etc.).
• Hard ground = High operating pressure
• Loose ground = Low operating pressure
A MA
3 1
B MB
Fig. 8Circuit diagram of vibration motor
1 Vibration motor
2 Flushing valve
BW 211 / 212 / 213 D-40 -F9-
226 BOMAG 008 910 32

Service Training
The vibration motor is equipped with an integrated flushing valve. When switching the vibration on a
pressure difference will appear between the two sides of the closed circuit. The higher pressure moves
the valve spool of the flushing valve against the neutral setting spring, so that oil can flow out of the low
pressure side.
1
A
Fig. 9 Flushing valve
1 Flushing spool
2 Flushing pressure limitation valve
The flushing valve is fitted with a downstream 13 bar pressure relief valve. This valve ensures that only
a certain quantity of hydraulic oil is flushed out of the low pressure side.
This oil flows via a thermostat valve back to the hydraulic tank. The flushed out oil is immediately
replaced with fresh and filtered oil through the corresponding boost check valve.
BW 211 / 212 / 213 D-40 - F 10 -
008 910 32 BOMAG 227

Service Training
Drum
4
14
5 9
7 13
6
10
3 8 11
12
Fig. 10Cross-section of drum
1 Drum shell 8 Change-over weight

2 Vibration bearing 9 Coupling vibr.-motor – vibrator shaft
3 Basic weight 10 Travel bearing
4 Vibrator housing 11 Travel bearing housing
5 Cooling fan 12 Rubber buffer
6 Vibrator shaft 13 Vibration motor
7 Elastic coupling between shafts 14 Flanged bearing housing
BW 211 / 212 / 213 D-40 - F 11 -
228 BOMAG 008 910 32

Service Training
Vibration system: Components and test ports
Vibration pump
11
2
3
2
5 6 3
6
5 4
4
diagram
1 Pressure test port, charge pressure MA 26 bar
2 Hydraulic oil filter (charge circuit) 07
with visual pressure differential
indicator
3 High pressure port, low MF
amplitude
4 High pressure port, high ME
amplitude
5 Solenoid valve, low amplitude Y08 12V / 3,33A
6 Solenoid valve, high amplitude Y07 12V / 3,33A
BW 211 / 212 / 213 D-40 - F 12 -
008 910 32 BOMAG 229

Service Training
Vibration pump

diagram
1 Pressure test port, vibration MF max. 371 bar
pressure low amplitude
2 Pressure test port, vibration ME max. 371 bar
pressure high amplitude
low amplitude high amplitude
BW 211 / 212 / 213 D-40 - F 13 -
230 BOMAG 008 910 32

Service Training
Vibration motor

diagram
1 High pressure port, high amplitude 16
2 High pressure port, low amplitude 16
3 Leak oil and flushing oil port 16 approx. 7 l/min,
incl. flushing
quantity
4 Flushing spool 16
5 Flushing valve 16 13 bar
BW 211 / 212 / 213 D-40 - F 14 -
008 910 32 BOMAG 231

Service Training
Trouble shooting
Procedure:
No vibration (charge pressure OK)

Vibration only with one amplitude
Exciter shaft speed too low
TROUBLE SHOOTING
VIBRATION
BW 211 / 212 / 213 D-40
SYMPTOMS
POSSIBLE CAUSES
Vibration switch (amplitude pre-selection) 1 1
Vibration push button (on/off) 1
Electrics defective / wiring 2 2
Pump control (electrical / hydraulic) 1 1
Pressure override / high pressure relief valves in vibration pump
2
soiled/out of adjustment/ defective
Charge pump / charge pressure relief valve
2
soiled/ defective
Vibration pump frequency adjustment 2
Vibration pump defective 2 2
Coupling between diesel engine and travel pump defective
Exciter shaft bearings defective 3
Vibration motor coupling defective 2
Vibration motor defective 2 1
Diesel engine 1
BW 211 / 212 / 213 D-40
232 BOMAG 008 910 32

Service Training
Steering
Single drum rollers of series BW 211 / 212 / 213 D-40 are equipped with a hydrostatically operated
articulated steering system.
The steering system mainly consists of steering pump, steering valve, steering cylinders and pressure
resistant connecting hoses.
to charge
system
1
7
6
5
3
2
4
from steering pump
Fig. 1Steering hydraulics
1 Rating pump
2 Distributor valve
3 Steering pressure relief valve (∆p =175 bar)
4 Check valve (pre-loaded to 0.5 bar)
5 Anti-cavitation valve
6 Shock valves (240 bar)
7 Steering cylinders
The steering pump draws the hydraulic oil out of the hydraulic oil tank and delivers it to the steering valve
and the connected steering unit under the operator's platform of the machine. If the steering is not
operated, the complete oil supply will flow through the fine filter to the charge system for the closed travel
circuits.
When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side
of the steering cylinder. A rating pump inside the steering unit measures the exact oil quantity
corresponding with the turning angle of the steering wheel and delivers the oil to the steering cylinders.
The steering cylinders retract or extend and steer the machine.
The steering unit is equipped with a pressure relief valve. This valve limits the steering pressure to 175
bar. The charge pressure must, however, be added to this value, because the oil leaving the steering
system enters the charge circuit. The actual steering pressure is therefore approx. 200 bar.
BW 211 / 212 / 213 D-40 -G1-
008 910 32 BOMAG 233

Service Training
Steering pump
The steering pump is a gear pump with fixed displacement. It is driven by the auxiliary drive of the diesel
engine, draws the hydraulic oil out of the hydraulic oil tank and pumps it through the steering valve to
the steering cylinders or to the boost check valves for travel and vibration circuits.
9 9 6 1 7
8
2
4 5
Fig. 2Steering pump
1 Housing
2 Flange
3 Shaft
4 Bearing plate
5 Bearing plate
6 Cover
7 Gear (driving)
8 Gear (driven)
9 Seals
BW 211 / 212 / 213 D-40 -G2-
234 BOMAG 008 910 32

Service Training
Working principle of the gear pumps
The drive gear of the steering pump is connected with the auxiliary drive of the diesel engine via a
coupling. Drive gear and driven gear are positioned by a bearing plate in such a way, that the teeth of
both gears mesh with minimum clearance when rotating.
The displacement chambers are created between the tooth flanks, the inside wall of the housing and
the faces of the bearing plates.
When the pump is running the chambers transport hydraulic oil from the suction side to the pressure
side. This causes a vacuum in the suction line by which the hydraulic oil is drawn out of the tank. The
tooth chambers transport the fluid to the outlet of the pump from where it is pressed to the consumers.
To ensure a safe function of the pump the tooth chambers must be so tightly sealed that the hydraulic
fluid can be transported from the suction side to the pressure side without any losses.
For this purpose external gear pumps are fitted with gap seals. This causes pressure dependent fluid
losses from the pressure side to the suction side. As a measure to ensure that these losses are reduced
to a minimum, the bearing plate on the cover side is pressed against the faces of the gears by an axial
pressure field.
This pressure field is always under the actual system pressure.
BW 211 / 212 / 213 D-40 -G3-
008 910 32 BOMAG 235

Service Training
Steering valve
The steering valve block consists mainly of distributor valve, measuring pump, pressure relief valve and
shock valves.
9 2
5
8
Fig. 3Cross-sectional view of steering valve
1 Neutral setting springs

2 Housing
3 Inner spool
4 Outer spool
5 Universal shaft
6 Ring gear
7 Gear
8 Check valve
9 Pressure relief valve
When turning the steering wheel the distributor valve guides the oil flow from the pump to the rating
pump. The rating pump guides the oil flow through the distributor valve to the corresponding
sides of the steering cylinders. The rating pump measures the exact oil quantity in accordance with the
rotation angle of the steering wheel.
This oil flow to the steering cylinders articulates the machine and causes a steering movement.
BW 211 / 212 / 213 D-40 -G4-
236 BOMAG 008 910 32

Service Training
240 bar
∆p = 175 bar
240 bar
0,5 bar
Fig. 4Steering valve, hydraulic diagram
The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar.
The charge pressure value must be added to this pressure, because the oil leaving the steering system
is fed into the charge circuit for the closed travel circuits.
The steering unit is fitted with so-called shock valves in each supply line to the steering cylinder. These
valves are adjusted to an opening pressure of 240 bar. The valves compensate extreme pressure peaks
which may occur, e.g. when driving over obstructions, and protect the system against overloads.
Each of these shock valves is fitted with an additional anti-cavitation valve. If the shock valves respond
these anti-cavitation valves protect the system against cavitation damage.
A check valve at the inlet of the steering unit makes sure that no oil will flow back to the pump in case
of pressure peaks caused by sudden steering movements. In such a case the steering cylinders would
act as pumps and press the oil back to the pump.
BW 211 / 212 / 213 D-40 -G5-
008 910 32 BOMAG 237

Service Training
Articulated joint
Front and rear frames of the single drum rollers are connected by an oscillating articulated joint. This
ensures that drum and wheels are at all times in contact with the ground, even when driving extreme
curves.
Fig. 5Articulated joint
BW 211 / 212 / 213 D-40 -G6-
238 BOMAG 008 910 32

Service Training
The rear console is tightly bolted to the rear frame.
The front console is fastened with screws to the rear cross-member of the front frame. The use of rocker
bearings between front and rear frame ensures that both frames can oscillate to each other for +/- 12°.
This gives drum and wheels excellent ground contact, even under extremely severe conditions.
The front console is connected with the rear console by two vertical bolts. The vertical bolts are mounted
in friction bearings.
The steering cylinder anchor point is welded to the front console.
When turning the steering wheel the steering cylinder will extend or retract. The piston rod swivels the
front console around the vertical bolts. This articulates the machine and results in a steering movement.
All bearings on the articulated joint are maintenance free and do not require any lubrication.
Notes on assembly:
When assembling or repairing the articulated joint the correct pretension of the centre pin is of highest
importance.
Please follow the instructions in the repair manual for the articulated joint.
BW 211 / 212 / 213 D-40 -G7-
008 910 32 BOMAG 239

Service Training
Steering: Components and test ports
Steering pump

diagram
1 Steering pump (and charge pump) 09
2 Steering pressure test port MB max. 175+26 bar
BW 211 / 212 / 213 D-40 -G8-
240 BOMAG 008 910 32

Service Training
Vibration and noise damper
The damper is located in the steering/charge circuit directly after the steering and charge pump.
It is subjected to hydraulic oil flow and has the function of eliminating any vibrations and noises.
The damper is mounted to the front plate of the rear frame, between both steering cylinders.
BW 211 / 212 / 213 D-40 -G9-
008 910 32 BOMAG 241

Service Training
Steering valve
The steering valve is located under the operator's stand
BW 211 / 212 / 213 D-40 - G 10 -
242 BOMAG 008 910 32

Service Training
Trouble shooting
Procedure:
TROUBLE SHOOTING STEERING

SYSTEM
BW 211 / 212 / 213 D-40
End stops are not reached
Steering hard to move
No steering function
SYMPTOMS
POSSIBLE CAUSES
Steering orbitrol valve 2 2 1
Steering/charge pump 1 1 2
Steering cylinder 3 3 3
Articulated joint 3 3 2
BW 211 / 212 / 213 D-40
008 910 32 BOMAG 243

Service Training
Electrics: Single drum rollers D-40
This chapter describes the peculiarities in the electric system and the necessary adjustments. This
instruction solely describes the electrical testing of D-40 machines belonging to single drum roller
series.
Function test:
Turn the ignition key to "Ignition ON".
• The round gauge runs a 3 second self test.
• All control lights are active during this time.
• Brake control light (travel lever in braking position), charge control light (engine stopped) and oil
pressure warning light (engine off) are active.
Warning and control lights are integrated in the instrument cluster!
Table 1: Inspection of display and shut-down functions
Control light Warning buzzer Shut down time Shut down time
10 s 2min
Water separator X X X
Fuel filter
Engine oil X X X
pressure
Coolant X X X
temperature
BW 211 / 212 / 213 D-40 H1
244 BOMAG 008 910 32

Service Training
Instrument cluster
Electric control cabinet with vibration module
Vibration module
BW 211 / 212 / 213 D-40 H2
008 910 32 BOMAG 245

246 BOMAG 008 910 32

Translation
Operating hour meter: Red 7-segment display
Holding strap: Steel, galvanized and yellow chromium coated
Foil: Dead Front (black RAL 9005)
Front screen: Printed, scratch-proof plastic foil (polyester resin)
Imprint: White RAL 9010
Printed symbol: Black Dead Front
Housing: Impact-proof plastic made of PBT GF20
Cover: Polycarbonate black
Knurled nut: Polyamide
Rated voltage: 12V
Operating voltage: 8V to 32V
Lights 1 - 12: 4 x SMD-Top-LED with max. 12oo mcd/mm
Fuel level gauge: LED-bar display (9 x green, 1 x red)
Degree of protection: Front side IP 67, back side IP 54
Operating temperature -40°C to +90°C
Storage temperature: -25°C to +85°C
Plug: Connection by means of 20 pin TYCO (1-174960-1)
plug and sealable 4-pin programming and service plug
008 910 32 BOMAG 247

Plug assignment with operating hour meter
Pin- Function
Number
1 OUT 1
2 Bar graph
3 Water separator L9
4 Water separator L9
5 L10
6 Low Active Preheating L11
7 High Active Hazard light L12
8 High Active Day + Night switching all LEDs and 7-segment display
9 OUT 2
10 -BATT/GND
11 High Active Brake L1
12 L2
13 L3
14 High Active Charge control L4
15 L5
16 Low Active Oil pressure L6
17 Low Active Engine temperature L7
18 High Active Direction indicator 1 L8
19 High Active Direction indicator 2 L8
20 + BATT
248 BOMAG 008 910 32

4.3 Speedometer Module
008 910 32 BOMAG 249

250 BOMAG 008 910 32

Speedometer Module 4.3
008 910 32 BOMAG 251

252 BOMAG 008 910 32

4.4 Vibration module
008 910 32 BOMAG 253

254 BOMAG 008 910 32

Vibration module 4.4
008 910 32 BOMAG 255

256 BOMAG 008 910 32

5 Air conditioning system
008 910 32 BOMAG 257

5.1 Notes on safety for the air conditioning system
5.1 Notes on safety for the air con- according to paragraph 32. . In this case
periodically recurring inspections consist of external
ditioning system examinations, normally on containers in opera-
tion . The refrigerant container must be vis-
Air conditioning system ually examined twice every year in connection with
the inspection. Special attention must thereby
be paid to signs of corrosion and mechanical dam-
i Note age. If the pressure vessel is in no good condi-
In some countries the legislator demands minimum tion, it should be replaced for safety reasons, thus
requirements concerning the qualification of the main- to make sure that sufficient precautions have been
tenance personnel. In the Federal Republic of Germa- applied to protect the operator and third par-
ny refrigeration and air conditioning equipment must ties. .
Wear safety goggles! Put on your safety goggles.
sion of a so-called qualification certificate.
This will protect your eyes against coming into con-
tact with refrigerant, which could cause severe
! Danger damage by freezing.
Do not open refrigerant containers which contain l
Wear safety gloves and an apron! Refrigerant are
refrigerant! excellent solvents for greases and oils. In contact
l
When opening refrigerant containers the contents with skin they will remove the protective grease film.
may escape in liquid or vaporous state. The higher However, degreased skin is very sensitive against
the pressure in the container, the fiercer this proc- cold temperatures and germs.
ess will take place. The height of the pressure de- l
Do not allow liquid refrigerants to come into contact
pends on two conditions. 1. Which type of with skin! Refrigerant takes the heat required for
refrigerant is in the container. The following applies: evaporation from the environment. Very low tem-
The lower the boiling point, the higher the pressure. peratures may be reached. The results may be local
2. The height of the temperature. The following ap- frost injuries (boiling point of R134a -26.5°C at am-
plies: The higher the temperature, the higher the bient pressure).
pressure. l
Do not inhale higher concentrations of refrigerant
l
In a refrigerant container there must be a steam vapours! Escaping refrigerant vapours will mix with
space above the liquid space. The liquid expands the ambient air and displace the oxygen required for
with increasing temperature. The steam filled space breathing.
becomes smaller. From a certain time on the con- l
Smoking is strictly prohibited! Refrigerants may be
tainer will be filled with just liquid. After this only a
decomposed by a glowing cigarette. The resulting
minor temperature increase is enough to generate
substances are highly toxic and must not be in-
very high pressures in the container, because the
haled.
liquid would like to expand, but there is no more
room. The related forces are high enough to cause l
Welding and soldering on refrigeration equipment!
the container to burst. In order to avoid overfilling of Before starting welding or soldering work on vehi-
a container the pressure gas directive clearly spec- cles, (in the vicinity
ifies how many kilograms of refrigerant may be filled of air conditioning components) all refrigerant must
into the container per litre volume. be drawn out and the rests removed by blowing out
the system with nitrogen. The decomposition prod-
l
In case of occurring mechanical damage or corro-
ucts created from the refrigerant under the influence
sion on the refrigerant container, the container must
of heat not only are highly toxic, but also have a
be replaced, in order to prevent it from bursting and
strong corrosive effect, so that pipes and system
causing further damage.
components may be attacked. The substance is
l
Since the fluid container is pressurized, the manu- mainly fluorohydrogen.
facture and testing of these pressure vessels is gov- l
Pungent smell! In case of a pungent smell the afore
erned by the pressure vessel directive. (New edition
mentioned decomposition products have already
from April 1989). This directive classifies the pres-
been created. Extreme care must be exercised not
sure vessels into the test groups in dependence on
to inhale these substances, as otherwise the respi-
their permissible operating pressure "p" in bar, its
ratory system, the lungs and other organs may be
volume "l" in litres and the pressurized product p x
harmed.
l. On the basis of these prerequisites
the fluid containers must be classified as per testing l
When blowing out components with compressed air
group II. Paragraph 10 of the pressure vessel direc- and nitrogen the gas mixture escaping from the
tive demands that these pressure containers must components must be extracted via suitable exhaust
be periodically inspected and tested by a specialist, facilities (workshop exhaust systems).
258 BOMAG 008 910 32

Notes on repair of the air conditioning system 5.2
5.2 Notes on repair of the air con- l
Compressor oil / refrigeration oil is highly hydro-
scopic. Oil cans must strictly be kept closed until
ditioning system use. Oil rests should not be used, if the can had
been opened over a longer period of time.
Air conditioning system l
All O-rings as well as pipe and hose fittings must be
oiled withcompressor oil / refrigeration oilibefore as-
i Note sembly.
In some countries the legislator demands minimum l
requirements concerning the qualification of the main- or condenser, any compressor oil / refrigeration oil
tenance personnel. In the Federal Republic of Germa- lost by exchanging the components, must be re-
ny refrigeration and air conditioning equipment must placed with fresh oil.
A too high compressor oil / refrigeration oil level ad-
sion of a so-called qualification certificate. versely affects the cooling performance and a too
l
In case of a repair on the refrigeration system you low oil level has a negative effect on the lifetime of
should first evacuate the air conditioning system for the compressor.
at least 45 minutes to remove any moisture from the l
If a air conditioning unit needs to be opened, the
system, before you start to refill. Moisture bonded in dryer must be replaced in any case.
the compressor oil / refrigeration oil (PAG oil) can
only be removed from the system by changing the
l
Always use new O-rings when reassembling the
oil. unit.
l
During repair work on refrigerant lines and compo-
l
Always use two spanners when connecting pipes or
nents, these must be kept closed as far as possible, hoses, to prevent the pipe end from being dam-
in order to prevent the invasion of air, moisture and aged.
dirt, because the operational reliability of the system l
Tighten screw fittings with the specified torque.
can only be assured if all components in the refrig- l
Check the connections of pipes, fittings or compo-
erant circuit are clean and dry from inside.
nents thoroughly; do not use if damaged.
l
Make sure that no dirt or foreign parts can enter into l
Do not leave the refrigerant circuit unnecessarily
the compressor or the air conditioning system. The
open to the atmosphere. Do not attempt to repair
area around the refrigerant hoses should be
bent or burst pipes.
cleaned with a gasoline free solvent.
l
Compressor valves must only be opened after the
l
All parts to be reused should be cleaned with a
system has been properly sealed.
gasoline free solvent and blow-dried with clean
compressed air or dried with a lint-free cloth. l
The use of leak detection colouring matter is not
permitted, because its chemical composition is un-
l
Before opening all components should have
known and its effect on compressor oil and rubber
warmed up to ambient temperature, to avoid that
elements is not predictable. The use of leak detec-
damp air is drawn into the component by the differ-
tion colouring matter makes any warranty claims
ence in temperatures.
null and void.
l
Damaged or leaking parts of the air conditioning l
Tools used on refrigeration circuits must be of ex-
must not be repaired by welding or soldering, but
cellent condition, thus to avoid the damage of any
must generally be replaced.
connections.
l
Do not fill up refrigerant, but extract existing refrig- l
The dryer is to be installed last, after all connections
erant and refill the system.
in the refrigerant circuit have been tightened.
l
Different types of refrigerant must not be mixed. l
After completion of repair work screw locking caps
Only the refrigerant specified for the corresponding
(with seals) on all connections with valves and on
air conditioning system must be used.
the service connections. Start up of the air condi-
l
Refrigerant circuits with refrigerant type R134a tioning system. Observe the filling capacity.
must only be operated with the compressor oil / re- l
Before start up of the air conditioning system after a
frigeration oil approved for the compressor.
new filling: - Turn the compressor approx. 10 revo-
l
Used compressor oil / refrigeration oil must be dis- lutions by hand using the clutch or V-belt pulley of
posed of as hazardous waste. the magnetic clutch. - Start the engine with the com-
l
Due to its chemical properties compressor oil / re- pressor/control valve switched off. - Once the idle
frigeration oil must never be disposed of together speed of the engine has stabilized switch on the
with engine or transmission oil.
008 910 32 BOMAG 259

5.2 Notes on repair of the air conditioning system
compressor and run it for at least 10 minutes at idle

speed and maximum cooling power.
l
Never operate the compressor over longer periods
of time with high engine speeds without a sufficient
amount of refrigerant in the system. This could
probably cause overheating and internal damage.
260 BOMAG 008 910 32

Physical basics 5.3
Physical basics A - heat absorption
5.3 Physical basics
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.
008 910 32 BOMAG 261

5.3 Physical basics
Pressure and boiling point i Note

The boiling point is the temperature at which fluid At absolute pressure 0 bar correspond with an abso-
changes to gaseous state. lute vacuum. The normal ambient pressure (overpres-
Changing the pressure above a fluid also changes the sure) corresponds with 1 bar absolute pressure. On
boiling point. It is a well known fact, that e.g. the lower the scales of most pressure gauges 0 bar corre-
the pressure applied to water, the lower the boiling sponds with an absolute pressure of 1 bar (indicated
point. by the statement -1 bar below the 0).
When looking at water, the following values do apply:
l
Atmospheric pressure, boiling point 100°C
l
Overpressure 0.4 bar, boiling point 126°C
l
Vacuum -0.6 bar, boiling point 71°C
For an optimal exchange of heat, liquid refrigerants
must have a low boiling point, so that they can absorb
and dissipate heat quickly.
Fig. 4
In the pressure - temperature diagram for the refriger-
ant the drawn in closed curve shows the cycle of the
refrigerant. This cycle permanently continues in direc-
tion of the arrow.
The characters A, B, C, D stand for:
A - compression
B- condensation
Fig. 3
C- relaxation
Steam pressure curve for refrigerant R134a D- evaporation.
The steam pressure curve is a means for explaining
the operation principle of an air conditioning system.
A- liquid
B- gaseous
The diagram shows the evaporation curve of R134a.
The diagram for example shows, that R134a is liquid
at 0°C and a pressure of 5 bar, but becomes gaseous
at 40°C and 5 bar.
For better understanding one must also be aware of
the following:
1. A gas heats up when being compressed (e.g. air
pump, turbo charger, ...).
2. When relieving gas it will cool down (e.g. white frost
forms on the valve when relieving air pressure from a
car tire).
3. Condensing gas dissipates a lot of heat energy.
4. If a fluid evaporates it requires a lot of heat, i.e. the
fluid thereby cools down the surrounding environment
(e.g. alcohol on skin)
262 BOMAG 008 910 32

Refrigerant R134a 5.4
5.4 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:

Physical properties of R134a:
- 26.5 °C
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. °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 32 BOMAG 263

5.5 Compressor oil / refrigeration oil
liquid container has absorbed approx. 8 gr. of water, 5.5 Compressor oil / refrigeration
the refrigerant circuit transports possibly existing wa-
ter in form of droplets. This water flows to the nozzle oil
of the expansion valve and turns to ice. The air condi- The compressor oil lubricates the movable parts in the
tioning system stops cooling. Water destroys the air compressor, seals e.g. the gap between piston and
conditioning system, because under high pressures cylinder inside the compressor to prevent refrigerant
and temperatures and in connection with other con- loss and prevents other seals in the system from dry-
taminants it forms acids. ing up.
Part of the compressor oil dissolves in the refrigerant
Inflammability: until saturation is reached, so that a gas mixture of re-
frigerant, water steam, compressor oil and contrast
Refrigerant is not inflammable. On the contrary, it has agent circulates through the system.
fire inhibiting or fire extinguishing properties. Refriger-
ant is decomposed by flames or glowing surfaces. Ul- Compressor oil (the oil quantity should be 10 % of the
traviolet light also cracks refrigerant (caused by refrigerant weight) mixes with the refrigerant and cir-
electric welding). This results in toxic fission products, culates permanently through the system.
these must not be inhaled. However, irritation of the In connection with R134a- air conditioning systems
mucous membranes is an early and in-time warning. special synthetic compressor oils, e.g. polyalkylene
glycol (PAG) oils, are used. This is necessary, be-
cause e.g. mineral oil does not mix with R134a. Apart
Filling factor: from this, the materials in the R134a air conditioning
In a container there must be a steam space above the system may be attacked when the mixture is flowing
liquid space. The liquid expands with increasing tem- through the refrigerant circuit under high pressure and
perature. The steam filled space becomes smaller. at high temperatures or if the lubrication film in the
From a certain time on the container will be filled with compressor tears off. The use of non-permitted oils
just liquid. After this only a minor temperature in- can cause damage to the air conditioning system, you
crease is enough to generate very high pressures in should therefore only used the approved oils.
the container, because the liquid would like to expand,
but there is no more room. The related forces are high
enough to cause the container to burst. In order to Properties of compressor oil / refrigeration oil:
avoid overfilling of a container the pressure gas direc- The most important properties are high solvency in
tive clearly specifies how many kilograms of refriger- connection with refrigerants, good lubrication charac-
ant may be filled into the container per litre volume. teristics, that they are free of acids and their low water
Multiplied with the internal volume this "filling factor" content. For this purpose only certain oils can be
determines the permissible filling capacity For refrig- used. PAG-oils suitable for use with refrigerant R134a
erants used in motor vehicles it is 1.15 kg/l. are highly hygroscopic and will not mix with other oil.
As a protection against the invasion of moisture drums
must immediately be closed again after they had been
opened. Compressor oil ages under the effect of
Environmental aspects moisture and acids, becomes dark, viscous and ag-
The contribution of R134a to the greenhouse effect is gressive against metals.
by factor 10 smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for
newly produced construction equipment were succes-
sively converted to refrigerant R134a. This refrigerant
does not contain any chlorine and is thus harmless for
the ozone layer. Until approx. 1992 air conditioning
systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decompo-
sition potential and also a potential to amplify the
greenhouse effect. Conversion programs for existing
old systems with the ozone damaging R12 are in ef-
fect. For reasons of protecting the environment refrig-
erant must not be discharged into the atmosphere.
264 BOMAG 008 910 32

Working principle of the air conditioning system 5.6
5.6 Working principle of the air
conditioning system
All air conditioning systems are based on the same

principle. They extract heat from the surrounding en-
vironment. Everybody knows the effect: if a sweating
body is exposed to wind it will cool down, because
heat is extracted. For this purpose a refrigerant circu-
lates in a closed circuit inside the vehicle. This refrig-
erant thereby continuously changes its physical state
between liquid and gaseous.
Fig. 1
An engine driven compressor (1) draws in gaseous re-
frigerant from the evaporator (5) and compresses it.
During this process the temperature of the refrigerant
increases tremendously.
The refrigerant vapour is then pumped to the con-
denser (2). This condenser is arranged directly in front
of the vehicle radiator, so that a sufficient air flow is as-
sured. In the condenser (2) the gas is cooled down
and consequently liquefied.
In the dryer / liquid container (3) the refrigerant is then
collected and freed of moisture and contaminants.
The expansion valve (4) regulates the flow rate from
the dryer / liquid container (3) back to the evaporator
(5) and the circuit starts again.
008 910 32 BOMAG 265

5.7 Refrigeration diagram
5.7 Refrigeration diagram
Fig. 1
1 High pressure - gaseous
2 High pressure - liquid
3 Low pressure - gaseous
4 Compressor
5 Compressor pressure switch (not used)
6 Vacuum switch
7 Evaporator
8 Expansion valve
9 Inspection glass
10 Filter dryer
11 Fluid container
12 Condenser
13 Manual shut-off valve (not used)
14 Overpressure switch
15 Defroster thermostat
266 BOMAG 008 910 32

Description of components 5.8
5.8 Description of components Reason of oil Amount of oil
loss lost
Compressor Loss when approx. 15 gr
emptying
Defective A/C approx. 30 gr
hose
Hose change approx. 15 gr
Replacement of approx. 30 gr
condenser
evaporator
liquid container
expansion
valve
! Caution
Fig. 1
Please bear in mind, that the new compressor is
The compressor is mounted to the engine and has the delivered with a filling of 207 gr. compressor oil.
duty to build up the refrigerant pressure required for To avoid excessive oil in the A/C-system and thus
the function of the system. Coupling and decoupling is a poor cooling effect, the oil level in the A/C-sys-
accomplished by an electromagnetically controlled tem must be adjusted accordingly.
mechanical clutch, which is integrated in the V-belt
pulley of the compressor. The quantity depends on the amount of oil that
may have been lost in connection with the possi-
Compressor data ble replacement of other components.
Displacement: 155 cm² The compressor oil quantity must be 10% of the
Weight: 6,9 kg refrigerant quantity in the complete system.
max. rpm: 6000 With a refrigerant filling of 1100 gr. the system re-
quires a compressor oil / refrigerant oil filling of
Sense of rotation: cw
100 gr.
Refrigerant: R134a
Procedure:
Oil quantity (scope of delivery): 207 gr
Drain and measure the compressor oil from the
Oil: PAG SP-20 (H14-003-404) old compressor.
Drain the compressor oil from the new compres-
! Caution sor and only fill in the exact quantity that had been
The compressor oil level must be checked after drained out of the old compressor. The compres-
replacing a system component or if a leak in the sor oil from the new compressor can be used for
system is suspected. Use only refrigeration oil this purpose.
PAG SP-20 (H14-003-404).
When replacing a heat exchanger, e.g. evaporator i Note
or condenser, any compressor oil / refrigeration Topping up compressor oil / refrigeration oil is possi-
oil lost by exchanging the components, must be ble on a pressureless compressor directly into the oil
replaced with fresh oil. pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
The actual quantity depends on the amount of oil
into the pressure side of the refrigeration system dur-
that may have been lost in connection with the
ing the evacuation process.
possible replacement of other components.
Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
The following table shows how much compressor oil /
refrigeration oil will be lost in connection with various
types of work on the air conditioning system.
008 910 32 BOMAG 267

5.8 Description of components
Condenser Dryer / filter / fluid container / inspection

glass
Fig. 1
The condenser is located in front of the the radiator for Fig. 1
the machine. It emits heat energy from the system into
the surrounding air and liquefies the gaseous refriger- Dryer / filter
ant. The fluid container collects the fluid drops and passes
these then as a constant flow to the expansion valve.
Moisture that has entered during assembly of the re-
i Note
frigerant circuit is absorbed by a dryer in the fluid con-
The fins must be free of dirt and damage.
tainer.
At evaporation temperatures below zero the refriger-
! Caution ant will deposit previously absorbed moisture on the
When replacing a heat exchanger, e.g. evaporator expansion valve, where this water turns into ice and
or condenser, any compressor oil lost by ex- thus adversely affects the controllability of the expan-
changing the components, must be replaced with sion valve. Moreover, moisture in the refrigerant cir-
fresh oil. cuit causes corrosion, forms acids and enters into
chemical compositions.
Inside the refrigerant container the heavy liquid refrig-
erant collects in the lower part of the container, flows
through a rising pipe to the outlet marked "A" and thus
ensures bubble free operation of the expansion valve.
i Note
Since the absorbing capacity of this filter/dryer is lim-
ited, it must be changed within certain service inter-
vals. We recommend to replace it 1 x per years,
before the start of the season.
! Caution
The filter/dryer must generally be replaced when-
ever opening the refrigerant circuit, because
moisture will enter in such a case.
This requires emptying the air conditioning sys-
tem!
Installation position:
The arrow marks on the filter/dryer must point in
flow direction, i.e. towards the expansion valve.
Filter/dryer cannot be treated for further use!
268 BOMAG 008 910 32

Safety valve
i Note
Air in the system is characterized by high pressures
and temperatures.
On R134a refrigeration systems from KONVEKTA the
inspection glasses are equipped with moisture indica-
tors. In addition to the float, the dryer/collector/inspec-
tion glass combination has an indicator pearl
integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection
glass and should only be checked after approx. 5 min-
utes continuous operation, because the refrigerant
must first evenly distribute all over the system.
Fig. 2 ! Danger
The fluid container is equipped with a safety valve. In case of mechanical damage or corrosion on
Opening pressure 32 +/- 4 bar this pressure container this collector unit must be
replaced, to avoid bursting and further damage.
Tightening torque 10 - 15 Nm
Inspection glass
Fig. 3
During operation the refrigerant must flow through the
inspection glass without air bubbles. In most cases
the presence of air bubbles is a sign for a too low re-
frigerant level in the system. Apart from this, the refrig-
erant may not sufficiently condense as a result of a
soiled evaporator or a defective condenser fan and
the fluid level in the refrigerant container may drop
down to a level, at which gaseous refrigerant could
flow through the rising tube to the inspection glass.
This results in abnormally high temperatures in and on
the fluid lines (between refrigerant container and ex-
pansion valve), as well as very high pressures in the
pressure side.
However, incorrect evacuation or filling may also be
the reason for air entering into the system and since
air cannot be condensed, one will not be able to get
rid of these bubbles by topping up refrigerant. In this
case the air conditioning system needs to be evacuat-
ed and refilled.
008 910 32 BOMAG 269

Expansion valve Evaporator
Fig. 1
The evaporator is mounted inside the HKL-module in
Fig. 1 the cabin. It consists of a heat exchanger (inside air -
The expansion valve is mounted inside the HKL-mod- refrigerant), with refrigerant flowing to a pipe system
ule in the cabin. The expansion valve always allows a with cooling flanges.
small amount of the high pressure liquefied refrigerant As with the condenser, correct operation of all fans
to flow into the evaporator, which has a much lower and cleanliness of the fins must be assured.
pressure. This lower pressure causes these liquid re-
frigerant to expand and to evaporate to gaseous state. Air conditioning systems have a circulation air filter
The heat required for this evaporation process is tak- mounted in the air flow in front of the evaporator,
en from the ambient air through the lamellas and sup- which should be cleaned or changed by the operator
plied to the refrigerant. This is the so-called cooling after each third trip, depending on the amount of dirt.
effect. A condensation water filter is mounted in the air flow
The thermostatic expansion valve operates with an after the evaporator. This filter has the function to col-
external pressure compensation. This type of expan- lect the water that has condensed from the air in the
sion valve works with high accuracy, because it uses evaporator block and to discharge this water into the
pressure and temperature at the evaporator outlet and water pan With a defective condensation water filter
adjusts and overheating of approx. 7 K. The already condensation water may flow into the inside of the ve-
installed expansion valves and the ones delivered as hicle.
spare parts have this overheating value pre-set. In or-
der to prevent a loss in performance or compressor ! Caution
damage you should only use original expansion
valves, because adjusting expansion valves takes a
or condenser, any compressor oil lost by ex-
lot of time and care.
changing the components, must be replaced with
fresh oil.
i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+
270 BOMAG 008 910 32

Defroster thermostat Pressure switch
Fig. 1
After a minimum pressure is reached in the low pres-
Fig. 1 sure side or a maximum pressure in the high pressure
side, the pressure switch will switch of the magnetic
The feeler of a defroster thermostat to switch off the
clutch of the compressor, thus to avoid destruction of
magnetic clutch in case of icing up or to switch the
system components by excessive pressure or draw-
clutch back on after defrosting, is mounted on the
ing in external gases and foreign matter as a result of
evaporator. The correct adjustment of the defroster
too low pressure.
thermostat as well as the correct feeler assembly
should be checked during maintenance. Working pressure:
Switching point on: + 1°C (+/- 1°C) Low pressure off: 1.5 +/- 0.5 bar
Switching point off: + 5.5°C (+/- 1°C) Low pressure on: 3.5 bar
Overpressure off: 25.0 +/- 1.5 bar
i Note Overpressure on: 18.0 +/- 1.5 bar
It is very important that the feeler is mounted down-
stream of the evaporator, but before the pressure sen-
sor, in countercurrent direction, with full length and
insulated against the outside temperature.
008 910 32 BOMAG 271

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
compressor oil / refrigeration oil. The O-rings must al-
ways be replaced when assembling A/C-components.
Recommended tightening torques for O-ring

sealed fittings
Thread Spanner width Torque

5/8“ 17 or 19 13,6 - 20,3 Nm
3/4“ 32,5 - 39,3 Nm
7/8“ 27 35,3 - 42,0 Nm
1 1/16“ 32 40,7 - 47,5 Nm
M30X2 36 105,0 - 115,0
Nm
M36X2 41 165.0 - 175.0
Nm
Bending radii for air conditioning hoses
Hose type Nominal width Bending radi-

us
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
272 BOMAG 008 910 32

Checking the compressor oil level 5.9
Checking the compressor oil level / refrig- Insert the oil dipstick.
5.9 Checking the compr esso r oil level
l
eration oil level l

Pull out the dipstick and count the notches covered
by oil.
! Caution l
Drain off oil or fill up as specified in the table.
The compressor oil level must be checked after
replacing a system component or if a leak in the Environment
system is suspected. Use only compressor oil / re-
Used compressor oil / refrigeration oil must be
frigeration oil PAG SP-20 (H14-003-404).
disposed of as hazardous waste.
l
Run the compressor for 10 minutes at engine idle
speed. Fastening an- Oil dipstick in
l
In order to avoid any compressor oil losses you gle (degree) increments
should slowly drain all refrigerant from the air condi- 0 5-7
tioning system. 10 6-8
20 7-9
30 8-10
40 9-11
50 10-12
60 11-13
90 16-18
l
Screw the oil filler plug back in.
! Caution
The contact area must be clean and should be free
of damage.
Use a new O-ring.
Tightening torque 15 to 25 Nm
l
Refill the air conditioning system.
Fig. 1
l
Measure the fastening angle (Fig. 1) of the com-
pressor (oil plug at top)
l
Remove the oil filler plug.
Fig. 2
l
Turn the nut that hold the armature clockwise with a
socket wrench, until the counterweight is correctly
positioned.
i Note
2 o'clock position with inclination to the right (Fig. 2).
10 o'clock position with inclination to the left
008 910 32 BOMAG 273

5.10 Checking the magnetic clutch
5.10 Checking the magnetic clutch i Note

l
Measure the voltage. The gap should be 0.4 to 0.8 mm.
l
Take off the drive V-belt and rotate the V-belt pulley
by hand while the magnetic clutch is disengaged.
i Note
Nominal value = vehicle voltage
l
Check the magnetic coil locking ring for secure fit.
i Note
In case of excessive flatness faults or deviations the
l
Check the current consumption. magnetic clutch needs to be replaced.
Fig. 1
i Note
Nominal value approx. 3.5 Amp.
Overcurrent indicates a short circuit inside the mag-
netic coil.
No current indicates an interrupted electric circuit.
Fig. 2
l
Measure the air gap on the magnetic clutch be-
tween V-belt pulley and thrust plate.
274 BOMAG 008 910 32

Inspection and maintenance work 5.11
5.11 Inspection and maintenance 5.12 Measuring the pressure in the
work refrigerant circuit
l
Visual inspection of the complete system for dam-
age.
l
Check the compressor mounting bracket on the ve-
hicle engine for tight fit and damage. i Note
l
Check the condition, alignment and tightness of the The temperature of the components in the refrigerant
V-belt. circuit must be the same as the ambient temperature.
l
Check the routing of refrigerant hoses and cables in If individual components in the refrigerant circuit are
the area of the vehicle engine and transmission, as warmer or colder, the pressure will differ from the val-
well as on the chassis for chafing and rectify any de- ues in the table.
tected faults. Ensure sufficient clearance to hot
Steam pressure curve for refrigerant R134a
parts, such as the exhaust; install a protective
shield, if necessary.
l
Check the routing of hoses and hoses on the at-
tachment box or in the cabin.
l
Check all hose and screw fittings for leaks.
l
Check the fastening of the condenser unit.
l
Clean the condenser fins, replace the condenser
block if damaged fins are found.
l
Check the fastening of the evaporator unit.
l
Check the function of evaporator and condenser
fans.
l
Check the electric control panel. If discolorations on
conductors are found, these should be replaced
and possibly also the corresponding relays.
l
Switch on the cooling system and check the refrig-
erant level.
l
Filter/dryer and filter/dryer/fluid container combina- Fig. 3
tions must always be replaced after opening the re- A- liquid
frigerant circuit. If these are in service for more than B- gaseous
1 year, there is a risk that they may be clogged by
excessive absorption of moisture! The filter/dryer Temperature Pressure in
should be replaced in regular intervals. in C° bar
l
Measure the temperature on the evaporator: Meas- -45 -0,61
ure the intake air temperature - Measure the blow -40 -0,49
out air temperature - The temperature difference -35 -0,34
should be at least 8-10 K. -30 -0,16
-25 0,06
l
Measuring the pressure in the refrigerant circuit -20 0,32
-15 0,63
-10 1
-5 1,43
0 1,92
5 2,49
10 3,13
15 3,90
20 4,70
25 5,63
30 6,70
35 7,83
40 9,10
45 10,54
50 12,11
008 910 32 BOMAG 275

5.13 Checking, replacing the refrigerant compressor V-belt
Temperature Pressure in 5.13 Checking, replacing the refrig-

in C° bar
55 13,83
erant compressor V-belt*
60 15,72
65 17,79 Danger
!
70 20,05
Danger of injury!
75 22,52
80 25,21 Work on the V-belt must only be performed with
85 28,14 the engine shut down.
90 31,34
Check the V-belt
The pressure in the refrigerant circuit is
lower than the value in the table
Refrigerant level in the circuit too low ?
l
Check for leaks in the refrigerant circuit with a leak
detector
l
Check the overpressure relief valve.
Has the overpressure relief valve responded ?

l
Check the control for the refrigerant fans.
l
Check refrigerant pipes and hoses for restriction
caused by too tight bending radii. Fig. 4
l
Check refrigerant lines and hoses for external dam-
l
Inspect the entire circumference of the V-belt (Fig.
age. 4) visually for damage and cracks. Replace dam-
aged or cracked V-belts.
l
Check with thumb pressure whether the V-belt can
i Note
be depressed more than 10 to 15 mm (0.4 – 0.6
If no fault is found: inches) between the V-belt pulleys, retighten if nec-
Blow out refrigerant circuit with compressed air and ni- essary.
trogen.
Replace the filter dryer. Tighten the V-belt.
Fig. 5
l
Slightly slacken fastening screws 1, 2 and 3 (Fig. 5).
l
Press the compressor in direction of arrow, until the
correct V-belt tension is reached.
l
Retighten all fastening screws.
* Optional equipment
276 BOMAG 008 910 32

Servicing the air conditioning 5.14
Changing the V-belt 5.14 Servicing the air conditioning*
l
Slightly slacken the fastening screws 1, 2 and 3.
l
Press the compressor against the direction of arrow Cleaning the condenser
completely against the engine.
l
Take the old V-belt off. ! Caution
l
Fit the new V-belt to the V-belt pulleys. A soiled condenser results in a considerable re-
duction of air conditioning power.
l
Tension the V-belt as previously described.
Under extremely dusty conditions it may be nec-
essary to clean the condenser several times per
Caution
!
day.
Check the V-belt tension after a running time of 30
minutes. If, during operation of the air conditioning system,
the warning buzzer sounds switch the air condi-
tioning off and clean the condenser.
Danger
!
Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
age or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.
!Caution
In case of formation of foam have the air condi-
tioning system inspected by the service depart-
ment.
Fig. 6
l
Clean the condenser fins (Fig. 6) with compressed
air or a cold water jet.
Checking the refrigerant level

l
Start the engine.
l
Switch the air conditioning on.
* Optional equipment
008 910 32 BOMAG 277

5.14 Servicing the air conditioning
i Note
The refrigerant level is correct.
Fig. 7
l
Turn the rotary fan switch (Fig. 7) to position "2",
middle fan stage.
l
Open the air outlet openings on both control units. Fig. 10
l
If the white float (Fig. 10) inside the inspection glass
of the drier/collector unit floats at the bottom, inform
the service department.
i Note
The refrigerant level is not correct.
l
Refrigerant must be filled up, if necessary the air
conditioning system must be checked for leaks.
Checking the moisture level of the drying

agent
Fig. 8
l
Turn the rotary switch for the air conditioning ther-
mostat (Fig. 8) clockwise. The air flow cools down.
i Note
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on.
Fig. 11
l
Check the moisture indication pearl (Fig. 11) inside
the inspection glass of the drier/collector unit.
blue = drying agent o.k.
purple = moisture level of drying agent too
high.
l
Inform the service department. Replace drier/col-
lector unit, check air conditioning system.
Fig. 9
l
Check whether the white float (Fig. 9) inside the in- ! Caution
spection glass of the drier/collector unit floats right Have the drier/collector unit replaced by the serv-
at the top. ice department every year before the operating
season.
278 BOMAG 008 910 32

Drying and evacuation 5.15
Checking the condition of the drier/col- 5.15 Drying and evacuation
lector unit
Evacuation of air conditioning systems using R-type
refrigerants not only has the purpose of emptying the
! Caution system of all air before filling in refrigerant, but also to
According to the regulation for pressure reser- verify the leak tightness over a longer lifetime in the
voirs all pressure reservoirs must be repeatedly achieved vacuum. However, the most important factor
inspected by a specialist. In this sense repeated in this work step is the drying of the system.
inspections are external examinations, normally Any water residues in the refrigerant circuit will com-
on pressure reservoirs in operation. In connection bine with the refrigerant, which will lead to the previ-
with this inspection the drier/collector unit must ously described consequential damage.
be visually examined twice every year. During
Vacuum pumps with a capacity of more than 100 l/min
these inspections special attention must be paid
and a final pressure of less than 30 micron, i.e. 0.039
to corrosion and mechanical damage. If the reser-
mbar should be used to evacuate the refrigeration
voir is not in proper condition it must be replaced
system.
for safety reasons, as a precaution to protect op-
erators and third parties against any danger aris- The refrigerant compressor is not suitable for the pur-
ing from the handling and operation of pressure pose of evacuation, because it is not able to achieve
reservoirs. a sufficient final vacuum and, apart from this, may be
mechanically damaged because of a lack of lubrica-
tion when running empty during evacuation.
Danger
!
It is common practice to evacuate the refrigeration
Danger of injury! system to a final vacuum of 1 Torr, i.e. 1.33 mbar.
In case of mechanical damage or corrosion on An exact time for evacuation and drying cannot be
this drier/collector unit this unit must be replaced, predicted. It can only be determined by means of a
to avoid bursting and further damage. vacuum meter. However, if there is no vacuum meter
at hand it is generally better to evacuate 1 hour longer
than 1 hour too less.
Function drying:
Under normal ambient pressure (1.013 mbar) evapo-
rates absolute at 100° C. If the pressure is reduced,
water will already evaporate, e.g. under a pressure of
10 mbar, at an ambient temperature of almost 7°C,
but the water will not evaporate all at once. Since it is
very difficult to separate the steam from the vacuum in
the system, the evacuation process is supported by
the co-called vacuum breaking (filling the circuit with
dried nitrogen). With vacuum breaking the filled in
dried nitrogen absorbs the moisture in the refrigerant
Fig. 12 circuit, which can then be easily discharged together
l
Check the drier/collector unit (Fig. 12) for mechani- with the nitrogen.
cal damage or rust.
008 910 32 BOMAG 279

5.16 Emptying in case of repair
5.16 Emptying in case of repair 5.17 Leak test

For repair work the air conditioning systems must very
often be emptied of all refrigerant. ! Caution
Especially with expensive refrigerants and larger The use of leak detection colouring matter is not
amounts of oil it may be necessary to keep the refrig- permitted, because its chemical composition is
erant for later use. unknown and its effect on compressor oil and rub-
For later use these refrigerants must be drawn out ber elements is not predictable. The use of leak
with suitable equipment and intermediately stored in detection colouring matter makes any warranty
collecting containers. claims null and void.
Before starting the evacuation process, the refrigerant
circuit is filled with nitrogen through a pressure reduc-
Environment
er valve (approx. 22 bar). After this all connections in
Contaminated refrigerant must be disposed of en- the air conditioning system are checked with the help
vironmentally of a suitable leak detection spray. A leak is thereby in-
Releasing refrigerant into the atmosphere is pro- dicated by means of foam bubbles.
hibited (see restrictive injunction concerning A leak test is required if a pressure drop is noticed.
CFC, day of enforcement 01. 08. 1991, § 8)
The leak test must be repeated after filling the air con-
ditioning system with refrigerant.
! Danger Small leaks with only very low amounts of refrigerant
For draining refrigeration systems you should not escaping can be detected, e.g. with an electronic leak
simply use any delivery containers, but only ap- tester. Such equipment is able to detect leaks of less
propriate pressure bottles, which must be special- than 5 gr. per year.
ly marked and should comply with the pressure The leak tester used must be specially designed for
gas directive. the refrigerant composition in the air conditioning sys-
When transferring refrigerant you must make sure tem. For example, leak detectors for refrigerant R12
that the bottle does not contain more than the per- are not suitable for R134a, because the refrigerant
mitted amount of refrigerant in litres and has suf- R134a is free of chlorine atoms, meaning that this leak
ficient gas space for expansion (filling factor: 0,7). detector will not respond.
In order to reduce the evacuation period in case of
short repairs, you may fill the refrigerant circuit with
approx. 0.5 bar nitrogen when opening. This ensures
that nitrogen will flow out of the refrigerant circuit while
it is open and no air or moisture can enter. However,
the necessity for vacuum generation and a dryer
change remains.
280 BOMAG 008 910 32

Filling instructions 5.18
5.18 Filling 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.
008 910 32 BOMAG 281

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 Overpressure switch
5 Compressor pressure switch (not used) 15 Defroster thermostat
6 Vacuum switch 16 Vacuum meter
7 Evaporator 17 Low pressure gauge
8 Expansion valve 18 High pressure gauge
9 Inspection glass 19 Pressure reducing valve
282 BOMAG 008 910 32

Filling instructions 5.18
20 Vacuum pump 17 Open the valve on the refrigerant bottle and open
21 Nitrogen bottle the black and red hand wheels on the pressure
gauge bar. Fill refrigerant into the system, until a
22 Refrigerant bottle
pressure equilibrium between suction and pres-
23 Pressure gauge bar sure side is reached (reading of pressure gaug-
es).
Filling instructions 18 Close the red hand wheel.
1 Connect the service adapter with the blue hand 19 Perform a leak test with the electronic leak detec-
wheel in the suction side. tor.
2 Connect the service adapter with the red hand 20 Start the engine and switch on the system.
wheel in the pressure side (the hand wheels on 21 Open the blue hand wheel and continue filling in
the service adapters must be fully backed out - left refrigerant until the inspection glass is free or air
hand stop) bubbles (in fluid container/dryer combinations the
3 Connect the blue suction hose below the blue white pearl should float in the upper third of the in-
hand wheel on the pressure gauge bar to the blue spection glass). Then close the refrigerant bottle.
service adapter. 22 Close the blue hand wheel on the pressure gauge
4 Connect the red pressure hose below the red bar.
hand wheel on the pressure gauge bar to the red 23 Preparing the test run: -Close windows and doors
service adapter. -Fan on full speed stage -Mount measuring feel-
5 Connect the yellow hose below the yellow hand ers to air discharge and air intake.
wheel on the manometer bar to the 2-stage vacu- 24 Run the system for approx. 20 minutes with medi-
um pump. um engine speed.
6 Connect the last hose below the black hand wheel 25 The temperature difference between air discharge
on the nitrogen bottle via the pressure reducing and air intake should be (depending on type of air
valve. condition) 8-10°C. The ambient temperature
7 Check on the pressure gauge bar that all hand thereby is approx. 20°C. (These data are only ref-
wheels are closed. erence values, which may be influenced by possi-
8 Turn the hand wheels on both service adapter ble insolation)
clockwise. This opens the valves (right hand 26 Switch off system and engine and check for leaks
stop). again.
9 Open the valve on the nitrogen bottle (only via 27 Turn out (left hand stop) and remove the hand
pressure reducer); pressure approx. 20 bar. wheels on both service adapters.
10 Open the black and red hand wheels on the pres- 28 Fit all valves with dust caps.
sure gauge bar and fill nitrogen into the system, 29 Perform a leak test.
until a pressure of approx. 3.5 to 5.0 bar is indicat-
ed on the suction side. 30 Mark the system with the corresponding type
plates and information decals, such as type of oil
11 Then open the blue hand wheel and raise the and refrigerant.
pressure in the suction side (max. 10 bar). Check
for leaks with a leak detection fluid or soapsuds.
12 If the system is leak tight, release the nitrogen
from the system. For this purpose disconnect the
hose from the nitrogen bottle and open the red,
blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand
wheels on the pressure gauge bar. In case of a
leak no or only an insufficient vacuum will be
reached. In this case proceed as described under
point 9-12. Once the leak is sealed continue with
point 14.
15 Once a sufficient vacuum is reached, both pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.
16 Switch off the vacuum pump, watch the pressure
gauges to see whether the vacuum is maintained.
008 910 32 BOMAG 283

284 BOMAG 008 910 32

5.19 Heating control / air conditioning control
008 910 32 BOMAG 285

286 BOMAG 008 910 32

Heating control / air conditioning control 5.19
008 910 32 BOMAG 287

288 BOMAG 008 910 32

Heating control / air conditioning control 5.19
008 910 32 BOMAG 289

290 BOMAG 008 910 32

6 Replacing the cab window panes
008 910 32 BOMAG 291

6.1 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
292 BOMAG 008 910 32

Special tools 6.2
6.2 Special tools
1. Locking handle for fastening element
Fig. 1
2. Suction lifter
commercial
Fig. 2
008 910 32 BOMAG 293

6.3 Auxiliary materials
6.3 Auxiliary materials

Safety gloves
3. Cutter
Commercial
Fig. 1
4. Window glass bonding agent
Fig. 2
5. Activator
Fig. 3
294 BOMAG 008 910 32

Auxiliary materials 6.3
6. Silicone sealant
Fig. 4
008 910 32 BOMAG 295

6.4 Removing and installing the window pane
6.4 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
296 BOMAG 008 910 32

Removing and installing the window pane 6.4
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 32 BOMAG 297

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
298 BOMAG 008 910 32

Removing and installing the window pane 6.4
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.
End of Import
Fig. 14
008 910 32 BOMAG 299

300 BOMAG 008 910 32

7 Drum
008 910 32 BOMAG 301

7.1 Special tools
7.1 Special tools

1. Disassembly device for side plate
Fig. 1
2. Assembly device for side plate
Fig. 2
3. Assembly device for coupling hub abd flanged
hub
Fig. 3
4. Pressing plate for cylinder roller bearing
Fig. 4
302 BOMAG 008 910 32

Special tools 7.1
5. Pressing plate for travel bearing
Fig. 5
6. Pressing bushing for radial seal
Fig. 6
7. Lifting device for exciter unit
Fig. 7
008 910 32 BOMAG 303

7.2 Repair overview for drum
304 BOMAG 008 910 32

Repair overview for drum 7.2
1 Drum 13 Flanged hub
2 Cylinder roller bearing 14 Vibrator shaft
3 Coupling 15 Coupling
4 Vibration motor 16 Vibrator shaft
5 Rear shell 17 Change-over weight
6 Grooved ball bearing 18 Cylinder roller bearing
7 Spacer block 19 Basic weight
8 Rectangular rubber buffer 20 Flanged housing
9 Side plate 21 Flange
10 Spacer ring 22 Cylinder roller bearing
11 Grooved ball bearing 23 Rear shell
12 Mechanical seal
008 910 32 BOMAG 305

306 BOMAG 008 910 32

008 910 32 BOMAG 307

308 BOMAG 008 910 32

008 910 32 BOMAG 309

310 BOMAG 008 910 32

008 910 32 BOMAG 311

7.3 Removing and installing the drum
i Note
After disassembling the side plate (vibration mo-
tor side) the drum can be lifted sideways out of
the frame (Fig. 1).
Fig. 1
i Note
However, the drum can also be removed without
having to disassemble the side plate, if it is lifted
up and out of the frame (Fig. 2).
Fig. 2
Removing the drum
i Note
The following section describes the procedure for
lifting the frame sideways out of the drum.
Environment
Environmental damage
Catch running out hydraulic oil and dispose
of environmentally.
1. Mark the hydraulic hoses (Fig. 3)on the travel mo-
tor and disconnect them from the ports.
2. Close all hydraulic hoses and motor ports with
suitable plugs.
Fig. 3
312 BOMAG 008 910 32

Removing and installing the drum 7.3
3. Mark the hydraulic hoses on the vibration motor
(Fig. 4) and disconnect them from the ports.
4. Close all hydraulic hoses and motor ports with
suitable plugs.
Fig. 4
5. Unscrew screws 1 (Fig. 5) from holding plate (2)
for hydraulic hoses from both sides.
Fig. 5
6. Unscrew screws (Fig. 6) from the spacer piece on
vibration and travel motors.
Fig. 6
7. Fasten the lifting gear to the side plate on the vi-
bration side.
8. Support the front cross-member safely with suita-
ble trestles or wooden blocks (Fig. 7).
9. Unscrew plugs (1) and screws (2).
Fig. 7
008 910 32 BOMAG 313

10. Support the rear cross-member safely with suita-

ble trestles or wooden blocks (Fig. 8).
11. Unscrew plugs (1) and screws (2).
! Danger
Danger of squashing! Do not stand or step
under loads being loaded.
12. Take off the side plate.
Fig. 8
13. Fasten the lifting tackle to the drum and lift the
drum carefully sideways out of the front frame
(Fig. 9).
! Danger

under loads being loaded.
Fig. 9
14. Check all rubber buffers (Fig. 10), replace if nec-
essary (see corresponding chapter).
Fig. 10
15. Check rectangular rubber buffers (Fig. 11), re-
place if necessary.
Fig. 11
314 BOMAG 008 910 32

Removing and installing the drum 7.3
Installing the drum
! Danger
Danger of squashing!
Do not stand or step under loads being load-
ed.
1. Place the drum into the frame and align it parallel
to the frame (Fig. 12).
Fig. 12
2. Attach the side plate, insert screws 2 (Fig. 13) into
the rear cross-member, slide on washers, turn on
and tighten the nuts.
i Note
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
3. Close the screw holes with plugs (1).
Fig. 13
4. Attach the side plate, insert screws 2 (Fig. 14) into
the rear cross-member, slide on washers, turn on
and tighten the nuts.
i Note
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
5. Close the screw holes with plugs (1).
Fig. 14
6. Fasten the spacer pieces with screws (Fig. 15)
and nuts to the side plate.
Fig. 15
008 910 32 BOMAG 315

Adjust the pretension of the rubber buffers.

7. Measure distance „X“ between spacer piece 1
(Fig. 16) and side plate.
8. Calculate the thickness of the compensation
plates.
Nominal value:
Distance "X" + 2 mm
9. Turn one screw (3) into the welded nut (2) at top
and bottom and open a sufficient gap to insert the
compensation plates.
Fig. 16
10. Insert the compensation plates (Fig. 17). Insert
screws (1), slide on washers (3), turn on and
tighten nuts (2).
11. Unscrew the screws from the welded nuts.
Fig. 17
12. Connect hydraulic hoses to the connections on
travel motor and vibration motor according to the
marking.
Fig. 18
13. Fasten holding plate 2 (Fig. 19) for hydraulic hos-
es with screws (1).
! Caution
After connecting the hydraulic components
and before starting operation bleed the hy-
draulic system, check the function and in-
spect the system for leaks.
Fig. 19
316 BOMAG 008 910 32

Repairing the drum 7.4
7.4 Repairing the drum
Removing the travel motor

!Danger
Do not stand or step under suspended loads.
1. Attach the lifting tackle to the travel motor.
2. Unscrew all nuts (Fig. 3) from the rubber buffers.
3. Take the drive disc with the travel motor off the
rubber buffers.
Fig. 1
4. Unscrew the nuts, pull out the screws and re-
move the support legs (Fig. 4).
Fig. 2
5. Attach the lifting tackle to the travel motor (Fig. 3).
! Danger
Fig. 3
008 910 32 BOMAG 317

6. Unscrew the bolts (Fig. 4) and separate the travel

motor from the drive disc.
! Caution
Flush the hydraulic system if dirt or chips are
found in the travel motor.
Fig. 4
Disassembling the exciter unit (travel

motor side)
1. Unscrew both socket head cap screws from the
flange (Fig. 5).
Fig. 5
2. Mount bracket 1 (Fig. 8) for the lifting device to
the flange.
3. Unscrew screws (2) from the flange.
i Note
Do not unscrew the thin drawn screws.
Fig. 6
318 BOMAG 008 910 32

4. Slide the lifting device over the bracket.
5. Force the exciter unit off with two forcing screws
(Fig. 7).
Fig. 7
! Danger
6. Pull the exciter unit out of the drum (Fig. 8).
7. Take the coupling element off the coupling half.
Fig. 8
Disassembling the exciter unit (travel

motor side)
1. Unscrew fastening screws 1 (Fig. 9) for the fan.
2. Loosen clamping screw (2).
3. Pull the coupling hub off the shaft.
Fig. 9
008 910 32 BOMAG 319

4. Unscrew all other fastening screws 1 (Fig. 10)

from the flange.
5. Press the flange off the flanged housing with forc-
ing screws (2).
Fig. 10
Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.
6. Lift the flange off the flanged housing (Fig. 11).
7. Take the O-ring out of the groove in the flanged
housing.
Fig. 11
8. Unclip the circlip from the groove in the flange
(Fig. 12).
Fig. 12
9. Press the cylinder roller bearing with forcing
screws out of the flange (Fig. 13).
Fig. 13
320 BOMAG 008 910 32

10. Take the exciter unit (Fig. 14) out of the flanged
housing.
Fig. 14
11. Knock the radial seal (Fig. 15) out of the flanged
housing.
Fig. 15
12. Unclip the circlip from the groove in the flanged
housing (Fig. 16).
Fig. 16
screws out of the flanged housing (Fig. 17).
Fig. 17
008 910 32 BOMAG 321

14. Extract inner ring 1 (Fig. 18) for the radial seal
and inner bearing races (2).
! Danger
Danger of burning!
Wear safety gloves.
i Note
If the rings are very tight, heat them up with a
torch.
Fig. 18
15. Unclip the circlip from the basic weight (Fig. 19).
Fig. 19
16. To change shaft 1 (Fig. 20) knock out dowel pins
(2 and 3) and press the shaft out of the basic
weight.
i Note
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).
Fig. 20
322 BOMAG 008 910 32

Disassembling the exciter unit (vibra-
tion motor side)
1. Unscrew fastening screw 1 (Fig. 21).
2. Take rectangular rubber buffer (2) with spacer
block (3) off the side plate.
i Note
Remove both rectangular rubber buffers.
Fig. 21
3. Unscrew fastening screws 1 (Fig. 22).
4. Force cover (2) together with the attached vibra-
tion motor off the side plate with forcing screws.
Fig. 22
5. To change the vibration motor loosen clamping
screw 1 (Fig. 23) and pull off coupling half (2).
Fig. 23
008 910 32 BOMAG 323

6. Unscrew nut 1 (Fig. 24), take off conical socket

(2) and conical disc (3).
7. Take the vibration motor off the cover.
Fig. 24
8. Remove the coupling element (Fig. 25).
Fig. 25
9. Fasten the lifting device.
! Caution
The four short fastening screws (2) must re-
main screwed in (the two others are not visi-
ble).
Fig. 26
11. Press the exciter unit out of the drum with forcing
screws (Fig. 27).
i Note
The second forcing screw is covered by the side
plate.
Fig. 27
324 BOMAG 008 910 32

! Caution
12. Pull the exciter unit out of the drum (Fig. 28).
Fig. 28
Removing, dismantling the side plate

1. Take off V-ring 1 (Fig. 29).
2. Unclip circlip (2).
Fig. 29
3. Attach the disassembly device to the side plate
(Fig. 30) and force off the side plate.
Fig. 30
4. Lift the side plate of the flanged hub (Fig. 31).
Fig. 31
008 910 32 BOMAG 325

5. Knock the grooved roller bearing out of the side

plate (Fig. 32) and take out the spacer ring.
Fig. 32
6. Unclip the circlip from the side plate (Fig. 33).
Fig. 33
7. Take the mechanical seal off the flanged hub
(Fig. 34).
Fig. 34
326 BOMAG 008 910 32

Dismantling the exciter unit (vibration
motor side)
1. Unscrew the fastening from the coupling hub.
2. Pull coupling hub (2) off the shaft using a pulling
device (Fig. 35).
Fig. 35
3. Loosen hose clamp 1 (Fig. 36).
4. Pull coupling hub (2) off the shaft.
Fig. 36
5. Unscrew all other fastening screws 1 (Fig. 37)
and press the flanged hub off the flanged housing
with forcing screws (2).
6. Take off the flanged hub.
7. Take the O-ring out of the groove in the flanged
housing.
Fig. 37
008 910 32 BOMAG 327


hub (Fig. 38).
Fig. 38
9. Knock the cylinder roller bearing out of the flang-
ed hub (Fig. 39).
Fig. 39
Environment
Environmental damage!
mentally.
10. Lift the exciter unit out of the flanged housing (Fig.
40).
Fig. 40
11. Knock the radial seal (Fig. 41) out of the flanged
housing.
Fig. 41
328 BOMAG 008 910 32

housing (Fig. 42).
Fig. 42
screws out of the flanged housing (Fig. 43).
Fig. 43
14. Extract inner rings 1 (Fig. 44) for the radial seals
and inner bearing races (2) from the shaft.
! Danger
Danger of burning!
Wear protective gloves.
i Note
If the rings are very tight, heat them up with a
torch.
Fig. 44
15. Unclip the circlip from the basic weight and re-
move the cover (Fig. 45).
i Note
The shafts cannot be pressed out. If damaged
they must be replaced with basic weight and cov-
er.
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).
Fig. 45
008 910 32 BOMAG 329

Assembling the exciter unit (vibration

motor side)
! Caution
Ensure strict cleanliness.
i Note
If the shafts are damaged they must be inserted
into the basic weight or the cover as follows.
! Danger
When working with liquid nitrogen protect
your face and wear gloves.
Do not place any unintended parts into liquid
Fig. 46 nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.
! Caution
Close the bores on the short shaft with a
screw.
1. Cool the shaft down in liquid nitrogen.
2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
46).
3. Secure shaft 1 (Fig. 47) with dowel pins (2 and 3).
! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.
i Note
Unscrew the screw from the shaft.
Fig. 47
! Caution
Close the bores on the short shaft with a
screw.
48).
Fig. 48
330 BOMAG 008 910 32

! Caution
i Note
Unscrew the screw from the shaft.
Fig. 49
7. Insert the fitting key into the keyway in the respec-
tive shaft (Fig. 50).
Fig. 50
8. Insert the circlip into the groove in the basic
weight and on the cover (Fig. 51).
Fig. 51
! Danger
Danger of burning!
Wear safety gloves.
9. Heat the inner bearing race up to approx. 100° C
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 52).
Fig. 52
008 910 32 BOMAG 331

! Danger
Danger of burning!
Wear safety gloves.
10. Heat the inner ring up to approx. 50° C and slide
it onto the short shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 53).
Fig. 53
! Danger
Danger of burning!
Wear safety gloves.
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 54).
Fig. 54
!Danger
Danger of burning!
Wear safety gloves.
it onto the longer shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 55).
Fig. 55
13. Press cylinder roller bearing 1 (Fig. 56) with
pressing plate (2) into the flanged housing until it
bottoms.
Fig. 56
332 BOMAG 008 910 32

14. Insert the circlip into the groove in the flanged
housing (Fig. 57).
Fig. 57
15. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 58).
16. Fill approx. 1.2 l oil SAE-15W/40 into the flanged
housing.
Fig. 58
!Caution
17. Insert the exciter unit with the longer shaft for-
ward into the flanged housing (Fig. 59).
Fig. 59
pressing plate (2) into the flanged hub until it bot-
toms.
Fig. 60
008 910 32 BOMAG 333

19. Insert the circlip into the groove in the flanged hub
(Fig. 61).
Fig. 61
20. Attach the flanged hub to the flanged housing
(Fig. 62).
! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
21. Unscrew eye bolts (1) and replace them with
short screws.
22. Turn short screws (2) into the tapped bores in the
flanged housing (four screws) and tighten them.
Fig. 62
23. Apply some grease to the sealing lip of radial seal
1 (Fig. 63).
24. Insert the radial seal into the flanged hub with the
sealing lip facing down and press it down against
the stop with pressing bushing (2).
Fig. 63 ! Danger
Danger of burning!
Wear protective gloves.
25. Heat the coupling hub up to approx. 80 °C and
slide it onto the shaft against the stop (Fig. 64).
Fig. 64
334 BOMAG 008 910 32

1 (Fig. 65).
27. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).
Fig. 65
28. Cover the thread of screw 1 (Fig. 66) with a screw
retention agent (e.g. Loctite CVX strong, blue,
582).
29. Slide on the new U-seal ring (2), turn in and tight-
en the screws.
Fig. 66 ! Danger
Danger of burning!
Wear safety gloves.
30. Heat coupling hub 1 (Fig. 67) with marking letter
“L“ up t approx. 80° C and slide it over the shaft
against the shoulder.
31. Turn in and tighten clamping screw (2).
Fig. 67
008 910 32 BOMAG 335

Assembling and installing the side

plate
1. Fill grooved ball bearing 1 (Fig. 68) on both sides
with grease.
2. Press the grooved ball bearing completely in us-
ing pressing plate (2).
Fig. 68
3. Insert the circlip into the groove in the side plate
(Fig. 69).
Fig. 69
4. Apply a thick coat of grease to the spacer ring on
both sides and insert it into the side plate (Fig.
70).
Fig. 70
336 BOMAG 008 910 32

5. Fill grooved ball bearing 1 (Fig. 71) on one sides
with grease.
6. Insert the grooved ball bearing with the grease
side forward and press it completely in with
pressing plate (2).
i Note
Grease the other side after installing the exciter
unit.
Fig. 71
7. Insert the oiled loop-ring into the mechanical seal
(Fig. 72).
8. Clean the sliding surfaces of the mechanical seal
and cover them with oil.
Fig. 72
9. Lay one half of the radial seal on the flanged hub
with the sliding surface pointing up (Fig. 73).
Fig. 73
10. Lay the second half of the mechanical seal down
with the sliding face pointing down (Fig. 74).
Fig. 74
008 910 32 BOMAG 337

11. Bolt the threaded section of the assembly device

to the flanged hub (Fig. 75).
Fig. 75 ! Caution
under suspended loads.
12. Lay the side plate on the flanged hub (Fig. 76).
Fig. 76
13. Attach bushing 2 (Fig. 77) of the assembly device
and turn on nut (1).
Fig. 77
14. Pull the side plate with the assembly device onto
the flanged hub.
! Caution
During assembly make sure that the mechan-
ical seal slides correctly into the side plate
and the loop rings are not damaged (Fig. 78).
Fig. 78
338 BOMAG 008 910 32

15. Remove the assembly device.
16. Insert the circlip into the groove in the flanged hub
(Fig. 79).
Fig. 79
Assembling the exciter unit (travel

motor side)
!Danger
When working with liquid nitrogen protect
your face and wear gloves.
Do not place any unintended parts into liquid
nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.
! Caution
Ensure strict cleanliness.
Fig. 80
80).
! Caution
Fig. 81
008 910 32 BOMAG 339

4. Insert the circlip into the groove in the basic

weight and on the cover (Fig. 82).
Fig. 82
! Danger
Danger of burning!
Wear safety gloves.
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 83).
Fig. 83
! Danger
Danger of burning!
Wear safety gloves.
it onto the shaft against the shoulder with the wid-
er chamfer facing towards the outside (Fig. 84).
Fig. 84 ! Danger
Danger of burning!
Wear safety gloves.
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 85).
Fig. 85
340 BOMAG 008 910 32

pressing plate (2) into the flanged housing until it
bottoms.
Fig. 86
9. Insert the circlip into the groove in the flanged
housing (Fig. 87).
Fig. 87
10. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 88).
11. Fill approx. 1.2 l oil SAE-15W/40 into the flanged
housing.
Fig. 88 ! Caution
12. Insert the exciter unit into the flanged housing
(Fig. 89).
Fig. 89
008 910 32 BOMAG 341


pressing plate (2) into the flange until it bottoms.
Fig. 90
14. Insert the circlip into the groove in the flange (Fig.
91).
Fig. 91
15. Lift the flange onto the flanged housing and align
it the bores (Fig. 92).
! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
Fig. 92
16. Turn the screws into the tapped bores of the
flanged housing and tighten them (Fig. 93).
Fig. 93
342 BOMAG 008 910 32

1 (Fig. 94).
18. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).
Fig. 94
19. Cover the thread of screw 1 (Fig. 95) with a screw
retention agent (e.g. Loctite CVX strong, blue,
582).
20. Slide on the new U-seal ring (2), turn in and tight-
en the screws.
Fig. 95
21. Insert the fitting key into the keyway of the shaft
(Fig. 96).
Fig. 96 ! Danger
Danger of burning!
Wear safety gloves.
22. Slide the fan with assembly disc over the shaft.
23. Heat coupling hub 1 (Fig. 97) with marking letter
“R“ up to approx. 80° C and slide it over the shaft
against the shoulder.
24. Turn in and tighten clamping screw (2).
25. Assemble the fan to the coupling hub.
Fig. 97
008 910 32 BOMAG 343

Assembling the exciter unit (travel

motor side)
1. Check coupling elements, replace if necessary.
2. Insert the coupling element into the coupling hub
(Fig. 98).
! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.
3. Fasten the lifting device to the exciter unit.
Fig. 98 ! Caution
4. Insert the vibrator unit into the drum (Fig. 99).
Fig. 99
i Note
Insert the exciter unit so that oil filler plug 1 (Fig.
100) is in line with bore (2) in the drum.
Fig. 100
344 BOMAG 008 910 32

5. Turn in and tighten screws 2 (Fig. 101).
6. Remove bracket (1) for the lifting device.
Fig. 101
7. Cover the thread of screws (Fig. 102) with a
screw retention agent (e.g. Loctite green 270).
8. Slide on the new U-seal ring, turn in and tighten
the screws.
Fig. 102
Installing the travel motor

! Danger
1. Fasten the lifting tackle to the travel motor and at-
tach the motor to the drive disc (Fig. 103).
Fig. 103
2. Turn in and tighten the fastening screws (Fig.
104).
Fig. 104
008 910 32 BOMAG 345

3. Mount the support leg to the travel motor, insert

the screws, turn on and tighten the nuts (Fig.
105).
Fig. 105
! Danger
4. Attach the drive disc with the assembled travel
motor to the rubber buffers. Turn on and tighten
the nuts (Fig. 106).
Fig. 106
Installing the exciter unit (vibration

motor side)
! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.
! Danger
1. Fasten the lifting gear to the exciter unit and insert
it into the drum (Fig. 107).
Fig. 107
346 BOMAG 008 910 32

! Caution
Ensure correct engagement of coupling and
alignment of shaft (Fig. 108).
If the shafts are not correctly in line determine
the cause, if necessary measure the drum.
Fig. 108
2. Turn in and tighten screws 1 (Fig. 109).
3. Remove the lifting gear.
4. Fit cover (2) to the drum.
Fig. 109
5. Check the end float of the exciter shafts (Fig.
110).
Nominal value: 0.6...1.8 mm
Fig. 110
6. Attach disc 1 (Fig. 111), turn in and tighten the
fastening screws (2).
Fig. 111
008 910 32 BOMAG 347

7. Lay a new V-ring over the journal of the flanged

hub (Fig. 112).
8. Fill the grooved ball bearing with grease.
Fig. 112
9. Check coupling element, replace if necessary.
10. Insert the coupling element into the coupling hub
(Fig. 113).
Fig. 113
11. Fasten the vibration motor to the cover so that
sockets 1 (Fig. 114) and ventilation bore (2) are
opposite each other.
Fig. 114
12. Slide on coupling half 2 (Fig. 115) and secure with
clamping screw (1).
Fig. 115
348 BOMAG 008 910 32

13. Attach the cover with the installed vibration mo-
tor, turn in and tighten the screws (Fig. 116).
Fig. 116
14. Install rectangular rubber buffers 2 (Fig. 117) with
attached spacer block (3) and screws (1) to the
side plate.
i Note
Assemble both rectangular rubber buffers.
Fig. 117
008 910 32 BOMAG 349

7.5 Disassembling and assembling the change-over weight
7.5 Disassembling and assembling the

change-over weight
Dismantling the change-over weight

1. Unscrew all screws (Fig. 3).
Fig. 1
2. Force the cover with forcing screws (Fig. 4) off the
basic weight.
Environment
Environmental hazard!
mentally.
Fig. 2
3. Take the change-over weight out of the basic
weight (Fig. 5).
Fig. 3
350 BOMAG 008 910 32

Disassembling and assembling the change-over weight 7.5
4. Take the O-rings 1 and 2 (Fig. 4) out of the
grooves.
Fig. 4
Assembling the change-over weight

1. Insert the new O-rings 1 and 2 (Fig. 5) with
grease.
Fig. 5
2. Place the change-over weight into the basic
weight (Fig. 6).
Fig. 6
3. Fill aprox 2,5 litres of silicone oil 47 V 1000 cst (up
to the upper edge of the change-over weight) into
the basic weight (Fig. 10).
Fig. 7
008 910 32 BOMAG 351

7.5 Disassembling and assembling the change-over weight
4. Lay the cover on (Fig. 11), so that the raised are-

as are in line.
5. Screw the screws in with screw locking agent
(e.g. Loctite green 270) and tighten them with
120 Nm.
6. Check the axial clearance of the shaft.
iNote
The shaft must have clearance.
Fig. 8
352 BOMAG 008 910 32

Changing the rubber buffers and adjusting the pretension 7.6
7.6 Changing the rubber buffers and ad-
justing the pretension
Relieve the rubber buffers
1. Lift the frame up by both sides, until rubber buff-
ers and rectangular buffers are relieved of any
load (Fig. 1).
2. Loosen all fastening screws.
Fig. 1
3. Turn one screw each into the welded nuts (Fig. 2)
on the spacer blocks.
Fig. 2
4. Remove the compensation shims 1 (Fig. 3).
Fig. 3
008 910 32 BOMAG 353

7.6 Changing the rubber buffers and adjusting the pretension
5. Unscrew the screws (Fig. 4) from the welded

nuts.
Fig. 4
Changing the rubber buffers
6. Unscrew nut 1 (Fig. 3) and remove the washer.
7. Unscrew screws (2).
8. Take off rubber buffer (3).
9. Attach the new rubber buffer to the drive disc and
align the bores to the tapped bores in the drum.
10. Turn in and tighten the fastening screws.
11. Assemble the washer, turn on and tighten the nut.
Fig. 5
Adjusting the pre-load
12. Measure distance „X“ between spacer piece and
side plate (Fig. 6).
13. Calculate the thickness of the compensation
plates.
Nominal value:
Distance „X“ + 2 mm
Fig. 6
14. Turn in screws into each welded nut and provide
sufficient space to insert the compensation plates
(Fig. 7).
Fig. 7
354 BOMAG 008 910 32

Changing the rubber buffers and adjusting the pretension 7.6
15. Insert the compensation shims 1 (Fig. 8).
Fig. 8
16. Unscrew the screws (Fig. 9) from the welded
nuts.
Fig. 9
17. Tighten the fastening screws (Fig. 10).
18. Lower the frame again.
Fig. 10
008 910 32 BOMAG 355

7.6 Changing the rubber buffers and adjusting the pretension
356 BOMAG 008 910 32

8 Oscillating articulated joint
008 910 32 BOMAG 357

8.1 Special tools
8.1 Special tools

1. Pressing mandrel for rocker bearings
Fig. 1
2. Pressing sleeve for outer race of rocker bearing
Fig. 2
3. Pressing sleeve for inner race of rocker bearing
Fig. 3
4. Guide journal
Fig. 4
358 BOMAG 008 910 32

Special tools 8.1
5. Clamping device
Fig. 5
6. Disassembly device
Fig. 6
008 910 32 BOMAG 359

8.2 Repair overview oscillating articulated joint
1 Housing 12 Rear shell

2 Seal ring 13 Rear shell
3 Rear shell 14 Intermediate ring
4 Self-aligning bearing 15 Self-aligning bearing
5 Bolt 16 Intermediate ring
6 Shim/supporting disc 17 Self-aligning bearing
7 Belleville springs 18 Beam
8 Self-aligning bearing 19 Friction bearing
9 Console 20 V-ring
10 Belleville springs 21 Seal ring
11 Shim/supporting disc
360 BOMAG 008 910 32

Repair overview oscillating articulated joint 8.2
008 910 32 BOMAG 361

8.2 Repair overview oscillating articulated joint
362 BOMAG 008 910 32

Removing and installing the oscillating articulated joint 8.3
8.3 Removing and installing the oscillat-
ing articulated joint
1. Jack up the frame (Fig. 1) at the back and secure
it with trestles or wooden blocks.
Fig. 1
2. Support the rear frame near the oscillating articu-
lated joint (Fig. 2) on both sides safely with tres-
tles or wooden blocks.
Fig. 2
3. Fasten the lifting tackle to the front frame near the
oscillating articulated joint (Fig. 3).
Fig. 3
008 910 32 BOMAG 363

8.3 Removing and installing the oscillating articulated joint
4. Unscrew fastening screws 1 (Fig. 4) and take off

axle holder (2).
5. Knock out bearing bolt (3).
6. Retract steering cylinder (4).
Fig. 4
! Danger
Danger of accident!
7. Support the oscillating articulated joint in the mid-
dle with a suitable jack or a similar device.
8. Unscrew fastening screws 1 (Fig. 5) and take off
with disc (2).
Fig. 5
9. Unscrew nuts 3 (Fig. 6) and take off the clamping
washers (2).
10. Pull out the fastening screws (1).
11. Slightly raise the front frame and lower the oscil-
lating articulated joint to the ground.
12. Pull out the oscillating articulated joint.
Fig. 6
Note on assembly
13. Insert the bolt for the steering cylinder so that
groove (2) is in line with tapped bores (1).
Fig. 7
364 BOMAG 008 910 32

Dismantling the oscillating articulated joint 8.4
8.4 Dismantling the oscillating articulated
joint
1. Unscrew the nuts from hexagon screw 1 (Fig. 1)
and pull out the hexagon screw.
2. Unscrew the screws (2) for the cover.
Fig. 1
3. Take off the cover with Belleville springs, shim
and backing disc (Fig. 2).
4. Disassemble also the cover from the opposite
side.
i Note
No Belleville springs, shim and backing disc are
under this cover.
Fig. 2
5. Drive the console with a plastic hammer to one
side against the end stop (Fig. 3).
i Note
The outer race of the rocker bearing is thereby
stripped off.
Fig. 3
008 910 32 BOMAG 365

8.4 Dismantling the oscillating articulated joint
6. Force inner race 1 (Fig. 4) of the rocker bearing

off the bolt.
7. Take of supporting disc (2).
8. Drive the console to the opposite side and re-
move the rocker bearing in the same way.
Fig. 4
10. Press bolt (3) out of the console with forcing
screws (2).
i Note
Remove the bolt on the opposite side in the same
way.
Fig. 5
11. Lift console 1 (Fig. 6) off housing (2).
Fig. 6
12. Take the seal rings out of the console (Fig. 7).
Fig. 7
366 BOMAG 008 910 32

13. Remove the cover from the housing.
14. Take off shims 1 (Fig. 8), backing disc (2) and
Belleville springs (3).
Fig. 8
15. Unscrew bolts 1 (Fig. 9) and take off cover (2).
Fig. 9
16. Take the intermediate ring out of the housing
(Fig. 10).
Fig. 10
17. Place the plate 1 (Fig. 11) on the beam.
18. Attach the puller (2) to the housing (3) and sepa-
rate the carrier from the rocker bearings.
Fig. 11
008 910 32 BOMAG 367

8.4 Dismantling the oscillating articulated joint
19. Pull the housing off the beam (Fig. 12).
Fig. 12
20. Drive the outer race of the friction bearing out of
the housing (Fig. 13).
Fig. 13
21. Drive the friction bearing out of the housing (Fig.
14).
Fig. 14
22. Take seal ring 1 (Fig. 15) and V-ring (2) off the
beam.
Fig. 15
368 BOMAG 008 910 32

23. Check rocker bearings, if necessary press out of
the housing (Fig. 16).
Fig. 16
008 910 32 BOMAG 369

8.5 Assembling the oscillating articulated joint
8.5 Assembling the oscillating articulated

joint
1. If previously disassembled, press the rocker
bearing fully into the housing with a pressing
mandrel (Fig. 1).
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
! Caution
Do not use any grease.
Fig. 1
2. Slide the new V-ring on the beam against the stop
with the lip facing up (Fig. 2).
Fig. 2
3. Lay the seal ring into the beam (Fig. 3).
4. Fill the space between V-ring and seal ring with
multi-purpose grease.
Fig. 3
370 BOMAG 008 910 32

Assembling the oscillating articulated joint 8.5
5. Press the friction bearing fully into the housing
with the chamfered side pointing towards the out-
side (Fig. 4).
Fig. 4
6. Slide the housing over the beam (Fig. 5).
i Note
The journal on the housing must be centrally in
the recess of the beam.
Fig. 5
7. Press the seal ring carefully towards the inside,
until it sits in the recess of the housing (Fig. 6).
Fig. 6
8. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.
! Caution
9. Press the outer rocker bearing race 1 (Fig. 7) in
until it bottoms with the wider outer rim forward
using pressing sleeve (2).
Fig. 7
008 910 32 BOMAG 371

10. Press inner rocker bearing race 1 (Fig. 8) in until

it bottoms, using pressing sleeve (2).
Fig. 8
11. Insert the intermediate ring (Fig. 9).
Fig. 9
12. Press inner rocker bearing race 1 (Fig. 10) in until
it bottoms, using pressing sleeve (2).
Fig. 10
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
! Caution
13. Press the outer rocker bearing race 1 (Fig. 11) in
until it bottoms with the wider outer rim pointing
up, using pressing sleeve (2).
Fig. 11
372 BOMAG 008 910 32

14. Press in intermediate ring 1 (Fig. 12) until it bot-
toms.
15. Attach cover (2) with the machined edge forward.
16. Turn in screws (3) and tighten crosswise.
Fig. 12
Determining the shim thickness
17. Determine the shim thickness, for this purpose
stand the cross-member on a wooden board with
an ∅ 18 mm bore.
! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
18. Slide the rod of the tensioning device in from un-
derneath, attach the plate, screw on the nut and
Fig. 13 tighten.
19. Measure the distance from housing edge to inter-
mediate ring (Fig. 13) and write it down, e.g. 4,7
mm.
i Note
From this measured value of 4.7 mm subtract the
fixed value of 4.0 mm to determine the shim thick-
ness.
Calculation example:
4,7 mm - 4,0 mm = 0,7 mm
measured value: 4,7 mm
fixed value: 4,0 mm
Shim thickness: 0,7 mm
20. Remove the tensioning device.
008 910 32 BOMAG 373

21. Insert shim 2 (Fig. 14) of appropriate thickness

and backing disc (1) into the cover.
Fig. 14
22. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 15).
Fig. 15
23. Assemble cover 2 (Fig. 16) with Belleville springs,
shim and backing disc.
Fig. 16
25. Press the new sealing rings into the respective
groove in the console (Fig. 17).
Fig. 17
374 BOMAG 008 910 32

26. Lift console 1 (Fig. 18) over the housing (2).
Fig. 18
27. Turn four guide pins into the housing bores (Fig.
19).
Fig. 19
i Note
Perform the following eight work steps on both
sides.
28. Slide the bolt over the guide pins (Fig. 20) and
drive in until it bottoms.
Fig. 20
! Caution
When driving in the bolt make sure that the
seal ring is not pressed out through the back
of the console (Fig. 21).
Fig. 21
008 910 32 BOMAG 375

29. Unscrew the guide pins .

30. Turn in the screws and tighten with 75 Nm (Fig.
22).
Fig. 22
31. Slide the backing discs over the bolt (Fig. 23).
Fig. 23
32. Drive the inner rocker bearing race on against the
end stop with the wider outer rim forward (Fig.
24).
Fig. 24
33. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.
! Caution
34. Attach the outer rocker bearing race with the wid-
er outer rim facing towards the outside (Fig. 25)
and drive it in until it bottoms.
Fig. 25
376 BOMAG 008 910 32

35. Attach cover 1 (Fig. 26) to the bottom side of the
console.
36. Turn in and tighten screws (2).
Fig. 26
Determining the shim thickness
37. Determine the shim thickness, for this purpose in-
sert rod 1 (Fig. 27) of the tensioning device from
underneath. Attach plate (2), screw on nut (3) and
tighten.
! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
Fig. 27
38. Measure the distance from outer rocker bearing
race to console surface (Fig. 28) and write it
down, e.g. 3.4 mm.
i Note
From this measured value of 3.4 mm subtract the
fixed value of 2.2 mm to determine the shim thick-
ness.
Calculation example:
3.4 mm - 2.2 mm = 1.2 mm
measured value: 3,4 mm
Fig. 28 fixed value: 2,2 mm
Shim thickness: 1.2 mm
39. Remove the tensioning device.
008 910 32 BOMAG 377

40. Insert shims 2 (Fig. 29) of appropriate thickness

and backing disc (1) into the cover.
Fig. 29
41. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 30).
Fig. 30
42. Assemble cover 1 (Fig. 31) with Belleville springs,
shims and supporting discs.
Fig. 31
44. Insert hexagon screw 1 (Fig. 32) so that the screw
head rests on the upper side of the console.
Fig. 32
378 BOMAG 008 910 32

45. Assemble the washer, turn on and tighten the nut
with 120 Nm (Fig. 33).
Fig. 33
008 910 32 BOMAG 379

380 BOMAG 008 910 32

9 Suppliers documentation
008 910 32 BOMAG 381

382 BOMAG 008 910 32
9.1 Travel pump series 90R
008 910 32 BOMAG 383

384 BOMAG 008 910 32

Travel pump series 90R 9.1
008 910 32 BOMAG 385

386 BOMAG 008 910 32

008 910 32 BOMAG 387

388 BOMAG 008 910 32

008 910 32 BOMAG 389

390 BOMAG 008 910 32

008 910 32 BOMAG 391

392 BOMAG 008 910 32

008 910 32 BOMAG 393

394 BOMAG 008 910 32

008 910 32 BOMAG 395

396 BOMAG 008 910 32

008 910 32 BOMAG 397

398 BOMAG 008 910 32

008 910 32 BOMAG 399

400 BOMAG 008 910 32

008 910 32 BOMAG 401

402 BOMAG 008 910 32

008 910 32 BOMAG 403

404 BOMAG 008 910 32

008 910 32 BOMAG 405

406 BOMAG 008 910 32

008 910 32 BOMAG 407

408 BOMAG 008 910 32

008 910 32 BOMAG 409

410 BOMAG 008 910 32

008 910 32 BOMAG 411

412 BOMAG 008 910 32

008 910 32 BOMAG 413

414 BOMAG 008 910 32

008 910 32 BOMAG 415

416 BOMAG 008 910 32

008 910 32 BOMAG 417

418 BOMAG 008 910 32

008 910 32 BOMAG 419

420 BOMAG 008 910 32

008 910 32 BOMAG 421

422 BOMAG 008 910 32

008 910 32 BOMAG 423

424 BOMAG 008 910 32

008 910 32 BOMAG 425

426 BOMAG 008 910 32

008 910 32 BOMAG 427

428 BOMAG 008 910 32

008 910 32 BOMAG 429

430 BOMAG 008 910 32

008 910 32 BOMAG 431

432 BOMAG 008 910 32

008 910 32 BOMAG 433

434 BOMAG 008 910 32

008 910 32 BOMAG 435

436 BOMAG 008 910 32

008 910 32 BOMAG 437

438 BOMAG 008 910 32

008 910 32 BOMAG 439

440 BOMAG 008 910 32

008 910 32 BOMAG 441

442 BOMAG 008 910 32

008 910 32 BOMAG 443

444 BOMAG 008 910 32

008 910 32 BOMAG 445

446 BOMAG 008 910 32

008 910 32 BOMAG 447

448 BOMAG 008 910 32

008 910 32 BOMAG 449

450 BOMAG 008 910 32

008 910 32 BOMAG 451

452 BOMAG 008 910 32

008 910 32 BOMAG 453

454 BOMAG 008 910 32

008 910 32 BOMAG 455

456 BOMAG 008 910 32

008 910 32 BOMAG 457

458 BOMAG 008 910 32

008 910 32 BOMAG 459

460 BOMAG 008 910 32

008 910 32 BOMAG 461

462 BOMAG 008 910 32

008 910 32 BOMAG 463

464 BOMAG 008 910 32

008 910 32 BOMAG 465

466 BOMAG 008 910 32

008 910 32 BOMAG 467

468 BOMAG 008 910 32

008 910 32 BOMAG 469

470 BOMAG 008 910 32

008 910 32 BOMAG 471

472 BOMAG 008 910 32

9.2 Travel drive series 51
008 910 32 BOMAG 473

474 BOMAG 008 910 32

Travel drive series 51 9.2
008 910 32 BOMAG 475

476 BOMAG 008 910 32

008 910 32 BOMAG 477

478 BOMAG 008 910 32

008 910 32 BOMAG 479

480 BOMAG 008 910 32

008 910 32 BOMAG 481

482 BOMAG 008 910 32

008 910 32 BOMAG 483

484 BOMAG 008 910 32

008 910 32 BOMAG 485

486 BOMAG 008 910 32

008 910 32 BOMAG 487

488 BOMAG 008 910 32

008 910 32 BOMAG 489

490 BOMAG 008 910 32

008 910 32 BOMAG 491

492 BOMAG 008 910 32

008 910 32 BOMAG 493

494 BOMAG 008 910 32

008 910 32 BOMAG 495

496 BOMAG 008 910 32

008 910 32 BOMAG 497

498 BOMAG 008 910 32

008 910 32 BOMAG 499

500 BOMAG 008 910 32

008 910 32 BOMAG 501

502 BOMAG 008 910 32

008 910 32 BOMAG 503

504 BOMAG 008 910 32

008 910 32 BOMAG 505

506 BOMAG 008 910 32

008 910 32 BOMAG 507

508 BOMAG 008 910 32

008 910 32 BOMAG 509

510 BOMAG 008 910 32

008 910 32 BOMAG 511

512 BOMAG 008 910 32

008 910 32 BOMAG 513

514 BOMAG 008 910 32

008 910 32 BOMAG 515

516 BOMAG 008 910 32

008 910 32 BOMAG 517

518 BOMAG 008 910 32

008 910 32 BOMAG 519

520 BOMAG 008 910 32

008 910 32 BOMAG 521

522 BOMAG 008 910 32

008 910 32 BOMAG 523

524 BOMAG 008 910 32

008 910 32 BOMAG 525

526 BOMAG 008 910 32

008 910 32 BOMAG 527

528 BOMAG 008 910 32

008 910 32 BOMAG 529

530 BOMAG 008 910 32

008 910 32 BOMAG 531

532 BOMAG 008 910 32

008 910 32 BOMAG 533

534 BOMAG 008 910 32

008 910 32 BOMAG 535

536 BOMAG 008 910 32

008 910 32 BOMAG 537

538 BOMAG 008 910 32

008 910 32 BOMAG 539

540 BOMAG 008 910 32

008 910 32 BOMAG 541

542 BOMAG 008 910 32

008 910 32 BOMAG 543

544 BOMAG 008 910 32

008 910 32 BOMAG 545

546 BOMAG 008 910 32

008 910 32 BOMAG 547

548 BOMAG 008 910 32

008 910 32 BOMAG 549

550 BOMAG 008 910 32

008 910 32 BOMAG 551

552 BOMAG 008 910 32

008 910 32 BOMAG 553

554 BOMAG 008 910 32

9.3 Vibration pump 42R 041
008 910 32 BOMAG 555

556 BOMAG 008 910 32

Vibration pump 42R 041 9.3
008 910 32 BOMAG 557

Series 42 Introduction
1. Introduction
1.1 Using This Manual

The Adjustment and Minor Repair procedures de- placed. Lightly lubricate all O-rings with clean petro-
tailed herein may be performed by trained personnel leum jelly prior to assembly. All gasket sealing sur-
without voiding the unit warranty. faces must be cleaned prior to installing new gaskets.
Cleanliness is a primary means of assuring satisfac- All exploded view drawings depict the 28cc frame
tory transmission life. Cleaning parts by using a clean size. For variances in the 41cc frame size, see the
solvent wash and air drying is usually adequate. As outline drawings in section 3. Differences in wrench
with any precision equipment, all parts must be kept size and torquing for the two frame sizes are noted in
free of foreign materials and chemicals. When per- the text. Note that exterior housing screws are mostly
forming service activities, protect all exposed sealing Torx-type T30 or T45.
surfaces and open cavities from damage and foreign
These symbols are used within drawings:
material.
Whenever removing a service component, it is rec- Apply petroleum jelly.
ommended that any gaskets and O-rings be re- Lubricate with clean hydraulic oil.
1.2 Safety Precautions

Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury.
The following general precautions should be taken into consideration whenever servicing a hydrostatic system.
Loss of Hydrostatic Braking Ability Fluid Under High Pressure
WARNING WARNING
When Series 42 units are used in vehicular Use caution when dealing with hydraulic fluid
hydrostatic drive systems, the loss of hydro- under pressure. Escaping hydraulic fluid un-
static drive line power in any mode of opera- der pressure can have sufficient force to pen-
tion (e.g. acceleration, deceleration or “neu- etrate your skin causing serious injury. This
tral” mode) may cause a loss of hydrostatic fluid may also be hot enough to burn. Serious
braking capacity. A braking system which is infection or reactions can develop if proper
independent of the hydrostatic transmission medical treatment is not administered immedi-
must, therefore, be provided which is adequate ately.
to stop and hold the system should the con-
dition develop. Flammable Cleaning Solvents
Disable Work Function WARNING

Some cleaning solvents are flammable. To
WARNING avoid possible fire, do not use cleaning sol-
Certain service procedures may require the vents in an area where a source of ignition may
vehicle/machine to be disabled (wheels raised be present.
off the ground, work function disconnected,
etc.) while performing them in order to prevent
injury to the technician and bystanders.
Copyright 1996-1998, Sauer-Sundstrand GmbH & Co.

F000719 All rights reserved. Contents subject to change. Printed in Germany.
558 2 BOMAG 008 910 32

Series 42 Introduction
Contents
1. Introduction ................................................................................................................................ 2
1.1 Using This Manual................................................................................................................................. 2
1.2 Safety Precautions ................................................................................................................................ 2
2. Model Code ................................................................................................................................. 4
3. Component and Port Locations ............................................................................................... 5

3.1 Component Locations ........................................................................................................................... 5
3.2 Ports and Pressure Gauges .................................................................................................................. 6
4. Adjustment and Minor Repair Instructions ............................................................................. 8

4.1 Size and Torque for Plugs and Fittings .................................................................................................. 8
4.2 Pump “Neutral” Adjustment ................................................................................................................... 9
4.3 Control “Neutral” Adjustment for MDC/EDC Controls .......................................................................... 10
4.4 MDC Control Module ............................................................................................................................ 11
4.5 EDC Control Module ........................................................................................................................... 12
4.6 MDC/EDC Control Spool, Control Linkage, and Control Neutral Adjustment Screw ........................... 13
4.7 MDC Neutral Start/Backup Alarm Switch ............................................................................................ 14
4.8 MDC Solenoid Override Valve ............................................................................................................. 16
4.9 FNR, NFPE, and NFPH Controls ........................................................................................................ 17
4.10 System Check Relief Valves (High Pressure Relief, Charge Check, & Bypass Valves) ...................... 18
4.11 Charge Relief Valve............................................................................................................................. 19
4.12 Loop Flushing Valve ............................................................................................................................ 21
4.13 Shaft Seal and Shaft Replacement ..................................................................................................... 22
4.14 Auxiliary Mounting Pads ...................................................................................................................... 24
4.15 Charge Pump ...................................................................................................................................... 25
4.16 Filtration .............................................................................................................................................. 28
4.17 Servo Piston Covers ........................................................................................................................... 29
4.18 Displacement Limiter Adjustment ........................................................................................................ 30
5. Exploded View Parts Drawings............................................................................................... 31

5.1 Shaft Options ...................................................................................................................................... 31
5.2 Filtration, Charge Relief, System Relief, and Loop Flushing ............................................................... 32
5.3 Charge Pump, Auxiliary Pads, and Servo Covers ............................................................................... 33
5.4 Control Options ................................................................................................................................... 34
008 910 32 BOMAG 3559

560 BOMAG 008 910 32

Series 42 Component and Port Locations
3. Component and Port Locations
3.1 Component Locations

A pump with a manual displacement control (MDC) and no filtration adapter is shown. With non-feedback and
automotive controls, the positions of the case drains vary (shown in gray). With a filtration adapter, the porting in
the "Filtration Options" area varies (see section 4.16).
Control Neutral Adjustment Pump Neutral Adjustment

Control Module (MDC/EDC)
(MDC Shown)
Servo Piston
Covers
System Check
Displacement
Relief Valves
Limiters
Charge
Pump Shaft
Seal
Filtration Options
Auxiliary (No Filtration Adapter Shown Here) Charge Relief Valve
Mounting Pad (Loop Flushing
Valve)
Left Side View (Side "2") Right Side View (Side "1")
P100101 E
Series 42 28cc Variable Pump
Control Neutral Adjustment Pump Neutral Adjustment

Control Module (MDC/EDC)
(MDC Shown)
Servo Piston
Covers
Displacement
Limiters System Check
Relief Valves
Charge
Pump
Shaft Seal
Auxiliary
Mounting Filtration Options
Pad Charge Relief Valve (No Filtration Adapter
(Loop Flushing Valve)
Shown Here)
P100102 E
Series 42 41cc Variable Pump
008 910 32 BOMAG 5561


3.2 Ports and Pressure Gauges
Proper servicing of pumps and motors requires that ments. The following outlines show the locations of
pressure be measured and monitored at various the various gauge ports. The tables show the recom-
points in the hydraulic circuit. The Series 42 pump mended gauge size and the fitting size for each port.
has several locations at which to take these measure- Refer to this page when installing pressure gauges.
Gauge Recommended Fitting

Pressure Measured
Port Name Gauge Size 028 041
System Pressure for
M1 & M2 600 bar or 10 000 psi 9/16-18 O-Ring Fitting 9/16-18 O-Ring Fitting
Ports A and B
M3 Charge Pressure 60 bar or 1000 psi 3/4-16 O-Ring Fitting 3/4-16 O-Ring Fitting
M4 & M5 Servo Pressure 60 bar or 1000 psi 9/16-18 O-Ring Fitting 9/16-18 O-Ring Fitting
L1 & L2 Case Pressure 35 bar or 500 psi 1-1/16-12 O-Ring Fitting 1-5/16-12 O-Ring Fitting
Charge Pump Inlet 1 bar, absolute
S 1-1/16-12 O-Ring Fitting 1-5/16-12 O-Ring Fitting
Vacuum or 30 in Hg Vacuum
T000 025E
System Pressure Servo Pressure

Gauge Port M2 Gauge Port M5
Charge Pressure
Servo Pressure Gauge Port M3
Gauge Port M4 (Charge Pressure
System
Case Drain Port L2 Supply For
Pressure
(Non-Feedback No Charge Pump
Port B
Controls) Option)
System
Pressure Case Drain
Port A Port L1
Case Drain Port L1 Charge Pump

(Non-Feedback Inlet Port S
Controls)
Case Drain
System Pressure
Port L2
Gauge Port M1
P100103 E
28cc Base Unit with MDC and No Filtration Adapter
562 6 BOMAG 008 910 32

System Pressure Servo Pressure

Servo Pressure Charge Pressure
System (Charge Pressure
Pressure Case Drain Supply For
Port B Port L2 No Charge Pump
Option)
System
Pressure
Port A
Case Drain Charge Pump
Port L1 Inlet Port S
System Pressure
Gauge Port M1
Left Side View (Side "2") Right Side View (Side "1") P100104 E
41cc Base Unit with MDC and No Filtration Adapter
To Filter, Port D
(Pressure Filtration)
Charge Pressure
Gauge Port M3
(Full Flow Pressure Filtration)
From Filter, Port E

(Pressure Filtration)
Charge Pressure
Gauge Port M3
(Partial Flow Pressure Filtration)
Charge Pressure
Gauge Port M3
(Suction Filtration)
P100105 E
Filtration Adapter (28cc and 41cc Models)
008 910 32 BOMAG 7563

Series 42 Adjustments and Minor Repairs
4. Adjustment and Minor Repair Instructions
4.1 Size and Torque for Plugs and Fittings

Plug and fitting sizes are given here. Place a fresh O-ring, lightly lubricated with petroleum jelly, whenever a plug
is removed. Each should be torqued as indicated. A 28cc unit with manual displacement control (MDC) is shown.
Servo Gage
Port M4
11/16 in Hex
27-47 Nm
(20-35 ft•lbf)
28cc: 9/16 in Int. Hex

95-135 Nm
(70-100 ft•lbf)
41cc: 5/8 in Int. Hex Case Drain
125-250 Nm Port L1
(90-190 ft•lbf) Charge Pressure Gage
Port M3 (Position Varies, Charge Pump Inlet
Refer to Filtration Options) Port S
Torque: 115 Nm (85 ft•lbf)
Case Drain 11/16 in Hex

Port L2 27-47 Nm
Port N (20-35 ft•lbf)
(Unused) Servo Gage
Port M5
System Gage
Ports M1 and M2
11/16 in Hex
27-47 Nm
(20-35 ft•lbf)

95-135 Nm
(70-100 ft•lbf)
125-250 Nm
(90-190 ft•lbf)
11/16 in Hex
System Ports 27-47 Nm
A and B (20-35 ft•lbf)
115 Nm (85 ft•lbf)
E100001 E
564 8 BOMAG 008 910 32

4.2 Pump “Neutral” Adjustment

The pump neutral adjustment sets the position of the
servo piston and pump swashplate relative to the
controlling mechanism.
WARNING
The following procedure requires the vehicle /
machine to be disabled (wheels raised off the
Pump "Neutral"
ground, work function disconnected, etc.) while Adjustment Screw
performing the procedure in order to prevent
1. Disconnect machine function. Pump "Neutral"

Adjustment Seal
2. Connect a hose between gauge ports M4 and M5 Lock Nut
to equalize the pressures on both ends of the
pump servo piston.
3. Install pressure gauges in gauge ports M1 and
M2 to measure system pressure.
4. Start the prime mover and operate at normal E100002 E
speed.
Pump Neutral Adjustment Screw
5. Loosen the pump "neutral" adjustment seal lock (MDC Control Shown)
nut [28cc 13 mm Hex; 41cc 17 mm Hex]. Turn
the pump "neutral" adjustment screw [28cc 5
mm Hex; 41cc 7 mm Hex] until the system
pressure gauge readings are equal.
6. Turn the adjustment screw clockwise until one of
the gauges registers an increase in system pres-
sure. Note the position of the adjustment screw.
Turn the screw counterclockwise until the other
gauge registers an increase in system pressure.
Note the position of the adjustment screw.
7. Turn the adjustment screw clockwise to a posi-
tion halfway between the positions noted above.
The system pressure gauges should indicate
equal pressures.
8. While holding the adjustment screw in position,
torque the seal lock nut [28cc 20-26 Nm (15-19
ft•lbf); 41cc 28-51 Nm (21-37 ft•lbf)] .
9. Stop the prime mover and remove the hose
between gauge ports M4 and M5. Remove the
pressure gauges installed in gauge ports M1 and
M2. Reinstall the plugs in the gauge ports.
10. Reconnect work function.
IMPORTANT
If the pump is equipped with an MDC or EDC,
the CONTROL "neutral" adjustment MUST also
be performed before putting the pump into
service (see next section).
008 910 32 BOMAG 9565


4.3 Control “Neutral” Adjustment for MDC/EDC Controls
The control neutral adjustment aligns the pump swash-

plate and the control spool so that a zero angle control MDC / EDC Control
setting provides a zero degree swashplate setting. "Neutral" Adjustment Screw
This adjustment should be performed whenever any
part of the control or swashplate mechanisms is
adjusted or removed or after the pump neutral setting
(previous section) is adjusted.
WARNING
The following procedure requires the vehicle /
machine to be disabled (wheels raised off the
ground, work function disconnected, etc.) while
performing the procedure in order to prevent
1. Disconnect the work function. Disconnect the

external control linkage (for MDC) or control
signal input (for EDC) from the pump.
2. Install pressure gauges in gauge ports M4 and MDC / EDC Control "Neutral"
M5 to measure pressure on the pump servo Adjustment Seal Lock Nut
piston. E100003 E
3. Start the prime mover and operate at normal Control Neutral Adjustment Screw
speed. (EDC Control Shown)
4. Loosen the CONTROL "neutral" adjustment seal
lock nut (see drawing) [17 mm Hex] . Turn the
control "neutral" adjustment screw [5 mm Int.
Hex] until the servo piston pressure gauge read-
ings are as close to equal as possible.
5. Turn the adjustment screw clockwise until one of
the gauges registers an increase in pressure on
the servo piston. Note the position of the adjust-
ment screw.
Turn the screw counterclockwise until the other
gauge registers an increase in pressure on the
servo piston. Note the position of the adjustment
screw.
6. Turn the adjustment screw clockwise to a posi-
tion halfway between the positions noted above.
The servo piston pressure gauges should indi-
cate nearly equal pressures.
7. While holding the adjustment screw in position,
torque the seal lock nut [14-24 Nm (10-18 ft•lbf)].
8. Stop the prime mover and remove the pressure
gauges installed in gauge ports M4 and M5.
Reinstall the plugs in the gauge ports.
9. Reconnect the external control linkage (for MDC)
or control signal input (for EDC) to the pump.
Reconnect the work function.
566 1 0 BOMAG 008 910 32

008 910 32 BOMAG 567


4.5 EDC Control Module
The Electric Displacement Control (EDC) provides a

control function through connections to the summing EDC Control
link pin within the pump housing. The following pro- Pressure Gauge
cedure shows how to remove and install the control Port X1
housings. The next section explains how to remove
and install the control spool and linkage.
1. Clean the external surfaces of the pump. If nec-
essary, remove control input signal.
2. Remove the seven (7) control retaining screws
[Torx T30] that secure the control to the pump
housing. Note the position of the different length
screws. Remove the control and control gasket
from the pump.
Note: See next section for instructions on remov- EDC Control
ing/installing the control spool and linkage. Pressure Gauge
Port X2 P100106 E
3. Clean the sealing surfaces of the control and the
EDC Module Showing Port Locations
pump housing. Place a new gasket in position on
the housing.
CAUTION
The control orifices are part of the control
Control Retaining
gasket. Refer to the appropriate Service Parts Screws (note different sizes)
List to determine the correct gasket.
4. Hold the summing link pin in position while install-

ing the control. (The spring on the control spool
will tend to push the link to an extreme position.)
The link pin MUST engage the hole in the control
piston fork.
Control
Note: It may be easiest to lay the servo piston Gasket Summing
side of the control down first, then watch the link link pin
Hold summing MUST enter
pin engage from the charge pump side of the link (and control the hole in
pump. spool) in the control
position piston fork!
5. Install and torque the control screws [15-17 Nm
(11-13 ft•lbf)]. Perform Control Neutral Adjust-
ment (Section 4.3).
WARNING
Failure to properly engage the link pin with
control piston fork will result in incorrect con- E100006 E
trol operation, which may lead to loss of con-
trol of the vehicle / machine. EDC Control Module Assembly
568 1 2 BOMAG 008 910 32

4.6 MDC/EDC Control Spool, Control Linkage, and Control Neutral

Adjustment Screw
The control spool, control linkage, and control neutral
adjustment screw can be removed for cleaning and to Summing Link
change the O-rings or the seal lock nut. Linkage Pivot Screw
Removal of Spool, Linkage, and Adjustment Opposite

Screw Feedback Link Bore Plug
Neutral
1. Clean the external surfaces of the pump. Adjustment
Seal Lock
Link
2. Remove the MDC or EDC module and the control Control Neutral Nut
Adjust Screw
gasket from the pump housing (see previous two Control
sections). Spool
and Spring
3. Remove the summing link. Note
orientation!
4. Remove the control spool bore plug [5/16 in Int.
Hex] or screws [Torx T30], cover, and gasket. Housing without
Remove the opposite bore plug [5/16 in Int. Hex], Filtration Adapter
and remove the control spool and spring.
5. Remove the linkage pivot screw [4 mm Int. Hex], Control Spool
feedback link, and neutral adjustment link. Bore Plug
6. Remove the seal lock nut [17 mm Hex] and the

control neutral adjustment screw [5 mm Int. Hex].
Installation of Spool, Linkage, and Adjustment Housing with

Gasket
Screw Filtration Adapter
1. Install the control neutral adjustment screw and
seal lock nut. Do not tighten the nut.
Control Spool
2. Assemble the "neutral" adjustment link and feed- Bore Cover E100007 E
back link, and install as shown. Install and torque
MDC/EDC Control Spool and Linkage
the linkage pivot screw [8-15 Nm (6-11 ft•lbf)].
3. Lubricate and install the control spool and spring
Feedback link
assembly noting proper orientation. must enter slot in
servo piston
WARNING Pivot screw
The control spool and spring assembly MUST
be oriented in the housing as shown for proper
control operation.
4. Install and torque the control spool bore plug [41- Fork on summing link
must engage flats on
94 Nm (30-70 ft•lbf)]. Or install the control spool
Slot in "neutral" adjust link control spool
cover (with a new gasket) or plug, and torque the must engage groove in
screws [15-17 Nm (11-13 ft•lbf)]. adjusting screw E100008 E
5. Install the summing link. Hold the control spool in Servo Piston Linkage and Control Spool
position while engaging the fork on the summing (Internal Parts Shown with Housing Removed)
link with the flats on the spool. If necessary, rotate
the spool to engage the summing link.
6. Install a new control gasket. Hold the summing
link and control spool in position while reinstalling
the MDC or EDC (see section 4.4 or 4.5). Perform
Control Neutral Adjustment (section 4.3).
008 910 32 BOMAG 1 3569


4.7 MDC Neutral Start/Backup Alarm Switch
The Neutral Start Switch (NSS) prevents the engine NSS Cover
and pump from being started when the pump is out of NSS Control Nut
neutral. The NSS should be wired in series with the
NSS Cam
engine starting circuit. The switch contact is closed at
the control handle's neutral position and opens when
the control handle is rotated 1.5 to 2° from neutral.
The Backup Alarm Switch (BUA) outputs an elec- NSS Cavity
tronic signal when the control handle is in a reverse
position. This switch is normally wired in series with
an audio output. The switch contact is open until the NSS with
control handle is rotated 2.6 to 3.75° in the reverse Weatherpack
direction.
CAUTION
The control handle's neutral position must
NSS with Screw
agree with the pump's neutral position for the Terminals
NSS/BUA to work effectively (see section 4.3).
E100009 E
The Neutral Start / Backup Alarm Switch assembly
can be configured for three different settings. NSS Assembly on MDC
i. A Neutral Start Switch only.
ii. A Neutral Start Switch with Backup Alarm for
units where clockwise (CW) handle rotation re-
sults in "reverse" motion.
iii. A Neutral Start Switch with Backup Alarm for Control
units where counterclockwise (CCW) handle ro- Yolk Cam
tation results in "reverse" motion.

The setting must be in accordance with the configu-
ration of the unit. See the model code (section 2) if
NSS only NSS with BUA NSS with BUA
uncertain of the type of NSS you have.
(CW = Reverse) (CCW = Reverse)
Alignment of the NSS requires a special alignment P100107 E
tool. Dimensions are given at right. Top View of NSS Showing Cam Positions
(continued) 9/16 -18UNF 2A THD

.04 x 45 Chamfer
R.125 ø .236–.030
Knurl
35.0
1.250
.306 .354
2.000
Material: .75 DIA x 3 ETD150

(All Dimensions in inches)
P100108 E
Alignment Tool
570 1 4 BOMAG 008 910 32

008 910 32 BOMAG 571

4.8 MDC Solenoid Override Valve

The solenoid override valve is a safety feature that
connects both ends of the servo control piston to- Port L4
gether when the solenoid is de-energized. Thus the
Port X7
pump can be put into stroke only when the solenoid
is energized.
The solenoid override with brake release includes
hydraulic control of a safety brake. When de-ener-
gized, a spring-applied, hydraulically-released brake
is drained through port X7. For conditions where case
back-pressure on the spring-applied brake is critical,
an external drain to the reservoir can be connected
through port L4.
The solenoid override valve can be removed to
inspect and remove foreign matter.
Removal Solenoid Override Valve

Assembly E100010 E
1. Remove retaining nut [9/16 in Hex].
Solenoid Override Valve Assembly
2. Remove solenoid housing.
3. Remove retaining ring at base of solenoid. Retaining Nut
4. Remove solenoid. This should be connected to Solenoid

internal spool. Housing
Installation
Washer
1. Replace O-ring. Retaining Ring
2. Place spring and plunger inside of solenoid.
Solenoid
3. Attach spool (male notch) to plunger (female
notch).
O-Ring
4. Insert solenoid/spool assembly in solenoid over- Spring
ride bore. Plunger
5. Snap retaining ring over base of solenoid.
Spool
6. Place washer at base of solenoid.
7. Install housing and retaining nut [2-4 Nm (1.5-3.5
ft•lbf)].
E100011 E
Exploded View of Solenoid Override Assembly
572 1 6 BOMAG 008 910 32

4.9 FNR, NFPE, and NFPH Controls

The 3-position FNR control and the electric and
hydraulic non-feedback proportional (NFPE and NFPH Ports
(Ports X1 and X2)
NFPH) controls are non-feedback type controls. The
FNR and NFPE controls consist of modules mounted
on the pump housing. The hydraulic input for NFPH
is received through ports on the top of the pump
[9/16–18 SAE O-ring fitting].
The non-feedback controls are set at the factory. The
control modules can be removed to clean the ports
and change the O-rings.
The orifice plugs for the FNR and NFPE are located
inside the servo piston covers. The orifice plugs for E100012 E
the NFPH are located in the NFPH ports. Orifice Position of NFPH Ports
plugs may be cleaned or replaced.
Note: Future models may contain orifice plate
Control Solenoid
between module and pump housing.
Control Module
Removal and Installation of FNR and NFPE
Modules
1. Clean pump and module housings.
2. Remove four (4) screws retaining module to
housing [4 mm Int. Hex], and remove module Control Ports
from pump housing. Locator Pin
3. Remove O-rings from the control ports. Examine

ports for cleanliness.
4. Clean sealing surfaces.
5. Replace locator pin.
6. Install new O-rings.
7. Replace screws [4.7-6.1 Nm (3.5-4.5 ft•lbf].
E100013 E
Removal and Installation of FNR and NFPE NFPE Assembly (FNR Similar)
Control Orifices
Note: Future models may contain an orifice plate Non-Feedback
between module and pump housing. This will Control Orifice
take the place of the orifice plugs beneath the
servo piston cover.
1. Remove servo piston cover (see section 4.17).
2. Remove orifice plug [1/8 in Int. Hex].
3. Examine orifice and port for cleanliness.
4. Install orifice plug [2.0-3.4 Nm (1.5-2.5 ft•lbf)].
E100014 E
Location of Non-Feedback Control Orifice
008 910 32 BOMAG 1 7573


4.10 System Check Relief Valves (High Pressure Relief, Charge Check,
& Bypass Valves)
The charge check, high pressure relief, and the loop
bypass functions are all contained within the system
check relief (SCR) valve assembly. This assembly
may be removed for cleaning and installation of fresh With
Bypass Valve
O-rings. The model code specifies whether high Seat
pressure relief valves, combination charge check/ Without
Bypass
high pressure relief valves, and/or loop bypass valves Retaining
Valve Ring
are present or not. Standard
Seat
Plug Bypass
1. Remove the valve seat plugs [9 mm Int. Hex] or Plunger
valve seat/bypass plugs [1 in Hex] from the pump Outer O-Ring
housing. O-Ring Valve
Seat
2. Remove the check poppet or relief valve assem- Backup Plug
Ring
blies from the pump housing. The smaller end of Outer
Inner
each conical spring is crimped to retain it on the O-Ring
O-Ring
check poppet or relief valve. Do not remove. Backup
Ring
3. Inspect the valves and mating seats in the special Inner
plugs for damage or foreign material. O-Ring
CAUTION
The relief valves are factory set and should not
be tampered with, except for replacing the
entire valve.
4. The O-ring on the standard bypass plunger may Check Poppet or

High Pressure
be replaced by removing the retaining ring and Relief Valve
removing the plunger from the special valve seat Conical Spring
plug. Remove the O-ring from the plunger and
install a new O-ring. Reinstall the plunger and
retaining ring.
5. Install a new outer O-ring, new backup ring, and
new inner O-ring on each valve seat plug.
6. Check that the conical springs are properly re-
tained on the check poppets or relief valves.
Install the check poppet or high pressure relief
valve assemblies into the pump housing .
CAUTION
The conical springs MUST be correctly posi-
tioned on the check poppets or relief valves
after installation for proper pump operation. E100015 E
System Check Relief Valve Components

7. Install the valve seat plugs or valve seat/bypass
plugs into the pump housing and torque [40-95
Nm (30-70 ft•lbf)].
574 1 8 BOMAG 008 910 32

4.11 Charge Relief Valve

The charge relief valve may be removed for cleaning
and installation of fresh O-rings. The pressure setting
may be changed. However, note that the setting will
vary for different charge flows which depends on
charge pump size and pump speed. The factory
setting is set relative to case pressure at 1800 rpm.
The actual charge pressure will vary at different
speeds.
Shim Adjustable Style

1. Remove the shim adjustable charge relief valve Shim Adjustable
Charge Relief Valve Plug
plug [1 in Hex] from the pump housing. Remove O-Ring
the O-ring from the plug.
Shims
2. Remove the spring and poppet from the housing.
Spring
3. Do not alter the shims which may be installed Poppet
between the spring and valve plug, or inter-
change parts with another valve. Inspect the
poppet and mating seat in the housing for dam-
age or foreign material.
4. If desired, the charge relief valve setting can be
changed. An approximate rule of thumb is 4 bar
/ 1.25 mm (58 psi / 0.050 in). The effective setting
will vary.
To confirm the charge relief valve setting, mea- E100016 E
sure charge pressure (port M3) with the pump in Shim Adjustable Charge Relief Valve Components
stroke. The charge pressure should level off
when the relief setting is reached.
Approximate Relief Setting vs Shim Thickness
5. Install a new O-ring on the valve plug. Reinstall
4 bar / 1.25 mm (58 psi / 0.050 in)
the poppet, spring, and plug (with shims and O-
T000 023E
ring) into the pump housing [55-135 Nm (40-100
ft•lbf)].
(continued)
008 910 32 BOMAG 1 9575

Screw Adjustable Style Charge Relief Lock Nut
1. Before removing the screw adjustable relief valve O-Ring

plug, mark the plug, lock nut, and housing so as Screw Adjustable
to approximately maintain the original adjust- Charge Relief Valve Plug
Spring
ment when assembling, Remove the screw ad- Poppet
justable charge relief valve plug by loosening the
lock nut [1-1/16 in Hex] and unscrewing the plug
[8 mm Int. Hex]. Remove the O-ring from the plug.
3. Inspect the poppet and mating seat in the hous-
ing for damage or foreign material.
4. Install a new O-ring on the valve plug. Reinstall
the poppet and spring. Reinstall the plug with its
lock nut [47-57 Nm (34-42 ft•lbf)], aligning the E100017 E
marks made at disassembly.
Screw Adjustable Charge Relief Valve Components
5. Check and adjust, if necessary, the charge pres-
sure. For screw adjustable "anti-stall" charge
relief valves, an approximate rule of thumb is 2.8 Approximate Relief Setting vs Screw Revolution
bar / quarter turn (40 psi / quarter turn).
2.8 bar / 1⁄4 turn (40 psi / 1⁄4 turn)
To confirm the charge relief valve setting, mea- T000 024E
sure charge pressure (port M3) with the pump in

stroke. The charge pressure should level off
when the relief setting is reached.
576 2 0 BOMAG 008 910 32

4.12 Loop Flushing Valve
The loop flushing function consists of the loop flush-

ing shuttle valve and the loop flushing relief valve. The Loop Flushing
assemblies may be removed for cleaning and instal- Relief Plug
lation of new O-rings. The relief valve poppet may be Loop Flushing Relief
Plug (Defeat) O-Ring
exchanged for one with a different flow rating, but the
O-Ring Shims
relief valve shims should not be changed out unless
specifically instructed so by Sauer-Sundstrand. The Spring
function also can be defeated.
Poppet
Loop Flushing Valve
1. Remove the loop flushing valve plug from the
Loop
pump housing [11/16 in Hex]. Remove the O-ring Loop Flushing
Flushing
from the plug. Plug (Defeat)
Plug
O-Ring
2. Remove the loop flushing valve spool assembly O-Ring
from the housing.
Loop
3. Inspect the parts for damage or foreign material. Defeat Flushing
Spool Spool
The centering spring must be securely retained to Assembly
the spool by the washer.
4. Install the loop flushing valve spool assembly into
its bore. Install a new O-ring on the loop flushing
plug and install [27-47 Nm (20-35 ft•lbf)].
Loop Flushing Relief Valve

1. Remove the loop flushing relief valve internal hex
plug [5/8 in Hex] from the pump housing. Remove
the O-ring from the plug.
3. Do not alter the shims which are installed be-
tween the spring and valve plug, or interchange
parts with another valve. Inspect the poppet and
mating seat in the housing for damage or foreign
E100018 E
material. Inspect the orifice in the valve poppet.
Loop Flushing Valve and Loop Flushing Defeat
4. Install a new O-ring on the valve plug. Reinstall Components
the poppet, spring, shims, and plug (with O-ring)
into the pump housing [15-34 Nm (15-25 ft•lbf)].
Defeating Loop Flushing

1. Remove the loop flushing valve from the pump
housing.
2. Install the defeat spool into the spool bore in the
housing. Install the plain plug with O-ring into the
housing [11/16 in Hex], and torque [27-47 Nm
(20-35 ft•lbf)].
3. Remove the charge relief valve (these parts are
not necessary).
4. Install the plain hex plug with O-ring into the end
cap [5/8 in Hex], and torque [15-34 Nm (15-25
ft•lbf)].
008 910 32 BOMAG 2 1577


4.13 Shaft Seal and Shaft Replacement
A lip type shaft seal is used in Series 42 pumps. This

seal and/or the shaft can be replaced without major
disassembly of the unit. Replacement generally re- Retaining
Ring
quires removal of the pump from the machine.
1. Position the pump with the shaft facing up. Seal Carrier
Assembly
NOTE: If the unit is positioned horizontally when
the shaft is removed, the cylinder block could
move out of place, making shaft installation diffi-
cult.
2. Remove the retaining ring from the housing.
3. Pull out seal carrier assembly.
4. Remove the O-ring from the seal carrier. To
install a new shaft only, proceed to step 8.
5. Place the seal carrier in an arbor press with the
shaft bearing side down, and press out the old
seal. An appropriately sized pipe spacer or socket
wrench can be used as a press tool. Once re-
moved, the seal is not reusable. E100019 E
6. Inspect the seal carrier and the new seal for Shaft Seal Components
damage. Inspect the sealing area on the shaft for
rust, wear, or contamination. Polish the sealing
area on the shaft if necessary. O-Ring
7. Press the new seal into the shaft bearing side of

the seal carrier. The seal lip must face the outside Sealant may
Seal be used on
of the pump. Be careful not to damage the seal.
outside diameter
The outside diameter of the seal may be coated
with a sealant (e.g. Loctite High Performance Inside Lip
Seal Carrier (face down)
Sealant #59231) prior to installation. This aids in
preventing leaks caused by damage to the seal
bore in the seal carrier.
(continued)
Press Seal
to bottom of Seal Carrier
E100020 E
Installation of Shaft Seal
578 2 2 BOMAG 008 910 32

If the shaft is not being replaced proceed to step

11. Retaining Ring
8. Remove the shaft and roller bearing assembly Roller Bearing
from the pump or motor. The bearing assembly
can be transferred to the new shaft (steps 9 and
10).
9. Remove the retaining ring that secures roller Key Shaft
bearing assembly with a snap ring plier. Remove
the roller bearing assembly. OR
Shaft Assembly
10. Place roller bearing assembly on new shaft and OR
secure with the retaining ring.
11. Wrap the spline or key end of shaft with thin
plastic to prevent damage to the seal lip during
installation. Lubricate the inside diameter of the
shaft seal with petroleum jelly.
12. Place the O-ring onto the shaft bearing and
lubricate with petroleum jelly.
13. Slide the seal carrier assembly over the shaft and
into the housing bore. Press against O-ring. Hold
inward pressure against the shaft to compress
the cylinder block spring while pressing the seal
carrier into place.
14. Install the retaining ring.
E100021 E
Shaft Components
008 910 32 BOMAG 2 3579


4.14 Auxiliary Mounting Pads
The following procedure can be used to remove and

install a new auxiliary mounting pad or to install a
fresh O-ring for the current auxiliary mounting pad.
Several auxiliary mounting pads are available.
Auxiliary mounting pads are integrated into the charge
pump cover. When nothing is mounted on the pads,
a flange cover is attached to protect the mounting Pad Cover Screws
flange. This cover is removed when mounting a
Charge Aux Mount Pad Cover
pump.
Pump Retaining
Cover
Removal of Auxiliary Mounting Pad Screws
1. Remove the auxiliary pump or remove the two O-Ring
screws retaining the flange cover ["A" Pad 9/16
in Hex; "B" Pad 3/4 in Hex]. Remove the O-ring.
2. Orient pump so that charge pump cover (auxiliary OR
pad) is facing up.
3. Remove the charge pump cover. The auxiliary
pad is integrated into the charge pump cover.
OR
Use a Torx T45 male driver to remove the screws. Auxiliary
Mounting
Note: If a different auxiliary pad is being installed, Pad "A"
then a new drive coupling must be installed. To do
Gasket
this follow the instructions in the section on re-
moving and installing the charge pump (next
section).
Auxiliary
Note: If the charge pump components come out Mounting
with the charge pump cover refer to section 4.15 Pad "B"
Locating
on how to properly reinstall them. No Charge Pin 1
Pump Defeat Charge Pump
4. Install a new charge pump cover gasket.
Components
5. Install the charge pump cover (auxiliary pump
mounting pad is integrated in cover).
NOTE: The threaded screw holes in the auxiliary Locating
Pin 2
pump mounting pad used on very early produc-
tion pumps with the SAE "A" pad option are drilled
through into the area between the gerotor cover
and charge pump cover. Any of these holes
which are not used to attach the flange cover or E100022 E
auxiliary pump should be plugged with internal
Auxiliary Pad Options and Components
hex set screws installed hand tight to prevent the
entrance of water or dirt into this area.
6. Attach the auxiliary pump. If no pump is to be
attached on an auxiliary mounting pad, the pad
should be protected with a flange cover and O-
ring to prevent leakage.
580 2 4 BOMAG 008 910 32

4.15 Charge Pump

The charge pump may be disassembled to inspect
and clean, or to change the auxiliary shaft drive
coupling.
(Screw used with
Note: For units without integral charge pumps "No Pad" and
"A Pad" Only)
see the last page of this section for additional
information. Cover
Retaining
1. Remove auxiliary pump, if necessary. Screws
Charge Pump Cover or Auxiliary Pad

2. Remove the screws retaining the charge pump
cover to the pump housing [Torx T45] (seven (7)
screws are used with the "no pad" or SAE "A"
auxiliary mounting pad charge pump cover, while
six (6) screws are used with the SAE "B" auxiliary
mounting pad charge pump cover). Remove the
charge pump cover, gasket, and the cover locat-
ing pins.
3. Remove the gerotor cover assembly from the
Gasket
charge pump cover or the back of the pump
O-Rings
housing. Remove the gerotor cover O-rings. Two
(2) O-rings are used on the gerotor cover of all
pumps. (An additional O-ring was used on the
gerotor cover of very early production pumps with
the SAE "A" pad option.) Geroter
Cover
Charge Pump Components

4. Remove the gerotor assembly from the gerotor
cover or pump housing.
Geroter
5. Remove the gerotor drive pin and drive coupling. Assembly
Remove the gerotor cover locating pin from the Drive Coupling
pump housing.
Geroter Cover Geroter Drive Pin
6. Each part should be inspected separately if they Locating Pin
Charge Pump
are to be reused. If either of the gerotor assembly Charge Pump
Cover Locating
parts needs to be replaced, they must both be Cover
Pin
Locating
replaced. Always replace the O-rings and charge Pin
pump cover gasket. Inspect the journal bearing in
the gerotor cover for excessive wear.
7. Prior to assembly, lubricate the gerotor assembly
with clean hydraulic oil.
8. Install the gerotor drive pin into the hole in the
drive coupling, and retain with grease or petro-
leum jelly.
9. Install the drive coupling onto the pump shaft with
the smaller outside diameter oriented away from
E100023 E
the pump shaft. Different couplings are used
Charge Pump Components
with the different auxiliary pad options.
10. Install the gerotor assembly onto the coupling.
(continued)
008 910 32 BOMAG 2 5581

11. Install the gerotor cover locating pin into the

pump housing. Install the gerotor cover assembly
over the gerotor. The locating pin must engage
the slot in the gerotor cover.
NOTE: The charge pump rotation is determined
by the location of the gerotor recess and pressure
balance hole in the gerotor cover. Different
gerotor covers are used for clockwise and
counterclockwise rotation pumps.
12. Install new pressure balance O-rings onto the
gerotor cover and retain with petroleum jelly or
grease. (An additional O-ring was used on the
gerotor cover of very early production pumps with
the SAE "A" pad option.)
13. Install the charge pump cover locating pins and a
new charge pump cover gasket.
14. Install the charge pump cover. The cover must
engage the gerotor cover and the locating pins. CW CCW
Install the charge pump cover screws and torque P100110 E
evenly [36-43 Nm (26-32 ft•lbf)]. Determining Charge Pump Orientation Looking
Inside of Gerotor Pump Cover
15. If necessary, reinstall auxiliary pump.
For units without an integral charge pump see the
next section.
(continued)
582 2 6 BOMAG 008 910 32

Units without Integral Charge Pump

Variable Pumps without an integral charge pump do (Screw used with
not have a gerotor assembly, gerotor drive pin, or "No Pad" and
gerotor cover locating pin installed. The charge pump "A Pad" Only)
inlet port is plugged with an O-ring plug.
Cover
For these units that are equipped with housings Retaining
Charge Pump Cover or Auxiliary Pad

Screws
without filtration adapters, the gerotor cavity outlet
is plugged with a special plug installed in a housing
passage. The 3/4—16 charge inlet fitting should be
torqued to 68 Nm (50 ft•lbf).
For these units that are equipped with housings that
include filtration adapters, the gerotor cavity outlet
is plugged with an O-ring plug installed in the "To
Filter" port of a "Full Filter Flow" (charge relief valve
after filter) filter adapter. The 7/8—14 charge inlet
fitting should be torqued to 95 Nm (70 ft•lbf). Gasket
O-Rings
CAUTION
A "Partial Filter Flow" (charge relief valve be-
fore filter) adapter must not be used on variable
"No Charge Pump" Components

pumps without an integral charge pump. If this
design adapter is used, the charge relief valve Geroter
Cover
will be defeated.
Charge Pump
Cover Locating
Drive Coupling Pin 1
Charge Pump
Cover Locating
Pin 2
Geroter
Cavity
Outlet Plug
(Charge Charge
Pump Defeat) Inlet
Charge Pump
Charge Pump Inlet Plug Inlet Plug
Charge Inlet
(For Wrench Sizes
and Torquing
See Filtration Section)
E100024 E
No Charge Pump Option Components No Charge Pump Option Components

(Housing with Filtration Adapter) (Housing without Filtration Adapter)
008 910 32 BOMAG 2 7583

4.16 Filtration
Filtration of foreign matter from the hydraulic fluid is M3 Gauge Partial Flow
of primary importance. Dirt and foreign fluids within Port Plug Pressure
Filtration
the hydraulic circuit will greatly reduce the life of the
Full Flow
hydraulic equipment. Pressure
Filtration
Filter-Related Pump Hardware Filtration Plate
Retaining Screws
Filtration mechanisms for the Series 42 pump may
be before (suction filtration) or after (charge pressure Suction
Filtration
filtration) the charge pump. Sauer-Sundstrand pro-
vides a filtration adapter to provide for each type of
filtration configuration. If filtration is provided for
elsewhere in the hydraulic circuit, the pump will not
have a filtration adapter.
Pumps equipped with housings without filtration
adapters have an additional construction bore next to
the charge relief valve which is unused and plugged
[5/8 in Hex, 21-33 Nm (15-25 ft•lbf)]. When these
pumps are equipped with suction filtration, the exter-
nal charge inlet is plugged [5/16 in Int. Hex, 41-94 Nm
(30-70 ft•lbf)].
Pumps equipped with housings that include filtration
adapters have the appropriate adapter and gasket
fastened to the housing with screws [Torx T30, 16
Nm (12 ft•lbf)]. The position of the M3 gauge port [11/ Housing with
16 in Hex, 11-13 Nm (8-10 ft•lbf)] will vary depending Filtration Adapter
on filtration type.
Filter Specifications
Charge Inlet
The selection of a filter depends on a number of
Plug
factors including the contaminant ingression rate,
the generation of contaminants in the system, the Plug
Construction
required fluid cleanliness, and the desired mainte- Bore Plug
nance interval. A filter capable of controlling the fluid
cleanliness to ISO 4406 Class 18/13 or better is
recommended and may be located either on the inlet
(suction filtration) or discharge (charge pressure
filtration) side of the charge pump. E100025 E
Housing without
Filter capacity depends on desired maintenance Filtration Adapter (Suction Filtration Only)
levels. As a rough guide, a capacity in grams equal
to twice the charge flow in gpm or 1/2 charge flow in
l/min has been found to be satisfactory for many Filtration Type β-ratio
closed circuit systems. Closed Circuit Suction Filtration or
β10 ≥ 2
Open Circuit Return Line Filtration
Filter efficiency as measured by a "Beta" (β) ratio* Systems Sharing a Reservoir with
should be as in the table at right. β10 ≥ 10
Other Gears, Clutches, or Cylinders
See Sauer-Sundstrand publication BLN-9887 or Charge Pressure Filtration β10 ≥ 10
697581 and ATI-E 9201 for more information on
* Filter ßx-ratio is a measure of filter efficiency defined by ISO
filtration. 4572. It is defined as the ratio of the number of particles greater
than a given size (x) upstream of the filter to number of particles
greater than the same size downstream of the filter. The ßx-ratio
applies to a specific particle size, measured in microns.
584 2 8 BOMAG 008 910 32

4.17 Servo Piston Covers

The servo piston cover can be removed to change the
gasket or to inspect/change the control orifices for
NFP or FNR controls (section 4.9). Pump Neutral Ajustment
Seal Lock Nut
1. On the right side (side “1”) of the pump, remove
the pump “neutral” adjustment seal lock nut [13
mm Hex]. (Not necessary on side "2") Servo Piston
Servo Piston Cover Cover Screw
2. Remove the servo piston cover screws [Torx
T30]. Servo Piston Cover
(Non-Feedback and
3. The left side (side "2") servo cover can be re-
Automotive controls only)
moved directly.
On the right side (side “1”) of the pump, the cover Pump "Neutral"
Adjustment Screw
should be pushed away from the pump housing.
It is then necessary to turn the “neutral” adjust-
ment screw [5 mm Hex] clockwise (inward) far
enough for the servo cover to clear the nearby
drain port. Then pull the cover away from the
housing and turn the cover counterclockwise to
disengage it from the adjustment screw.
Servo Piston Cover – Right Side (Side "1")
4. Remove the gasket.
Note: FNR and NFPE control orifice plugs are
located here, see section 4.9 for more informa- Servo Piston
tion. Cover Screws
5. Install new gasket. Servo Piston

Cover
6. On the right side (side "1"), screw the servo piston
cover on the neutral adjustment screw. Then,
while holding the cover, turn the neutral adjust-
ment screw CCW to engage the cover to the
screw threads.
7. Install servo piston cover screws (15-17 Nm (11-
13 ft•lbf)].
8. On the right side (side "1"), loosely install neutral Servo Piston Cover – Left Side (Side "2")
adjustment seal lock nut. Perform pump neutral
adjustment (section 4.2). E100026 E
Servo Piston Cover Components
WARNING
After installing the servo piston cover on right
side (side “1”) of the pump, the pump “neutral”
adjustment and control neutral adjustment
MUST be performed before the vehicle / ma-
chine is put back into service.
CAUTION
Performance of the above procedure may ad-
just the position of the displacement limiter
somewhat.
008 910 32 BOMAG 2 9585


4.18 Displacement Limiter Adjustment
Displacement limiters can limit the maximum swash- Displacement Limiter

plate position. For Series 42 pumps, displacement Seal Lock Nut
limiters are available on one or both sides of the servo
Displacement Limiter
piston.
Servo Piston
Adjustment of the displacement limiters should be Cover
performed on a test stand.
WARNING
Care should be taken in adjusting displace-
ment limiters to avoid undesirable speed con-
ditions. The limiter screw must have full thread
engagement in the servo piston cover, and the
seal lock nut must be retorqued after every
adjustment to prevent unexpected changes in
operating conditions and external leakage dur-
ing unit operation.
Displacement Limiter – Right Side (Side "1")
1. Mount pump on test stand. (Exploded View, No Need to Remove Limiter or Nut)
2. Loosen displacement limiter seal lock nut [13 mm
Hex]. Do not remove.
Displacement Limiter
3. Adjust displacement limiter [4 mm Int. Hex]. Seal Lock Nut
Tighten the seal lock nut every time the pump
Displacement
is to be tested [20-26 Nm (15-19 ft•lbf)].
Limiter
One full turn of the displacement limiter adjust-
ment screw will change the displacement of the Servo Piston
Cover
pump approximately as follows.
28 cc 3.6 cc/rev 0.22 in3/rev

41 cc 5.0 cc/rev 0.31 in3/rev
T000 026E
4. After reaching proper displacement tighten the

Displacement Limiter – Left Side (Side "2")
seal lock nut [20-26 Nm (15-19 ft•lbf)]. (Exploded View, No Need to Remove Limiter or Nut)
If necessary, repeat procedure for displacement lim- E100027 E
iter on other side. Displacement Limiters
586 3 0 BOMAG 008 910 32

Series 42 Exploded View Parts Drawings
5. Exploded View Parts Drawings
5.1 Shaft Options
F096
C020
C017
C018
C015
C005
C002
C003
C001
C015 F001
OR
C001
OR
C001
E100028
008 910 32 BOMAG 3 1587


5.2 Filtration, Charge Relief, System Relief, and Loop Flushing
(F086)
(F086A)
(F043)
(F043A)
(F040)
(F042)
(F043)
(F043A)
(F040) OR
(F042)
F043
F043A OR K001
F040 OR K001
F042
K005
F091 K001A
K002
F091A K001B
F030 K001C K006
F030A K007
G043
F041
G042
G040 K008
G040A G043 K009
G041 G042 K010
G041
G040A
G040
OR
J005
J002
045A F062
G045 F061 J003
F063 H005
F060A
F060 H002
H003
OR F051 F0511
(F060A)
(F060) F0512
F0513
F0514
F0515
F050A
F050 (F091A)
F093
(F091)
OR F093A
F093
(F051)
(F050A) F093A
(F050) N002A
N002
E100029
588 3 2 BOMAG 008 910 32

5.3 Charge Pump, Auxiliary Pads, and Servo Covers
L010
L010A
F020
F020A
G005
G010
(G075)
G015
G002 G020
(G021)
G022
G065
G075
G030 G023
F009
G001
M001
OR
(M001)
OR
(G001)
M005
M010A
G036
M010
(M005) OR
(M010A)
(M010) (G080)
G085
M020
M025
(G001) (G036) G090
(G090)
(G036) (G080)
(G085)
E100030
008 910 32 BOMAG 3 3589


5.4 Control Options
D038 D039
D037
D081
D003
D003A
(D017)
D080 D082 D019
D016
D002 OR
OR
D056 D017
D040
D010
F035 D012
F035A E001 D070

OR
OR
D011
D013 D004
F036
F035
F034 D081
D081
OR
D060
(F010)
F010
D090
D014
D015
D032A
E100031
D032
590 3 4 BOMAG 008 910 32


Notes
008 910 32 BOMAG 3 5591

592 BOMAG 008 910 32

9.4 Vibration motor A10FM
008 910 32 BOMAG 593

594 BOMAG 008 910 32

Vibration motor A10FM 9.4
A10FM
A10FE
RDE 92172-01-R/08.01
ersetzt / replaces 06.99
Reparaturanleitung - A10FM 28 - 60 Baureihe 5

A10FE 28 - 60 Baureihe 5
Repair instructions - A10FM 28 - 60 Series 5
A10FE 28 - 60 Series 5
008 910 32 BOMAG 595

RDE 92172-01-R/08.01
9.4
Hinweis / Inhalt
Vibration motor A10FM
Reparaturanleitung A10FM / A10FE
Notice / Contents Repair Instructions A10FM / A10FE
HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen Specifications, descriptions and illustrative material shown
entsprechen dem Informationsstand zum Zeitpunkt der herein were as accurate as known at the time this
Drucklegung dieser Unterlage. publication was approved for printing.
Änderungen können den Service am Produkt beein- BRUENINGHAUS HYDROMATIK reserves the right to
flussen, Verpflichtungen entstehen uns daraus nicht. discontinue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für specifications, materials, or design without notice and
deren Resultat wir keine Haftung übernehmen können. without incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Anga- Optional equipment and accessories may add cost to the
be der Fabrik-Nr. bestellt, sind die Basis guter Reparatu- basic unit, and some options are available only in
ren. combination with certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf For the available combinations refer to the relevant data
dem Teststand vorzunehmen. sheet for the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vor- Adjustment and tests have to be carried out on the test
kehrungen sicherzustellen. bench under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, Protection of personnel and property has to be guar-
vermitteln wir in unseren Schulungskursen. anteed by appropriate measures.
Expert knowledge, the precondition of any service work,
can be obtained in our training courses.
INHALT Seite/ CONTENTS

Page
A10FM / A10FE A10FM / A10FE
Schnittbild 3 Sectional view

Allgemeine Reparaturhinweise 4 General repair guidelines
Triebwelle abdichten 5-7 Sealing the drive shaft
Motor demontieren 8-14 Disassemble the motor
Überprüfungshinweise 15 Inspection hints
Motor montieren 16-19 Motor assembly
Spülventil demontieren 20 Disassembly of the flushing valve
Abstimmung- Lagerung / Hinweise 21 Bearing adjustment / Note
Werkzeuge / Hilfswerkzeuge / Tools / auxiliary tools /
Anziehdrehmomente 27 tightening torques
2 Brueninghaus Hydromatik
596 BOMAG 008 910 32
RDE 92172-01-R/08.01
Schnittbild
9.4
Reparaturanleitung A10FM / A10 FE
Sectional view Repair Instructions A10FM / A10FE
A10FM
A10FE
Optional Option
Ausführung mit Spülventil Unit with flushing valve
für geschlossenen Kreislauf for closed circuit application
008 910 32 BOMAG Brueninghaus Hydromatik

597 3
598 BOMAG 008 910 32

008 910 32 BOMAG 599

600 BOMAG 008 910 32

008 910 32 BOMAG 601

RDE 92172-01-R/08.01
9.4
Motor demontieren
Disassemble the motor Repair Instructions A10FM / A10FE
A10FM
602 BOMAG 008 910 32
RDE 92172-01-R/08.01
Motor demontieren
9.4
A10FE
10

603 9
604 BOMAG 008 910 32

RDE 92172-01-R/08.01
Motor demontieren
9.4
14 Verteilerplatte abheben.
Remove control plate.
15 Lageraußenring mit Abziehvorrichtung ausbauen.

Dichtfläche Verteilerplatte nicht beschädigen.
Remove bearing outer ring with withdrawal tool.

Do not damage the sealing surface.
16 Abheben des Kegelrollenlagers (anschlußplattenseitig).

Entfernen der Abstimmscheibe.
Disassemble the taper roller bearing (near by port plate)

Remove the adjustment shim.

605 11
RDE 92172-01-R/08.01
9.4
Motor demontieren
17 Triebwerk in horizontaler Lage herausziehen.
Remove the rotary group in a horizontal position.
18 Welle nach hinten herausziehen.
Remove the drive shaft to rear side.
19 Hubscheibe mit Sonderwerkzeug ausbauen (siehe Bild 20).
Remove swash plate with special tool (see picture 20).
20 Der Ausbau der Hubscheibe erfolgt mit einer Schleuder,

ein kleiner Haken - aus Rundmaterial Durchmesser 6 mm -
greift dabei unter die Hubscheibe.
Loosen the swash plate with a slide hammer ( a small

hook - diameter 6 mm - catches the end of the swash
plate at the bottom).
21 Lager mit Presse abziehen.
Press down bearing.
606 BOMAG 008 910 32
RDE 92172-01-R/08.01
Motor demontieren
9.4
22 Abziehen des Lageraußenringes im Pumpengehäuse.

Zweckmäßige Unterlage benutzen, zur Vermeidung von
Gehäusebeschädigungen (s. a. Hinweis Abb.xx).
The external front bearing ring is pulled out of the pump

housing (tool and surface infos see picture xx, too).
23 Sicherungsring entfernen.
Disassemblecirclip and shaft seal.
24 Wellendichtring und Fixierscheibe entnehmen
Remove shaft seal ring and shim.

607 13
608 BOMAG 008 910 32

008 910 32 BOMAG 609

610 BOMAG 008 910 32

008 910 32 BOMAG 611

612 BOMAG 008 910 32

RDE 92172-01-R/08.01
Motor montieren
9.4
Motor assembly Repair Instructions A10FM / A10FE
44 Verteilerplatte montieren.
Montagehilfe: Fett
Fit distributor plate.

Assembly aid: Grease
45 Anschlußplatte aufsetzen und mit Schrauben

über Kreuz anziehen.
Fit the connection plate and fix it with

the screws crosswise.
A10FM A10FE
46

613 19
RDE 92172-01-R/08.01
9.4
Spülventil demontieren
Disassembly of the flushing valve Repair Instructions A10FM / A10FE
47 Beidseitig Schrauben 1 lösen und Federn mit Scheiben 2

entnehmen.
Loosen screws 1, take out springs and shims 2.
1
2
2
1
48 Spülschieber 3 vorsichtig zu einer Seite heausdrücken.
Take out spool carefully.
49 Verschlußschraube Speisedruckventil 4 lösen,

Feder und Einsatz entnehmen.
Loosen the screw of the boost valve and take out

the spring and the cartridge.
Montage in umgekehrter Reihenfolge!
Assembling by opposite steps!
614 BOMAG 008 910 32
RDE 92172-01-R/08.01
Abstimmung- Lagerung / Hinweise
9.4
Bearing adjustment / Note Repair Instructions A10FM / A10FE
Montage - Abstimmung (Kegelrollenlager) / Taper roller bearing initial tension
AA10FM Baureihe 50
AA10FM Series 50
0 .... 0,05 mm
Pos. 12
Abstimmung der Triebwerkslagerung Adjustment of stopper min displacement

Die Vorspannung der Triebwerkslagerung muß im Cast iron housing must have initial tension of bearings:
Gußgehäuse von 0 bis 0,05 mm durch Abschleifen der 0 ...... 0,05 mm , grind Pos. 12 if necessary.
Abstimmscheibe Pos. 12 hergestellt werden.
Adjustment: Qmin- stopper
Einstellhinweis: Qmin-Anschlag With a given inflow and pressureless circulation adjust
Bei gegebenem Zusatzstrom wird bei drucklosem the stopper Qmin displacement so that the measured
Umlauf der Anschlag Qmin so eingestellt, daß die gemes- speed of the motors results in a displacement of 12 cm3
sene Drehzahl des Motors einem Schluckvolumen von (vgmin).
12 cm3 entspricht (vgmin). Increase of adjustment is possible to vgmax = 45 cm3
Eine kontinuierliche Verstellung bis vgmax = 45 cm3 ist Differential volume is appr. 3,1 cm3 (see page 3).
möglich - Volumenänderung pro Gewindestiftum-
Q inflow x 1000
drehung ca. 3,1 cm3 (s. a. Seite 3). Displacement vgmin =
Measurement speed
Q Zulauf x 1000
Schluckvolumen vgmin =
Meßdrehzahl
Achtung: Falsch eingestellte Qmin Anschläge können zu Attention: Wrong adjustments of stopper Qmin
überhöhten Drehzahlen bis hin zum Ausfall der Bauteile displacement increases the speed of the motor up to a
führen. possible failure of parts of the unit.

615 21
616 BOMAG 008 910 32

9.5 MS/MSE 02 to 18
008 910 32 BOMAG 617

9.5 MS/MSE 02 to 18
618 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
Hydraulikmotoren
MS
Hydraulic motors
Reparaturen
Repairs
02 05 08 11 18
MS T T T T T
MSE T T T T T
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 32 BOMAG 619

9.5 MS/MSE 02 to 18
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
620 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
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 32 BOMAG 621

9.5 MS/MSE 02 to 18
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
622 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
Identifizierung des Bauteils Identification of the component
MS18-2-D11-F19-2A10-K000
B D
000143896J
C 40712
001
0349
A : Handelsbezeichnung: A: Commercial description:

Ex : MSE18-2-D11-F19-2A10-K000 E.g : MSE18-2-D11-F19-2A10-K000
B : Code : Artikelnr.: B: Code: Part number.

Ex : 000143896J E.g : 000143896J
C : Serie : Herstellungsnummer C: Series: Manufacturing batch number.

Ex : 001 E.g : 001
D : Num : Chronologische Ordnungsnummer D: Num: Chronological serial number.

Ex : 40712 E.g : 40712
Bei sämtlichen Ersatzteilbestellungen The part number and the chronological

müssen die Artikelnummer und die chro- serial number must be specified to order
nologische Ordnungsnummer angege- spare parts.
ben werden.
800378128J REPAR MS2-18 D/GB 5
008 910 32 BOMAG 623

9.5 MS/MSE 02 to 18
POCLAIN HYDRAULICS
Störungsbeseitigung
BECHÄDIGUNG → ABRIEB → ERKENNUNG DURCH FILTER → VORBEUGUNG……
Störung Ursachen Abhilfe

Regelmäßiges Lagerteil verschlissen Lagerteil ersetzen
Ohne Brummen
Last Lockere Befestigungen Mit entsprechendem Drehmo-
LAUTE Vibrationen
und / oder Anschlüsse ment anziehen
GERÄUSCHE DES
MOTORS Speise- und Austauschdruck-
Klappern Speisedruck zu niedrig
Unter ventil kontrollieren.
Last Zylinderblock und Ölverteiler
Kavitation Interne Lecks zu groß ersetzen
Der Motor wird nicht ver- Den Antrieb der Pumpe und ih-
sorgt re Versorgung überprüfen
Kein Druckanstieg im Hochdruck-Begrenzungsventile
MOTOR DREHT SICH Kreis kontrollieren (Regler)
NICHT Zylinderblock und Ölverteiler
Interne Lecks zu groß
ersetzen
Die Bremse bleibt angezo- Den Steuerkreis der Bremse
gen kontrollieren
Die Antriebsdrehzahl und den

Der Fördermenge der
Zustand der Pumpe kontrollie-
Pumpe ist unzureichend
ren
DER MOTOR DREHT
SICH NICHT MIT Den Zustand des Zylinder-
NORMALER LAST- Interne Lecks zu groß blocks und des Ölverteilers
DREHZAHL überprüfen
Der Betriebsdruck ist zu Den Zustand des Sicherheits-
niedrig ventils kontrollieren (Regler)
Die Fördermenge der Steuerdruck und Fördermenge

DER MOTOR DREHT Pumpe schwankt der Pumpe kontrollieren
SICH UNREGEL- Den Zustand des Zylinder-
MÄSSIG Interne Lecks zu groß blocks und des Ölverteilers
überprüfen.
Gehäusedruck zu groß Den Leckagekreis und den Zu-

stand des Filters überprüfen
Dichtungen beschädigt Die Dichtungen ersetzen
ÄUSSERE ÖLUN-
DICHTIGKEITEN Das Anziehmoment der Monta-
geschrauben, der Entlüftungs-
Fehlerhafte Montage
schrauben und der Anschlüsse
kontrollieren
6 REPAR MS2-18 D/GB 800378128J
624 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
Trouble shooting
DAMAGE → IRON PARTICLES → DETECTION BY FILTERS → PREVENTION……
Troubles Causes Remedies

Regular rum- Worm bearing support Replace the bearing support
Without bling
load Mountings and/or hydraulic
Vibrations Tighten to torque
piping becoming loose
NOISY MOTOR Check the setting and condi-
Clattering Boost pressure too low
tion of counter-pressure valve
Under load Replace the cylinders- block
Cavitation Excessive internal leaks and distribution valve assem-
bly
Check pump drive and pump

No supply to the motor
inlet
The circuit does not reach Check condition of safety
THE MOTOR DOES working pressure valve (regulator)
NOT REVOLVE Replace the cylinders block
Excessive internal leaks and distribution valve assem-
bly
The brake stays engaged Check the brake pilot circuit
Check drive speed and condi-

Pump flow is too low
tion of the pump
THE MOTOR DOES
Check condition of cylinders-
NOT REVOLVE AT
Excessive internal leaks block and distribution valve
ITS NORMAL SPEED
assembly
UNDER LOAD
Working pressure is too Check safety valve setting
low pressure (regulator)
Irregular flow Check the pump flow

THE MOTOR RE-
VOLVES IRREGU- Check condition of cylinders-
LARLY Excessive leaks block and distribution valve
assembly
Too high casing pressure Check the leakage circuit and

filter condition
EXTERNAL OIL Seals damaged Replace seals
LEAKS
Check tightening of mounting
Incorrect assembling screws, bleed screws and
unions
800378128J REPAR MS2-18 D/GB 7
008 910 32 BOMAG 625

9.5 MS/MSE 02 to 18
POCLAIN HYDRAULICS
Wartungsarbeiten Maintenance
Austauschen des Motors Replacing the motor
Ausbau Removal
• Druck im Arbeitskreis abbauen. • Release the pressure in the supply circuit.
• Leckageleitung am Tank abschrauben, um ein • Disconnect the drain line at the tank level to avoid
Leerlaufen zu verhindern. its siphoning.
• Die Rohre oder Schläuche, die am Motor ange- • Disconnect and plug the pipes or hoses which are
schlossen sind, abklemmen. connected to the motor.
• Drehzahlsensor abklemmen. • Disconnect the speed sensor.
• Die Befestigungsschrauben demontieren und den • Disconnect the mounting screws, and remove the
Motor ausbauen. motor.
• Das Motorgehäuse entleeren. • Drain the casing.
Einbau 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
626 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
Mechanische Bremslösung Mechanical brake release
Bei bestimmten Reparaturfällen In certain service situations, it may

oder zum Abschleppen der Maschi- be necessary to release the motor
ne muß die integrierte Parkbremse brake.
gelöst werden.
• Stopfen (142) aus der Schutz- • Extract and release the plug 142
kappe (141) herausziehen. (142) from the brake cover (141).
6499
• Schraube im Kolben festziehen • Tighten the screw in the piston
6556
• Mutter so weit anziehen, bis die • And tighten the nut until the
Welle frei dreht. motor shaft turns freely.
6555
Entsprechendes
Bremsen Brakes Kraft N Force [lbf] Equivalent torque [lbf.ft] Mutter Nut
Drehmoment Nm
F02-F04 18000 [4.000] 42 [30.9] M12
F05-F07 20000 [4.500] 47 [34.6] M12
F08 34000 [7.600] 110 [81.1] M16
F11 45000 [10.000] 140 [103] M16
F12 45000 [10.000] 140 [103] M16
F19 45000 [10.000] 140 [103] M16
Nach Bremslösung, einen neuen Stopfen After brake release, mount a new plug
! (142) einbauen. ! (142).
800378128J REPAR MS2-18 D/GB 9
008 910 32 BOMAG 627

9.5 MS/MSE 02 to 18
POCLAIN HYDRAULICS
Kontrolle der statische Haltebremse. Checking the parking brake efficiency.
Bei fahrbaren Maschinen den Test auf ebenem For a rolling machine, make the test on a hori-
! Grund durchführen. ! zontal ground.
Bremssteuerdruck: mini 12 bar Pilot brake pressure : minimum 12 bar [174 PSI]
Maxi 30 bar. Maximum 30 bar [435 PSI]
• Sich vergewissern, daß der Bremsversorgungs- 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
628 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
Reparaturen. Repairs.
Auswechseln der Brems- Replacement of the O-ring

kolbendichtung of the brake piston.
Demontage Disassembly
• Den Motor ausbauen. • Remove the motor.
• Motor auf das Lagerteil stellen. • Place the motor on the bearing
support.
Muttern zum Schutz der

Protect the studs by
! Gewindebolzen wieder
aufsetzen
! reinstalling the nuts
• Schutzkappe (141) abnehmen • Remove and discard the brake

und beseitigen. cover.(141) 141
6500
• O-Ring (143) herausziehen und • Extract and discard the O-ring

143
beseitigen. (143).
6501
• Tellerfeder (108) zusammen- • Compress the washer (108).

drücken:
• Mit Hilfe des Dorns und Ab- • 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 32 BOMAG 629

9.5 MS/MSE 02 to 18
POCLAIN HYDRAULICS
• Sicherungsring (109) mit Hilfe • Remove the snap ring (109)
einer Zange für Innenringe heraus- using internal snap ring pliers. (see
nehmen (siehe Werkzeuge Seite tools page 36)
36)
• Extractor and pliers (fig 6504 6504 6505
• Abzieher und Zange (fig and 6505)
6504 und 6505) • Press and pliers (fig 6506
• Presse und Zange (fig 6506 and 6507)
und 6507)
6506 6507
Bei Verwendung der Pres- If you use the press do
se das Lagerteil nicht auf
! den Gewindebolzen ab- ! not place the bearing
support on the studs.
stützen.
• Tellerfeder (108) herausziehen. • Extract the washer (108).
108
6508
• Bremskolben (107) herauszie- • Extract the brake piston (107)

hen.
6513
• O-Ring (106) beseitigen. • Discard the O-ring (106).

106
6511
12 REPAR MS2-18 D/GB 800378128J
630 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
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 32 BOMAG 631

9.5 MS/MSE 02 to 18
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
632 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
• Schutzkappe mit Hilfe des • Click the cover into place using
Dorns einrasten lassen (siehe the right mandrel. (see tools page
Werkzeug Seite 36). 36).
Sich vergewissern, daß Make sure that the outer
!
der Außenrand des
Schutzkappe in die Nut ! edge of the cover is en-
gaged in the groove.
eingreift ist.
6517
• Neuen Stopfen (142) einsetzen. • Install a new plug (142).
Sich vergewissern, daß Make sure about the con- 142

zwischen Schutzkappe
! und Stopfenrille ein- ! tact between the cover
and the plug groove.
wandfreier Kontakt be-
steht.
6518
• Motor wieder einsetzen. • Install the motor.
800378128J REPAR MS2-18 D/GB 15
008 910 32 BOMAG 633

9.5 MS/MSE 02 to 18
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
634 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
• O-Ring (027) vom Verteiler- • Discard the O-ring (027)
deckel (041) entfernen. from the valving cover (041). 027
041
6525
• O-Ring (027) vom Lagerteil • Discard the O-ring (027)

(071) entfernen. from the bearing support (071) 027
071
6522
800378128J REPAR MS2-18 D/GB 17
008 910 32 BOMAG 635

9.5 MS/MSE 02 to 18
POCLAIN HYDRAULICS
Wiedereinbau Reassembly
Vor dem Wiedereinbau ist unbe- Before reassembling it is necessary

dingt sicherzustellen, daß die Nut to ensure that the groove is clean
sauber ist
Es dürfen keine Rost-, All traces of rust, mud,
! Schmutz- oder Wasser-
spuren vorhanden sein.
! water must be removed
• Neuen, mit Korrosions- • Install a new O-ring (027) 027

schutzfett eingeschmierten O-Ring coated with anti-oxidizing grease
(027) in die Nut des Lagerteiles (see tools page 36) in the groove of
(071) einsetzen (siehe Werkzeuge the bearing support (071).
Seite 36) .
071
6523
• Neuen, mit Korrosions- • Install a new O-ring (027)

schutzfett eingeschmierten O-Ring coated with anti-oxidizing grease
(027) in die Nut des Verteilerdek- (see tools page 36) in the groove of
kels (041) einsetzen (siehe Werk- the valving cover (041)
zeuge Seite 36) .
041
6525
• Nockenring (026) gemäß der • Install the cam (026) in line

bei der Demontage markierten with the marks made during disas- 026
Kennzeichnung montieren. sembling.
Große Ansenkungen in The big chamfers oriented

! Richtung Lagerteil ! towards bearing support
Den Nockenring anhand von zwei Center the cam using two screws 6526
einander gegenüberliegenden (042) diametrically opposite.
Schrauben (042) zentrieren.
18 REPAR MS2-18 D/GB 800378128J
636 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
• Lagerteil montieren • Install the bearing support
Bei Wellenmotoren For shaft motors the

müssen die Anschlüsse ports must be perpen-
! quer zur Einbauachse
des Motors liegen.
! dicular to the mounting
axis of the motor. (Fig
(Abb. 6521) 6521)
6521
6527
• Befestigungsschrauben (042) • Install and tighten the mounting

einsetzen und mit dem angegebe- screws (042) to the right torque.
nen Drehmoment anziehen. (siehe (see table page 38).
Schaubild Seite 38).
042
6520
• Motor wieder einsetzen. • Install the motor.
800378128J REPAR MS2-18 D/GB 19
008 910 32 BOMAG 637

9.5 MS/MSE 02 to 18
POCLAIN HYDRAULICS
Auswechseln der Brems- Replacing the brake shoes.

backen
Vor der Demontage kann man die Before disassembling it is possible

Abnutzung der Bremsbeläge durch to make a visual checking of the
die Inspektionsöffnungen kontrollie- brake pads wear via the inspection
ren. ports.
2055
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
638 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
• Rückholfeder (154.a) abbauen. • Remove the return spring
(154.a).
154.a
6529
6530
• Halterungsfedern (154.b) ab- • Remove the retention springs

bauen. (154.b). 1
154.b
2
6531
• Bremsbacken aus der Betäti- • Release the brake shoes from

gungsvorrichtung lösen. the regulating mechanism.
6532
• Rückholfedern (154.c) abbau- • Remove the return springs

en. (154.c).
154.c
6533
800378128J REPAR MS2-18 D/GB 21
008 910 32 BOMAG 639

9.5 MS/MSE 02 to 18
POCLAIN HYDRAULICS
• Bremsbacke (154.1) abbauen. • Remove the brake shoe (154.1)
154.1
6534
• Den mechanischen Bremshebel • Releasing the mechanical brake

vom Bremsseil lösen und Brems- control lever from its cable, remove
backe (154.2) entfernen the brake shoe (154.2)
154.2
6535
6536
22 REPAR MS2-18 D/GB 800378128J
640 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
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 32 BOMAG 641

9.5 MS/MSE 02 to 18
POCLAIN HYDRAULICS
• Rückholplatte an die Brems- • Mount the return plate on the
backe (154.2) montieren. brake shoe (154.2)
6537
6538
• Bremsbacke (154.1) einsetzen. • Install the brake shoe (154.1)
6539
• Bremsbacken auf der Betäti- • Position the brake shoes on the

gungseinrichtung positionieren. regulating mechanism.
6532
• Rückholfedern (154.c) einset- Install the return springs (154.c)

zen.
154.c
6533
24 REPAR MS2-18 D/GB 800378128J
642 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
• Bremsbacken in die Betäti- • Install the brake shoes in the
gungseinrichtung einbauen. regulating mechanism
6532
• Halterungsfedern (154.b) ein- • Install the retention springs

setzen. (154.b).
1
154.b
2 6531
• Rückholfedern (154.a) einset- • Install the return spring (154.a).

zen.
154.a
6530
• Reibungsdurchmesser D der • Measure the brake drum friction

Trommel und der eingesetzten Ba- diameter D and that of the brake
cken messen. shoes, which have been installed.
Durchmesser D diameter
6529
800378128J REPAR MS2-18 D/GB 25
008 910 32 BOMAG 643

9.5 MS/MSE 02 to 18
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
644 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
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 32 BOMAG 645

9.5 MS/MSE 02 to 18
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
646 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
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-,

Schmutz- oder Wasser- 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
teilerdeckel (041) drücken
cover (041).
800378128J REPAR MS2-18 D/GB 29
008 910 32 BOMAG 647

9.5 MS/MSE 02 to 18
POCLAIN HYDRAULICS
Die Einbaurichtung des Respect the assembly

Verteilers (047) in bezug sense of the valving
! auf den Verteilerdeckel ! (047) in relation to the
cover (041).
(041) beachten).
Den Einsatz des Vertei-

Do not force when in-
lers (047) in den Vertei- stalling the valving
! lerdeckel (041) nicht
! (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
648 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
D/R Rechts D/R Right
047
R L 041
6757
R A
053
3 2 2 8
• Falls kein Buchstabe vorhanden • If there is no letter, do the in-

ist, die Ausrichtung anhand der beim dexing according to the marks
Ausbau festgelegten Markierungen made during disassembly.
vornehmen.

« 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 32 BOMAG 649

9.5 MS/MSE 02 to 18
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
650 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
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 32 BOMAG 651

9.5 MS/MSE 02 to 18
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
652 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
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 32 BOMAG 653

9.5 MS/MSE 02 to 18
POCLAIN HYDRAULICS
Werkzeug-Liste Tooling inventory
Standard Werkzeug Standard tools

Hollow head
• Innensechskant-Schlüssel 5 6 8 10 12 14
wrench
• Ring-/Maulschlüssel für
Hex head wrench 13 17 19 22 24
Sechskantschraube
• Drehmoment-Schlüssel FACOM J 250 A Torque wrench 6 bis 30 N.m [4.4 to 22.1 lbf.ft]
• Drehmoment-Schlüssel FACOM S 250 A Torque wrench 50 bis 240 N.m [35 to 175 lbf.ft]
• Drehmoment-Schlüssel FACOM K 250 A Torque wrench 160 bis 800 N.m [120 à 600 lbf.ft]
Auto-top 2000 Anti-oxidizing Leuchtend grüne Farbe / fluores-
• Korrosionsschutzfett
origine AGIP grease cent green color
Internal snap ring

• Zange für Innenringe FACOM 499.32
pliers
• Abzieher FACOM U 20 B Extractor
6553
• Sechskantschlüssel für
Hex head wrench 13 17 19 22 24
Innensechskantschraube
• Drehmoment-Schlüssel FACOM J 250 A Torque wrench 6 à 30 N.m [4.4 to 22.1 lbf.ft]
• Drehmoment-Schlüssel FACOM S 250 A Torque wrench 50 à 240 N.m [35 to 175 lbf.ft]
• Drehmoment-Schlüssel FACOM K 250 A Torque wrench 160 à 800 N.m [120 à 600 lbf.ft]
36 REPAR MS2-18 D/GB 800378128J
654 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
Spezialwerkzeuge Special tools
Ø A
Ø B
• Montagewerkzeug
zum Anheben der • Mandrel for reassembling the
Schutzkappe oder zum brake cover or to compress the
F
E
G
Komprimieren der Tel- spring washer.
lerfeder.
Ø C
Ø D
0759
ØA ØB ØC ØD E F G
mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch]
F02
110 [4.3] 100 [4.0] 125 [4.9] 135 [5.3]
F03
F04 M12 50 [1.96] 10 [0.39] 20 [0.78]
F05 125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25]
F07
F08
125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25] 50 [1.96] 10 [0.39] 20 [0.78]
F09
F11
50 [1.96] 20 [0.78]
F12 M16
F18 190 [7.48] 180 [7.08] 205 [8.07] 215 [8.46] 10 [0.39]
F19 70 [2.75] 30 [1.18]
F21
• Rohr zum Festsetzen

[0 .9 8 " d ia ]
Tube to immobi-
Ø 2 5
Ø 1 6
des Motors lize the motor [0 .6 2 " d ia ]
5 5
[2 .1 6 " ]
7 0 0
[2 7 .5 5 " ]
M 1 2 x 1 2 0 M 1 6 x 1 2 0
c l. 1 0 .9
H M 1 2 H M 1 6
Z 1 2 N
A = 2 0 0 A = 2 8 0 A
• Werkzeuge zur me- Tools for me-
F 0 2 F 1 1
chanischen Bremslö- chanical brake F 0 3 F 1 2
sung. release F 0 4 F 1 8
F 0 5 F 1 9 Ø 1 6 .5
F 0 7 F 2 1 [0 .6 4 ]
F 0 8
F 0 9
6 0 x 3 0 5 0 x 5
800378128J REPAR MS2-18 D/GB 37
008 910 32 BOMAG 655

9.5 MS/MSE 02 to 18
POCLAIN HYDRAULICS
Anziehdrehmomente Tightening torques
Nm ± 10% in [lbf.ft] ± 10%
(Gemäß Norm DIN 912) (According to the standard DIN 912)
Größe Size 8.8 10.9 12.9 8.8 10.9 12.9

M6 10 14 17 7.5 10 12.5
M8 25 35 41 18.4 26 30
M10 49 69 83 36 51 61
M12 86 120 145 63.4 88.4 107
M14 135 190 230 100 140 170
M16 210 295 355 155 218 262
M18 290 405 485 214 299 358
M20 410 580 690 302 428 509
38 REPAR MS2-18 D/GB 800378128J
656 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
Ersatzteile Spare parts list

Nummer Bezeichnung Item Description
} 010 Kompletter Zylinderblock } 010 Cylinders-block assembly
012 Kompletter Kolben Cl. 0 012 Piston Cl 0 assembly
013 Kompletter Kolben Cl. 1 013 Piston Cl 1 assembly
015 Reparatursatz 015 Repair kit
} 026 Kompletter Nockenring } 026 Cam assembly

027 O-Ring 027 O-ring
} 040 Komplettes Verteilerdeckel } 040 Valving cover assembly

041 Verteilerdeckel 041 Valving cover part
042 Schraube 042 Screw
043 Dichtungsring 043 Seal washer
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 32 BOMAG 657

9.5 MS/MSE 02 to 18
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
658 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 41
008 910 32 BOMAG 659

9.5 MS/MSE 02 to 18
POCLAIN HYDRAULICS
Motoren mit konstantem Hubvolumen MS, MSE 02-05-08-11-18.

Single displacement motors MS, MSE 02-05-08-11-18.
0987
42 REPAR MS2-18 D/GB 800378128J
660 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
Dichtungssatz
Seal kit 0988
800378128J REPAR MS2-18 D/GB 43
008 910 32 BOMAG 661

9.5 MS/MSE 02 to 18
POCLAIN HYDRAULICS
Motoren mit umschaltbarem Hubvolumen MS, MSE 02-05-08-11-18.

Dual displacement motors MS, MSE 02-05-08-11-18.
0990
44 REPAR MS2-18 D/GB 800378128J
662 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
Dichtungssatz
Seal kit
0989
800378128J REPAR MS2-18 D/GB 45
008 910 32 BOMAG 663

9.5 MS/MSE 02 to 18
POCLAIN HYDRAULICS
46 REPAR MS2-18 D/GB 800378128J
664 BOMAG 008 910 32

MS/MSE 02 to 18 9.5
POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 47
008 910 32 BOMAG 665

9.5 MS/MSE 02 to 18
China España & Portugal

POCLAIN HYDRAULICS BEIJING rep. office POCLAIN HYDRAULICS SPAIN S.L.
Unit A0808, Hui Bin Officies Gran Via Carlos III no84 – 1o 3a
No.8 Beichendong St. 08028 BARCELONA
BEIJING 100101 ESPAÑA
CHINA Tel.: 349 3 409 54 54
Tel.: 86 10 6499 3988 Fax: 349 3 490 21 79
Fax: 86 10 6499 3979 e-mail: info-espana@poclain-hydraulics.com
e-mail: info-china@poclain-hydraulics.com
ýHVNi 5HSXEOLND France
POCLAIN HYDRAULICS SRO POCLAIN HYDRAULICS France SAS

Kšírova 186 B.P. 106
61900 BRNO 60411 VERBERIE CEDEX
ý(6.È 5(38%/,.$ 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
666 BOMAG 008 910 32

9.6 Axle DANA 192
008 910 32 BOMAG 667

9.6 Axle DANA 192
668 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 669

9.6 Axle DANA 192
670 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 671

9.6 Axle DANA 192
672 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 673

9.6 Axle DANA 192
674 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 675

9.6 Axle DANA 192
676 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 677

9.6 Axle DANA 192
678 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 679

9.6 Axle DANA 192
680 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 681

9.6 Axle DANA 192
682 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 683

9.6 Axle DANA 192
684 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 685

9.6 Axle DANA 192
686 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 687

9.6 Axle DANA 192
688 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 689

9.6 Axle DANA 192
690 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 691

9.6 Axle DANA 192
692 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 693

9.6 Axle DANA 192
694 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 695

9.6 Axle DANA 192
696 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 697

9.6 Axle DANA 192
698 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 699

9.6 Axle DANA 192
700 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 701

9.6 Axle DANA 192
702 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 703

9.6 Axle DANA 192
704 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 705

9.6 Axle DANA 192
706 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 707

9.6 Axle DANA 192
708 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 709

9.6 Axle DANA 192
710 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 711

9.6 Axle DANA 192
712 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 713

9.6 Axle DANA 192
714 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 715

9.6 Axle DANA 192
716 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 717

9.6 Axle DANA 192
718 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 719

9.6 Axle DANA 192
720 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 721

9.6 Axle DANA 192
722 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 723

9.6 Axle DANA 192
724 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 725

9.6 Axle DANA 192
726 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 727

9.6 Axle DANA 192
728 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 729

9.6 Axle DANA 192
730 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 731

9.6 Axle DANA 192
732 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 733

9.6 Axle DANA 192
734 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 735

9.6 Axle DANA 192
736 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 737

9.6 Axle DANA 192
738 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 739

9.6 Axle DANA 192
740 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 741

9.6 Axle DANA 192
742 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 743

9.6 Axle DANA 192
744 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 745

9.6 Axle DANA 192
746 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 747

9.6 Axle DANA 192
748 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 749

9.6 Axle DANA 192
750 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 751

9.6 Axle DANA 192
752 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 753

9.6 Axle DANA 192
754 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 755

9.6 Axle DANA 192
756 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 757

9.6 Axle DANA 192
758 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 759

9.6 Axle DANA 192
760 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 761

9.6 Axle DANA 192
762 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 763

9.6 Axle DANA 192
764 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 765

9.6 Axle DANA 192
766 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 767

9.6 Axle DANA 192
768 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 769

9.6 Axle DANA 192
770 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 771

9.6 Axle DANA 192
772 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 773

9.6 Axle DANA 192
774 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 775

9.6 Axle DANA 192
776 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 777

9.6 Axle DANA 192
778 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 779

9.6 Axle DANA 192
780 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 781

9.6 Axle DANA 192
782 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 783

9.6 Axle DANA 192
784 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 785

9.6 Axle DANA 192
786 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 787

9.6 Axle DANA 192
788 BOMAG 008 910 32

Axle DANA 192 9.6
008 910 32 BOMAG 789

9.6 Axle DANA 192
790 BOMAG 008 910 32

10 Circuit diagrams
008 910 32 BOMAG 791

Circuit diagrams
l
The circuit diagrams valid at the date of printing are
part of these repair instructions.
l
The circuit diagrams valid for the machine serial
number can be found in the spare parts catalogue
for the machine.
792 BOMAG 008 910 32

10.1 Wiring diagram
008 910 32 BOMAG 793

10.1 Wiring diagram
794 BOMAG 008 910 32

Inhaltsverzeichnis: BW 177..219 D−4/D−40
008 910 32
table of contents: BW 177..219 D−4/D−40
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
Wiring diagram
001 582 702 09 Stromlaufplan Circuit Diagram

002 582 702 09 Versorgung, Starten, Motordrehzahl supply, starting unit, engine−speed
003 582 702 09 Motor−Heizflansch, Signalhorn, Geschwindigkeit−Anz. engine heating−flange cont., warning horn, speedometer
004 582 702 09 Bremse, Rückfahrwarneinr., Anzeige brake, back up alarm, indicator
005 582 702 09 Fahrstufen, Sitzkontaktsch., Vibration speed−ranges, seat−switch, vibr.
006 582 702 09 ZA Messtechnik option measurement equipm.
007 582 702 09 BOMAG Compaction Management BCM BOMAG Compaction Management BCM
008 582 702 09 ZA Beleuchtung und StvZO opt. illumination and StvZO
009 582 702 09 ZA Kabine, Beleuchtung, Radio, Tachograph opt. cabin, headlights, radio, tachograph
010 582 702 09 ZA Kabinenheizung, Klimaanlage, Zusatzheizung opt. cabin−heater, air conditioning, add. heater
101 582 702 09 Bauteilliste component listing
BOMAG
16.11.2005
001 001
Vogt Stromlaufplan 582 702 09
16.11.2005
795
10.1
circuit diagram 001

Seis
796
30 6:1
K30
9:2
15:54
10.1
2:10 K11 30
X1
X1:15E 2:10
17E
87 87a
1
X1:9
F13 1
X1:10
F105
30A
2 20A
X1:15A 2 K11/87 3:1
X1
X37:A
17A X1
S00 30 X1:30E
X36:B
X36:A
30 27E
B+
2:11 K35 1
2:16 F14 1 F39
15A 15A
4qmm
Startschalter 87a 87 2 2
starting switch 15 54 58 19 17 50a
X1 X1 X1:30A
15:54 27A
2:13 80 K32:86
X1 9:2
79 S120 11 23
30 F14:2
5:9
K114
X37:B 2:14 S01:21
X1:3 X1:4 5:9
nur ohne Sitzkontaktschalter
without switch seat−contact
V01
3:2 87a 87
switch engine speed

30 12 24
Schalter Motordrehzl
2 1 K11:86 K05 X1:151
4:5
6:5
30(3)
main fuse
125mA
4:3
Hauptsicherung
K14 21 11 31 ?
heating−flange
K61 87 87a
Sicherung Heizflansch
3:5 86 1 K61 30 S01
87(4) 86
F48 2 F00 2 R10 2:5 22 12 32 ?
82 OHM K35
87 87a NOT−AUS
85 2 K05/87
125A
125A
1 1 3:2 85 Emerg.−Stop
X1:53
BOMAG
4:13 X1:152
K61/85
6:2 B+ X1 X1 X1 X1 30
X1:60 K22
X1 D+ MESX 2:5 7 8 58 59
1 4:9
G03 + G01 + X1 2x2.5qmm 87 87a
65 X38:A 2
nur bei Klimaanlage

B+ X1
− − D+ 3.9A
81 V47 X1
only acc.to air conditioning

G02
125mA
50A / 10A
30 50 1 AW 54
86
AUX
86 86 86 Y01 2 + HW 1
167A
K09 Y13
B− W M01 K114 Y120
1 1 K36 K11 M
S30 W 1 70A/1A − 2
31−1
R19 85
X1:66 85 85 85 −
2 X1
X1 X1 55
nur bei BW 219D−4 und D−40 USA Version, sonst Option

only at BW 219 D−4 and D−40 USA version, otherwise option
X1:55 X1:56
2
3.8A
62 63
Option
option
X1:168
31 31 3:1
2:8 4:4 10:7 2:18 2:16 2:13
Trennschalter Batterie
break switch battery
Heizflansch Batterie Batterie Generator Starter Startmehrmenge Hubmagnet Drehzahl Kraftstoffabschaltug
heating−flange battery battery generator starter start boost fuel sol. engine speed fuel shut off
16.05.2005
1 1
008 910 32
Wiring diagram
Vogt Versorgung, Starten, Motordrehzahl 582 702 09

16.05.2005
Seis supply, starting unit, engine−speed 002
2:20 K11/87 K11/87 4:1
F24:2
4:10
4:19
GLÜH
2:10 K11:86 X1
008 910 32
52
2:13 K05/87 X1
78 X1
X1 28E
Wiring diagram
75
F23 1
10A
2 X1
X1 92
28A
X1:155 +
15/54
Lern
Test
OUT+
Modul Geschw. A05 P04

13 23 modul speedometer
speedometer
5 2 7 1 S03 −
−
in
Geschwindigkeitsanz.
X1
OUT−
14 24
A13
93
X1 X1
3 4 6 97 98
Anbau im Motorbereich
X1 X1 ZA Geschwindigkeitsanzeige
assembled in engine−area
101 102 option speedometer
Modul Heizflanschsteuerung
modul heating−flange−control
1
Taster Signalhorn
push but. warning horn
BOMAG
X1:171
K14
2
2
+
V21
V22
dir. X1:173
4.2A
4.2A
1
1
B60 DIR MESX 6:2
Relais Heizflansch
Nur bei BW 219 D−4 und D−40 USA Version, sonst Option
only at BW 219 D−4 and D−40 USA version, otherwise option
speed
relais heating−flange
B11 1 B11 1 SPEED MESX 6:2
Anbau im Motorbereich
assembled in engine−area
− X1:172
2 SPEED TAC
9:6
1 2 2
nicht bei D−40/BW211D−4 ohne SN1
not at D−40/BW211D−4 ohne SN1
B113
2
X1 X1 X1 X1
57 64 99 100 X1:174
2:20 31 31 4:1
Kühlmitteltemperatur Signalhorn Signalhorn Sensor Achse

collant temperature warning horn warning horn sender axle
nur bei ZA Messtechnik, Geschw.−Anzeige und Tachograph

only at opt. measurement−equ., speedometer and tachograph
16.11.2005
1 1 582 702 09
Vogt Motor−Heizflansch, Signalhorn, Geschwindigkeit−Anz.
797
10.1
16.11.2005
Seis engine heating−flange cont., warning horn, speedometer 003
798
3:20 K11/87 K11/87 5:1
Zentralstecker Sammelanzeige (Ansicht von hinten)
X1 X1:31E mainplug monitoring module (view from backside)
29E
10.1
9 8 7 6 5 4 3 2 1
1 1
F25 F24
10A 10A
2 2 X5:1−20
Sammelanzeige 201918 1716151413 121110
X1
X1:31A monitoring module
29A 6 Vorglühen
A15 GLÜH
F24:2 3:5
3:15 Warnbl.
7 BL−W
8:16
X1 15/54 Blinker rechts
20 FUEL 19 BL−R
HOURS 8:17
X1:156 86 OUT2 Blinker links
9 18 BL−L
F25:2 8:17
5:2 OUT1 Sitz
1 12 A68/6
5:9
Bel.
8 4
X12 X13 8:5
1 1 BEL 10 3
geöffnet in 0
Position (Bremse ein)
BR/BN 30 BR/BN
30 2 14 11 13 15 17 16 5
D+
K48 K26
GND
B13 B14
4:2 4:6
Bremse
5:9
5:9
Luftfilter
87a 87 87a 87
Tankanzeige
BL/BU SW/BK BL/BU SW/BK
Motoröldruck
Öltemperatur
Hydraulikölfilter
D+
Wasserabscheider
30 X1 X1 X1
B06:1
Kühlmittelfüllstand
K36 69 87 76
Initiator Farhebel"0
2:7
Initiator Vorw. und Null

87a 87 X1 X1 X1 X1
X12 3 X12 2 X13 3 X13 2 110 71 X1:77 X1:72 111 112
X1 X1 X1 X1 X1
K48:87A 106 67 X1:74 73 X1:68 107 108
4:13
BOMAG
X1:147 K26/87A
proximity switch travel lever "0"−position

5:9
proximity switch forwards and "0"−position

11
S01 X1
K61/85
2:18 109 2:6
X1:61
12 SITZWARN.
K48/86 5:9 5:9 X1
X1:150 X1 X1
105
X1:148 X1:153 114 90 K48:87A X8 1 X8 2
6:2 4:3
X10
300mA
X1:113 BRAKE MESX 2 X21:1
Sensor
X1 or B21 3 B03 3 2 1 B06 1 B55 B124
2.5A
125mA
X9 89 +
86 86 Y04 86 1 86 R03
K48 K05 1 K26 K22 P P _t P Q
H14+ + bl 4 4 B30 2 −
− P
H07
85 85 2 85 X9 85 X10 X21:2
2 3 X1:117 X1:57
125mA
125mA
X1:149 X1 X1:82 X1:117
X1:117 129 X1:117
3:20 31 31 5:1
4:3 2:11 4:8 2:18 nicht bei D−40

not at D−40 nicht bei D−40/BW177 D−4
not at D−40/BW177 D−4
Magnetventil Bremse Rückfahrwarnsummer Warnsummer Störung Tankgeber Luftfilter Motoröldruck Sensor Wasserabschei
solenoid valve brake buzzer back up alarm buzzer failure sender fuel
air cleaner engine oil pressure sens. water separator
Hydraulikölfilter Öltemperatur Kühlmittelstand
Resist. buzzer hydraulik oil cleaner oil temperature coolant stock level
16.11.2005
1 1
008 910 32
Wiring diagram
Vogt Bremse, Rückfahrwarneinr., Anzeige 582 702 09

16.11.2005
Seis brake, back up alarm, indicator 004
4:20 K11/87 K11/87 8:1
X1:32E
D+ F03 1
4:13
15A 2
008 910 32
B06:1
4:17 X1:32A
4:3 K48/86
F14:2 Nur mit Sitzkontaktschalter

Wiring diagram
2:20
only with switch seat−contact
nur D−40/BW177D−4 Standard D−Maschinen/D−40 USA
only D−40/BW177D−4 Standard D−maschines/D−40 USA
Fahren
Öldruck
D+
F25:2 1 12 13 14 30 56
4:8
K04
31
A68 Modul Sitzschalter/Vibration
module seatswitch/vibration
S 56b
modul vibration
Modul Vibration
13 4 6 9 11 15 5
S42 1234 2
S42
1 5 7 3 S01:21
14 2:20 X1:158 X1:157
Fahrstufensch.
switch speed ranges K26/87A
switch speed ranges

Nur ohne Sitzkontaktschalter
without switch seat−contact
4:8 X14 X11
Schalter Fahrstufen
2
1
B 1 X1:159
V09 X1 14
S13
88
23 13
A68/6 3 S35
S58
4:19 13
X1:143 X1:144 X1:162 X1:143 SITZWARN. 4

4:10 24 14
BOMAG
2
1
V05 X1:161 X1:160
V02 V03
2 1 1 2
GA MESX
6:2
Taster Vibration
pushbutton vibration
KA MESX 6:2
X1:141 X1:137 X1:142 X1:141
X1:116 X1:115
switch seat−contact
Sitzkontaktschalter
1.23A
1.23A
1.23A
X6 X7
Y31 Y30 Y31 X14 X11 1 1
1 1 1 1 Y07 Y08
3.33A
3.33A
A 2
9:7 KA
9:6 GA
a b
2 2 2 2
X6 X7
2 2
X1:124 X1:138 X1:124 X1:124
X1:149
X1:154
X1:149
X1:149
31
X1:118
4:20 31 6:1
Schalter Vibration klein/groß

nur BW216+219D−4 switch vibration small/big ampl.
only BW216+219D−4
Stufenumsch. hinten Stufenumschaltung vorn Stufenumschaltung hinten Vibration vorne groß
switching axle switching drum switching axle vibration big ampl.
Vibration vorne klein
Stufenumschaltung vorn
switching drum vibration small ampl.
16.11.2005
1 1 582 702 09
Vogt Fahrstufen, Sitzkontaktsch., Vibration
799
10.1
16.11.2005
Vogt speed−ranges, seat−switch, vibr. 005
800
Beschleunigungssensoren Beschleunigungssensoren Drucker Anzeige BMFSA Display Messtechnik BOP
acc. sensor front acc. sensor rear printer Display BMFSA display measurem. BOP
GND
30
10.1
2:20 30 8:1
Pot 30
K11/87
8:20 Pot 15
X2:66 X2:70 X2:47 X2:48 X2:49

X1:145 X42:1 X42:2 X42:3
X2:71
X46:B X46:A X46:E
X1:33E X1:35E 31
+ −
1 1 S01
F148 F146 2:18 X2:56 X2:53 X2:60 X2:57
10A 15A
2 2 32
X48:2 X48:1 X49:2 X49:1 P33
X1:33A X1:35A X1:146
X4:C
X4:E
X4:D
P16
B62 B62 F1 F2
+/sw
+/sw
nur bei BEM
only at BEM
F148:2 X1:34E −/gg −/gg

7:15
CAN+ CAN−
nur bei BTM+/BTM prof
only at BTM+/BTM prof
F84 1 X46:D X46:F

10A 15g/bl 15g/bl
X74:3
X74:5
X74:4
2 X42:4 X42:5
X2:57 X1:34A P11
20g/br
20g/br
nur bei BTM prof
X48:3 X48:4 X49:3 X49:4
only at BTM prof

X74:1 X74:2
X2:50 X2:51
X2:54 X2:55 X2:58 X2:59 X4:A X4:B R20
1 2
60OHM
X2:64 X2:65
Pot. 15
Leistung
Elektronik
AGND MESX
Aufn. vorne 15g

Aufn. vorne 20g
Aufn. hinten 15g
Aufn. hinten 20g
CAN1+
CAN1−
RxD TxD
BOMAG
X44:1
X44:7
X44:5
X44:4
X44:31
X44:56
X44:57
X44:59
X44:60
X44:30
X44:58
X44:29
X44:27
X44:26
X44:28
X44:54
A83
Messtechnik−Rechner
X44:38
X44:15
X44:35
X44:14
X44:32
X44:36
X44:37
X44:38
X44:41
X44:53
X44:33
measurement calc. unit

X44:3
X44:55
X44:65
X44:66
X44:67
X44:68
GA MESX CAN3+ CAN3−
GND
5:17
EVIB
KA MESX
GND
5:17 CAN3− 7:15

SPEED MESX X1:85
3:16
DIR MESX X2:49 X2:52 + CAN3+
3:16 7:15
PITCH MESX P07 E
VIB
4:5 BRAKE MESX
−
D+ MESX
2:6 X2:63 X2:66 X1:82
8:4 BEL MESX

31 31 7:1
5:20
EVIB−Meter
EVIB−meter
nur bei BEM
only at BEM
16.11.2005
1 1
008 910 32
Wiring diagram
Vogt ZA Messtechnik 582 702 09

16.11.2005
Seis option measurement equipm. 006
F148:2
6:2
008 910 32
CAN3−
6:18
6:18 CAN3+
Wiring diagram
CAN3+ CAN3−
1 R242
120 OHM
X2:61 X2:62
R25
1 2
120 OHM
X4:N X4:M
X75:7 X75:2
A87
USB−CAN Schnittst.
USB−CAN Interface BCM
X2:70
BOMAG
X76:1 X4:G
X76:2
P15
X4:F
X2:63
BCM 05
nur bei BCM

only at BCM
6:20 31 31 8:1
16.11.2005
1 1 582 702 09
Vogt BOMAG Compaction Management BCM
801
10.1
16.11.2005
Seis BOMAG Compaction Management BCM 007
802
5:20 K11/87 K11/87 6:2
6:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
10.1
F11 F18 F07 F08

15A 10A 15A 15A
30
X1:18A K06 X1:19A X1:25A
X1:26A
8:4 X1:305
X1:83
X1:301
Schalter StvZO 87 87a
switch, StvZO
13 23
012 31 11 23 Anschluß Arbeitsschein− L0R
werfer ohne StvZO L0R Schalter Blinker
S37
connection working head X1:21E X1:22E switch indicator
lights without StvZO 5 4 14 24
S15 F22 F19
32 12 24 15A 15A
Anschluß Arbeitsscheinwerfer
X1:21A E X1:22A D bei Kabine
Connection head lights
X1:306
X1:307
X3:4 X3:5 with cabin 30 49L 49R

STV1
X1:302
9:17 A02
STV2
9:17
X1:23E X1:24E
K16 30 31 82 L R
8:9 F09 F10
15A 15A
87 87a X1:23A X1:24A
4:11 BL−L X1:91

4:19
13 BEL BL−R
4:19
X1:96
S53 14
BOMAG
switch, working head lights
Schalter Arbeitsbeleuchtung
X1:308
X1:304
X1:303
13 23
01
01
S14
X1:311
X1:310
X1:319
X1:312
lights without StvZO

X1:313
Anschluß Arbeitsschein−
werfer ohne StvZO
connection working head
X1:314
X1:84
Warnblinkschalter 14 24
6:2 switch, hazard light
Arbeitsscheinwerfer hinten links

working head lights, rear lh.
Arbeitsscheinwerfer hinten rechts
working head lights, rear rh.
Arbeitsscheinwerfer vorne links
working head lights, front lh.
Arbeitsscheinwerfer vorne rechts
working head lights, front rh.
X61:3 X1:320
X59:5
X60:3
X59:3
X58:5 X1:309
X58:3
X61:1 X1:322
X60:1 X1:321
X59:2
X58:2
BEL MESX BL−W
0,125A
0,125A
E16 1 E17 1 E13 1 E12 1 E14 1 E15 1 E27 1 E28 1 E23 1 E25 1 4:19 E08 1 E09 1 E10 1 E11 1
+
2 2 86 2 2 2 2 86 2 2 2 2 H06 2 2 2 2
K06 K16
4,6A
4,6A
4,6A
4,6A
−
X61:2
X59:6
X58:6
X60:2
85 85
X3:1
X1:315 X58:6
X1:316 X59:6
X1:315 X58:6
X1:316 X59:6
4,6A
4,6A
0,42A
0,42A
0,42A
0,42A
1,75A
1,75A
1,75A
1,75A
X1:323 X60:4
X1:324 X61:4
X1:315
X1:316
X1:323
X1:324
7:20 9:1
31
8:10 Schlußleuchte links 8:2 Bel. Warnbinkschalter 31
Scheinwerfer links tail light, LH illumination, switch hazard light
head light LH Parkleuchte links Blinkleuchte VL Blinkleuchte HR
Anschluß Arbeitsscheinwerfer
Scheinwerfer rechts parking light, LH bei ROPS/SD Aufbau indicator front, LH indicator rear, RH
head light RH Parkleuchte rechts Blinkleuchte HL
parking light, RH Connection head lights indicator rear, LH
acc.to ROPS/SD
Schlußleuchte rechts Blinkleuchte VR
tail light, RH indicator front, RH
16.11.2005
1 1
008 910 32
Wiring diagram
Vogt ZA Beleuchtung und StvZO 582 702 09

16.11.2005
Seis opt. illumination and StvZO 008
F42:H 10:13 F41:5 10:13
X3:6
2:11 K30 2:11 K32:87 10:2
X3:7
K32:86 K32 30 STV2
X3:8 8:13
2:20 9:2 STV1
008 910 32
8:13
87 87a E F
G H A B C
X3:3
F143 F42 F43 F44 F130 F41 F144
15A 10A 15A 15A 10A 10A 15A
7 8 1 2 3
5 6
Wiring diagram
F42 10:8
F130 9:9 F130 F130 10:7
9:14
A12
15
1,75A
0,83A
K141 30 1 B51 + + 30 01W 7 2 01W 7 2 1 S163 5 1 S38 5
+ + B51
01 01 E72
9:16 E29 E70
− − − − 1
87 87a 2 2 2 1
31 S21 5 4 S20 5 4
Radio
radio
Steckdose Fahrerst.
3,8A
3,8A
1 Tachographenmodul
socket operator platform

E71 1 module, tachograph
XS
+ R80 A2+A3
X3:17
4,6A
4,6A
4,6A
4,6A
2 4 6 A1 XS
Nachtleuchte
− 3:16 P09 +
indicator
X55:1
X56:1
X55:3
X56:3
12V 2 1
X55:4
X56:4
night illumination
SPEED TAC A16 1 B3 E27 1 E28 1 E23 1 E25
Kontrolleuchte
Innenleuchte
inside light, cabin
socket cabin
−
12V
Steckdose Kabine
+ 7,8,9 2 B4 2 2 2 2
A01 5 3 C3
A5+A6
S45 TK −
Heizung Heckscheibe
4 1
BOMAG
heating rear screen
A51
Schalter Innenleuche
switches interior lights
3
5A
86 S86 + 3 2 5 + + S158 I 15 +
K32 E32
M05 M M04 M K141
M M
31
X3:16
X3:15
− −
3 min
85 − M07 − M06 4
KA
GA
2,9A
ZA
Nur bei Geländer/Rops/SD

4,7A
X55:2 X56:2 option

Abfallverzögert
only at hand−rail/Rops/sun−roof
5:17
5:16
10:18
Relais Kabine Türkontaktschalter Frequenzmodul Tachograph KABINE 31
relais cabin door switch module, frequency tachograph Schalter Nachtleuchte
switch, night illumination
X3:1
X3:2
Schalterbel.
switch illum.
8:20 31 31 10:1
9:6 Wascher hinten Wascher vorn 9:2 Arbeitsscheinwerfer vorn

washer rear washer front working head lights, front
Wischer hinten Wischer vorne Arbeitsscheinwerfer hinten Rundumkennleuchte

windscreen wiper, rear windscreen wiper, rear working head lights, rear rotary beacon
16.11.2005
1 1 582 702 09
Vogt ZA Kabine, Beleuchtung, Radio, Tachograph
803
10.1
16.11.2005
Seis opt. cabin, headlights, radio, tachograph 009
804
9:20 K32:87 9:19 F41:5
Potential 15 aus Kabine
9:17 F130 F42:H
9:4
F42 Potential 15 aus Kabine
9:9
10.1
D Potential 30 aus Kabine A B

F31 F40 BOX2 F15 BOX2
20A 20A 5A
4 1 2
2.5qmm
Bedienteil Kabinenheizung/Klimaanlage
1 2 3 12 11 13 14 16
X53:B X53:C control−unit cab−heater /air conditioning X54:4 X54:3 X54:2
0123 4 3 2 5 7 11 3 10 1
S44 A72
Steuergerät
control unit
6 11 12 1 Regel aus = 0,4A
S28
Schalter Kabinenlüfter
E30 Kleine Stufe = 0,67A
switch blower cabin X54:6 X54:11 X54:12 X54:1 Zusatzheizung mittleter Stufe = 1,0A
add. heater große Stufe = 1.9A
heater timer
X3:13 Power Stufe = 2,8A

Schaltuhr Heizung
Anlaufstrom beim Start = 8,3A

30 2 6 8 9 4 12
K09
X3:14
X53:L
X53:H
X53:M
2:8
87 87a X1:167 5 9 10 6 8 7 4 15
2.5qmm
X1:169 X18:1
X3:9
X3:11
X3:10
X3:12
X19:1
B131
B103 1 1
_t
BOMAG
_t 2 2
Thermofühler Klimaanlage
X19:2
X20:1 X18:2
X17:1 X1:163
temperature sensor air conditioning
X17:3 X1:166
X17:2 X1:165
Thermofühler Heizung
temperature sensor heating unit
B104 4
P
HP X77:1
1A
LP 3
ge rt or ge rt or
Y138 1 1
X1:170 9:19
X20:4
X20:3
V06 Y14 KABINE 31
Überwachung Kühlmitteldruck
monitoring coolant pressure
M09 M M09 M
Kabinenlüfter 2 2
br br
X20:2
X77:2
Y15 1 2
X17:4 V04 X1:168
2 1
3,5A
X1:164
9:20 31 31
Kabinenlüfter Klimakompressor Magnetventil Heizung Kraftstoffpumpe

cab ventilator air conditioning compr. solenoid valve, heating unit fuel pump heating unit
Vogt
1 1
008 910 32
Wiring diagram
Seis ZA Kabinenheizung, Klimaanlage, Zusatzheizung 582 702 09

16.11.2005
Seis opt. cabin−heater, air conditioning, add. heater 010
Wiring diagram 10.1
Name Bl. Pf. Benennung title TYP
005 4 MAX. 1,67A
A02 008 17 Blinkrelais indicator relay

A05 003 17 Elektronik Geschwindigkeitsanzeige Electronic system, speedometer MODUL
A12 009 5 Radio Radio
A13 003 3 Steuergeraet Heizung Control unit, heating
A15 004 16 Ueberwachungsmodul monitoring module
A16 009 7 Elektronik Tachograph Electronic system, tachograph
A51 009 6 Platine Frequenzanzeige Circuit board,frequenzy meter
A68 005 10 Modul Sitzkontakt Modul seat contact MAX. 0,12A
A72 010 11 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A83 006 6 Elektronik Messtechnik electronic measurement−equipment
A87 007 15 USB−CAN Schnittstelle BCM USB−CAN Interface BCM
Seis
16.11.2005
Vogt
16.11.2005
B03 004 15 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B06 004 17 Druckschalter Motoroel Pressure switch, engine oil
B11 003 9 Signalhorn Warning horn MAX.5A
B11 003 11 Signalhorn Warning horn MAX.5A
B13 004 2 Naeherungsinitiator Fahrhebel links Proximity switch, travel lever, lh.
B14 004 6 Naeherungsinitiator Fahrhebel rechts Proximity switch, travel lever, rh.
B21 004 14 Differenzdruckschalter Hydr.−Oelfilter Pressure diff. switch, hydr. oil filter
B30 004 16 Temperaturschalter Motoroel Temperature switch, engine oil
B51 009 5 Lautsprecher Radio Speaker radio
B51 009 6 Lautsprecher Radio Speaker radio
B55 004 17 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B60 003 14 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 006 12 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 006 8 Beschleunigungsaufnehmer Acceleration sensor
B62 006 10 Beschleunigungsaufnehmer Acceleration sensor
B103 010 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning
B104 010 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B113 003 3 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B124 004 19 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B131 010 10 Temperaturschalter Heizung Temperature switch, heating
E08 008 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
E09 008 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 008 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 008 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 008 7 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 008 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 008 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 008 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
component listing
E16 008 2 Scheinwerfer links Head light, lh. MAX. 4,6A

E17 008 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
Bauteilliste
E23 008 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 009 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 008 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 009 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 008 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 009 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 008 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 009 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 009 4 Innenleuchte Kabine Inside light, cabin 1,75A
E30 010 13 Heizgeraet Heating unit
E32 009 19 Kennleuchte Warning light 5A
E70 009 15 Nachtleuchte Night lamp 0,83A
E71 009 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 009 16 Beleuchtung Bedienschalter illum. Switches
F00 002 4 Hauptsicherung Batterie Fuse, main, battery 125A

F03 005 18 Sicherung Vibration Fuse, vibration MAX. 1,23A
F07 008 15 Sicherung Warnblinker Fuse, hazard light 15A
F08 008 18 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 008 6 Sicherung Park− u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 008 8 Sicherung Park− u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 008 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 002 10 Sicherung Startschalter Fuse, starter switch 30A
F14 002 18 Sicherung Hubmagnet Motor Fuse, shut off solenoid, engine 15A
F15 010 18 Sicherung Heizgeraet Fuse, heating unit BOX2
F18 008 5 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
F19 008 12 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 30A
F22 008 10 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 30A
F23 003 9 Sicherung Signalhorn Fuse, warning horn 10A
F24 004 10 Sicherung Ueberwachungsmodul Fuse, monitoring module 10A
F25 004 2 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 10A
F31 010 3 Sicherung Kabinenluefter Fuse, cabin ventilator
F39 002 19 Hauptsicherung Kabine Main fuse, cab 15A
F40 010 13 Sicherung Kabinenheizung Fuse, heating unit cab BOX2
F41 009 19 Sicherung Rundumkennleuchte Fuse, rotary beacon
F42 009 4 Sicherung Kabineninnenleuchte Fuse, inside light cab
F43 009 10 Sicherung Wischermotor hinten Fuse, wipermotor rear
1
F44 009 13 Sicherung Wischermotor vorn Fuse, wipermotor front

F48 002 3 Sicherung Gluehanlage Fuse, glow plug system 125A
F84 006 5 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
FM4 006 11 Platinensicherung Multifuse
F105 002 16 Sicherung Motordrehzahl Fuse, motor speed 20A
6
F130 009 15 Sicherung Nachtleuchte Fuse, night lamp

F143 009 2 Sicherung Heckscheibenheizung fuse rear screen heating unit
F144 009 20 Sicherung Kabinensteckdose Fuse cabin−socket
F146 006 4 Sicherung Steuerung MESX (Potential 30) Fuse Controller (Pot. 30)
582 702 09
F148 006 2 Sicherung Steuerung MESX (Potential 15) Fuse Controller (Pot. 15)
G01 002 4 Batterie Battery 103A

G02 002 5 Generator Generator
G03 002 3 Batterie Battery 103A
101
H06 008 15 Meldeleuchte Warnblinker Indicator light, hazard light

H07 004 10 Warnsummer Betriebsstoerung Warning buzzer, breakdown MAX. 0,12A
008 910 32 BOMAG 805

10.1 Wiring diagram
H14 004 8 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer MAX. 0,12A
K04 005 18 Schrittrelais Vibration Toggle relay, vibration MAX. 1,23A

K05 004 3 Relais Startstrom Relay, starting current BOSCHW
K06 008 4 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 8 Relais Klimageraet Relay, air conditioning BOSCHW
K11 002 10 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHW
K14 003 5 Relais Vorgluehen Relay, glow plug system BOSCHL
K16 008 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K22 004 9 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K26 004 6 Relais Rueckfahrwarneinrichtung Relay, back up alarm BOSCHW
K32 009 2 Relais Kabine Relay, cabin BOSCHW
K35 002 16 Relais Selbsthaltung Relay, holding contact BOSCHW
K36 002 7 Relais Bremskontrolle Relay, brake control BOSCHW
Seis
16.11.2005
Vogt
16.11.2005
K48 004 2 Relais Fahrhebel 0−Stellung Relay, travel lever 0−position BOSCHW
K61 002 5 Relais Ladekontrolle Relay, charge control BOSCHW
K114 002 14 Relais Motordrehzahl Relay, engine rpm BOSCHW
K141 009 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW
M01 002 11 Starter Starter 2.3 KW

M04 009 13 Scheibenwischermotor vorne Windscreen wiper motor, front 4,7A
M05 009 10 Scheibenwischermotor hinten Windscreen wiper motor, rear 2,9A
M06 009 14 Scheibenwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 009 11 Scheibenwaschermotor hinten Windscreen washer motor, rear MAX. 3,8A
M09 010 3 Kabinenluefter Cabin ventilator
M09 010 4 Kabinenluefter Cabin ventilator
P04 003 19 Geschwindigkeitsanzeige Speedometer

P07 006 15 Omegameter Omegameter
P09 009 8 Frequenz− und Geschwindigkeitsanzeige Frequency− and Speedometer
P11 006 14 Drucker Printer
P15 007 16 BCM 03 Bildschirm BCM 03 terminal
P16 006 16 Diagnose, Variomatic Diagnostics, varimatic
P33 006 18 Opus 21 Opus 21
R03 004 12 Geber Tankanzeige Sender, level gauge

R10 002 6 Parallelwiderstand Parallel resistor 82 OHM
R19 002 2 Heizflansch heater flange 167A
R20 006 17 Widerstand Resistor 60OHM
R24 007 15 Widerstand Resistor 120 OHM
R25 007 15 Widerstand Resistor 120 OHM
R80 009 2 Heizung Heckscheibe heating rear screen
component listing
S00 002 10 Startschalter Starter switch

S01 002 18 Schalter NOT AUS Switch, emergency off
Bauteilliste
S03 003 9 Taster Signalhorn Push button, warning horn

S13 005 13 Vibrationsschalter Fahrhebel rechts Switch, vibration, travel lever, rh.
S14 008 15 Warnblinkschalter Switch, hazard light
S15 008 4 Beleuchtungsschalter StVZO Switch, lighting StVZO
S20 009 13 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 009 10 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S28 010 17 Schalter Kabinenheizung Switch, cabin heating
S30 002 3 Batterietrennschalter Switch, battery disconnect
S35 005 15 Vibrationsschalter klein/gross Switch, vibration low/high
S37 008 18 Schalter Blinker Switch, indicator
S38 009 19 Schalter Kennleuchte Switch, warning light
S42 005 3 Stufenumschalter schnell−langsam Speed range selector, fast−slow
S42 005 7 Stufenumschalter schnell−langsam Speed range selector, fast−slow
S44 010 3 Schalter Kabinenluefter Switch, cabin ventilator
S45 009 4 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 008 4 Schalter Arbeitsbeleuchtung Switch, working lights
S58 005 13 Schalter Aetherstartanlage Push button, ether starting unit
S86 009 4 Schalter Tuer, links Switch door, lh.
S120 002 14 Schalter Motordrehzahl Switch, engine speed
S158 009 15 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 009 16 Schalter Heckscheibenheizung switch rear screen heating unit
V01 002 6 Diode Diode 4UF004

V02 005 6 Diode Diode MAX. 1,23A
V04 010 8 Diode Diode FE5B
V06 010 9 Diode Diode
V47 002 15 Diode (A7) Diode (A7) FE5B
X1:1 002 5 WAGO,E−Kasten WAGO,E−BOX

X1:2 008 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
2

6

582 702 09

102

806 BOMAG 008 910 32

Wiring diagram 10.1
X1:69 004 13 WAGO,E−KASTEN WAGO, E−box
Seis
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Vogt
16.11.2005

component listing

Bauteilliste

3

X1:15A 002 10 WAGO,E−Kasten WAGO,E−BOX
X1:15E 002 10 WAGO,E−Kasten WAGO,E−BOX
6

582 702 09

103

008 910 32 BOMAG 807

10.1 Wiring diagram
X1:18A 008 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:18E 008 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
Seis
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Vogt
16.11.2005

component listing

Bauteilliste

X2:47 006 18 WAGO−MESSTECHNIK Wago−measurement equip.
4

6

582 702 09

104

808 BOMAG 008 910 32

Wiring diagram 10.1
X3:1 008 11 STECKER ROPS/SD conn. ROPS/SR
X3:1 009 10 STECKER KABINE/ROPS conn. cabin/ROPS
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Vogt
16.11.2005

X4:A 006 14 KABINENST. MESST. con. measurem.equipm.
X4:B 006 14 KABINENST. MESST. con. measurem.equipm.
X4:C 006 14 KABINENST. MESST. con. measurem.equipm.
X4:D 006 14 KABINENST. MESST. con. measurem.equipm.
X4:E 006 15 KABINENST. MESST. con. measurem.equipm.
X4:F 007 18 KABINENST. MESST. con. measurem.equipm.
X4:G 007 18 KABINENST. MESST. con. measurem.equipm.
X4:M 007 16 KABINENST. MESST. con. measurem.equipm.
X4:N 007 15 KABINENST. MESST. con. measurem.equipm.
X6:1 005 14 DEUTSCH DEUTSCH connector
XS 009 1 Steckdose Socket
XS 009 20 Steckdose Socket
X10:2 004 12 AMP SUPERSEAL AMP connector
component listing
X10:3 004 12 AMP SUPERSEAL AMP connector

Bauteilliste

X14:A 005 13 DEUTSCH DEUTSCH connector
X14:B 005 13 DEUTSCH DEUTSCH connector
X17:1 010 3 STECKER LÜFTER HKL conn. blower
X18:1 010 10 STECKER THERMOFÜHLER conn. sender temp.
X18:2 010 10 STECKER THERMOFÜHLER conn. sender temp.
X19:1 010 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X19:2 010 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X20:1 010 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X21:1 004 17 STECKER KÜHLMITTEL connector coolant sensor
X21:2 004 17 STECKER KÜHLMITTEL connector coolant sensor
X36:A 002 4 EINSPEISUNG SCHALTKAS supply e−box
X36:B 002 4 EINSPEISUNG SCHALTKAS supply e−box
X37:A 002 10 ST. ZÜNDSCHLOß E−KAST connector ignition switch
X37:B 002 11 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X38:A 002 11 ST.STARTER E−KASTEN connector starter e−box
X42:1 006 18 STECKER ADAPTER BOP conector adapter BOP
X44:1 006 13 MESX STECKER MESX Stecker
5

6

582 702 09

105

008 910 32 BOMAG 809

10.1 Wiring diagram
Seis
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Vogt
16.11.2005

X46:A 006 19 STECKER BOP Connector BOP
X46:B 006 18 STECKER BOP Connector BOP
X46:D 006 18 STECKER BOP Connector BOP
X46:E 006 19 STECKER BOP Connector BOP
X46:F 006 18 STECKER BOP Connector BOP
X47:A 006 11 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:B 006 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:C 006 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X48:1 006 8 STECKER AUFN. VORNE conn. sender front
X49:1 006 10 STECKER AUFN. HINTEN conn. sender rear
X53:B 010 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:C 010 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:H 010 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:L 010 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:M 010 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X54:1 010 11 STECKER HEIZSTEUERUNG conn. heating controller
component listing

X55:1 009 11 STECKER WISCHER HINTE connector wiper rear
Bauteilliste

X56:1 009 14 STECKER WISCHER VORNE conn. wiper front
X58:2 008 17 STECKER STVZO VL Con. STVZO FL
X59:2 008 19 STECKER STVZO VR Con. STVZO FR
X60:1 008 18 STECKER STVZO HL Con. STVZO BL
X61:1 008 19 STECKER STVZO HR Con. STVZO BR
X74:1 006 14 STECKER DRUCKER con. printer
X75:2 007 16 SUB−D STECKER BCM INT con. SUB−D BCM
X75:7 007 15 SUB−D STECKER BCM INT con. SUB−D BCM
X76:1 007 17 STECKER VERS. BCM con. Power−sup. BCM
X76:2 007 17 STECKER VERS. BCM con. Power−sup. BCM
X77:1 010 13 STECKER PUMPE STANDHE Conn. pump add. heater
6
X77:2 010 13 STECKER PUMPE STANDHE Conn. pump add. heater
Y01 002 12 Magnetventil Startmehrmenge Solenoid valve, start boost fuel MAX. 3.9A
Y04 004 5 Magnetventil Bremse Solenoid valve, brake MAX. 1,8A
Y07 005 14 Magnetventil Vibration vorne gross Solenoid valve, vibration, front, high MAX. 2,5A
6
Y08 005 16 Magnetventil Vibration vorne klein Solenoid valve, vibration, front, low MAX. 2,5A
Y13 002 18 Hubmagnet Motor Shut off solenoid, engine MAX. 3.8A
Y14 010 13 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 010 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
582 702 09
Y30 005 6 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front MAX. 1,67A
Y31 005 3 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
Y31 005 8 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
Y120 002 16 Magnetventil Motordrehzahl hoch Solenoid valve, rpm engine high
Y138 010 10 Magnetveentil Heizung Solenoid valve, heating unit 3,5A
106
Y140 006 10 Magnetventil Erreger auf solenoid valve exciter up

Y141 006 11 Magnetventil Erreger ab solenoid valve exciter down
810 BOMAG 008 910 32

Wiring diagram 10.1
008 910 32 BOMAG 811

10.1 Wiring diagram
812 BOMAG 008 910 32

Wiring diagram 10.1
008 910 32 BOMAG 813

10.1 Wiring diagram
814 BOMAG 008 910 32

Wiring diagram 10.1
008 910 32 BOMAG 815

10.1 Wiring diagram
816 BOMAG 008 910 32

Wiring diagram 10.1
008 910 32 BOMAG 817

10.1 Wiring diagram
818 BOMAG 008 910 32

Wiring diagram 10.1
008 910 32 BOMAG 819

10.1 Wiring diagram
820 BOMAG 008 910 32

Wiring diagram 10.1
008 910 32 BOMAG 821

10.1 Wiring diagram
822 BOMAG 008 910 32

Wiring diagram 10.1
008 910 32 BOMAG 823

10.1 Wiring diagram
824 BOMAG 008 910 32

Wiring diagram 10.1
008 910 32 BOMAG 825

10.1 Wiring diagram
826 BOMAG 008 910 32

Wiring diagram 10.1
008 910 32 BOMAG 827

10.1 Wiring diagram
828 BOMAG 008 910 32

10.2 Hydraulic diagram
008 910 32 BOMAG 829

830 BOMAG 008 910 32

Hydraulic diagram 10.2
008 910 32 BOMAG 831

832 BOMAG 008 910 32

Instructions For Repair: BW 211 D-40 / BW 212 D-40 BW 213 D-40

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Available Formats

Instructions For Repair: BW 211 D-40 / BW 212 D-40 BW 213 D-40

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Copyright:

Available Formats

Instructions for repair

BW 211 D-40 / BW 212 D-40

Single drum roller

008 910 32 BOMAG 3

5.12 Measuring the pressure in the refrigerant circuit 275

4 BOMAG 008 910 32

008 910 32 BOMAG 5

These repair instructions contain all necessary infor-

You should only use genuine BOMAG spare parts.

6 BOMAG 008 910 32

auxiliary equipment must be fully functional and in

008 910 32 BOMAG 7

8 BOMAG 008 910 32

008 910 32 BOMAG 9

General Fill new hydraulic units with hydraulic oil before

10 BOMAG 008 910 32

008 910 32 BOMAG 11

12 BOMAG 008 910 32

Tightening torques for screws with metric unified thread

Tightening torque Nm* (ft-lb)

Tightening torques Nm * (ft-lb)

008 910 32 BOMAG 13

Fig. 1 Travel pump

14 BOMAG 008 910 32

008 910 32 BOMAG 15

16 BOMAG 008 910 32

008 910 32 BOMAG 17

18 BOMAG 008 910 32

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Engine Engine oil ACEA: E3-96/E5-02 or approx. 8,5 litres without

(-20 °C to +40 °C)

(-15 °C to +40 °C)

Diesel Winter diesel fuel approx. 150 litres

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

Air conditioning system Refrigerant R134A approx. 1400 g

Tires (only BW 213) Water approx. 295 litres

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

Engine cooling system Cooling system protection agent approx. 16 litres

008 910 32 BOMAG 27

2.1 Special tools, tests and adjustments

BOMAG part-no.: 300 120 80

BOMAG part-no.: 059 711 12

BOMAG part-no.: 007 610 03

BOMAG part-no.: 079 930 01

28 BOMAG 008 910 32

1000 mm BOMAG part-no.: 079 930 02

2500 mm BOMAG part-no.: 079 930 03

60 bar BOMAG part-no.: 059 721 07

600 bar BOMAG part-no.: 059 721 04

BOMAG part-no.: 055 439 02

BOMAG part-no.: 007 610 05

008 910 32 BOMAG 29

9. Vacuum pump for hydraulic oil tank

BOMAG part-no.: 007 610 04 (12 Volt)

BOMAG part-no.: 007 610 24 (24 Volt)

BOMAG part-no.: 057 505 70

30 BOMAG 008 910 32

008 910 32 BOMAG 31

2.3 Checking the rotation speeds

Check the engine speed

Nominal value idle speed:

Nominal value nominal speed: