BW 211 D-40 - Service Training

Service Training
BW 211 D/PD-40 / BW 212 D/PD-40 /

BW 213 D/PD-40
S-582-0037
S/N 101 583 48 1095> / SN 861 583 55 1001> / S/N 861 583 56 1001> /
S/N 101 582 42 1940> / SN 101 582 43 2399> / S/N 101 582 44 1209> /
S/N 101 582 47 1053> / S/N 101 582 48 1239> / S/N 101 582 49 1019>
Single drum roller
008 401 91 EN © 12/2016

2
Table of contents
Table of contents
1 General................................................................................................................................................... 9
1.1 General......................................................................................................................................... 10
1.2 Concerning your safety.............................................................................................................. 12
1.2.1 General prerequisites................................................................................................................. 12
1.2.2 Definition of responsible persons............................................................................................... 15
1.2.3 Fundamentals for safe operation............................................................................................... 16
1.2.4 Handling fuels and lubricants..................................................................................................... 17
1.2.5 Parking the machine in secured condition................................................................................. 23
1.2.6 Emergency procedures.............................................................................................................. 23
1.2.7 Maintenance work...................................................................................................................... 24
1.2.8 Repair......................................................................................................................................... 27
1.3 Fuels and lubricants................................................................................................................... 28
1.3.1 Fuels and lubricants................................................................................................................... 28
1.4 List of fuels and lubricants........................................................................................................ 35
2 Overview of machine.......................................................................................................................... 37
2.1 Diesel engine............................................................................................................................... 38
2.2 Travel / vibration pump............................................................................................................... 39
2.3 Drum............................................................................................................................................. 41
3 Technical data...................................................................................................................................... 43
3.1 Technical data BW 211 D/PD-40................................................................................................. 44
3.2 Technical data BW 212 D/PD-40 (58243, 58248, 58356)........................................................... 48
3.3 Technical data BW 212 D-40 (58348, 58356)............................................................................. 52
3.4 Technical data BW 213 D/PD-40................................................................................................. 55
3.5 Additional technical data............................................................................................................ 59
4 Electric systems.................................................................................................................................. 63
4.1 Table of fuels and lubricants...................................................................................................... 66
4.2 Central electrics.......................................................................................................................... 73
4.3 Fuse assignment......................................................................................................................... 75
4.3.1 Notes on safety.......................................................................................................................... 75
4.3.2 Central electrics......................................................................................................................... 75
4.3.3 Main fuses.................................................................................................................................. 76
4.3.4 Fuses, cabin............................................................................................................................... 76
4.4 Operator’s stand......................................................................................................................... 78
4.4.1 Monitoring board, A15................................................................................................................ 81
4.5 Wiring........................................................................................................................................... 84
4.6 Starting the engine with jump leads.......................................................................................... 97
4.7 Proximity switches on travel lever, B13 and B14..................................................................... 98
4.8 Differential pressure switch for hydraulic oil filter, B21........................................................ 101
4.9 Level sensor in diesel tank, R03.............................................................................................. 102
4.10 Float switch, coolant tank, B55.............................................................................................. 103
4.11 Air filter vacuum switch, B03................................................................................................. 104
4.12 Sensor for water in fuel, B124................................................................................................ 105
4.13 Fuel pre-heating, R79.............................................................................................................. 106
4.14 Oil pressure switch, B06........................................................................................................ 107
BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40 3

Table of contents
4.15 Coolant temperature switch, B30.......................................................................................... 108

4.15.1 Removing and assembling the coolant temperature switch................................................... 108
4.16 Boost fuel solenoid valve, Y01............................................................................................... 110
4.17 Solenoid actuator to shut down the engine, Y13................................................................. 111
4.18 Engine solenoid actuator, Y120............................................................................................. 112
4.19 Charge control light, engine tachometer.............................................................................. 114
4.20 Heating flange on engine, R19............................................................................................... 115
4.20.1 Checking the heating flange control....................................................................................... 117
4.21 MESSX, A83............................................................................................................................. 119
4.22 Acceleration transducer, B62................................................................................................. 188
4.23 Control unit for air conditioning, A108................................................................................. 190
4.24 Module for seat contact monitoring, A68............................................................................. 191
4.25 Vibration module, K04............................................................................................................ 199
4.26 Speedometer module, A05..................................................................................................... 203
4.27 Telemecanique switch............................................................................................................ 206
4.28 Deutsch plug, series DT and DTM......................................................................................... 208
4.29 Magnetic coil plug................................................................................................................... 212
4.30 Inspection and maintenance work........................................................................................ 215
4.30.1 Maintenance Table................................................................................................................. 215
4.30.2 Every 500 operating hours..................................................................................................... 215
5 Diesel engine..................................................................................................................................... 217
5.1 Diesel engine, general.............................................................................................................. 218
5.2 Service side............................................................................................................................... 220
5.3 Starter side................................................................................................................................ 221
5.4 Lubrication oil circuit................................................................................................................ 222
5.5 Coolant circuit........................................................................................................................... 224
5.6 Replacing the thermostat......................................................................................................... 226
5.7 Fuel supply................................................................................................................................ 228
5.8 Injection system........................................................................................................................ 232
5.9 Injection pump replacement during service........................................................................... 234
5.9.1 Disassembling the injection pump............................................................................................ 234
5.9.2 Determining the start of injection.............................................................................................. 236
5.9.3 Installing the injection pump..................................................................................................... 239
5.10 Injection valve replacement during service.......................................................................... 244
5.11 Checking / repairing injection valves.................................................................................... 247
5.12 Checking the compression.................................................................................................... 253
5.13.2 Checks prior to start up.......................................................................................................... 255
5.13.4 Every 1000 operating hours................................................................................................... 258
5.13.7 As required............................................................................................................................. 267
6 Hydraulic system.............................................................................................................................. 273
6.1 Overview of travel/vibration pump connections.................................................................... 274
4 BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40

Table of contents
6.2 Open and closed hydraulic circuit.......................................................................................... 277

6.3 Hydraulic units.......................................................................................................................... 279
6.3.1 Travel pump............................................................................................................................. 279
6.3.2 Vibration pump......................................................................................................................... 286
6.3.3 Swash plate principle, pump.................................................................................................... 289
6.3.4 Drum drive motor..................................................................................................................... 290
6.3.5 Travel motor............................................................................................................................. 293
6.3.6 Vibration motor......................................................................................................................... 295
6.3.7 Swash plate principle, motor.................................................................................................... 296
6.3.8 External gear pumps................................................................................................................ 298
6.3.9 Steering valve.......................................................................................................................... 300
6.4 Charge circuit............................................................................................................................ 302
6.5 Travel circuit.............................................................................................................................. 304
6.6 Vibration circuit......................................................................................................................... 307
6.7 Steering circuit.......................................................................................................................... 313
6.8 Tests and adjustments............................................................................................................. 317
6.8.1 Checking / adjusting the neutral positions of the travel pump.................................................. 319
6.8.2 Pressure tests in the travel circuit............................................................................................ 321
6.8.3 Checking / adjusting the exciter shaft speeds.......................................................................... 323
6.8.4 Checking / adjusting the exciter shaft speeds.......................................................................... 324
6.8.5 Checking the leakage rate of the vibration motor..................................................................... 325
6.8.6 Pressure tests in the steering circuit........................................................................................ 326
6.9 Flushing and bleeding.............................................................................................................. 330
6.9.1 Flushing - general.................................................................................................................... 330
6.9.2 Flushing the travel circuit......................................................................................................... 333
6.9.3 Flushing the vibration circuit..................................................................................................... 342
6.9.4 Bleeding the hydraulic system................................................................................................. 346
6.10.2 Checks prior to start up.......................................................................................................... 351
7 Air conditioning................................................................................................................................. 357
7.1 Overview.................................................................................................................................... 358
7.2 Physical principles.................................................................................................................... 359
7.3 Refrigerant R134a..................................................................................................................... 362
7.4 Compressor oil / refrigeration oil............................................................................................ 365
7.5 Working principle of the air conditioning system.................................................................. 368
7.6 Monitoring devices................................................................................................................... 369
7.7 Description of components...................................................................................................... 370
7.8 Compressor............................................................................................................................... 376
7.9 Emptying in case of repair....................................................................................................... 378
7.10 Drying and evacuation............................................................................................................ 379
7.11 Filling instructions.................................................................................................................. 380
7.12 Steam table for R134a............................................................................................................. 384

Table of contents

7.13.4 As required............................................................................................................................. 393
8 Oscillating articulated joint.............................................................................................................. 395
8.1 Overview oscillating articulated joint...................................................................................... 396
9 Drum................................................................................................................................................... 399
9.1 Overview drum.......................................................................................................................... 400
9.2 Inspection and maintenance work.......................................................................................... 403
9.2.1 Maintenance Table................................................................................................................... 403
9.2.2 Every 250 operating hours....................................................................................................... 403
9.2.4 As required............................................................................................................................... 405
10 Drive axle........................................................................................................................................... 407
10.1 Drive axle................................................................................................................................. 408
10.2 Checks prior to start up.......................................................................................................... 409
10.2.1 Checking wheels and tyres.................................................................................................... 409
10.3 Every 250 operating hours..................................................................................................... 410
10.3.1 Checking the oil level in the drive axle................................................................................... 410
10.3.2 Checking the oil level in the wheel hubs................................................................................ 410
10.4 Every 1000 operating hours................................................................................................... 412
10.4.1 Change the oil in the drive axle.............................................................................................. 412
10.4.2 Changing the oil in the wheel hubs........................................................................................ 413
10.4.3 Retightening the fastening of the axle on the frame............................................................... 414
10.4.4 Retightening the wheel nuts................................................................................................... 414
10.5 As required.............................................................................................................................. 415
10.5.1 Adjust the parking brake........................................................................................................ 415
11 Troubleshooting................................................................................................................................ 417
11.1 Preliminary remarks................................................................................................................ 418
11.2 Emergency procedures.......................................................................................................... 419
11.2.1 Actuating the emergency stop switch..................................................................................... 419
11.2.2 Disconnecting the battery....................................................................................................... 419
11.2.3 Towing in case of an engine failure........................................................................................ 419
11.3 Troubleshooting, electrical systems..................................................................................... 422
11.3.1 Preliminary remarks............................................................................................................... 422
11.3.2 Starting the engine with jump leads....................................................................................... 425
11.3.3 Fuse assignment.................................................................................................................... 426
11.3.4 Understanding electric circuit diagrams................................................................................. 428
11.3.5 Measuring method.................................................................................................................. 441
11.4 Troubleshooting, diesel engine............................................................................................. 446
11.4.1 Starting the engine with jump leads....................................................................................... 446
11.4.2 Fault - Cause - Remedy......................................................................................................... 447
11.4.3 Trouble shooting "Starter"...................................................................................................... 449
11.4.4 Trouble shooting procedure on generator.............................................................................. 450
11.5 Trouble shooting, hydraulics................................................................................................. 456

Table of contents
11.5.1 Insufficient hydraulic power.................................................................................................... 456

11.5.2 Trouble shooting axial piston pumps...................................................................................... 459
11.5.3 Trouble shooting axial piston motors...................................................................................... 461
11.5.4 Fault table hydraulic components........................................................................................... 463
11.6 Trouble shooting, air conditioning system........................................................................... 471
11.6.1 Trouble shooting in refrigerant circuit, basic principles........................................................... 471
11.6.2 Trouble shooting procedure.................................................................................................... 477
11.6.3 Leak test................................................................................................................................. 486
11.6.4 Checking the magnetic clutch ............................................................................................... 487
12 Disposal............................................................................................................................................. 489
12.1 Final shut-down of machine................................................................................................... 490
13 Special tools...................................................................................................................................... 491
13.1 Special tools, electrics........................................................................................................... 492
13.2 Special tools, hydraulic system............................................................................................. 493
13.2.1 Special tools, tests and adjustments...................................................................................... 493
13.2.2 Special tools for flushing........................................................................................................ 495
13.3 Special tools for oscillating articulated joint........................................................................ 496
13.4 Special tools, drum................................................................................................................. 498
14 Index................................................................................................................................................... 501
Appendix............................................................................................................................................ 511
A Circuit diagrams............................................................................................ 513

Table of contents

General
1 General

General – General
1.1 General
General This manual:
n addresses the BOMAG customer service or professionally
trained personnel.
n explains the design of the machine and its functions.
n serves as
– document to be used during the training course
– reference book for the purpose of repeating or deepening
the training contents you have learned.
This manual describes components, assemblies and the essential
functions of the machine. (As far as required for the BOMAG After
Sales Service)
Index The index is a reference register that will help you to find informa-
tion in this Service Manual. The index lists keywords in alphabet-
ical order. Cross references (keywords related to page numbers)
enable quick and convenient search/navigation.
Keywords concerning the following subjects are listed in the index:
n Electrical operating means
n Plug designations
n Overviews
n Fault codes
n Troubleshooting
n ...
Documentation For the BOMAG machines described in this manual the following
documentation is additionally available:
n Operating and maintenance instructions
n Spare parts catalogue
n Service information (if necessary)
Genuine BOMAG spare parts

Use only genuine BOMAG spare parts.
Spare parts needed for repairs can be taken from the spare parts
catalogue for the machine.
Updating service This manual is not subject of an updating service. For this reason
we would like to draw your attention to the additionally published
service informations.
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 notification.

General – General
Copyright Information and illustrations in this manual must not be reproduced

and distributed, nor must they be used for the purpose of competi-
tion without the consent of BOMAG. All rights according to the
copyright law remain expressly reserved.

General – Concerning your safety
1.2 Concerning your safety

1.2.1 General prerequisites
1.2.1.1 General
This BOMAG machine has been built in compliance with the latest
technical standard and complies with the applicable regulations
and technical rules.
However, dangers for persons and property may arise from this
machine, if:
n it is used for purposes other than the ones it is intended for,
n it is operated by untrained personnel,
n it is changed or converted in an unprofessional way,
n the safety instructions are not observed.
Each person involved in the operation, maintenance and repair of
the machine must therefore read and comply with these safety reg-
ulations. If necessary, the operating company must obtain the rele-
vant signatures as confirmation.
Furthermore, the following obviously also applies:
n applicable accident prevention instructions,
n generally accepted safety and road traffic regulations,
n country specific safety regulations.
It is the duty of the operator to be acquainted with the safety regu-
lations and to apply these accordingly. This also applies for local
regulations and regulations concerning different types of handling
activities. Should the recommendations in these instructions be dif-
ferent from the regulations valid in your country, you must comply
with the safety regulations valid in your country.
1.2.1.2 Explanation of signal words used:
DANGER!
Danger to life if failing to comply!
Sections marked accordingly indicate an extremely
dangerous situation that could lead to fatal or
severe injuries, if this warning is disregarded.
WARNING!
Danger to life or danger of severe injuries if
failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.

CAUTION!
Danger of injury if failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
NOTICE!
Danger of material damage if failing to comply!
Sections marked accordingly indicate possible
dangers for machines or components.
Sections marked accordingly indicate technical

information or notes on using the machine or its
components.
ENVIRONMENT!
Environmental damage if failing to comply!
Paragraphs marked accordingly indicate practices
for safe and environment-friendly disposal of fuels
and lubricants as well as replacement parts.
1.2.1.3 Personal protective equipment

Depending on the work to be carried out, personal protective equipment is required (to be provided
by the operating company):
Working clothes Tight fitting working clothes with low tear resistance, tight
sleeves and without any projecting parts protect against
being caught by moving components.
Safety shoes To protect against heavy falling parts and slipping on

slippery ground.
Protective gloves To protect the hands against excoriation, punctures or

deep injuries, against irritating and caustic substances
as well as against burns.

Safety goggles To protect the eyes against airborne particles and

squirting fluids.
Face protection To protect the face against airborne particles and

squirting fluids.
Hard hat To protect the head against falling parts and to protect
against injuries.
Hearing protection To protect the hearing against too loud noise.
1.2.1.4 Intended use

This machine must only be used for:
n Compaction work in earth construction and road bases.
n Compaction of bituminous material, e.g. road surface layers,
Intended use also includes compliance with the specified oper-
ating, maintenance and repair measures.
1.2.1.5 Improper use

Dangers may arise from the machine when it is used for purposes
other than the one it is intended for.
Any danger caused by improper use is the sole responsibility of the
operating company or driver/operator, the manufacturer cannot be
made liable.
Examples for improper use are:
n work with vibration on hard concrete, cured bitumen layers or
extremely frozen ground
n driving on unstable subbases or too small contact area (danger
of tipping over)
n Using the machine for towing
n use to pull down walls or demolish buildings
transporting persons, except the machine driver, is prohibited.

starting and operation of the machine in explosive environments

and in underground mining is prohibited.
1.2.2 Definition of responsible persons

1.2.2.1 Operating company
The operating company is the natural or juridical person who uses
the machine or in who's name the machine is used.
The operating company must make sure that the machine is only
used for the purpose it is intended for and in strict compliance with
the safety regulations mentioned in these operating and mainte-
nance instructions.
The operating company must determine and assess the danger in
his company. It must then take appropriate action to ensure health
and safety at work for his employees and point out any remaining
dangers.
The operating company must determine whether there are special
operational hazards such as a toxic atmosphere or limiting soil
conditions. Such conditions require special, additional measures to
remove or reduce the hazard.
The operating company must make sure that all users read and
understand the information concerning safety.
The operating company is responsible for the planning and profes-
sional execution of regular safety inspections.
1.2.2.2 Expert / qualified person

An expert / qualified person is a person who, based on his/her pro-
fessional education and experience, has profound knowledge in
the field of construction equipment and the machine in question in
particular.
This person is acquainted with the applicable governmental indus-
trial safety regulations, accident prevention instructions, guidelines
and generally acknowledged technical rules and regulations
(standards, directives, technical rules of other member states of
the European Union or other contractual states concerning the
agreement about the European Economic Area) in as far as is nec-
essary to be able to judge the safe condition of this machine.
1.2.2.3 Driver / operator

This machine must only be operated by trained, instructed persons
entrusted by the operating company aged 18 or more.
Observe your local laws and regulations.
Rights, obligations and rules of conduct for driver or operator:

The driver or operator must:

n be instructed about his rights and obligations,
n wear protective equipment as appropriate for the application,
n have read and understood the operating instructions,
n have made himself familiar with the operation of the machine,
n be physically and psychologically able to drive and operate the
machine.
Persons under the influence of alcohol, medication or drugs are not
allowed to operate, service or repair the machine.
Maintenance and repair work requires specific knowledge and
must therefore only be performed by trained specialists.
1.2.3 Fundamentals for safe operation

1.2.3.1 Remaining dangers, remaining risks
Despite careful work and compliance with standards and regula-
tions it cannot be ruled out that further dangers may arise when
working with and handling the machine.
Both the machine as well as all other system components comply
with the currently valid safety regulations. Nevertheless, remaining
risks cannot be ruled out completely, even when using the machine
for the purpose it is intended for and following all information given
in the operating instructions.
A remaining risk can also not be excluded beyond the actual
danger zone of the machine. Persons remaining in this area must
pay particular attention to the machine, so that they can react
immediately in case of a possible malfunction, an incident or failure
etc.
All persons remaining in the area of the machine must be informed
about the dangers that arise from the operation of the machine.
1.2.3.2 Regular safety inspections

Have the machine inspected by an expert / qualified person as
required for the conditions the machine is working under, but at
least once every year.
1.2.3.3 Modifications and alterations to the machine

Unauthorized changes to the machine are prohibited for safety rea-
sons.
Original parts and accessories have been specially designed for
this machine.
We wish to make explicitly clear that we have not tested or
approved any parts or accessories not supplied by us.
The installation and/or use of such products may have an adverse
effect on the active and/or passive safety.

1.2.3.4 Damage, defects, misuse of safety devices

Machines which are not safe to operate or in traffic must be imme-
diately taken out of service and shall not be used, until these defi-
ciencies have been properly rectified.
Safety installations and switches must neither be removed nor
must they be made ineffective.
1.2.3.5 Roll Over Protective Structure (ROPS)
On machines with cab the ROPS is an integral part

of the cab.
The frame of the machine must not be warped, bent or cracked in

the area of the ROPS fastening.
The ROPS must not show any rust, damage, hairline cracks or
open fractures.
The real machine weight must never exceed the testing weight for
the ROPS.
No accessories may be welded or bolted on and no additional
holes must be drilled without the consent of the manufacturer,
since this will impair the strength of the unit.
The ROPS must therefore also not be straightened or repaired if it
is damaged.
A defect ROPS must generally be replaced with an original spare
part in close coordination with the manufacturer.
1.2.4 Handling fuels and lubricants

1.2.4.1 Preliminary remarks
The operating company must ensure that all professional users
have read and follow the corresponding safety data sheets for the
individual fuels and lubricants.
Safety data sheets provide valuable information about the following
characteristics:
n name of substance
n possible dangers
n composition / information on constituents
n first-Aid measures
n fire fighting measures
n measures in case of accidental release
n handling and storage
n limitation and monitoring of exposure / personal protective
equipment
n physical and chemical properties
n stability and reactivity

n toxicological data
n environmental data
n notes on waste disposal
n information on transport
n legislation
n other data
1.2.4.2 Safety regulations and environmental protection regulations for handling diesel fuel
WARNING!
Danger of burning by ignited diesel fuel!
– Do not allow diesel fuel to come into contact
with hot components.
– Smoking and open fire is prohibited!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
Fig. 1 CAUTION!
Health hazard caused by contact with diesel
fuel!
– Do not inhale any fuel fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled diesel fuel!
– Immediately bind spilled diesel fuel with an oil-
binding agent.
ENVIRONMENT!
Diesel fuel is an environmentally hazardous
substance!
– Always keep diesel fuel in proper containers.
– Immediately bind spilled diesel fuel with an oil-
binding agent and dispose of properly.
– Dispose of diesel fuel and fuel filters according
to regulations.

1.2.4.3 Safety regulations and environmental protection regulations for handling AdBlue®/DEF
CAUTION!
Health hazard caused by ammonia vapours!
– Do not inhale ammonia vapours.
– Avoid contact and consumption.
AdBlue®/DEF has not been classified as environ-

Fig. 2 mentally harmful.
1.2.4.4 Safety regulations and environmental protection regulations for handling oil
WARNING!
Danger of burning by ignited oil!
– Do not allow oil to come into contact with hot
components.
Fig. 3 CAUTION!
Health hazard caused by contact with oil!
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
– Immediately bind spilled oil with an oil-binding
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
agent.
– Dispose of oil and oil filter according to regula-
tions.

1.2.4.5 Safety regulations and environmental protection regulations for handling hydraulic oil
WARNING!
Danger of injury caused by escaping pressure
fluid!
– Always depressurize the hydraulic system
before starting work in the hydraulic system.
tective gloves, protective clothing, goggles).
Fig. 4 Should pressure fluid penetrate the skin, imme-

diate medical help is required.
WARNING!
Danger of burning by ignited hydraulic oil!
– Do not allow hydraulic oil to come into contact
with hot components.
CAUTION!
Health hazard caused by contact with hydraulic
oil!
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
agent.
– Dispose of oil and oil filter according to regula-
tions.

1.2.4.6 Safety regulations and environmental protection regulations for handling coolants
WARNING!
Danger of scalding by hot fluid!
– Open the compensation tank only when the
engine is cold.
CAUTION!
Fig. 5 Health hazard caused by contact with coolant
and coolant additives!
– Do not inhale any fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled coolant!
– Immediately bind spilled coolant with an oil-
binding agent.
ENVIRONMENT!
Coolant is an environmentally hazardous sub-
stance!
– Always keep coolant and coolant additives in
proper containers.
– Immediately bind spilled coolant with an oil-
binding agent and dispose of it according to
regulations.
– Dispose of coolant according to regulations.

1.2.4.7 Safety regulations and environmental protection regulations for handling battery acid
WARNING!
Danger of cauterization with acid!
– Do not allow clothes, skin or eyes to come into
contact with acid.
– Rinse off spilled battery acid immediately with
lots of water.
Fig. 6:
Rinse acid off clothes, skin or eyes immediately
with lots of clean water.
Immediately call for medical advice in case of cau-
terization.
WARNING!
Danger of injury caused by exploding gas mix-
ture!
– Remove the plugs before starting to recharge
the battery.
– Ensure adequate ventilation.
– Do not lay any tools or other metal objects on
the battery.
– Do not wear jewellery (watch, bracelets, etc.)
when working on the battery.
ENVIRONMENT!
Battery acid is an environmentally hazardous
substance!
– Dispose of battery and battery acid according
to regulations.

1.2.5 Parking the machine in secured condition

1. Drive the machine onto level and firm ground.
2. To stop the machine return the travel lever to middle position
and shift it to the right to lock (parking brake position).
ð The parking brake warning lamp lights up.
NOTICE!
Danger of engine damage!
– Do not shut down the engine all of a sudden
from full load speed, but let it idle for about two
minutes.
Fig. 7
3. Turn the ignition key to position “0” and pull it out.

4. Open and secure the engine hood.
Fig. 8
5. Turn the main battery switch counter-clockwise and pull it

out.
6. Close the engine hood and lock it if necessary.
Fig. 9
1.2.6 Emergency procedures

1.2.6.1 Actuating the emergency stop switch
In events of emergency and in case of danger actuate the emer-
gency stop switch immediately.
The machine is braked immediately, the engine is shut down.
Restart the machine only after the danger that caused the actua-
tion of the emergency stop switch has been eliminated.
In case of frequent use the wear on the multi-discs brakes will be
very high, you should therefore never use the emergency stop
switch as a service brake.

1.2.6.2 Disconnecting the battery

In events of emergency, e.g. in case of a cable fire, disconnect the
battery from the vehicle network.
Pull out the main battery switch or lift off the battery pole to do so.
1.2.6.3 Towing the machine

Tow the machine only in a case of emergency or to avoid an acci-
dent.
Before releasing the parking brake apply suitable measures to
secure the machine against unintended rolling.
Use a tractor vehicle with sufficient traction and braking power for
the unbraked towed load.
If no tow bar is used, towing is only permitted uphill.
Before starting towing operations make sure that the fastening
means are able to withstand the load and are fastened at the
points provided for this purpose.
Before removing the towing facility apply appropriate measures to
secure the machine against unintended rolling.
1.2.7 Maintenance work

1.2.7.1 Preliminary remarks
Adhere to the specified operating, maintenance and repair meas-
ures.
The machine must only be serviced by qualified and authorized
personnel.
Keep unauthorized persons away from the machine.
Do not perform maintenance work while the machine is driving or
the engine is running.
Make sure that the engine cannot be accidentally started during
maintenance work.
Do not touch hot components.
Before mounting the machine, check whether all access steps,
grips and platforms are free of obstacles, grease, oils, fuel, dirt,
snow and ice.
Use only the intended access steps and grips to mount the
machine.
For overhead maintenance work use the access steps and working
platforms provided or other secure means.
Do not step on machine parts which are not intended for this pur-
pose.
Do not leave any tools or other objects, that could cause damage,
in or on the machine.

1.2.7.2 Work on hydraulic lines

Relieve hydraulic pressures before working on hydraulic lines.
Hydraulic oil escaping under pressure can penetrate the skin and
cause severe injury. Immediately call for medical advice when
injured by hydraulic oil.
Do not step in front of or behind the machine when performing
adjustment work in the hydraulic system.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature – danger of
scalding!
Any hydraulic oil must be collected and disposed of in an environ-
mentally friendly way.
Always collect and dispose of hydraulic oils separately.
Do not start the engine after draining the hydraulic oil. Once all
work is completed (with the system still depressurized!) check all
connections and fittings for leaks.
Hydraulic hoses must be visually inspected at regular intervals.
Do not mix up hoses by mistake.
Only genuine BOMAG replacement hydraulic hoses ensure that
the correct hose type (pressure range) is used at the right location.
1.2.7.3 Working on the engine

Do not work on the fuel system while the engine is running -
danger to life due to high pressures!
Wait until the engine has stopped, then wait approx. another 15
minutes.
Keep out of the danger zone during the initial test run.
In case of leaks return to the workshop immediately.
Drain the engine oil at operating temperature – danger of scalding!
Wipe off spilled oil, collect leaking oil and dispose of it in an envi-
ronmentally friendly way.
Store used filters and other oil contaminated materials in a sepa-
rate, specially marked container and dispose of them in an environ-
mentally friendly way.
The settings for idle speed and highest speed must not be
changed, since this would affect the exhaust gas values and cause
damage to engine and power train.
Engine and exhaust system work with high temperatures. Keep
combustible materials away and do not touch any hot surfaces.
Check and change coolant only when the engine is cold. Collect
coolant and dispose of it in an environmentally friendly way.

1.2.7.4 Exhaust gas aftertreatment system, regeneration at standstill

During regeneration at standstill the exhaust gas reaches very high
temperatures and the exhaust gas quantity increases - fire hazard!
When performing regeneration at standstill park the machine out-
doors at a safe distance from any combustible or explosive mate-
rials.
Components of the exhaust gas aftertreatment system get very
hot.
Do not touch hot components or exhaust gases.
Should there be an endangerment caused by high exhaust gas
temperatures and quantities, the operator needs to suppress the
regeneration at standstill.
1.2.7.5 Maintenance work on electric components and battery

Before starting to work on electric parts of the machine disconnect
the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and do not bridge
fuses.
When working on the battery, smoking or open fire is prohibited!
Do not lay any tools or other metal objects on the battery.
Do not wear jewellery (watch, bracelets, etc.) when working on the
battery.
The connection cables of the battery must not touch or rub against
machine parts.
1.2.7.6 Working on the air conditioning

Faults on the air conditioning should only be remedied by author-
ized service personnel.
Do not perform welding work in the vicinity of the air conditioning.
Danger of explosion!
Do not clean the condenser in the air conditioning system with a
hot water jet. Danger of explosion!
Do not release refrigerant into the atmosphere, but dispose of envi-
ronmentally.
1.2.7.7 Working on wheels and tyres

Explosion-like bursting of tyres or parts of tyres and rims can cause
most severe or even fatal injuries.
Do not drive with damaged wheels or tyres.
Install the tyres only if you are sufficiently experienced and with the
right tools at hand. If necessary have the tyres assembled in a
qualified workshop.

Always ensure the correct tyre pressure and do not exceed the
specified maximum pressure.
When checking the tyre pressure stand in the extended path of the
tyre track. Use an at least 6 meter air hose, so that you can keep a
safe distance to the tyre.
Always consider the heavy weight of a wheel during disassembly
and assembly. Use a crane or forklift truck equipped with suitable
claws or a belt-type hoisting device.
1.2.7.8 Cleaning work

Do not perform cleaning work while the motor is running.
Allow the engine to cool down before starting cleaning work on
engine and exhaust system.
Do not use gasoline or other easily inflammable substances for
cleaning.
When cleaning with a high pressure cleaner do not direct the wter
jet to electrical insulation material or cover it beforehand.
Do not guide the water jet into the exhaust pipe and into the air
filter.
1.2.7.9 After maintenance work

Reassemble all guards and protective devices.
Close all maintenance flaps and doors again.
1.2.8 Repair
Identify a defective machine with a warning sign.
Only operate the machine after it has been repaired.
Repairs must only be performed by an expert/qualified person.
When replacing safety relevant components, only original spare
parts must be used.

General – Fuels and lubricants
1.3 Fuels and lubricants
1.3.1 Fuels and lubricants

1.3.1.1 Engine oil
1.3.1.1.1 Oil quality
Engine oils for use in DEUTZ engines are classified in DEUTZ
Engine Oil Quality Classes (DQC).
The following engine oil specifications are permitted:

DEUTZ ACEA API DHD
DQC II-10 E3-96 CH-4 DHD-1
E4-12 CI-4
E5-02 CI-4 Plus
E7-12
DQC III-10 - - -
DQC IV-10 - - -
Avoid mixing of engine oils.
The list of approved engine oils is also available on the

Internet under the following address:
www.deutz.com
de SERVICE \ Maintenance \ Betriebsstoffe \ Öle \
DEUTZ Quality Class \ DQC Freigabeliste
en SERVICE \ Maintenance \ Operating Liquids\ Oils \
DEUTZ Quality Class \ DQC Release List

1.3.1.1.2 Oil viscosity

Since engine oil changes its viscosity with the temperature, the
ambient temperature at the operating location of the engine is of
utmost importance when choosing the viscosity class (SAE-class).
Only use multi-purpose oils.
The temperature indications of the SAE-class always refer to fresh
oils. In travel operation engine oil ages because of soot and fuel
residues. This adversely affects the properties of the engine oil,
especially under low ambient temperatures.
Optimal operating conditions can be achieved by using the oil vis-
cosity chart as a reference.
Fig. 10: Oil viscosity diagram
1.3.1.1.3 Oil change intervals

If the oil change intervals are not reached over a period of one
year, the oil change should be performed at least 1 x per year, irre-
spective of the operating hours reached.
The oil change interval must be halved if at least one of the fol-
lowing conditions applies:
n Permanent ambient temperatures below -10 °C (14 °F)
n Engine oil temperatures below 60 °C (84 °F).
n Sulphur content in fuel exceeding 0.5 %
1.3.1.2 Fuel
1.3.1.2.1 Fuel quality
You should preferably use commercial diesel fuel with a sulphur
content of less than 0.5 %.
When using a diesel fuel with a high sulphur content of 0.5 % to
1.0 % the oil change intervals must be halved.
Fuels with a sulphur content of more than 1.0 % are not permitted.

In order to fulfil national emission regulations one must strictly use

the legally required fuels (e.g. sulphur content).
The following fuel specifications are recommended:
n EN 590
n ASTM D975 Grade-No. 1-D and 2-D
n JIS K 2204 Grade Fuel 1 and Grade Fuel 2 with lubrication
properties acc. to EN 590
1.3.1.2.2 Winter fuel

For winter operation use only winter diesel fuel, to avoid clogging
because of paraffin separation.
At very low temperatures disturbing paraffin separation can also be
expected when using winter diesel fuel.
Diesel fuels suitable for temperatures down to -44 °C (-47 °F) are
available for Arctic climates.
NOTICE!
– The admixture of petroleum and the addition of
“flow enhancing additives” (fuel additives) is
not permitted.
1.3.1.2.3 Storage
Even traces of zinc, lead and copper can cause deposits in the
injection nozzles, especially in modern Common-Rail injection sys-
tems.
Zinc and lead coatings in refuelling systems and fuel lines are not
permitted.
Copper containing materials (copper lines, brass items) should be
avoided, because they can cause catalytic reactions in the fuel with
subsequent depositing in the injection system.
1.3.1.3 Coolant
1.3.1.3.1 General
For fluid cooled engines the cooling fluid must be prepared by
admixing a cooling system protection agent to the fresh water and
should be checked within the specified maintenance intervals.
This prevents damage caused by corrosion, cavitation, freezing
and overheating.

1.3.1.3.2 Water quality

The correct quality of water is highly important when preparing
coolant. Clear and clean water within the boundaries of the fol-
lowing analysis values should generally be used.
Analysis values
pH-value at 20 °C (68 °F) 6.5 - 8.5
Chlorine-ion content max. 100 mg/l
Sulphate ion content max. 100 mg/l
Water hardness (ion content of max. 3.56 mmol/l
calcium and magnesium )
max: 356 mg/l (ppm)
Germ degree: max. 20 °dH
English degree: max: 25 °eH
French degree: max: 35.6 °fH
Bacteria, fungi, yeasts not permitted
Information concerning the water quality can be obtained from the

waterworks.
If the fresh water analysis values are unknown, these must be
determined with the help of a water analysis.
If the values of the analysis deviate, the water must be treated
accordingly:
pH-value too low - Adding of caustic lye of soda or caustic
potash solution.
Water hardness too - Mix with soft, distilled or fully demineral-
high ized water
Chlorides and/or sul- - Mix with distilled or fully demineralized
phates too high water
NOTICE!
– Another analysis must be made after the fresh
water has been prepared.
1.3.1.3.3 Cooling system protection agent

As a protection against frost, corrosion and boiling point anti-freeze
agents must be used under any climatic conditions.
Coolant is prepared by adding an ethylene-glycol based anti-freeze
agent with corrosion inhibiting properties to the cooling water.
We therefore highly recommend our BOMAG cooling system pro-
tection agent.

If our cooling system protection agent is not available for any

important reasons, you may, in exceptional cases, use products
that have been approved by the engine manufacturer.
The list of approved lubrication oils is also available in the

Internet under the following address:
www.deutz.com
de SERVICE \ Maintenance \ Betriebsstoffe \ Kühlsys-
temschutz
en SERVICE \ Maintenance \ Operating Liquids \
Coolant
Products of the same product group (see Deutz Technical Circular

Cooling System Protection Agents) can be mixed with each other.
The BOMAG cooling system protection agent corresponds with
product group A.
NOTICE!
– Do not mix different coolants and additives of
any other kind.
– Before changing the product you must clean
the entire cooling system.
– Consult our customer service if in doubt.
– The cooling system protection agent must be
used all year round, to provide adequate corro-
sion protection.
The mixing ratio must not be below or exceed the following

value:
Cooling system Fresh water Cold protection
protection agent down to
min. 35% 65% -22 °C (-8 °F)
40% 60% -28 °C (-18 °F)
45% 55% -35 °C (-31 °F)
max. 50% 50% -41 °C (-42 °F)
NOTICE!
– A proportion of more than 50% of cooling
system protection agent causes a drop in
cooling power.
– The use of corrosion protection oils as cooling
system protection agents is not permitted.

1.3.1.4 Hydraulic oil

1.3.1.4.1 Mineral oil based hydraulic oil
The hydraulic system is operated with hydraulic oil HV 46 (ISO)
with a kinematic viscosity of 46 mm2/s at 40 °C (104 °F) and
8 mm2/s at 100 °C (212 °F).
For topping up or for oil changes use only hydraulic oil, type HVLP
according to DIN 51524, part 3, or hydraulic oils type HV according
to ISO 6743/3.
The viscosity index (VI) should be at least 150 (observe informa-
tion of manufacturer).
1.3.1.4.2 Bio-degradable hydraulic oil

The hydraulic system can also be operated with a synthetic ester
based biodegradable hydraulic oil.
The biologically quickly degradable hydraulic oil Panolin HLP
Synth.46 meets all demands of a mineral oil based hydraulic oil
according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.46 always use
the same oil to top up.
When changing from mineral oil based hydraulic oil to an ester
based biologically degradable hydraulic oil, you should consult the
lubrication oil service of the oil manufacturer, or our customer
service for details.
NOTICE!
Risk of damage!
– Check the filter more frequently after this
change.
– Perform regular oil analyses for content of
water and mineral oil.
– Replace the hydraulic oil filter element every
500 operating hours.
1.3.1.5 Gear oil SAE 80W-140

Use a fully synthetic gear oil in accordance with SAE 80W-140,
API GL5 with a kinematic viscosity of at least 20 mm2/s at 100 °C
(212 °F).
It is a hypoid lubricant of highest quality class for transmissions
under extreme strain.

1.3.1.6 Gear oil SAE 75W-90

Use a fully synthetic gear oil in accordance with SAE 75W-90,
API GL5 with a kinematic viscosity of at least 16 mm2/s at 100 °C
(212 °F).

General – List of fuels and lubricants
1.4 List of fuels and lubricants
Assembly group Fuel or lubricant Spare parts Filling quantity

number
Summer Winter Observe the
level mark!
Engine oil SAE 10W-40 009 920 06 10.5 l
Specification: Ä Chapter 1.3.1.1 „Engine 20 l (2.8 gal us)
oil“ on page 28
SAE 15W-40
SAE 5W-40
SAE 5W-30
Fuel Diesel Winter diesel fuel 250 l
Specification: Ä Chapter 1.3.1.2 (66 gal us)
„Fuel“ on page 29
Coolant Mixture of water and anti-freeze agent 009 940 08 16 l
Specification: Ä Chapter 1.3.1.3 20 l (4.2 gal us)
„Coolant“ on page 30
Hydraulic system Hydraulic oil (ISO), HVLP 46 009 930 09 80 l
Specification: Ä Chapter 1.3.1.4.1 „Mineral 20 l (21 gal us)
oil based hydraulic oil“ on page 33
or ester based biodegradable hydraulic oil
Specification: Ä Chapter 1.3.1.4.2 „Bio-
degradable hydraulic oil“ on page 33
Vibration bearings Gear oil SAE 75W-90 009 925 05 1.0 l each
Specification: Ä Chapter 1.3.1.6 „Gear oil 20 l (0.26 gal us)
SAE 75W-90“ on page 34
Drive axle Gear oil SAE 80W-140, API GL-5 009 925 07 11 l
Wheel hubs SAE 80W-140, API GL-5 009 925 07 2.0 l
Tyres Water + calcium chloride 295 l + 100 kg
(80 gal us + 220
lbs)
or water + magnesium chloride 308 l + 87 kg
(81 gal us + 192
lbs)
Air conditioning Refrigerant R134a 1500 g
(3.3 lbs)

General – List of fuels and lubricants

Overview of machine
2 Overview of machine

Overview of machine – Diesel engine
2.1 Diesel engine

This BOMAG machine is driven by a 4 cylinder Deutz diesel engine
series BF4M 2012C with intercooler.
The intercooler reduces the thermal load on the engine, the
exhaust gas temperature and the fuel consumption and thus ena-
bles a higher power output.
These engines are characterized by the following positive features:
n short and compact design
n low noise level
n almost vibration free operation
n low fuel consumption
n exhaust emissions (EPA II)
n high power reserves and
n good access to all service points.
Fig. 11

Overview of machine – Travel / vibration pump
2.2 Travel / vibration pump
4 Y07
MB
Y08
5
M3 B
3 MA 6
2
1 M1
B
M2
L1
M3
D
S
E
M2
L1
M1
A
S
L2
MA
MB
S-582-0038
Fig. 12
1 Travel pump
2 Multi-function valve, travel pump
4 Solenoid valve vibration (Y07), high amplitude
5 Solenoid valve vibration (Y08), low amplitude
6 Vibration pump
M3 Charge pressure, 26+ 3 bar
1/MA Travel pressure against block, forward travel, MA 420 bar
1/MB Travel pressure against block, backward travel, MA 420 bar
6/MA Vibration pressure, MA 420 bar
6/MB Vibration pressure, MB 420 bar

Overview of machine – Travel / vibration pump
Vibration pump
High amplitude Low amplitude
Current on coil C1 C2
Plugs Y07 Y08
Pressure on port A B

Overview of machine – Drum
2.3 Drum
Fig. 13
1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel motor
5 Drum shell
6 Rubber buffer
7 Rectangular rubber buffers
8 Travel bearings

Overview of machine – Drum

Technical data
3 Technical data

Technical data – Technical data BW 211 D/PD-40
3.1 Technical data BW 211 D/PD-40
Fig. 14
BW 211 D-40 A B D H H2 K L O1/2 S W

Dimensions in mm 2960 2250 1500 2268 2985 490 5840 60 25 2130
Dimensions in inch 117 89 59 89 118 19.2 230 2.4 1.0 84
Weights
Max. operating weight 13000 kg 28660 lbs
Operating weight (CECE) with ROPS-cabin 9500 kg 20944 lbs
Axle load, drum (CECE) 5750 kg 12677 lbs
Axle load, wheels (CECE) 3750 kg 8267 lbs
Static linear load 27.0 kg/cm 151.2 pli
Travel characteristics
Travel speed (1) 0 – 6 km/h 0 – 3.7 mph
Max. gradability without/with vibration (soil 45% / 43% 45% / 43%
dependent)
Drive
Engine manufacturer Deutz Deutz
Type BF4M 2012 C BF4M 2012 C
Cooling Water Water

Number of cylinders 4 4
Rated power ISO 3046 98 kW 98 kW
Rated power SAE J 1995 132 hp 132 hp
Rated speed 2300 min-1 2300 rpm
Electrical equipment 12 V 12 V
Drive system Hydrostatic Hydrostatic
Permissible ambient temperatures -20 .... +50 °C -4 .... +122 °F
Brakes
Service brake Hydrostatic Hydrostatic
Parking brake hydro-mechanical hydro-mechanical
Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation Hydrostatic Hydrostatic
Steering angle ± 35 ° ± 35 °
Oscillation angle ± 12 ° ± 12 °
Inner track radius 3494 mm 138 in
Vibration
Frequency (1/2) 30/36 Hz 1800/2160 vpm
Amplitude (1/2) 1.80/0.95 mm 0.071 – 0.037 in
Centrifugal force (1/2) 236/170 kN 53055/ 38218 lbf
Tyres
Tyre size 23.1-26 12PR 23.1-26 12PR
Air pressure, nominal value 1.1 bar 16 psi
Air pressure, range 0.8 – 1.4 bar 12 – 20 psi
Filling capacities
Fuel (diesel) 250 l 66 gal us

Fig. 15
BW 211 PD-40 A B D H H2 K L O1/2 S W

Dimensions in mm 2960 2250 1480 2268 2985 490 5840 60 25 2130
Weights
Travel speed (1) 0 – 6 km/h 0 – 3.7 (machine type
dependent)
dependent)
dependent)
Drive
Cooling Water Water


Drive system hydrostatic hydrostatic
Permissible ambient temperatures -20 ... +50 °C -4 ... +122 °F
Brakes
Service brake hydrostatic hydrostatic
Steering
Steering operation hydrostatic hydrostatic
Vibration
Frequency (1/2) 30/36 Hz 1800/2160 vpm
Amplitude (1/2) 1.70/0.95 mm 0.067 – 0.037 in
Tires
Tire size 23.1-26 12PR 23.1-26 12PR
Air pressure, span 0.8 – 1.4 bar 12 – 20 psi
Padfeet, quantity 150 150
Height of padfeet 100 100
Area of one padfoot 137 cm2 21.2 in2
Filling capacities

Technical data – Technical data BW 212 D/PD-40 (58243, 58248, 58356)
3.2 Technical data BW 212 D/PD-40 (58243, 58248, 58356)
Fig. 16
BW 212 D-40 A B D H H2 K L O1/2 S W

Dimensions in mm 2960 2250 1500 2268 2985 490 5840 60 25 2130
Weights
dependent)
Drive
Cooling Water Water

Brakes
Steering
Vibration
Frequency (1/2) 30/36 Hz 1800/2160 vpm
Amplitude (1/2) 1.80/0.95 mm 0.071 – 0.037 in
Tyres
Tyre size 23.1-26 12PR 23.1-26 12PR
Filling capacities

Fig. 17
BW 212 PD-40 A B D H H2 K L O1/2 S W

Dimensions in mm 2960 2250 1480 2268 2985 490 5840 60 25 2130
Weights
dependent)
dependent)
dependent)
Drive
Cooling Water Water


Brakes
Steering
Vibration
Frequency (1/2) 30/36 Hz 1800/2160 vpm
Amplitude (1/2) 1.70/0.95 mm 0.067 – 0.037 in
Tires
Tire size 23.1-26 12PR 23.1-26 12PR
Filling capacities

Technical data – Technical data BW 212 D-40 (58348, 58356)
3.3 Technical data BW 212 D-40 (58348, 58356)
Fig. 18
Dimensions in mm A B D H H2 K L O1 O2 S W
BW 212 D-40 2960 2250 1500 2268 2985 490 5840 60 60 25 2130
The right for technical modifications remains reserved BW 212 D-40

Weights
Operating weight (CECE) with ROPS-cabin kg 10900
Axle load, drum (CECE) kg 7150
Rear axle load (CECE) kg 3750
Static linear load kg/cm 33.6
Max. operating weight kg 14670
Travel speed (1) km/h 0–6
Travel speed (2) km/h 0 – 10
Max. gradability without/with vibration (soil dependent) % 45/43
Drive
Engine manufacturer Deutz
Type BF4M 2012C
Cooling Water
Number of cylinders 4

The right for technical modifications remains reserved BW 212 D-40

Rated power DIN ISO 3046 kW 98
Power SAE J1995 hp 132
Rated speed rpm 2300
Fuel Diesel
Electrical equipment V 12
Drive system hydrostatic
Permissible ambient temperatures °C -20 ... +50
Brakes
Service brake hydrostatic
Parking brake hydr.-mech.
Steering
Type of steering Oscill.-articul.
Steering operation hydrostatic
Steering/oscillation angle ±° 35/12
Inner track radius mm 3494
Vibration
Drive system hydrostatic
Frequency (1/2) Hz 30/36
Amplitude (1/2) mm 1.8/0.95
Centrifugal force (1/2) kN 236/125
Tires
Tire size 23.1-26/12PR
Air pressure, nominal value bar 1.4
Air pressure, range bar 0.8 - 1.4
Filling capacities
Motor l approx. 10,5
Fuel l approx. 250
Hydraulic oil l approx. 80
Coolant l approx. 16


3.4 Technical data BW 213 D/PD-40
Fig. 19
BW 213 D-40 A B D H H2 K L O1/2 S W

Dimensions in mm 2960 2250 1500 2268 2985 490 5840 60 35 2130
Weights
dependent)
Drive
Cooling Water Water

Brakes
Steering
Vibration
Frequency (1/2) 30/36 Hz 1800/2160 vpm
Amplitude (1/2) 1.90/0.96 mm 0.075 – 0.038 in
Tyres
Tyre size 23.1-26 12PR 23.1-26 12PR
Filling capacities

Fig. 20
BW 213 PD-40 A B D H H2 K L O1/2 S W

Dimensions in mm 2960 2250 1480 2268 2985 490 5840 60 25 2130
Weights
dependent)
dependent)
dependent)
Drive
Cooling Water Water


Brakes
Steering
Vibration
Frequency (1/2) 30/36 Hz 1800/2160 vpm
Amplitude (1/2) 1.70/0.86 mm 0.067 – 0.034 in
Tires
Tire size 23.1-26 12PR 23.1-26 12PR
Filling capacities

Technical data – Additional technical data
3.5 Additional technical data

Additional engine data
Combustion principle 4-stroke diesel
Low idle speed rpm 900 ± 200
High idle speed rpm 2430 ± 50
Specific fuel consumption g/kWh 243
Valve clearance intake mm 0.3
Valve clearance exhaust mm 0.5
Injection valves opening pressure bar 220
Travel pump
Manufacturer Sauer
Type 90R 075
System Axial piston/swash plate
Max. displacement cm3/rev 75
Max. pumping delivery l/min 172.9
High pressure limitation bar 400 + 20
Charge pressure, high idle bar 26 + 3
Drum drive motor

Manufacturer Poclain
Type MSE 18 1 CX
System Radial piston
Displacement (stage 1) cm3/rev 2800
Perm. leak oil rate l/min 2 ± 10
Travel motor of axle

Manufacturer Sauer
Type 51D 110
System Axial piston – bent axle
Max. displacement (stage 1) cm3/rev 110
Min. displacement (stage 2) cm3/rev 33
Perm. leak oil rate l/min 2 ± 10
Flushing rate l/min 16

Flushing pressure limitation bar 16
Vibration pump
Manufacturer Sauer
Type 42R 041
Max. displacement cm3/rev 41
Starting pressure bar 420 + 20
Operating pressure (soil dependent) bar approx. 100
Integrated charge pump cm3/rev 11
Vibration motor
Type A10FM 45
Displacement cm3/rev 45
Flushing rate l/min 6
Flushing pressure limitation bar 13
Steering/charge pump
Type HY/ZFS11/16
System Gear
Displacement cm3/rev 16
Max. steering pressure when steered against end stops bar 200 + 20
Steering valve
Manufacturer Danfoss
Type OSPC 500 ON
System Rotary spool valve
Rear axle
Manufacturer Dana
Type CHC 192/51HD
Differential No-Spin

Degree of locking % 100

Reduction ratio 43.72


Electric systems
4 Electric systems

Electric systems
Fig. 21
1 Machine with Telematic
2 GPS satellite
3 Mobile communications network
4 External partner
5 Internet (Cloud)
6 User
7 Telematic server
BOMAG TELEMATIC is a Fleet Management System. BOMAG
TELEMATIC enhances the effective use of machines. The POWER
variant enables continuous recording of the fuel consumption.
With BOMAG TELEMATIC the machine operator can localize his
machines and also detect and save operating states. Actual oper-
ating hours are documented. Maintenance planning and documen-
tation is entirely mapped in BOMAG TELEMATIC.
BOMAG TELEMATIC is able to recognize unauthorized use or
theft. Many insurance companies award this with reduced insur-
ance premiums.
The system consists of a machine integrated hardware and an
internet application. All data are saved in a database. Access is
individual for each user and password protected.
Optional modules In addition, the system can also be extended with further modules.
The technical requirements for surface covering compaction con-
trol are achieved with BOMAG COMPACTION METER (BCM) and
GPS, the satellite-assisted location system. This means that all
compaction data of a construction project can be recorded, pro-
cessed, managed, graphically displayed and, if required, printed
out.

Electric systems
Continuous compaction control
Fig. 22: BCM05, example single drum roller

1 PC or Laptop
2 Printer
3 Print-outs
4 BCM 05mobile
5 CAN-USB communication
6 Output of measuring data in from of a file on any type of data
storage medium for transfer to third parties (e.g. client, con-
struction supervision, etc.)
The assignment of individual measuring values to the coordinates
is accomplished by manual selection of a track and within the track
by the tachometer signals from the displacement transducer on the
roller.
n Indication of end of compaction
n Office software for evaluation
n Interchangeable between machines

Electric systems – Table of fuels and lubricants
Position detection for GPS-fields (A93)
Fig. 23
n To exactly 22 cm
n No local referencing station
The assignment of the individual measuring values to the meas-
uring position is accomplished with the help of an automatic posi-
tion acquisition system.
4.1 Table of fuels and lubricants

This table contains all electrical components used in the machine,
except terminal strips and plugs.
Operating means Function text Technical characteristics

A02 Flasher encoder
A05 Speedometer electronics
A06 Electronics of frequency display, front
A12 Radio
A13 Pre-heating time control unit
A15 Monitoring board
A16 Tachograph electronics
A51 Circuit board of frequency display
A66 Electronics of control unit
A67 Keyboard
A68 Module for seat contact


A83 Metrology control
A87 USB CAN interface BCM
A93 GPS receiver StarFire
A108 Heating/air conditioning unit
A124 Electronics for BOMAG Telematic
A138 Aerial for BOMAG Telematic
B03 Air filter service switch
B06 Engine oil pressure switch
B11 Warning horn 4.2A
B13 Initiator for travel lever “0”
B14 Initiator for travel lever forwards and “0”
B16 Transducer for front vibration frequency

B21 Differential pressure switch for hydraulic oil filter
B30 Engine oil temperature switch
B51 Radio loudspeaker
B55 Float switch in coolant compensation tank
B60 Axle speed transducer
B62 Acceleration transducer
B104 Pressure switch for air conditioning
B113 EMR coolant temperature
B124 Water separator
E03 Illumination of tachometer 12V
E04 Illumination of speedometer 12V
E07 Illumination of EVIB meter 12V
E08 Direction indicator, front left 21W
E09 Direction indicator, rear left 21W
E10 Direction indicator, front right 21W
E11 Direction indicator, rear right 21W
E12 Parking light, left 5W
E13 Tail light, left 5W
E14 Parking light, right 5W
E15 Tail light, right 5W
E16 Head lights, left 55W


E17 Head lights, right 55W
E23 Working head lights, front left 55W
E25 Working head lights, front right 55W
E27 Working head lights, rear left 55W
E28 Working head lights, rear right 55W
E29 Cabin light 21W
E30 Heating unit max. 8.3A
E32 Flashing beacon 5A
E70 Night light 5W
E71 Control light for rear windscreen heating switch 12V
E72 Illumination of control switch 24V
EXX Illumination of additional gauge 12V
F00 Main fuse for central electrics 125A
F03 Fuse for vibration 15A
F07 Fuse for hazard light 15A
F08 Fuse for direction indicator 15A
F09 Fuse for parking and tail light left 15A
F10 Fuse for parking and tail light right 15A
F11 Fuse for working head lights, front 15A
F13 Fuse for starter switch 30A
F14 Fuse for solenoid actuator 15A
F15 Fuse for heater unit 5A
F18 Backup fuse for working head lights 10A
F19 Fuse for working head lights, front 15A
F22 Fuse for working head lights, rear 15A
F23 Fuse for warning horns 10A
F24 Fuse for monitoring board, displays 10A
F25 Fuse for solenoid valve for driving and braking 10A
F31 Fuse for cabin fan 25A
F39 Main fuse for cabin 15A
F40 Fuse for cabin heater 20A
F41 Fuse for flashing beacon 10A
F42 Fuse for cabin light 10A
F43 Fuse for wiper motor, rear 15A


F44 Fuse for wiper motor, front 15A
F48 Fuse for heating flange 125A
F68 Fuse for anti-theft protection 5A
F84 Fuse for control (contact 54) 10A
F97 Fuse for fresh air fan 3A
F105 Fuse for engine speed 20A
F124 Fuse for fuel pre-heater 25A
F130 Fuse for night light 10A
F143 Fuse for rear windscreen heating 15A
F144 Fuse for cabin socket 15A
F146 Fuse for control MESX (potential 30) 15A
F148 Fuse for control MESX (potential 15) 10A
F150 Fuse for GPS receiver 5A
F158 Fuse for glow plug 1 50A
F159 Fuse for glow plug 2 50A
G01 Battery 12V / 100 Ah
G02 Generator
G03 Battery 12V / 100 Ah
H06 Control light for hazard light
H07 Warning buzzer for malfunctions 70mA
H14 Reversing alarm buzzer 300mA
K04 Vibration module
K05 Relay for start current
K06 Relay for working head lights
K09 Relay for air conditioning
K11 Relay for potential 30 to 15
K14 Relay for pre-heating
K14.1 Relay for pre-heating
K16 Relay for working head lights, front
K22 Relay for engine shut-down solenoid actuator
K26 Relay for reversing alarm buzzer
K32 Relay for cabin
K35 Relay for self latching
K36 Relay for brake control


K48 Relay for travel lever “0” position
K61 Relay for charge control
K69 Relay for engine shut-down
K114 Relay for engine speed
K141 Relay for rear windscreen heating
M01 Starter
M04 Windscreen wiper motor, front 4.7A
M05 Windscreen wiper motor, rear 2.9A
M06 Windscreen washer motor, front 3.8A
M07 Windscreen washer motor, rear 3.8A
M10 Compressor of air cushioned seat 12V / < 9A
M17 Additional fan 185 mA
P02 Hydraulic oil temperature gauge
P03 Tachometer
P04 Speedometer
P05 Frequency display
P07 EVIB meter 0-6V
P09 Tachograph
P11 Printer
P12 Voltmeter
P14 Display of coolant temperature
P15 BCM05
P16 Diagnostics of Variomatic
P33 Opus 21
R01 Terminating resistor CAN 60 Ω
R02 Glow plug 1 50A
R03 Fuel level sensor 65.4 Ω
R04 Hydraulic oil temperature sensor
R10 Parallel resistor 82 Ω
R19 Heating flange 167A
R25 Terminating resistor CAN 60 Ω
R26 Resistance 220 KΩ
R78 Glow plug 2 50A
R79 Fuel pre-heating 200W


R80 Rear windscreen heating
S00 Starter switch
S01 Emergency stop switch
S03 Push button for warning horn
S06 Switch for seat contact
S13 Vibration switch of travel lever, right
S14 Switch for hazard light
S15 Switch for StVZO lighting
S20 Switch for windscreen wiper, front
S21 Switch for windscreen wiper, rear
S28 Switch for cabin heater
S29 Switch for air suspended seat
S30 Battery isolator switch 250A
S35 Vibration control switch low/high
S37 Switch for direction indicator
S38 Switch for flashing beacon
S42 Travel stage switch
S45 Switch for cabin light
S53 Switch for working lights
S120 Switch for engine speed
S158 Switch for night light
S163 Switch for rear windscreen heating
V01 Diode
V02 Diode
V03 Diode
V04 Diode FE5B
V05 Diode
V09 Diode
V21 Diode
V22 Diode
V47 Diode
Y01 Boost fuel solenoid valve
Y04 Brake solenoid valve 2.41A
Y07 Solenoid valve for front vibration, large 3.33A


Y08 Solenoid valve for front vibration, small 3.33A
Y13 Solenoid valve for engine shut-down 3.8A
Y14 Fuel pump for heater unit
Y15 Magnetic clutch for air conditioning compressor 3.5A
Y30 Solenoid valve for drum travel range 1.23A
Y31 Solenoid valve for axle travel speed range 1.23A
Y120 Solenoid valve, engine speed high 70A/1A
Y139 Solenoid valve for minus alignment

Electric systems – Central electrics
4.2 Central electrics
X3
X38
X37 A124
X36
X1
F150
8 R10 K05
8 88 80
X1
P16 K06
X2
K22
K35
A02
K48
K16 K61
K11 K36
K114
K09
K26
K69
A68
F23 F25
A05 F14 F39
X44 K04 F18
29 F24
F08
F10 28 30
27 F03
A83 F09 26 31
F19 25
24 32
F22
23
F07 22
F11 21
F105 19
18
F68 17
F13 16
15
37
35
34
33
X1 F124
F146
F148 F84
S-582-0034
Fig. 24
A68 Only when a seat contact is installed
K04 Only when no seat contact is installed

Electric systems – Central electrics

Electric systems – Fuse assignment
4.3 Fuse assignment

4.3.1 Notes on safety
WARNING!
Danger of injury by fire in the machine!
– Do not use fuses with higher ampere ratings
and do not bridge fuses.
4.3.2 Central electrics

n Fuses in electric junction box
WARNING!
Fire hazard!
Do not use fuses with higher ampere ratings and
do not bridge fuses.
(15) 30A (F13) Start switch

Fig. 25
(16) 5A (F68) Electronic immobilizer
(17) 20A (F105) Engine speed
(18) 15A (F11) Front head lightsOptional equipment
(19) 15A (F07) Hazard light
(21) 15A (F22) Working headlights, rear
(23) 15A (F09) Parking and tail light, left*
(24) 15A (F10) Parking and tail light, right*
(25) 15A (F08) Direction indicators*
(26) 10A (F18) Pre-fuse for working head lights
(27) 15A (F14) Engine solenoid
(28) 10A (F23) Warning horn
(29) 10A (F25) solenoid valve for driving and
braking
(30) 15A (F39) Main fuse for cabin
(31) 10A (F24) Instruments
(32) 15A (F03) Vibration
(33) 10A (F148) Control MESX, potential 15*

(34) 10A (F84) control, contact 54

(37) 25A (F124) Fuel pre-heating*
(80) 5A (F150) GPS Receiver*
Fig. 26
4.3.3 Main fuses

n Fuses battery
125A (F00) Main fuse

125A (F48) Fuse for pre-heating syste,
Fig. 27
4.3.4 Fuses, cabin
Fig. 28
Position Fuse Amperage Designation

1 F43 15 A Front windscreen wiper/washer
2 F44 15 A Rear windscreen wiper/washer
3 F130 10 A Night light
4 F31 25 A Cabin fan
5 F41 10 A Flashing beacon


6 F144 15 A 12-V socket
7 F143 15 A Rear windscreen heating
8 F42 10 A Cabin light

Electric systems – Operator’s stand
4.4 Operator’s stand
Fig. 29: Control panel, cabin
Pos. Designation Note

1 [S38] Toggle switch for flashing beacon Optional equipment
2 [S20] Toggle switch windscreen wiper/washer, front Windscreen wiper on/off
hold pressed down: The windscreen is sprayed
while wiping
3 [S21] Toggle switch windscreen wiper/washer, rear Windscreen wiper on/off
hold pressed down: The windscreen is sprayed
while wiping
4 [S53] Toggle switch for cabin working lights
5 [S163] Toggle button for rear windscreen heating The rear windscreen heating is shut down after
three minutes.
1 [E70] Inside cabin light

2 [S45] Toggle switch for inside cabin light
3 [S158] Toggle switch for reading and dashboard light
4 [E29] Reading and dashboard light
Fig. 30: Cabin light

Fig. 31
1 [S00] Starter switch
2 [A15] Instrument cluster
3 [S44] Rotary switch for cabin fan (optional equipment)
4 [A108] Rotary switch for air conditioning (optional equipment)
5 Vent for heating and ventilation, driver
6 Vent for heating and ventilation, footwell
7 [S13] Push button for vibration
8 Travel lever
9 [S35] Rotary switch for vibration, amplitude pre-selection
10 [S42] Rotary switch for travel speed ranges
11 [S01] Emergency stop switch
12 [S03] Push button for warning horn
13 [S120] Rotary button for engine speed
14 [S37] Rotary switch for direction indicators (optional equipment)
15 [S14] Rotary switch for hazard light system (optional equipment)

16 [S15] Rotary switch for lighting system (optional equipment)

17 [S53] Rotary switch for working lights (optional equipment)
18 Steering wheel adjustment lever
19 Rotary switch for cabin heater (optional equipment)
n Instrument cluster
With the ignition switch in position "I" all control

and warning lights are switched on for a moment.
a yellow Water in fuel warning light Lights when

the water content in the fuel pre-
cleaner reaches the sensor contacts.
Warning buzzer sounds. The engine is
shut down after 2 seconds. Clean the
water separator.
b yellow Preheating control light Lights when
Fig. 32 temperatures are low (pre-heating for
starting)
c not used
d red Engine oil pressure warning light
Flashes when the engine oil pressure
is too low, the warning buzzer sounds,
the engine is shut down after 10 sec-
onds. Check engine oil level, repair
the engine if necessary.
e red Coolant level warning lamp Flashes if
the coolant level is too low, the
warning buzzer sounds, the engine is
shut down after 10 seconds. Check
coolant level. Check cooling system
for leaks, repair if necessary.
f yellow Charge control light Lights if the bat-
tery is not being charged. Check the
V-belt, if necessary repair the gener-
ator.
g not used
h red Warning light engine overheating
Flashes if the engine overheats, the
shut down after approx. 2 minutes.
Clean engine oil cooler, repair the
engine is necessary.
i not used
j green Indicator control light
k red Parking brake warning light Lights
when the parking brake is applied

l Operating hour meter Counts the

operating hours while the engine is
running. All maintenance work must
be performed according to the indi-
cated operating hours.
m Fuel level gaugeOptional equipment
4.4.1 Monitoring board, A15
Fig. 33: Monitoring board, new design, A15

n Output warning buzzer, Pin 23: +UB switching
n Output engine shut down, Pin 24: +UB switching
n Tank gauge, Pin 1: (0Ω ⇒ tank full, 65Ω ⇒ tank empty, 26Ω ⇒
tank ½. If no level switch is connected or the cable is broken,
the gauge will go out
n Water separator, Pin 21 and 22: Resistance <500kΩ

Pos. Designation Control light Warning Engine Engine Remedy

buzzer shut- shut-
down down
time time
10 sec. 2 min.
g Control light for red, flashing X X Switch off vibration, run
engine overheating engine with idle speed
Low-active or shut down engine if
necessary, clean engine
oil cooler and radiator, if
necessary repair engine
d Control light for red, flashing X X Check the engine oil
engine oil pressure level, if necessary repair
Low-active the engine
h Control light for not used
engine air filter
Low-active
f Control light for yellow, lights Check V-belt, if neces-
charge sary repair the gener-
High-active ator
a Control lamp for yellow, lights X X Checking, cleaning the
water in diesel filter water separator
Low-active
b Control lamp for pre- yellow, lights
heating monitoring
Low-active
e Coolant provision not used
Low-active
i Hydraulic oil filter yellow, lights X X Change the hydraulic oil
filter
Low-active
Checking engine shut-down func-

tion by water separator
1. Start the engine.
2. Disconnect the plug-in connection.
3. Bridge the contacts in the wiring loom.
ð Control lamp [a] Ä Fig. 33 lights up. An audible warning
will sound and the engine is shut down after 2 minutes.
4. Join the plug-in connection again.
ð The plug-in connection clicks into place.
5. Check the plug interlock by lightly pulling on the cable.
Fig. 34: Sensor, water in fuel filter,

B124


tion by engine oil pressure
2. Disconnect the plug-in connection.
3. Apply the contact in the wiring loom to engine ground.
ð Control lamp [d] Ä Fig. 33 flashes. An audible warning
will sound and the engine is shut down after 10 seconds.
Fig. 35: Oil pressure switch, B06

tion by coolant temperature
2. Disconnect the plug-in connection Ä Fig. 36.
3. Bridge both contacts in the wiring loom.
ð Control lamp [g] Ä Fig. 33 flashes. An audible warning
will sound and the engine is shut down after 2 minutes.
Fig. 36: Coolant temperature switch,

B30

Electric systems – Wiring
4.5 Wiring
X5
C
H07
AS
A15
S120
OPTION
EMR
S15
S53
S118
H04
nicht benötigt
S00 not required
H124
S291
OPTION
E03
E04
E07
P03
P04
P07
P12
EXX
PXY
X1
S-582-0023
Fig. 37
1 Wiring loom, dashboard <> central electrics

S42 S01
S03
S35
X11 X12 X13
Option/option
X42
X14
S06
X1
X2
S-582-0024
Fig. 38
1 Wiring loom, arm rest, right <> central electrics

Fig. 39
1 Wiring loom, engine <> central electrics

3
-
M01
1 4
F00:2
F00:1
X36
G01:-
G01:+
5
-
S-582-0040
Fig. 40
1 Wiring loom, central electrics supply
2 Wiring loom, battery <> starter motor
3 Wiring loom, frame <> diesel engine
4 Wiring loom, frame <> battery (-)
5 Wiring loom, battery (+) <> main battery fuse

Fig. 41
1 Wiring loom, rear frame <> central electrics

Fig. 42
1 Wiring loom, cabin <> central electrics

B104 X20
X17
Y15
X1 2
S-582-0009
Fig. 43
1 Wiring loom, heating / air conditioning
2 Wiring loom, air conditioning compressor

E28
E27
E25
E23
XS
X3
S-582-0010
Fig. 44
1 Wiring loom, working lights

Fig. 45
1 Wiring loom, acceleration transducer

Fig. 46
4 Wiring loom, tachometer module

Fig. 47
11 Wiring loom, lighting on railing

Fig. 48
13 Wiring loom, cabin tachograph

S-582-0008
Fig. 49

Electric systems – Starting the engine with jump leads
4.6 Starting the engine with jump leads
NOTICE!
A wrong connection will cause severe damage
in the electric system.
– Bridge the machine only with a 12 Volt auxiliary
battery.
1. Connect the plus pole of the external battery first with the
plus pole of the vehicle battery using the first jump lead.
2. Then connect the second battery cable first to the minus pole
of the current supplying auxiliary battery and then to engine
or chassis ground, as far away from the battery as possible.
NOTICE!
Danger of damage to the electronic system!
If no powerful consuming device is switched on,
Fig. 50
voltage peaks may occur when separating the con-
necting cables between the batteries, which could
damage electrical components.
4. Once the engine is running switch on a powerful consumer

(working light, etc.).
5. After starting disconnect the negative poles first and the posi-
tive poles after.
6. Switch off the consumer.

Electric systems – Proximity switches on travel lever, B13 and B14
4.7 Proximity switches on travel lever, B13 and B14

B13 Initiator for brake
B14 Initiator for reverse detection
Fig. 51
General
In all automated sequences the use of sensors as a source of
information for the electronic control is indispensable. The sensors
deliver the necessary signals about positions, end positions, filling
levels or serve as pulse transducers for counting tasks or speed
detection. In industrial applications inductive and capacitive prox-
imity switches are today indispensable. Compared with mechanical
switches they provide almost ideal prerequsites: contactless, wear-
free operation, high switching frequency and switching accuracy as
well as high protection against vibration, dust and moisture. Induc-
tive sensors detect all metals without contact, capacitive sensors
detect almost all solid and liquid media, such as metal, glass,
wood, plastic, water, oil, etc.
Working principle
The working principle is based on the principle of the dampened
LC-oscillator. The coil of the oscillation circuit forms a high-fre-
quency magnetic stray field.
This stray field leaks out from the active area of the proximity
switch. If metal or non-ferrous metal enters into the response range
energy is absorbed. The oscillator is thus dampened and the
resulting change in current consumption is evaluated.
Fig. 52

PNP circuitry
On sensors with PNP circuitry the output stage contains a PNP
transistor, which switches the load against the positive operating
voltage. The load is connected between the output and the nega-
tive operating voltage. The switch is designed with a normally open
contact, i.e. the contact closes when the initiator comes in “contact”
with metal.
Fig. 53: PNP circuitry
NPN circuitry
On sensors with NPN-circuitry the output stage contains a NPN-
transistor, which switches the load against the negative operating
voltage. The load is connected between the output and the positive
operating voltage.
Fig. 54: NPN circuitry
Breaking and making contacts

Proximity switches are used as breaking or making contacts.
Depending on the design the switching distances are 2 or 4 mm.
The maximum amperage is 300 mA.
The LED Ä Fig. 55 lights up, when the initiator has detected metal
in its stray field.
Fig. 55

The circuit diagram Ä Fig. 56 shows a proximity switch with nor-

mally open contact.
Brown = voltage supply
Blue = ground supply
Black = switching output
The initiator switches the relay (K05)
Fig. 56: Circuit diagram, making con-

tact

Electric systems – Differential pressure switch for hydraulic oil filter, B21
4.8 Differential pressure switch for hydraulic oil filter, B21

The differential pressure switches Ä Fig. 57 switch to ground at a
differential pressure of Δ 3.6 bar.
Fig. 57
Monitoring module, new design
i yellow Lights when the hydraulic oil filter is

dirty, the warning buzzer sounds. The
engine is shut down after 2 minutes.
Check hydraulic system, replace
hydraulic oil filter.
The warning buzzer is activated by the monitoring

board (Pin23).
The engine is shut down by the monitoring board
(Pin24) via relay (K22).
Fig. 58: new design

Electric systems – Level sensor in diesel tank, R03
4.9 Level sensor in diesel tank, R03

The sensor inside the tank is equipped with a float, which drops or
rises with the fuel level. Contact springs mounted on the float
thereby slide along two resistor wires arranged parallel to the
movement of the float and generate a resistance value, which is
proportionate to the fluid filling level. The corresponding resistance
value is measured by an electric meter and displayed as fluid level
value.
Fig. 59: R03
Monitoring module, new design
m Fuel level gauge
00 Ohm = Tank full

40 OHM = Tank 1/2 full
95 Ohm = Tank empty
If no level switch is connected or the cable is broken, the fuel level
gauge will go out.
Fig. 60: new design

Electric systems – Float switch, coolant tank, B55
4.10 Float switch, coolant tank, B55

The float switch switches if the coolant level is too low.
Fig. 61
Coolant level warning lamp, new The switch contact connects the monitoring board (A15, Pin15) to
design ground. The coolant level warning lamp e flashes.
e red Coolant level warning lamp flashes if

the coolant level is too low, the
shut down after 10 seconds. Check
the coolant level. Check cooling
system for leaks, repair if necessary.

board (Pin23).
Fig. 62: Monitoring board, new (Pin24) via relay (K22).
design, A15

Electric systems – Air filter vacuum switch, B03
4.11 Air filter vacuum switch, B03
Fig. 63
Air filter warning lamp, new design The vacuum switch operates at a vacuum of > 50 mbar.
The switch contact connects the monitoring board (A15, Pin16) to
ground. The air filter warning lamp gÄ Fig. 64 lights.
g yellow The air filter warning lamp lights up

when the combustion air filter car-
tridge is contaminated. Clean or
replace if necessary.
Fig. 64: Monitoring board, new

design, A15

Electric systems – Sensor for water in fuel, B124
4.12 Sensor for water in fuel, B124
Fig. 65
1 Water separator sensor connection

2 Fuel pre-heating connection (R79) 200 Watt optional equipment
Water in fuel warning lamp, new

design
a yellow The water in fuel warning lamp lights

when the water content in the fuel pre-
cleaner reaches the sensor contacts.
The warning buzzer sounds. The
engine is shut down after 2 minutes.

board (Pin23).
design, A15

Electric systems – Fuel pre-heating, R79
4.13 Fuel pre-heating, R79

Fuel pre-heating optional equipment
1 Water separator sensor connection (B124)
2 Fuel pre-heating connection (R79) 200 Watt (option)
In diesel engines the pre-heating of the fuel prevents malfunctions
caused by the formation of jelly (paraffin separation) in the fuel
under low temperatures.
Operating the ignition switch activates the heater, this should take
place at least 5 minutes before starting the engine.
The generated heat works directly under the filter element and
melts the wax crystals that have formed, so that the fuel can flow
through the filter element without restriction. The 200W heating is
supplied with 12V DC current.
Fig. 67

Electric systems – Oil pressure switch, B06
4.14 Oil pressure switch, B06

The oil pressure switch is located on the oil filter. Below 0.8 bar the
oil pressure switch switches to engine ground, it is closed without
pressure.
Tightening torque 20±2 Nm with copper ring.
Fig. 68
Engine oil pressure warning lamp With a too low engine oil pressure the monitoring board (A15,
Pin11) is connected to ground. The warning lamp d flashes.
d red The engine oil pressure warning lamp

flashes when the engine oil pressure
is too low, the warning buzzer sounds,
the engine is shut down after 10 sec-
onds.

board (Pin23).
design, A15

Electric systems – Coolant temperature switch, B30
4.15 Coolant temperature switch, B30

The temperature switch is arranged in the coolant circuit of the
engine in such a way, that its tip is surrounded by coolant.
n If the engine overheats, it switches to engine ground.
Fig. 70
Control lamp engine overheating
The switch contact connects the monitoring board (A15, Pin8) to

ground. The warning lamp for overheating of engine hÄ Fig. 71
lights up.
h red The warning lamp for overheating of engine flashes if

the engine overheats, the warning buzzer sounds, the
engine is shut down after approx. 2 minutes.

Fig. 71: Monitoring board, new board (Pin23).
design, A15
4.15.1 Removing and assembling the coolant temperature switch

Removal 1. Turn the battery disconnecting switch to position "OFF".
WARNING!
Danger of scalding!
Do not remove the cap from the compensa-
tion tank when the engine is still hot.
2. Open the lid on the coolant reservoir.

Electric systems – Coolant temperature switch, B30
3. Press in the wire lock and pull off the plug.

4. Lay a cloth around the temperature switch and catch running
out coolant.
ENVIRONMENT!
Dispose of escaping coolant environmentally
6. Unscrew the temperature switch.

Fig. 72: Temperature switch
7. Remove the seal and dispose of.
Fig. 73: Coolant temperature switch
Assembly 1. Clean thread and seat for switch.

2. Install the temperature switch with Loctite 577 and a new
seal, tightening torque 20 Nm.
3. Push the plug back on (plug interlock clicks into place).
4. Check the plug interlock by lightly pulling on the wiring loom.
5. Fill in coolant up to the “MAX” mark.
6. Run the engine up to operating temperature.
Check the area around the coolant temperature

sensor for leaks.
7. Let the engine cool down and check the coolant level again,
top up if necessary.

Electric systems – Boost fuel solenoid valve, Y01
4.16 Boost fuel solenoid valve, Y01

1 Boost fuel solenoid valve, approx. 3.5 Ampere.
During the starting process the solenoid valve is supplied with 12
Volt.
This injection adaptation serves the purpose of compensating for
condensation and leakage losses and for rising the engine torque
during the acceleration phase after starting. For this compensation
and to assure starting of the cold engine additional fuel needs to be
injected at the time of starting and accelerating.
Fig. 74

Electric systems – Solenoid actuator to shut down the engine, Y13
4.17 Solenoid actuator to shut down the engine, Y13

When switching the ignition on, the engine solenoid actuator is
supplied with 12 Volt. The current consumption is approx. 4
Ampere.
Interrupting this voltage supply shuts down the engine.
The engine shut-down can be triggered through the ignition switch
(S00), the emergency stop button (S01) or the monitoring board
(A15) or the seat contact module (A68).
Fig. 75
Nominal values:
n Pick-up current 0.5 seconds, 4 Amp.
n Holding current, 0.5 Amp.
n Resistance, 280 Ω

Electric systems – Engine solenoid actuator, Y120
4.18 Engine solenoid actuator, Y120
Fig. 76: Engine solenoid actuator
Function
The throttle control switch (S120) is used to change from "MIN" idle
speed to "MAX" full throttle and vice versa.
Fig. 77: Throttle control switch
Throttle control solenoid Y120

The throttle control solenoid (5) Ä Fig. 78 is equipped with a pick-
up winding (4) and a holding winding (3), both switched in series.
The holding winding has a far higher resistance than the pickup
winding. The "aux"-connection is connected between the two wind-
ings. The engine solenoid is equipped with a limit switch (2), which
is mechanically connected with the governor rod (1) on the diesel
engine. This switch bridges the holding winding until the end posi-
tion of the governor rod is reached (high engine speed).
This bridging has the effect, that the "aux"-terminal has the same
potential as the "Plus"-terminal. If the bridge is open, the "aux"-ter-
minal has almost the same potential as the "Minus" terminal,
because of the low resistance of the pick-up winding and the high
resistance of the holding winding.
Fig. 78: Electric circuit of solenoid
Nominal values for lift magnet

Measurement between termi- Plunger extended Plunger tightly pressed against
nals the stop in the housing
+ <> aux 0.4 Ω 15.1 Ω
aux <> - 0.6 Ω 0.6 Ω
+ <> - 0.6 Ω 15.3 Ω

Electric systems – Engine solenoid actuator, Y120
Adjusting the solenoid

1. Switch the ignition on.
2. Turn the rotary switch Ä Fig. 79 to position "MAX".
When switching on, the solenoid plunger is

pulled against the stop. The limit switch then
switches the pick-up and holding winding in
series. The current flow is reduced from
approx. 70 A to approx. 3.5 A.
Fig. 79
3. Measure the gap between stop screw 1 Ä Fig. 80 and

throttle lever (2).
NOTICE!
With the governor rod retracted the gap
should be min. 0.1 mm and max. 0.5 mm.
If the gap is too small, the limit switch in the
solenoid may not be able to operate.
In case of a too wide gap the engine will not
reach its maximum speed.
Fig. 80
Make adjustments to the threaded rod.
Fig. 81

Electric systems – Charge control light, engine tachometer
4.19 Charge control light, engine tachometer

1 Terminal B+
2 Terminal W
3 Terminal D+
Fig. 82
Charge control light, new design If the battery is not being charged, a ground signal is applied to D+
terminal 3 . Current flows from the monitoring board (A15) through
the charge control light and through (Pin10) to the D+ terminal. The
charge control lamp fÄ Fig. 83 lights up.
f yellow Charge control lamp Lights if the bat-

tery is not being charged.
Fig. 83: Monitoring module, new

design, A15
Engine PRM-meter Terminal "W" on the generator delivers a pulsating direct voltage,
which can be utilized to determine the rotary speed of the engine.

Electric systems – Heating flange on engine, R19
4.20 Heating flange on engine, R19

The heating flange is a component with an electrically operated
heating wire and high energy density used to heat up the intake air
in case of very low ambient temperatures.
The heating power is approx. 2000 Watt.
The heating power improves the cold starting characteristics and
the exhaust emissions (white smoke) of the diesel engine.
A differentiation is made between preheating, to assure the cold
starting ability of the engine, and after-heating.
Fig. 84: Heating flange R19
The heating process is started by switching the

ignition on.
With a coolant temperature of -30°C the pre-
heating time will be max. 52 seconds, at +5°C the
minimum time will be 38 seconds. During the pre-
heating period the control lamp [b] in the moni-
toring board Ä Fig. 86 is permanently on. In case
of a fault the lamp will flash.
After-heating is triggered by the voltage applied to
the starter (terminal 50) in dependence on the tem-
Fig. 85: Ignition switch perature. With a coolant temperature of -30°C the
subsequent heating time will be max. 180 seconds,
with +25°C the minimum time will be 35 seconds.
This after-heating time is not indicated by the con-
trol lamp in the monitoring board.
NOTICE!
Multiple activation of the heater control in short
term operation (low generator running time) dis-
charges the starter battery.
If the engine does not start properly in case of
automatic starting of the heating flange because
the starter does not get energized due to a fault
and does not crank the engine, the starting
process must be completely aborted (ignition key
to OFF, voltage supply to heating flange inter-
rupted). In order to avoid damage to heating flange
design, A15
or charge air hoses caused by overheating,
another start of the engine must be avoided and
trouble shooting should be performed instead.
Several successive starting attempts can cause
overheating of the heating flange .

1 B113, temperature sensor for heating flange control

2 B30, Coolant temperature switch
Fig. 87
1 A13, Control unit for heating

2 K14, Relay for heating
Fig. 88
Designation Technical data

A13, Control unit for heating 12 Volt
B30, temperature sensor for approx. 2 Ohm at 20°C
heating flange control
B113, Coolant temperature Contact switches at approx. 110° C to ground.
switch
K14, Relay for heating 12 Volt
R19, Heating flange With a coolant temperature of -30°C the preheating time will be max. 52
seconds, with +5°C the minimum time will be 38 seconds.
With a coolant temperature of -30°C the after-heating time will be max.
180 seconds, with +25°C the minimum time will be 35 seconds.
approx. 2000 Watt
approx. 167 A.
approx. 0.07 Ohm

1 Heating start
2 Signal lamp
3 Start
4 Switching relay
5 Status
6 Terminal 15/S
7 Terminal L
8 Terminal 50
9 Terminal R
10 Start process
Fig. 89: Heating flange function dia- 11 Ready for starting: 0 sec.
gram
4.20.1 Checking the heating flange control
The heating flange only becomes active at a

coolant temperature below 25°C. When the plug of
the temperature sensor is pulled off (simulated
sensor failure), a coolant temperature of 0° C is
assumed.
During the preheating period the control lamp [b]

Ä Fig. 90 in the monitoring board is permanently
on. In case of a fault the lamp will flash.
design, A15
n The lamp flashes with a frequency of 1 Hz during the pre-
heating phase; sensor failure.
– Either short circuit or cable breakage at the input to the
control unit, terminal T(4).
n The lamp flashes with a frequency of 2.5 Hz over the entire
heating phase; heating flange failure.
– Either short circuit or cable breakage at the output of the
control unit, terminal R(6).

Starting the heating process

The control lamp [b] Ä Fig. 90 in tghe monitoring
board lights, depending on coolant temperature,
from 30 to 50 seconds. The heating flange relay
picks up.
1. Place a tong-test ammeter over the heating flange con-

necting line.
ð Rated current: 165 ±10A.
The relay must remain energized for

another approx. 15 seconds, after the
control light has gone out.
After the engine has started the after
heating time must continue for 35 to 180
seconds. This after-heating time is not
indicated by the control light.

Electric systems – MESSX, A83
4.21 MESSX, A83
The documentation "Service Training Electrics

MESX" contains also the documentation BEM
(BOMAG Evib-meter).
The BOP (BOMAG Operation Panel) is only
installed in connection with BVC machines, BEM-
machines are equipped wit display module. The
display module is used for the output of fault codes
and display values, as well as for the input of code
numbers.
Fig. 91: BEM display module, P16
Fig. 92: BAM (BOP) operation panel,

P33

Service Training
Electrics
MESX
Version 4.06
Status: 10.06.2015 Page 1 of 67

Author: T.Löw / TE

Service Training MESX
Table of contents
1 Document alteration list .....................................................................................................................3
2 Proof of software change MESX .......................................................................................................4
3 Proof of software change BOP ..........................................................................................................6
4 Known faults ......................................................................................................................................7
5 How to proceed when replacing components? .................................................................................8
5.1 How to proceed when replacing an ESX control? .....................................................................8
5.2 How to proceed when replacing a rear axle sensor?.................................................................8
5.3 Which components can be replaced without a subsequent adjustment procedure? ................8
5.4 List of machine types .................................................................................................................9
6 Possible adjustments on machines without BOP ............................................................................12
6.1 Description of the Display Module ...........................................................................................12
6.2 Input of code numbers .............................................................................................................12
6.3 Changing the machine type (only via display module) ............................................................13
6.4 Inverting the direction signal (only via display module) ...........................................................14
6.5 Changing the bit rate (only with display module) .....................................................................15
7 Adjustment/display possibilities on machines with BOP .................................................................16
7.1 Adjusting the machine type (BOP) ...........................................................................................16
7.2 Inverting the direction signal via the BOP control terminal ......................................................18
7.3 Accessing the diagnostics menu..............................................................................................20
7.3.1 Extended diagnostics on machines with circular exciter (BTMplus, BTMprof)................ 22
7.3.2 Operating hours meter on machines with circular exciter (BTMplus, BTMprof) .............. 23
7.3.3 Extended diagnose BVC machines ................................................................................. 24
7.3.4 Operating hour meter BVC machines .............................................................................. 25
7.4 Simulation mode ......................................................................................................................26
7.5 Changing the printout language ...............................................................................................30
7.6 Setting the machine serial number ..........................................................................................32
7.7 Teaching distance pulses ........................................................................................................34
7.8 Activating the amplitude limitation (only BVC machines).........................................................36
7.9 Changing the display mode (metric/imperial) ..........................................................................38
7.10 Position to switch over the acceleration transducer (only BVC machines) ..........................40
7.11 Switching the GPS Receiver Voltage Supply Mode .............................................................42
8 Possible settings on the BCM05mobile...........................................................................................44
8.1 Reading the software version ..................................................................................................44
8.2 Changing the language ............................................................................................................44
8.3 Changing the unit system (metric/imperial) .............................................................................44
9 Block diagram BEM .........................................................................................................................45
10 Block diagram BTMplus / VARIOCONTROL ...............................................................................46
11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile ................................................47
12 Description of the signals on the ESX-control .............................................................................48
13 Fault codes of the ESX control ....................................................................................................53
13.1 Overview...............................................................................................................................53
13.2 Description of fault reactions ................................................................................................54
13.3 Detailed description of fault codes and their possible causes ............................................55
14 Input codes for ESX control (only via BEM display module) .......................................................59
14.1 Travel system .......................................................................................................................59
14.2 Vibration ...............................................................................................................................60
14.3 Light ......................................................................................................................................60
14.4 Acceleration transducer ........................................................................................................61
14.5 Diesel engine ........................................................................................................................61
14.6 Setting the machine type ......................................................................................................62
14.7 Parameter change ................................................................................................................63
15 Terminology in connection with ESX ...........................................................................................64
Status: 10.06.2015 Page 2 of 67

Author: T.Löw / TE

1 Document alteration list
Version Date Description of changes resp.

0.00 27.04.2004 Creation of version 1 Löw
1.00 05.05.2004 Block diagrams added Löw
Description of display module extended
"Proof of software change" added
1.01 23.07.2004 Description of BOP display pages added. Löw
2.00 31.08.04 Input code 4602 replaced by code 4606 Löw
Machine type BW219D added
3.00 15.10.2004 Item "How to proceed when replacing components?" added Löw
Description for ESX Pin 0:35 added
Description fault code 4601 and 4606 corrected
Description Software Version 3.00 added
3.01 14.02.2005 Description Code 7534 from version 3.00 added Löw,
Description Software change V3.01 added Horch
Description Code 7573 from version 3.01 added
Description of menus "Amplitude limitation" and "Imperial
display" added
Description Software Version up to 3.03 added
Terminal designation MESX changed from X0 to X44
Description of codes 7502, 7511, 7512, 7532, 7541, 7542,
7550, 7551, 7552, 7562, 7571, 7572, 7576 from version 3.03
added
Proof of "Software change" changed to "Software MESX"
Item "Proof of software change BOP" added
Item "Adjustment possibilities on BCM05mobile" added
Block diagram BTMplus / VARIOCONTROL and
BCM05mobile added
Serial numbers added to list of machine types
4.00 01.05.2007 Description of "GPS Mode" menu added Löw
Item "Change language" changed for BCM 05
Description fault code 4531 and 4532 extended
List of machine types extended
4.01 20.11.2009 further SN added Vogt,

List of machine types extended Löw
Software version history extended
4.02 10.03.2010 List of machine types extended Löw
30.03.2010 further SN added Vogt
4.03 02.12.2011 New part-number added Kahren
Description of "Operating hour meter" menu added
Description of "Acc Sensor Position" menu added
Description of simulation screen added
4.04 13.01.2015 Proof of change edited Kahren
4.05 28.05.2015 Failure code 4620added Kahren
4.06 10.06.2015 Proof of change revised Kahren
Status: 10.06.2015 Page 3 of 67

Author: T.Löw / TE

2 Proof of software change MESX

1.00 25.03.2004 Creation of version 1.00 Löw
1.01 05.04.2004 Printout modified Löw
Amplitude limitation for Automatic changed to 0.3 mm
Default setting in Automatic changed to "MAX"
1.02 13.04.2004 BW213 BVC implemented Löw
Printer control modified (Xon, Xoff protocol)
Software version and revision documented in printout
Finished criterion extended (weak spots of 2 m are tested)
Bmfsa code input for DH machines modified
1.03 05.05.2004 Learning mode for travel distance modified (value range Löw
check)
Finished criterion for polygonal drum deactivated
2-stage jump information implemented
Self-latching of control during shut-down implemented
Saving of current adjustment values during shut-down
implemented.
Bmfsa code input for DH machines modified
BW211 D, BW213 D and BW213 DH implemented
Query for software version of BOP implemented
1.04 16.04.2004 BW226 BVC Polygon implemented Löw
Max. adjustment angle limited to 80°
Max. valve current for BW177 limited to 1000mA
1.05 26.07.2004 BW219DH and BW213 BVC Polygon implemented Löw
Termination criteria for while loops incorporated into Evib
calculation
2.00 31.08.2004 Number of machine variants extended to 25 (BW219D) Löw
Problem with sporadic SW crash eliminated
3.00 15.10.2004 Distance pulse changed to 10m for BW226 Löw
Amplitude limitation realized in automatic mode
Simulation mode realized
Changeover metric/imperial realized
minimum required BOP version changed to 3.00 (always
the same version as MESX)
3.01 16.11.2004 The ESC-key does not abort the printout, it only resets the Löw
measurement
Machine variant BW226BVC added
3.02 01.12.2004 Machine type BW216D activated Löw
Completion report for BW226BVC with smooth drum
activated
3.03 14.02.2005 Designation on printout modified (RC; DI) Löw
Default setting for amplitude limitation set to "inactive".
Machine types 177PDH, 179DH, 179PDH, 213PDH,
214DH, 214PDH 216D, 216DH,216PDH, 219PDH,
226DH, 226PDH, 226BVC RC" enabled.
Controller settings for BW213BVC and BW226BVC
optimized with respect to pressure peaks
Minimum speed for swivelling of of exciter changed to
0.18 km/h => Build-up of the machine with vibration at
standstill is thereby avoided
3.04 10.05.2005 Vibration detection for BW177DH/PDH and Löw

BW179DH/PDH corrected
3.05 19.05.2005 Phase response correction acceleration transducer Löw
activated
"Flash Request" activated
Status: 10.06.2015 Page 4 of 67

Author: T.Löw / TE


4.00 01.05.2005 Languages Slovakian, Slovenian, Czech, Romanian Löw
added
Function "vCheckMMISoftwareVersion" corrected
Teach mode for distance via BCM implemented
Triggering of a relay for GPS receiver voltage supply
implemented
GPS mode changed: Off and ON now independent from
engine run, Automatic depending on engine run!
Setting of work number in serial number has been realized
ATTENTION: Signal distribution for CAN message
MMI_CONFIG_DATA_2 0x156 was changed!!!
new machine types:211PD, 213PD, 216PD, 219PD + "low
cost" designs:
177D40,1777DHC,177D_40,177DHC,177PDHC,177PDH
_40,179DHC,179PDHC,211D_40,211PD_40,213D_40,21
3DHC,213PDHC,213PD_40,214DHC,214PDHC,216DHC,
216PDHC,212D_40,212PD_40
Pulse numbers changed to 10m for BW219D
VM classes taken from V3.90, VM class is sent to BCM
4.01 23.05.2007 Vibration detection low/high amplitude adapted Löw
4.02 07.05.2008 Pulse numbers for BW213DHC and PDHC adapted Löw,
Faulty input for VM8 for machine type BW219DHC Nick
corrected
4.03 27.01.2009 Minimum Evib-value limited to 1, so that BCM does no Löw
longer interpret this value incorrectly
4.04 17.11.2009 Machine types BW216D_40, BW216PD_40 and Löw
BW218D_40 implemented
4.05 10.03.2010 Machine type BW332XL implemented. Löw
5.00 09.11.2011 PI-controller of the circular exciter changed Kahren
Position of the acceleration transducer selectable
Plausibility check of whether the position of the
acceleration transducer is correct
Default Position for machines BW213, BW226 has been
added under New BOP menu "Hourmeter" and "Acc
Postion Menu"
CANccp driver implemented
5.01 30.03.2015 Amplitudevalue of BW226PDH for BCM documentation Kahren
adapted
5.02 10.06.2015 GPS-receiver turned on permanently Kahren
Status: 10.06.2015 Page 5 of 67

Author: T.Löw / TE

3 Proof of software change BOP

1.00 25.03.2004 first software version for series production Löw
1.01 13.04.2004 Revision of BVC diagnostics screen Löw
1.02 23.04.2004 2-stage jump information (yellow and red) Löw
3.00 15.10.2004 Realization of imperial display Löw

Simulation mode implemented on BOP
New TN 582 701 92
3.01 24.1.2005 Part-No. changed to 58 701 93 Löw

Designation "ESX" replaced by "MESX" and "BOP" by
"BOP"
3.02 10.02.2005 Amplitude bar graph in imperial display mode corrected Löw
4.00 01.05.2007 Flags for all EU-languages and additionally Japan and Löw
China stored in OPUS
Page for changing over GPS Receiver Mode implemented
Triggering for fault LED in BVC diagnostics page 2
activated
4.01 04.11.2008 - additional variable for brightness control OPUS21C Löw

added
- Representation of SW TN instead of "High-TN"
- Return to diagnostic page corrected for French
version
- SimulScreen activated for French version
- Changeover of GPS-mode prevented (jump to
page GPS-mode deactivated)
4.02 13.01.2009 Return to selection page "Scale type" corrected. Löw
5.00 09.11.2011 Menu "Hourmeter" and "Acc Sensor Position" created Kahren
Status: 10.06.2015 Page 6 of 67

Author: T.Löw / TE

4 Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
Behaviour of machine Possible cause
During initial commissioning the display shows the Bit rate on bmfsa not set to 125 kBit
reading "ct0" => see "Setting the bit rate"
Status: 10.06.2015 Page 7 of 67

Author: T.Löw / TE

5 How to proceed when replacing components?

Each machine is adjusted individually during initial commissioning. This is mainly accomplished by
setting the correct machine type (see "5.4 List of machine types", or "7.1 Adjusting the machine type
(BOP)").
The following chapter describes the necessary adjustments to the control when replacing individual
components in the measuring system.
5.1 How to proceed when replacing an ESX control?
Attention: A machine must not be operated with a wrong type setting,

because in such a case the correct function of the control cannot
be assured!
You should therefore set the machine type first! see "5.4 List of
machine types, or "7.1 Adjusting the machine type (BOP)").
After setting the machine type check the following items:
• Check the direction signal, invert the signal if necessary, see 6.4, or 7.2.
• Set the machine serial number (only on machines with BOP), see: 7.6
• Set the printer language (only machines with printer), see: 7.5
5.2 How to proceed when replacing a rear axle sensor?
Check the direction signal, invert the signal if necessary, see 6.4, or 7.2.
5.3 Which components can be replaced without a subsequent

adjustment procedure?
• BOP
• Acceleration transducer
• Valve block for exciter adjustment
• Printer
• Bmfsa display module
• All switches in the dashboard
Note: A final function test of the complete machine is highly

recommended.
Status: 10.06.2015 Page 8 of 67

Author: T.Löw / TE

5.4 List of machine types

Since the same control is used for all single drum rollers with the new measuring technology, it is
necessary to adjust the machine type after installing a new control.
This is necessary during first time commissioning as well as in case of a spare parts installation. This
type adjustment is necessary, because the machines have e.g. different axle loads or different drum
widths, which requires the calculation of measuring values to be adapted. The adjustment procedure
is described under items "6.3 Changing the machine type (only via display module)" or "7.1 Adjusting
the machine type (BOP)".
The following machine types can be adjusted:
Machine type First serial number Last serial number Code Available from
version
177 D 101 582 20 1001 XXX XXX XX XXXX 7500 1.00
101 583 27 1001
177 PD 101 583 43 1001 XXX XXX XX XXXX
177 DH 101 582 21 1001 XXX XXX XX XXXX 7501 1.00
101 583 32 1001
101 584 10 1001
177 PDH 101 582 22 1001 XXX XXX XX XXXX 7502 3.03
101 583 31 1001
177 BVC 101 582 23 1001 XXX XXX XX XXXX 7503 1.00
101 583 28 1001
179 DH 101 582 24 1001 XXX XXX XX XXXX 7511 3.03
101 583 33 1001
101 583 35 1001
211 D 101 582 40 1001 XXX XXX XX XXXX 7520 1.03
101 582 41 1001
101 583 09 1001
101 583 51 1001
211 PD 101 582 45 1001 XXX XXX XX XXXX 7529 4.00
101 583 10 1001
213 D 101 582 50 1001 XXX XXX XX XXXX 7530 1.03
101 583 08 1001
213 DH 101 582 51 1001 XXX XXX XX XXXX 7531 1.03
101 583 14 1001
101 583 37 1001
101 584 11 1001
101 584 12 1001
213 PD 101 582 46 1001 XXX XXX XX XXXX 7539 4.00
101 583 13 1001
101 583 15 1001
101 583 16 1001
213 BVC plates 101 582 54 1001 XXX XXX XX XXXX 7534 3.00
101 583 06 1001
213 BVC DI 101 582 53 1001 XXX XXX XX XXXX 7535 1.05
101 583 16 1001
214 D 101 583 42 1001 XXX XXX XX XXXX
214 DH 101 582 58 1001 XXX XXX XX XXXX 7541 3.03
101 583 19 1001
101 583 20 1001
216 D 101 582 62 1001 XXX XXX XX XXXX 7550 3.03
101 583 23 1001
101 584 13 1001
Status: 10.06.2015 Page 9 of 67

Author: T.Löw / TE

216 DH 101 582 60 1001 XXX XXX XX XXXX 7551 3.03

101 582 64 1001
101 584 00 1001
216 PD 101 582 63 1001 XXX XXX XX XXXX 7559 4.00
101 583 24 1001
101 582 65 1001
101 584 01 1001
version
219 D 101 582 72 1001 XXX XXX XX XXXX 7560 2.00
101 582 10 1001
861 582 75 1001
101 584 02 1001
219 DH 101 582 70 1001 XXX XXX XX XXXX 7561 1.05
101 582 77 1001
101 584 04 1001
219 PD 101 582 73 1001 XXX XXX XX XXXX 7569 4.00
101 582 11 1001
101 584 03 1001
101 582 78 1001
101 584 05 1001
226 DH 101 582 80 1001 XXX XXX XX XXXX 7571 3.03
101 582 83 1001
101 582 88 1001
101 584 06 1001
101 582 84 1001
101 582 89 1001
101 584 07 1001
101 582 85 1001
101 582 86 1001
101 584 08 1001
226 BVC DI 101 582 82 1001 XXX XXX XX XXXX 7575 1.04
101 582 85 1001
101 582 86 1001
101 584 08 1001
226 BVC RC 101 582 82 1001 XXX XXX XX XXXX 7576 3.03
101 582 85 1001
101 582 86 1001
101 584 08 1001
332 DEEP IMPACT 101 583 44 1001 XXX XXX XX XXXX 7585 4.05
101 583 52 1001
101 584 09 1001
101 584 14 1001
version
VARIOCONTROL 101 582 12 1001 XXX XXX XX XXXX 7537 4.00
VARIOCONTROL+ 101 582 13 1001 XXX XXX XX XXXX 7538 4.00
Status: 10.06.2015 Page 10 of 67

Author: T.Löw / TE

version
177 D-40 901 582 26 1001 XXX XXX XX XXXX 7600 4.00
177 DH-40 901 582 27 1001
177 DHC-4 101 582 00 1001 XXX XXX XX XXXX 7601 4.00
101 583 29 1001
177 PDHC-4 101 582 01 1001 XXX XXX XX XXXX 7602 4.00
101 583 30 1001
177 PDH-40 901 582 28 1001 XXX XXX XX XXXX 7609 4.00
101 583 34 1001
101 583 36 1001
211 D-40 101 582 42 1001 XXX XXX XX XXXX 7620 4.00
901 583 02 1001
901 583 25 1001
211 PD-40 101 582 47 1001 XXX XXX XX XXXX 7629 4.00
901 583 03 1001
901 583 26 1001
212 D-40 101 582 43 1001 XXX XXX XX XXXX 7680 4.00
101 582 48 1001
101 583 49 1001
212 PD-40 101 583 48 1001 XXX XXX XX XXXX 7689 4.00
101 583 50 1001
213 D-40 101 582 44 1001 XXX XXX XX XXXX 7630 4.00
901 582 55 1001
901 583 07 1001
213 DH-40 901 582 56 1001
101 583 11 1001
101 583 12 1001
213 PD-40 101 582 49 1001 XXX XXX XX XXXX 7639 4.00
213 PDH-40 901 582 57 1001
101 583 17 1001
101 583 18 1001
216 D-40 101 583 39 1001 XXX XXX XX XXXX 7650 4.04
101 583 21 1001
216 PD-40 101 583 40 1001 XXX XXX XX XXXX 7659 4.04
101 583 22 1001
218 D-40 101 583 34 1001 XXX XXX XX XXXX 7670 4.04
101 583 41 1001
Status: 10.06.2015 Page 11 of 67

Author: T.Löw / TE

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

For the diagnostics of control inputs and outputs various code numbers can be entered via the display
module of the control. The input of a code number is performed as follows:
1. Press both keys (F1 and F2) on the instrument cluster for 2 seconds.
The value 0 0 0 0 will be displayed, whereby the 1st digit is flashing.
2. The value of the flashing digit can be increased by pressing the left hand key (F1). When the figure
9 is displayed and the left hand key (F1) is pressed again, the display will return to the value 0 .
3. When pressing the right hand key (F2) the flashing digit will move one digit to the right. When the
4th digit is flashing, the right hand key (F2) is pressed once again to confirm the input. The desired
function is then executed or the desired value is displayed respectively.
In order to terminate a display function you must either enter code number 0 0 0 0 or switch the ignition
off.
Status: 10.06.2015 Functiona of the ESX control Page 12 of 67

Author: T.Löw / TE

6.3 Changing the machine type (only via display module)

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

Author: T.Löw / TE

6.4 Inverting the direction signal (only via display module)

Depending on the installation position, the axle sensor used delivers a 12V output signal in forward
and reverse.
This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the the travel direction correspond with the actual travel direction.
• Enter code number 7 6 0 0 . This code number activates the function "Invert direction signal“.
The display module now permanently shows the code 7 6 0 0 .
• Enter code number 7 6 0 1 . This code number inverts the direction signal.
The display module now permanently shows the code 0 0 0 1 (signal inverted), or the code 0 0 0 0 (signal
not inverted).
In succession the code number 1 0 0 1 can be used to check whether the direction signal is correctly
interpreted (see item 14"Input codes for ESX control").

Author: T.Löw / TE

6.5 Changing the bit rate (only with display module)

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

Author: T.Löw / TE

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

Setting the machine type requires the following sequence:
• Press key "?" to open the screen page "MENU". The following screen is displayed:
• Press key "F2" to open the screen page "Adjust machine type". The following screen is displayed:

Author: T.Löw / TE

• The desired machine type can be selected by pressing the keys "F11" and "F12". (see List of
machine types under item 5.4 "List of machine types" ).
• After selecting the desired machine type press key "F14", until the symbol (F14) lights green for
confirmation (approx. 4s).
When releasing the key the start screen will automatically be displayed and the control will initiate a
restart.
• Switch the ignition off and on again.
BOP and MESX are now adjusted to the new machine type.

Author: T.Löw / TE

7.2 Inverting the direction signal via the BOP control terminal
Depending on the installation position, the axle sensor used delivers a 12V output signal in forward
and reverse.
This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the the travel direction correspond with the actual travel direction.
• Press key "F1" to open the screen page "Invert direction signal". The following screen is displayed:

Author: T.Löw / TE

• The direction signal can now be inverted or not inverted by pressing key "F5" ("Invert = 1" or
"Invert = 0").
• After the desired change press key "F14" to save the adjustment. The symbol lights green for a
moment as a sign of confirmation.
• Press "ESC" to exit the screen page.
Check on the printout or in the diagnostics menu whether the travel direction has been correctly
detected.

Author: T.Löw / TE

7.3 Accessing the diagnostics menu

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

Author: T.Löw / TE

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

Author: T.Löw / TE

7.3.1 Extended diagnostics on machines with circular exciter (BTMplus,

BTMprof)
4.23 V Ubv: actual voltage front acceleration transducer
4.24 V Ubh: actual voltage rear acceleration transducer
98% Small Ampl: Triggering of solenoid valve for low amplitude in percent
0% Big Ampl: Triggering of solenoid valve for high amplitude in percent
Direction: Status MESX input travel direction (LED on = 12V)
Ligths: Status MESX input light detection (LED on = 12V)
MD+ Status MESX input MD+ (detection engine running) (LED on = 12V)
Vibration: Status of vibration detection in the MESX (LED on = Vibration ON)
+01234 Distance pulses detected by the MESX (10cm steps). The actually detected
travel direction can be recognized by the roller symbol above.

• By pressing key "B" you can display an operating hour meter (see below).

Author: T.Löw / TE

7.3.2 Operating hours meter on machines with circular exciter (BTMplus,

BTMprof)
Engine: Operating hours of engine
Vib. manual: Operating hours with vibration driven in manual mode
Vib. auto: Operating hours with vibration driven in automatic mode
Vib. small ampl.: Operating hours with vibration driven with small amplitude mode

Author: T.Löw / TE

7.3.3 Extended diagnose BVC machines
4,25 V Uexciter: actual voltage of exciter position potentiometer
4,23 V Ubv: actual voltage front acceleration transducer
4.24 V Ubh: actual voltage rear acceleration transducer
98% Ampl: Triggering of solenoid valve for vibration valve in percent
Direction: Status MESX input travel direction (LED on = 12 V)
Ligths: Status MESX input light detection (LED on = 12 V)
MD+ Status MESX input MD+ (detection engine running) (LED on = 12 V)
Vibration: Status of vibration detection in the MESX (LED on = Vibration ON)
+01234 Distance pulses detected by the MESX (10cm steps). The actually detected
travel direction can be recognized by the roller symbol above.
• By pressing key "B" you can display an operating hour meter (see below).

Author: T.Löw / TE

7.3.4 Operating hour meter BVC machines
Engine: Operating hours of engine
Vib. manual: Operating hours with vibration driven in manual mode
Vib. auto: Operating hours with vibration driven in automatic mode
Ampl. < 1.25 mm: Operating hours with vibration driven with small amplitude mode

Author: T.Löw / TE

7.4 Simulation mode

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

Author: T.Löw / TE

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

Author: T.Löw / TE

• Press key "A" again to open the screen page "simulation mode". The following screen is
displayed:

Author: T.Löw / TE

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

Author: T.Löw / TE

7.5 Changing the printout language

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

Author: T.Löw / TE

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

Author: T.Löw / TE

7.6 Setting the machine serial number

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

Author: T.Löw / TE

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

Author: T.Löw / TE

7.7 Teaching distance pulses

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

Author: T.Löw / TE

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

Author: T.Löw / TE

7.8 Activating the amplitude limitation (only BVC machines)

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

Author: T.Löw / TE

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

Author: T.Löw / TE

7.9 Changing the display mode (metric/imperial)

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

Author: T.Löw / TE

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

Author: T.Löw / TE

7.10 Position to switch over the acceleration transducer (only BVC

machines)
• Press key "F9" to open the screen page "Acc Position". The following screen is displayed:

Author: T.Löw / TE

• Press key "F1" to activate the upper position or press key "F3" to activate the lower position.
• After the desired change press and hold key "F14" to save the adjustment. The symbol lights
green after a few seconds as a sign of confirmation. Then release the key again.

Author: T.Löw / TE

7.11 Switching the GPS Receiver Voltage Supply Mode

• Press key "F14" to open the screen page "GPS Mode". The following screen is displayed:

Author: T.Löw / TE

This function enables the GPS Receiver Power Supply to be controlled via MESX, so that the receiver
can be switched on and off in a defined way.
• The GPS Mode can now be changed over by pressing the "F5"-key:
"0" OFF GPS Receiver always switched off

"1" ON GPS Receiver switched on as soon as the ignition is switched on.
"2" AUTO GPS Receiver switched on as soon as the BCM transmits data to MESX

Author: T.Löw / TE

8 Possible settings on the BCM05mobile

Insert the BCM05mobile into the holder and close the clamp. Switch on the ignition and subsequently
the BCM05mobile by holding the yellow switch on the right depressed for approx. 1-2 seconds; wait
and confirm the time dialog.
For functions beyond the following description, please refer to the BCM05 user manual.
8.1 Reading the software version

Select "Configuration" at the right hand edge of the window.
The software currently installed in the BCM05mobile is displayed at the top left under the name
BOMAG.
8.2 Changing the language
Note: This function is only available from software version 1.37!
Select "Configuration" at the right hand edge of the window.

Press the field "Language". A list with the available languages pops up. Choose the desired language
and confirm with "Select".
8.3 Changing the unit system (metric/imperial)

Open the service window: press the top switch of the three switches at the right hand edge of the
touchscreen "Configuration" for about 5 seconds, until a roller symbol appears under the software
version number at the left hand side of the display. Release the "Configuration" switch and press the
symbol within 3 seconds. The touchscreen now shows 4 switches near the right hand edge, choose
the bottom switch "Service".
Note: After this setting the service window must be closed to avoid unauthorized
access. Press "Close window" at the bottom right in the service window.
Shift the switch in the "Unit" field to the desired position.

Author: T.Löw / TE

164
Service Training MESX Block diagram
9 Block diagram BEM

BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40

Status: 10.06.2015 Block diagram Page 45 of 67
Author: T. Löw / TE
10 Block diagram BTMplus / VARIOCONTROL

165
166
11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile


Service Training MESX Description of signals
12 Description of the signals on the ESX-control

Notes:
1. Wherever the value of 12 V is mentioned in the following text, it refers to the current battery
voltage under due consideration of voltage drops in the lines.
ESX terminal Signal description Nominal values (voltage / current)

X44:1 AGND = Analogue ground: Ground potential for sensors (steering approx. 0 V measured against ground (terminal 31)
joystick, speed range switch etc.)
X44:2
X44:3 Output Evib Display PWM signal (100Hz): ca. 0..6 V

PWM (max. 2.5 A)
X44:4 Interface RS 232 RxD, used for printer control. Measurement not possible!
X44:5 Interface RS 232 TxD, used for printer control. Measurement not possible!
X44:6
X44:7 Input acceleration transducer VH20g/HR15g Acceleration signal (measured against AGND)
Open circuit voltage (vibration off): 4.2 .. 4.3 V

Analog input / voltage input 0..8.5 V
X44:8
X44:9 Input exciter position front Position of front exciter (measured against AGND)
Analog input / voltage input 0..8.5 V Stop bottom approx. 2.2 V
Neutral position approx. 4.25 V
Stop top approx. 6.6 V

Status: 10.06.2015 Description of signals Page 48 of 67
167
168

X44:10
X44:11
X44:12
X44:13
X44:14
X44:15 Input vibration 1 On Vibration on: >6V

Digital input active high Vibration off: approx.0 V
X44:16 Input button START (option) Push button pressed 12 V

Digital input active high Button not pressed 2V
X44:17 Input button STOP (option) Push button pressed 12 V
X44:18 Input button PRINT (option) Push button pressed 12 V
X44:19 Input button CLEAR (option) Push button pressed 12 V
X44:20
X44:21
X44:22
X44:23 Output voltage supply for sensors Nominal voltage = 8.5 V

This output supplies steering joystick, speed range selector switch, etc. Permissible range: approx. 7.65 .. 9.35 V
Without this voltage the control cannot work correctly and will switch to This voltage must be measured against AGND.
override mode (emergency function).

X44:24


X44:25
X44:26 Interface CAN-Bus Wire -, is used to communicate with the BOP Measurement not possible!
operating unit.
X44:27 Interface CAN-Bus Wire +, is used to communicate with the BOP Measurement not possible!
operating unit.
X44:28 Input potential terminal 15 Control switched on 12 V

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

X44:30 Input acceleration transducer VH/VR15g Acceleration signal (measured against AGND)

X44:31 Input acceleration transducer VV20g/HR15g Acceleration signal (measured against AGND)

X44:32
X44:33 Interface CAN-Bus2 Wire -, is used to communicate with the BCM05. Measurement not possible!
X44:34
X44:35 Input distance transducer Transducer delivers square-wave pulses Frequency depends on machine
type.
Digital input active high

169
170

X44:36
X44:37 Input D+ generator Engine running / engine being started 12 V

Digital input active high Engine stopped 0V
X44:38 Input vibration 2 On Vibration on: >6V
Digital input active high Vibration off: approx.0 V
X44:39
X44:40
X44:41
X44:42
X44:43
X44:44
X44:45
X44:46 Output valve 1 front valid current range: approx. 0..1.5 A

PWM digital output (max. 4 A)
X44:47 Output valve 2 front valid current range: approx. 0..1.5 A
PWM digital output (max. 4 A)
X44:48
X44:49
X44:50

X44:51
X44:52


X44:53 Interface CAN-Bus2 Wire +, is used to communicate with the BCM05. Measurement not possible!
X44:54 Voltage supply for electronics Emergency stop not actuated 12 V
Emergency stop actuated 0V
X44:55 Ground connection electronics 0 V measured against ground
X44:56 Voltage supply for outputs approx. 12 V measured against ground
X44:61
X44:62
X44:63
X44:64
X44:65 Mouse port Baby Boards approx. 0 V

171
Service Training Fault codes of the ESX control
13 Fault codes of the ESX control
13.1 Overview
Fault code Description of fault

4501 - 4540 Position controller (exciter potentiometer, valves)
4601 - 4620 Acceleration transducer
8000 - 8250 Internal software errors
Status: 10.06.2015 Fault codes of the ESX control Page 53 of 67

Author: T.Löw / TE

Service Training MESX Description of fault codes of the ESX control
13.2 Description of fault reactions
Fault reaction Description of fault reaction

1 Warning.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
2 Impairment of function, the faulty function is overridden by an emergency function.
3 Fault of a partial function, the partial function cannot be overridden by an emergency function.
After the occurrence of the fault the machine is stopped, after returning the travel lever to neutral the machine can move
again.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
4 Fault of a partial function, the partial function cannot be overridden by an emergency function.
The machine is no longer able to drive, e.g. because parts of the travel system are defective
the diesel engine is shut down.
5 Fatal fault. The function of the control is no longer assured.
The control will be switched off.
Error code is displayed.
Signal light in BOP (option) lights permanently.
Note: Errors with error reaction 1 are only warning messages and are NOT saved in the error log!

Status: 10.06.2015 Fault Code Description ESX control Page 54 of 67
173
174
13.3 Detailed description of fault codes and their possible causes
Fault Description of fault Possible cause Termina Input Fault

code l on code for reaction
ESX diagnose
4501 Input exciter potentiometer front Wire breakage in current path X44:09 5
The voltage applied to the input is below the Current path has short circuit to ground
specified range (see signal description). No voltage supply to potentiometer
Fuse FM ? has tripped or wire breakage in voltage supply current
path
Potentiometer defective
4502 Input exciter potentiometer front Current path has connection to +12 V / +8,5 V X44:09 5
The voltage applied to the input is above the Potentiometer not connected to ground
specified range (see signal description). Potentiometer defective


ESX diagnose
4521 Output proportional solenoid front Current path has short circuit to voltage supply X44:46 2
Valve for exciter up Current path has non-permitted connection to another current
Output current too low. path
Current path is interrupted
4522 Output proportional solenoid front Current path has short circuit to ground X44:46 2
Valve for exciter up Current path has non-permitted connection to another current
Output current too high. path
4523 Output proportional solenoid front Current path is interrupted X44:46 2

Valve for exciter up Current path has impermissible connection to another current
Fault when calibrating the valve path / ground
4526 Output proportional solenoid front Current path has short circuit to voltage supply X44:47 2
Valve for exciter down Current path has non-permitted connection to another current
Output current too low. path
Current path is interrupted
4527 Output proportional solenoid front Current path has short circuit to ground X44:47 2
Valve for exciter down Current path has non-permitted connection to another current
Output current too high. path
4528 Output proportional solenoid front Current path is interrupted X44:47 2

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

175
176

ESX diagnose
4531 Position controller positive limit reached Supply and ground terminal on exciter potentiometer mixed up X44:09 5000 2
The exciter does not move to the desired Valves for "Exciter up" and "Exciter down" mixed up X44:37
direction or does not move at all. MD+ input has 12 V potential, even though the engine is not
running
Air in hydraulic system, hydraulic pressure too low
4532 Position controller negative limit reached Supply and ground terminal on exciter potentiometer mixed up X44:09 5000 2
The exciter does not move to the desired Valves for "Exciter up" and "Exciter down" mixed up X44:37
direction or does not move at all. MD+ input has 12 V potential, even though the engine is not
running
Air in hydraulic system, hydraulic pressure too low
4601 Input acceleration transducer 1 Current path has no connection to +12 V / +8,5 V X44:29, 4601 2
The voltage applied to the input is below the Current path connected to ground or
specified range (see signal description). Transducer defective X44:31
4602 Input acceleration transducer 1 Current path has connection to +12 V / +8,5 V X44:29, 4601 2
The voltage applied to the input is above the Current path not connected to ground or
4606 Input acceleration transducer 2 Current path has no connection to +12 V / +8,5 V X44:30, 4606 2
The voltage applied to the input is below the Current path connected to ground or
4607 Input acceleration transducer 2 Current path has connection to +12 V / +8,5 V X44:30, 4606 2
The voltage applied to the input is above the Current path not connected to ground or

4620 Position of acceleration transducer inverted Failure at assembling transducer 2
Failure at selecting position of transducer at BOP menu


ESX diagnose
8000 Error message "Incorrect BOP Software version" - - 2
The software version of the BOP is too old, i.e.
various functions cannot be displayed.
This fault cannot be rectified on the machine.
The BOP needs to be replaced.
8 0 0 1 - Fault message "severe software fault in control" - - - 5
This fault cannot be rectified on the machine.
8999 The control must be immediately replaced.
9 0 0 0 - Error message "Communication via CAN bus Wire breakage in CAN bus lines X44:26 - 2
disturbed" Short circuit between CAN bus lines X44:27-
9199 The modules controlled via the CAN bus cannot One or both CAN bus line(s) has (have) connection to +12 V or
be addressed by the main control (ESX). The ground
respective machine functions are not available
9 2 0 0 - Fault message "Severe internal fault in control" - - - 5

The control has automatically switched off. This
9999 fault cannot be rectified on the machine. The
control must be immediately replaced.
Ct0 Display module has no connection to ESX- Wire breakage in CAN bus lines X44:26 - -
control. Short circuit between CAN bus lines X44:27
One or both CAN bus line(s) has (have) connection to +12 V or
ground
Incorrect bit rate in display module (nominal value: 125 kBit)

177
178
Service Training MESX Description of input codes of the ESX control
14 Input codes for ESX control (only via BEM display module)
14.1 Travel system
Input code Description of display function Display values

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

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

The distances pulses summarized since starting the machine are
displayed. If the machine has travel a longer distance in reverse than
in forward, the value will be negative.
1003 Travel speed Display value = max. speed in km/h
Shows the actual speed.
1010 Parameter "Show distance pulses per 10m" Depending on the selected machine type, e.g. 5896 for
Eeprom Parameter is displayed BW177 BVC
1011 Parameter "Invert travel direction" 0000 Direction signal is not inverted
Eeprom Parameter is displayed
000I Direction signal is inverted

Status: 10.06.2015 Description of Control Input Codes Page 59 of 67
14.2 Vibration

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

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

179
180
14.4 Acceleration transducer

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

5000 Input MD+ 0000 Engine OFF
Show status of diesel engine.

0001 Engine ON

14.6 Setting the machine type

7000 Shows the adjusted machine type
7010 Switches on function "Set machine type"
7011 Confirms entered machine type
7500..7699 Pre-select machine type

181
182
14.7 Parameter change

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

15 Terminology in connection with ESX

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

• loosened, slipped off
• broken off,
• corroded,
• socket / plug faulty
Status: 10.06.2015 Terminology Page 64 of 67

Author: T.Löw / TE

Short circuit to ground

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

Author: T.Löw / TE

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

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

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

Author: T.Löw / TE

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

In the event of a major fault the control will switch off and the override function will take over.
This has the effect that the machine can still be moved and steered with reduced speed.
Steering and dozer blade movements are only possible with a constant speed.
(see also: page 46, "")
GND - AGND
Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional
analogue ground, which is only to be used for sensors. (see description of the signals on the
ESX-control)
PWM – digital output

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

Author: T.Löw / TE


Electric systems – Acceleration transducer, B62
4.22 Acceleration transducer, B62
Fig. 93
BVC machines and machines with E-VIB meter are equipped with
two piezo electric acceleration transducers, which are mounted to
the drum.
During operation these transducers transmit the acceleration sig-
nals to the measuring ESX.
The function of the piezo electric acceleration transducer is based
on the self-charging effect of quartz crystals under mechanical load
(pressure, tension, torsion) in vertical direction to the polar axes,
which was discovered in 1880 by J. and P. Curie.
Mode of action
1 Seismic mass (m)Seismic mass

2 Piezo electric material
3 Acceleration (a)
The piezo electric acceleration transducer consists of two basic
components:
n Piezo electric material
n Seismic mass
Fig. 94

Electric systems – Acceleration transducer, B62
Once side of the piezo disc is connected with the so-called seismic
mass, the other one with a rigid carrier. When this combination is
set to oscillate, the seismic (sluggish) mass transfers a force to the
piezo disc. According to Newton's Law the resultant force is the
product of acceleration and mass.
A small wire connects the piezo element with the sensor socket.
The piezo electric effect generates a charge (u) on the electrodes,
which is proportional to the force and thus also to the acceleration
(a).

Electric systems – Control unit for air conditioning, A108
4.23 Control unit for air conditioning, A108
Fig. 95
1 [S44] Rotary switch for fan
2 Rotary switch for air conditioning
3 Cabin fan (M09)
B104 Pressure switch for air conditioning
Y15 Solenoid valve of air conditioning compressor

Electric systems – Module for seat contact monitoring, A68
4.24 Module for seat contact monitoring, A68








Electric systems – Vibration module, K04
4.25 Vibration module, K04




Electric systems – Speedometer module, A05
4.26 Speedometer module, A05
Fig. 96: Speedometer module
Description of function
With the programmable module BM UPM the software realizes a
speedometer function. To ensure that the tachometer function is
not only realized for one special roller, there is a possibility to adapt
the module to any machine with the help of a self-teaching mode.
1. Whenever the module is switched on the system runs a self-
test by passing through the entire display range in both direc-
tions. The display self-test takes approx. 15 seconds.
2. After this the module changes to measuring mode. The fre-
quency of the travel pulses of the roller is detected and con-
verted to a proportional output voltage that triggers the dis-
play.
3. The output signal for the display is a PWM-signal.
Manual testing of the speedometer

When the module is in learning mode a manual display test can be

performed via the input "Test". For this purpose the input "IN" must
be energized with 12 Volt, whereupon the speedometer is con-
stantly triggered with 3 Volt.
Pin-no. module Pin name Description
Test E_ANZEIGENTEST Input HIGH active: Activate manual display test

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

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

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

In self-teach mode the number of arriving path pulses is detected
at the input (IN). The number of recorded pulses is referred to as
pulse number per 10 or 18 m (machine dependent) travel distance
of the roller.
1. Connect the ground cable (-).
2. Connect the sensor signal (speed sensor) to frequency input
(IN).
3. Install a cable bridge from terminal "15/54" to the connection
"Teach".
4. Connect potential "Ignition / 15" to connection "15/54".
5. Switch on the ignition, start the engine and travel a distance
of exactly 10 m.
NOTICE!
BW24RH, BW27RH, C550H and C560H = travel
18 meters.
All other machines = travel 10 meters.
If the module is in teach mode the LED on output

"OUT +" will flash with the frequency of the path
pulses arriving at input (IN).

1. Disconnect the cable bridge from "Teach" to "15/54“.

2. Switch the ignition off and on again (Reset).
The module has now learned the pulses of the speed sensor.
1. Connect the speedometer (0 to 6 Volt) to "OUT +" and "OUT
–“.

Electric systems – Telemecanique switch
4.27 Telemecanique switch

Dismantling
Fig. 97
1. Lift up the interlock (5).
2. Fold down the switch block (4).
3. Loosen the screw (1).
Fig. 98: Folding down the switch

block
4. Lift up the interlock (2) and pull out the front element (3).
Fig. 99: Pulling out the front element

Electric systems – Telemecanique switch
Assembly
Fig. 100: Assembly

1. Insert the front element (3) into the bore in the control panel.
2. Clip the fastening adapter (6) onto the front element (3).
Watch the marks on front element and fas-

tening flange.
3. Tighten the screw (1) with a tightening torque of 0.6 Nm.
Fig. 101: Observe the marks.
4. Clip on the switch block (4).
Hook in the switch block at the bottom first.
Fig. 102: Install the switch block

Electric systems – Deutsch plug, series DT and DTM
4.28 Deutsch plug, series DT and DTM

General
NOTICE!
Do not crimp more than one lead per pin or per
socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
Fig. 103: Crimp connections When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).
Removing DT contacts
Fig. 104: DT Series

Plug connectors DT and DTM have a wedge to hold the pins and
sockets in their position. This wedge can be removed and
replaced, without having to cut any leads.
Fig. 105
1. Pull the orange wedge out with long nose pliers.

2. Slightly pull the lead and unlock the interlocking hook with a
screw driver.
3. Pull the contact out of the socket.
Use the same method when assembling the

socket.
In this case the interlock disassembly tool
serves as an aid to remove the wedges.
Installing DT contacts
Fig. 106
1. Insert the contacts through the rubber grommet until they
click into place.
2. Insert the orange wedge in direction of arrow.

socket.
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in
the housing.
1. Perform a pull test on each lead, each of the terminals and

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

Removing DTM contacts
Fig. 107: DTM Series

Plug connectors DT and DTM have a wedge to hold the pins and
sockets in their position. This wedge can be removed and
replaced, without having to cut any leads.
Fig. 108
1. Pull the orange wedge (interlock) out with long nose pliers.
2. Slightly pull the lead and unlock the interlocking hook with a
screw driver.
3. Pull the contact out of the socket.

socket.
In this case the interlock disassembly tool
serves as an aid to remove the wedges.

Installing DTM contacts
Fig. 109
1. Insert the contacts through the rubber grommet until they
click into place.
2. Insert the orange wedge, until it clicks into place.

socket.
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in
the housing.
1. Perform a pull test on each lead, each of the terminals and

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

Electric systems – Magnetic coil plug
4.29 Magnetic coil plug

Solenoid valve plug with pointed
cable
These instructions describe the correct assembly of a plug. It is the
objective to assemble the plug correctly, in order to prevent failures
in the field caused by the entry of moisture.
Fig. 110
Assembly
1. Connect the plug with the coil connection and press it firmly
onto the connecting housing.
Fig. 111
2. Fasten the screw with a suitable screwdriver.
Fig. 112

3. Press the plug firmly on again.
Fig. 113
4. Retighten the screw.
Fig. 114
Fig. 115: Correctly installed plug

without gap

Fig. 116: Incorrectly installed plug

with gap

Electric systems – Inspection and maintenance work
4.30 Inspection and maintenance work

4.30.1 Maintenance Table
No. Maintenance works Page

Every 500 operating hours
4.30.2.1 Battery service 215
4.30.2 Every 500 operating hours

4.30.2.1 Battery service
WARNING!
Danger of cauterisation ! Danger of explosion!
When working on the battery do not use open fire,
do not smoke!
The battery contains acid. Do not let acid come in
contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
For recharging remove the plugs from the battery
to avoid the accumulation of highly explosive
gases.
ENVIRONMENT!
Dispose of the old battery environmentally.
Maintenance free batteries also need care. Mainte-

nance free only means that the fluid level does not
need to be checked. Each battery suffers under
self-discharge, which may, in not checked occa-
sionally, even cause damage to the battery as a
result of exhaustive discharge.
The following therefore applies for the service life:

1. Switch off all consumers (e.g. ignition, light, inside light,
radio).
2. Check open-circuit voltage of the battery at regular intervals.
At least once per month.

Electric systems – Inspection and maintenance work
Reference values: 12.6 V = fully charged; 12.3 V = 50% dis-

charged.
1. Recharge the battery immediately after an open-circuit
voltage of 12.25 V or less is reached. Do not perform quick
charging.
The open-circuit voltage of the battery occurs approx. 10 hours

after the last charging process or one hour after the last discharge.
1. After each charging process allow the battery to rest for one
hour before taking it into service.
2. For resting periods of more than one month you should
always disconnect the battery. Do not forget to perform reg-
ular open-circuit voltage measurements.
NOTICE!
Exhausted batteries (batteries with formation of
sulphate on the plates) are not covered under war-
ranty!
1. Open the engine hood and remove the covering
1. Remove the batteries Ä Fig. 117 and clean the battery com-
partment.
2. Clean the outside of the battery.
3. Clean battery poles and pole clamps and grease them with
pole grease (Vaseline).
4. Check the fastening of the battery.
5. On serviceable batteries check the acid level, if necessary
top up to the filling mark with distilled water.
Fig. 117

Diesel engine
5 Diesel engine

Diesel engine – Diesel engine, general
5.1 Diesel engine, general
Fig. 118: Engine compartment

Single drum rollers of series BW211/213 D/PD-4 and BW213/214
DHC/PDHC-4 are powered by Deutz diesel engines type BF4M
2012 C with intercooling. The intercooler reduces the thermal load
on the engine, the exhaust gas temperature and the fuel consump-
tion and thus enables a higher power output.
These engines are characterized by the following positive features:
n short and compact design
n low noise level
n almost vibration free operation
n low fuel consumption
n exhaust emissions (EPA II)
n high power reserves and
n good access to all service points.
Crankcase and cylinders on this engine are made of alloyed cast

iron. This provides rigidness and high wear resistance.
The forged steel conrods are designed with balancing weights in
the area of the conrod bearing seats. These weights compensate
manufacturing tolerances with respect to weight and position of the
centre of gravity.
The pistons are made of aluminium alloy. The side walls of the
slightly externally arranged combustion trough are inclined towards
the inside by 10°. All pistons are fitted with three piston rings and a
cast iron ring carrier for the first ring. The pistons are oil mist lubri-
cated.
The forged crankshaft is designed with integrated counter weights.

Diesel engine – Diesel engine, general
The block-type cylinder head is made of cast steel. Each of the cyl-
inders has an inlet and an outlet valve. The valve guides are
shrunk into the cylinders. The valve seat rings are made of high
quality steel and also shrunk fit.

Diesel engine – Service side
5.2 Service side
9 1
8
7
6
5
4 2
S-582-0041
3
Fig. 119
1 Heating flange
2 Main fuel filter
3 Oil filter
4 Oil cooler
5 Oil pressure switch
6 Oil dipstick
7 Plug-in injection pumps
8 Crankcase ventilation valve
9 Engine solenoid actuator

Diesel engine – Starter side
5.3 Starter side
11 12 1
10
8 3
4
7 6 5
S-582-0042
Fig. 120
1 Exhaust manifold
2 Starter motor
3 Exhaust turbo charger
4 Oil return line from turbo charger
5 Oil drain plug
6 Coolant outlet
7 Coolant inlet
8 Ribbed V-belt
9 Coolant pump
10 Fuel pump
11 Generator
12 Oil filler cap

Diesel engine – Lubrication oil circuit
5.4 Lubrication oil circuit
Fig. 121: Lubrication oil circuit

1 Oil sump
2 Return flow from turbo charger to crankcase
3 Turbo charger
4 Oil line to turbo charger
5 Line to mass balancing gear (2 x)
6 Oil pressure sensor
7 Valve with pulse lubrication
8 Push rod, oil supply to rocker arms
9 Line to spray nozzles
10 Rocker arm
11 Return flow to oil sump
12 Nozzle for piston cooling
13 Camshaft bearings
14 Main oil channel
15 Lubrication oil cooler
16 Oil pump
17 Pressure relief valve
18 Leak oil return line

Diesel engine – Lubrication oil circuit
19 Oil filter
20 Suction line
21 Crankshaft bearings
22 Conrod bearings
The oil inside the combustion engine has the function of lubricating
and cooling all drive components, removing impurities and neutral-
izing chemically effective combustion products, transferring forces
and damping vibrations.. The oil is only able to fulfil this function, if
sufficient quantities are transported to the critical points in the
engine and if its properties are adapted to the prevailing require-
ments by corresponding manufacturing processes and refining
(additives).
Figure (1) shows pressure circulation lubrication in combination
with splash and oil mist lubrication. Here oil is transported under
pressure to all bearing locations by the oil pump (16), while sliding
surfaces are splash or oil mist lubricated. After flowing through the
bearing locations and along sliding surfaces the oil is collected in
the oil sump (1) under the drive, where the oil is cooled, defoamed
by calming and stored.
The oil filter (19) removes solid foreign particles from the engine oil
(combustion residues, metal abrasion, dust) and thus maintains the
function of the lubrication oil during the maintenance intervals.

Diesel engine – Coolant circuit
5.5 Coolant circuit
Fig. 122: Coolant circuit

1 Radiator
2 To radiator
3 From radiator
4 Coolant pump
6 Cylinder cooling
7 Cylinder head cooling
8 Ventilation connection between cylinder head and heat exchanger
9 Fan
In order to avoid thermal overloads, burning of lubrication oil on

piston sliding surfaces and uncontrolled burns caused by high
component temperatures, the components surrounding the com-
bustion chamber, like cylinders, cylinder head, valves and possibly
also the pistons, must be cooled intensively.

Diesel engine – Coolant circuit
Short description
The coolant pump ("water pump") draws coolant through the hose
lines directly out of the radiator and forces it first of all through the
lubrication oil cooler, which is integrated in the engine. The coolant
then enters into the engine, flows up along the cylinders into the
cylinder head and to the thermostat at the coolant outlet. Form
their the coolant is returned through the corresponding lines to the
radiator inlet. When the engine is cold the coolant is pumped in a
short circuit through the engine, until the response temperature of
the thermostat (start of opening) is reached. The water pump
draws cold coolant out of the radiator, as required to replenish the
hot out flowing coolant.
The coolant is a mixture of water and anti-freeze agent. The anti-
freeze agent increases the boiling temperature of the mixture and
thus enables temperatures of up to 120° C at an overpressure of
up to 1.4 bar.
The coolant compensation tank enables reliable gas separation,
thus avoiding cavitation in the cooling system, which mainly occurs
in the suction side of the pump. The air volume inside the compen-
sation must be so high, that quick build-up of pressure in case of
heating and expansion of coolant is assured and any escape of
coolant during after-boiling is avoided.
The radiator (1) dissipates the waste heat generated in the engine
into the into the environment.
Part of the combustion heat is transferred to the lubrication oil. The
lubrication oil cooler (5) serves the function of cooling the lubrica-
tion oil.
Heating
Water-cooled DEUTZ diesel engines utilize the coolant to heat the

driver's cab. For this purpose the engine coolant is guided directly
to the heat exchanger and the heat is directly dissipated into the
environment (direct heating).
1 Thermostat
2 Coolant pump
4 Heat exchanger
Fig. 123: Direct heating

Diesel engine – Replacing the thermostat
5.6 Replacing the thermostat
WARNING!
Danger of scalding!
Do not remove the cap from the compensation
tank when the engine is still hot.
1. Open the lid on the coolant reservoir.
ENVIRONMENT!
Catch running out coolant and dispose of environ-
mentally.
2. Drain the coolant from the engine and catch it.

3. Disconnect the coolant hose.
4. Remove the outlet socket.
5. Remove the thermostat.
Fig. 124
6. Fit a new seal to the thermostat.
Mind the installation position. The arrow (ventila-

tion groove) points up.
7. Insert the new thermostat with a new seal ring.
Fig. 125

Diesel engine – Replacing the thermostat
8. Install the outlet socket.

Tightening torque: 30 Nm
9. Install the coolant hose again.
10. Fill in coolant up to the “MAX” mark.
Check for leaks around the thermostat.
11. Let the engine cool down and check the coolant level again,
Fig. 126 top up if necessary.

Diesel engine – Fuel supply
5.7 Fuel supply
Fig. 127: Fuel supply

1 Water separator sensor connection

2 Flow to fuel lift pump
3 Fuel lift pump
4 Connecting line between fuel lift pump and main filter (fuel pre-pressure up to 10 bar)
5 Main fuel filter (pressure proof)
6 Connecting line between main filter and flow to injection pumps
7 Single-cylinder injection pump
8 High pressure line
9 Injection nozzle
10 Leak oil line
11 Pressure retaining valve - 5 bar
12 Return flow to tank
13 Fuel tank
14 Manual fuel pump
15 Fuel pre-filter
16 Water separator
17 Fuel pre-heating connection (option)
18 Fuel pre-heating (R79) 200 Watt (option)
19 Water separator sensor (B124)
Work in the low pressure system

Service and repair work in the low pressure system, including main
fuel filter changes, are only permitted under absolutely clean envi-
ronmental conditions, because even smallest dirt particles entering
into the high pressure fuel system will cause considerable damage.
Air pollution, like dirt, dust, moisture etc. must be strictly avoided.
Before starting work in the fuel system (including filter changes) the
engine must be thoroughly cleaned and dried (steam cleaning
equipment). Engine compartments in which dirt deposits may come
loose, must be covered with new and clean foil. When working in
the open you may need to apply protective measures against dust
entering because of wind.
WARNING!
For diesel fuel the ignition temperature, i.e. the
temperature at which fuel will ignite when coming
into contact with air, is approx. 220°C, but may
deviate strongly because of impurities.
Fuel conducting components and lines therefore
are a source of danger inside the engine compart-
ment, because leaks may lead to fire resulting in
considerably damage to material and persons.

Check valve
Fig. 128
1. According to our experience, it is not always assured that
only clean fuel will be used. Fuel tanks are frequently filled
without suitable precautions against contamination or fuel fil-
ters are inappropriately serviced. Many damage analyses on
injection pumps and injection valves have revealed that most
of these components had failed due to premature wear. Wear
on injection pump plunger and injection valve needle seat is
caused by contaminated fuel. Modern exhaust optimized
diesel engines with high pressure injection systems strictly
require clean fuel to be able to work reliably over their entire
lifetime. If the throttle resistances of pre-cleaner/main filter
caused by contaminated fuel are so high that the fuel pump
is no longer able to ensure a sufficient fuel supply, the injec-
tion pumps will draw the required fuel through the leak fuiel
return line from the tank without filtration. The engine is no
longer able to provide its full power, operation of construction
equipment or other machines, however, may still be possible
to a limited extent. After short time operation under such con-
ditions the injection system components may already be pre-
damaged.

From August 2006 the check valve Ä Fig. 129 is

used by BOMAG in series machines.
NOTICE!
Fig. 129: Observe the direction of This valve must strictly be installed into the fuel
flow return line by our customers.

Diesel engine – Injection system
5.8 Injection system

The injection system serves the fuel supply for the diesel engine.
The low pressure side of an injection system includes fuel tank,
fuel filter and fuel lines.
In the high pressure side the injection pump generates the pres-
sure required for injection. The fuel is pumped through the pres-
sure line to the injection pump, from where it is injected into the
combustion chamber.
Load and speed of the diesel engine are adjusted via the fuel
quantity without throttling the intake air. With a sufficient injection
quantity the speed of an unloaded diesel engine may therefore rise
up to the point of self destruction. A governor for engine speed limi-
tation is therefore required.
Single cylinder plug-in injection Deutz diesel engines series 2012/1013 are equipped with Bosch
pumps cylinder plug-in injection pumps series PF 33.
The concept of plug-in injection pumps enables the realization of
high injection pressures, combined with short injection lines, which
is necessary to ensure a high hydraulic stiffness of the injection
system. This in turn provides the prerequisite for low exhaust emis-
sion values (soot) in combination with a low fuel consumption.
The start of injection is influenced by:
n fuel consumption
n the power
n the exhaust emission
of the engine.
The term "start of injection" refers to the start of the injection pump
delivering fuel.
The drive cams 2 Ä Fig. 130 for the single PF-injection pumps are
located on the camshaft (1) for engine valve control.
Permissible manufacturing tolerances for the components:
n Cylinder crankcase
n Camshaft
n plunger
n 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.
Fig. 130: Single cylinder plug-in injec-
tion pump

Diesel engine – Injection system
Injection valves
Injection valves have the following functions:

n Preparation of fuel
n Forming of the injection sequence
n Sealing against the combustion chamber
The peak injection pressure of the diesel fuel is up to 1000 bar.
Under these conditions the fuel no longer behaves like a rigid fluid,
but it is compressible. During the short injection period (1ms) the
injection system is "blown up" and, depending on the nozzle size,
more or less fuel will enter into the combustion chamber.
1 Tensioning nut
2 Nozzle
3 Intermediate piece
4 Pressure bolt
5 Compression spring
6 Shim
A thicker shim 6 Ä Fig. 131 increases the opening

pressure.
Fig. 131: Design of injection valve
NOTICE!
When replacing an injection pump and/or an injec-
tion valve, you must also replace the high pressure
line between pump and valve.

Diesel engine – Injection pump replacement during service
5.9 Injection pump replacement during service

5.9.1 Disassembling the injection pump
NOTICE!
Ensure strict cleanliness when working on the
injection system.
1. Remove pressure control valve and cylinder head cover.

2. Disconnect the cable plugs from shut-down solenoid, gov-
ernor and temperature sensor.
3. Swing the holding plate to the side.
Fig. 132
4. Remove the engine shut-down assy.
Fig. 133
5. Use the shut-down lever to push the governor rod to stop

position.
6. Insert and fasten the pressing device 100 830.
Fig. 134

7. Turn the knurled fastening screw to press the governor rod to

stop position.
8.
Tighten the knurled fastening screw by hand.
Fig. 135
9. Set the cylinder of the injection pump to be replaced to igni-

tion top dead centre (valves overlapping).
Illustration shows view on flywheel.
10. Turn the crankshaft for approx. 120° against the sense of
rotation.
Fig. 136
11. Remove the injection line.

12.
Close the connections with protection caps.
Fig. 137
13. Take the compensation shim carefully out with the rod
magnet.
Fig. 138

5.9.2 Determining the start of injection
Old injection pump and shim are not required for

this purpose.
Fig. 139: Injection pump code BFM 2012

Example:
The injection pump for cylinder 3 is to be replaced on an engine
BF6M 2012.
Procedure:
1. Read the EP-code for cylinder 3 in the column "EP" on the
type plate (table) Ä Fig. 139, e.g. 295.
2.
Sequence of reading: Line 1 = cyl.1, line 2 =
cyl.2, etc.
3. Take the corrected injection pump installation measurement

(EK) matching the EP-code from the table , e.g. 120.875 mm.
4. Read the coefficient for the injection pump length (A) on the
new injection pump, e.g. 42.
Fig. 140: Length of injection pump (A)

5.
Measurement "A" determines by how many
1/100 of a mm the distance between cylinder
crankcase contact surface and plunger foot is
longer than the basic measurement Lo.
Basic measurement of injection pump (Lo) =
117.5 mm.
6. Determine the theoretical thickness of the shim (TS).

TS = EK - (Lo + A/100)
TS = 120.875 mm - (117.5 mm + 42/100 mm)
TS = 2.955 mm
7. Choose the shim thickness (SS) from the table.
TS 2.955 mm = SS 3.0 mm
Fig. 141: Injection pump length "A"

and Lo
Theor. thickness „TS„ (mm) Shim thickness „SS Theor. thickness „TS„ (mm) Shim thickness „SS
„ (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 - 3,849 3.8
2.35 - 2,449 2.4

Fig. 142: Table of injection pump codes BFM 2012

5.9.3 Installing the injection pump

1. Lay the newly determined shim on roller plungers Ä Fig. 143
and Ä Fig. 144.
Fig. 143:
Fig. 144:
3. Turn the injection pump control lever to approx. middle posi-

tion.
Fig. 145:

4.
NOTICE!
The roller plunger for the corresponding
injection pump must be positioned on the
base circle of camshaft.
Apply some oil to the locating bore in the crankcase and the
O-rings on the injection pump.
5. Carefully insert the injection pump control lever into the gov-
ernor rod.
Fig. 146:
6.
NOTICE!
The chamfer must face towards the injection
pump body.
Attach the flange.
Fig. 147:
7. Slightly oil the screws and tighten with a torque of 5 Nm .
Fig. 148:
8. Loosen the screws again for 60°.
Fig. 149:

9. Carefully turn the injection pump with and open end spanner
in counter-clockwise direction against the noticeable stop
Fig. 150:
10.
Always start with the outer screw furthest
away from the flywheel.
Turn the screws in again for 60°, then tighten in steps to a

torque of 7 Nm, 10 Nm and 30 Nm.
Fig. 151:
11. Turn the knurled fastening screw back.

12. Remove the pressing device.
13.
NOTICE!
Check whether the governor rod is light
moving between stop and start position.
Operate the shut-down lever to do so.
Fig. 152:

14.
Cover the O-ring slightly with oil.
Install a new loop ring .
Fig. 153:
15. Use the shut-down lever to push the governor rod to stop
position and hold it.
16. Install the engine shut-down assy.
17. Tighten the screws with 21 Nm.
18. Plug the cable plug onto the shut-down magneto.
Fig. 154:
19.
NOTICE!
Take care that the sealing cones match
exactly when assembling the injection line.
Subsequent bending is not permitted. The
injection line must never be used twice.
Install the new injection line with the sealing rubber.

20. Pre-tension the injection line cap nuts on injection pump and
injection valve with a torque of approx. 5 Nm (use claw
Fig. 155: spanner 8018).
21. Tighten the cap nut with 25 ± 3.5 Nm.
22. Install the gasket.
Fig. 156:

23. Install cylinder head cover and holding plate.

25.
Ensure the sealing rubber is fitted correctly.
If necessary assemble the pressure control valve with a new

seal.
26. Tighten the screws with 8.5 Nm.
Fig. 157:

Diesel engine – Injection valve replacement during service
5.10 Injection valve replacement during service
Injection valves may wear mechanically over the

course of time. Spray pattern and injection pres-
sure should be tested on an injection valve test
bench ("hydrostesting"). The nozzles must be dis-
assembled for this purpose. In case of excessive
deposits on the nozzles these may be cleaned in
an ultrasonic bath with gasoline. The injection
pressure can be corrected by means of shims.
NOTICE!
injection system. Use only clean testing oil acc. to
ISO 4113 or clean diesel fuel to test the injection
valves.
Removal
1. Remove pressure control valve and cylinder head cover.
2. Disconnect the cable plugs from shut-down solenoid, gov-
ernor and temperature sensor.
3. Swing the holding plate to the side.
Fig. 158
4. Remove the injection lines.

5.
Close connections on injection valves and
injection pumps with protective caps.
Fig. 159

6. Remove the claws and take out the injection valves .

7.
In case of tight fit use the extracting device
150 800 with puller 110 030.
Pull out the seal ring with the extracting
device 120 680.
Fig. 160
Assembly
1. Slide the new seal rings with some grease over the injection
valves and insert the injection valves .
2.
NOTICE!
The chamfer on the injection valves must
point away from the claws.
Fig. 161
3. Attach the claws and turn the screws in loosely.
Fig. 162
4.
NOTICE!
Take care that the sealing cones match
exactly when assembling the injection line.
Subsequent bending is not permitted. The
injection line must never be used twice.
5. Install the new injection lines with the sealing rubbers.

6. Tighten the cap nuts finger tight.
Fig. 163

7. Tighten the screws for the claws with 16 + 5 Nm.
Fig. 164
8. Pre-tension the injection line cap nuts on injection pumps and

injection valves with a torque of approx. 5 Nm.
9. Tighten the cap nuts with 25 + 3.5 Nm.
10.
Use a claw spanner 8018.
Fig. 165
11. Install the gasket.
Fig. 166:
12. Install cylinder head cover and holding plate.

14.
Ensure the sealing rubber is fitted correctly.
15. If necessary assemble the pressure control valve with a new

seal.
16. Tighten the screws with 8.5 Nm.
Fig. 167:

Diesel engine – Checking / repairing injection valves
5.11 Checking / repairing injection valves

Special tools:
Nozzle tester 8008
Holder for Injection valve 110 110
Long socket 8012
NOTICE!
injection system. Use only clean testing oil acc. to
ISO 4113 or clean diesel fuel to test the injection
valves.
Check the injection valves
The injection valves are leak fuel free. Fuel cannot

flow off and will accumulate above the nozzle
needle in the spring chamber of the nozzle holder.
Operation of the nozzle tester hand leever is in this
case no longer possible. In order to eliminate the
pressure inside the spring chamber the clamping
nut must be slackened and retightened again
before each test.
1. Loosen the clamping screw by approx. 180° and tighten it

again.
Tightening instructions: 30 - 40 Nm
2.
Use injection valve holder 110 110.
Fig. 168

3. Mount the injection valve to the nozzle tester .

4.
WARNING!
Keep your hands away from the nozzle spray
jet. Fuel will penetrate deeply into the flesh
and may cause blood poisoning.
Fig. 169
5. Slowly press the lever of the nozzle tester 8008 down with
the pressure gauge connected.
Opening pressure: 220 bar
6.
The opening pressure is reached, when the
pointer stops or suddenly drops.
The pressure inside the spring chamber will
have build up again after approx. 3 - 4
strokes. In order to repeat the test the
clamping nut needs to be slackened and
Fig. 170 retightened again, as specified.
Once identical values are measured during 3
tests, the values can be considered valid.
Adjusting tze opening pressure on

the injection valve If the opening pressure needs toi be corrected:
Detach the injection valve from the nozzle tester
8008. Unscrew the clamping nut and remove all
parts. Use injection valve holder 110 110.
1. Unscrew the clamping nut and remove all parts.
Fig. 171

3. Clean all parts with clean diesel fuel and blow off with com-
pressed air.
Fig. 172
Sequence of individual disas-
sembly:
1 Tensioning nut
2 Injection nozzle
3 Intermediate piece
4 Pressure bolt
5 Compression spring
6 Shim
4.
NOTICE!
Nozzle needle and nozzle body have been
fitted by lapping and must never be mixed up
by mistake or replaced individually. Do not
touch the nozzle needle with your fingers.
With the nozzle body in vertical position, the
nozzle needle must smoothly slide on its seat
just by its own weight .
5.
Fig. 173
If the needle slides down jerkily, wash out the
nozzle body with diesel fuel again, replace if
necessary. Clean the new injection nozzle
also in clean diesel fuel.
6. Check the seat areas of the intermediate piece for signs of

wear. Make sure that the centring pins are present.
Fig. 174

7. Install the shim.

8.
Adjust the opening pressure by choosing the
required shim. A thicker shim increases the
opening pressure.
Fig. 175
9. Install the pressure spring.
Fig. 176
10. Install the pressure bolt with the centring collar towards the
pressure spring.
Fig. 177
11. Insert the centring pins of the intermediate piece into the
bores of the nozzle holder.
12.
The chamfer points towards the pressure
bolt.
Fig. 178

13. Attach the centring bores of the injection nozzle to the cen-
tring pins of the intermediate piece.
14.
The nozzle needle must not drop out of the
nozzle body.
Fig. 179
15. Screw on the clamping nut.
Fig. 180
16. Tighten the clamping nut.

Tightening torque: 30 to 40 Nm
17.
Use the injection valve holder 110 110 and a
long socket 8012.
Fig. 181
Leak test
1. Dry nozzle and nozzle holder - blow dry with compressed air.
2. Press the hand lever of the tester slowly down, to a point
about 20 bar before the previously indicated opening pres-
sure.
Fig. 182

3.
The nozzle is leak tight, if no drop drips off
within a period of 10 seconds.
4.
NOTICE!
If a drop drips off , the injection valve must be
dismantled and the leak must be eliminated
by thorough cleaning. If this does not lead to
a success, replace the injection nozzle.
Fig. 183 Rework is not permitted!
Rattle and spray pattern test
1. Switch off the pressure gauge on the tester.
The rattle test enables audible testing of the nozzle

needle movement inside the nozzle body. In com-
parison with used injection valves, new ones have
a different rattling behaviour. It becomes worse as
the wear in the needle seat area progresses.
Fig. 184
NOTICE!
A used injection valve must audibly rattle and
spray off well atomized fuel when operating the
lever quickly. The spray pattern may be noticeably
different from the one produced by a new injection
valve.
If an injection nozzle does not rattle despite of
cleaning, it nees to be replaced by a new one!

Diesel engine – Checking the compression
5.12 Checking the compression

1. Adjust the valves.
2. Remove the injection valves.
3. Insert the connecting piece 100 110 with seal ring.
Fig. 185
4. Attach the claws.

5. Tighten the screw.
Fig. 186
6. Screw on the adapter for connecting piece 100 110.
Fig. 187

Diesel engine – Checking the compression
7. Connect the compression tester 8005.

8. Crank the engine with the starter.
9.
Check the compression on each of the cylin-
ders.
Compression: 30 - 38 bar
The measured compression depends on the
starter speed during the measuring process
and the altitude of the engine location. Limit
Fig. 188 values can therefore not be specified exactly.
It is recommended to use the compression
measurement to compare the cylinders of an
engine among each other. Should a deviation
of more than 15% be measured, the affected
cylinders should be dismantled to examine
the cause.
10. Remove the compression tester 8005 and the connecting

piece 100 110.
11. Install the injection valves.

Diesel engine – Inspection and maintenance work


Checks prior to start up
5.13.2.1 Check the engine oil level 255
5.13.2.2 Check the coolant level 256
5.13.3.1 Changing engine oil and oil filter cartridge 257
5.13.4.1 Adjusting the valve clearance 258
5.13.4.2 Change the fuel filter cartridge 260
5.13.4.3 Change the fuel pre-filter cartridge 261
5.13.4.4 Checking / replacing the ribbed V-belt 263
5.13.4.5 Check the engine mounts 264
5.13.5.1 Changing the coolant 264
5.13.6.1 Replace the injection valves 266
As required
5.13.7.1 Air filter maintenance 267
5.13.7.2 Check, clean the water separator 270
5.13.7.3 Engine conservation 271
5.13.2 Checks prior to start up

5.13.2.1 Check the engine oil level
WARNING!
Danger of injury!
Support the engine hood for all maintenance and
repair work.
The machine must be parked horizontally with the

engine shut down.

1. Pull the dipstick Ä Fig. 189 out, wipe it off with a lint-free,
clean cloth and reinsert it until it bottoms.
2. Pull the dipstick back out again.
3. If the oil level is below the "MAX" mark fill in oil.
4. If the oil level is above the “Max” mark determine the cause
and drain the oil off.
NOTICE!
Fig. 189
Before longer work periods you should always top
the oil up to the "MAX"-mark.
For quality and quantity of oil refer to the table of fuels and
lubricants.
5.13.2.2 Check the coolant level
WARNING!
Danger of scalding!
Fill up coolant only when the engine is cold.
NOTICE!
If, during the daily inspection the coolant level is
found to have dropped, check all lines, hoses and
engine for leaks.
Do not use radiator sealant to seal leaks.
For quality and quantity of coolant refer to the
"table of fuels and lubricants".
1. Check the coolant level Ä Fig. 190.

2. To top up unscrew the filler cap and fill in coolant up to the
MAX-mark.
Fig. 190


5.13.3.1 Changing engine oil and oil filter cartridge
Perform this maintenance work at the latest after

one year.
WARNING!
Danger of scalding!
When draining off hot oil.
By hot oil when unscrewing the engine oil filter.
NOTICE!
Drain the oil only when the engine is warm.
For quality and quantity of oil refer to the "table of
fuels and lubricants".
1. Unscrew the drain plug and catch running out oil.

2. Turn the drain plug tightly back in.
Fig. 191
3. Thoroughly clean the outside of the filter cartridge.

4. Unscrew the filter cartridge using an appropriate filter
wrench.
5. Clean the sealing face on the filter carrier from any dirt.
6. Slightly oil the rubber seal on the new filter cartridge.
Fig. 192

7. Turn the new filter cartridge on by hand, until the seal con-
tacts.
8. Tighten the filter element for another half turn.
Fig. 193
9. Fill in new engine oil .

10. Tighten the oil filler cap properly.
11. After a short test run check the oil level on the dipstick . The
oil level should reach the MAX-mark, top up oil if necessary.
12. Check filter cartridge and drain plug for leaks.
13. Dispose of oil and oil filter cartridge environmentally.
Fig. 194

5.13.4.1 Adjusting the valve clearance
NOTICE!
We recommend to have this work carried out by
trained personnel or our after sales service.
– Before checking the valve clearance let the
engine cool down for at least 30 minutes. The
engine oil temperature must be below 80 °C
(176 °F).
Protective equipment: n Working clothes

n Protective gloves
1. Park the machine in secured condition Ä Chapter 1.2.5
„Parking the machine in secured condition“ on page 23.
2. Allow the engine to cool down.

3. Remove the valve covers.
Fig. 195
4. Turn the crankshaft, until the valves on cylinder 1 are over-

lapping.
ð The valves marked black can be checked and adjusted.
Fig. 196
5. Turn the crankshaft, until the valves on cylinder 4 are over-

lapping.
ð The valves marked black can be checked and adjusted.
Fig. 197
Checking the valve clearance

1. Check valve clearance (2) between rocker arm (1) and valve
(3) with a feeler gauge. The feeler gauge must fit through the
gap with little resistance.
Valve clearance:
Intake valve 0.3 mm (0.012 in)
Exhaust valve 0.5 mm (0.020 in)
2. If the gap is too narrow or too wide for the feeler gauge,
adjust the valve clearance.
Fig. 198

Adjusting the valve clearance

1. Slightly slacken the counter nut.
2. Adjust the setscrew with a screwdriver (7), until the feeler
gauge (6) can be inserted and pulled out with little resistance
after retightening the counter nut.
Fig. 199
1. Install the cylinder head cover with a new gasket.

2. After a short test run check the engine for leaks.
5.13.4.2 Change the fuel filter cartridge
WARNING!
Fire hazard!
When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground.
Do not inhale any fuel fumes.
1. Loosen and unscrew the fuel filter cartridge Ä Fig. 200 using
an appropriate filter wrench.
2. Clean the sealing face on the filter carrier from any dirt.
Fig. 200

1. Slightly oil the rubber seal Ä Fig. 201 on the new filter car-
tridge.
2. Fill the filter cartridge with clean diesel fuel.
3. Turn the new filter cartridge on by hand, until the seal con-
tacts.
4. Tighten the filter element for another half turn.
5. Check the filter cartridge for leaks after a short test run.
Fig. 201
5.13.4.3 Change the fuel pre-filter cartridge
WARNING!
Danger of fire, health hazard!
When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Do not inhale any fuel fumes.
NOTICE!
Ensure strict cleanliness! Thoroughly clean the
area around the fuel filters.
The filter cartridge must never be filled beforehand.
After work on the fuel system bleed the system,
perform a test run and check for leaks.
Additional bleeding of the fuel system by a 5
minute test run in idle speed or low load is manda-
tory.
ENVIRONMENT!
Any fuel must be caught and disposed of in an
environmentally friendly manner.

Change the fuel pre-filter cartridge

1. Tighten the cable on the water separator Ä Fig. 202.
2. (1) Loosen the bleeding screw and drain off fuel from the
bleeding screw.
3. (2) Loosen and unscrew the fuel pre-filter cartridge using an
appropriate filter wrench.
4. (3) Unscrew the water separator from the filter cartridge.
5. (4) Apply a thin coat of oil to the rubber seal of the water sep-
arator.
6. (5) Turn the water separator on by hand, until the seal con-
Fig. 202 tacts, then tighten hand-tight.
7. (6) Apply a thin coat of oil to the rubber seal of the filter ele-
ment (5).
8. (7) Turn the filter cartridge on by hand, until the seal contacts,
then tighten hand-tight.
9. Plug the water sensor cable back on.
Bleed the fuel system

Air in the fuel system causes irregular running of
the engine, a drop in engine power, stalls the
engine and makes starting impossible.
Therefore bleed the fuel system after changing the
fuel pre-filter or working on the fuel system.
1. Slacken the bleeding screw Ä Fig. 203 on the fuel pre-filter

for 2 to 3 turns.
Fig. 203
1. Operate the hand pump manually, until fuel flows out of the
slackened bleeding screw without air bubbles.
2. Then tighten the bleeding screw while pumping.
3. Check the filter cartridge for leaks

5.13.4.4 Checking / replacing the ribbed V-belt
WARNING!
Danger of injury!
Work on the V-belt must only be performed with
the engine shut down.
Checking the wear limit of the

ribbed V-belt
1. Check the distance between the tongue of the moveable ten-
sioner arm and the fixed tensioner housing Ä Fig. 204.
Fig. 204
1. If measurement "a" is smaller than 3 mm, replace the ribbed

V-belt.
Changing the ribbed V-belt

1. Unscrew the fastening screws Ä Fig. 205 and slide the fan
forward.
Fig. 205

1. Release the idler pulley Ä Fig. 206 in direction of arrow until

the ribbed V-belt is free.
Fig. 206
1. Pull the ribbed V-belt first to the smallest pulley.
1. Install the new ribbed V-belt.
1. Release the idler pulley against the direction of arrow until

the V-belt is tensioned.
1. Measure the V-belt tension, tighten if necessary.
Retighten the new fan V-belt after a running time of

20 minutes.
5.13.4.5 Check the engine mounts

1. Tighten fastenings of intake and exhaust manifolds
Ä Fig. 207 on the cylinder heads.
2. Check sockets and clamps between air filter, exhaust turbo-
charger and charge air line as well as the lubrication air line
for tight fit and leaks.
3. Retighten the fastening screws for oil sump and engine
mounts.
Fig. 207

5.13.5.1 Changing the coolant

two years.

WARNING!
Danger of scalding!
Change the coolant only when the engine is cold.
NOTICE!
Do not start the engine after draining off the
coolant.
In case of lubrication oil entering into the cooling
system or a suspicious turbidity caused by corro-
sion residues or other suspended matter, the
coolant must be drained off and the complete
cooling system needs to be cleaned. Lubrication oil
can damage the sealing materials used in the
engine.
When changing the coolant without any signs of
contamination, cleaning of the cooling system is
not necessary.
For quality and quantity of coolant refer to the
"table of fuels and lubricants".
Do not mix different coolants and additives, see
section "Fuelds and Lubricants - Coolant".
ENVIRONMENT!
Catch coolant and dispose of in an environmentally
friendly manner.
1. Unscrew the lid from the compensation tank.
Fig. 208

2. Unscrew the plug, let the coolant run out and catch it.
3. Check the condition of the coolant.
NOTICE!
Thoroughly flush the cooling system if the
coolant is contaminated by corrosion resi-
dues or other suspended matter.
If lubrication oil has entered you must add a
cleansing agent in order to remove any resi-
dues from the system. Follow the instructions
Fig. 209
of the manufacturer. If in doubt consult your
local service station or the engine manufac-
turer.
4. Remove the thermostat.

5. Fill in clean water.
6. Start the diesel engine and run it warm to operating tempera-
ture.
7. Allow the engine to cool down to approx. 50 °C.
8. Drain all water off.
9. When using a cleansing agent repeat the flushing process
twice with clear water.
10. Screw the plug back in once all coolant has run out.
11. Reinstall the thermostat .
12.
NOTICE!
The anti-freeze concentration (additive) must
be at least 35 Vol% and maximum 50 Vol%.
Fill in coolant up to the MAX-mark and screw the filler cap

back on.
13. Start the diesel engine and run it warm to operating tempera-
ture.
Fig. 210 14. Check the coolant level again, top up if necessary.

5.13.6.1 Replace the injection valves
This work must only be performed by authorized service per-
sonnel.

5.13.7 As required
5.13.7.1 Air filter maintenance
NOTICE!
Do not start the engine after having removed the
air filter.
If necessary, the air filter may be cleaned up to six
times. After one year at the latest it must be
replaced together with the safety element.
Cleaning does not make sense if the air filter ele-
ment is covered with a sooty deposit.
Do not use gasoline or hot fluids to clean the filter
element.
After cleaning the air filter must be inspected for
damage using a torch.
Do not continue to use a damaged air filter ele-
ment. If in doubt use a new air filter.
If the air filter is damaged, the safety element must
be replaced as well.
The safety element must not be cleaned.
We generally recommend to renew the air filter. A

new filter element is far less expensive than a pos-
sible engine damage.
Servicing of the dry air filter is necessary when the yellow piston
Ä Fig. 211 has reached the red underlaid inscription "Service", but
at the latest after one year.
Fig. 211
1. After completion of the filter service reset the indicator back

to "Zero" by pressing the button.

1. Open the engine hood Ä Fig. 212 completely and secure it.
Fig. 212
1. Loosen both locking hooks Ä Fig. 213 on the housing cover

and take the cover off.
2. Clean cover and dust discharge valve.
Fig. 213
1. Pull out the main filter element Ä Fig. 214 with light turning
movements.
WARNING!
Danger of injury!
Wear protective clothing (goggles, gloves).
Fig. 214
1. Blow the air filter Ä Fig. 215 out with dry compressed air
(max. 5 bar (70 psi)) from inside to outside by moving the
gun up and down inside the element, until it if free of dust.
Fig. 215

1. Examine the air filter with a torch for cracks and holes in the
paper bellows Ä Fig. 216.
2. In case of damage replace the air filter and the safety ele-
ment.
Fig. 216
1. Slide the air filter carefully into the housing Ä Fig. 217.
NOTICE!
The dust discharge valve must point vertically
downwards.
Make sure that the cover locks engage correctly.
Fig. 217
1. Reassemble the housing cover.
Replacing the safety element

NOTICE!
The safety element must not be cleaned and
should not be used again after it has been
removed.
The safety element must be replaced:

1. if the air filter is damaged.
2. at the latest after 1 year.
3. if the air filter warning lamp comes on again after the air
filter has been cleaned.

1. Remove the housing cover and pull the air filter off.
2. Pull the safety element Ä Fig. 218 out by turning it lightly.
3. Push in a new safety filter element.
4. Insert the air filter and reassemble the housing cover.
Fig. 218
5.13.7.2 Check, clean the water separator
WARNING!
Danger of injury!
Support the engine hood for all maintenance and
repair work.
The service intervals for the water separator

depend on the water content in the fuel and can
therefore not be determined precisely. After taking
the engine into operation you should therefore
check the water separator every day for signs of
water.
If a to high quantity is drained off, the filter must be
refilled with fuel. See chapter "maintenance as
required", bleeding the fuel system.
ENVIRONMENT!
Catch running out fuel and dispose of environmen-
tally.
1. Slacken the drain plug Ä Fig. 219 for a few turns and catch
running out fuel / water.
2. Tighten the drain plug again and check for leaks, if necessary
replace the seal ring.
Fig. 219

5.13.7.3 Engine conservation

If the engine is to be shut down for a longer period of time (e.g.
over winter), please consult the service department of the engine
manufacturer for further details.


Hydraulic system
6 Hydraulic system

Hydraulic system – Overview of travel/vibration pump connections
6.1 Overview of travel/vibration pump connections
4 Y07
MB
Y08
5
M3 B
3 MA 6
2
1 M1
B
M2
L1
M3
D
S
E
M2
L1
M1
A
S
L2
MA
MB
S-582-0038
Fig. 220
1 Travel pump
6 Vibration pump

Vibration pump
Plugs Y07 Y08
Connections of travel pump
Fig. 221
1 Pressure test port M2 system pressure, B
2 Leak oil connection L1
3 Pressure test port M4 control pressure
6 Pressure test port M1 system pressure, A
7 System pressure, port A
8 Suction port S
9 System pressure, port B
10 Speed transducer (optional equipment)
11 Charge pressure port
12 Charge pressure test port, M3

13 Control pressure port, X3

14 Adjustment screw, mechanical neutral position
15 Multi-function valves

Hydraulic system – Open and closed hydraulic circuit
6.2 Open and closed hydraulic circuit

Open circuit
Fig. 222: Open circuit

Open in this case means that the suction line of a pump (1) nor-
mally is situated below the fluid level, the surface of which is in
open contact with atmospheric pressure. Reliable equalization of
pressure between the air in the hydraulic oil tank and the ambient
air ensures problem free suction of the pump.
In an open circuit the hydraulic oil is fed to the consumer (2 or 3)
and also returned to the tank through way valves.

Hydraulic system – Open and closed hydraulic circuit
Closed circuit
Fig. 223: Closed circuit

One talks about a closed hydraulic system, when the hydraulic oil
flows from the consumer (3) directly back to the pump (2).
The closed circuit consists of a high and a low pressure side,
depending on the load direction (take-off moment on the con-
sumer).
The high pressure side is protected by high pressure relief valves
(4), which release oil into the low pressure side. The medium
remains in the circuit.
Only the leakage on pump and motor needs to be replenished.
This is accomplished by a charge pump (1) which permanently
draws a sufficient amount of hydraulic fluid (charge capacity) from
the tank and feeds it through a check valves (5) into the low pres-
sure side of the closed circuit. The excess quantity delivered by the
charge pump flows through a charge pressure relief valve (6) back
into the tank. Charging the low pressure side enables the pump (2)
to work with higher operating data.

Hydraulic system – Hydraulic units
6.3 Hydraulic units
6.3.1 Travel pump

6.3.1.1 Travel pump, 90R 075 MDC
Variable displacement pumps, The axial piston variable pump generates, controls and regulates a
90R055 and 90R075 volumetric pressure fluid flow. It has been designed for mobile
applications, e.g. in construction equipment.
The pump is an axial piston variable pump in swash plate design
for hydrostatic drives in closed circuits. The volumetric flow is pro-
portional to drive speed and displacement. The volumetric flow can
be infinitely changed by adjusting the swash plate accordingly.
NOTICE!
Components may get damaged!
– The aggregate must always be filled with
hydraulic oil and purged before start-up and
during operation.
– This must also be considered for longer
periods of rest, because the aggregate may
run empty through the hydraulic lines.
Fig. 224
1 Actuating lever
2 Drive shaft
3 Bearing for swashing cradle
4 Pistons with slipper pads

5 Cylinder block
6 Valve plate
7 Control piston
Fig. 225
1 Drive shaft
2 Drive shaft bearing
3 Swash plate
4 Pistons with slipper pads
5 Cylinder block
7 Charge pump (optional)
8 Valve plate
MDC control, mechanical displace- The mechanical displacement control converts a mechanical input
ment control signal into a position controlling output signal by means of a spring
centred 4-way servo valve. This valve opens the hydraulic pres-
sure to one side of the control cylinder. The control piston inside
the control cylinders moves the swash plate within a swashing
angle range of ±17° and thereby changes the displacement of the
pump from maximum displacement to the one direction to the max-
imum displacement to the opposite direction.
The mechanical displacement control has no adjustment elements.
The control is held in neutral position by resetting springs and
washers at both ends of the control piston. Since there are no fur-
ther resetting springs on the input shaft of the control, the shaft will
automatically be correctly positioned when it is mounted to the
pump.

Fig. 226
1 to the control
3 Charge pump
4 Charge pressure relief valve
5 Control pressure relief valve
6 Drive shaft
7 to the control piston
8 to the control piston
9 Servo control
A Connection A
B Connection B
With the servo control (9) the swashing angle can be infinitely
adjusted from neutral position to the maximum displacement posi-
tion.
When altering the swash plate position through the neutral posi-
tion, the oil flow will be reversed and the machine will drive to the
opposite direction.

Since the control is spring centred, the swash plate will automati-
cally return to neutral position under the following conditions,
thereby interrupting the oil flow and braking the machine:
n when shutting the engine down
n if the external control cable comes loose
n if the pressure in the charge circuit drops below a certain value.
Multi-function valves Pumps of series 90 are equipped with multi-function valves, which
activate a pressure override valve and a high pressure limitation,
one after the other.
The multi-function valve consists of:
n No-stroke pressure controller
n High pressure relief valve
n Boost check valve
n Bypass function
No-stroke pressure controller
The multi-function valve contains a no-stroke pressure controller
and a high pressure relief valve. When the pre-adjusted pressure
value is reached, the no-stroke pressure controller will return the
pump very quickly back towards neutral, thereby limiting the
system pressure. In case of a unusually sudden pressure increase
the high pressure relief valve will immediately limit the system
pressure by opening the system flow to the low pressure side of
the hydraulic circuit. The no-stroke pressure controller serves as
pre-control unit for the piston of the high pressure relief valve. The
high pressure relief valve is designed for responding to pressures
approx. 35 bar above the nominal value of the no-stroke pressure.
Fig. 227: Multi-function valves

Boost check valves
The boost check valves are cone valves inside the multi-function
valve. It enables flow from the charge pump into the low pressure
side of the working circuit, if the system pressure drops below a
certain value. With this feature pressure losses caused leakages or
other factors can be compensated. Since the variable displace-
ment pump is able to work to either direction, two boost check
valves are needed.

Bypass function
The bypass function is also integrated in the multi-function valves
and can be manually operated.when the vehicle (or the mechanical
function) is to be moved, without the pump running.
Opening the by-pass function
NOTICE!
When working on the bypass valves switch off the
drive and keep the high pressure circuit pressure-
less. The bypass valves must be open on both
multi-function valves to be able to achieve the
bypass function.
1. Attach an open end spanner to the medium size hexagon of

the multi-function valve and attach an open end spanner to
the large hexagon to prevent the valve body from turning.
Turn the medium size hexagon for three turns in anti-clock-
wise direction to open the bypass valve. Do not turn more
than 3-1/2 turns, because otherwise pressure fluid will
run out.
2. Before moving the vehicle set the control lever for the
mechanical displacement control on the pump to full forward.
Hold the control lever in this position throughout the bypass
function.
Fig. 228
Charge pressure relief valve Pumps of series 90 are equipped with a charge pressure relief
valve that can be adjusted from the outside. Charge pressure is
adjusted by loosening the counter nut and turning the setscrew
accordingly with a large screwdriver or a 1/2" open end spanner.
Turning the setscrew clockwise increases the value, turning anti-
clockwise reduces the value (by approx. 3.9 per revolution). Tight-
ening torque for counter nut: 52 Nm!

Fig. 229
The charge pressure relief valve has the function of maintaining
the charge pressure at a specified value. A cone valve reduces the
charge pressure if this value is exceeded. This nominal value is
measured against case pressure and adjusted at 1500 rpm. This
nominal setting assumes that the pump is running in idle position
(zero flow); the charge pressure is slightly lower in forward or
reverse.

Fig. 230
8 Suction port S

6.3.2 Vibration pump

6.3.2.1 Vibration pump, 42R 041 EDC
Variable displacement pumps, The axial piston variable pump generates, controls and regulates a
42R041 / 42R055 volumetric pressure fluid flow. It has been designed for mobile
applications, e.g. in construction equipment.
The 42R041/055 is a axial piston variable pump in swash plate
design for hydrostatic drives in closed circuits. The volumetric flow
is proportional to drive speed and displacement.
NOTICE!
during operation.
EDC, electric two-point control,

with control solenoid
Fig. 231
1 Control unit
2 Servo piston
3 Bearing for swashing cradle
4 Attachment plate
5 Spool valve
6 Charge pump, optional
7 Drive shaft
8 Pistons with sliding blocks
9 Swash plate
10 Valve plate
11 Control lever, not used with EDC-control

Hydraulic diagram
5 6
7
1
2
3
4
S-HYD-583883
Fig. 232
1 From the charge pump
2 Closed circuit
3 High pressure relief valve with integrated boost check valve
4 4/3 way valve
5 Pump drive
6 Charge pump
7 High pressure limitation
8 Charge pressure relief valve, blocked

When operating a 4/3-way solenoid valve on the pump control,

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 exciter 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 in 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.
n Large angle = high displacement = high vibrator shaft speed
(frequency)
n Small angle = low displacement = slow vibrator shaft speed
(frequency)
High pressure relief valves Pressure peaks occurring during very fast swashing processes, as
well as the maximum pressures are safeguarded by superordinate
high pressure relief valves, which open when the adjusted value is
exceeded and release oil into the low pressure side. The fluid
quantity always remains constant in the closed hydraulic circuit.
Leakages in pump and motor are compensated by the charge
pump.
The boost check valves are integrated in the high pressure relief
valves. These valves open to the low pressure side and let cool
and filtered oil flow from the charge oil circuit into the closed
hydraulic circuit, in order to compensate leaks and flushing quanti-
ties.
Charge pump The charge pump is needed to supply the system with cool
hydraulic fluid, to maintain a positive pressure in the working cir-
cuit, to ensure a certain pressure level, to operate the control
system and to compensate internal leakages.
The charge pump is a fixed displacement Gerotor-type pump, inte-
grated in the variable displacement pump and driven by the pump
shaft.

6.3.3 Swash plate principle, pump
Fig. 233
The swash plate pump is a positive displacement machine with oil
displacing pistons arranged axially to the drive shaft. The pistons
are thereby supported by the swash plate.
Axial piston units based on the swash plate principle with fixed or
variable displacement can be used as hydraulic pumps or hydraulic
motors. In pump mode the mechanical energy is converted to
hydrostatic energy, when used in motor mode the hydrostatic
energy is converted to mechanical energy. When used as a pump,
the flow volume is proportional to the drive speed and the
swashing angle. The available (pump) torque increases with the
pressure drop between high and low pressure side.
Variable displacement pumps and motors can be change their dis-
placement, i.e. the pump delivery rate or motor throughput, by
simply changing the angle of the swash plate.
Fig. 234
1 Drive shaft
2 Piston
3 Piston area
4 Piston stroke
5 Slipping disc
6 Adjusting angle
7 Cylinder

8 Through drive
9 Valve plate
10 Top dead centre TDC
11 Bottom dead centre BTC
12 Control slots in suction side of swash plate (for sense of rota-
tion shown)
13 Control slot on pressure side
Driven by the engine, the drive shaft rotates and drives the cylinder
via a splined connection. The cylinder rotates with the drive shaft
and drives the 9 pistons. The pistons rest with their slipper pads on
the sliding face of the swashing cradle and perform an axial move-
ment. The slipper pads are held on the sliding face and are posi-
tively guided by a retaining device. During a complete rotation of
the cylinder block each piston moves through the bottom and top
dead centre back to its initial position. From dead centre to dead
centre is performs a full piston stroke. During this process the flow
volume determined by the stroke is drawn in through the control
slots in the valve plate or pumped out. During the suction stroke
the hydraulic fluid is drawn into the increasing piston chamber, i.e.
it is actually pressed in. On the opposite side the oil is pressed out
of the piston bores into the hydraulic system during the compres-
sion stroke.
6.3.4 Drum drive motor

Radial piston motor without multi-
disc brake NOTICE!
during operation.

2 3
6 5 4 S-HYD-583885
Fig. 235: Cross-sectional view

1 Drive shaft with output flange
2 Piston with roller
3 Oil distributor
4 Cylinder block
5 Cam ring
6 Bearing plate
Function
Fig. 236: Cross-sectional view of working piston positions

1 Piston position: Beginning of descending flank
2 Piston position: Middle of descending flank
3 Piston position: Top dead centre
4 Piston position: Middle of ascending flank
5 Piston position: End of ascending flank
6 Distributor

7 Descending flanks of cam race

8 Cylinder chambers
9 Ascending flanks of cam race
The high pressure hydraulic oil, which is controlled by the distrib-
utor (6) Ä Fig. 236 (axial bores and ring channels), flows into the
cylinder rooms (8) (radial arrangement) of the working pistons (2),
which are positioned on the descending flanks (7) of the cam race.
The working pistons "pressing against and rolling along" the cams
convert the linear movement of the working pistons into a radial
movement of the drive shaft with output flange.
Piston position (1) The hydraulic oil is delivered to the distributor under Pressure. The
distributor guides the hydraulic oil through ring channels and bores
to the cylinders on the descending flanks of the cam race so that
the oil presses against the working pistons.
Due to the pressure on the back of the piston the roller will move
along the cam, thereby causing a rotary movement of the cylinder
block.
Piston position (2) At this point of the piston stroke the opening cross-sections of
bores and ring channels in the distributor to the working piston
have their biggest size. As the cylinder block continues to rotate,
the opening cross-sections become smaller towards the valley
between the cams.
Piston position (3) At the deepest point of the cam race (dead centre) the hydraulic oil
flow through the distributor to the working piston is interrupted, the
bores and ring channels block one another.
Other working pistons are driven by the hydraulic oil flowing
through the distributor (see piston positions 1 to 3), so that the
working piston is moved out of this top dead centre position.
Piston position (4) The distributor now connects the cylinder with the low pressure
side. The working pistons moving along the ascending flank of the
cam race (9) away from the bottom dead centre pump the
hydraulic oil through the bores and ring channels in the distributor
back to the travel pump.
At this point of the piston stroke the opening cross-sections of
bores and ring channels in the distributor for the hydraulic oil flow
have their biggest size.
Piston position (5) As the cylinder block continues to rotate, the opening cross-sec-
tions become smaller towards the peak of the cam. At the highest
point of the cam race (dead centre) the hydraulic oil flow through
the distributor back to the travel pump is interrupted and a new
working cycle is started (see piston positions 1 to 5).

6.3.5 Travel motor

6.3.5.1 Swash plate motor with variable displacement
Designs: C and D
Fig. 237
Product description A plug-in fixed displacement motor converts the hydrostatic volu-
metric flow into mechanical rotary motion. It has mainly been
designed for installation into mechanical gear drives.
Function The hydraulic oil flows under high pressure through the corre-
sponding port to the back of the working pistons. Since the working
pistons are arranged under an angle to the output shaft, the pres-
surized pistons will perform an axial stroke, thereby causing a
rotary motion 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 rota-
tion 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.
Flushing valve In a closed circuit the same pressure fluid keeps permanently cir-
culating between pump and motor. This can cause overheating of
the pressure fluid.

The flushing valve has the function to support cooling of the oil cir-
cuit by flushing the motor and thus to prolong the service life of the
motor. If the hydraulic motor is operated under load, the flushing
valve opens during clockwise and anti-clockwise rotation, whereby
a defined flushing quantity is discharged through an orifice from the
low pressure side of the circuit. This flushed out amount of oil then
flows through the case drain back to the tank, normally through a
cooler. Any pressure fluid removed from the closed circuit must be
replaced by cool oil from the charge pump. The flushing valve
thereby ensures permanent renewal and cooling of the pressure
fluid. The flushing pressure relief valve has a fixed setting of 16 bar
and has the function of securing the minimum charge pressure.
Control 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 dis-
placement, slow speed and high torque.
When changing the swash plate position to minimal angle the
motor works with minimum displacement, high speed and low
torque.
The displacement is changed by a control piston, which is tightly
connected with the valve segment. The piston rod side (pressure
test port M4) is thereby permanently pressurized with the actual
travel pressure. In 1st gear (solenoid de-energized) the piston side
(pressure test port M3) is connected with the hydraulic oil tank. In
speed range 2 the solenoids are energized, the valve switches and
the piston side is also pressurized with the current travel pressure.
Due to the area differential between piston rod side and piston side
and the force resulting from this, the pilot control moves to Qmin
position.
Fig. 238
1 Control piston
2 4-way valve

3 Proportional valve
4 Minimum swashing angle setting
5 Valve segment
6 Bearing plate
7 Tapered roller bearing
8 SAE-flange
9 Synchronizing joint
10 Speed sensor
11 Piston
12 Flushing pressure relief valve
6.3.6 Vibration motor

6.3.6.1 Vibration motor A10FE/FM
NOTICE!
during operation.
The hydfraulic motor is available in standard design (A10FM) and

as a plug-in version (A10FE) The Hydraulikmotor is a fixed dis-
placement axial piston motor in swash plate design for hydrostatic
drives in open and closed hydraulic circuits.
Fig. 239: Cross-sectional drawing

1 Drive shaft
2 Retracting plate
3 Piston
4 Connecting plate
5 Valve plate
6 Cylinder
7 Slipper pad

8 Swash plate
S1 Hydraulic diagram with flushing valve
S2 Speed detection
The output speed of the motor depends on the oil quantity supplied
by the vibration pump. 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 motor.
When switching the vibration on the hydraulic motor must first start
to move the resting exciter shaft. This resistance causes a
hydraulic starting pressure, which is limited by the pressure over-
ride (vibration pump). Once the exciter shaft has reached its final
speed, the pressure will drop to 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

Soft ground Low operating pressure
Flushing valve The vibration motor is equipped with an integrated flushing valve.
In the closed hydraulic circuit the flushing and charge pressure
relief valve is used to avoid excessive temperatures and to secure
the minimum charge pressure. The valve is integrated in the con-
necting plate. A certain amount of pressure fluid, which is deter-
mined by the size of an orifice, is taken out of the corresponding
low pressure side and discharged into the motor housing. This fluid
is returned to the tank, together with the leak oil. The pressure fluid
taken out of the circuit is then replaced by cooled oil from the
charge pump.
Speed detection In this case the rotating, geared drive generates a signal propor-
tionate to the speed, which is then detected by a sensor and for-
warded for evaluation.
6.3.7 Swash plate principle, motor
Fig. 240

The swash plate pump is a positive displacement machine with oil

displacing pistons arranged axially to the drive shaft. The pistons
are thereby supported by the swash plate.
Axial piston units based on the swash plate principle with fixed or
variable displacement can be used as hydraulic pumps or hydraulic
motors. In pump mode the mechanical energy is converted to
hydrostatic energy, when used in motor mode the hydrostatic
energy is converted to mechanical energy. Variable displacement
motors can change their displacement, i.e. the pump delivery rate
or motor throughput, by simply changing the angle of the swash
plate.
If the unit is used as motor, the output speed is proportional to the
supplied volume of fluid. The available (motor) torque increases
with the pressure drop between high and low pressure side.
Fig. 241
1 Drive shaft
2 Piston
3 Piston area
4 Piston stroke
5 Slipping disc
6 Adjusting angle
7 Cylinder
8 Through drive
9 Valve plate
10 Top dead centre TDC
11 Bottom dead centre BTC
12 Control slots in suction side of swash plate (for sense of rota-
tion shown)
13 Control slot on pressure side
The motor function is a reversal of the pump function. In this case
the hydraulic fluid the hydraulic system directs the oil flow to the
hydraulic motor. The medium flows through control slots in the
valve plate to the cylinder bores. 4 or 5 cylinder bores are opposed
to the kidney shaped control slots in the pressure side. The other
control slot is in this case connected with the rest of the cylinder
bores, which in turn are connected with the return flow side or are
partly covered by the connecting web between the kidney shaped
control slots. By loading the piston it slides down the slanted swash

plate and drives the cylinder that guides it. The cylinder with the 9
pistons rotates with the drive shaft, whereby the piston perform a
stroke-like movement. The hydraulic pressure generates the torque
on the cylinder and thus the rotation of the drive shaft. The sup-
plied fluid quantity determines the output speed.
6.3.8 External gear pumps

External gear pumps mainly consist of the friction bearing mounted
gear pair and the housing with front and rear covers. The drive
shaft, which is sealed with a radial seal, protrudes from the front
cover. The bearing forces are absorbed by friction bearings. These
have been designed for high pressures and have excellent antifric-
tion properties - particularly at low speeds. The gears have 12
teeth each. This keeps flow pulses and noise emissions at a low
level.
Fig. 242: Axial compensation of gear pump
1 Axial seal 5 Cover

2 Outer pressure field 6 Flange
3 Inner pressure field 7 Sealing zone
4 Radial seal 8 Compensation forces
Internal sealing of the pressure chambers is achieved by flow

volume dependent forces. This results in an excellent rate of effi-
ciency. On the rear side the moveable bearing bushings are pres-
surized and thus tightly pressed against the gears. The pressurized
pressure fields are thereby limited by special seals. Sealing around
the circumference of the gears to the housing is assured by small
gaps, which appears between gears and housing in dependence
on the pressure.

Function
Fig. 243
The increasing volume caused by a tooth exiting a tooth gap
results in a vacuum in the suction chamber. The pressure fluid is
transported into the pressure chamber. There the meshing of teeth
and tooth gaps displaces the pressure fluid into the upper supply
line.
Fig. 244
1 Cover 6 Gear (driven)

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

Multiple gear pumps Gear pumps are most suitable for multiple pump arrangements,
whereby the drive shaft of pump 1 is extended to drive a second or
3. pump. The shafts are connected by drivers in between. The indi-
vidual pump stages are sealed to each other, i.e. the suction ports
are separated from each other.
Fig. 245
6.3.9 Steering valve

The steering unit works hydrostatically, i.e. there is no mechanical
connection between the steering wheel and the wheels to be
steered (articulated joint, drum, etc.). The mechanical link is
replaced by hydraulic piping and hoses between the steering unit
and the steering cylinder(s).
When the steering wheel is operated, the steering unit measures
the exact oil quantity proportional to the rotation of the steering
wheel. This oil quantity is directed to the steering cylinders.
The steering unit mainly comprises of a rotary spool valve and a
rating pump (gear set). The steering column connects the steering
unit to the steering wheel of the vehicle. When operating the
steering wheel the rotary spool valve makes sure that oil from the
steering pump is guided through the gear set to the cylinder ports L
or R, depending on the operating direction of the steering wheel.
The gear set measures the oil flow to the steering cylinder propor-
tionally to the turning angle of the steering wheel.
Fig. 246

1 Check valve 8 Outer spool

2 Shock valve 9 Universal shaft
3 Pressure relief valve 10 Distributor plate
4 Housing with anti-cavitation valves 11 Gear
5 Inner spool 12 Ring gear
6 Neutral setting spring 13 Cover
7 Pin
The steering valve is additionally equipped with a pressure relief

valve, it limits the steering pressure.
Suddenly occurring pressure peaks, which may be caused by e.g.
external influences like driving against a curb stone, are compen-
sated by two shock valves, which are integrated in the steering
valve. Each of these shock valves is fitted with an additional anti-
cavitation valve. These anti-cavitation valves protect the system
against cavitation which could be caused by the reaction of the
shock valves.
A check valve inside the steering unit makes sure that the
hydraulic oil cannot flow to the steering pump if forces are intro-
duced from outside. In such a case the steering cylinders would act
as pumps and press the oil back to the pump.

Hydraulic system – Charge circuit
6.4 Charge circuit
T
P 4
3
5
2
ML M3 M3
E
D
1
B21
6
S
P
8
Y04
7 S-582-0044
Fig. 247
1 Hydraulic oil tank
2 Steering/charge pump
3 Steering valve
4 Silencer optional equipment for cabin with heating; it is always subjected to hydraulic oil flow
5 Vibration pump with integrated charge pump
6 Charge circuit filter
7 Brake valve
8 Travel pump
B21 Differential pressure switch on charge circuit filter
M3 Pressure test ports for charge pressure, 26+ 3 bar
ML Steering pressure test port
The charge circuit provides the hydraulic oil for the charge system
and the control functions in the closed circuits for travel and vibra-
tion drive, as well as to release the parking brake.
The steering/charge pump is a gear pump with constant displace-
ment. The gear pump unit is driven by the auxiliary drive of the
diesel engine and draws the hydraulic oil directly out of the oil tank.
Another charge pump is integrated in the vibration pump.

Hydraulic system – Charge circuit
The flows from steering/charge pump and integrated charge pump

(in vibration pump) are joined together before the charge circuit
filter.
The charge circuit is equipped with a 12 µ fine filter with bypass
valve. This valve opens at a pressure differential (pressure differ-
ence between filter inlet and filter outlet) of Δp = 3.5 bar. This pres-
sure differential depends on the filter contamination and the vis-
cosity of the hydraulic oil.
The differential pressure switch (B21) switches when a differen-
tial pressure of Δp 2.5 bar is reached. The fault information will
therefore already be available before the bypass valve opens.

Hydraulic system – Travel circuit
6.5 Travel circuit
M3
B
L1
10 S
E
L1
A
L2
2
1
MB
MA
M3
L1
L1
9 E
B
S
A
L2 3
Y04 P
8 A1.1
55-70°C H
K B
D T
L
G
C L1 B
B
Y31
R A
7
T1
L
1 5 4
6
S-582-0043
Fig. 248
1 Travel pump
2 Vibration pump
3 Brake valve

4 Axle with brake discs

5 Travel motor of axle drive
6 Travel motor without brake
7 Return flow filter optional equipment
8 Return flow manifold with thermostat
10 Radiator
MA Travel pressure against block, forward travel, MA 420 bar
MB Travel pressure against block, backward travel, MA 420 bar
M3 Pressure test ports for charge pressure, 26+ 3 bar
Each travel circuit is a closed hydraulic circuit, it consists mainly of
travel pump and travel motors.
Travel pump and vibration pump are mounted together to a tandem
unit which is driven by the flywheel side of the diesel engine via an
elastic coupling. The travel pump has the function of supplying the
travel circuit with hydraulic oil.
Flushing valve in the axle motor

The flushing valves are used to discharge heat
from the hydraulic circuit.
When the travel circuit is switched on, a pressure difference will be

generated between the two sides (A & B) 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 pres-
sure side.
The flushing valve is fitted with a downstream flushing pressure
relief valve. This valve makes sure that only a certain quantity of
hydraulic oil is flushed out. The oil flows back to the hydraulic oil
tank and is immediately replaced by oil from the charge circuit.
Return flows All return flows pass through the return flow manifold block with
thermostat. This thermostat guides the oil flow directly back to the
hydraulic oil tank, until the operating temperature is reached. At an
oil temperature of 55 °C the valve starts to switch over and at
70 °C the total amount of oil will flow through the hydraulic oil
cooler.
Service brake During operation the closed hydrostatic travel circuit has the func-
tion of a service brake. When the travel lever is returned towards
neutral position, the displacement of the travel motor is adjusted
towards zero accordingly and the machine is hydraulically braked.
Parking brake To avoid creeping movements of the machine, the machine is addi-
tionally equipped with a multi-disc parking brake in the drive axle. It
closes in neutral position of the travel lever and when the engine is
stopped.

Fig. 249
1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel motor
5 Drum shell
6 Rubber buffer
8 Travel bearings

Hydraulic system – Vibration circuit
6.6 Vibration circuit
Y07
MB B
Y08 2
1 MA
L1
S
E
L1
L1
L1
A
T
M3
E
7
6 F
H T
A
B A
K
B
L 55-70°C
5
4
S-582-0045
Fig. 250
1 Radiator
2 Vibration pump with integrated charge pump
3 Travel pump

4 Vibration motor
5 Return flow filter optional equipment
6 Return flow manifold with thermal element
MA Vibration pressure, MA 420 bar
MB Vibration pressure, MB 420 bar
Vibration pump
Plugs Y07 Y08
The vibration circuit is a closed hydraulic circuit, it consists mainly

of the vibration pump with the integrated safety elements and the
vibration motors.
Travel pump and vibration pump are mounted together to a tandem
unit which is driven by the flywheel side of the diesel engine via an
elastic coupling. The vibration pump has the function of supplying
the vibration circuit with hydraulic oil.
When changing the swashing angle in the vibration pump through

the neutral position to the opposite side, the flow direction of the oil
and the sense of rotation of the vibration motor will change.
Since the displacement of the vibration pump is different to the two
flow directions, the speeds of the vibration motor are also different.
Fig. 251
The vibration system is designed in such a way, that the high
exciter shaft speed (frequency) is coupled with the low amplitude
and the low exciter shaft speed (frequency) with the high ampli-
tude.

The eccentric weights on the vibrator shaft are fitted with additional
change-over weights. Depending on the sense of rotation of the
exciter shaft these change-over weights add to or subtract from the
basic weights.
n Basic weight plus change-over weight = high amplitude
n Basic weight minus change-over weight = low amplitude
Fig. 252
1 Basic weight
2 Changeover weight
3 Exciter shafts
When switching the vibration on the motor must first start to move
the resting exciter shaft. This resistance causes a hydraulic starting
pressure, which is limited by the pressure override. Once the
exciter shaft has reached its final speed, the pressure will drop to
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

Soft ground Low operating pressure

Fig. 253: low amplitude

Use of low amplitude
n thin layers
n gravels, sands, mixed soils
n gravel and road metal bearing courses
n surface compaction
Fig. 254: high amplitude

Use of high amplitude
n thick layers
n non-cohesive soils and cohesive soils
n gravel and road metal bearing courses
n hydraulically bonded base courses
n frost protection layers
n subsoils
n dam constructions

Fig. 255
1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel motor
5 Drum shell
6 Rubber buffer
8 Travel bearings
The vibration motor output shaft is joined with the exciter shaft in
the drum via a Bowex coupling. The rotation of the exciter shaft
with the bolted on eccentric weights causes the vibration of the
elastically suspended drums.
Return flows All return flows pass through the return flow manifold with tempera-
ture controlled valve (thermostat). This thermostat guides the oil
flow directly back to the hydraulic oil tank, until the operating tem-
perature is reached. At an oil temperature of 55 °C the valve starts
to switch over and at 70 °C the total amount of oil will flow through
the hydraulic oil cooler.

Vibration motor with flushing valve The vibration motor is equipped with an integrated flushing valve.
In the closed hydraulic circuit the flushing and charge pressure
relief valve is used to avoid excessive temperatures and to secure
the minimum charge pressure. The valve is integrated in the con-
necting plate.
A certain amount of pressure fluid, which is determined by the size
of an orifice, is taken out of the corresponding low pressure side
and discharged into the motor housing. This fluid is returned to the
tank, together with the leak oil. The pressure fluid taken out of the
circuit is then replaced by cooled oil from the charge pump.
Fig. 256
1 High pressure port, high amplitude
2 High pressure port, low amplitude
3 Leak oil and flushing port
4 Flushing spool
5 Flushing valve

Hydraulic system – Steering circuit
6.7 Steering circuit

One steering cylinder
2 T
1 L
R
3
ML
B21
5 4
S-582-0046
Fig. 257
2 Steering valve
5 Steering cylinder
ML Pressure test port for steering

Two steering cylinders
2 T
1 L
R
3
ML
B21
S-582-0018
Fig. 258
2 Steering valve
5 Steering cylinder
ML Pressure test port for steering
The steering/charge pump is a gear pump with constant displace-
ment. The gear pump unit is driven by the auxiliary drive of the
diesel engine and draws the hydraulic oil directly out of the oil tank.

Oscillating articulated joint
Fig. 259
1 Drum
2 Front frame
3 Oscillating articulated joint with two steering cylinders
4 Oscillating articulated joint with one steering cylinder
5 Steering cylinder
6 Rear frame
7 Drive axle
8 Single drum roller with one steering cylinder
9 Single drum roller with two steering cylinders
Front and rear frames of the single drum rollers are connected by
an oscillating articulated joint.
The front console of the joint is fastened with screws to the rear
cross-member of the front frame. The rear console is tightly bolted
to the rear frame.

The use of rocker bearings between front and rear frame ensures
that both frames can oscillate to each other for +/- 12°. This ena-
bles good ground contact of drum and wheels, even under severe
soil conditions.
When turning the steering wheel, the steering cylinders will extend
or retract and swivel the front console around the vertical bolt. This
articulates the machine and results in a steering movement.

Hydraulic system – Tests and adjustments
6.8 Tests and adjustments
4 Y07
MB
Y08
5
M3 B
3 MA 6
2
1 M1
B
M2
L1
M3
D
S
E
M2
L1
M1
A
S
L2
MA
MB
S-582-0038
Fig. 260
1 Travel pump
6 Vibration pump

Vibration pump
Plugs Y07 Y08
Fig. 261
8 Suction port S


6.8.1 Checking / adjusting the neutral positions of the travel pump
Special tools
Hydraulic test case
NOTICE!
Perform measurements at operating temperature
of the hydraulic oil (50 °C).
1. Block drums and wheels with suitable chocks Ä Fig. 262.
Fig. 262
2. Unhook the travel cable Ä Fig. 263 from the pump.
Fig. 263

3. Pull the plug Ä Fig. 264 off the brake solenoid valve to close
the brake.
Fig. 264
4. Connect 600 bar pressure gauges to high pressure test ports

MA and MB Ä Fig. 265.
Fig. 265
5. Connect the control pressure ports M4 and M5 Ä Fig. 266

and Ä „Connections of travel pump“ on page 275 with hose
lines.
Fig. 266

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

ð
Nominal value
Both pressure gauges Ä Fig. 267 must
show equal pressure (charge pressure).
If necessary repeat the pressure test with

60 bar pressure gauges, for more accu-
rate readings.
Fig. 267
Evaluation of measurement
1. If pressure builds up on one side, adjust the mechanical neu-
tral position, until the pressures on both pressure gauges are
identical.
Fig. 268
6.8.2 Pressure tests in the travel circuit
Special tools
Hydraulic test case
NOTICE!
1. Block drums and wheels with suitable chocks Ä Fig. 269.
Fig. 269

2. Pull the plug Ä Fig. 270 off the brake solenoid valve to close
the brake.
Fig. 270
3. Connect 600 bar pressure gauges to the high pressure test

ports for “forward travel” and “reverse travel” and a 60 bar
pressure gauge Ä Fig. 271 to the charge pressure test port.
5. Read charge and high pressure gauges.
ð
Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pres-
Fig. 271 sure at high idle
High pressure gauge = charge pressure
at high idle
Evaluation of test
If the nominal value is not reached, check
the steering/charge pump.

Measurement with quickly operated

travel lever
1. Move the travel lever Ä Fig. 272 quickly forward, read the
pressure gauge.
ð
Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pres-
sure at high idle
High pressure gauge = pressure override
Fig. 272
Evaluation of test
If the specified high pressure is not
reached, check the travel pump.
If the charge pressure drops considerably
during the high pressure test, check the
components individually.
6.8.3 Checking / adjusting the exciter shaft speeds
Special tools
Vibration reed frequency meter
NOTICE!
1. Drive the machine onto an elastic base (rubber tyres)

Ä Fig. 273.
2. Apply the parking brake and block the wheels additionally
with suitable chocks.
4. Switch on vibration high frequency / low amplitude or low fre-
quency / high amplitude.
Fig. 273

5. Measure the speed Ä Fig. 274, rest the tester on your

thumb.
ð
Nominal value
high amplitude/ low frequency = see
technical data
low amplitude/ high frequency = see
technical data
Fig. 274 Evaluation of test

In case of deviations exceeding 10%
determine the cause, perform trouble
shooting for engine / vibration circuit and
check vibration motor.
6. Adjust the speed on the corresponding adjustment screw

Ä Fig. 275.
ð
Turning the adjustment screw in reduces
the speed, turning the screw out
increases the speed.
Fig. 275
6.8.4 Checking / adjusting the exciter shaft speeds
Special tools
Hydraulic test case
NOTICE!
1. Drive the machine with the drum onto an elastic base (rubber
tyres) Ä Fig. 276.
2. Block the wheels with suitable chocks.
3. Apply the brake.
Fig. 276

4. Connect a 60 bar pressure gauge to the charge pressure test

port Ä Fig. 277.
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.
ð
Nominal value
Charge pressure = charge pressure at
high idle (see technical data of travel
Fig. 277
pump).
Start-up pressure = vibration pump start-

up pressure (see technical data of vibra-
tion pump).
Operating pressure = vibration pump
operating pressure (see technical data of
vibration pump).
Evaluation of test
If the charge pressure drops, check the
components individually.
If the starting pressure is not reached,
check the vibration pump.
If the starting pressure is only reached for
one frequency, check the high pressure
relief valves.
6.8.5 Checking the leakage rate of the vibration motor
NOTICE!

1. Drive the machine with the drum onto an elastic base (rubber
tyres) Ä Fig. 278 and block the wheels additionally with suit-
able chocks.
2. Apply the brake.
Fig. 278
3. Block the flushing valve Ä Fig. 279 with washers.
Fig. 279
4. Disconnect the leak oil hose Ä Fig. 280, connect a meas-

uring hose and hold it into a measuring beaker.
6. Switch the vibration on and measure the running out leak oil
during one timed minute.
ð
Nominal value
max. 1.5 litre/min
Fig. 280
Evaluation of test
If the permissible leak oil rate is
exceeded, replace the vibration motor.
6.8.6 Pressure tests in the steering circuit
WARNING!
Danger of crushing, do not access the articulation
area of the machine!

NOTICE!
of the hydraulic oil (approx. 50 °C).
Special tools
Hydraulic test case, gear pump testing equipment
Measurement 1
1. Connect a 600 bar pressure gauge to the steering pressure
test port Ä Fig. 281.
2. Start the diesel engine and run it at idle speed.
3. Turn the steering against an end stop.
4. Read the pressure gauge.
ð
Nominal value
see technical data, max. steering pres-
sure of steering/charge pump.
Fig. 281
Evaluation of measurement 1
n If the nominal value is not reached, check the steering cylinder.

Measurement 2
Fig. 282: Machine with two steering

cylinders
1. Disconnect the hydraulic hoses from ports L and R

Ä Fig. 282 or Ä Fig. 283 on the steering cylinders and
close them with plugs.
2. Start the diesel engine and run it at idle speed.
3. Turn the steering wheel.
4. Read the pressure gauge.
ð
Nominal value
see technical data for steering/charge
Fig. 283: Machine with one steering pump.
cylinder
n If the nominal value is reached, replace the steering cylinder.
n If the nominal value is not reached, check the steering/charge
pump.
Measurement 3
1. Reconnect the hydraulic hoses to the steering cylinders.
2. Actuate the emergency stop switch.
Fig. 284

3. Close the pump outlet port Ä Fig. 285 with the gear pump
test equipment.
4. Crank the diesel engine only with the starter motor.
ð
Nominal value
see technical data for steering/charge
pump.
Fig. 285
n If the nominal value is reached, replace the steering valve.
n If the nominal value is not reached, replace the steering/charge
pump.

Hydraulic system – Flushing and bleeding
6.9 Flushing and bleeding

6.9.1 Flushing - general
Flushing - general
NOTICE!
Changing a component
– Always flush the complete oil circuit after you
have replaced a component.
– Solid particles in the circuit will very quickly
cause damage to machine components.
Fig. 286
Effect of contamination
n Coarse particles (> 15 µm)
– Sudden failure of components.
n Fine particle contamination (5 – 15 µm)
– Wear of components, internal leaks, inaccurate controlling
behaviour, blockage of valves.
n Extra fine particle contamination (< 2 – 5 µm)
– Silting of oil, accelerated aging of oil, corrosion.

n Water in oil
– Increased wear, accelerated aging of oil.
n Chips (abrasion) in the oil
– Open and clean all components in the oil circuit, replace if
necessary.
– Clean all high pressure hoses in the oil circuit, replace if
necessary.
– If abrasion is found in the travel circuit you should also
flush the vibration circuit.
– If abrasion is found in the vibration circuit you should also
flush the travel circuit.
Before flushing
1. Change the filter element
Fig. 287
2.
NOTICE!
Clean the hydraulic tank
Change the oil in case of excessive contami-
nation, oil discoloration or if the oil change
interval is almost due.
Filter the tank content with the filling and filtering unit and
pump it into an oil container.
3. Mark all hoses and disconnect them from the hydraulic oil
Fig. 288 tank.
4. Clean the oil tank thoroughly from inside, remove the tank
cover, if necessary.
5. Reconnect all hoses.
6. Fill the hydraulic oil tank again with the filling and filtering
unit.

Bleeding
1. Always bleed closed hydraulic circuits if lines had been
removed or connected.
Fig. 289
Servicing the flushing filter kit

1. Replace the filter element of the flushing filter when the red
control pin of the contamination indicator is pressed out
during the filtering process.
2. Clean hoses and connections and store the flushing kit in a
clean and protected environment.
Fig. 290

6.9.2 Flushing the travel circuit

6.9.2.1 Flushing diagram for travel system
Fig. 291
1 Elbow union (tool)
2 Connecting union (tool)
3 Drum drive motor

4 Axle motor
5 Screw socket R1 - 25S (tool)
6 not used
7 not used
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)
13 High pressure hose (drum drive motor forward)
14 High pressure hose (B, axle motor reverse)
15 High pressure hose (A, axle motor forward)
16 High pressure port (B, axle motor reverse)
17 not used
18 Flushing hose 25S - 20S (tool)

Fig. 292
3 Drum drive motor
4 Axle motor


6 not used
7 not used
9 not used
10 Reducing fitting (tool)
11 Travel pump
12 High pressure hose (drum drive motor reverse)
13 High pressure hose (drum drive motor forward)
14 High pressure hose (B, axle motor reverse)
15 High pressure hose (A, axle motor forward)
16 High pressure port (B, axle motor reverse)
17 not used
6.9.2.2 Flushing the travel system
Observe the chapter "Flushing - General"
Installing the flushing filter
NOTICE!
Before the installation of the filters check hoses
and connections for cleanliness.
The flushing filter must be installed in the low pres-
sure side in the return flow to the pump, so that
only cleaned oil will enter the travel pump in for-
ward travel.
With the connection shown in the illustration the
travel pump must therefore be actuated to forward
Fig. 293 direction.
1. Disconnect the high pressure hose (14) from the travel pump
(port B) and connect it with the flushing hose (19) (flushing
filter inlet “IN”).
2. Connect the flushing hose (18) (flushing filter outlet “OUT”) to
the high pressure port (B) on the travel pump.

Disconnect the drum drive motor

1. Take the drum drive motor out of the hydraulic circuit by
joining the high pressure hoses (12 and 13) on the drum
drive motor together.
Fig. 294
Bleeding the travel circuit

1.
Bleeding the travel circuit, see chapter
"Bleeding the travel circuit".
Fig. 295
Flushing the hoses

1. Keep circulating the complete tank content with the filling and
filtering unit throughout the entire flushing process.
Fig. 296

2. Block drum and wheels with suitable chocks.
Fig. 297
3.
NOTICE!
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
Start the engine and shift the travel lever to travel direction
forward.
4. Perform the flushing process at various engine speeds for
approx. 10 minutes.
5. Shut down the engine.
Fig. 298 6. Reconnect the high pressure hoses (12 and 13) to the drum
drive motor.
Flushing the drum drive motor

WARNING!
Danger of accident!
The drum must rotate freely.
1. Jack up the front of the machine, so that the drum can rotate
freely.
2. Secure the rear wheels with chocks.
3. Pre-select the slow speed range.
Fig. 299

Fig. 300
5.
NOTICE!
Start the engine, run it with maximum speed and shift the
travel lever to travel direction forward.
6. Run the flushing procedure for approx. 10 minutes. During
this process, keep changing the pump flow by shifting the
travel lever several times between full and half forward travel.
Fig. 301
Flushing the axle motor

WARNING!
Danger of accident!
Both wheels must be off the ground. The wheels
must be able to rotate freely.
1. Jack up the rear of the machine, so that the wheels can

rotate freely.
2. Secure the drum with wheel chocks.
3. Pre-select the slow speed range.
Fig. 302

Fig. 303
5.
NOTICE!
Start the engine, run it with maximum speed and shift the
travel lever to travel direction forward.
6. Run the flushing procedure for approx. 10 minutes. During
this process, keep changing the pump flow by shifting the
travel lever several times between full and half forward travel.
Fig. 304
8. Remove the flushing filter and reconnect the high pressure
hoses.
Bleeding the travel circuit

1.
Bleeding the travel circuit, see chapter
"Bleeding the travel circuit".
Fig. 305

Circulating the tank content

1. After completing the bleeding process, circulate the tank con-
tent with the filling and filtering unit for approx. 15 minutes.
Fig. 306
Function test
1. Check the hydraulic oil level in the tank, fill up if necessary.
2. Check all connections for leaks with the engine running
(visual inspection).
3. Perform a test drive, load the travel system in forward and
reverse, e.g. by driving uphill or starting on a gradient.
4. Check all ports and connections once again for leak tightness
Fig. 307

6.9.3 Flushing the vibration circuit

6.9.3.1 Flushing diagram for vibration drive
B A 1
9
2
10 A
3
8
OUT
5 4 A
IN
B
5
7
6 S-582-0031
Fig. 308
1 Vibration pump
2 High pressure hose, A <> A
3 High pressure hose, B <> B
6 Vibration motor
6.9.3.2 Flushing the vibration circuit
Observe the chapter "Flushing - General"

Installing the flushing filter
NOTICE!
Before the installation of the filters check hoses
and connections for cleanliness.
The flushing filter must be installed in the low pres-
sure side in the return flow to the pump, so that
only cleaned oil will enter the vibration pump in
high frequency.
D, DH and PDH machines: For the connection
schematic shown here the vibration must always
Fig. 309 be filtered with “high frequency / low amplitude”.
Disconnect the vibration motor

1. Take the vibration motor (6) out of the hydraulic circuit by
joining the hoses (3 & 9) together.
Fig. 310
Bleeding the vibration circuit

1.
Bleeding the vibration circuit, see chapter
"Bleeding the vibration circuit".
Fig. 311

Flushing the hoses

1. Block drum and wheels with suitable chocks.
Fig. 312
Fig. 313
3.
NOTICE!
D, DH and PDH machines: Use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-
tion.
Switch on vibration with high frequency.

Fig. 314 5. Flush the circuit for approx. 10 minutes, thereby switch the
vibration on and off at intervals of approx. 30 seconds.

Flushing the vibration motor 1. Reconnect the hoses (3 and 9) to the vibration motor.
2. Unscrew the fastening screws for the vibration motor and pull
the motor out of the coupling.
Fig. 315
Fig. 316
4.
NOTICE!
D, DH and PDH machines: Use only high
tion.
Start the engine and run it with maximum speed.

5. Run the flushing procedure for approx. 10 minutes. Switch
the vibration on and off at intervals of approx. 30 seconds.
Fig. 317
Removing the flushing filter and 1. Remove the flushing filter, install the vibration motor and
reinstalling the vibration motor reconnect the high pressure hoses (2 & 3).

Bleeding the vibration circuit

1.
Bleeding the vibration circuit, see chapter
"Bleeding the vibration circuit".
Fig. 318
Circulating the tank content

1. After completing the bleeding process, circulate the tank con-
tent with the filling and filtering unit for approx. 15 minutes.
Fig. 319
Function test
1. Check the hydraulic oil level in the tank, fill up if necessary.
2. Perform a test drive.
3. Check all ports and connections once again for leak tightness
Fig. 320
6.9.4 Bleeding the hydraulic system

6.9.4.1 Bleeding the travel circuit
1. Install a pressure test hose to the charge pressure test port.
2. Install a pressure test hose each to the high pressure test
ports.

WARNING!
The engine must not start.
Fig. 321
4. Hold the open ends of the pressure test hoses into a con-
tainer.
5. Operate the starter motor for approx. 30 seconds. Wait one
minute and repeat this procedure, until oil starts to run out of
the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 322
7. Unlock the emergency stop switch.
Fig. 323


port and run the diesel engine max. 15 seconds at idle
speed.
9. Wait for approx. 30 seconds and keep repeating this proce-
dure, until the gauge shows a constant charge pressure
reading.
Fig. 324
10.
NOTICE!
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.
WARNING!
Run the engine with idle speed.
Fig. 325
Start the diesel engine.
11. Shift the travel lever approx. 1/3 to forward direction.
12. After approx. 1 to 2 minutes shut down the diesel engine for
a minute.
ð
This waiting time is necessary to allow air
bubbles to escape through the leak oil
return line.
13. After a waiting time of approx. 1 minute keep repeating this

procedure, until the indicated charge pressure drops directly
to zero when shutting down the diesel engine.
6.9.4.2 Bleeding the vibration circuit

1. Install a pressure test hose to the charge pressure test port.
2. Install a pressure test hose each to the high pressure test
ports.

WARNING!
The engine must not start.
Fig. 326
4. Hold the open ends of the pressure test hoses into a con-
tainer.
5. Crank the diesel engine approx. 10 seconds with the starter
motor. Wait one minute and repeat this procedure, until oil
starts to run out of the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 327
7. Unlock the emergency stop switch.
Fig. 328


port and run the diesel engine max. 15 seconds at idle
speed.
9. Wait for approx. 30 seconds and repeat the procedure, until
the pressure gauge shows a constant charge pressure.
Fig. 329
10.
NOTICE!
With the flushing filter installed use only high
tion.
For bleeding, switch on vibration with high frequency.

11. Start the diesel engine.
Fig. 330 12. After running the engine 1 to 2 minutes, pause for approx.
one minute.
ð
This waiting time is necessary to allow air
bubbles to escape through the leak oil
return line.
13. After a waiting time of approx. 1 minute keep repeating this

procedure, until the indicated charge pressure drops directly
to zero when shutting down the diesel engine.

Hydraulic system – Inspection and maintenance work


6.10.2.1 Check the hydraulic oil level 351
6.10.3.1 Changing the bypass filterOptional equipment 352
6.10.4.1 Changing hydraulic oil and breather filter 353
6.10.4.2 Changing the hydraulic oil filter 354
6.10.2 Checks prior to start up

6.10.2.1 Check the hydraulic oil level
NOTICE!
In hydraulic systems filled with Panolin HLP Synth.
46 always use the same oil to top up. With other
ester based oils consult the lubrication oil service
of the respective oil manufacturer.
1. Check the hydraulic oil level in the inspection glass

Ä Fig. 331.
Normal level
approx. 3 cm below the top edge of the inspection glass.
Minimum level
Middle of inspection glass.
Fig. 331 NOTICE!

If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped, check
all lines, hoses and components for leaks.
1. If necessary fill in hydraulic oil through the filler neck.
For quality and quantity of oil refer to the table of fuels and
lubricants.


6.10.3.1 Changing the bypass filterOptional equipment
WARNING!
Danger of scalding!
Danger of scalding by hot oil when unscrewing the
oil filter.
NOTICE!
If the filter has to be changed together with the
hydraulic oil, the filter must only be changed after
the oil change and after the test run.
Replace the filter element at the latest after one
year
ENVIRONMENT!
Dispose of the old filter element environmentally.
1. Open the engine hood Ä Fig. 332 completely and secure it.
Fig. 332
1. Unscrew the fastening screws Ä Fig. 333 and take off the
cover.
2. Replace the filter element, attach the cover and fasten it with
the screw.
Fig. 333


6.10.4.1 Changing hydraulic oil and breather filter
See also the notes on the hydraulic system in the

chapter "General notes on maintenance".
WARNING!
Danger of scalding!
When draining off hot hydraulic oil!
NOTICE!
The hydraulic oil must also be changed after major
repairs in the hydraulic system.
Perform the oil change when the hydraulic oil is
warm.
Replace the hydraulic oil filter elements with every
hydraulic oil change.
Change the filter only after the hydraulic oil change
and after the test run.
Clean the area round hydraulic oil tank, filler
opening and breather filter.
Do not start the engine after draining the hydraulic
oil.
Do not use any detergents to clean the system.
Use only lint-free cleaning cloths.
For quality and quantity of oil refer to the "table of
fuels and lubricants".
When changing from mineral oil based hydraulic oil
to an ester based biologically degradable oil, you
should consult the lubrication oil service of the oil
manufacturer for details.
ENVIRONMENT!
Catch running out hydraulic oil and dispose of
environmentally.

two years.

1. Unscrew the plug and drain off all hydraulic oil.

2. Check the seal ring, replace if necessary and turn the plug
tightly back in.
Fig. 334
1. Remove the filler cap.

2. Fill in new hydraulic oil through the screen.
We recommend to use our filling and filtering unit

with fine filter to fill the system. This ensures finest
filtration of the hydraulic oil, prolongs the lifetime of
the hydraulic oil filter and protects the hydraulic
system.
Fig. 335
1. Check the oil level in the inspection glass.
Nominal value:
approx. 3 cm below the upper edge of the inspection glass
The breather filter for the hydraulic oil tank is inte-

grated in the filler cap, you must therefore replace
the complete filler cap.
1. Close the tank with a new cap.
6.10.4.2 Changing the hydraulic oil filter
WARNING!
Danger of scalding!
Danger of scalding by hot oil when unscrewing the
oil filter.

NOTICE!
If the filter has to be changed together with the
hydraulic oil, the filter must only be changed after
the oil change and after the test run.
Do not use the oil in the filter bowl again.
ENVIRONMENT!
Catch running out oil, dispose of oil and filter ele-
ment environmentally.
The filter element must be changed with every

hydraulic oil change and after major repairs in the
hydraulic system.
1. Unscrew the cap nut 4 Ä Fig. 336 and take the filter bowl (5)
with the filter element (3) off.
2. Examine the sealing face on the filter element thoroughly for
any visible dirt.
NOTICE!
Visible dirt may be an early sign for the failure of
system components and indicate the possible
Fig. 336 failure of components. In this case determine the
cause and replace or repair the defective compo-
nents, if necessary. Negligence may cause
destruction to the entire hydraulic system.
Do not clean or reuse the filter element.
1. Take the old filter element (3) out and clean the filter bowl
and the thread.
2. Reinstall the filter bowl with the new filter element, check the
condition of the O-rings (1) and (2), replace if necessary.
3. After a test run check the filter for leaks.


Air conditioning
7 Air conditioning

Air conditioning – Overview
7.1 Overview
Fig. 337
1 Compressor
2 Condenser
3 Drier / collector
4 HKL module

Air conditioning – Physical principles
7.2 Physical principles

In order to understand the working principle of an air 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
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 reversible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into water and finally
into ice.
Fig. 338
A - heat absorption
B- Heat dissipation
Heat always flows from the warmer to the colder matter. Any
matter consists of a mass of moving molecules. 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 mol-
ecules in the warmer matter becomes slower and the molecules in
the cooler matter are accelerated. This process continued, until all
molecules in the two matters move with identical speed. The mat-
ters have then reached an identical temperature and the transfer of
heat stops.
Fig. 339
Pressure and boiling point The boiling point is the temperature at which fluid changes to gas-
eous state.
Changing the pressure above a fluid also changes the boiling
point. It is a well known fact, that e.g. the lower the pressure
applied to water, the lower the boiling point.
When looking at water, the following values do apply:
n Atmospheric pressure, boiling point 100°C
n Overpressure 0.4 bar, boiling point 126°C
n 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.

Steam pressure curve for refrigerant R134a

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).
Fig. 340: Steam pressure curve 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)
At absolute pressure 0 bar correspond with an

absolute vacuum. The normal ambient pressure
(overpressure) corresponds with 1 bar absolute
pressure. On the scales of most pressure gauges
0 bar corresponds with an absolute pressure of 1
bar (indicated by the statement -1 bar below the 0).
In the pressure - temperature diagram for the refrigerant the drawn

in closed curve shows the cycle of the refrigerant. This cycle per-
manently continues in direction of the arrow.
The characters A, B, C, D stand for:
A - compression
B- condensation
C- relaxation
D- evaporation.
Fig. 341: Pressure - Temperature

Diagram
Excerpt from the wet steam table

R134aThis table is used for the determination of
evaporation and condensation temperature.
Saturation temperature Overpressure (pressure gauge Absolute pressure (pamb = 1 bar P

reading Pe in bar) in bar)
-20 0,33 1,33
-10 1,01 2,01

Saturation temperature Overpressure (pressure gauge Absolute pressure (pamb = 1 bar P

reading Pe in bar) in bar)
0 1,93 2,93
10 3,15 4,15
20 4,72 5,72

Air conditioning – Refrigerant R134a
7.3 Refrigerant R134a

General
The evaporation and condensation process is the method com-
monly used in mobile air conditioning systems. The system in this
case works with a substance that boils at low temperature, a sub-
stance referred to a refrigerant. The refrigerant used is tetrafluoro-
ethane R134a, which boils at a temperature of -26.5°C and under a
steam pressure of 1 bar.
Although the refrigerant circuit is a hermetically closed loop, the
system loses approx. 100g of refrigerant over the course of 1 year
by diffusion through hoses, pipes and seals, even though the
system is free of leaks. If too much refrigerant is lost the cooling
power of the system will drop.
Physical data of the refrigerant R134a
Chemical formula:
CH2F-CF3 or CF3-CH2F
Chemical designation:
Tetrafluoroethane
Boiling point at 1 bar:

- 26.5 °C
Solidification point:
-101.6 °C
Critical temperature:
100,6 °C
Critical pressure:
40.56 bar (absolute)
Critical point:
Critical point (critical temperature and critical pressure) means that
above this point there is no separating interface between liquid and
gas. Above its critical point any substance is gaseous. At tempera-
tures below the critical point all refrigerant types in pressure con-
tainers have a liquid and a gaseous phase, i.e. a gas cushion is
above the liquid. As long as gas is in the container, besides the
liquid, the pressure depends on the ambient temperature.
Characteristics of the refrigerant R134a:

Refrigerant R134a is currently available under the following trade
marks. H-FKW 134a SUVA 134a KLEA 134a
Colour:

Refrigerant in form of vapour or liquid is colourless as water. The

gas is invisible. Only the bordering layer between gas and liquid is
visible. (Fluid level in rising pipe of filling cylinder or bubbles in
inspection glass). In the inspection glass the liquid refrigerant
R134a may appear coloured (milky). This turbidity results from par-
tially dissolved refrigeration oil and is no indicator for a fault.
Steam pressure:
In an incompletely filled, closed container, vaporous refrigerant will
volatilize from the surface in the same quantity that will turn liquid
in combination with steam particles. This state of equilibrium
occurs under pressure and is frequently referred to as steam pres-
sure. The steam pressure is independent from the temperature.
Physical properties of R134a:

The steam pressure curves of R134a and other refrigerants are
partly very similar, making a clear differentiation solely by pressure
impossible. With R 134a the compressor is lubricated by special
synthetic refrigeration oils, e.g. PAG-oils (polyalkylene glycol oils).
Behaviour with metals:

In pure condition refrigerant R134a is chemically stable and does
not attack iron and aluminium. However, contamination of the
refrigerant, e.g. with chlorine compounds, leads to aggressiveness
against certain metals and plastics. This can cause clogging, leaks
or deposits on the pistons of the compressor.
Critical temperature / critical pressure:

Up to a gas pressure of 39.5 bar overpressure (this corresponds
with a temperature of 101 °C) the refrigerant R134a remains chem-
ically stable, above this temperature the refrigerant decomposes
(see combustibility).
Water content:
In liquid refrigerant water can only be dissolved in very low quanti-
ties. In contrast to this refrigerant steam mixes with water steam at
any ratio. If the dryer in the liquid container has absorbed approx. 8
gr. of water, the refrigerant circuit transports possibly existing water
in form of droplets. This water flows to the nozzle of the expansion
valve and turns to ice. The air conditioning system stops cooling.
Water destroys the air conditioning system, because under high
pressures and temperatures and in connection with other contami-
nants it forms acids.
Inflammability:
Refrigerant is not inflammable. On the contrary, it has fire inhibiting
or fire extinguishing properties. Refrigerant is decomposed by
flames or glowing surfaces. Ultraviolet light also cracks refrigerant
(caused by electric welding). This results in toxic fission products,
these must not be inhaled. However, irritation of the mucous mem-
branes is an early and in-time warning.
Filling factor:

In a container there must be a steam space above the liquid space.

The liquid expands with increasing temperature. The steam filled
space becomes smaller. From a certain time on the container will
be filled with just liquid. After this only a minor temperature
increase is enough to generate very high pressures in the con-
tainer, because the liquid would like to expand, but there is no
more room. The related forces are high enough to cause the con-
tainer to burst. In order to avoid overfilling of a container the pres-
sure gas directive clearly specifies how many kilograms of refrig-
erant may be filled into the container per litre volume. Multiplied
with the internal volume this "filling factor" determines the permis-
sible filling capacity For refrigerants used in motor vehicles it is
1.15 kg/l.
Environmental aspects The contribution of R134a to the greenhouse effect is by factor 10

smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for newly pro-
duced construction equipment were successively 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 decomposition potential
and also a potential to amplify the greenhouse effect. Conversion
programs for existing old systems with the ozone damaging R12
are in effect. For reasons of protecting the environment refrigerant
must not be discharged into the atmosphere.

Air conditioning – Compressor oil / refrigeration oil
7.4 Compressor oil / refrigeration oil

General
The compressor oil lubricates the movable parts in the compressor,

seals e.g. the gap between piston and cylinder inside the com-
pressor to prevent refrigerant loss and prevents other seals in the
system from drying up.
Part of the compressor oil dissolves in the refrigerant until satura-
tion is reached, so that a gas mixture of refrigerant, water steam,
compressor oil and contrast agent circulates through the system.
Compressor oil (the oil quantity should be 10 % of the refrigerant
weight) mixes with the refrigerant and circulates permanently
through the system.
In connection with R134a- air conditioning systems special syn-
thetic compressor oils, e.g. polyalkylene glycol (PAG) oils, are
used. This is necessary, because e.g. mineral oil does not mix with
R134a. Apart from this, the materials in the R134a air conditioning
system may be attacked when the mixture is flowing through the
refrigerant circuit under high pressure and at high temperatures or
if the lubrication film in the compressor tears off. The use of non-
permitted oils can cause damage to the air conditioning system,
you should therefore only used the approved oils.
Properties of compressor oil / The most important properties are high solvency in connection with
refrigeration oil refrigerants, good lubrication characteristics, that they are free of
acids and their low water content. For this purpose only certain oils
can be used. PAG-oils suitable for use with refrigerant R134a are
highly hygroscopic and will not mix with other oil. As a protection
against the invasion of moisture drums must immediately be closed
again after they had been opened. Compressor oil ages under the
effect of moisture and acids, becomes dark, viscous and aggres-
sive against metals.
Compressor oil level / refrigeration

oil level in the compressor NOTICE!
The refrigeration oil level in the compressor must
be checked after replacing a system component or
if a leak in the system is suspected. Use only
refrigeration oil PAG SP-20 (H14-003-404).
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil / refrigeration oil
lost by exchanging the components, must be
replaced with fresh oil.
The actual quantity depends on the amount of oil
that may have been lost in connection with the
possible replacement of other components.

ENVIRONMENT!
Used compressor oil / refrigeration oil must be dis-
posed of as hazardous waste.
The following table shows how much compressor oil / refrigeration

oil will be lost in connection with various types of work on the air
conditioning system.
Reason of oil loss Amount of oil lost

Loss when emptying approx. 15 gr
Defective A/C hose approx. 30 gr
Hose change approx. 15 gr
Replacement of condenser approx. 30 gr
Replacement of evaporator approx. 30 gr
Replacement of liquid container approx. 30 gr
Replacement of expansion valve approx. 15 gr
NOTICE!
Compressor replacement
New compressors are delivered with an approx.
250 gr.compressor oil filling. To avoid excessive oil
in the A/C-system and thus a poor cooling effect,
the oil level in the A/C-system must be adjusted
accordingly.
The quantity depends on the amount of oil that
may have been lost in connection with the possible
replacement of other components.
The compressor oil quantity must be 10% of the
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system
requires a compressor oil / refrigerant oil filling of
110 gr.
Procedure
– Drain and measure the compressor oil from the

old compressor.
– Drain the compressor oil from the new com-
pressor and only fill in the exact quantity that
had been drained out of the old compressor.
The compressor oil from the new compressor
can be used for this purpose.

Topping up compressor oil / refrigeration oil is pos-

sible on a pressureless compressor directly into
the oil pan, in a pressureless refrigeration system
directly into the pressure side, but it is also pos-
sible to draw it into the pressure side of the refrig-
eration system during the evacuation process.

Air conditioning – Working principle of the air conditioning system
7.5 Working principle of the air conditioning system

All air conditioning systems are based on the same principle. They
extract heat from the surrounding environment. 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 circulates
in a closed circuit inside the vehicle. This refrigerant thereby con-
tinuously changes its physical state between liquid and gaseous.
An engine driven compressor (1) draws in gaseous refrigerant from
the evaporator (5) and compresses it. During this process the tem-
perature of the refrigerant increases tremendously.
The refrigerant vapour is then pumped to the condenser (2). This
condenser is arranged directly in front of the vehicle radiator, so
that a sufficient air flow is assured. 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.
Fig. 342: Principle sketch of an air The expansion valve (4) regulates the flow rate from the dryer /
conditioning system liquid container (3) back to the evaporator (5) and the circuit starts
again.

Air conditioning – Monitoring devices
7.6 Monitoring devices

Pressure switch, B105 The pressure switch (8) is used as monitoring feature for too high
and too low pressures. The switching contacts (4 and 5) effect the
magnetic clutch of the compressor via a relay (6).
If the system pressure increases excessively, e.g. because of a
excessively soiled condenser, a failed fan or a defective expansion
valve, the high pressure contact (5) will cut off the electric power
supply to the magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off pressure by the
set differential pressure, the magnetic clutch of the compressor is
switched on again.
The low pressure contact (4) interrupts the electric power supply to
the magnetic clutch when the set pressure is fallen short of (pos-
sible causes: lack of refrigerant, defective expansion valve, too low
heat load, defective evaporator fan, ...). Since the refrigerant
R134a has an evaporation temperature of 0 °C at an overpressure
of 2 bar, the low pressure contact (4) is set to approx. 1.5 bar to
avoid icing. The switch on pressure is 0.5 to 2 bar higher than the
shut-off pressure (depending on system, see description of compo-
nents).
Thermostat A frost protection thermostat (3) protects the evaporator against

icing. Similar to the pressure switch, the thermostat activates or
deactivates the magnetic clutch for the compressor. Depending on
the design, the feeler of the temperature control is mounted
between the fins of the evaporator or attached to the evaporator
outlet (suction side). With fixed temperature controls the control
switches the compressor off at about 1 °C and back on again at
about 2.5°C to 5.5 °C (depending on system, see description of
components.)
With adjustable temperature regulators the switching point can be
changed so that the compressor is already shut down at higher
temperatures. This enables regulation of the air temperature.
Monitoring chain
1 Switches
2 Fuse
3 Thermostat
4 Low pressure switch contact
5 High pressure switch contact
6 Relays
7 Connection for magnetic clutch
8 Pressure switch
Fig. 343: Monitoring chain

Air conditioning – Description of components
7.7 Description of components

Condenser
The condenser is located in front of the radiator for the machine. It
emits heat energy from the system into the surrounding air and liq-
uefies the gaseous refrigerant.
WARNING!
Danger of injury caused by exploding compo-
nent!
– Do not clean the condenser in the air condi-
tioning system with a hot water jet.
Fig. 344
The fins must be free of dirt and damage.
NOTICE!
or condenser, any compressor oil lost by
exchanging the components, must be replaced
with fresh oil.
Dryer / filter / fluid container /

inspection glass
Dryer / filter
The fluid container collects the fluid drops and passes these then
as a constant flow to the expansion valve. Moisture that has
entered during assembly of the refrigerant circuit is absorbed by a
dryer in the fluid container.
At evaporation temperatures below zero the refrigerant will deposit
previously absorbed moisture on the expansion valve, where this
water turns into ice and thus adversely affects the controllability of
the expansion valve. Moreover, moisture in the refrigerant circuit
causes corrosion, forms acids and enters into chemical composi-
tions.
Fig. 345
Inside the refrigerant container the heavy liquid refrigerant 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.
Since the absorbing capacity of this filter/dryer is

limited, it must be changed within certain service
intervals. We recommend to replace it 1 x per
years, before the start of the season.

NOTICE!
The filter/dryer must generally be replaced when-
ever opening the refrigerant circuit, because mois-
ture will enter in such a case.
This requires emptying the air conditioning system!
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!
Pressure relief valve

The fluid container is equipped with a safety valve.
Response pressure 32 +/- 4 bar
Tightening torque 10 - 15 Nm
Fig. 346
Inspection glass
During operation the refrigerant must flow through the inspection
glass without air bubbles. In most cases the presence of air bub-
bles is a sign for a too low refrigerant level in the system. Apart
from this, the refrigerant 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 expansion
valve), as well as very high pressures in the pressure side.
However, incorrect evacuation or filling may also be the reason for
Fig. 347 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 refrig-
erant. In this case the air conditioning system needs to be evacu-
ated and refilled.
Air in the system is characterized by high pres-

sures and temperatures.
On R134a refrigeration systems from KONVEKTA the inspection

glasses are equipped with moisture indicators. In addition to the
float, the dryer/collector/inspection glass combination has an indi-
cator 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 minutes continuous opera-
tion, because the refrigerant must first evenly distribute all over the
system.
WARNING!
In case of mechanical damage or corrosion on this
pressure container this collector unit must be
replaced, to avoid bursting and further damage.
Expansion valve
The expansion valve is mounted inside the HKL-module in the

cabin. The expansion valve always allows a small amount of the
high pressure liquefied refrigerant to flow into the evaporator, which
has a much lower pressure. This lower pressure causes these
liquid refrigerant to expand and to evaporate to gaseous state. The
heat required for this evaporation process is taken from the
ambient air through the lamellas and supplied to the refrigerant.
This is the so-called cooling effect.
The thermostatic expansion valve operates with an external pres-
sure compensation. This type of expansion valve works with high
accuracy, because it uses pressure and temperature at the evapo-
rator outlet and adjusts and overheating of approx. 7 K. The
already installed expansion valves and the ones delivered as spare
parts have this overheating value pre-set. In order to prevent a loss
Fig. 348 in performance or compressor damage you should only use orig-
inal expansion valves, because adjusting expansion valves takes a
lot of time and care.
In case of dirt in the refrigerant system you should

also check or clean the screen at the expansion
valve inlet.+

Evaporator
The evaporator is mounted inside the HKL-module in the cabin. It

consists of a heat exchanger (inside air - refrigerant), with refrig-
erant flowing to a pipe system with cooling flanges.
As with the condenser, correct operation of all fans and cleanliness
of the fins must be assured.
Air conditioning systems have a circulation air filter mounted in the
air flow in front of the evaporator, which should be cleaned or
changed by the operator after each third trip, depending on the
amount of dirt.
A condensation water filter is mounted in the air flow after the
evaporator. This filter has the function to collect the water that has
condensed from the air in the evaporator block and to discharge
this water into the water pan With a defective condensation water
Fig. 349 filter condensation water may flow into the inside of the vehicle.
NOTICE!
or condenser, any compressor oil lost by
exchanging the components, must be replaced
with fresh oil.
Thermostat
Thermostat with fixed setting

The feeler of a defroster thermostat to switch off the magnetic
clutch in case of icing up or to switch the clutch back on after
defrosting, is mounted on the evaporator.
With fixed temperature controls the control switches the com-
pressor off at about +1 °C and back on again at about +2.5°C to
+5.5 °C.
Fig. 350
Adjustable thermostat
With adjustable temperature regulators the switching point can be
changed so that the compressor is already shut down at higher
temperatures. This enables regulation of the air temperature.

The adjusted temperature must be below the

actual temperature inside the cabin, so that the
compressor will be switched on.
Fig. 351: adjustable temperature con-

troller
Pressure switch
Pressure switch, B104

After a minimum pressure is reached in the low pressure side or a
maximum pressure in the high pressure side, the pressure switch
will switch of the magnetic clutch of the compressor, thus to avoid
destruction of system components by excessive pressure or
drawing in external gases and foreign matter as a result of too low
pressure.
Working pressure:
Low pressure off: 1,5 ±0,5 bar
Low pressure on: 3.5 bar
Overpressure off: 25,0 ±1,5 bar
Fig. 352
Overpressure on: 18,0 ±1,5 bar
Pipes and hoses
Pipes and hoses in air conditioning systems must meet very high
requirements with respect to resistance 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 conditioning 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 provided with
a special heat insulation.
O-rings are made of a special type of chloroprene rubber (neo-
prene). Before assembly of the air conditioning system these O-
rings must be lubricated with compressor oil / refrigeration oil. The
O-rings must always be replaced when assembling A/C-compo-
nents.
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 radius

GH 134 NW8 min. 50 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm

Air conditioning – Compressor
7.8 Compressor
Structure
Fig. 353: Refrigerant compressor
1 Refrigerant compressor 7 Pressure plate

2 Belt pulley 8 Driver disc
3 Melting fuse 9 Swash disc
4 Refrigerant compressor shaft 10 Piston (7 pieces, uniformly distributed over the entire circumference)
5 Ball bearing 11 Slipper pad
6 Magnetic coil 12 Swash plate chamber
A Suction valve B Pressure valve
Magnetic clutch The belt pulley (2) runs on a bearing on the refrigerant compressor
housing. It is driven by the ribbed V-belt and rotates on the ball
bearing (5) around the magnetic coil (6), which is mounted to the
refrigerant compressor housing. The pressure plate (7) is con-
nected to the shaft of the refrigerant compressor (4) by means of a
splined connection. It consists of 2 rings, which are connected by a
resilient plate.
The magnetic coil (6) is energized to start up the refrigerant com-
pressor (1). The magnetic force pulls the outer ring of the pressure
plate (7) against the belt pulley (2) and holds it in position. This
causes a positive connection between pressure plate (7) and belt
pulley (2).
Once the magnetic coil (6) is de-energized, spring force will return
the outer ring of the pressure plate (7) back to its rest position and
the flow of force is interrupted. This ensures switching off of the
refrigerant compressor in case of a mechanical defect.

Air conditioning – Compressor
Delivery process Once the magnetic coupling of the refrigerant compressor (1) has
caused the frictional connection, the shaft of the refrigerant com-
pressor (4) will drive the swash plate (9) via the driver disc (8). The
revolving slanted swash plate (9) causes a stroke movement of the
7 pistons (10), which are evenly distributed along the circumfer-
ence.
The pistons (10) are thereby actuated by slipper pads (11).
During the suction stroke gaseous refrigerant flows through the
suction valve (A) into the corresponding cylinder. When the stroke
of the piston (10) is reversed, it compresses the gaseous refrig-
erant, until the pressure inside the cylinder becomes so high, that
the pressure valve (B) opens and allows the refrigerant to flow
through the compressor outlet and thus into the refrigerant circuit.
The refrigerant compressor (1) has integrated chambers both on
the suction and on the pressure side, which have the function to
dampen resonances, which are generated by suction and com-
pression.
Displacement control The refrigerant compressor (1) is designed in such a way, that
already has sufficient flow rate to keep up the refrigerant circuit,
even at a slow vehicle speed and low engine speed.
Since the flow rate of the refrigerant compressor (1) rises with
increasing engine and travel speed, the flow rate needs to be
reduced or regulated.
This is to avoid that the refrigerant compressor (1) unnecessarily
uses engine power.
The flow rate is controlled by switching the magnetic coupling on
and off.
Safety contgrol of the refrigerant To prevent the ribbed V-belt jumping off in case of a mechanical
compressor (1) defect of the refrigerant compressor (1), the magnetic coupling will
disengage automatically.
In case of a mechanical defect the refrigerant compressor (1) will
be harder to turn or may even block completely. The heat created
on the friction surface of the V-belt (2) blows a meting fuse (3) in
the magnetic coil (6). This interrupts the power supply to the mag-
netic coil (6) and releases the frictional connection.
Service valves The service valves are installed directly on the compressor. These
are used to e.g. evacuate and fill the system.

Air conditioning – Emptying in case of repair
7.9 Emptying in case of repair

For repair work the air conditioning systems must very often be
emptied of all refrigerant.
Especially with expensive refrigerants and larger amounts of oil it
may be necessary to keep the refrigerant for later use.
For later use these refrigerants must be drawn out with suitable
equipment and intermediately stored in collecting containers.
ENVIRONMENT!
Contaminated refrigerant must be disposed of
environmentally
Releasing refrigerant into the atmosphere is pro-
hibited (see restrictive injunction concerning CFC,
day of enforcement 01. 08. 1991, § 8)
WARNING!
For draining refrigeration systems you should not
simply use any delivery containers, but only appro-
priate pressure bottles, which must be specially
marked and should comply with the pressure gas
directive.
When transferring refrigerant you must make sure
that the bottle does not contain more than the per-
mitted amount of refrigerant in litres and has suffi-
cient gas space for expansion (filling factor: 0,7).
In order to reduce the evacuation period in case of short repairs,

you may fill the refrigerant circuit with approx. 0.5 bar nitrogen
when opening. This ensures that nitrogen will flow out of the refrig-
erant circuit while it is open and no air or moisture can enter. How-
ever, the necessity for vacuum generation and a dryer change
remains.

Air conditioning – Drying and evacuation
7.10 Drying and evacuation

Evacuation of air conditioning systems using R-type refrigerants
not only has the purpose of emptying the system of all air before
filling in refrigerant, but also to verify the leak tightness over a
longer lifetime in the achieved vacuum. However, the most impor-
tant factor in this work step is the drying of the system.
Any water residues in the refrigerant circuit will combine with the
refrigerant, which will lead to the previously described consequen-
tial damage.
Vacuum pumps with a capacity of more than 100 l/min and a final
pressure of less than 30 micron, i.e. 0.039 mbar should be used to
evacuate the refrigeration system.
The refrigerant compressor is not suitable for the purpose of evac-
uation, because it is not able to achieve a sufficient final vacuum
and, apart from this, may be mechanically damaged because of a
lack of lubrication when running empty during evacuation.
It is common practice to evacuate the refrigeration system to a final
vacuum of 1 Torr, i.e. 1.33 mbar.An exact time for evacuation and
drying cannot be predicted. It can only be determined by means of
a vacuum meter. However, if there is no vacuum meter at hand it is
generally better to evacuate 1 hour longer than 1 hour too less.
Function drying:
Under normal ambient pressure (1.013 mbar) evaporates absolute
at 100° C. If the pressure is reduced, water will already evaporate,
e.g. under a pressure of 10 mbar, at an ambient temperature of
almost 7°C, but the water will not evaporate all at once. Since it is
very difficult to separate the steam from the vacuum in the system,
the evacuation process is supported by the co-called vacuum
breaking (filling the circuit with dried nitrogen). With vacuum
breaking the filled in dried nitrogen absorbs the moisture in the
refrigerant circuit, which can then be easily discharged together
with the nitrogen.

Air conditioning – Filling instructions
7.11 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 complicated equip-
ment is available for this purpose, whereas 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 watching 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).
NOTICE!
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 addi-
tional 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 refrigerant con-
tainer should be about 1/3 filled with liquid refrigerant, the evapo-
rator should be maximally filled at the calculated evaporation tem-
perature, i.e. the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the pressure gauge.
White frost on the suction line is no measure for

assessing the filling.

Fig. 354
Pos Designation Pos Designation

1 High pressure - gaseous 13 Manual shut-off valve (not used)
2 High pressure - liquid 14 Pressure switch with high and low pressure contacts
3 Low pressure - gaseous 15 Defroster thermostat
4 Compressor 16 Vacuum meter
5 Compressor pressure switch (not used) 17 Low pressure gauge
6 not used 18 High pressure gauge
7 Evaporator 19 Pressure reducing valve
8 Expansion valve 20 Vacuum pump
9 Inspection glass 21 Nitrogen bottle
10 Filter drier 22 Refrigerant bottle


11 Collecting container 23 Pressure gauge bar
12 Capacitor
Filling instructions
1 Connect the service adapter with the blue hand wheel in the
suction side.
2 Connect the service adapter with the red hand wheel in the
pressure side (the hand wheels on the service adapters must
be fully backed out - left hand stop)
3 Connect the blue suction hose below the blue hand wheel on
the pressure gauge bar to the blue service adapter.
4 Connect the red pressure hose below the red hand wheel on
the pressure gauge bar to the red service adapter.
5 Connect the yellow hose below the yellow hand wheel on the
manometer bar to the 2-stage vacuum pump.
6 Connect the last hose below the black hand wheel on the
nitrogen bottle via the pressure reducing valve.
7 Check on the pressure gauge bar that all hand wheels are
closed.
8 Turn the hand wheels on both service adapter clockwise. This
opens the valves (right hand stop).
9 Open the valve on the nitrogen bottle (only via pressure
reducer); pressure approx. 20 bar.
10 Open the black and red hand wheels on the pressure gauge
bar and fill nitrogen into the system, until a pressure of approx.
3.5 to 5.0 bar is indicated on the suction side.
11 Then open the blue hand wheel and raise the pressure in the
suction side (max. 10 bar). Check for leaks with a leak detec-
tion 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 pressure 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.
17 Open the valve on the refrigerant bottle and open the black and
red hand wheels on the pressure gauge bar. Fill refrigerant into
the system, until a pressure equilibrium between suction and
pressure side is reached (reading of pressure gauges).
18 Close the red hand wheel.
19 Perform a leak test with the electronic leak detector.
20 Start the engine and switch on the system.

21 Open the blue hand wheel and continue filling in refrigerant

until the inspection glass is free or air bubbles (in fluid con-
tainer/dryer combinations the white pearl should float in the
upper third of the inspection glass). Then close the refrigerant
bottle.
22 Close the blue hand wheel on the pressure gauge bar.
23 Preparing the test run: -Close windows and doors -Fan on full
speed stage -Mount measuring feelers to air discharge and air
intake.
24 Run the system for approx. 20 minutes with medium engine
speed.
25 The temperature difference between air discharge and air
intake should be (depending on type of air condition) 8-10°C.
Ambient temperature in this case approx. 20 °C. (These data
are only reference values, which may be influenced by possible
insolation)
26 Switch off system and engine and check for leaks again.
27 Turn out (left hand stop) and remove the hand wheels on both
service adapters.
28 Fit all valves with dust caps.
29 Perform a leak test.
30 Mark the system with the corresponding type plates and infor-
mation decals, such as type of oil and refrigerant.

Air conditioning – Steam table for R134a
7.12 Steam table for R134a

Tempera- Pressure Density spec. volume spec. enthalpy Evapora-
ture tion heat
of the of the of the of the of the of the
fluid steam fluid steam fluid steam
t p p' p'' v' v'' h' h'' r
°C bar kg/dm3 kg/dm3 dm3/kg dm3/kg kJ/kg kJ/kg kJ/kg
-60 0.16 1.469 0.92 0.681 1082.6 123.17 359.85 236.68
-55 0.22 1.456 1.24 0.687 803.83 129.49 362.99 233.5
-50 0.29 1.443 1.65 0.693 606.45 135.75 366.14 230.39
-45 0.39 1.429 2.15 0.7 464.29 141.98 369.28 227.3
-40 0.51 1.415 2.78 0.707 360.3 148.21 372.41 224.19
-35 0.66 1.401 3.53 0.714 283.08 154.47 375.52 221.05
-30 0.84 1.387 4.45 0.721 224.97 160.78 378.61 217.84
-25 1.06 1.373 5.53 0.728 180.67 167.14 381.68 214.55
-24 1.11 1.37 5.78 0.73 173.12 168.42 382.29 213.88
-23 1.16 1.367 6.03 0.732 165.95 169.7 382.9 213.2
-22 1.22 1.364 6.28 0.733 159.14 170.98 383.51 212.53
-21 1.27 1.361 6.55 0.735 152.66 172.27 384.12 211.85
-20 1.33 1.358 6.83 0.736 146.5 173.56 384.72 211.16
-19 1.39 1.355 7.11 0.738 140.64 174.86 385.33 210.47
-18 1.45 1.352 7.4 0.74 135.06 176.15 385.93 209.78
-17 1.51 1.349 7.71 0.741 129.75 177.45 386.53 209.08
-16 1.57 1.346 8.02 0.743 124.68 178.75 387.13 208.38
-15 1.64 1.343 8.34 0.745 119.86 180.06 387.73 207.67
-14 1.71 1.34 8.68 0.746 115.26 181.37 388.33 206.96
-13 1.78 1.337 9.02 0.748 110.87 182.68 388.93 206.25
-12 1.85 1.334 9.37 0.75 106.68 183.99 389.52 205.53
-11 1.93 1.331 9.74 0.752 102.68 185.31 390.11 204.8
-10 2.01 1.328 10.12 0.753 98.86 186.63 390.71 204.07
-9 2.09 1.324 10.5 0.755 95.21 187.96 391.3 203.34
-8 2.17 1.321 10.9 0.757 91.73 189.28 391.88 202.6
-7 2.26 1.318 11.31 0.759 88.39 190.61 392.47 201.86
-6 2.34 1.315 11.74 0.76 85.21 191.94 393.06 201.11
-5 2.43 1.312 12.17 0.762 82.16 193.28 393.64 200.36
-4 2.53 1.309 12.62 0.764 79.24 194.62 394.22 199.6


ture tion heat
t p p' p'' v' v'' h' h'' r
-3 2.62 1.305 13.08 0.766 76.44 195.96 394.8 198.84
-2 2.72 1.302 13.56 0.768 73.77 197.3 395.38 198.08
-1 2.82 1.299 14.04 0.77 71.2 198.65 395.96 197.31
0 2.93 1.296 14.55 0.772 68.75 200 396.53 196.53
28 7.27 1.196 35.66 0.836 28.04 238.96 411.71 172.75
29 7.48 1.192 36.73 0.839 27.22 240.4 412.21 171.81
30 7.7 1.189 37.83 0.841 26.44 241.83 412.71 170.87
31 7.93 1.185 38.95 0.844 25.67 243.28 413.2 169.92
32 8.16 1.181 40.1 0.847 24.94 244.72 413.69 168.97
33 8.39 1.177 41.28 0.85 24.22 246.17 414.18 168
34 8.63 1.173 42.49 0.853 23.53 247.63 414.66 167.03
35 8.87 1.169 43.74 0.856 22.86 249.08 415.14 166.05
36 9.12 1.164 45.01 0.859 22.22 250.55 415.61 165.07
37 9.37 1.16 46.31 0.862 21.59 252.01 416.08 164.07
38 9.63 1.156 47.65 0.865 20.99 253.48 416.55 163.07
39 9.9 1.152 49.02 0.868 20.4 254.96 417.01 162.05
40 10.17 1.148 50.43 0.871 19.83 256.44 417.47 161.03
41 10.44 1.143 51.87 0.875 19.28 257.92 417.92 160
42 10.72 1.139 53.35 0.878 18.74 259.41 418.37 158.96
43 11.01 1.135 54.87 0.881 18.23 260.9 418.81 157.9
44 11.3 1.13 56.42 0.885 17.72 262.4 419.24 156.84
45 11.6 1.126 58.02 0.888 17.24 263.91 419.68 155.77
46 11.9 1.121 59.65 0.892 16.76 265.42 420.1 154.68
47 12.21 1.117 61.33 0.895 16.3 266.94 420.52 153.58
48 12.53 1.112 63.06 0.899 15.86 268.46 420.93 152.47
49 12.85 1.108 64.82 0.903 15.43 269.99 421.34 151.35
50 13.18 1.103 66.64 0.907 15.01 271.53 421.74 150.21
51 13.51 1.098 68.5 0.91 14.6 273.07 422.14 149.06
52 13.85 1.094 70.41 0.914 14.2 274.62 422.52 147.9
53 14.2 1.089 72.38 0.919 13.82 276.18 422.9 146.72


ture tion heat
t p p' p'' v' v'' h' h'' r
54 14.55 1.084 74.39 0.923 13.44 277.75 423.28 145.53
55 14.91 1.079 76.47 0.927 13.08 279.32 423.64 144.32
56 15.28 1.074 78.59 0.931 12.72 280.91 424 143.09
57 15.66 1.069 80.78 0.936 12.38 282.5 424.35 141.85
58 16.04 1.064 83.03 0.94 12.04 284.1 424.69 140.58
59 16.42 1.059 85.34 0.945 11.72 285.71 425.02 139.3
60 16.82 1.053 87.72 0.949 11.4 287.34 425.34 138
61 17.22 1.048 90.16 0.954 11.09 288.97 425.65 136.68
62 17.63 1.043 92.68 0.959 10.79 290.61 425.95 135.34
63 18.04 1.037 95.27 0.964 10.5 292.26 426.24 133.97
64 18.47 1.032 97.94 0.969 10.21 293.93 426.51 132.58
65 18.9 1.026 100.69 0.975 9.93 295.61 426.78 131.17
66 19.34 1.02 103.53 0.98 9.66 297.3 427.03 129.74
67 19.78 1.014 106.45 0.986 9.39 299 427.27 128.27
68 20.24 1.009 109.46 0.992 9.14 300.72 427.5 126.78
69 20.7 1.003 112.58 0.997 8.88 302.45 427.71 125.26
70 21.17 0.996 115.79 1.004 8.64 304.19 427.9 123.71
71 21.65 0.99 119.11 1.01 8.4 305.95 428.08 122.13
72 22.14 0.984 122.55 1.016 8.16 307.73 428.25 120.52
73 22.63 0.977 126.11 1.023 7.93 309.52 428.39 118.87
74 23.13 0.971 129.79 1.03 7.7 311.33 428.51 117.19
75 23.65 0.964 133.6 1.037 7.48 313.15 428.62 115.46
76 24.17 0.957 137.56 1.045 7.27 315 428.7 113.7
77 24.7 0.95 141.67 1.052 7.06 316.86 428.76 111.9
78 25.23 0.943 145.95 1.06 6.85 318.74 428.79 110.05
79 25.78 0.936 150.4 1.069 6.65 320.64 428.8 108.15
80 26.34 0.928 155.03 1.078 6.45 322.57 428.77 106.21
81 26.9 0.92 159.87 1.087 6.26 324.51 428.72 104.21
82 27.48 0.912 164.92 1.096 6.06 326.48 428.63 102.15
83 28.06 0.904 170.22 1.106 5.87 328.47 428.5 100.04


ture tion heat
t p p' p'' v' v'' h' h'' r
84 28.66 0.895 175.77 1.117 5.69 330.48 428.34 97.86
85 29.26 0.887 181.6 1.128 5.51 332.52 428.12 95.61
86 29.88 0.878 187.75 1.14 5.33 334.58 427.86 93.29
87 30.51 0.868 194.25 1.152 5.15 336.67 427.55 90.88
88 31.14 0.858 201.14 1.165 4.97 338.78 427.17 88.39
89 31.79 0.848 208.48 1.179 4.8 340.92 426.72 85.8
90 32.45 0.837 216.31 1.195 4.62 343.09 426.2 83.1
91 33.12 0.826 224.73 1.211 4.45 345.29 425.58 80.29
92 33.8 0.813 233.84 1.229 4.28 347.53 424.86 77.33
93 34.49 0.801 243.77 1.249 4.1 349.79 424 74.21
94 35.19 0.787 254.71 1.271 3.93 352.08 422.99 70.91
95 35.91 0.771 266.92 1.296 3.75 354.41 421.78 67.37
96 36.64 0.755 280.84 1.325 3.56 356.77 420.3 63.53
97 37.39 0.736 297.17 1.359 3.37 359.17 418.44 59.27
98 38.14 0.714 317.43 1.4 3.15 361.6 415.97 54.37
99 38.92 0.687 346.24 1.455 2.89 364.07 412.16 48.09
100 39.71 0.65 636.32 1.537 1.57 366.58 375.04 8.46
101.06 40.56 0.515 515.3 1.941 1.94 390.05 390.05 0

Air conditioning – Inspection and maintenance work


7.13.2.1 Service the V-belt for the refrigerant compressor 388
7.13.3.1 Servicing the air conditioning systemoptional equipment 389
As required
7.13.4.1 Checking the compressor oil level / refrigeration oil level 393

7.13.2.1 Service the V-belt for the refrigerant compressor
WARNING!
Danger of injury!
Work on the belt drive must only be performed with
the engine shut down.
NOTICE!
Replace a damaged or cracked V-belt.
1. Shut down the engine, pull off the ignition key

2. Open the engine hood.
Check the V-belt

1. Inspect the entire circumference of the V-belt Ä Fig. 355 vis-
ually for damage and cracks. Replace damaged or cracked
V-belts.
2. Check with thumb pressure whether the V-belt can be
depressed more than 10 to 15 mm (0.4 – 0.6 inches)
between the V-belt pulleys, retighten if necessary.
Fig. 355

Tightening the V-belt

1. Slightly slacken the fastening screws.
2. Set the correct V-belt tension by swivelling the air condi-
tioning compressor.
3. Retighten the fastening screws.
Fig. 356
Replace the V-belt

1. Slightly slacken the fastening screws.
2. Press the compressor completely against the engine.
3. Remove the old V-belt.
4. Fit the new V-belt to the V-belt pulleys.
5. Tension the V-belt as previously described.
NOTICE!
Fig. 357 Check the V-belt tension after a running time of 30
minutes.

7.13.3.1 Servicing the air conditioning systemoptional equipment
Clean the condenser
WARNING!
Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause damage
or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.

NOTICE!
A soiled condenser results in a considerable
reduction of air conditioning power.
Under extremely dusty conditions it may be neces-
sary to clean the condenser several times per day.
If, during operation of the air conditioning system,
the warning buzzer sounds switch the air condi-
tioning off and clean the condenser.
In case of formation of foam have the air condi-
tioning system inspected by the service depart-
ment.
1. Unscrew the condenser fastening screws Ä Fig. 358 and

fold the condenser forward.
Fig. 358
1. Clean the condenser fins on front and back with compressed

air or cold water .
Checking the refrigerant level

2. Turn the rotary switch for the cabin fan to position "1".
Fig. 359

3. Choose a cooling temperature with the rotary switch for the

air conditioning system in the blue section.
4. Open the air outlet nozzles.
The adjusted temperature must be below the

actual temperature inside the cabin, so that the
compressor will be switched on.
5. Check, whether the out flowing air is noticeably cooler.
Fig. 360
6. Check whether the white float inside the inspection glass of

the drier/collector unit floats right at the top.
ð The refrigerant level is correct.
Fig. 361
7. If the white float inside the inspection glass of the drier/

collector unit floats at the bottom, inform the service depart-
ment.
ð The refrigerant level is not correct.
8. Refrigerant must be filled up, if necessary check the air con-
ditioning system for leaks.
Fig. 362
Checking the moisture level of the

drying agent
1. Check the moisture indication pearl Ä Fig. 363 inside the
inspection glass of the drier/collector unit.
orange Drying agent o.k.

colourless moisture level of drying agent too
high.
Fig. 363

1. Inform the service department. Replace drier/collector unit,

check air conditioning system.
NOTICE!
Have the drier/collector unit replaced by the
service department every year before the oper-
ating season.
Checking the condition of the drier/

collector unit NOTICE!
According to the regulation for pressure reservoirs
all pressure reservoirs must be repeatedly
inspected by a specialist. In this sense repeated
inspections are external examinations, normally on
pressure reservoirs in operation. In connection with
this inspection the drier/collector unit must be visu-
ally examined twice every year. During these
inspections special attention must be paid to corro-
sion and mechanical damage. If the reservoir is not
in proper condition it must be replaced for safety
reasons, as a precaution to protect operators and
third parties against any danger arising from the
handling and operation of pressure reservoirs.
WARNING!
Danger of injury!
In case of mechanical damage or corrosion on this
drier/collector unit this unit must be replaced, to
avoid bursting and further damage.
1. Check the drier/collector unit Ä Fig. 364 for mechanical

damage or rust.
Fig. 364

7.13.4 As required
7.13.4.1 Checking the compressor oil level / refrigeration oil level
NOTICE!
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only compressor oil /
refrigeration oil PAG SP-20 (H14-003-404).
1. Run the compressor for 10 minutes at engine idle speed.

2. remove the refrigerant from the air conditioning system.
3. Turn the compressor, as shown in Ä Fig. 365, if necessary
remove V-belt and hoses.
4. Remove the oil plug (the oil level must reach the bottom edge
of the bore, top up or drain off oil if necessary).
5. Turn the oil plug back in (tightening torque 15 to 25 Nm).
6. Refill the air conditioning system.
Fig. 365


Oscillating articulated joint
8 Oscillating articulated joint

Oscillating articulated joint – Overview oscillating articulated joint
8.1 Overview oscillating articulated joint

1 Housing
2 Seal ring
3 Cover
4 Rocker bearing
5 Bolt
6 Shim/supporting disc
7 Belleville springs
8 Rocker bearing
9 Console
10 Belleville springs
11 Shim/supporting disc
12 Cover
13 Cover
14 Intermediate ring
15 Rocker bearing
16 Intermediate ring
17 Rocker bearing
18 Carrier
19 Friction bearing
20 V-ring
21 Seal ring


Drum
9 Drum

Drum – Overview drum
9.1 Overview drum
Fig. 366
1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel motor
5 Drum shell
6 Rubber buffer
8 Travel bearings

Fig. 367: Repair overview for drum

NOTICE!
Notes on repair
– 1
Install the O-ring with some grease.
– 2
Fitting and contact surface of the connection
must be absolutely dry and free of grease, oil,
paint and conserving agent.
– 3
Grease radial seals + running surface on shaft
before assembling.
– 4
Install the dowel pins with the grooves offset by
180° to each other, but in line with the axis of
the shaft.
– 5
The thread must be free of grease, oil, paint
and conserving agents.
– 6
Wet the elastomer part + bore in flanged hub
with spirit (no oil) to ease assembly of the
mechanical seal.
– Clean the sliding surfaces on the seal and
apply a thin film of oil.
– During assembly fill the cavity up to 1/3 with
grease.
– 7
Fill the bearing completely with grease.
– Bearing space to 1/3 filled with grease.
– 8
Ventilation bore in cover pointing down.
– 9
Check the end float of the shaft: Nominal
value 0.6 to 1.8 mm.

Drum – Inspection and maintenance work


9.2.2.1 Checking the oil level in the exciter housing 403
9.2.3.1 Change the oil in the exciter housing 404
As required
9.2.4.1 Retightening the padfoot shell 405
9.2.4.2 Adjust the scrapers 406

9.2.2.1 Checking the oil level in the exciter housing
NOTICE!
– Use only gear oil of the permitted specification
Ä Chapter 1.3.1.6 „Gear oil SAE
75W-90“ on page 34.

n Protective gloves
1. Before checking the oil level, run the machine warm with
vibration for about 1/2 hour.
2. Move the drum, until the oil level inspection plug is in bottom
position.
4. Clean the area around the level inspection plug and unscrew
the plug.
ð The oil level must reach the bottom edge of the level
bore.
Fig. 368

5. Clean the area around the filler plug and unscrew the filler
plug.
6. Fill in oil through the filler bore, until it starts to run out
through the level inspection bore.
8. Retighten the filler and level inspection plugs.

9. Repeat this inspection on the other side.
10. If a loss of oil is found, perform trouble shooting, repair the
drum if necessary.
Fig. 369

9.2.3.1 Change the oil in the exciter housing
NOTICE!
– Drain gear oil only at operating temperature.
75W-90“ on page 34.
– Filling quantity: Ä Chapter 1.4 „List of fuels and
lubricants“ on page 35.

one year.

n Protective gloves
1. Before changing the oil level run the machine warm for about
1/2 hour with vibration.
2. Move the drum, until the drain plug is in bottom position.
4. Clean the area around the drain plug.
WARNING!
Danger of burning on hot components!
Fig. 370 – Avoid touching hot components.
5. Unscrew the drain plug and catch any oil running out.
6. Turn the drain plug tightly back in.

7. Clean the area around the oil level inspection plug.

8. Unscrew the oil level inspection plug.
Fig. 371
9. Unscrew the oil filler plug and fill in new oil through the oil
filler bore, until oil starts to drip out through the inspection
bore.
10. Retighten the filler and level inspection plugs.
11. Change the oil on both sides.
12. Dispose of oil in an environmentally friendly way.
Fig. 372
9.2.4 As required
9.2.4.1 Retightening the padfoot shell
After the installation of the padfoot shell, all fastening screws must
be retightened.
1. Run an approx. two minute test drive with vibration.
3. Retighten all fastening screws.
4. After approx. 60 minutes work retighten all fastening screws
again.
Fig. 373

9.2.4.2 Adjust the scrapers

1. Check adjustment and condition of front and rear scrapers, if
necessary adjust or replace the scraper rubber.
2. In order to adjust the scrapers, slacken the fastening screws
(1) in the slots and push the scraper towards the drum to
contact.
3. Fasten the fastening screws again.
Fig. 374
1. Check adjustment and condition of scrapers, adjust or

replace the teeth if necessary.
2. To adjust the scrapers slacken the clamping screws and push
the scrapers towards the drum, leaving a gap of about
25 mm.
3. Retighten the clamping screws.
Fig. 375

Drive axle
10 Drive axle

Drive axle – Drive axle
10.1 Drive axle

10.2.1 Checking wheels and tyres 409
10.3.1 Checking the oil level in the drive axle 410
10.3.2 Checking the oil level in the wheel hubs 410
10.4.1 Change the oil in the drive axle 412
10.4.2 Changing the oil in the wheel hubs 413
10.4.3 Retightening the fastening of the axle on the frame 414
10.4.4 Retightening the wheel nuts 414
As required
10.5.1 Adjust the parking brake 415

Drive axle – Checks prior to start up
10.2 Checks prior to start up

10.2.1 Checking wheels and tyres
WARNING!
Danger of being injured by bursting tyres!
– Wear your personal protective equipment
(safety shoes, gloves, goggles, hard hat).
– When checking the tyre pressure stand in the
extended path of the tyre track.
– Use an air hose with a length of min. 6 meters.
– Never exceed the permitted maximum pres-
sure.
The tire pressure can be adapted to the operating

conditions within the specified limits.
A reduced tire pressure improves the traction
especially on sandy soils.
Higher tires pressures improve the driving stability
of the machine.
The total height of the machine can also be influ-
enced by changing the tire pressure.
Protective equipment: n Safety shoes

n Protective gloves
n Safety goggles
n Hard hat
1. Move the machine until the tire inflation valve (1) is in top
position.
3. Check the tyres for cuts, bulges, damaged rims, missing
wheel studs or nuts.
4. Have damaged wheels or tyres replaced immediately.
5. Unscrew the valve caps and check the front and rear tire
pressure, correct if necessary.
Fig. 376 Ensure equal pressure in all tires.
Tire pressure, nominal value Ä Chapter 3

„Technical data“ on page 43
6. Screw the valve caps back on again.

Drive axle – Every 250 operating hours
10.3 Every 250 operating hours

10.3.1 Checking the oil level in the drive axle
NOTICE!
80W-140“ on page 33.

n Protective gloves
2. Clean the area around the level inspection plug (1) and
unscrew the plug.
ð The oil level must reach the bottom edge of the level
bore.
A second inspection plug is located on

the left front side of the drive axle.
3. If necessary clean the area around the filler plug (2) and
unscrew the filler plug.
Fig. 377
5. After filling in oil wait until the oil has evenly distributed inside
the axle.
6. Retighten level inspection and filler plugs.
10.3.2 Checking the oil level in the wheel hubs
NOTICE!
80W-140“ on page 33.


n Protective gloves
1. Move the machine until the oil level inspection plug is in hori-
zontal position.
3. Clean the area around the level inspection plug and unscrew
the plug.
4. The oil level must reach the bottom edge of the bore, top up
oil if necessary.
5. Turn the level inspection plug tightly back in.
Fig. 378 6. Change the oil in both wheel hubs.

10.4 Every 1000 operating hours

10.4.1 Change the oil in the drive axle
NOTICE!
80W-140“ on page 33.

one year.

n Protective gloves
2. Clean the area around the drain plug.
WARNING!
– Avoid touching hot components.
3. Unscrew the drain plug and catch any oil running out.
Fig. 379 4. Turn the drain plug tightly back in.
5. Clean the area around the filler plug (2) and the level inspec-
tion plug (1).
6. Unscrew the oil level inspection plug.
A second inspection plug is located on the

left front side of the drive axle.
7. Unscrew the filler plug.

Fig. 380 through the level inspection bore.
9. After filling in oil wait until the oil has evenly distributed inside
the axle, if necessary fill in some more oil.
10. Retighten level inspection and filler plugs.

10.4.2 Changing the oil in the wheel hubs
NOTICE!
80W-140“ on page 33.

one year.

n Protective gloves
1. Move the drum, until the oil level inspection plug is in bottom
position.
3. Clean the area around the oil level inspection plug.
WARNING!
Fig. 381
– Avoid touching hot components.
4. Unscrew the level inspection plug and catch any oil running
out.
5. Move the drive wheel, until the oil level inspection plug is in
horizontal position.
6. Fill in oil through the inspection bore, until it starts to run out
7. Turn the level inspection plug tightly back in.
8. Change the oil in both wheel hubs.
Fig. 382

10.4.3 Retightening the fastening of the axle on the frame

n Protective gloves
1. Check all fastening nuts on axle mounting bolts for tight fit,
retighten if necessary, tightening torque: 710 Nm (524 ft·lbs).
Fig. 383
10.4.4 Retightening the wheel nuts

n Protective gloves
1. Tighten the wheel nuts cross-wise, tightening torque: 550 Nm
(405 ft·lbs).
Fig. 384

Drive axle – As required
10.5 As required
10.5.1 Adjust the parking brake
NOTICE!
Have adjustment work on the brakes only carried
out by a specialist! Always adjust both sides.
1. Secure the machine with wheel chocks against rolling.

2. Start the diesel engine to relieve the brake.
1. Disengage the travel lever Ä Fig. 385 to the left, but do not
move to position "I" or "II".
The parking brake is released
Fig. 385
1. Unscrew locking plate 2 Ä Fig. 386.

2. Turn the square (1) in anti-clockwise direction against the
stop.
Fig. 386
1. In order to adjust the brake clearance turn the square 1

Ä Fig. 387 three turns back in clockwise direction.
2. Fasten the locking plate again.
3. Pull the plug off the brake solenoid valve and perform the
drive test.
The machine must be braked.
Fig. 387

Drive axle – As required

Troubleshooting
11 Troubleshooting

Troubleshooting – Preliminary remarks
11.1 Preliminary remarks

Malfunctions are frequently caused by incorrect operation of the
machine or insufficient maintenance. Whenever a fault occurs you
should therefore thoroughly read these instructions on correct
operation and maintenance.
If you cannot locate the cause of a fault or rectify it yourself by fol-
lowing the trouble shooting chart, you should contact our customer
service department.

Troubleshooting – Emergency procedures
11.2 Emergency procedures

11.2.1 Actuating the emergency stop switch
1. In events of emergency and in case of danger actuate the
emergency stop switch immediately.
ð The engine is shut down and the parking brake is closed.
Fig. 388
11.2.2 Disconnecting the battery

1. In events of emergency, e.g. in case of a cable fire, discon-
nect the battery from the vehicle network. For this purpose
turn the main battery switch counter-clockwise and pull it out
or pull the battery terminal off the battery.
Fig. 389
11.2.3 Towing in case of an engine failure
WARNING!
Danger of accident! Danger of injury!
Apply appropriate measures (e.g. with metal wheel
chocks, to be provided by the operating company)
to secure the machine against rolling away before
releasing the parking brake.
When using towing ropes tow the machine only
uphill.
When towing downhill you must use a tow bar.
The machine cannot be steered.
Use a towing vehicle with sufficient traction and
braking power for the unbraked towed load.
Do not touch hot engine parts.

NOTICE!
Tow the machine only after having released the
parking brake.
Towing speed 1 km/h, max. towing distance 500 m.
1. Secure the machine with wheel chocks against unintentional

rolling.
2. Attach chains or towing ropes securely to the towing points.
3. Open the engine compartment hood and secure it.
Fig. 390
Travel pump
4.
NOTICE!
Do not turn the valves out completely!
Slacken the middle hexagon on both valves for approx. 2 to 3

turns.
Fig. 391
Drive axle
5. To release the brake turn counter nuts (1) approx. 8 mm
back.
6.
NOTICE!
From this stop turn the screw in for maximum
another turn to release the brake!
Turn the screws in evenly on both sides.
Turn the brake releasing screws (2) in alternately for ¼ turn

Fig. 392 at a time.
7. Repeat this measure on the opposite wheel side.

After towing
NOTICE!
Apply appropriate measures (e.g. with metal wheel
chocks) to secure the machine against rolling away
before disconnecting the tow bar.
1. Turn the high pressure relief valve cartridges tightly back in.
2. Turn all brake releasing screws of the axle evenly back out,
until they are light moving again.
3. Turn the brake releasing screws back in again, until they abut
against the brake piston.
Fig. 393
4. Unscrew the brake releasing screws for two turns and tighten
the counter nuts.
5. Repeat this adjustment procedure on the opposite wheel
side.
If necessary replace the sealing ring under

the counter nut if it is leaking.
For this purpose completely unscrew the
brake releasing screw, replace the seal ring
and lubricate the screw with silicone grease.
Fig. 394
Reinstall the screw with a new seal ring and
adjust the protrusion as described above.

Troubleshooting – Troubleshooting, electrical systems
11.3 Troubleshooting, electrical systems
11.3.1 Preliminary remarks

Malfunctions are frequently caused by incorrect operation of the
machine or insufficient maintenance. Whenever a fault occurs you
should therefore thoroughly read these instructions on correct
operation and maintenance.
If you cannot locate the cause of a fault or rectify it yourself by fol-
lowing the trouble shooting chart, you should contact our customer
service department.
Due to the fast technical development electric and electronic

vehicle systems become more intelligent and more comprehensive
day by day, and can hardly be dispensed with in hydraulic and
mechanical vehicle systems.
Diagnostics according to plan
Well structured trouble shooting procedures can save time and
money.
Random tests have revealed that purely electronic components or
control units only very rarely are the actual cause of failures:
n In approx. 10 % of the examined cases the problems were
caused by control units.
n In approx. 15 % sensors and actuators were the cause of the
problems.
By far the highest proportion of all faults could be traced back to
wiring and connections (plugs, etc.).
General:
Before changing any expensive components, such as control units,
you should run a systematic trouble shooting session to eliminate
any other possible fault sources. Knowledge in basic electrics is
required for this purpose. If a fault was diagnosed without having
pulled the plug of the control unit or inspected the wiring, this
should be done before changing any parts.
Check for good cable and ground contacts, therefore keep all
mechanical transition points between electric conductors (termi-
nals, plugs) free of oxide and dirt, as far as this is possible.
Always use the machine related wiring diagram for testing. If one
or more faults were detected, these should be corrected immedi-
ately.
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 after the battery has been removed.

Sensors and electric actuators on control units must never be con-

nected individually or between external power sources for the pur-
pose of testing, but only in connection with the control unit in ques-
tion.
It is not permitted to pull plugs off while the voltage supply is
switched on (terminal 15 "ON")! Switch the voltage supply "OFF"
first and pull out the plug.
Even with an existing polarity reversal protection incorrect polarity
must be strictly avoided. Incorrect polarity can cause damage to
control units!
Plug-in connectors on control units are only dust and water tight if
the mating connector is plugged on! Control units must be pro-
tected against spray water, until the mating connector is finally
plugged on!
Unauthorized opening of control electronics (Microcontroller MC),
modifications or repairs in the wiring can cause severe malfunc-
tions.
Do not use any radio equipment or mobile phones in the vehicle
cab without a proper aerial or in the vicinity of the control elec-
tronics!
Switches, plugs, wiring looms Over the years corrosion and contamination can create high con-
tact resistances in plugs and switches, wiring looms affected by
“copper worm” (corrosion) are poor conductors. In extreme inci-
dents such a component will be absolutely dead, while minor
damage more or less reduces the performance of the affected con-
sumers to a noticeable extent.
In many cases it is enough to examine the components visually:
Green male connectors of plugs, neglected switch contacts must
be mechanically cleaned and reassembled with some contact
spray. Cables core showing green discolouration must be replaced.
A resistance measurement provides exact information about the
conductivity.
Leakage currents The machine has not been driven for a few days, and the battery is
almost empty? This may be caused by a “surreptitious consumer”
in the electrical network of the machine, of a leakage current
simply “draws” your battery empty. Such a leakage current can be
caused by e.g. the ignition lock, a defect switch, a relay or a
clamped or chafed cable.
A leakage current can be located by a amperage

measurement with a multimeter.
Measuring fault Whenever the electrical system of the vehicle behaves in an unex-
pected way, one should first consider that there may be a ground
problem! The older the electrical system and the lower the voltage,
the more likely this will be the cause.

As we all know, being able to utilize electric current requires the

existence of a closed electric circuit, the electrons leaving the bat-
tery must be able to return to the battery. In vehicles numerous
existing metal parts can be used for this purpose. The negative
pole of the battery is connected with the metal of the frame. The
current then flows through an insulated cable to e.g. a lamp should
light, and instead of a return line, the socket of the lamp is also, in
some way, connected to the frame, through which the current can
flow back to the battery. However, should the connection between
lamp and frame corrode causing a high electrical resistance at that
point, the current will try to find a different way. If no other way can
be found, the component will simply not work, even if the meter
shows that voltage arrives. Very often the current finds a different
way back to the battery, sometimes through other consumers.
Measuring sensors and actuators

Sensor signals are best checked where they are
needed, i.e. on the control unit. If the correct signal
is received you can be sure that not only the
sensor, but also the wiring to the control unit is in
good working order.
It is a common procedure to pick up the signals
with a break-out-box, the Y-cable of which is fas-
tened between control unit and control unit plug. If
no break-out-box is available, the measurement
takes place directly on the sensor, or one must try
to gain access to the back of the plug.
Trouble shooting procedure:

n First check the corresponding actuator, in case of a faulty
signal the output signal must be checked directly on the control
unit.
n If the output signal is correct, check the wiring to the actuator.
n In case of an incorrect output signal, check the corresponding
input signals after.
n In case of incorrect input signals check the signal on the
sensor itself.
n If the sensor signal is correct, check the wiring to the control
unit for continuity and against ground (short circuit).
n If the sensor delivers a correct signal, the sensor itself may be
the cause of the problem, or the sensor may be affected by
other incorrectly working components.
n However, the voltage supply and the ground connection of the
control unit as well as the power supply for sensors and actua-
tors must also be checked. Because an incorrect voltage value
can distort the input and output signals.
n If the action steps described above do not deliver a result, the
periphery is OK and the fault must be in the control unit, but be
cautious, most faults are caused by poor contacts in the plug
connections.
If the battery is empty If the battery is empty, the fault is normally quite quickly identified.

There are the following possibilities:

n because it is no longer charged by the generator
n because one of the consumers (light, radio, etc.) has not been
switched off
n because a hidden consumer “surreptitiously” empties the bat-
tery
n because the battery is defective
n generator or regulator are defective
n wiring between generator, starter and battery in poor condition
Check and measure the charge

system for faults It makes sense to be familiar with the working prin-
ciple of the charge system.
Necessary if:
n the battery is permanently discharged
n the battery has boiled over and acid has escaped
n the headlights light considerably brighter when accelerating
n light bulbs burn out frequently at irregular intervals
11.3.2 Starting the engine with jump leads
NOTICE!
battery.
NOTICE!
Fig. 395

tive poles after.

11.3.3 Fuse assignment

11.3.3.1 Notes on safety
WARNING!
Danger of injury by fire in the machine!
– Do not use fuses with higher ampere ratings
and do not bridge fuses.
11.3.3.2 Central electrics

n Fuses in electric junction box
WARNING!
Fire hazard!
Do not use fuses with higher ampere ratings and
do not bridge fuses.
(15) 30A (F13) Start switch

Fig. 396
(16) 5A (F68) Electronic immobilizer
(17) 20A (F105) Engine speed
(18) 15A (F11) Front head lightsOptional equipment
(19) 15A (F07) Hazard light
(23) 15A (F09) Parking and tail light, left*
(24) 15A (F10) Parking and tail light, right*
(25) 15A (F08) Direction indicators*
(26) 10A (F18) Pre-fuse for working head lights
(27) 15A (F14) Engine solenoid
(28) 10A (F23) Warning horn
(29) 10A (F25) solenoid valve for driving and
braking
(30) 15A (F39) Main fuse for cabin
(31) 10A (F24) Instruments

(32) 15A (F03) Vibration

(34) 10A (F84) control, contact 54
(37) 25A (F124) Fuel pre-heating*
(80) 5A (F150) GPS Receiver*
Fig. 397
11.3.3.3 Main fuses

n Fuses battery
125A (F00) Main fuse

125A (F48) Fuse for pre-heating syste,
Fig. 398
11.3.3.4 Fuses, cabin
Fig. 399

1 F43 15 A Front windscreen wiper/washer
2 F44 15 A Rear windscreen wiper/washer
3 F130 10 A Night light


4 F31 25 A Cabin fan
5 F41 10 A Flashing beacon
6 F144 15 A 12-V socket
7 F143 15 A Rear windscreen heating
8 F42 10 A Cabin light
11.3.4 Understanding electric circuit diagrams

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

Structure of electric circuit diagram
n Table of contents, see section "Table of contents"
n Structuring symbol overview, see section "Structuring symbol
overview"
The structuring symbol overview is NOT present in

circuit diagrams, which are sorted by systems and
local identification!
n Sheets with illustration of function, see section"Sheets with

illustration of function"
n List of fuels and lubricants, see "List of fuels and lubricants"
n Terminal strip overview, see section "Terminal strip overview"
n Plug overview, see section "Plug overview"
n Pin overview, see section "Pin overview"

Cover sheet
Fig. 400: Example: Cover sheet

The cover sheet contains general information.

Table of contents
Fig. 401: Example: Table of contents

The table of contents lists the individual functions and informs
about where to find them in the electric circuit diagram (Blatt/
Page).
Overview of structural symbols

The structuring symbol overview is NOT present in
circuit diagrams, which are sorted by systems and
local identification!
The structural identification overview represents the structure of

the machine with respect to equipment, functions and installation
locations.
Structuring symbols are mainly abbreviations for machine parts/
machines, functions and installation locations, which were derived
from designations in English.

Fig. 402: Example: MPH122-2
Fig. 403: Example: MPH122-2

1 Identification of structure, example EBOX

Sheets with representations of n The main reading direction is sheet by sheet, from top to
functions bottom and from left to right.
n All sheets are successively numbered.
n BOMAG used the resolved type of representation. In this case
parts and components with different functions, which belong to
the same components (e.g. relay coil and relay contact), can
be represented on different sheets. Cross-references, which
refer to the sheet and current path, serve as linkage between
these partial components.
Fig. 404: Example: Sheet with functions

1 Relay cross references serve the tracking of signals, which need to be tracked for components with out-
going contacts. A mimic diagram with information about the contact types of a relay and their positions in
the wiring diagram is additionally attached to the bottom of each contactor coil.
2 Structuring symbols
3 Potential cross references serve the purpose of tracking signals, which are transmitted from one repre-
sentation of a function to another. Potential cross-references may additionally have structuring symbols
assigned to them.
4 Mimic diagram of relay
5 Current paths are successively numbered from 0 to 9.
Example: Potential cross-reference (3) → 15_54 ∼ +SEAT/16.1 is
continued to the right to page 16, current path 1. +SEAT is the
structuring symbol.
Example: The relay cross-reference 8-K61/$.2) indicates that the
relay coil on page 4 is found in current path 2.

List of components
Fig. 405: Example: List of components

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

Component identifications are used in both the

electrical and the hydraulic documentation and are
identical.
Overview of terminal strips
Fig. 406: Example: Terminal strip overview X1

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

Overview of plugs
Fig. 407: Example: Plug overview X0

The overview of plugs contains all plugs used in the circuit dia-
gram.
The following information is listed for each plug:
n Contact numbering
n Structuring symbols
n Function text
n Use in wiring diagram.

Overview of pins
Fig. 408: Example: Overview of pins, control A66

The overview of pins informs about the type of inputs and outputs
of the electronic controls (E-BOX) used in the machine, as well as
their signals and potentials.
11.3.4.2 Circuit symbols in E-Plan

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

Fig. 409: For example: Circuit symbol

1 Current source
2 Conductor
3 Switches
4 Ground
5 Filament lamp
6 Filament lamp with two luminous elements
7 Voltmeter
8 Ammeter
9 Resistance
10 Fuse
11 Terminal strip
12 Plugs
Different symbols are used to simplify the differentiation of terminal
strips 11 Ä Fig. 409 and plugs (12) in a wiring diagram.
Plugs are mainly used to connect two wiring looms

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

Black-Box representation
Fig. 410: Example: Central lubrication system

The Black-Box representation shows the device as a Box with the
connections required for the machine function. Connections which
are not needed do not need to be represented.
The Blackbox representation is mainly used if there is no differenti-
ated information (e.g. signals from pins) available from the sub-
supplier.
Identification of externally supplied
documentation
Fig. 411: Example: Identification of externally supplied documenta-

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

PLC-Box representation (-A66)
Fig. 412: PLC representation

The PLC-Box representation of connecting pins uses a table with
associated connecting plugs, which are used in connection with the
machine functions. The table symbols can be arranged in a line, if
necessary. Connections which are not needed do not need to be
represented. The PLC-Box representation enables the representa-
tion of further reaching functional descriptions to the individual
component connections.
The PLC-Box representation is mainly used for controls with
BOMAG software, or for electronic devices which were specified
accordingly, and where information on the assignment of signals is
available.
Identification of similar, adjacent switching symbols
In wiring diagrams you will frequently find the situation that sym-
bols of the same type appear in a line or are arranged just next to
each other. In such cases it is common practice to reduce the iden-
tification on the subsequent symbol to the criteria, which are dif-
ferent to the previous symbol to the left.
Example: -X0 36 and -X0 37 In the example illustrated here the
component identification "-X0" for the left plug symbol is also valid
for the right plug symbol.

11.3.4.3 Identification of switch blocks

Switches of modular design
Fig. 413
F Direction
n For normally open contacts the contact symbols _3/_4 are
used.
n For normally closed contacts the contact symbols _1/_2 are
used.
In combination with the contact block numbering described above
each individual connection is clearly defined.
Example:
The contact block marked with 4 is called 43/44, if it is a normally
open contact and 41/42, if it is a normally closed contact.
open contact and 21/22 , if it is a normally closed contact.

11.3.5 Measuring method

Test lamp
NOTICE!
This type of tester must not be used for testing on
electronic components. The high power consump-
tion of the test lamp may destroy electronic compo-
nents in the control units.
Fig. 414: Test lamp
Diode test lamp

This instrument is used for simple voltage measurements. The test
lamp consists of two test points. The negative measuring cable is
connected to ground and the positive measuring cable to the corre-
sponding measuring location.
If voltage is present, the corresponding light emitting diode will light
up.
Fig. 415: Diode test lamp

Multimeter
This tester is a multimeter and can be used to measure e.g. cur-
rent, voltage and resistance. Furthermore, depending on the
design you must carry out transistor and frequency tests.
In order to avoid damage:
n the range selector switch must be correctly set for the corre-
sponding measurement.
n the test cable must be plugged into the correct socket.
n the voltage type (AC/DC) must be set.
n In case of direct voltage the correct polarity must be assured.
n the measuring range should be chosen higher at the beginning
Fig. 416: Multimeter of the test.
n In order to avoid any influence on the circuitry to be measured,
the internal resistance of the voltage tester should be as high
as possible.
Resistance and continuity measurement with multimeter

The continuity tester of the multimeter can be used to measure
whether there is a connection between 2 measuring points.
Fig. 417
The following information should be observed when measuring

resistance and continuity:
n The component to be measured must not be connected to the
power supply during the measurement.
n At least one side of the component to be measured must be
disconnected from the circuitry, as otherwise the measuring
result may be influenced by parallel components.
n Polarity is of no significance.
Fig. 418

Voltage and voltage drop measurement with multimeter

n Measurement at the voltage source measures the currently
available voltage.
n The meter is always connected parallel to consumer, compo-
nent or power source.
Fig. 419: Measuring voltage
n A measurement at the consumer measures the voltage drop at

this component.
Fig. 420: Voltage measurement
Current measurement with the multimeter

n The meter is connected in series with the consumer.
n During the measurement the current must be able to flow
through the meter, i.e. the electric circuit must be opened.
Fig. 421: Measuring current

Advice
If the electric circuit is difficult to access and the internal resistance
of the consumer is known, the voltage may also be measured at
the consumer.
The current value can then be calculated with the help of Ohm's
law.
Fig. 422: Current measurement
Clip-on measuring instrument

The clip-on measuring instrument can be used to measure current,
voltage and resistance.
Fig. 423: Clip-on measuring instru-

ment
n For measuring current the individual conductor must be fully

enclosed by the measuring tongs, the actual measurement
takes place without contact.
Fig. 424

Magnet tester
The magnet tester is used to test solenoid valves and magnetic
coils.
The test lamp responds to the magnetic fields of A.C-voltage, D.C.-
voltage and permanent magnets.
n The component to be tested does not need to be removed.
n The magnetic coil can also be tested under a protective cap.
Fig. 425: Magnet tester
Power measurement
The electric power of a module within a circuit can be indirectly
determined (calculated) by separate measuring of current and
voltage.
However, there are also pure power meters with 4 connections
available. The power meter has a electro-dynamic measuring
mechanism. The current circuit must be opened for measuring.
Take care when performing power measurements: Voltage or cur-
rent path may already be overloaded during the measurement,
even though the end stop in the meter has not yet been reached.
Fig. 426

Troubleshooting – Troubleshooting, diesel engine
11.4 Troubleshooting, diesel engine
11.4.1 Starting the engine with jump leads
NOTICE!
battery.
NOTICE!
Fig. 427

tive poles after.

11.4.2 Fault - Cause - Remedy

Fault Possible cause Remedy
Engine does not Fuel tank empty Refuel, bleed the fuel system
start or starts poorly
Temperature below starting limit Check
Engine oil with wrong SAE viscosity class Change the engine oil
The fuel quality does not meet the Change the fuel
requirements
Battery defective or not charged Check
Cable to starter loose or oxidized Check cable connection
Starter defective or pinion does not Check starter
engage
V-belt torn or loose Check, replace if necessary
Air in the fuel system Bleeding the fuel system
Fuel filter soiled Check, clean the water separator /
replace the fuel filter
Incorrect valve clearance Check, adjust if necessary
Injection line leaking Check
Injection valve defective Check, replace if necessary
Engine starts, but V-belt torn or loose Check, replace if necessary
runs irregularly or
misfires Air in the fuel system Bleeding the fuel system
requirements
The engine over- Engine oil with wrong SAE viscosity class Change the engine oil
heats, the coolant
temperature Engine oil filter dirty Replace
warning lamp lights Engine oil level too low or too high Check, top up or drain off as necessary
Charge air pipe leaking Check, replace if necessary
Air filter clogged / exhaust turbocharger Check, replace if necessary
defective
Lack of coolant Check the coolant level, top up if neces-
sary.
Insufficient engine Engine oil level too high Check, drain off if necessary
power

Fault Possible cause Remedy

Air in the fuel system Bleeding the fuel system
requirements
Air filter clogged / exhaust turbocharger Check, replace if necessary
defective
Radiator dirty Check, clean if necessary
Engine does not Air in the fuel system Bleeding the fuel system
work with all cylin-
ders Fuel filter soiled Check, clean the water separator /
Engine has too low Engine oil level too low Check, fill up if necessary
or no oil pressure
Engine oil with wrong SAE viscosity class Change the engine oil
Engine has exces- Engine oil level too high Check, drain off if necessary
sive oil consump-
tion Engine oil with wrong SAE viscosity class Change the engine oil
Blue engine Engine oil level too high Check, drain off if necessary
exhaust smoke
White engine Temperature below starting limit Check
exhaust smoke
requirements
Black engine Air filter clogged / exhaust turbocharger Check, replace if necessary
exhaust smoke defective
Radiator dirty Check, clean if necessary

11.4.3 Trouble shooting "Starter"

Starter turns too slowly, possible reasons:
n Brushes partly worn
n Short circuit in exciter or armature winding
n Oxidised electrical contacts
n Poor ground connection
This results in a high voltage loss in the starter system, which
causes the starter to turn too slowly.
Starter only clicks, possible reasons:
n Magnetic switch broken or soiled
– Remedy: Dismantle and clean the magnetic switch
n Main contacts of the magnetic switch are worn or soiled
– Remedy: Carefully rasp and clean the main contacts of the
magnetic switch
n Starter motor broken or soiled
– Remedy: Disassemble and clean the armature
Other possible reason for a starter which does not work
n A jammed return mechanism
n Worn contacts on the magnetic return switch
Defects on the actual starter motor including pinion

and carbon brushes are rare.
Trouble shooting chart for the starter system

With a trouble shooting chart the faults in the starter system can be
narrowed down.
The starter system can only work when the following conditions are
fulfilled:
n Immobilizer deactivated?
n Starter switch OK?
n Travel lever in correct position?
n Emergency stop switch not activated?
n Battery sufficiently charged?
n Battery poles OK?
n Main battery fuse OK?
n Main battery switch closed?
n Main starter cable (terminal 30) OK?
n Starter control cable (terminal 50) OK? (no voltage drop?)
n Ground cable OK?
n Switching of magnetic switches OK?
Only if all criteria have been met, must the fault be in the starter
itself. In this case it can be repaired or replaced.
Testing and measuring the starter
Function control with the starter removed

NOTICE!
Fasten the starter to make sure that it will not come
loose during the test.
n Connect a jumper lead between start terminal (1) and battery

plus (2).
n Connect a jumper cable instantaneously between starter
housing and battery minus (3).
If the motor does not start, the starter is defective.

Repair or replace the starter.
Fig. 428
Checking the magnetic switch

n Connect a jumper lead between start terminal (1) and battery
plus (2).
n Connect a jumper cable instantaneously between starter
housing and battery minus (3).
If the pinion does not disengage, the magnetic

switch is defective. Repair or replace the starter.
Fig. 429
Continuity test for the magnetic switch

n Use a continuity tester to check for continuity between terminal
(1) and terminal (29 while holding the pin depressed.
n Replace the magnetic switch if no continuity is detected.
Fig. 430
11.4.4 Trouble shooting procedure on generator

Checking the generator First, check whether the generator is actually defective.
n This can be easily found out by checking whether the charge
control light in the dashboard lights up. If the light does not go
out, even at higher speeds, there must be a defect on the gen-
erator, the regulator, the wiring or the V-belt.
n When the engine is at rest, the charge control light must light
up. If not, the lamp may probably be defective. Defects on gen-
erator or wiring are obviously also possible.

The following points allow to contain faults in the voltage supply

within certain limits.
n Cable connections on the generator OK?
n V-belt OK?
n Generator ground (engine ground) OK?
n Pre-excitation from vehicle electronics OK?
Only if all criteria mentioned above are OK, the fault must be in the
generator itself. In this case it must be replaced or the following
trouble shooting procedure must be performed.
Checking the pre-exciter circuit, D+

generator
The most common reason for a three-phase alternator not
charging is a too low pre-excitation current. The pre-excitation cur-
rent through connection D+ depends on the connected consumer
(resistor), e.g. charge control lamp or relay of a MD+ engine con-
trol.
The pre-excitation current should be approx. 250 mA at 12 Volt.
This corresponds with a 3 Watt light bulb or an equivalent combina-
tion of light bulb + resistor or an LED + resistor.
The total resistance of the disconnected dead supply line D+ max.
should not exceed 48 Ohm.
In case of faults like:
n charge control lamp stays on
n no voltage increase, e.g. from 12 V to 14 V
Fig. 431: Connections on the three- one should check that the correct resistance is assured.
phase alternator (exemplary design)
If the charge control lamp or LED stays on when the engine is run-
ning, you should proceed as follows:
n Temporarily bridge connections D+ and B+ on the three-phase
alternator Ä Fig. 431. The bridging must be made using an
insulated cable with a cross-section of approx. 1.0 mm, which
is stripped for approx. 5 mm on either end. This cable must be
fitted with a consumer (X), e.g. a light bulb of 21 W, 12 V, in
case of a 12 V system.
If this measure does not clear the fault, the alternator must be
defective.
Measuring the charge current n All plug-and-socket connectors must be free of corrosion and
intermittent contact.
n The generator ground connection must be OK.
n During the measurement switch on as many consumers as
possible.

1. Attach the clip-on ammeter around the B+ line.

2. Gradually increase the engine speed.
ð
The generator current must be at least as
high as the total current of all consumers.
Checking the rotor

The rotor coils can only be measured in disassem-
bled state.
n Measure the resistance between the sliprings.

n If the resistance does not comply with the factory specification,
replace the rotor.
n Use the resistance range of the continuity tester to check the
continuity between slipring and core.
n Replace the rotor if no infinite value is indicated.
Factory specification for resistance: 2.8 to 5 OHM.
Fig. 432
Checking the stator

The stator coils can only be measured in disas-
sembled state.
n Use the resistance range of the continuity tester to measure

the resistance between the individual lines of the stator
winding.
n If the measuring value does not comply with the factory specifi-
cation, replace the stator.
n Use the resistance range of the continuity tester to check the
continuity between the individual stator windings and the core.
n Replace the stator if no infinite value is indicated.
Fig. 433 Factory specification for resistance: Less than 1

OHM.

Checking the bearings

n Check whether the bearing rotates without obstruction.
n Replace the bearing if it does not rotate properly.
Fig. 434
Checking the regulator voltage with The battery and generator tester comes with an 8-line LC display
the generator tester with background illumination and is able to print out test results via
an (optional) thermal printer.
The generator test assesses the regulator voltage and the ripple
factor of the generator voltage.
n All plug-and-socket connectors must be free of corrosion and
n The battery should be in good condition – the idle voltage of
the battery should be at least 12.6 Volt.
n If possible switch off all consumers.
n Perform the measurement at raised engine speed.
Fig. 435
Checking the regulator voltage with

the multimeter
n All plug-and-socket connectors must be free of corrosion and
n The battery should be in good condition – the idle voltage of
the battery should be at least 12.6 Volt.
n If possible switch off all consumers.
n Perform the measurement at raised engine speed.
n The voltage (B+) should adjust itself at 13 to 14 Volt.
Fig. 436
Checking the regulator in disas- On a Bosch generator unscrew two fastening screws for the regu-
sembled state lator and lift the regulator off. For this work the generator does not
need to be removed.
The Delco-Remy generator needs to be removed and partly dis-
mantled, if the regulator needs to be disassembled. Unscrew the
housing screws to do so. Pull rotor with drive bearing and V-belt
pulley out of the stator. Unscrew the ends of the stator winding
from the diode carrier and separate the stator from the collector
ring bearing. Disassemble exciter diodes and brush holders and
remove also the regulator.

When testing the regulator one should be aware

that there are 2 different types of regulators:
n If the carbon brush is not connected to ground the regulator is

a so-called minus controlled regulator. The exciter winding is
positioned between D+ and DF, the regulator therefore regu-
lates the exciter winding on the ground side. The other carbon
brush is connected with the cathodes of the exciter diodes, ter-
minal D+. This leaves one further terminal, this is DF.
D+ (vehicle wiring system)
D- (ground contact, mostly located on one of the fastening screws)
DF (Dynamo Field)
n If the carbon brush is connected to ground the regulator is a
so-called plus controlled regulator. The exciter winding is posi-
tioned between DF and D-, the regulator therefore regulates
the exciter winding on the plus side. The other carbon brush is
then connected with terminal DF. This leaves one further ter-
minal, this is D+.
The basic function of a disassembled regulator can be easily
tested with a 12V lamp and an adjustable D.C. power supply unit
(0V ... 20V).
Fig. 437
E.g minus controlled regulator

One connects the regulator Ä Fig. 438 with D+ and D- to the
power source, as shown in the illustration, and the lamp to both
carbon brushes, instead of the exciter winding. When slowly
increasing the voltage the lamp will first become brighter, because
the regulator allows all lamp current (= exciter current) to flow at
voltage values up to 14.4V. Once the regulator voltage is reached,
the regulator switches the lamp current off. When returning the
voltage back below the control voltage, the regulator will switch the
lamp back on.
With this test the major difficulty is the problem to remove the regu-
lator an identify terminals D+, DF and D-.
Fig. 438

Fig. 439
The illustrations Ä Fig. 439 and Ä Fig. 440 show two different
regulator types.
Fig. 440
Replacing carbon brushes

1. On a Bosch generator unscrew two fastening screws for the
regulator and lift the regulator off. Pull out the carbon brushes
from underneath. Their minimum length is 5 mm, shorter
carbon brushes need to be replaced, unsolder both connec-
tion litz wires. Solder the litz wires of the new carbon
brushes, insert these and fasten the regulator again. For this
work the generator does not need to be removed.
2. For replacing the carbon brushes in the Delco-Remy gener-
ator the generator needs to be disassembled and partly dis-
mantled. The carbon brush holder is located inside the col-
lector ring bearing.

Troubleshooting – Trouble shooting, hydraulics
11.5 Trouble shooting, hydraulics
11.5.1 Insufficient hydraulic power

Trouble shooting charge pressure,
example travel circuit If the charge pressure is not inside the nominal
range, no high pressure can be built up in the
system.
Diesel engine running, travel lever

position "0"
Fig. 441: Charge pressure (6S) present

1 Charge pump
2 Variable displacement pump
3 Hydraulic motor
4 Charge pressure relief valve (example 30 bar)
5 Pressure relief valve (example 300 bar)
6 Pressure gauge, (6S) charge pressure, (6H) high pressure
7 Cooler (optional)
8 Filter
9 Connection for pump control

n If the charge pressure in the system drops, there is an internal

leak in the hydraulic circuit.
n But there may also be an internal leak in an external compo-
nent, which is also controlled by charge pressure. For example:
Brake valve, brake piston, etc.
n However, the steering pump could also be defective, because
the steering pump delivers the the oil that is fed into the closed
hydraulic circuit.
Trouble shooting closed travel cir-
cuit, example travel circuit
Fig. 442
10 Pressure resistance plugs
1. Connect pressure gauges (6) for high pressure and charge
pressure.
2. Disconnect hydraulic motor / ´hydraulic motors (3) and close
the ports with pressure resistant plugs (10).
ð The variable displacement pump can now be pressure

tested.

NOTICE!
Do not run the test over a longer period of time
(danger of overheating).
3. Start the engine and accelerate to full speed.

4. Shift the travel lever to forward and reverse.
5. Read the pressure gauges (6).Read the pressure gauge.
ð If the pressure gauges show the correct values, the vari-
able displacement pump is OK. The fault is in the
hydraulic motor /hydraulic motors (3).

11.5.2 Trouble shooting axial piston pumps

The following table should be of help when performing trouble-
shooting. This table is by no means complete. In practice you may
encounter problems that have not been listed here.
Procedure: 1. Always proceed systematically, even under time pressure.
Indiscriminate, ill-considered disassembly and changing of
settings can lead to a situation in which the original cause of
a fault can no longer be detected.
2. Get an overview over the function of the product in connec-
tion with the overall system.
3. Try to clarify whether the product was able to deliver the
required function within the overall system before the fault
occurred.
4. Develop a clear understanding of the troubleshooting
process. If necessary ask the direct operator or machine
driver.
5. Have conditions or area of application of the product been
changed?
6. Were changes (e.g. changeovers) or repairs made to the
overall system (machine/plant, electrics, control) or to the
product? If yes: What kind?
7. Has the product or the machine been operated as intended?
8. How does the fault occur?
Fault description Cause Remedy

Unusual noises Insufficient suction conditions, e.g. air in the Machine or system manufacturer
suction line, inadequate diameter of the suc- (e.g. optimize feed conditions, use
tion line, excessive viscosity of the pressure suitable pressure fluid).
fluid, extreme suction height, too low suction
Completely purge the axial piston
pressure, foreign bodies in the suction line.
unit, fill the suction line with pres-
sure fluid.
Remove foreign bodies from
inside the suction line.
Inappropriate fastening of the axial piston unit. Check the fastening of the axial
piston unit as specified by the
machine or plant manufacturer.
Observe the tightening torques.
Inappropriate fastening of attachment parts, Fasten attachment parts as speci-
e.g. coupling and hydraulic lines. fied by the coupling or fittings
manufacturer.
Pressure relief valves of the axial piston unit Purge the axial piston unit, check
(charge pressure, high pressure, pressure the viscosity of the pressure fluid,
override valve). consult the service department.
Consult the service department.
Mechanical damage to the axial piston unit. Replace the axial piston unit, con-
sult the service department.


No or insufficient Faulty mechanical drive (e.g. defective cou- Check and repair the drive.
volumetric flow pling).
Drive speed too low. Consult the service department.
Insufficient suction conditions, e.g. air in the Completely purge the axial piston
suction line, inadequate diameter of the suc- unit, fill the suction line with pres-
tion line, excessive viscosity of the pressure sure fluid.
Pressure fluid not within the optimal viscosity Use appropriate pressure fluid.
range.
External control and setting facilities defective. Check the external control.
Pilot or control pressure too low. Check pilot and control pressure,
consult the service department.
Functional disturbance in the control facility or Consult the service department.
the regulator on the axial piston unit.
Mechanical damage to the axial piston unit. Replace the axial piston unit.
No or insufficient Faulty mechanical drive (e.g. defective cou- Check and repair the drive.
pressure pling).
Poor drive power. Consult the service department.
Pressure fluid not within the optimal viscosity Use appropriate pressure fluid.
range.
External control and setting facilities defective. Check the external control.
Pilot or control pressure too low. Check pilot and control pressure.
Functional disturbance in the control facility or Consult the service department.
the regulator on the axial piston unit.
Wear of the axial piston unit. Replace the axial piston unit.
Mechanical damage to the axial piston unit. Replace the axial piston unit.
Drive unit defective (e.g. hydraulic motor or Check the drive unit, replace if
cylinder). necessary.
Fluctuations in pres- Axial piston unit not or insufficiently purged. Completely purge the axial piston
sure/volumetric flow unit.


Insufficient suction conditions, e.g. air in the Remove foreign bodies from
suction line, inadequate diameter of the suc- inside the suction line.
tion line, excessive viscosity of the pressure
Pressure fluid too hot Excessive input temperature on axial piston Check the system, e.g. malfunc-
unit. tion of the cooler, pressure fluid
level in tank too low.
Malfunction of the pressure control valves (e.g. Consult the service department.
high pressure relief valve, pressure override
valve, pressure controller).
Malfunction of the flushing valve (not for nom- Consult the service department.
inal size 18).
Wear of the axial piston unit. Replace the axial piston unit.
11.5.3 Trouble shooting axial piston motors

The following table should be of help when performing trouble-
shooting. This table is by no means complete. In practice you may
Procedure: 1. Always proceed systematically, even under time pressure.
Indiscriminate, ill-considered disassembly and changing of
settings can lead to a situation in which the original cause of
a fault can no longer be detected.
2. Get an overview over the function of the product in connec-
tion with the overall system.
3. Try to clarify whether the product was able to deliver the
required function within the overall system before the fault
occurred.
4. Develop a clear understanding of the troubleshooting
process. If necessary ask the direct operator or machine
driver.
5. Have conditions or area of application of the product been
changed?
6. Were changes (e.g. changeovers) or repairs made to the
overall system (machine/plant, electrics, control) or to the
product? If yes: What kind?
7. Has the product or the machine been operated as intended?
8. How does the fault occur?

Unusual noises Inappropriate fastening of the axial Check the fastening of the axial
piston unit piston unit as specified by the
machine or plant manufacturer.
Observe the tightening torques!


Inappropriate fastening of attachment Fasten attachment parts as specified
parts, e.g. coupling and hydraulic lines. by the coupling or fittings manufac-
turer.
Mechanical damage to the axial piston Replace the axial piston unit
unit.
Fluctuations in pressure/ Axial piston unit not or insufficiently Completely purge the axial piston
volumetric flow purged. unit.
Operation data are not Insufficient flow from hydraulic pump Check the function of the hydraulic
reached. pump
Minimum displacement incorrectly set Consult the service department.
External control and setting facilities Check the external control.
defective.
Control pressure too low Check control pressure, consult the
service department.
Functional disturbance in the control Consult the service department.
facility or the regulator on the axial
piston unit.
Pressure fluid not within the optimal vis- Use appropriate pressure fluid.
cosity range.
Wear of the axial piston unit Replace the axial piston unit
Mechanical damage to the axial piston Replace the axial piston unit
unit.
Pressure fluid too hot Excessive input temperature on axial Check the system, e.g. malfunction
piston unit. of the cooler, pressure fluid level in
tank too low.
Malfunction of the pressure control Consult the service department.
valves (e.g. high pressure relief valve,
pressure override valve, pressure con-
troller).
Failure of the flushing valve Consult the service department.
Wear of the axial piston unit Replace the axial piston unit

11.5.4 Fault table hydraulic components

The following table shows possible malfunctions of hydraulic com-
ponents. This table is by no means complete. In practice you may
Drive elements
Malfunction Possible cause
n Mechanical parts on the drive side defective (coupling seat, alignment
Abnormal noises
faults, etc.)
No or insufficient volumetric n Speed transfer of distance transfer defective
flow
No or insufficient pressure n Torque transfer defective
Fluctuation of pressure / flow n Drive elements defective
volume
Hydraulic cylinder / hydraulic motor

n Insufficient rotary speed or velocity
n Overtaking processes (hydraulic motor is driven by machine back to
he pump)
n Braking noises
Abnormal noises
n faulty inside sealing
n Drive damage
n Internal losses
n leaking cuffs
No or insufficient volumetric
n Wear caused by dirt
flow
n Inn er and outer leaks

No or insufficient pressure n Wear caused by dirt
n Drive damage
n Not or insufficiently vented
n defective cuffs
n
Fluctuation of pressure / flow
StickSlip effect
n
volume
changing load direction
n Displacement of hydraulic motor not correct (to low or too high)
n Internal leakage
n Gap losses
n
Pressure fluid too hot
Wear damage
n Hydraulic motor and cylinder too small

Flow valves
n Trapped air
Abnormal noises n Pressure differential too small
n vibrations
No or insufficient volumetric n Control orifice blocked
flow n One-way restrictor deadjusted
n Trapped air
Fluctuation of pressure / flow n Pressure differential too small
volume n Flow valve contaminated
n Check valve defective
n Wear
n Gap losses
Pressure valves / anti-cavitation valves (secondary)

n Vibrations and noises point to trapped air or missing damping
n wrong pressure setting
Abnormal noises n Anti-cavitation valve working insufficiently
n Opening pressure of anti-cavitation valves too high
n Cavitation on oil motor
n Setting too low
n Valve seat damaged
n jammed by dirt
flow
n Setting too low

n
No or insufficient pressure
Broken spring
n Foreign body in valve seat
n Intermittent counter pressure
n Pressure valve set too low
volume
Setting too high:

n Increase of gap losses in all components
n increased leakage
n Excessive load rhythm caused by machine
Setting too low:
n Power loss
n Generation of heat
n Valve cone jams in open position

Way valves
n Control defective
Abnormal noises n Design fault (nominal width)
n Restrictions
n Incorrect or inaccurate spool position
n negative overlap
n Pilot pressure too low - does not switch
flow
n Incorrect position
n mechanically jammed
No or insufficient pressure n Resetting spring broken
n leaking
n Dummy plug loosened
n Flow forces influence the spool action and the opening distances
Fluctuation of pressure / flow n Positioning fault
volume n unstable position
n Pilot pressure fluctuation
n Incorrect position
n Throttle losses
Pressure fluid too hot n too small dimensioned
n Cross-section too small
n Wear
Pressure valves (primary)

n Vibrations and noises point to trapped air or missing damping
n wrong pressure setting
Abnormal noises
n Setting too low

n jammed by dirt
flow
n Setting too low

n
Broken spring
n Foreign body in valve seat

Pressure valves (primary)

n Intermittent counter pressure
n Pressure valves set too low
volume
Setting too high:

n Increase of gap losses in all components
n increased leakage
n Excessive load rhythm caused by machine
Setting too low:
n Power loss
n Generation of heat
n Valve cone jams in open position
Pressure accumulator
n Accumulator bladder defective
n Nitrogen filling enters into hydraulic circuit
n defective seals
n
Abnormal noises
Inflow and outflow velocity too high
Note: Accumulators in connection with throttle losses can form resonant
systems
No or insufficient volumetric n Nitrogen filling level too low
flow
n Nitrogen filling pressure too low or too high _ Stored power is not
enough
Fluctuation of pressure / flow n Resonant system between hydraulic accumulator, pressure and flow
volume valves and pump
Return flow lines

n Line not connected below the pressure fluid level
n Turbulences towards the suction side
Abnormal noises n missing shut-off
n mechanical oscillations
n insufficient fastening
Pressure fluid too hot n Cross section too small

Filter
n Insufficient fastening
Abnormal noises
No or insufficient volumetric n In case of high pressure filters: Insert contaminated

flow n Bypass vale jammed
n In case of high pressure filters: Insert contaminated
n Bypass vale jammed
Pressure fluid too hot n Opening pressure of bypass valves too high
Radiator
n Air-oil radiator fan noises
Abnormal noises
n too small dimensioned

n Insufficient cooling effect
n Room or ambient temperature too high
n
External ventilation or water supply interrupted
n Surface contaminated
n Bypass valve open
Pressure lines
n Inappropriate operation
Abnormal noises n Structure borne noise
n Pipe cross-section too small
n Screw fittings leaking
n Cross section too small
n Throttle actuator pressure increase
flow
n Cable breakage
No or insufficient pressure n Screw fittings leaking
n Display or measuring equipment defective
n Not correctly ventilated
n Display or measuring equipment defective
n Display fault
volume
n Cross section too small

n Necking caused by too small bending radii

Engine
n Incorrect sense of rotation
n Too high speed
n
Abnormal noises
Bearing play
n Bearing damage
No or insufficient volumetric n Speed too low
flow
n Incorrect sense of rotation
n Poor drive power
Fluctuation of pressure / flow n Inhomogeneity of engine too high

volume n too low idle speed of engine
Pressure fluid too hot n Too high speed
Clutch
n Coupling seat defective
Abnormal noises n Alignment fault
n elastic elements defective
No or insufficient volumetric n Rotary speed transfer defective
flow
No or insufficient pressure n Torque transfer defective
Pump
n Too high speed
n Air intake
n
Abnormal noises
Cavitation
n mechanical damage
No or insufficient volumetric n Internal leakage
flow n Wear caused by dirt
n Internal leakage
No or insufficient pressure n Wear caused by dirt
n Drive damage

Pump
n Air intake
n Internal leakage
n Wear caused by dirt
Fluctuation of pressure / flow n Drive damage
volume n With engine under load or temporary overloading disturbed control
behaviour caused by contamination
n Engine overload caused by power take-up on auxiliary drive
n Regulator oscillates
n Internal leakage
n Wear damage
Leakage line
Abnormal noises n insufficient fastening
n High temperatures caused by high leakage indicate an expected
failure of a component
Suction conditions
n Insufficient suction cross-section
n too high suction height
n direction changes
n cross-sectional constrictions
n
Abnormal noises
leaking suction line
n Air bubbles
n Tank shut-off valve not opened
n Resistance on filter
n Suction behaviour disturbed
n insufficient suction cross-section
No or insufficient volumetric n too high suction height
flow n direction changes
n leaking suction line

Suction conditions
No or insufficient pressure n direction changes
n Trapped air
n
direction changes
n
volume
cross-sectional constrictions
n Trapped air
Hydraulic oil tank

n Engine oil level too low
n Frothing of oil
n Water in oil
n
Abnormal noises
cold pressure fluid
n Too high viscosity
n Tank ventilation ineffective
No or insufficient volumetric n Engine oil level too low
flow n Tank ventilation ineffective
n Oil level too low
No or insufficient pressure n too low viscosity of pressure fluid _ caused by high leakage losses
n Gap losses
n Air bubbles
n Turbulences from return flow to suction side
n no partitioning between return flow and suction space
volume
n Incorrect viscosity
n Oil filling too low
n In case of extreme local heating up the lubricity, pressure loading
Pressure fluid too hot ability and ageing resistance of the pressure fluid is impaired
n Wear of components
n Gap losses
n Heating up

Troubleshooting – Trouble shooting, air conditioning system
11.6 Trouble shooting, air conditioning system

General n Visual inspection of the complete system for damage.
n Check the compressor mounting bracket on the vehicle engine
for tight fit and damage.
n Check the condition, alignment and tightness of the V-belt.
n Check the routing of refrigerant hoses and cables in the area of
the vehicle engine and transmission, as well as on the chassis
for chafing and rectify any detected faults. Ensure sufficient
clearance to hot parts, such as the exhaust; install a protective
shield, if necessary.
n Check the routing of refrigerant hoses and cables in the area of
the vehicle engine and transmission, as well as on the chassis
for chafing and rectify any detected faults. Ensure sufficient
clearance to hot parts, such as the exhaust; install a protective
shield, if necessary.
n Check the routing of hoses and hoses on the attachment box
or in the cabin.
n Check all hose and screw fittings for leaks.
n Check the fastening of the condenser unit.
n Clean the condenser fins, replace the condenser block if dam-
aged fins are found.
n Check the fastening of the evaporator unit.
n Check the function of evaporator and condenser fans.
n Check the electric control panel. If discolorations on conductors
are found, these should be replaced and possibly also the cor-
responding relays.
n Switch on the cooling system and check the refrigerant level.
n Filter/dryer and filter/dryer/fluid container combinations must
always be replaced after opening the refrigerant circuit. If these
are in service for more than 1 year, there is a risk that they may
be clogged by excessive absorption of moisture! The filter/
dryer should be replaced in regular intervals.
n Measure the temperature on the evaporator: Measure the
intake air temperature - Measure the blow out air temperature -
The temperature difference should be at least 8-10 K.
n Measuring the pressure in the refrigerant circuit
11.6.1 Trouble shooting in refrigerant circuit, basic principles

Requirements For trouble shooting two requirements must be fulfilled:
n Expert knowledge
n technical equipment

Technical equipment Pressure gauge and thermometer are the most important auxiliary
means for trouble shooting. The refrigerant states, such as over-
heating and undercooling, provide important information when per-
forming trouble shooting. Even your own senses should not be
underrated in trouble shooting. Bubbles in the inspection glass,
contamination and white frost are visible indicators. If the com-
pressor draws in wet steam, this is visible in the suction line and
may also be audibly perceptible. An overloaded compressor can
even be smelled.
The following tools and auxiliary means should be available for
trouble shooting:
n Service station
n Pressure gauge
n Thermometer
n dry nitrogen
n Refrigerant bottle for new refrigerant
n Container for old oil
n Vacuum pump
n Hoses
n Scales
n Suction station
n Leak detector
The measuring equipment must be checked at regular intervals.
Calibration can only be made by an approved testing authority.
Pressure gauge Most pressure gauges used in practice are (for cost reasons) over-
pressure gauges. These pressure gauges measure the excess
pressure in relation to the ambient pressure (air pressure). In order
to achieve the absolute (actual) pressure the ambient pressure
must be added to the pressure gauge reading. The absolute pres-
sure is needed for the calculation and determination of material
data.
Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = Overpressure (pressure gauge reading)

Example:
A totally empty air conditioning system holds an atmospheric pres-
sure of approx. Pambp = 1 bar.
Filling the system with refrigerant causes an overpressure of Pe = 3
bar.
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
Evacuating the system down to Pe = -0.6 bar, creates a "vacuum"
(negative overpressure).
Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
Fig. 443: Pressure gauge
Pressure gauge with saturation

temperature scale
Temperature scales on the pressure gauges always refer to the
absolute pressures Pabs. Please note that it is not possible to
measure a temperature directly with a pressure gauge. The indi-
cated temperatures are just reference values. Only the saturation
temperature is assigned to the measured pressure.
If the refrigerant is fluid, the temperature is below the saturation
temperature.
If the refrigerant is gaseous, the temperature is above the satura-
tion temperature.
Pressure gauges must indicate 0 bar when not connected to the
system.
Low pressure gauges have a blue, high pressure gauges a red
border.
Fig. 444: Absolute pressure gauge
Thermometer The thermometers used are normally digital thermometers with

surface or attachment sensors. Good heat insulation of the meas-
uring location must be assured, especially in case of big tempera-
ture differences. An economical use of heat-conduction paste is
recommended. If the measuring location is excessively contami-
nated, it needs to be cleaned and possibly treated with a fine
emery cloth. Only the temperature of the sensor is measured. Tem-
perature differences between the measured and the actual values
of a few degree Kelvin may be caused by missing heat insulation
and by insulating oxide layers on the cable.
Overheating
Due to its design a refrigerant compressor can only deliver gas-

eous or vaporous substances. Fluids are not compressible and
must therefore not enter into the compression chamber of the com-
pressor.

If the suction condition of the compressor is directly on the dew

line, an e.g. incorrect evaporator load can cause "wet suction".
This can lead to two processes, which are destructive for the com-
pressor. The liquid refrigerant washes off the lubricating film
between piston and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in the cylinder
causes a direct energy transfer from piston to cylinder cover during
compression. The valve plate may then be damaged by so-called
fluid strokes.
Apart from protecting the compressor against fluid, overheating
has further advantages. Since the fluid proportions in the drawn in
steam reduces the flow rate of the compressor, it may be increased
by a overheating. Overheating also improves the oil recirculation.
Common overheating values The optimal overheating value is approx. 5 - 8 Kelvin. With this
overheating the maximum system power is reached. However, the
thermostatic expansion valve is unable to regulate this value
exactly. Depending on design and operating conditions overheating
fluctuates within a range between 4 and 12 Kelvin. The influence of
the ambient air on the suction line causes an additional over-
heating effect.
Overheating is calculated as fol- Δ t o2h = t o2h - t o

lows:
Δ t o2h, overheating at evaporator outlet in K
to2h, temperature at evaporator outlet in °C
to, evaporation temperature in °C
"h" represents "overheated"
Supercooling
It is the function of the expansion valve to reduce the refrigerant to

a lower pressure level (evaporation pressure) after it has been liq-
uefied. For an optimal function of the valve pure fluid must be
applied to its inlet port.
The refrigerant must "squeeze" (literally speaking) through a
throttle gap inside the expansion valve. When comparing a certain
mass of refrigerant in liquid and vaporous condition (under con-
stant pressure), the vaporous refrigerant requires a much higher
volume. That's why the vaporous refrigerant needs a much longer
time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve reduces the
flow rate and results in an undersupply of the evaporator with
refrigerant. Evaporation pressure and evaporator power will drop.
If the refrigeration system is operated with the "expansion valve
inlet" condition directly on the boiling curve, slightest fluctuations in
operating condition may cause a formation of bubbles in front of
the expansion element.

For this reason one shifts the condition "Expansion Valve Inlet"
away from the boiling curve into the fluid area and refers to this
condition as Supercooling. This supercooling ensures a fluid
supply in front of the expansion valve.
Common supercooling values In systems with fluid container the supercooling at the fluid con-
tainer outlet is approx. Zero "0" Kelvin (assumed that the system is
filled with the correct refrigerant quantity). In this case the fluid con-
tainer provides the required fluid supply.
Supercooling is calculated as fol- Δ t c2u = t c - t c2u

lows:
Δ t c2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
"u" represents "supercooled"
Fig. 445: Refrigerant circuit with t, h- diagram


1 Hot gas line (overheated steam) 9 Evaporator
2 Deheating (overheated steam) 10 Overheating (overheated steam)
3 Condenser / liquefier 11 Suction steam line (overheated steam)
4 Condensation (wet steam) 12 Compressor
5 Fluid line (supercooled fluid) 13 Supercooling (fluid)
6 Expansion valve 14 Compaction
7 Injection line (wet steam) 15 Expansion
8 Evaporation (wet steam)
Fig. 446: Refrigerant circuit diagram


1 Cold air 9 Pressure switch with high and low pressure contacts
2 Evaporator 10 Dryer
3 Thermostat 11 Fluid container
4 Warm air 12 Hot air
5 Gebläse 13 Compressor
6 Inspection glass 14 Condenser
7 Expansion valve 15 Cooling air
8 Pressure gauge, high pressure 16 Pressure gauge, low pressure
11.6.2 Trouble shooting procedure

Knowledge Trouble shooting is not possible with exact knowledge about the
system design, the installed components and their function in the
system trouble shooting is not possible:
Visual inspection With the appropriate experience some faults can be visually
detected or felt. Frequently occurring condenser soiling or forma-
tion of steam bubbles in the inspection glass can be quickly
detected.
In case of unusual formation of hoarfrost on the evaporator the
hoarfrost pattern provides useful information. Hoarfrost only occur-
ring at the inlet side is a clear indication of insufficient refrigerant
feed, which in turn indicates an incorrectly working expansion valve
or a lack of refrigerant.. Complete hoarfrost covering indicates load
problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the naked eye.
At the end of the evaporator there should be an area which is dry
or at least drier at evaporator temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a local cooling
can be felt or if condensation develops, this is a clear indicator for
an extreme pressure drop in the line. Similar phenomena can be
noticed in case of blocked filters.
Unusually cold pressure lines indicate "wet" intake of the com-
pressor.
The oil level in the compressor sight glass provides information
about the oil quantity and the oil recirculation in the system. How-
ever, the oil level may also be considerably influenced by con-
densing refrigerant. Discoloration informs about the state of the oil.
Water in the system can simply be detected through the inspection
glass with moisture indicator.

The dangerous part of common rules is that they

apply in most, but not in all cases. The refrigerant
states in the individual piping sections or compo-
nents must therefore be exactly determined by
means of pressure and temperature measure-
ments.
Test prerequisites n Cooler and condenser are clean, clean if necessary.

n The ribbed belt for compressor and generator is correctly tight-
ened.
n All air ducts, covers and seals are OK and correctly fitted.
Flaps reach their end positions.
n The engine has operating temperature.
n Evaporator and heating (with highest fresh air fan speed) do
not draw leak air.
n The fresh air fan runs when the engine is running and the air
conditioning system is set to max. cooling power.
n Ambient temperature above 15 °C.
n The thermostat is correctly installed and the switching tempera-
tures are correct.
Measuring points and measure-

ments
Fig. 447: Flow diagram with measuring points

n C, condenser measuring points

n E, expansion valve measuring points
n O, evaporator measuring points
n V, compressor measuring points
The flow diagram contains "Minimum Requirements" which must
be fulfilled to be able to check the system or perform trouble
shooting.Temperature and pressure at the evaporator outlet can be
used to derive the overheating of the evaporator. Overheating is a
clear indicator for the evaporator filling level. In case of excessive
overheating the refrigerant quantity fed into the evaporator is too
low, in case of insufficient overheating it is too high. In individual
cases one must then check if this situation is caused by the expan-
sion element or by insufficient filling. A differentiation is only pos-
sible if there is a clear indicator for the refrigerant filling quantity.
Pressure and temperature at the condenser outlet can be used to
derive the supercooling. This can be used to assess the filling
quantity. In systems with fluid container the inspection glass is
most suitable to check the minimum filling quantity. Supercooling is
in this case the between indicator for overfilling.The hot gas tem-
perature can be used to check whether the compressor runs in the
permissible operating range.
Example: Measurement of over- n a) Which measuring equipment is required?

heating n b) Where to measure with which size?
n c) A pressure gauge connected to the evaporator indicates
"Peo2 = 1.7 bar". How high is the evaporator pressure "Po" ?
n d) How high is the evaporator temperature "to" ?
n e) A thermal sensor attached to the evaporator outlet meas-
ures the temperature "to2h = +3 °C". How high is the over-
heating „Δto2h“ ?
n f) Evaluation of the measured overheating.
Solution: n a) Pressure gauge, thermometer, steam table

n b) Evaporation pressure "Peo2" and temperature "to2h" are
measured at the same point on the evaporator outlet.
n c) Po = Peo2 + Pamb, "Evaporation pressure = pressure on evap-
orator + atmospheric pressure" = 1.7 bar + 1 bar = 2.7 bar.
n d) "Pc" = 2,7 bar can then be used to derive an condensing
temperature "to" of -2,2 °C from the steam table for R134a.
n e) Δto2h = to2h - to, „Overheating at evaporator outlet = evapo-
rator outlet temperature - evaporation temperature" = 3 °C -
(-2.2 °C) = 5.2 Kelvin.
n f) The determined overheating is within the usual range of 4 -
12 Kelvin.
Example: Measuring supercooling n a) Which measuring equipment is required?

n b) Where to measure with which size?
n c) A pressure gauge connected to the condenser indicates
"Pec2 = 15 bar". How high is the condensing pressure "Pc" ?
n d) How high is the condensing temperature "tc" ?

n e) A thermal sensor attached to the condenser outlet measures

the temperature "tc2u = 58 °C". How high is the supercooling
"Δtc2u" ?
n f) Evaluation of the measured supercooling.
Solution: n a) Pressure gauge, thermometer, steam table

n b) Condensing pressure "Pec2" and temperature "tc2u" are
measured at the same point on the condenser.
n c) Pc = Pec2 + Pamb, "Evaporation pressure = pressure on evap-
orator + atmospheric pressure" = 15 bar + 1 bar = 16 bar.
n d) "Pcc = 16 bar can then be used to derive an condensing
temperature "tc" of 57.9 °C from the steam table for R134a.
n e) Δtc2u = tc - tc2u, "Supercooling at condenser outlet = con-
densing temperature - condenser outlet temperature" = 57.9°C
- 58 °C) = -0.1 Kelvin.
n f) The determined overheating is within the usual range of
approx. "0" Zero Kelvin.
Typical faults and possible causes Most of the faults in the refrigerant side can be assigned with the
help of the checklist. In many cases faults have a quite similar
appearance, but totally different causes. White frost on an evapo-
rator, for instance, may be quite normal. However, in this case the
expansion valve may be defective or there may be oil return prob-
lems.
The following list contains pressure values in a system, that can be
expected at various ambient temperatures (measured at medium
speeds).
Suction pressure (low pressure gauge)

Ambient temperature in °C Excess pressure in bar
25 approx. 2.0
30 approx. 2.5
35 approx. 3
High pressure (high pressure gauge)

Ambient temperature in °C Excess pressure in bar
25 approx. 8.0
35 approx. 13
40 approx. 16
45 approx. 18

Values effecting the operating pres- Since the pressures occurring in a refrigeration system are highly
sures dependent on environmental conditions, it is mandatory to know
these dependencies. The following table contains some of these
dependencies.
Measured variable Suction pressure High pressure

increases drops increases drops
Compressor increases X X
speed
drops X X
Vehicle interior increases X X
temperature
drops X X
Ambient tem- increases X X
perature
drops X X
Humidity increases X X
drops X X
Suction pressure too low (1), high

pressure too low to normal (2)
Fig. 448

Cause Possible effect Remedy

Lack of refrigerant no supercooling, bubbles in inspection glass, high Check for leaks,
overheating, hoarfrost on evaporator refill
Evaporator fins or air filter Cooling power too low clean
soiled
Evaporator fan failed Low pressure shut off Repair the fan
Expansion valve defective Suction pressure gauge shows vacuum, because the Replace the valve
valve has closed
Screen or nozzle in expan- high overheating clean
sion valve clogged
Filter dryer clogged Bubbles in inspection glass, high overheating, filter Change filter dryer
dryer cold
Heat power too low Frequent low pressure shut off, thawing thermostat / Check the control
rotary thermostat switching too frequently
Suction pressure normal (1), high

pressure too high (2)
Fig. 449

Condenser dirty high hot gas temperature, low cooling power clean
Condenser fan failed high hot gas temperature, high pressure shut down repair
overfilled high hot gas temperature, low supercooling, low cooling Correct the filling
power capacity


Leak gas (air) high hot gas temperature, low measured supercooling, renew filling
low cooling power
Restriction between com- high hot gas temperature, low cooling power Check lines and
pressor and condenser valves
Suction pressure too high (1), high

pressure too low to normal (2)
Fig. 450

Compressor defective Cooling power too low Replace the compressor

Suction pressure too high (1), high

pressure too high (2)
Fig. 451

Expansion valve defective overheating too low, wet operation of compressor Replace the valve
Other faults
Symptom Cause Possible effect Remedy

Hot gas temperature Lack of refrigeration oil increased com- Refill refrigeration oil
too high, the hot gas pressor wear
line becomes so hot
that it cannot be
touched long with a
hand
Compressor does not Pressure switch or any other System stopped Check the control units,
start safety feature has triggered, check cause for switching
electrical fault, cylinder filled and rectify
with liquid refrigerant
Compressor switches Switching difference too small, Cycling of com- Check the control units,
continuously triggering of a switching ele- pressor, increased check cause for switching
ment (overpressure switch, low wear, too low and rectify
pressure switch), lack of refrig- cooling power
erant, fan defective, overfilled
Excessive overheating Expansion valve deadjusted or low cooling power, Replace the expansion
screen blocked, lack of refrig- hot gas tempera- valve, clean the screen,
erant tures too high fill in refrigerant, leak test
Hoarfrost on inlet side incorrectly working expansion too low infeed of Check the expansion
of evaporator valve, lack of refrigerant refrigerant into the valve, check the refrig-
evaporator erant filling

Symptom Cause Possible effect Remedy

Evaporator fully cov- Load problem, too low air flow low cooling power of Clean the evaporator,
ered with hoarfrost volume system check the evaporator fan
Fluid line is warm and Pressure drop in fluid line, filter low cooling power Eliminate the pressure
shows condensation dryer clogged drop, replace the filter
dryer
Exceptionally cold pres- "Wet intake" of the compressor low cooling power, Clean the compressor,
sure lines due to insufficient overheating excessive wear of replace if necessary,
of evaporator compressor replace the expansion
valve if necessary
Noise in system
Faults Possible cause Remedy

V-belt loose or excessively worn V-belt slips and generates Retention or renew the V-belt
noise
Magnetic clutch loud Magnetic clutch runs until high Repair or replace the mag-
pressure builds up, then the netic clutch
clutch starts to slip
Refrigerant compressor is loud Mounting bracket is loose, Repair the mounting bracket,
internal parts worn, low oil replace the compressor,
level in compressor renew the refrigeration oil
Fan is loud, fan motor excessively worn Replace the fan motor
Whistling and rattling noise in operation, V-belt pulley and bearing worn Replace the bearing, check
noticeable unevenness when turning by V-belt pulley for wear
hand
Rattling noise or vibration of high pressure System overfilled Draw out refrigerant
line, knocking noise in compressor, ball in
inspection glass floating at the top
Expansion valve loud excessive moisture in system Replace the dryer
Hissing noise in evaporator housing, on refrigerant level in system too Perform a leak test, fill up the
expansion valve, turbidity in inspection low system
glass or ball does not float
Inspection glass

Steam bubbles in inspection No supercooling before expansion valve, Fill up the system, replace the
glass lack of refrigerant in system, pressure loss in filter dryer, perform a leak test
system, supercooling caused by excessively
soiled filter dryer
Discolouration of inspection Lubricant destroyed by excessive operating Replace the refrigeration oil,
glass (black from inside) temperatures examine the temperature
increase


Moisture indicator changes Moisture level of drying agent too high Replace the filter dryer
to pink
Ball floats at bottom lack of refrigerant Fill the system
Monitoring devices

The high pressure contact System pressure exceeded, condenser Clean the condenser, replace
has switched off the mag- excessively soiled, condenser fan defective, the expansion valve, check the
netic clutch expansion valve defective condenser fan
The low pressure contact System pressure fallen short of, refrigerant Clean the evaporator, replace
has switched off the mag- level too low, expansion valve defective, the expansion valve, check the
netic clutch evaporator fan defective, heat load too low, evaporator fan
ambient temperature below 1.5 °C
The thermostat has Ambient temperature below 1°C, expansion Check the thermostat switching
switched off the magnetic valve defective, thermostat defective, air flow point, replace the expansion
clutch volume too low valve, clean the evaporator,
check the evaporator fan
11.6.3 Leak test
NOTICE!
The use of leak detection colouring matter is not
permitted, because its chemical composition is
unknown and its effect on compressor oil and
rubber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Before starting the evacuation process, the refrigerant circuit is

filled with nitrogen through a pressure reducer valve (approx. 22
bar). After this all connections in the air conditioning system are
checked with the help of a suitable leak detection spray. A leak is
thereby indicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air conditioning
system with refrigerant.
Leak test with electronic leak tester

Small leaks with only very low amounts of refrigerant escaping can
be detected, e.g. with an electronic leak tester. Such equipment is
able to detect leaks of less than 5 gr. per year.
The leak tester used must be specially designed for the refrigerant
composition in the air conditioning system. For example, leak
detectors for refrigerant R12 are not suitable for R134a, because
the refrigerant R134a is free of chlorine atoms, meaning that this
leak detector will not respond.
Fig. 452
Leak test with soap bubbles

Points susceptible for leakage are sprayed with a soapy solution.
Bubbles indicate the leak. The detection limit for R 134a is 250 g/
year.
Fig. 453: Soap bubble test
11.6.4 Checking the magnetic clutch

Cross-section of non-operated
magnetic clutch
If the coil (7) is not supplied with operating voltage, there is no con-
tact between the front plate of the clutch (1) and the V-belt pulley
(2). A spring presses the front plate away from the belt pulley. The
V-belt pulley rotates with the bearing (3) in idle speed, the com-
pressor does not work. When the coil is supplied with operating
voltage (12 or 24 V), a magnetic field is generated and pulls the
front plate of the clutch. Both front plate and compressor shaft (8)
are then driven by the V-belt pulley, the compressor works.
In case of excessive flatness faults or deviations

the magnetic clutch needs to be replaced.
Fig. 454

Checking the magnetic clutch

1. Take off the drive V-belt and rotate the V-belt pulley by hand
while the magnetic clutch is disengaged.
2. Measure the air gap on the magnetic clutch between V-belt
pulley (2) and thrust plate (1). The gap should be 0.4 to 0.8
mm.
3. Measure the voltage (nominal value: vehicle voltage)
4. Check the current consumption.
at 12 Volt vehicle voltage approx. 3.5 Amp.

Fig. 455: Measuring the air gap
at 24 Volt vehicle voltage approx. 1.75 Amp.
Overcurrent indicates a short circuit inside the
magnetic coil.
No current indicates an interrupted electric circuit.

Disposal
12 Disposal

Disposal – Final shut-down of machine
12.1 Final shut-down of machine

If the machine can no longer be used and needs to be finally shut
down you must carry out the following work and have the machine
disassembled by an officially recognized specialist workshop.
WARNING!
Health hazard caused by fuels and lubricants!
– Safety regulations and environmental protec-
tion regulations when handling fuels and lubri-
cants must be followed Ä Chapter 1.2.4 „Han-
dling fuels and lubricants“ on page 17.

n Safety shoes
n Protective gloves
n Safety goggles
1. Remove the batteries and dispose of in compliance with legal

regulations.
2. Empty the fuel tank.
3. Drain the hydraulic oil tank.
4. Empty the AdBlue®/DEF tank.
5. Drain coolant from cooling system and engine.
6. Drain off engine oil.
7. Drain off gear oil.

Special tools
13 Special tools

Special tools – Special tools, electrics
13.1 Special tools, electrics
Special tool kit
n Special pliers tool kit consisting of:

n BOMAG part-no.: 079 950 03
n - different tool heads
n - unlocking tools
n - manual
n - operating instructions and plastic box to store the different
Fig. 456: TOO-07995003 contacts
The contacts are not contained in the kit.

Depending on the contact to be crimped, the
matching tool head must be attached to the
handle.
Equipment kit for special tool kit (1)
n Equipment kit
Fig. 457
Electric measuring case
n Electric measuring kit consisting of:

n - Prong-type instrument
n - Measuring adapter
n - Measuring cables
n - Screwdriver
Fig. 458 n - Other accessories

Special tools – Special tools, hydraulic system
13.2 Special tools, hydraulic system

13.2.1 Special tools, tests and adjustments
n Hydraulic test case, large
4 X 600 bar pressure gauges

4 X 60 bar pressure gauges
8 pressure test hoses
Fig. 459
n Hydraulic test case, small

2X 60 bar pressure gauge

2X 600 bar pressure gauges
4 pressure test hoses
Fig. 460
n Pressure test hoses

n 1000 mm BOMAG part-no.: 079 930 02
n 2500 mm BOMAG part-no.: 079 930 03
Fig. 461

n Pressure gauge
n 60 bar BOMAG part-no.: 059 721 07
n 600 bar BOMAG part-no.: 059 721 04
Fig. 462
n Adapter for pressure test hose

Fig. 463
n Gear pump testing device

Fig. 464

n Vacuum pump for hydraulic oil tank

n BOMAG part-no.: 007 610 04 (12 Volt)
n BOMAG part-no.: 007 610 24 (24 Volt)
Fig. 465
13.2.2 Special tools for flushing
The following list informs about special tools for

flushing. You should choose the corresponding tool
for the work to be carried out.
n Filling and filtering unit

n BOMAG part no.: 058 240 22
Fig. 466
n Flushing filter (S connection)

n Filter element 1μ
n Flushing hose 20S - 25S (2 pieces)
n Screw socket R1“ - 25S (2 pieces)
Fig. 467
n Flushing filter (L connection)

n Filter element
n Flushing hose 15L (2 pieces)
n Screw socket R3/4“ -- 15L (2 pieces)
Fig. 468

Special tools – Special tools for oscillating articulated joint
13.3 Special tools for oscillating articulated joint

n Pressing device for rocker bearings
Fig. 469
n Pressing bushing for outer rocker bearing race
Fig. 470
n Pressing bushing for inner rocker bearing race
Fig. 471
n Guide pin
Fig. 472

Special tools – Special tools for oscillating articulated joint
n Clamping device
Fig. 473
n Disassembly device
Fig. 474

Special tools – Special tools, drum
13.4 Special tools, drum

n Disassembly device for side plate
Fig. 475
n Assembly device for side plate

Fig. 476
n Assembly device for coupling hub and flanged hub
Fig. 477
n Pressing plate for cylinder roller bearing
Fig. 478

n Pressing plate for travel bearing
Fig. 479
n Pressing bushing for radial seal
Fig. 480
n Lifting device for exciter unit

Fig. 481


Index
14 Index

Index
B
Betriebsmittel
A83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
F
Fuels and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
H
Hydraulic units
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
L
List of fuels and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
M
Maintenance
Fuels and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
List of fuels and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Maintenance intervals
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Electric systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
O
Operating means
A02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 73
A05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 73, 93, 203
A06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
A12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 89
A13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 86, 116
A15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 79, 81, 84
A16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 89, 95
A51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 89, 95
A66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
A67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
A68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 73
A83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 73, 92
A87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
A93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66, 67
A108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 79, 190

Index
A124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 73
A138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
B03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 86, 104
B06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 83, 86
B11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 88
B13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 98
B14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 98
B16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
B21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 88, 101, 302, 313, 314
B30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 83, 86, 108, 116
B51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
B55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 86, 103
B60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 88, 93
B62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 92, 188
B104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 90, 190, 374
B105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358, 369
B112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
B113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 86, 116
B124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 82, 88, 105, 106
E03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 84
E04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 84
E07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67, 84
E08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
E17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
E23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 89, 91, 94
E25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 89, 91, 94
E27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 89, 91, 94
E28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 89, 91, 94
E29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 78, 89
E30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
E32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 89
E70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 78, 89
E71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 89

Index
E72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
EXX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 84
F00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 87
F03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
F05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
F07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
F18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
F31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 76, 89, 427
F39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 73
F40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
F41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 76, 89, 427
F42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 76, 95, 427
F43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68, 76, 89, 427
F44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 76, 89, 427
F48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
F67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
F68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
F84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
F97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
F105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
F124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
F130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 76, 89, 95, 427
F143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 76, 89, 427
F144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 76, 89, 427
F145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
F146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
F148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
F150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
F158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Index
F159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
G01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 87
G02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
G03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
H04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
H06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
H07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 84
H14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 88
H124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
K04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73, 191, 199
K05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 86, 116
K14.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 89
K35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69, 73
K41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
K48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 73
K61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 73
K69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 73
K114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 73
K141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 89
K150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
M01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 86, 87
M04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
M05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 89
M06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 89
M07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
M09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
M17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
P02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
P03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 84
P04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 84
P05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Index
P07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 84, 92

P09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 95
P11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
P12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 84
P14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
P15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
P16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 73, 92, 119
P33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 119
R01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
R02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
R03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 88, 102
R04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
R10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 73
R19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 115, 116
R25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
R26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
R78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
R79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70, 105, 106
R80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 89
S00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 79, 84
S01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 79, 85
S03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 79, 85
S06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 85, 89
S13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 79
S14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 79
S15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 79, 84
S16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
S20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 78, 89
S21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 78, 89
S28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
S29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
S30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
S35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 79, 85
S37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 79
S38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 78, 89
S42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 79, 85
S44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79, 190
S45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 78, 89
S53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 78, 79, 84
S55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
S118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Index
S120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 79, 84, 112

S158 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 78
S163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 78
S291 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
V01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
V02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
V03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
V04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
V05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
V09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
V21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
V22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
V47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Y01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 86, 110
Y04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71, 88, 302, 304
Y07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40, 71, 88, 275, 307, 318
Y08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40, 72, 88, 275, 307, 318
Y13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72, 86, 111
Y14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Y15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72, 90, 190, 358
Y30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72, 86, 88, 304
Y31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72, 88, 304
Y120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72, 86, 112
Y139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Overview
Central electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41, 306, 311, 400
Hydraulic system, charge circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Hydraulic system, flushing diagram for vibration circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Hydraulic system, steering circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313, 314
Hydraulic system, travel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Hydraulic system, travel circuit flushing diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Hydraulic system, vibration circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Hydraulics, closed circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
Hydraulics, open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Hydraulics, travel / vibration pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39, 274, 317

Index
P
Plugs
X1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 84, 85, 86, 88, 90, 92, 93, 96
X2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 85, 96
X3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 89, 91, 94, 96
X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84, 89
X6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88, 96
X7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88, 96
X8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88, 96
X9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88, 96
X10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88, 96
X11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85, 96
X15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
X16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
X17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90, 96
X18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90, 96
X21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86, 96
X22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
X36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 87, 96
X37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 96
X38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 86, 96
X42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85, 96
X44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73, 92, 96
X46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92, 96
X49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92, 96
X53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89, 96
X58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Index
X67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X70 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X71 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X74 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
X77 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
XS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91, 94
T
Table of operating means . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Trouble shooting
Axial piston motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461
Axial piston pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
Electric systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
Fault table hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456

Index

Appendix
Appendix

Appendix
A Circuit diagrams

Circuit diagrams
A Circuit diagrams
A.1 Hydraulic diagram 581 202 10 (58215, 58243, 58244, 58248, 58249)

Circuit diagrams

Circuit diagrams
A.2 Hydraulic diagram 581 202 11 (58242, 58247, 58355)

Circuit diagrams

Circuit diagrams
A.3 Hydraulic diagram 581 202 13 (58348, 58356)

Circuit diagrams

Circuit diagrams
A.4 Circuit diagram, 9

520
Bomag GmbH
Circuit diagrams
Industriegebiet Hellerwald
D-56154 Boppard

0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created M. Vogt Anlage = Blatt 1 von 47
Erstellt 25.08.2010 Cover sheet Function
==
BW 177-219 D-4/D-40 Funktion 9
Checked M. Werner Mounting location
Geprüft 25.08.2010
Deckblatt Einbauort + EPE / 000 / 00
Table of contents
Inhaltsverzeichnis
Page Higher-level function Function
Blatt Anlage Funktion Description Beschreibung
1 Cover sheet Deckblatt
2 Table of contents Inhaltsverzeichnis
3 Table of contents Inhaltsverzeichnis
4 Supply, Starting unit Versorgung, Starten
5 Pre-heating, Fuel-pre-heating Vorglühen, Kraftstoffvorwärmung
6 Fuse protection potential 30 Absicherung Potential 30
7 Fuse protection potential 15 Absicherung Potential 15
8 Engine speed, Brake, Back-up alarm Motordrehzahl, Bremse, Rückfahrwarneinrichtung
9 Seat contact, Vibration Sitzkontakt, Vibration
10 Speed range selection, Warning horns Fahrstufen, Warnhörner
11 Monitoring, Failure indicators Überwachung, Störmeldungen
12 Indicators, Speedsensor Anzeigen, Geschwindigkeitsaufnehmer
13 Supply Measurement controller Versorgung Messtechniksteuerung
14 Option Measurement equipment Option Messtechnik
15 Option Measurement equipment Option Messtechnik
16 BOMAG Compaction Management BCM, GPS BOMAG Verdichtungsmanagement BCM, GPS
17 Option StvZO illumination Option StvZO Beleuchtung
18 Rops - Lighting, Socket Rops - Beleuchtung, Steckdose
19 Cabin - Supply, Fuse protection Kabine - Versorgung, Absicherung
20 Cabin - Lighting, Socket Kabine - Beleuchtung, Steckdose
21 Cabin - Cabin equipment, Radio, Tachograph Kabine - Kabinenausrüstung, Radio, Tachograph
22 Cabin - Heating, Air conditioning, Additional Heater Kabine - Heizung, Klimaanlage, Zusatzheizung
23 Electronical Burglary protection Elektronische Diebstahlsicherung
24 Bomag telematics Bomag Telematik
25 Device tag list Betriebsmittelliste
31 Terminal strip overview X1 Klemmleistenübersicht X1

32 Terminal strip overview X2 Klemmleistenübersicht X2
33 Plug overview Steckerübersicht
38 Pin overview A15 Pin Übersicht A15
39 Pin overview A83 Pin Übersicht A83
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Table of contents Function
==
Geprüft 25.08.2010
Inhaltsverzeichnis Einbauort + EPE / 000 / 00
Circuit diagrams
521
522
Table of contents
Inhaltsverzeichnis
Page Higher-level function Function
Blatt Anlage Funktion Description Beschreibung
Circuit diagrams
40 Overview Central Electric Übersicht Zentralelektrik

41 Overview Central Electric Übersicht Zentralelektrik
42 View Terminal strip X1 below Ansicht Klemmleiste X1 unten
43 View Terminal strip X1 above Ansicht Klemmleiste X1 oben
44 View Terminal strip X1 above Ansicht Klemmleiste X1 oben
45 View Terminal strip X1 StVZO Ansicht Klemmleiste X1 StVZO
46 View Terminal strip X2 Ansicht Klemmleiste X2
47 Overview plug location Übersicht Steckerposition

0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Table of contents Function
==
Geprüft 25.08.2010
Inhaltsverzeichnis Einbauort + EPE / 000 / 00
F48:2 / 5.0 30 / 6.0
F158:2 / 5.0 K11:30 / 7.0
F159:2 / 5.0
X36 A B F13:2 / 6.4
X37 A
2 2 2 2 30
F48 F158 F159 F00 S00

125A 1 50A 1 50A 1 125A 1 15/54 58 19 17 50a
Ignition switch
Startschalter
S120:23 / 8.0
X1 79 X37 B
X1 4 X1 3
Fuse, glow plug 1

Fuse, glow plug 2
30
Fuse, heating-flange
Sicherung Heizflansch
Sicherung Glühkerze 1
Sicherung Glühkerze 2
K05
1 /8.5 87 87a
Fuse, main Central-electric

X1:4 / 8.0
Only at BW 177 D/PD-4

Nur bei BW 177 D/PD-4
Relay, starting current
V01
Hauptsicherung Zentralelektrik
Relais Startstrom
2
X1 8 7
86 1 30 15/54 / 5.0
R10 K61 X1 53
82 Ω /4.4 87 87a K05:87a / 5.0
K61 85 2
Relay, charge control
12V
Relais Ladekontrolle
Relais Ladekontrolle
Relay, charge control

G03 + G01 + 2
12V / 100 Ah 12V / 100 Ah A68:14 / 9.0 Y01
Battery Battery A
- - X1 1 1 X38
Batterie Batterie
D+ MESX/ 15.0 BW 211...219D-4/D-40
BW 177...213D-40 USA
D+ TM/ 24.0
option
Option 45 50 30
Only at D-40 USA version and BW 219 D-4, otherwise option winterpackage
Nur bei D-40 USA Version und BW 219 D-4, sonst Option Winterpacket
D+ / 11.0
X1 65 M01
1
S30 B+ D+ -
Only at air conditioning

250A 86 86 Nur bei Klimaanlage 86
2 1 1
Disconnect switch, battery G Y01 Y139
Batterietrennschalter
G02 K36 K09 K11
12V 12V 12V 2 2
85 85 85
B- W
BW 177 D/PD-4
BK X1 66
70mm²
BK W / 12.0 X1 168 55 55
70mm²
Ground Central Electric
Masse Zentralelektrik
31 31 31 31

Ground Engine
Masse Motor
31 31 31 31 31 31 31 31
Ground Frame Rear
Masse Hinterrahmen
87 87 87 87 30 /7.2
87a 30 /4.5 87a 30 /8.6 87a 30 /22.1
Generator Relay, brake control Relay, potential 30 on 15 Solenoid valve, start boost fuel Starter
Generator Relais Bremskontrolle Relais Potential 30 auf 15 Magnetventil Startmehrmenge Starter
Relay, air conditioner Solenoid valve, boost fuel
Relais Klimaanlage Magnetventil Minusangleichung
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Supply, Starting unit Function
==
Geprüft 25.08.2010
Versorgung, Starten Einbauort + EPE / 000 / 00
Circuit diagrams
523
524
4.2 / F159:2
F124:2 / 7.0
4.2 / F158:2
4.8 / K05:87a
4.6 / 15/54
X1
52
Circuit diagrams
4.2 / F48:2
A13
/5.5
Glow control unit
Glühzeitsteuergerät
2 7 5
A13 15 TK 50 30
/5.1
3 1 30
K14 R26
/5.3 4 220 kΩ H
Glow control unit

2
Glühzeitsteuergerät
Relais Vorglühen
Relay, glow plug system
L 31 R H
3 4 6 1
3
K14.1
/5.6 4
Relay, glow plug system
Relais Vorglühen
X1 217
Option Winterpackage
Option Winterpaket
X1 75 X67 1
1 1 86 86 1 1 1
R19 B113 K14 Glow / 11.0 K14.1 R02 R78 R79
Only at D-40 USA version and BW 219 D-4, otherwise option winterpackage
Nur bei D-40 USA Version und BW 219 D-4, sonst Option Winterpacket
167A 2 2 12V 12V 50A 2 50A 2 200W 2
85 85
X67 2
X1 57 64 57 218
Ground Engine
Masse Motor
31 31 31

31 31 31 31
3 4 /5.1 3 4 /5.7
Heating-flange Relay, glow plug system Relay, glow plug system Glow plug 1 Glow plug 2 Fuel-pre-heater
Heizflansch Relais Vorglühen Relais Vorglühen Glühstiftkerze 1 Glühstiftkerze 2 Kraftstoffvorheizung
Sensor, coolant temperature
Sensor Kühlmitteltemperatur
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Pre-heating, Fuel-pre-heating Function
==
Geprüft 25.08.2010
Vorglühen, Kraftstoffvorwärmung Einbauort + EPE / 000 / 00
Erstellt
Geprüft
Created
Checked
0
4.9 / 30
M. Vogt
25.08.2010
25.08.2010
M. Werner
15A
F22
Relais Arbeisscheinwerfer
Relay, working lights
/17.3
K06
X1
X1
Fuse, working lights rear

Sicherung Arbeisscheinwerfer hinten
2
1
87
21E
21A
X1
2
30
87a
15A
F19
1
X1
X1
Fuse, working lights front

Sicherung Arbeitsscheinwerfer vorne
2
1
22E
22A
Only at option measurement equipment

Nur bei Messtechnik
10A
F84
/9.1
S01
X1
X1
X1
X1
Fuse, controller (pin 54)

Sicherung Steuerung (Kontakt 54)
2
1
32
31
146
145
34E
34A
BW 177-219 D-4/D-40
2
15A
F146
X1
X1
Fuse, controller MESX (pot.30)

Sicherung Steuerung MESX (Potential 30)
2
1
35E
35A
Only at option GPS

3
Nur bei Option GPS

5A
F150
WH
X2
X2
Fuse, GPS receiver

2,5mm²
Sicherung GPS Receiver

2
1
WH
80E
80A
2,5mm²
X1
9
4
X1
10
X1:2 / 17.0
4.7 / F13:2
30A
F13
X1
X1
Fuse, ignition switch

Sicherung Startschalter
2
1
15E
15A
Absicherung Potential 30
Only at option electronical burglary protection
Fuse protection potential 30

Nur bei Option elektronische Diebstahlsicherung
5A
F68
X1
X1
Fuse, burglary protection

Sicherung Diebstahlsicherung
2
1
16E
16A
6
20A
F105
X1
X1
Fuse, engine speed

Sicherung Motordrehzahl
2
1
17E
17A
Only at StvZO-illumination
Nur bei StvZO-Beleuchtung
15A
F11
X1
X1
Fuse, head light front

Sicherung Scheinwerfer vorne
2
1
7
18E
18A
15A
F07
X1
X1
Anlage
Fuse, hazard light
Function
Funktion
Einbauort
Sicherung Warnblinker
2
1
19E
19A
Mounting location
Higher-level function
8
+
=
==
Blatt
Page
6
F22:2 / 18.0
F19:2 / 18.0
F84:2 / 13.0
X1:10 / 19.0
F11:2 / 17.0
F07:2 / 17.0
F105:2 / 8.0
F146:2 / 13.0
F150:2 / 16.0
F68:2.1 / 24.0
9
von
from
47
EPE / 000 / 00
Circuit diagrams
526
4.9 / K11:30
30
K11
/4.6 87
Relay, potential 30 on 15
Relais Potential 30 auf 15
Circuit diagrams
X1 37E X1 25E X1 26E X1 27E X1 28E X1 29E X1 30E X1 31E X1 32E X1 33E
1 1 1 1 1 1 1 1 1 1
F124 F08 F18 F14 F23 F25 F39 F24 F03 F148
25A 2 15A 2 10A 2 15A 2 10A 2 10A 2 15A 2 10A 2 15A 2 10A 2
X1 37A X1 25A X1 26A X1 27A X1 28A X1 29A X1 30A X1 31A X1 32A X1 33A
Fuse, vibration
Fuse, indicators
Fuse, main cabin
Sicherung Blinker
Fuse, signal horns
Sicherung Vibration
Fuse, fuel-pre-heating
Hauptsicherung Kabine
Sicherung Signalhörner
Sicherung Hubmagnet Motor

Fuse, shut off solenoid engine
Primary fuse, work. head light

Fuse, controller MESX (pot.15)
Sicherung Kraftstoffvorheizung
Vorsicherung Arbeitsscheinwerfer
Only without seat contact
Nur ohne Sitzkontakt
Fuse, monitoring-module, indicators
Fuse, soleonid valves travel and brake

Sicherung Magnetv. Fahren u. Bremse
Sicherung Steuerung MESX (Potential 15)
Sicherung Überwachungsmodul, Anzeigen

5.9 / F124:2 F148:2 / 14.0
Only at StvZO-illumination
Nur bei StvZO-Beleuchtung
F03:2 / 9.0
F24:2 / 11.0
F39:2 / 18.0
F25:2 / 8.0
F23:2.1 / 10.0

F14:2.1 / 9.0
F18:2 / 17.0
F08:2 / 17.0
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Fuse protection potential 15 Function
==
Geprüft 25.08.2010
Absicherung Potential 15 Einbauort + EPE / 000 / 00
7.8 / F25:2
6.8 / F105:2
4.6 / S120:23 X1 156
4.5 / X1:4 F25:2 / 10.0
X12 1 3 X13 3 1
BN BU BU BN
30 30 B13 B14
+ - - +
K35 K114 Proximity switch, travel lever "0" position Proximity switch, travel lever forw. and "0" position
/8.2 87a 87 /8.1 87 87a Initiator Fahrhebel "0" Initiator Fahrhebel vorwärts u. "0"
Relay, holding contact Relay, engine rpm Opened in break position BK Closed in forward and "0" position BK
Relais Selbsthaltung Relais Motordrehzahl geöffnet in Bremsposition geschlossen in vorwärts und "0" position
30
X12 2 K48 X13 2
/8.4 87a 87
Relay, travel lever 0-position
X1 80
Fwd Relais Fahrhebel 0-Stellung
11 23 86 148 30 30
X1
S120 K35 K36 K26
Switch, engine speed 12 24 12V /4.5 87a 87 /8.7 87a 87
85
Schalter Motordrehzahl Relay, holding contact Relay, brake control Relay, backup-alarm
Relais Selbsthaltung Relais Bremskontrolle Relais
Rückfahrwarnsummer
Rev K48:87a / 11.0
K26:87a / 9.4
X1 81 60 59 58 147 153 114

11
S01
Switch, emergency off /9.1 12
Schalter NOT AUS 150
X1
A68:12 / 9.0 Brake MESX/ 15.0
X1 113 X9 1
AW/HW
86 AUX + 2 86 86 1 86 +
K114 Y120 V47 K48 K05 Y04 K26 H14
2,41A
12V 70A/1A - 1 12V 12V 2 12V 300mA -
85 85 85 85
X9 2
X1 118 62 63 56 118 117 117 104 149 117

31 31 31 31 31 31 31 31 31 31
87 87 87 87 87
87a 30 /8.2 87a 30 /8.1 87a 30 /8.5 87a 30 /4.7 87a 30 /8.9
Relay, engine rpm Solenoid valve, rpm engine high Relay, travel lever 0-position Solenoid valve, brake Relay, backup-alarm Back-up alarm Buzzer
Relais Motordrehzahl Magnetventil Motordrehzahl hoch Relais Fahrhebel 0-Stellung Magnetventil Bremse Relais Rückfahrwarnsummer Rückfahrwarnsummer
Relay, starting current
Relais Startstrom
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Engine speed, Brake, Back-up alarm Function
==
Geprüft 25.08.2010
Motordrehzahl, Bremse, Rückfahrwarneinrichtung Einbauort + EPE / 000 / 00
Circuit diagrams
527
528
7.8 / F03:2
4.4 / A68:14
8.5 / A68:12 A68:13 / 11.6
7.8 / F14:2.1
A68
Module, seat contact 12 14 13
Circuit diagrams
Modul Sitzkontakt
Fahren
Driving
D+ Alternator
D+ Generator
Motoröldruck
Only without seat contact
Nur ohne Sitzkontakt
Engine oil pressure

1
30 56
Not at BW 177 D/PD-4
Nicht bei BW 177 D/PD-4
4 K04
Module, vibration
Modul Vibration
S 56b 31
9 11 6 15 5
ohne Sitzkontakt
without seat contact
ohne Sitzkontakt

ohne Sitzkontakt
X1 151 V09

2 1
21 11 31 30 8.9 11.0
S01 K69 K26:87a A68:6
Switch, emergency off 22 12 32 /9.3 87 87a
Schalter NOT AUS 159
X1
/8.6
/6.2
Relay, engine shut off
152 Relais Motorabschaltung 13 23
low
0
high
X1
S35
Switch, vibration low/high 14 24
Vibrationsschalter klein/groß
30 X1 158 157 X1 160 161
K22 GA TAC/ 21.7
/11.3 87a 87
KA TAC/ 21.7

KA MESX/ 15.0
X1 54 X14 B X11 1 X1 115 116
Relay, shut off solenoid engine

GA MESX/ 15.0
Relais Hubmagnet Abschaltung Motor

S06 BU S13 3 X7 1 X6 1
1 86
Y13 K69 SW 4 Y08 Y07
3,8A
2 12V 3,33A A 3,33A B
85
X14 A X11 2 X7 2 B - BW 214 D-4, X6 2 A - BW 214 D-4,
BW 218 D-40 BW 218 D-40
BW 219 D-4 BW 219 D-4
b - 177 D-4 a - 177 D-4
Only at BW 177 D/PD-4 with seat contact

Nur bei BW 177 D/PD-4 mit Sitzkontakt
X1 55 63 149 154 149 118 149

31 31 31 31 31 31 31
87
87a 30 /9.2
Shut off solenoid, engine Relay, engine shut off Switch, seat contact Solenoid valve, vibration front low
Hubmagnet Motorabschaltung Relais Motorabschaltung Schalter Sitzkontakt Magnetventil Vibration vorne klein
Switch, vibration travel lever right Solenoid valve, vibration front high
Schalter Vibration Fahrhebel rechts Magnetventil Vibration vorne gross
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Seat contact, Vibration Function
==
Geprüft 25.08.2010
Sitzkontakt, Vibration Einbauort + EPE / 000 / 00
7.8 / F23:2.1
8.8 / F25:2
only D-40, BW 177 D/PD-4 Standard D-machines, D/PD-40 USA, 216+218 D/PD-40
nur D-40, BW 177 D/PD-4 Standard D-Maschinen, D/PD-40 USA, 216+218 D/PD-40 X1 155
13 1234 2 13 23
S42 S42 S03
Switch, speed range selector 14 Switch, speed range selector 1 5 7 3 Pushbutton, warning horn 14 24
Schalter Fahrstufen Schalter Fahrstufen Taster Signalhorn
X1 143 X1 144 162 143 97 98
V02 V03
2 1 1 2
X1 141 137 142 141 101 102
1 1 1 1 2 + + 2
Y31 Y30 Y30 Y31 V21 B11 B11 V22
1,23A
1,23A 2 1,23A 2 2 1,23A 2 1 4,2A - 4,2A - 1
X1 124 138 124 99 103 104 100
only BW 216-219 D/PD-4/-40

nur BW 216-219 D/PD-4/-40
not at BW 216-219 D/PD-4/-40
nicht bei BW 216-219 D/PD-4/-40

31 31 31 31 31 31 31
Solenoid valve, speed range selection axle Solenoid valve, speed range selection drum Solenoid valve, speed range selection axle Warning horn Warning horn
Magnetventil Fahrstufe Achse Magnetventil Fahrstufe Bandage Magnetventil Fahrstufe Achse Signalhorn Signalhorn
Solenoid valve, speed range selection drum
Magnetventil Fahrstufe Bandage
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Speed range selection, Warning horns Function
==
Geprüft 25.08.2010
Fahrstufen, Warnhörner Einbauort + EPE / 000 / 00
Circuit diagrams
529
530
7.8 / F24:2 F24:2 / 12.0 A15
Monitoring-module
Überwachungsmodul
X1 86 Armature carrier
Armaturenträger
X1:86 / 12.0 14 X5 Hazard light
Warnblinklicht HAZ / 17.7
14
+ Ub X5 26
+ Ub 12 X5 Indicator right X1
26
Circuit diagrams
Blinker rechts 96
IND-R / 17.8
12
X1 Glowing X5 3
5.5 / Glow 13
78 Glühen 3 X5 Indicator left X1
Blinker links 91
IND-L / 17.8
13
X1 Charge control X5 10
4.4 / D+ 5
69 Ladekontrolle 10 X5 Night dimout
Nachtabdunklung ILL / 17.0
5
X1 Brake X5 4
8.5 / K48:87a 22
87 Bremse 4 X5 Water trap
Shutoff 2 min. 22 Wasserabscheider
X1 Seat X5 9
9.5 / A68:6 21
88 Sitz 9 X5 Water trap
Shutoff 2 min. 21 Wasserabscheider
23 25 24 1 17 16 8 11 15
Shutoff 2 min. Shutoff 2 min. Shutoff 10 sec. Shutoff 10 sec.
X5 23 25 24 1 17 16 8 11 15
GND
GND
Luftfilter
Air cleaner
Fuel gauge
1
Tankanzeige
Coolant level
Motoröldruck
Hydr. oil filter
Out Motor stop

V05
Out Motor-Stop
Hydraulikölfilter
Out Warnsummer
2
Kühlmittelfüllstand
Engine oil pressure
Out warning buzzer

Coolant temperature
Kühlmitteltemperatur
X1 89 90 109 110 71 77 76 72 111 112
9.6 / A68:13
B30:2 / 12.3
X1 105 106 67 74 61 73 68 107 108
X10 2 X21 1 X8 1 2
+ 86 1 3 (1) 3 (1) 1 2 1 3
Θ 1
H07 K22 R03 B21 P B03 P B30 B06 P B55 B124
70mA - 12V 65,4 Ω 4 (2) 4 (2) 2 4 2
85 2
X10 3 X21 2
X1 82 117 117 117 57 56

Ground Engine
Masse Motor
only at D-4/D-40 USA, option at D-40

nur bei D-4/D-40 USA, Option bei D-40
31 31

not at D-40 and BW 177 D/PD-4
nicht bei D-40 und BW 177 D/PD-4
31 31 31 31 31 31
87 not at D-40
87a 30 /9.1 nicht bei D-40
Warning buzzer, breakdown Sender, level gauge Vacuum switch, air cleaner Pressure switch, engine oil Water trap
Warnsummer Betriebsstörung Geber Tankanzeige Luftfilterwartungsschalter Druckschalter Motoröl Wasserabscheider
Relay, shut off solenoid engine Pressure diff. switch, hydr. oil filter Temperature switch, engine oil Floating switch, Coolant expansion tank
Relais Hubmagnet Abschaltung Motor Differenzdruckschalter Hydr.-Ölfilter Temperaturschalter Motoröl Schwimmerschalter Kühlmittelausgleichsbehälter
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Monitoring, Failure indicators Function
==
Geprüft 25.08.2010
Überwachung, Störmeldungen Einbauort + EPE / 000 / 00
11.1 / F24:2
11.1 / X1:86
X1 225 187
BN
X22 1
4.4 / W 11.6 / B30:2
X1 70 226 189 191 171 175 92
BN
G + +
at BW177 and BW219 BN

at BW 211-216 PIN C
+ G + GNYE P05 + P04 +
+ +
at BW177 and BW219 WH

not at BW 211-216
X22 DIR MESX/ 15.0
dir dir WH X1
P03 n P12 V P02 P14 B16
speed 4 Hz B60
speed 173
BU X1
- - G - 3 - 172
SPEED MESX/ 15.0 -
Speedometer
- X22 BK
- -
Frequenzanzeige
Frequency meter
E03 EXX EXX EXX
Sensor, axle speed

/17.0 /17.2 /17.2 /17.2 EXX Speed TAC/ 21.0 E04
Geschwindigkeitsanzeige
/17.2 BK /17.1
X1 188 192
Aufnehmer Vibrationsfreq.vorne
Aufnehmer Achsgeschwindigkeit
Voltmeter
Voltmeter
RPM meter
X1 93
Transducer, vibration frequency, front

at BW 211-216 PIN A
Drehzahlmesser
at BW177 and BW219 BU
at BW177 and BW219 BK

at BW 211-216 PIN B
2 A06 A05
Temperature gauge, coolant

X22
Anzeige Kühlmitteltemperatur
IN 15/54 OUT+ OUT- IN 15/54 OUT+ OUT-
Temperaturanzeige Hydrauliköl
Temperature gauge, hydraulic oil
BU
X1 227
Electronic, speedometer
X1 223
Electronic, frequency-meter front

Elektronik Frequenzanzeige vorne
Elektronik Geschwindigkeitsanzeige
GND 1 3 4 GND 1 3 4
2
Θ
R04
1
BW 177-179 D-4/40 ----
BW 177-179 DHC-4 / DH-40 ----
Sensor Hydrauliköltemperatur
Sensor, hydraulic oil temperature
BW 211-216 D-4/40 PIN 1 - GND
BW 213-214 DHC-4 / DH-40 PIN 1 - GND
BW 216 DHC-4 PIN 3 - 15/54
X1 82 224 228 190 174
BW 219 D-4 PIN 3 - 15/54

31 31 31 31 31
only at option
measurement-equipment,
Option Option frequency meter speedometer and tachograph Option speedometer
Option Option Frequenzanzeige Nur bei Option Messtechnik, Option Geschwindigkeitsanzeige
Geschwindigkeitsanzeige, Tachograph
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Indicators, Speedsensor Function
==
Geprüft 25.08.2010
Anzeigen, Geschwindigkeitsaufnehmer Einbauort + EPE / 000 / 00
Circuit diagrams
531
532
6.8 / F146:2
6.8 / F84:2 A83:28 / 14.2
Ground housing Ground Electronic Ground Baby-Board 1 Ground Baby-Board 1 Ground Baby-Board 2 Ground Baby-Board 2
Masse Gehäuse Masse Elektronik Masse Baby-Board 1 Masse Baby-Board 1 Masse Baby-Board 2 Masse Baby-Board 2
Circuit diagrams
ESX2 ESX2 ESX2 ESX2 ESX2 ESX2

Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller
A83 A83 A83 A83 A83 A83

Ground Housing GND XGND1 XGND1 XGND2 XGND2
box X44 55 X44 65 X44 66 X44 67 X44 68
X44 55 65 66 67 68
X44 54 28 56 57 58 59 60
X44 54 X44 28 X44 56 X44 57 X44 58 X44 59 X44 60

UE D+ UB UB UB UB UB
A83 A83 A83 A83 A83 A83 A83
Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller
ESX2 ESX2 ESX2 ESX2 ESX2 ESX2 ESX2
Ignition Power Supply (Electronic) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs)
Zündung Spannungsvers. (Elektronik) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge)
A83
Measurement controller
Messtechnik Steuerung
X2 49 52 63 66

31 31 31 31
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Supply Measurement controller Function
==
Geprüft 25.08.2010
Versorgung Messtechniksteuerung Einbauort + EPE / 000 / 00
7.8 / F148:2 F148:2 / 16.0
13.2 / A83:28
X2 53 57 X2 47 48 49
X42 1 2 3
X2 56 60 71 66 70
X4 C D E X46 B A E
X48 1 2 X49 1 2
X74 3 5 4
P16 P33
BK GNYE BK GNYE P11 15 GND GY(GR) RD(RT) WH(WS)
+ +
- -
Opus 21
Opus 21
B62 B62
15g 15g
Printer
Drucker
20g 20g
BN BU BN BU
Transducer acceleration
Transducer acceleration
Diagnose Variomatic
Beschleunigungsaufnehmer
Beschleunigungsaufnehmer
Diagnostics, variomatic
X48 4 3 X49 4 3
CAN + CAN - PK(RS) BU(BL)

Only at BTMprof Only at BEM Only at BTMprof
Nur bei BTMprof Nur bei BEM Nur bei BTMprof
X74 1 2
X46 D F
X4 A B X42 4 5
R01
X2 55 54 59 58 68 64 65 50 51
2 1
60 Ω
X44 31 X44 29 X44 7 X44 30 X44 1 X44 4 X44 5 X44 27 X44 26
X44 31 X44 29 X44 7 X44 30 X44 1 X44 4 X44 5 X44 27 X44 26

AI/6 AI/2 AI/3 AI/4 AGND RxD TxD +Wire1 -Wire1
A83 A83 A83 A83 A83 A83 A83 A83 A83
Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller
ESX2 ESX2 ESX2 ESX2 ESX2 ESX2 ESX2 ESX2 ESX2
Transducer Acceleration front 20g Transducer Acceleration front 15g Transducer Acceleration rear 20g Transducer Acceleration rear 15g AGND RxD TxD CAN 1 + CAN 1 -
Beschleunigungsaufn. vorne 20g Beschleunigungsaufn. vorne 15g Beschleunigungsaufn. hinten 20g Beschleunigungsaufn. hinten 15g Analogmasse RxD TxD CAN 1 + CAN 1 -

31
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Option Measurement equipment Function
==
Geprüft 25.08.2010
Option Messtechnik Einbauort + EPE / 000 / 00
Circuit diagrams
533
534
9.8 /KA MESX ILL MESX/ 17.2
9.8 /GA MESX ILL MESX STVZO/ 17.5
12.8 /SPEED MESX
12.8 /DIR MESX

Circuit diagrams
8.7 /Brake MESX
4.4 /D+ MESX
X44 37 X44 36 X44 14 X44 35 X44 38 X44 15 X44 41
X44 37 X44 36 X44 14 X44 35 X44 38 X44 15 X44 41

DI(D)/7 DI(D)/5 DI(D)/6 DI(D)/3 DI(D)/9 DI(D)/8 DI(D)/15
A83 A83 A83 A83 A83 A83 A83
Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller Measurement controller
ESX2 ESX2 ESX2 ESX2 ESX2 ESX2 ESX2
D+ Alternator Brake Driving direction Driving speed Vibration high amplitude Vibration low amplitude Illumination
D+ Generator Bremse Fahrtrichtung Fahrgeschwindigkeit Vibration große Amplitude Vibration kleine Amplitude Beleuchtung
Evib-Meter
Evib-Meter
ESX2
A83
DO(2,5A)/4
X44 3
X44 3
X1 85
P07
0-6V
Evib-Meter -
Evib-Meter
Only at BEM
Nur bei BEM
E07
/17.1
X1 82

31
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Option Measurement equipment Function
==
Geprüft 25.08.2010
Option Messtechnik Einbauort + EPE / 000 / 00
6.8 / F150:2 Power supply GPS
Spannungsversorgung GPS
ESX2
14.9 / F148:2
A83
DO(2,5A)/3
CAN 3 + CAN 3 -
CAN 3 + CAN 3 - X44 25
ESX2 ESX2
X44 25
Measurement controller Measurement controller
X2 79
A83 A83
+Wire2 -Wire2
X2 43 X2 44
X44 53 X44 33
X44 53 X44 33 X4 G X4 H X4 J
R25
2 1
X2 61 60 Ω 62 X73 A X73 B
X4 N M
X72 A X72 B
X75 7 2
A93
A87 GPS Receiver StarFire
USB-CAN Interface BCM GPS Empfänger StarFire
USB-CAN Schnittstelle BCM X71
12
X78
X71 1
6
X78
X71 2
5
USB
X78
USB X71 3
8
X78
4
X71 3 10 7
USB
P15
BCM05 USB X76
Vcc
BCM05 1
X72 D E C
X70
RxD
2
X70
TxD
3
X73 C
X70
AGND
5
X4 F

X76
GND X2 63
2
31
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 BOMAG Compaction Management BCM, GPS Function
==
Geprüft 25.08.2010
BOMAG Verdichtungsmanagement BCM, GPS Einbauort + EPE / 000 / 00
Circuit diagrams
535
536
6.8 / F07:2
7.8 / F08:2
6.8 / F11:2
7.8 / F18:2
304 308 305

Circuit diagrams
6.4 / X1:2 X1
X1 301 83
13 23 L 0R 13 23
S14 S37
012 31 11 23 Switch, hazard light 14 24 Switch, indicator 14 24
S15 Connection working head lights Warnblinkschalter Schalter Blinker
without StvZO
Switch, lighting StVZO 32 12 24 Anschluß Arbeitsscheinwerfer
Schalter Beleuchtung StVZO ohne StvZO 30 11.9 / HAZ 306 307
X1
K16
X1 302 303 /17.6 87a 87
Relay, head lights front X1 Wb LE RE 30
Relais Scheinwerfer vorne
H06
X2 A02
Flasher
11.9 / ILL
Blinkgeber
31 LA RA
Switch, working lights X1 23E X1 24E

Schalter Arbeitsbeleuchtung 1 1
+ + + + 13
E03 E04 E07 EXX S53 F09 F10
/12.0 - /12.9 - /15.3 - /12.1 - 14 15A 15A 11.9 / IND-R
Fuse, parking and 2 Fuse, parking and 2
12V 12V 12V /12.2
X1 23A X1 24A
Meldeleuchte Warnblinker
/12.3 tail light, lh tail light, rh

Indicator light, hazard light
/12.6 Sicherung Park- Sicherung Park- 11.9 / IND-L

12V u. Schlussl. links u. Schlussl. rechts
Connection illumination /
15.9 ILL MESX STVZO
instruments without StvZO
Anschluß Beleuchtung
Instrumente ohne StvZO
Beleuchtung Evibmeter
Illumination, evib meter
Illumination, RPM meter

X1 84 319 311 312 320 309 310 313 321 314 322
Illumination, speedometer
15.9 /ILL MESX
Beleuchtung Drehzahlmesser
Beleuchtung Zusatzinstrument
Connection Illumination
MESX without StvZO
Illumination, additional instrument

X60 3 X58 3 X59 3 X61 3 X58 5 X59 5 X58 2 X60 1 X59 2 X61 1
Anschluß Beleuchtung
Beleuchtung Geschwindigkeitsanzeige
MESX ohne StvZO
86 1 1 1 1 86 1 1 1 1 1 1
K06 E13 E12 E14 E15 K16 E16 E17 E08 E09 E10 E11
12V 85 5W 2 5W 2 5W 2 5W 2 12V 85 55W 2 55W 2 21W 2 21W 2 21W 2 21W 2
X60 4 X58 6 X59 6 X61 4 X60 2 X61 2
X1 82 117 324 315 316 315 323

31 31 31 31 31 31 31
87 87
87a 30 /6.0 87a 30 /17.6
Relay, working lights Relay, head lights front

Relais Arbeisscheinwerfer Relais Scheinwerfer vorne
Tail light, lh Parking light, rh Head light, lh Indicator, front left Indicator, front right
Schlussleuchte links Parkleuchte rechts Scheinwerfer links Blinkleuchte vorne links Blinkleuchte vorne rechts
Parking light, lh Tail light, rh Head light, rh Indicator, rear left Indicator, rear right
Parkleuchte links Schlussleuchte rechts Scheinwerfer rechts Blinkleuchte hinten links Blinkleuchte hinten rechts
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Option StvZO illumination Function
==
Geprüft 25.08.2010
Option StvZO Beleuchtung Einbauort + EPE / 000 / 00
7.8 / F39:2 F39:2 / 22.0
6.8 / F19:2
6.8 / F22:2
X3 4 5 3
Accession at Cabin
Anschluß bei Kabine
K32:86 / 19.0
Wl rear-Cab / 20.0
Wl front-Cab/ 20.0
Working head light, rear, lh.

Arbeitsscheinwerfer hinten links.
Working head light, rear, rh.
Arbeitsscheinwerfer hinten rechts.
Working head light, front, lh.
Arbeitsscheinwerfer vorne links.
Working head light, front, rh.
Arbeitsscheinwerfer vorne rechts.
Rops Socket
Ropssteckdose
+
1 1 1 1
E27 E28 E23 E25
55W 2 55W 2 55W 2 55W 2 XS -
12V
Accession at Rops
Anschluß bei Rops
X3 1

31
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Rops - Lighting, Socket Function
==
Geprüft 25.08.2010
Rops - Beleuchtung, Steckdose Einbauort + EPE / 000 / 00
Circuit diagrams
537
538
6.8 / X1:10
18.3 / K32:86
RD RD RD
4mm² 4mm² 4mm²
X3 6 7 8
Circuit diagrams
RD RD RD
4mm² 4mm² 4mm²
RD
6mm²
30
K32
/19.2 87
Relay, cabin
WH
Relais Kabine 6mm²
WH
6mm²
F44:B / 22.0
A C E G
F43 F130 F41 F143

15A 10A 10A 15A
1 3 Fuse, rotary 5 7
Fuse, wipermotor rear Fuse, night lamp Fuse, rear screen heating unit
Sicherung Wischermotor hinten Sicherung Nachtleuchte beacon Sicherung Heckscheibenheizung
Sicherung
Rundumkennleuchte
F43:1 F130:3 F41:5-2 F41:5-1 F143:7

21.0 20.0 22.6 20.0 21.0
Option
86
K32
BN BN 12V 85
6mm² 1,5mm² B D F H
F44 F31 F144 F42

15A 2 25A 4 15A 6 10A 8
Fuse, wipermotor front Fuse, cabin ventilator Fuse cabin-socket Fuse, inside light cab
Sicherung Wischermotor vorn Sicherung Kabinenlüfter Sicherung Kabinensteckdose Sicherung Kabineninnenleuchte
X3 1 2

31 31 31 31 31
Ground Central Electric Ground Cabin F44:2 F31:4 F144:6 F42:8 F42:H
Masse Zentralelektrik Masse Kabine 21.0 22.0 20.0 20.0 22.6
87 30 /19.4
Relay, cabin Option

Relais Kabine
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Cabin - Supply, Fuse protection Function
==
Geprüft 25.08.2010
Kabine - Versorgung, Absicherung Einbauort + EPE / 000 / 00
19.8 / F42:8 F42:8 / 21.0
19.5 / F130:3 F130:3 / 21.0
19.6 / F144:6
19.6 / F41:5-1
18.3 /Wl front-Cab
18.3 / Wl rear-Cab
5 1 1 1 1
S38 E29 E70 E72
Switch, Rotary beacon 1 21W 2 5W 2 24V 2 1 2
Schalter Rundumkennleuchte Inside light, cabin Night lamp
Innenleuchte Kabine Nachtleuchte
2
illum. Switches
Beleuchtung Bedienschalter
+ 3
S45 S158
TK - 4
Working head light, rear, lh

Arbeitsscheinwerfer hinten links
Working head light, rear, rh
Arbeitsscheinwerfer hinten rechts
Working head light, front, lh
Arbeitsscheinwerfer vorne links
Working head light, front, rh
Arbeitsscheinwerfer vorne rechts
+
1 1 1 1 +
E27 E28 E23 E25 E32
55W 2 55W 2 55W 2 55W 2 5A - XS -
12V
Option

Ground Cabin
Masse Kabine
31 31 31 31 31 31
Ground Cabin
Rotary beacon Cabin socket Switch, cabin inside light Switch, cabin night lamp
Rundumkennleuchte Kabinensteckdose Schalter Kabineninnenleuchte Schalter Nachtbeleuchtung
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Cabin - Lighting, Socket Function
==
Geprüft 25.08.2010
Kabine - Beleuchtung, Steckdose Einbauort + EPE / 000 / 00
Circuit diagrams
539
540
20.9 / F42:8
12.8 /Speed TAC
20.9 / F130:3
19.8 / F143:7
17
Circuit diagrams
19.4 / F44:2 X3
19.4 / F43:1
Electronic system A1
tachograph
Elektronik
P09
Tachograph A2+A3
A16 B3
1
7 2 7 2
5 6
01 01 B4
S163 2
1 B51 30 15 B51 4
Switch, rear
S21 5 4 S20 5 4 C3
screen heating + + 3 A = white
unit
- - B = yellow
Schalter A5+A6
31 8 C = red
Switch, windscreen wiper rear

Switch, windscreen wiper front
A12
Schalter Scheibenwischer vorne

Heckscheibenheizung
Schalter Scheibenwischer hinten

Radio
Radio Tachograph
9 Tachograph
5
7
/21.4
30
K141 Only at option Radio
Nur bei Option Radio
87 87a
A51
Circuit board,frequenzy meter 4 1
Platine Frequenzanzeige
Relay, heating rear screen

Relais Heckscheibenheizung
31b 53 31b 53
[blu/wht] [blu] [blu/wht] [blu]
X55 1 4 3 X56 1 4 3 X3
4 3 4 3 9.8 /KA TAC 2
15
2 1 53a 31b 53 2 1 53a 31b 53
31 53a 31 53a X3
1 9.8 /GA TAC 3
[blk] [blk/blu] [blk] [blk/blu] 16
M05 M04 1 I 15
2,9A 4,7A
+ + R80 E71 K141
31 31 12V 2 12V 31
2
M07 M06 5
3,8A 3,8A
Indicator light, switch rear screen heater

Kontrolleuchte Schalter Heckscheibenheizung
- -
Only at option Tachograph
Nur bei Option Tachograph
X55 2 X56 2

31 31 31 31 31 31 31 31 31 31
Ground Cabin
Masse Kabine
87
87a 30 /21.3
Windscreen wiper motor, rear Windscreen wiper motor, front Heater rear screen Relay, heating rear screen
Scheibenwischermotor hinten Scheibenwischermotor vorne Heckscheibenheizung Relais Heckscheibenheizung
Windscreen washer motor, rear Windscreen washer motor, front
Scheibenwaschermotor hinten Scheibenwaschermotor vorne
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Cabin - Cabin equipment, Radio, Tachograph Function
==
Geprüft 25.08.2010
Kabine - Kabinenausrüstung, Radio, Tachograph Einbauort + EPE / 000 / 00
19.5 / F44:B
18.3 / F39:2 19.6 / F41:5-2
19.5 / F31:4 19.9 / F42:H
X3 9 10
163 1 A B
X1
F97 F40 F15
3A 2 20A 1 5A 2
A108 Inline-Fuse Fuse, heating unit cab Fuse, heating unit
X17 1
Heating climatic unit Inlinesicherung Sicherung Kabinenheizung Sicherung Heizgerät
Heiz-Klima-Einheit Fuse, blower fresh air BOX2 BOX2
Supply
Sicherung Frischluftlüfter BOX2 BOX2
RD
11 2 3 1 12 13 14 16
Switch, cabin heating
5 7 11 3 10 1 Schalter Kabinenheizung
BK/GN BK S28
Out Gnd
E30
X17 4 2 Heating unit
Heizgerät
max. 8,3A
X1 166 219
2
X79 1
30 2 6 8 9 4 12
1 5 9 15 10 6 8 7 4
K09
/4.5 87 87a
Relay, air conditioner
Relais Klimaanlage
3
S29
X1 167 Switch, suspension seat 4
Schalter Luftfedersitz
X20 1 3
sw br
B104 P
LP HP MP
sw/ge br/sw
1
X20 2 4 X69 1 X77 1
Druckschalter Klimaanlage
M10
M
12V / < 9A rt
Pressure switch, air conditioning

2
Delivery equipment GRAMMER

Lieferumfang GRAMMER
2 1 1
V04 Y15 M17 Y14
1 3,5A 2 185 mA 2
X79 2 sw
X1 190 168 164 220 X69 2 X77 2

Ground Central Electric Ground Cabin
Masse Zentralelektrik Masse Kabine
31 31 31 31 31 31 31 31 31
Option Air conditioner Option suspension seat Option activated charcoal filter Option Additional heater
Option Klimaanlage Option Luftfedersitz Option Aktivkohlefilter Option Zusatzheizung
Magnetic clutch, air conditioning compressor Compressor, suspension operators seat Additional blower Fuel pump, heating unit
Magnetkupplung Klimakompressor Kompressor Luftfedersitz Zusatzlüfter Kraftstoffpumpe Heizgerät
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Cabin - Heating, Air conditioning, Additional Heater Function
==
Geprüft 25.08.2010
Kabine - Heizung, Klimaanlage, Zusatzheizung Einbauort + EPE / 000 / 00
Circuit diagrams
541
542
A67
Keyboard
Tastatur
Circuit diagrams
A66
Electronic control unit
Elektronik Steuereinheit
X68
1-9

0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Electronical Burglary protection Function
==
Geprüft 25.08.2010
Elektronische Diebstahlsicherung Einbauort + EPE / 000 / 00
A124
Electronic system, bomag telematics
Elektronik Bomag Telematik
A138
Antenna, bomag telematics
Antenne Bomag Telematik
GPS GSM
CAN_L
CAN_H
Pot. 30
Pot. 15
IN0
IN1
GND
GSM
GPS
4 3 12 2 8 11 1
6.8 / F68:2.1
4.4 /D+ TM

31
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Bomag telematics Function
==
Geprüft 25.08.2010
Bomag Telematik Einbauort + EPE / 000 / 00
Circuit diagrams
543
544
Device tag list
Betriebsmittelliste
Higher-level
Device tag Page Path Mounting location function characteristics
BMK Blatt Pfad Einbauort
Function text Funktionstext Techn.-Kenngrößen
Anlage
Circuit diagrams
A02 17 8 Flasher Blinkgeber

A05 12 8 Electronic, speedometer Elektronik Geschwindigkeitsanzeige
A06 12 5 Electronic, frequency-meter front Elektronik Frequenzanzeige vorne
A12 21 5 Radio Radio
A13 5 1 Glow control unit Glühzeitsteuergerät
A15 11 1 Monitoring-module Überwachungsmodul ---> Pin overview
A16 21 7 Electronic system tachograph Elektronik Tachograph
A51 21 8 Circuit board,frequenzy meter Platine Frequenzanzeige
A66 23 3 Electronic control unit Elektronik Steuereinheit
A67 23 6 Keyboard Tastatur
A68 9 3 Module, seat contact Modul Sitzkontakt
A83 13 2 Measurement controller Messtechnik Steuerung ---> Pin overview
A87 16 1 USB-CAN Interface BCM USB-CAN Schnittstelle BCM
A93 16 5 GPS Receiver StarFire GPS Empfänger StarFire
A108 22 0 Heating climatic unit Heiz-Klima-Einheit
A124 24 3 Electronic system, bomag telematics Elektronik Bomag Telematik
A138 24 6 Antenna, bomag telematics Antenne Bomag Telematik
B03 11 5 Vacuum switch, air cleaner Luftfilterwartungsschalter
B06 11 7 Pressure switch, engine oil Druckschalter Motoröl
B11 10 7 Warning horn Signalhorn 4,2A
B13 8 4 Proximity switch, travel lever "0" position Initiator Fahrhebel "0"
B14 8 7 Proximity switch, travel lever forw. and "0" position Initiator Fahrhebel vorwärts u. "0"
B16 12 4 Transducer, vibration frequency, front Aufnehmer Vibrationsfreq.vorne
B21 11 4 Pressure diff. switch, hydr. oil filter Differenzdruckschalter Hydr.-Ölfilter
B30 11 6 Temperature switch, engine oil Temperaturschalter Motoröl
B51 21 6 Speaker radio Lautsprecher Radio
B55 11 7 Floating switch, Coolant expansion tank Schwimmerschalter Kühlmittelausgleichsbehälter
B60 12 7 Sensor, axle speed Aufnehmer Achsgeschwindigkeit
B62 14 0 Transducer acceleration Beschleunigungsaufnehmer
B104 22 1 Pressure switch, air conditioning Druckschalter Klimaanlage

B113 5 2 Sensor, coolant temperature Sensor Kühlmitteltemperatur
B124 11 9 Water trap Wasserabscheider
E03 17 0 Illumination, RPM meter Beleuchtung Drehzahlmesser 12V
E04 17 1 Illumination, speedometer Beleuchtung Geschwindigkeitsanzeige 12V
E07 17 1 Illumination, evib meter Beleuchtung Evibmeter 12V
E08 17 8 Indicator, front left Blinkleuchte vorne links 21W
E09 17 8 Indicator, rear left Blinkleuchte hinten links 21W
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Device tag list Function
==
Geprüft 25.08.2010
Betriebsmittelliste Einbauort + EPE / 000 / 00
Device tag list
Betriebsmittelliste
Higher-level
Anlage
E10 17 9 Indicator, front right Blinkleuchte vorne rechts 21W

E11 17 9 Indicator, rear right Blinkleuchte hinten rechts 21W
E12 17 4 Parking light, lh Parkleuchte links 5W
E13 17 4 Tail light, lh Schlussleuchte links 5W
E14 17 5 Parking light, rh Parkleuchte rechts 5W
E15 17 5 Tail light, rh Schlussleuchte rechts 5W
E16 17 6 Head light, lh Scheinwerfer links 55W
E17 17 7 Head light, rh Scheinwerfer rechts 55W
E23 18 2 Working head light, front, lh. Arbeitsscheinwerfer vorne links. 55W
E25 18 2 Working head light, front, rh. Arbeitsscheinwerfer vorne rechts. 55W
E27 18 1 Working head light, rear, lh. Arbeitsscheinwerfer hinten links. 55W
E28 18 2 Working head light, rear, rh. Arbeitsscheinwerfer hinten rechts. 55W
E29 20 5 Inside light, cabin Innenleuchte Kabine 21W
E30 22 5 Heating unit Heizgerät max. 8,3A
E32 20 3 Rotary beacon Rundumkennleuchte 5A
E70 20 7 Night lamp Nachtleuchte 5W
E71 21 4 Indicator light, switch rear screen heater Kontrolleuchte Schalter Heckscheibenheizung 12V
E72 20 8 illum. Switches Beleuchtung Bedienschalter 24V
EXX 17 2 Illumination, additional instrument Beleuchtung Zusatzinstrument 12V
F00 4 3 Fuse, main Central-electric Hauptsicherung Zentralelektrik 125A
F03 7 6 Fuse, vibration Sicherung Vibration 15A
F07 6 8 Fuse, hazard light Sicherung Warnblinker 15A
F08 7 1 Fuse, indicators Sicherung Blinker 15A
F09 17 4 Fuse, parking and tail light, lh Sicherung Park- u. Schlussl. links 15A
F10 17 5 Fuse, parking and tail light, rh Sicherung Park- u. Schlussl. rechts 15A
F11 6 7 Fuse, head light front Sicherung Scheinwerfer vorne 15A
F13 6 5 Fuse, ignition switch Sicherung Startschalter 30A
F14 7 3 Fuse, shut off solenoid engine Sicherung Hubmagnet Motor 15A
F15 22 8 Fuse, heating unit Sicherung Heizgerät 5A
F18 7 2 Primary fuse, work. head light Vorsicherung Arbeitsscheinwerfer 10A

F19 6 1 Fuse, working lights front Sicherung Arbeitsscheinwerfer vorne 15A
F22 6 0 Fuse, working lights rear Sicherung Arbeisscheinwerfer hinten 15A
F23 7 3 Fuse, signal horns Sicherung Signalhörner 10A
F24 7 5 Fuse, monitoring-module, indicators Sicherung Überwachungsmodul, Anzeigen 10A
F25 7 4 Fuse, soleonid valves travel and brake Sicherung Magnetv. Fahren u. Bremse 10A
F31 19 5 Fuse, cabin ventilator Sicherung Kabinenlüfter 25A
F39 7 5 Fuse, main cabin Hauptsicherung Kabine 15A
0 1 2 3 4 5 6 7 8 9
==
Geprüft 25.08.2010
Circuit diagrams
545
546
Device tag list
Betriebsmittelliste
Higher-level
Anlage
Circuit diagrams
F40 22 6 Fuse, heating unit cab Sicherung Kabinenheizung 20A

F41 19 6 Fuse, rotary beacon Sicherung Rundumkennleuchte 10A
F42 19 8 Fuse, inside light cab Sicherung Kabineninnenleuchte 10A
F43 19 4 Fuse, wipermotor rear Sicherung Wischermotor hinten 15A
F44 19 4 Fuse, wipermotor front Sicherung Wischermotor vorn 15A
F48 4 0 Fuse, heating-flange Sicherung Heizflansch 125A
F68 6 5 Fuse, burglary protection Sicherung Diebstahlsicherung 5A
F84 6 2 Fuse, controller (pin 54) Sicherung Steuerung (Kontakt 54) 10A
F97 22 4 Fuse, blower fresh air Sicherung Frischluftlüfter 3A
F105 6 6 Fuse, engine speed Sicherung Motordrehzahl 20A
F124 7 1 Fuse, fuel-pre-heating Sicherung Kraftstoffvorheizung 25A
F130 19 5 Fuse, night lamp Sicherung Nachtleuchte 10A
F143 19 8 Fuse, rear screen heating unit Sicherung Heckscheibenheizung 15A
F144 19 6 Fuse cabin-socket Sicherung Kabinensteckdose 15A
F146 6 2 Fuse, controller MESX (pot.30) Sicherung Steuerung MESX (Potential 30) 15A
F148 7 7 Fuse, controller MESX (pot.15) Sicherung Steuerung MESX (Potential 15) 10A
F150 6 3 Fuse, GPS receiver Sicherung GPS Receiver 5A
F158 4 1 Fuse, glow plug 1 Sicherung Glühkerze 1 50A
F159 4 2 Fuse, glow plug 2 Sicherung Glühkerze 2 50A
G01 4 3 Battery Batterie 12V / 100 Ah
G02 4 4 Generator Generator
G03 4 0 Battery Batterie 12V / 100 Ah
H06 17 7 Indicator light, hazard light Meldeleuchte Warnblinker
H07 11 2 Warning buzzer, breakdown Warnsummer Betriebsstörung 70mA
H14 8 9 Back-up alarm Buzzer Rückfahrwarnsummer 300mA
K04 9 9 Module, vibration Modul Vibration
K05 8 5 Relay, starting current Relais Startstrom 12V
K06 17 3 Relay, working lights Relais Arbeisscheinwerfer 12V
K09 4 5 Relay, air conditioner Relais Klimaanlage 12V
K11 4 6 Relay, potential 30 on 15 Relais Potential 30 auf 15 12V

K14 5 3 Relay, glow plug system Relais Vorglühen 12V
K14.1 5 6 Relay, glow plug system Relais Vorglühen 12V
K16 17 6 Relay, head lights front Relais Scheinwerfer vorne 12V
K22 11 3 Relay, shut off solenoid engine Relais Hubmagnet Abschaltung Motor 12V
K26 8 7 Relay, backup-alarm Relais Rückfahrwarnsummer 12V
K32 19 2 Relay, cabin Relais Kabine 12V
K35 8 2 Relay, holding contact Relais Selbsthaltung 12V
0 1 2 3 4 5 6 7 8 9
==
Geprüft 25.08.2010
Device tag list
Betriebsmittelliste
Higher-level
Anlage
K36 4 5 Relay, brake control Relais Bremskontrolle 12V

K48 8 4 Relay, travel lever 0-position Relais Fahrhebel 0-Stellung 12V
K61 4 4 Relay, charge control Relais Ladekontrolle 12V
K69 9 3 Relay, engine shut off Relais Motorabschaltung 12V
K114 8 1 Relay, engine rpm Relais Motordrehzahl 12V
K141 21 4 Relay, heating rear screen Relais Heckscheibenheizung 12V
M01 4 9 Starter Starter
M04 21 2 Windscreen wiper motor, front Scheibenwischermotor vorne 4,7A
M05 21 1 Windscreen wiper motor, rear Scheibenwischermotor hinten 2,9A
M06 21 3 Windscreen washer motor, front Scheibenwaschermotor vorne 3,8A
M07 21 1 Windscreen washer motor, rear Scheibenwaschermotor hinten 3,8A
M10 22 3 Compressor, suspension operators seat Kompressor Luftfedersitz 12V / < 9A
M17 22 4 Additional blower Zusatzlüfter 185 mA
P02 12 2 Temperature gauge, hydraulic oil Temperaturanzeige Hydrauliköl
P03 12 1 RPM meter Drehzahlmesser
P04 12 9 Speedometer Geschwindigkeitsanzeige
P05 12 6 Frequency meter Frequenzanzeige
P07 15 3 Evib-Meter Evib-Meter 0-6V
P09 21 8 Tachograph Tachograph
P11 14 5 Printer Drucker
P12 12 1 Voltmeter Voltmeter
P14 12 3 Temperature gauge, coolant Anzeige Kühlmitteltemperatur
P15 16 1 BCM05 BCM05
P16 14 7 Diagnostics, variomatic Diagnose Variomatic
P33 14 8 Opus 21 Opus 21
R01 14 8 Terminating resistor CAN Abschlußwiderstand CAN 60 Ω
R02 5 6 Glow plug 1 Glühstiftkerze 1 50A
R03 11 3 Sender, level gauge Geber Tankanzeige 65,4 Ω
R04 12 2 Sensor, hydraulic oil temperature Sensor Hydrauliköltemperatur
R10 4 4 Parallel resistor Parallelwiderstand 82 Ω

R19 5 1 Heating-flange Heizflansch 167A
R25 16 2 Terminating resistor CAN Abschlußwiderstand CAN 60 Ω
R26 5 4 Resistor Widerstand 220 kΩ
R78 5 7 Glow plug 2 Glühstiftkerze 2 50A
R79 5 8 Fuel-pre-heater Kraftstoffvorheizung 200W
R80 21 3 Heater rear screen Heckscheibenheizung
S00 4 6 Ignition switch Startschalter
0 1 2 3 4 5 6 7 8 9
==
Geprüft 25.08.2010
Circuit diagrams
547
548
Device tag list
Betriebsmittelliste
Higher-level
Anlage
Circuit diagrams
S01 9 1 Switch, emergency off Schalter NOT AUS

S03 10 8 Pushbutton, warning horn Taster Signalhorn
S06 9 4 Switch, seat contact Schalter Sitzkontakt
S13 9 5 Switch, vibration travel lever right Schalter Vibration Fahrhebel rechts
S14 17 7 Switch, hazard light Warnblinkschalter
S15 17 4 Switch, lighting StVZO Schalter Beleuchtung StVZO
S20 21 3 Switch, windscreen wiper front Schalter Scheibenwischer vorne
S21 21 1 Switch, windscreen wiper rear Schalter Scheibenwischer hinten
S28 22 7 Switch, cabin heating Schalter Kabinenheizung
S29 22 3 Switch, suspension seat Schalter Luftfedersitz
S30 4 2 Disconnect switch, battery Batterietrennschalter 250A
S35 9 7 Switch, vibration low/high Vibrationsschalter klein/groß
S37 17 8 Switch, indicator Schalter Blinker
S38 20 3 Switch, Rotary beacon Schalter Rundumkennleuchte
S42 10 5 Switch, speed range selector Schalter Fahrstufen
S45 20 5 Switch, cabin inside light Schalter Kabineninnenleuchte
S53 17 3 Switch, working lights Schalter Arbeitsbeleuchtung
S120 8 1 Switch, engine speed Schalter Motordrehzahl
S158 20 7 Switch, cabin night lamp Schalter Nachtbeleuchtung
S163 21 4 Switch, rear screen heating unit Schalter Heckscheibenheizung
V01 4 4 Diode Diode
V02 10 5 Diode Diode
V04 22 0 Diode Diode FE5B
V09 9 4 Diode Diode
V47 8 3 Diode Diode
Y01 4 7 Solenoid valve, start boost fuel Magnetventil Startmehrmenge

Y04 8 6 Solenoid valve, brake Magnetventil Bremse 2,41A
Y07 9 8 Solenoid valve, vibration front high Magnetventil Vibration vorne gross 3,33A
Y08 9 7 Solenoid valve, vibration front low Magnetventil Vibration vorne klein 3,33A
Y13 9 1 Shut off solenoid, engine Hubmagnet Motorabschaltung 3,8A
Y14 22 5 Fuel pump, heating unit Kraftstoffpumpe Heizgerät
Y15 22 1 Magnetic clutch, air conditioning compressor Magnetkupplung Klimakompressor 3,5A
Y30 10 4 Solenoid valve, speed range selection drum Magnetventil Fahrstufe Bandage 1,23A
0 1 2 3 4 5 6 7 8 9
==
Geprüft 25.08.2010
Device tag list
Betriebsmittelliste
Higher-level
Anlage
Y31 10 6 Solenoid valve, speed range selection axle Magnetventil Fahrstufe Achse 1,23A
Y120 8 2 Solenoid valve, rpm engine high Magnetventil Motordrehzahl hoch 70A/1A
Y139 4 8 Solenoid valve, boost fuel Magnetventil Minusangleichung

0 1 2 3 4 5 6 7 8 9
==
Geprüft 25.08.2010
Circuit diagrams
549
550
Terminal strip overview
Klemmleistenübersicht
Terminal strip central electric
X1 Klemmleiste Zentralelektrik
Mounting location Electrobox
Circuit diagrams
Einbauort Elektrokasten
Device tag Page Path Device tag Page Path Device tag Page Path Device tag Page Path Device tag Page Path Device tag Page Path
BMK Blatt Pfad BMK Blatt Pfad BMK Blatt Pfad BMK Blatt Pfad BMK Blatt Pfad BMK Blatt Pfad
X1:1 4 4 X1:30A 7 5 X1:68 11 7 X1:103 10 7 X1:146 6 2 X1:191 12 6
X1:2 6 1 X1:30E 7 5 X1:69 11 1 X1:104 8 7 X1:147 8 6 X1:192 12 6
X1:3 4 6 X1:31A 7 5 X1:70 12 0 X1:104 10 9 X1:148 8 4 X1:217 5 8
X1:4 4 5 X1:31E 7 5 X1:71 11 5 X1:105 11 3 X1:149 8 8 X1:218 5 8
X1:7 4 7 X1:32A 7 6 X1:72 11 7 X1:106 11 4 X1:149 9 3 X1:219 22 3
X1:8 4 7 X1:32E 7 6 X1:73 11 7 X1:107 11 9 X1:149 9 5 X1:220 22 3
X1:9 6 4 X1:33A 7 7 X1:74 11 6 X1:108 11 9 X1:149 9 9 X1:223 12 2
X1:10 6 4 X1:33E 7 7 X1:75 5 4 X1:109 11 3 X1:150 8 6 X1:224 12 2
X1:15A 6 5 X1:34A 6 2 X1:76 11 7 X1:110 11 4 X1:151 9 1 X1:225 12 2
X1:15E 6 5 X1:34E 6 2 X1:77 11 6 X1:111 11 9 X1:152 9 1 X1:226 12 3
X1:16A 6 5 X1:35A 6 2 X1:78 11 1 X1:112 11 9 X1:153 8 7 X1:227 12 2
X1:16E 6 5 X1:35E 6 2 X1:79 4 6 X1:113 8 6 X1:154 9 4 X1:228 12 2
X1:17A 6 6 X1:37A 7 1 X1:80 8 1 X1:114 8 9 X1:155 10 8 X1:301 17 4
X1:17E 6 6 X1:37E 7 1 X1:81 8 1 X1:115 9 7 X1:156 8 4 X1:302 17 4
X1:18A 6 7 X1:52 5 0 X1:82 11 2 X1:116 9 8 X1:157 9 5 X1:303 17 4
X1:18E 6 7 X1:53 4 7 X1:82 12 1 X1:117 8 5 X1:158 9 4 X1:304 17 7
X1:19A 6 8 X1:54 9 1 X1:82 15 3 X1:117 8 6 X1:159 9 7 X1:305 17 9
X1:19E 6 8 X1:55 4 6 X1:82 17 0 X1:117 8 9 X1:160 9 7 X1:306 17 8
X1:21A 6 0 X1:55 4 7 X1:83 17 4 X1:117 11 3 X1:161 9 8 X1:307 17 9
X1:21E 6 0 X1:55 9 1 X1:84 17 3 X1:117 11 3 X1:162 10 5 X1:308 17 7
X1:22A 6 1 X1:56 8 3 X1:85 15 3 X1:117 11 4 X1:163 22 1 X1:309 17 6
X1:22E 6 1 X1:56 11 7 X1:86 11 0 X1:117 17 3 X1:164 22 2 X1:310 17 7
X1:23A 17 4 X1:57 5 2 X1:87 11 1 X1:118 8 1 X1:166 22 1 X1:311 17 4
X1:23E 17 4 X1:57 5 5 X1:88 11 1 X1:118 8 4 X1:167 22 1 X1:312 17 5
X1:24A 17 5 X1:57 11 5 X1:89 11 0 X1:118 9 7 X1:168 4 5 X1:313 17 8
X1:24E 17 5 X1:58 8 2 X1:90 11 3 X1:124 10 1 X1:168 22 1 X1:314 17 9
X1:25A 7 1 X1:59 8 2 X1:91 11 9 X1:124 10 5 X1:171 12 7 X1:315 17 4
X1:25E 7 1 X1:60 8 2 X1:92 12 9 X1:137 10 3 X1:172 12 7 X1:315 17 6

X1:26A 7 2 X1:61 11 6 X1:93 12 9 X1:138 10 3 X1:173 12 7 X1:316 17 5
X1:26E 7 2 X1:62 8 2 X1:96 11 9 X1:141 10 1 X1:174 12 7 X1:319 17 4
X1:27A 7 3 X1:63 8 2 X1:97 10 8 X1:141 10 6 X1:175 12 8 X1:320 17 5
X1:27E 7 3 X1:63 9 3 X1:98 10 8 X1:142 10 4 X1:187 12 4 X1:321 17 8
X1:28A 7 3 X1:64 5 2 X1:99 10 7 X1:143 10 1 X1:188 12 5 X1:322 17 9
X1:28E 7 3 X1:65 4 4 X1:100 10 9 X1:143 10 6 X1:189 12 5 X1:323 17 8
X1:29A 7 4 X1:66 4 4 X1:101 10 7 X1:144 10 4 X1:190 12 4 X1:324 17 4
X1:29E 7 4 X1:67 11 5 X1:102 10 9 X1:145 6 2 X1:190 22 0
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Terminal strip overview X1 Function
==
Geprüft 25.08.2010
Klemmleistenübersicht X1 Einbauort + EPE / 000 / 00
Terminal strip overview
Klemmleistenübersicht
Terminal strip central electric measurement equipment
X2 Klemmleiste Zentralelektrik Messtechnik
Mounting location Electrobox
Einbauort Elektrokasten
Device tag Page Path
BMK Blatt Pfad
X2:43 16 8
X2:44 16 8
X2:47 14 8
X2:48 14 9
X2:49 13 7
X2:49 14 9
X2:50 14 7
X2:51 14 8
X2:52 13 8
X2:53 14 0
X2:54 14 1
X2:55 14 0
X2:56 14 1
X2:57 14 2
X2:58 14 3
X2:59 14 2
X2:60 14 3
X2:61 16 2
X2:62 16 2
X2:63 13 8
X2:63 16 7
X2:64 14 5
X2:65 14 6
X2:66 13 9
X2:66 14 6
X2:68 14 4
X2:70 14 6
X2:71 14 4

X2:79 16 8
X2:80A 6 3
X2:80E 6 3
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Terminal strip overview X2 Function
==
Geprüft 25.08.2010
Klemmleistenübersicht X2 Einbauort + EPE / 000 / 00
Circuit diagrams
551
552
Plug overview
Steckerübersicht
Designation Mounting location Function text Designation Mounting location Function text
Bezeichnung Einbauort Funktionstext Bezeichnung Einbauort Funktionstext
Electrobox Plug, supply cabin, rops, sun-roof Armature carrier Plug, monitoring module
X3 Stecker Versorgung Kabine, Rops, Sonnendach X5 Stecker Überwachungsmodul
Circuit diagrams
Elektrokasten Armaturenträger
Contact Page Path Type Contact Page Path Type
Kontakt Blatt Pfad Typ HDP-26-24-18 Kontakt Blatt Pfad Typ AMP Superseal 26 pole
1 18 2 15 11 7
1 19 0 16 11 5
2 19 1 17 11 4
3 18 3 21 11 8
4 18 1 22 11 8
5 18 2 23 11 2
6 19 4 24 11 3
7 19 4 25 11 2
8 19 4 26 11 1
9 22 1 Rear frame Plug, Solenoid valve vibration front high
10 22 1
X6 Hinterrahmen Specker Magnetventil Vibraiton vorne groß
Contact Page Path Type
15 21 7 Kontakt Blatt Pfad Typ AMP JPT / DT 2 pole
16 21 7 1 9 8
17 21 7 2 9 8
Electrobox Plug, connection measurement equipment cabin Rear frame Plug, Solenoid valve vibration front low
X4 Elektrokasten Stecker Messtechnik Kabine X7 Hinterrahmen Specker Magnetventil Vibraiton vorne klein
Kontakt Blatt Pfad Typ HDP-24-18-14 Kontakt Blatt Pfad Typ AMP JPT / DT 2 pole
A 14 5 1 9 7
B 14 6 2 9 7
C 14 5 Rear frame Plug, WaterInFuel Sensor
D 14 6 X8 Hinterrahmen Stecker Sensor "Wasser im Kraftstoff"
E 14 6 Kontakt Blatt Pfad Typ DT 2 pole
F 16 7 1 11 9
G 16 4 2 11 9
H 16 8 Rear frame Plug, backup alarm buzzer
J 16 8 X9 Hinterrahmen Stecker Rückfahrwarnsummer
M 16 2 Contact Page Path Type
Kontakt Blatt Pfad Typ DT 2 pole
N 16 2
Armature carrier Plug, monitoring module 1 8 9
X5 Armaturenträger Stecker Überwachungsmodul 2 8 9
Contact Page Path Type Rear frame Plug, sender level gauge
Kontakt Blatt Pfad Typ AMP Superseal 26 pole X10 Hinterrahmen Stecker Tauchrohrgeber
1 11 3 Contact Page Path Type
Kontakt Blatt Pfad Typ AMP Superseal 3 pole
3 11 1
4 11 1 2 11 3
3 11 3

5 11 8 Console right, seat Plug, pushbutton vibration travel-lever
8 11 6 X11 Konsole Sitz rechts Stecker Taster Vibration Fahrhebel
10 11 1 Kontakt Blatt Pfad Typ DTM 2 pole
11 11 7 1 9 5
12 11 8 2 9 5
13 11 8
14 11 8
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Plug overview Function
==
Geprüft 25.08.2010
Steckerübersicht Einbauort + EPE / 000 / 00
Plug overview
Steckerübersicht
Console right, seat Plug, proximity switch travel lever "0" position Electrobox Plug, supply central electric
X12 Konsole Sitz rechts Stecker Initiator Fahrhebel "0" X36 Elektrokasten Stecker Versorgung Zentralelektrik
Kontakt Blatt Pfad Typ DTM 3 pole Kontakt Blatt Pfad Typ MTA 2 pole
1 8 4 A 4 3
2 8 4 B 4 3
3 8 4 Electrobox Plug, supply ignition switch
Console right, seat Plug, proximity switch travel lever forward and "0" position
X37 Elektrokasten Stecker Versorgung Startschalter
X13 Konsole Sitz rechts Stecker Initiator Fahrhebel vorwärts u. "0" Contact Page Path Type
Contact Page Path Type Kontakt Blatt Pfad Typ MTA 2 pole
Kontakt Blatt Pfad Typ DTM 3 pole A 4 6
1 8 7 B 4 7
2 8 7 Electrobox Plug, supply starter
3 8 7
X38 Elektrokasten Stecker Versorgung Starter
Seat Plug, switch seat-contact
X14 Kontakt Blatt Pfad Typ MTA 2 pole
Sitz Stecker Sitzkontaktschalter
Contact Page Path Type A 4 9
Kontakt Blatt Pfad Typ DT 3 pole Console right, seat Plug, connection adapter BOP
A 9 4
X42 Konsole Sitz rechts Stecker Anschluß Adapter BOP
B 9 4 Kontakt Blatt Pfad Typ DTM 6 pole
Cabin Plug, heating climatic unit
X17 Kabine Stecker Heiz-Klima-Einheit
1 14 8
Contact Page Path Type 2 14 9
Kontakt Blatt Pfad Typ DTP 4 pole 3 14 9
1 22 1 4 14 8
2 22 2 5 14 9
4 22 1 Electrobox Plug, measurement controller
Rear frame Plug, pressure switch air conditioning
X44 Elektrokasten Stecker Messtechniksteuerung
X20 Hinterrahmen Stecker Druckschalter Klimaanlage Contact Page Path Type
Contact Page Path Type Kontakt Blatt Pfad Typ AMP 64 pole
Kontakt Blatt Pfad Typ DT 4 pole 1 14 4
1 22 1 3 15 3
2 22 1 4 14 5
3 22 1 5 14 6
4 22 1 7 14 2
Rear frame Plug, Floating switch Coolant expansion tank 14 15 4
X21 Hinterrahmen Stecker Schwimmerschalter Kühlmittelausgleichsbehälter
15 15 6
Kontakt Blatt Pfad Typ DTM 2 pole 25 16 8
1 11 7 26 14 8
2 11 7 27 14 7
Front frame Plug, transducer vibration frequency front 28 13 1
X22 Vorderrahmen Stecker Aufnehmer Vibrationsfrequenz vorne 29 14 1

Kontakt Blatt Pfad Typ DT 4 pole
30 14 3
1 12 4 31 14 0
2 12 4 33 16 2
3 12 5 35 15 5
4 12 5 36 15 3
37 15 2
38 15 6
41 15 7
0 1 2 3 4 5 6 7 8 9
==
Geprüft 25.08.2010
Circuit diagrams
553
554
Plug overview
Steckerübersicht
Electrobox Plug, measurement controller Cabin Plug, windscreen wiper motor front
X44 Stecker Messtechniksteuerung X56 Stecker Scheibenwischermotor vorne
Circuit diagrams
Elektrokasten Kabine
Kontakt Blatt Pfad Typ AMP 64 pole Kontakt Blatt Pfad Typ P4NAT
53 16 2 1 21 2
54 13 0 2 21 2
55 13 5 3 21 3
56 13 2 4 21 2
57 13 3 Cabin/Rops Plug, headlight front left
58 13 4
X58 Kabine/Rops Stecker Scheinwerfer vorne links
59 13 5 Kontakt Blatt Pfad Typ DT 6 pole
60 13 6 2 17 8
65 13 6 3 17 4
66 13 7 5 17 6
67 13 8 6 17 4
68 13 9 Cabin/Rops Plug, headlight front right
Console right, seat Plug, bomag operation panel (BOP) X59 Kabine/Rops Stecker Scheinwerfer vorne rechts
X46 Konsole Sitz rechts Stecker Bomag Operation Panel (BOP) Contact Page Path Type
Contact Page Path Type Kontakt Blatt Pfad Typ DT 6 pole
Kontakt Blatt Pfad Typ Burndy 12 pole 2 17 9
A 14 9 3 17 5
B 14 8 5 17 7
D 14 8 6 17 5
E 14 9 Rear frame Plug, tail light rear left
F 14 9 X60 Hinterrahmen Stecker Rückleuchte links
Front frame Plug, transducer acceleration front Contact Page Path Type
X48 Vorderrahmen Stecker Beschleunigungsaufnehmer vorne Kontakt Blatt Pfad Typ DT 4 pole
1 14 0 3 17 4
2 14 1 4 17 4
3 14 1 Rear frame Plug, tail light rear right
4 14 0 X61 Hinterrahmen Stecker Rückleuchte rechts
Front frame Plug, transducer acceleration rear Contact Page Path Type
X49 Vorderrahmen Stecker Beschleunigungsaufnehmer hinten Kontakt Blatt Pfad Typ DT 4 pole
1 14 2 3 17 5
2 14 3 4 17 5
3 14 3 Electrobox Plug, electronical burglary protection
4 14 2 X65 Elektrokasten Stecker Elektronische Diebstahlsicherung

Cabin Plug, windscreen wiper motor rear Contact Page Path Type
X55 Kabine Stecker Scheibenwischermotor hinten Kontakt Blatt Pfad Typ DT 12 pole
Kontakt Blatt Pfad Typ P4NAT 2 23 2
1 21 1 3 23 2
2 21 1 4 23 2
3 21 1 5 23 2
4 21 1 7 23 2
8 23 2
0 1 2 3 4 5 6 7 8 9
==
Geprüft 25.08.2010
Plug overview
Steckerübersicht
Electrobox Plug, electronical burglary protection Cabin Plug, access GPS-Receiver
X65 Elektrokasten Stecker Elektronische Diebstahlsicherung X72 Kabine Stecker Anschluß GPS-Antenne
Kontakt Blatt Pfad Typ DT 12 pole Kontakt Blatt Pfad Typ Burndy 12 pole
9 23 2 E 16 6
10 23 2 Cabin Plug, supply GPS System
11 23 2
X73 Kabine Stecker Spannungsversorgung GPS System
Rear frame Plug, fuel pre heater
X67 Hinterrahmen Stecker Kraftstoffvorheizung
A 16 8
Contact Page Path Type B 16 8
Kontakt Blatt Pfad Typ DTP 2 pole C 16 7
1 5 8 Cabin Plug, printer
2 5 8
X74 Kabine Stecker Drucker
Plug, keyboard electronical burglary protection
X68 Kontakt Blatt Pfad Typ AMP Mate´n´loc 6pole
Stecker Tastatur Elektronische Diebstahlsicherung
Kontakt Blatt Pfad Typ SUBD 9 pole 2 14 6
1-9 23 6 3 14 5
Cabin Plug, additional blower 4 14 6
X69 Kabine Stecker Zusatzlüfter
5 14 6
Cabin Plug, CAN BCM Dongle
Kontakt Blatt Pfad Typ DTM 2 pole X75 Kabine Stecker CAN BCM Dongle
2 22 4 Kontakt Blatt Pfad Typ SUBD 9 pole
Cabin Plug, Access GPS - BCM 2 16 2
X70 Kabine Stecker Anschluß GPS - BCM
7 16 2
Cabin Plug, supply BCM
Kontakt Blatt Pfad Typ SUBD 9 pole X76 Kabine Stecker Versorgung BCM
5 16 4 1 16 4
GPS Receiver StarFire Plug, GPS-Receiver StarFire 2 16 4
X71 GPS Empfänger StarFire Stecker GPS-Antenne StarFire Rear frame Plug, fuel pump additional heater
Contact Page Path Type X77 Hinterrahmen Stecker Kraftstoffpumpe Zusatzheizung
Kontakt Blatt Pfad Typ DT 12 pole Contact Page Path Type
3 16 6 Kontakt Blatt Pfad Typ DTM 2 pole
5 16 7 1 22 5
6 16 7 2 22 5
7 16 7 GPS Receiver StarFire Plug, additional options GPS-Receiver
8 16 7
X78 GPS Empfänger StarFire Stecker Zusatzoptionen GPS-Antenne
12 16 7

1 16 9
Cabin Plug, access GPS-Receiver
X72 Kabine Stecker Anschluß GPS-Antenne
2 16 9
Kontakt Blatt Pfad Typ Burndy 12 pole 4 16 9
A 16 8 Cabin/Rops Plug, suspension seat
B 16 8
X79 Kabine/Rops Stecker Luftfedersitz
C 16 7 Kontakt Blatt Pfad Typ P2NAT
D 16 6 1 22 3
0 1 2 3 4 5 6 7 8 9
==
Geprüft 25.08.2010
Circuit diagrams
555
556
Plug overview
Steckerübersicht
Cabin/Rops Plug, suspension seat
X79 Stecker Luftfedersitz
Circuit diagrams
Kabine/Rops
Kontakt Blatt Pfad Typ P2NAT
2 22 3

0 1 2 3 4 5 6 7 8 9
==
Geprüft 25.08.2010
Pin overview
Pin Übersicht
Monitoring-module
A15 Überwachungsmodul
Pin Page Path Description
Signal Signal
Kontakt Blatt Pfad Beschreibung
X5 : 1 11 3 Fuel gauge Tankanzeige
X5 : 3 11 2 Glowing Glühen
X5 : 4 11 2 Brake Bremse
X5 : 5 11 8 Night dimout Nachtabdunklung
X5 : 8 11 6 Shutoff 2 min. Coolant temperature Kühlmitteltemperatur
X5 : 9 11 2 Seat Sitz
X5 : 10 11 2 Charge control Ladekontrolle
X5 : 11 11 7 Shutoff 10 sec. Engine oil pressure Motoröldruck
X5 : 12 11 8 Indicator right Blinker rechts
X5 : 13 11 8 Indicator left Blinker links
X5 : 14 11 8 Hazard light Warnblinklicht
X5 : 15 11 7 Shutoff 10 sec. Coolant level Kühlmittelfüllstand
X5 : 16 11 5 Air cleaner Luftfilter
X5 : 17 11 4 Shutoff 2 min. Hydr. oil filter Hydraulikölfilter
X5 : 21 11 8 Shutoff 2 min. Water trap Wasserabscheider
X5 : 22 11 8 Shutoff 2 min. Water trap Wasserabscheider
X5 : 23 11 2 Out warning buzzer Out Warnsummer
X5 : 24 11 3 Out Motor stop Out Motor-Stop
X5 : 25 11 2 GND GND
X5 : 26 11 2 + Ub + Ub

0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Pin overview A15 Function
==
Geprüft 25.08.2010
Pin Übersicht A15 Einbauort + EPE / 000 / 00
Circuit diagrams
557
558
Pin overview
Pin Übersicht
A83 Messtechnik Steuerung
Pin Page Path Description
Circuit diagrams
Signal Signal
Kontakt Blatt Pfad Beschreibung
: box 13 4 Ground Housing Ground housing Masse Gehäuse
X44 : 1 14 4 AGND AGND Analogmasse
X44 : 3 15 3 DO(2,5A)/4 Evib-Meter Evib-Meter
X44 : 4 14 5 RxD RxD RxD
X44 : 5 14 6 TxD TxD TxD
X44 : 7 14 2 AI/3 Transducer Acceleration rear 20g Beschleunigungsaufn. hinten 20g
X44 : 14 15 4 DI(D)/6 Driving direction Fahrtrichtung
X44 : 15 15 6 DI(D)/8 Vibration low amplitude Vibration kleine Amplitude
X44 : 25 16 8 DO(2,5A)/3 Power supply GPS Spannungsversorgung GPS
X44 : 26 14 8 -Wire1 CAN 1 - CAN 1 -
X44 : 27 14 7 +Wire1 CAN 1 + CAN 1 +
X44 : 28 13 1 D+ Power Supply (Electronic) Spannungsvers. (Elektronik)
X44 : 29 14 1 AI/2 Transducer Acceleration front 15g Beschleunigungsaufn. vorne 15g
X44 : 30 14 3 AI/4 Transducer Acceleration rear 15g Beschleunigungsaufn. hinten 15g
X44 : 31 14 0 AI/6 Transducer Acceleration front 20g Beschleunigungsaufn. vorne 20g
X44 : 33 16 2 -Wire2 CAN 3 - CAN 3 -
X44 : 35 15 5 DI(D)/3 Driving speed Fahrgeschwindigkeit
X44 : 36 15 3 DI(D)/5 Brake Bremse
X44 : 37 15 2 DI(D)/7 D+ Alternator D+ Generator
X44 : 38 15 6 DI(D)/9 Vibration high amplitude Vibration große Amplitude
X44 : 41 15 7 DI(D)/15 Illumination Beleuchtung
X44 : 53 16 2 +Wire2 CAN 3 + CAN 3 +
X44 : 54 13 0 UE Ignition Zündung
X44 : 55 13 5 GND Ground Electronic Masse Elektronik
X44 : 56 13 2 UB Power Supply (Outputs) Spannungsvers. (Ausgänge)
X44 : 65 13 6 XGND1 Ground Baby-Board 1 Masse Baby-Board 1

0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Pin overview A83 Function
==
Geprüft 25.08.2010
Pin Übersicht A83 Einbauort + EPE / 000 / 00
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Overview Central Electric Function
==
Geprüft 25.08.2010
Übersicht Zentralelektrik Einbauort + EPE / 000 / 00
Circuit diagrams
559
560
Circuit diagrams

0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Overview Central Electric Function
==
Geprüft 25.08.2010
Übersicht Zentralelektrik Einbauort + EPE / 000 / 00
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 View Terminal strip X1 below Function
==
Geprüft 25.08.2010
Ansicht Klemmleiste X1 unten Einbauort + EPE / 000 / 00
Circuit diagrams
561
562
Circuit diagrams

0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 View Terminal strip X1 above Function
==
Geprüft 25.08.2010
Ansicht Klemmleiste X1 oben Einbauort + EPE / 000 / 00
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 View Terminal strip X1 above Function
==
Geprüft 25.08.2010
Ansicht Klemmleiste X1 oben Einbauort + EPE / 000 / 00
Circuit diagrams
563
564
Circuit diagrams

0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 View Terminal strip X1 StVZO Function
==
Geprüft 25.08.2010
Ansicht Klemmleiste X1 StVZO Einbauort + EPE / 000 / 00
0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 View Terminal strip X2 Function
==
Geprüft 25.08.2010
Ansicht Klemmleiste X2 Einbauort + EPE / 000 / 00
Circuit diagrams
565
566
Circuit diagrams

0 1 2 3 4 5 6 7 8 9
Erstellt 25.08.2010 Overview plug location Function
==
Geprüft 25.08.2010
Übersicht Steckerposition Einbauort + EPE / 000 / 00
Head Office/Hauptsitz
BOMAG
Hellerwald
D-56154 Boppard
Germany
Telefon: +49 6742 100-0
Fax: +49 6742 3090
e-mail: info@bomag.com
BOMAG BOMAG BOMAG

Niederlassung Berlin Niederlassung Boppard Niederlassung Chemnitz
Gewerbestraße 3 Hellerwald Querstraße 6
15366 Hoppegarten 56154 Boppard 09247 Chemnitz
GERMANY GERMANY GERMANY
Tel.: +49 3342 369410 Tel.: +49 6742 100360 Tel.: +49 3722 51590
Fax: +49 3342 369436 Fax: +49 6742 100392 Fax: +49 3722 515951
e-mail: nlberlin@bomag.com e-mail: nlboppard@bomag.com e-mail: nlchemnitz@bomag.com
BOMAG BOMAG BOMAG

Niederlassung Hannover Niederlassung München Niederlassung Stuttgart
Dieselstraße 44 Otto-Hahn-Ring 3 Uferstraße 22
30827 Garbsen-Berenbostel 85301 Schweitenkirchen 73630 Remshalden-Grunbach
GERMANY GERMANY GERMANY
Tel.: +49 5131 70060 Tel.: +49 8444 91840 Tel.: +49 7151 986293
Fax: +49 5131 6766 Fax: +49 8444 918420 Fax: +49 7151 9862959
e-mail: nlhannover@bomag.com e-mail: nlmuenchen@bomag.com e-mail: nlstuttgart@bomag.com
BOMAG Maschinenhandelsgesellschaft m.b.H. BOMAG MARINI EQUIPAMENTOS LTDA BOMAG (CANADA), INC.
Klausenweg 654 Rua Comendador Clemente Cifali, 530 3455 Semenyk Court
2534 Alland Distrito Industrial Ritter Missisauga, Ontario
AUSTRIA Cachoeirinha – RS L5C 4P9
BRAZIL CANADA
ZIP code 94935-225
Tel.: +43 2258 20202 Tel.: +55 51 2125-6677 Tel.: +1 905 361 9961
Fax: +43 2258 20202-20 Fax: +55 51 3470-6220 Fax: +1 905 361 9962
e-mail: austria@bomag.com e-mail: brasil@bomag.com e-mail: canada@bomag.com
BOMAG (China) Construction BOMAG France S.A.S. BOMAG (GREAT BRITAIN), LTD
Machinery Co. , Ltd 2, avenue du Général de Gaulle Sheldon Way, Larkfield
No. 2808, West Huancheng Road, 91170 VIRY-CHATILLON Aylesford
Shanghai Comprehensive Industrial FRANCE Kent ME20 6SE
Zone Fengxian Shanghai 201401 GREAT BRITAIN
CHINA
Tel.: +86 21 3365 5566 Tel.: +33 1 69578600 Tel.: +44 1622 716611
Fax: +86 21 3365 5508 Fax: +33 1 69962660 Fax: +44 1622 710233
e-mail: china@bomag.com e-mail: france@bomag.com e-mail: gb@bomag.com
BOMA Equipment Hong Kong LTD BOMAG Italia Srl. FAYAT BOMAG Polska Sp. z.o.o.
Room 1003, 10/F Charm Centre Via Roma 50 Ul. Szyszkowa 52
700, Castle Peak Road 48011 Alfonsine 02-285 Warzawa
Kowloon, ITALY POLAND
HONG KONG
Tel.: +852 2721 6363 Tel.: +39 0544 864235 Tel.: +48 22 4820400
Fax: +852 2721 3212 Fax: +39 0544 864367 Fax: +48 22 4820401
e-mail: bomahk@bomag.com e-mail: italy@bomag.com e-mail: poland@bomag.com
FAYAT BOMAG Rus OOO BOMAG GmbH, Singapore BOMAG Americas, Inc.
Klyazma block, h 1-g 300, Beach Road 125 Blue Granite Parkway
141400 Khimki, Moscow region The Concourse, ‚ 18-06 Ridgeway SC 29130
RUSSIA Singapore 199555 U.S.A.
SINGAPORE
Tel.: +7 (495) 2879290 Tel.: +65 294 1277 Tel.: +1 803 3370700
Fax: +7 (495) 2879291 Fax: +65 294 1377 Fax: +1 803 3370800
e-mail: russia@bomag.com e-mail: singapore@bomag.com e-mail: usa@bomag.com

BW 211 D-40 - Service Training

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

BW 211 D-40 - Service Training

Uploaded by

Copyright:

Available Formats

Service Training

BW 211 D/PD-40 / BW 212 D/PD-40 /

Single drum roller

008 401 91 EN © 12/2016

BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40 3

4.15 Coolant temperature switch, B30.......................................................................................... 108

4 BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40

6.2 Open and closed hydraulic circuit.......................................................................................... 277

BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40 5

7.13.1 Maintenance Table................................................................................................................. 388

6 BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40

11.5.1 Insufficient hydraulic power.................................................................................................... 456

BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40 7

8 BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40

BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40 9

Genuine BOMAG spare parts

10 BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40

Copyright Information and illustrations in this manual must not be reproduced

BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40 11

1.2 Concerning your safety

1.2.1.2 Explanation of signal words used:

12 BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40

Sections marked accordingly indicate technical

1.2.1.3 Personal protective equipment

Safety shoes To protect against heavy falling parts and slipping on

Protective gloves To protect the hands against excoriation, punctures or

BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40 13

Safety goggles To protect the eyes against airborne particles and

Face protection To protect the face against airborne particles and

Hearing protection To protect the hearing against too loud noise.

1.2.1.4 Intended use

1.2.1.5 Improper use

14 BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40

starting and operation of the machine in explosive environments

1.2.2 Definition of responsible persons

1.2.2.2 Expert / qualified person

1.2.2.3 Driver / operator

BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40 15

The driver or operator must:

1.2.3 Fundamentals for safe operation

1.2.3.2 Regular safety inspections

1.2.3.3 Modifications and alterations to the machine

16 BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40

1.2.3.4 Damage, defects, misuse of safety devices

1.2.3.5 Roll Over Protective Structure (ROPS)

On machines with cab the ROPS is an integral part

The frame of the machine must not be warped, bent or cracked in

1.2.4 Handling fuels and lubricants

BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40 17

18 BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40

AdBlue®/DEF has not been classified as environ-

BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40 19

Fig. 4 Should pressure fluid penetrate the skin, imme-

20 BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40

BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40 21

22 BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40

1.2.5 Parking the machine in secured condition

3. Turn the ignition key to position “0” and pull it out.

5. Turn the main battery switch counter-clockwise and pull it

1.2.6 Emergency procedures

BW 211 D/PD-40 / BW 212 D/PD-40 / BW 213 D/PD-40 23

1.2.6.2 Disconnecting the battery

1.2.6.3 Towing the machine