Service - Manual

BC 972 RB-2 / BC 1172 RS-2

S/N 101 570 82 ... > S/N 101 570 83 ... >

Sanitary landfill compactor

Catalogue number.
008 911 57 04/2008
 Table of Contents

General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 26
Technical data 31
2.1 Technical data 32
Maintenance 37
3.1 General notes on maintenance 38
3.2 Fuels and lubricants 39
3.3 Table of fuels and lubricants 41
3.4 Running-in instructions 42
3.5 Maintenance chart 43
Fundamental electrics 45
4.1 Understanding circuit diagrams 46
4.2 Terminal designations 51
4.3 Battery ground and analog ground 55
4.4 Current and voltage 55
4.5 CAN-Bus 58
4.6 Resistance 60
4.7 Series / parallel connection 62
4.8 Ohm's law 64
4.9 Electrical energy 64
4.10 Formula diagram 65
4.11 Metrology 66
4.12 Diodes, relays, fuses 69
4.13 Batteries 72
4.14 Three-phase generator 75
4.15 Electric starter 83
4.16 Telemecanique switch 86
4.17 Inductive proximity switches 89
4.18 Angle sensors 90
4.19 Plug connectors 92
4.20 Deutsch plug, series DT and DTM 92
4.21 Plugs and terminals in spring clamping technology 99
4.22 Electric modules 102
Special tools, electrics 103
5.1 Special tools, electrics 104
Electronic control 113
6.1 ESX control 115
Electronic modules 185
7.1 Blower monitoring module A53 187
Trouble shooting 189
8.1 General 190
8.2 The machine drives with the travel lever in "NEUTRAL" 191
8.3 The machine does not drive 193

008 911 57 BOMAG 3

Table of Contents

8.4 Machine travels to one direction only or to one travel direction with reduced power
196
8.5 Hydraulic oil overheating 200
8.6 Insufficient travel power, max speed is not reached 202
8.7 No steering function / steering stiff, end stops are not reached 207
8.8 Failure of central lubrication system (grease emerges from relief valve) 209
8.9 Trouble shooting travel system 212
8.10 Trouble shooting working hydraulics 213
8.11 Fault diagnose TCD 2015 214
8.12 List of fault flash codes TCD 2015 217
8.13 General trouble shooting chart TCD 2015 218
Installed components / connection overview 221
9.1 List of installed components 223
9.2 Measuring and adjustment points on tandem travel pump unit 224
9.3 Connection overview 226
9.4 Connection overview 228
9.5 Measuring and adjustment points on control valve block 230
9.6 Cab electrics 231
9.7 Machine related electrics 235
Air conditioning system 241
10.1 Physical basics 242
10.2 Refrigerant R134a 245
10.3 Compressor oil / refrigeration oil 246
10.4 Working principle of the air conditioning system 247
10.5 Monitoring devices 247
10.6 Description of components 249
10.7 Climatronic control 258
10.8 Checking the compressor oil level 263
10.9 Checking the magnetic clutch 264
10.10 Inspection and maintenance work 265
10.11 Service the air conditioning (summer operation) 265
10.12 Check condition and tension of refrigerant compressor V-belt, replace the V-
belt 268
10.13 Drying and evacuation 269
10.14 Emptying in case of repair 269
10.15 Leak test 270
10.16 Filling instructions 271
10.17 Trouble shooting in refrigerant circuit, basic principles 274
10.18 Trouble shooting, refrigerant circuit diagram 278
10.19 Trouble shooting procedure 279
10.20 Steam table for R134a 289
Central lubrication system 295
11.1 System layout 296
11.2 Description of components 297
11.3 Check the central lubrication system, topping up 305
Engine 307
12.1 Diesel engine 308
12.2 Engine description TCD 2015 V 6 cylinder 309

4 BOMAG 008 911 57

 Table of Contents

12.3 Engine description TCD 2015 V 8 cylinder 311

12.4 Lubrication oil circuit TCD 2015 313
12.5 Coolant circuit TCD 2015 314
12.6 Fuel circuit TCD 2015 315
12.7 Injection system (MVS) TCD 2015 318
12.8 Sensors TCD 2015 321
12.9 Exhaust gas recirculation TCD 2015 326
12.10 Engine control EDC 7 with EMR 3 TCD 2015 327
12.11 Fan V-belt tension TCD 2015 332
12.12 Valve adjustment TCD 2015 334
12.13 Fault diagnose TCD 2015 337
12.14 List of fault flash codes TCD 2015 340
12.15 SerDia Service-Software TCD 2015 341
12.16 EMR3 List of fault codes 344
12.17 General trouble shooting chart TCD 2015 354
12.18 Check the engine oil level 356
12.19 Change the engine oil 357
12.20 Changing the engine oil filter 358
12.21 Change the fuel pre-filter cartridge 358
12.22 Changing the fuel filter cartridge 360
12.23 Checking condition of radiator, intercooler and hydraulic oil cooler, clean,
cleaning the engine 360
12.24 Changing the coolant, venting the cooling system 362
12.25 Checking the anti-freeze concentration 363
12.26 Checking the condition and tension of the generator V-belt, replacing the V-belt
363
12.27 Check the engine mounts 364
12.28 Check fastening of engine / turbocharger / combustion air hoses 365
12.29 Checking the preheating system. Maintenance in case of frost. 365
12.30 Special tools, Deutz engine (TCD 2015) 367
Working hydraulics 387
13.1 Hydraulic system 388
13.2 Working hydraulics 388
13.3 Steering and working pump 389
13.4 Control valve block, steering and dozer blade 391
Tests and adjustments in working hydraulics 405
14.1 Tests and adjustments on the steering/working pump 406
14.2 Measuring and adjustment points on control valve block 409
Travel hydraulics 411
15.1 Hydraulic system 412
15.2 Travel system (general description) 413
15.3 Travel pump 415
15.4 Travel motors 426
15.5 Filtration 429
15.6 Transfer box filter unit 431
Tests and adjustments in travel hydraulics 433
16.1 Measuring and adjustment points on tandem travel pump unit 434
16.2 Pressure tests in the travel circuit 435

008 911 57 BOMAG 5

Table of Contents

16.3 Checking high pressure relief valves and pressure override 440
16.4 Travel pump high pressure test (individual test) 444
16.5 Check charge pressure 446
16.6 Adjusting the DA-control valve 447
16.7 Checking the control chamber pressure 450
16.8 Measuring and adjustment points on travel motors 452
16.9 Checking the displacement setting of the travel motors 454
16.10 Filter unit for transfer box / pressure relief valve 456
Special tools, tests and adjustments 459
17.1 Special tools, tests and adjustments 460
Oscillating articulated joint 465
18.1 Articulated joint, repair overview 466
18.2 Disassembling and assembling the top bolt 468
18.3 Removing and installing the steering cylinders 474
Suppliers documentation 481
19.1 Travel pump 483
19.2 Steering/working pump 545
19.3 Travel motor 571
19.4 Wheel drive gear up to S/N 625
19.5 Wheel drive gear from S/N 715
Circuit diagrams 807
20.1 Hydraulic diagram 571 908 16 809
20.2 Wiring diagram 570 700 35 813
20.3 Wiring diagram 570 700 37 843
20.4 Wiring diagram 570 700 39 873
20.5 Wiring diagram 570 700 42 903

6 BOMAG 008 911 57

 1 General

008 911 57 BOMAG 7

1.1 Introduction

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

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

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

You should only use genuine BOMAG spare parts.

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

Danger
!

Please observe strictly the safety regulations in

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

8 BOMAG 008 911 57

Safety regulations
Important notes
1.2 Safety regulations
These safety regulations must be read and ap-
plied by every person involved in the repair of this
machine. The applicable accident prevention in-
structions and the safety regulations in the oper-
ating and maintenance instructions must be
additionally observed.
Repair work shall only performed by appropriately
trained personnel or by the after sales service of
BOMAG.
Any suggestions, safety precautions and warn-
ings in this section are intended as a mnemonic
aid for well trained and experienced expert me-
chanics. This manual should not be considered a
bible on workshop safety.
Workshop equipment and facilities as well as the
use and waste disposal of solvent, fluids, gases
and chemicals are subject to legal regulations,
which are intended to provide a minimum on safe-
ty. It is obviously your own responsibility to know
and adhere to these regulations.
This manual contain headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to avoid dangers for health and
for the environment.
Danger
! welding work
Paragraphs marked like this highlight possible
dangers for persons.
Caution
! Danger
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
i Note
Paragraphs marked like this contain technical infor-
mation for the optimal economical use of the machine.
Environment
Paragraphs marked like this point out practices
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Observe the regulations for the protection of the
environment.
General
l
Before starting repair work stand the machine on
level and solid ground.
l Always secure the machine against unintended roll-
ing.
l Secure the engine reliably against unintentional
starting.
008 911 57 BOMAG
1.2
Mark a machine that is defective or being repaired
l
by attaching a clearly visible warning tag to the
steering wheel.
l On machines with articulated joint keep the articu-
lated joint locked during work.
l Use protective clothes like hard hat, safety boots
and gloves.
l Keep unauthorized persons away from the machine
during repair work.
l Tools, lifting gear, lifting tackle, supports and other
auxiliary equipment must be fully functional and in
safe condition.
l Use only safe and approved lifting gear of sifficient
load bearing capacity to remove and install parts or
components from and to the machine.
l Be careful with cleansing agents. Do not use easily
inflammable or harmful substances, such as gaso-
line or paint thinners for cleaning.
l Cleaning or repair work on the fuel tank is very dan-
gerous. Do not smoke or allow any ignitable sparks
or open fire in the vicinity when cleaning or repairing
a tank. .
l
When performing welding work strictly comply with
the respective welding instructions.
Precautions and codes of conduct for
Welding work should only be performed by specially
instructed expert personnel.
!
Electric shock!
Sparks, fire hazard, burning of skin!
Infrared or ultraviolet radiation (arc), flashing of
eyes!
Health hazard caused by welding work on highly
alloyed work pieces, metal coatings, paint coat-
ings, plastic coatings, oil containing dirt deposits,
grease or solvent residues, etc.!
l Check welding equipment and cables for damage
before use (also the validity of inspection stickers).
l Ensure good conductivity between earth cable and
work piece.
l Start the extraction fan before starting work and
guide with the progressing work as required.
l
Always isolate the burner when laying it down (re-
move possible electrode residues).
l Protect cables from being damaged, use cables
with insulated couplings.
l
Ensure sufficient fire protection, keep a fire extin-
guisher at hand.
9
1.2
l In case of welding work in fire or explosion endan-
gered environments, you should always ask for a
welding permission.
l Remove combustible parts from the vicinity or cover
such parts.
l Name a fire watch during and after welding work.
l Do not clamp the welding rod holder and the inert
gas welding gun under your arm and lay these parts
only on an insulated top.
l Place the inert gas bottles in a safe place and se-
cure them against falling over.
l Use a protective screen or an arcing shield with
welding glass, wear welding gloves and clothes,
this applies also for assisting persons.
l Switch the welding unit off before connecting weld-
ing cables.
Behaviour in case of faults
l Check electrode holders and electric cables at reg-
ular intervals.
l
In case of deficiencies switch off the welding unit
and inform supervising persons.
l
In case of an extractor fan failure or any other fault
inform the supervising persons.
Maintenance; waste disposal
l
Replace damaged insulating jaws and welding rod
holders immediately.
l
Replace the welding wire reels only in deenergized
state.
What to do in case of accidents; First Aid
l
Keep calm.
l
Call first air helpers.
l
Report the accident.
l In case of an electric accident: Interrupt the power
supply and remove the injured person from the
electric circuit. If breathing and heart have stopped
apply reactivation measures and call for an emer-
gency doctor.
Old oils
Prolonged and repetitive contact with mineral oils will
remove the natural greases from the skin and causes
dryness, irritation and dermatitis. Moreover, used en-
gine oils contain potentially hazardous contaminants,
which could cause skin cancer. Appropriate skin pro-
tection agents and washing facilities must therefore
be provided.
l
Wear protective clothes and safety gloves, if possi-
ble.
l If there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
10 BOMAG
Safety regulations
full face visor; a facility suitable for rinsing the eyes
should also be available.
l Avoid prolonged and repetitive contact with oil, es-
pecially with old oil. In case of open incisions and in-
juries seek medical advice immediately.
l Apply protective cream before starting work, so that
oil can be easier removed from the skin.
l Wash with soap and water to ensure that all oil has
been removed (a skin cleaning agent and a nail
brush will help). Lanolin containing agents will re-
place natural skin oils that were lost.
l Do not use gasoline, kerosene, diesel, thinner or
solvents to wash the skin.
l Do not put oil soaked cloths into your pockets.
l Avoid clothes, especially underpants, getting soiled
by oil.
l Overalls must be washed at regular intervals.
Clothes that cannot be washed, must be disposed
of.
l
If possible degrease components before handling.
Environment
It is strictly prohibited to drain off oil into the soil,
the sewer system or into natural waters. Entrust
special companies with the waste disposal of old
oil. If in doubt you should consult your local au-
thorities.
Hydraulics
l Hydraulic oil escaping under pressure can pene-
trate the skin and cause severe injury. You should
therefore relieve the pressure in the system before
disconnecting any lines.
l Before applying pressure to the system make sure
that all line connections and ports have been prop-
erly tightened and are in perfect condition.
l Hydraulic oil leaking out of a small opening can
hardly be noticed, therefore please use a piece of
cardboard or wood when checking for leaks. When
being injured by hydraulic oil consult a physician im-
mediately, as otherwise this may cause severe in-
fections.
l Do not step in front of or behind the drums/wheels/
crawler tracks when performing adjustment work in
the hydraulic system while the engine is running.
Block drums and/or wheels / crawler tracks with
wedges.
008 911 57
Safety regulations
Reattach all guards and safety installations after
all work has been completed.
Environment
It is strictly prohibited to drain off hydraulic oil
into the soil, the sewer system or into natural wa-
ters. Entrust special companies with the waste
disposal of old oil. If in doubt you should consult
your local authorities.
Fuels
Danger
!
Repair work on fuel systems must only be per-
formed by appropriately trained personnel.
The following notes refer to general safety precau-
tions for danger free handling of fuel. These notes are
only general instructions; in case of uncertainties you
should consult the person responsible for fire protec-
tion.
Fuel vapours not only are easily inflammable, but also
highly explosive inside closed rooms and toxic; dilu-
tion with air creates an easily inflammable mixture.
The vapours are heavier than air and therefore sink
down to the ground. Inside a workshop they may eas-
ily become distributed by draft. Even the smallest por-
tion of spilled fuel is therefore potentially dangerous.
l Fire extinguishers charged with FOAM, SCHAUM,
CO2 GAS or POWDER must be available wherever
fuel is stored, filled in, drained off, or where work on
fuel systems is performed.
l The vehicle battery must always be disconnected,
BEFORE work in the fuel system is started. While
working on the fuel system you should not discon-
nect the battery, because this could generate
sparks, which would ignite explosive fuel vapours.
l
Wherever fuel is stored, filled, drained off or where
work on fuel systems is carried out, all potential ig-
nition sources must be extinguished or removed.
Search lights must be fire proof and well protected
against possible contact with running out fuel.
Hot fuels
Before draining fuel off the tank for repair work, you
must strictly apply the following measures:
l Allow the fuel to cool down, to prevent any contact
with a hot fluid.
l Vent the system, by removing the filler cap in a well
ventilated area. Screw the filler cap back on, until
the tank is finally emptied.
Synthetic rubber
Many O-rings, hoses and similar parts, which are ap-
parently made of natural rubber, are actually made of
008 911 57 BOMAG
1.2
plastic material, a so-called fluoroelastomer. Under
normal operating conditions this material is safe and
does not impose any danger to health.
However, if this material becomes damaged by fire or
extreme heat, it may decompose and form highly
caustic hydrofluoric acid, which can cause severe
burns in contact with skin.
l If the material is in such a state it must only be
touched with special protective gloves. These
gloves must be disposed of directly after use.
l If the material has contacted the skin despite these
measures, take off the soiled clothes and seek
medical advice immediately. In the meantime wash
the affected parts of the skin for 15 to 60 minutes
with cold water or lime water.
Poisonous substances
Some of the fluids and substances used are toxic and
must under no circumstances be consumed.
Skin contact, especially with open wounds, should be
strictly avoided.
These fluids and substances are, amongst others,
anti-freeze agents, hydraulic oils, washing additives,
lubricants and various bonding agents.
Engine
Danger
!
Do not work on the fuel system while the engine is
running - danger to life!
After the engine has stopped wait until the pres-
sure has dropped (on Commonm Rail engines ap-
prox. 5 minutes, other engines 1 minute), because
the system is under high pressure - danger to life!
Keep out of the danger zone during the initial test
rung. Danger caused by high pressure in case of
leaks - danger to life!
When performing work on the fuel system make
sure that the motor cannot be started unitention-
ally - danger to life!
l Maintenance and cleaning work on the engine must
onyl be performed with the engine stopped and
cooled down. Make sure that the electric system
has been switched off (ignition key pulled out).
l Observe the accident prevention regulations for
electric systems (e.g. -VDE-0100/-0101/-0104/-
0105 Electric precautions against dangerous con-
tact voltages).
l Cover all electric components properly before wet
cleaning.
11
1.2
Air conditioning system
Caution
!
Lines in the air conditioning system must only be
loosened by trained and explicitly instructed ex-
perts.
l Wear safety goggles! Put on your safety goggles.
This will protect your eyes against coming into con-
tact with refrigerant, which could cause severe
damage by freezing.
l Wear safety gloves and an apron! Refrigerant are
excellent solvents for greases and oils. In contact
with skin they will remove the protective grease film.
However, degreased skin is very sensitive against
cold temperatures and germs.
l Do not allow liquid refrigerants to come into contact
with skin! Refrigerant takes the heat required for
evaporation from the environment. Very low tem-
peratures may be reached. The results may be local
frost injuries (boiling point of R134a -26.5°C at am-
bient pressure).
l Do not inhale higher concentrations of refrigerant
vapours! Escaping refrigerant vapours will mix with
the ambient air and displace the oxygen required for
breathing.
l Smoking is strictly prohibited! Refrigerants may be
decomposed by a glowing cigarette. The resulting
substances are highly toxic and must not be in-
haled.
l Welding and soldering on refrigeration equipment!
Before starting welding or soldering work on vehi-
cles, (in the vicinity
of air conditioning components) all refrigerant must
be drawn out and the rests removed by blowing out
the system with nitrogen. The decomposition prod-
ucts created from the refrigerant under the influence
of heat not only are highly toxic, but also have a
strong corrosive effect, so that pipes and system
components may be attacked. The substance is
mainly fluorohydrogen.
l Pungent smell! In case of a pungent smell the afore
mentioned decomposition products have already
been created. Extreme care must be exercised not
to inhale these substances, as otherwise the respi-
ratory system, the lungs and other organs may be
harmed.
l When blowing out components with compressed air
and nitrogen the gas mixture escaping from the
components must be extracted via suitable exhaust
facilities (workshop exhaust systems).
Handling pressure vessels
l Since the fluid container is pressurized, the manu-
facture and testing of these pressure vessels is gov-
erned by the pressure vessel directive. (New edition
12 BOMAG
Safety regulations
from April 1989). Paragraph 10 of the pressure ves-
sel directive demands that these pressure contain-
ers must be periodically inspected and tested by a
specialist, according to paragraph 32. In this case
periodically recurring inspections consist of external
examinations, normally on containers in operation.
The refrigerant container must be visually inspected
two times per year, within the frame work of major
inspections. Special attention must thereby be paid
to signs of corrosion and mechanical damage. If the
container is in no good condition, it should be re-
placed for safety reasons, in order to protect the op-
erator or third parties against the dangers when
handling or operating pressure vessels.
l Secure pressure vessels against tipping over or roll-
ing away.
l Do not throw pressure vessels. Pressure vessels
may thereby be deformed to such an extent, that
they will crack. The sudden evaporation and escape
of refrigerant releases excessive forces. This ap-
plies also when snapping off valves on bottles. Bot-
tles must therefore only be transported with the
safety caps properly installed.
l
Refrigerant bottles must never be placed near heat-
ing radiators. Higher temperatures will cause higher
pressures, whereby the permissible pressure of the
vessel may be exceeded. The pressure vessel di-
rective therefore specifies that a pressure vessel
should not be warmed up to temperatures above 50
°C.
l
Do not heat up refrigerant bottles with an open
flame. Excessive temperatures can damage the
material and cause the decomposition of refriger-
ant.
l
Do not overfill refrigerant bottles, since any temper-
ature increase will cause enormous pressures.
Environment
In operation, during maintenance and repair work
and when taking refrigeration systems our of
service it is not permitted to let refrigerant escape
into the atmosphere, which would contradict the
current status of technology.
Battery
l Wear goggles and face protection (acid).
l Wear suitable clothes to protect face, hands and
body (acid).
l
Work and store accumulators only well ventilated
rooms. (Development of oxyhydrogen gas).
l Do not lean over the battery while it is under load,
being charged or tested. (Danger of explosion).
l Burning cigarettes, flames or sparks can cause ex-
plosion of the accumulator
l Keep ignition sources away from the battery.
008 911 57
Safety regulations
l Always shield eyes and face towards the battery.
l Do not use battery chargers or jump leads without
following the operating instructions.
l Keep the cell plugs closed.
l After an accident with acid flush the skin with water
and seek medical advice.
l Do not allow children access to batteries.
l When mixing battery fluid always pour acid into wa-
ter, never vice-versa.
Poisonous substances
Some of the fluids and substances used are toxic and
must under no circumstances be consumed.
Skin contact, especially with open wounds, should be
strictly avoided.
These fluids and substances are, amongst others,
anti-freeze agents, hydraulic oils, washing additives,
lubricants and various bonding agents.
1.2
l Do not heat up oil higher than 160 °C because it
may ignite.
l Wipe off spilled oil and fuel.
l Do not smoke when refuelling or when checking the
acid level in the battery.
l Do not check the acid level of the battery with a na-
ked flame, danger of explosion!
l Old batteries contain lead and must be properly dis-
posed of.
l
There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature.
l on machines with rubber tires a tire may busr if in-
correctly assembled. This can cause severe injury.
l Do not exceed the specified highest permissible tire
pressure.

Special safety regulations

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

008 911 57 BOMAG 13

1.3 General repair instructions

General Electrics
1.3 General repair instructions

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

Diagnostics according to plan

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

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

14 BOMAG 008 911 57

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

Electrical system and welding work

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

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

008 911 57 BOMAG 15

1.3
Hydraulic system
Caution
!
Do not open any hydraulic components if you
have not been properly trained and without exact
knowledge.
Please note
Cleanliness is of utmost importance. Make sure that
no dirt or other contaminating substances can enter
into the system.
l Clean fittings, filler covers and the area around such
parts before disassembly to avoid entering of dirt.
l Before disconnecting hoses, pipes or similar relieve
the system pressure with the engine shut down.
l During repair work keep all openings closed with
clean plastic plugs and caps.
l Do not run pumps and motors without oil.
l When cleaning hydraulic components take care not
to damage any fine machine surfaces.
l Chemical and rubber soluble cleansing agents may
only be used to clean metal parts. Do not let such
substances come in contact with sealing material.
l Rinse of cleaned parts thoroughly, dry them with
compressed air and apply anti-corrosion oil immedi-
ately. Do not install parts that show traces of corro-
sion.
l Avoid the formation of rust on fine machined caused
by hand sweat.
l Grease must not used as a sliding agent for assem-
bly work. Use hydraulic oil.
l
Do not start the engine after the hydraulic oil has
been drained off.
l Use only the specified pressure gauges. Risk of
damaging the pressure gauges under too high pres-
sure.
l Clean ports and fittings before removal so that no
dirt can enter into the hydraulic system.
l
Check the hydraulic oil level before and after the
work.
l Use only clean oil according to specification.
l Check the hydraulic system for leaks, find and rec-
tify the cause.
l Fill new hydraulic units with hydraulic oil before
starting operation.
l
After changing a component thoroughly flush and
bleed the entire hydraulic system.
l Perform measurements at operating temperature of
the hydraulic oil (approx. 40 ¯C).
16 BOMAG
General repair instructions
l After changing a component perform a high and
charge pressure test, if necessary check the speed
of the exciter shaft.
l The operating pressure of the exciter shaft to a
great extent depends on the base under the vibrat-
ing drum. If the soil is too hard place the drums on
old rubber tires. Do not activate the vibration on a
hard, concreted base, danger of bearing damage.
l
After the completion of all tests perform a test run
and then check all connections and fittings for leaks
with the engine still stopped and the hydraulic sys-
tem depressurized.
Before commissioning
l After changing a component clean the hydraulic oil
tank thoroughly.
l Fill the housings of hydraulic pumps and motors
with hydraulic oil.
l Use only hydraulic oils according to the specifica-
tion in the maintenance instructions.
l
After changing a component clean the hydraulic
system as described in the flushing instructions in
order to prevent all other components from being
damaged by abrasion and metal chips remaining in
the system.
l
Change the hydraulic oil filter.
Commissioning
l
Bleed the hydraulic circuits.
l
Start up the system without load.
l
Check the hydraulic oil level in the tank, fill up oil if
necessary.
After commissioning
l
Check system pressures and speeds.
l Check fittings and flanges for leaks.
l After each repair check all adjustment data, rota-
tional speeds and nominal values in the hydraulic
system, adjust if necessary.
l Do not adjust pressure relief valves and control
valves to values above their specified values.
008 911 57
General repair instructions
Air conditioning system
CFC - halon prohibition
The CFC - halon prohibition from May 06, 1991 regu-
lates the withdrawal from the use of CFC and the han-
dling of these refrigerants.
Contents:
Since 1995 CFC (R12) is no longer permitted for use
in new systems.
In operation, during maintenance and repair work and
when taking refrigeration systems our of service it is
not permitted to let refrigerant escape into the atmos-
phere, which would contradict the current status of
technology.
Work on refrigeration systems must only be carried
out by persons with well founded knowledge about
such systems and who have the necessary technical
equipment available.
The use of refrigerant must be documented.
Old systems should be converted to refrigerants
harmless to ozone (refrigerant substitutes).
For this reason the Federal Environmental Agency at
the end of 1995 published suitable replacement refrig-
erants for R 12. As a consequence old systems must
no longer be filled with R12. As soon as such a system
is opened for service, the system must be converted
to a suitable replacement or service refrigerant. Old
systems may still be used, as long as they are leak
tight. R 134a was nominated as replacement for R 12.
Inside the European Union the "EU-Directive 2037/
2000 on substances causing decomposition of the
ozone layer" regulates the production, use and avail-
ability of CFC and H-CFC.
l In case of a repair on the refrigeration system you
should first evacuate the air conditioning system for
at least 45 minutes to remove any moisture from the
system, before you start to refill. Moisture bonded in
the compressor oil / refrigeration oil (PAG oil) can
only be removed from the system by changing the
oil.
l
During repair work on refrigerant lines and compo-
nents, these must be kept closed as far as possible,
in order to prevent the invasion of air, moisture and
dirt, because the operational reliability of the system
can only be assured if all components in the refrig-
erant circuit are clean and dry from inside.
l Make sure that no dirt or foreign parts can enter into
the compressor or the air conditioning system. The
area around the refrigerant hoses should be
cleaned with a gasoline free solvent.
l All parts to be reused should be cleaned with a
gasoline free solvent and blow-dried with clean
compressed air or dried with a lint-free cloth.
l Before opening all components should have
warmed up to ambient temperature, to avoid that
008 911 57 BOMAG
1.3
damp air is drawn into the component by the differ-
ence in temperatures.
l Damaged or leaking parts of the air conditioning
must not be repaired by welding or soldering, but
must generally be replaced.
l Do not fill up refrigerant, but extract existing refrig-
erant and refill the system.
l Different types of refrigerant must not be mixed.
Only the refrigerant specified for the corresponding
air conditioning system must be used.
l Refrigerant circuits with refrigerant type R134a
must only be operated with the compressor oil / re-
frigeration oil approved for the compressor.
l Used compressor oil / refrigeration oil must be dis-
posed of as hazardous waste.
l Due to its chemical properties compressor oil / re-
frigeration oil must never be disposed of together
with engine or transmission oil.
l Compressor oil / refrigeration oil is highly hydro-
scopic. Oil cans must strictly be kept closed until
use. Oil rests should not be used, if the can had
been opened over a longer period of time.
l
All O-rings as well as pipe and hose fittings must be
oiled with compressor/refrigeration oil be-
foreiassembly.
l
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil / refrigeration oil
lost by exchanging the components, must be re-
placed with fresh oil.
l
A too high compressor oil / refrigeration oil level ad-
versely affects the cooling performance and a too
low oil level has a negative effect on the lifetime of
the compressor.
l
If a air conditioning unit needs to be opened, the
dryer must be replaced in any case.
l Always use new O-rings when reassembling the
unit.
l
Always use two spanners when connecting pipes or
hoses, to prevent the pipe end from being damaged
.
l Tighten screw fittings with the specified torque.
l
Check the connections of pipes, fittings or compo-
nents thoroughly; do not use if damaged.
l
Do not leave the refrigerant circuit unnecessarily
open to the atmosphere. Do not attempt to repair
bent or burst pipes.
l
Compressor valves must only be opened after the
system has been properly sealed.
l The use of leak detection colouring matter is not
permitted, because its chemical composition is un-
known and its effect on compressor oil and rubber
elements is not predictable. The use of leak detec-
17
1.3 General repair instructions

tion colouring matter makes any warranty claims Notes on cleanliness for Common Rail
null and void. engines
l Tools used on refrigeration circuits must be of ex- Special requirements with respect to cleanliness in
cellent condition, thus to avoid the damage of any the fuel system do apply for commissioning, mainte-
connections. nance and repair work, particularly for TEIRIII engines
l The dryer is to be installed last, after all connections with the DEUTZ Common Rail System. Contamina-
in the refrigerant circuit have been tightened. tion like dirt, welding residues or similar can lead to the
failure of individual components and adversely affect
l After completion of repair work screw locking caps engine operation.
(with seals) on all connections with valves and on
the service connections. Start up of the air condi-
tioning system. Observe the filling capacity.
l Before start up of the air conditioning system after a
new filling: - Turn the compressor approx. 10 revo-
lutions by hand using the clutch or V-belt pulley of
the magnetic clutch. - Start the engine with the com-
pressor/control valve switched off. - Once the idle
speed of the engine has stabilized switch on the
compressor and run it for at least 10 minutes at idle
speed and maximum cooling power.
l
Never operate the compressor over longer periods
of time with high engine speeds without a sufficient
amount of refrigerant in the system. This could
probably cause overheating and internal damage.

Fig. 1
l
Spare parts should be left in their original packaging
as long as possible and should only be unpacked
just before use.
l
When parts are unpacked any connections must be
closed with suitable plugs or caps, in order to pre-
vent (Fig. 1) contamination of hose connections. If
e.g. fuel hoses are connected to one side, while the
second side cannot yet be connected, there is a
danger of dirt entering into the system. The free
connection must in this case also be appropriately
closed.

Notes and measures to be applied before starting

work in the fuel system
l
The fuel system must be closed. Visual examination
for leaks / damage in the fuel system.
l
Before starting work in the fuel system clean the
complete engine and the engine compartment with
the system still closed.
l
The engine should be dry before work is started in
the fuel system.

18 BOMAG 008 911 57

General repair instructions
l Blow drying with compressed air is only permitted
while the fuel system is still closed.
l When using steam cleaning equipment cover con-
trol unit, cable plugs, all other electrical connections
and the generator beforehand and do not expose
these items to the direct steam jet.
l Electrical plug connections must be plugged in dur-
ing jet cleaning.
l Remove loose parts (e.g. paint scales that may
have come off during assembly work) with an indus-
trial vacuum cleaner or any means of extraction.
l Vacuum cleaning equipment must generally be
used for cleaning when the fuel system is open.
l Perform work on the fuel system only in a clean en-
vironment (no dust, no grinding or welding work).
Avoid draughts (dust). The workshop floor must be
cleaned at regular intervals. No brake or power test
stand should be present or operated in the same
room.
l
Air movements, which could swirl up dust, such as
brake repairs or starting of engines, must be strictly
avoided.
l
For work, such as disassembly and assembly of de-
fective hydraulic components in the Common Rail
System, it is strongly recommended to set up a sep-
arate workshop area, i.e. an area which is spatially
separated from all other areas (general vehicle re-
pairs, brake repairs).
l
No general machine tools should be operated in this
room.
l
Periodic cleaning of this workshop area is obligato-
ry, draughts, ventilation system and heating blow-
ers must be minimized.
l
Engine compartment area where dirt particles could
come loose, should be covered with new, clean foil.
l
Working means and tools must be cleaned before
being used for work. Use only tools without dam-
aged chromium coating, or tools without chromium
coating.
Notes and measures to be applied during work in
the fuel system
l
Wear clean working clothes.
l Use only lint-free cleaning cloths for work in the fuel
system.
l
Remove loose parts (e.g. paint scales that may
have come off during assembly work) with an indus-
trial vacuum cleaner or any means of extraction.
Vacuum cleaning equipment must generally be
used for cleaning when the fuel system is open.
l Working means and tools must be cleaned before
being used for work. Use only tools without dam-
aged chromium coating, or tools without chromium
coating.
008 911 57 BOMAG
1.3
l Do not use any previously used cleaning or testing
fluids for cleaning.
l Compressed air should never be used for cleaning
when the fuel system is open.
l Work on disassembled components must only be
carried out at a specially furnished work place.
l When disassembling or assembling components
you should not use any materials from which parti-
cles or fibres could flake off (cardboard, wood, tow-
els).
l Dismantled parts must only be wiped off with clean,
lint-free cloths if required. No dirt particles must be
wiped into the components.
l Close openings on components and engine imme-
diately with suitable plugs/caps.
l Plugs/caps must only be removed just before the in-
stallation.
l Keep plugs/caps in their original packaging, where
they are protected against dust and dirt, dispose of
after one time use.
l
Take new parts out of their original packaging just
before installation.
l
Disassembled components must be stored in new,
sealable bags or – if available – in the packaging
material of the new components.
l
Always use the original packaging material of the
new part to return the disassembled old component.
Notes and measures concerning the workshop
area
l
For work, such as disassembly and assembly of de-
fective hydraulic components in the Common Rail
System, it is strongly recommended to set up a sep-
arate workshop area, i.e. an area which is spatially
separated from all other areas (general vehicle re-
pairs, brake repairs).
l The workshop floor must be sealed or tiled.
l
No welding equipment, grinding machines, general
machine tools, brake or power test benches must
be operated in this room.
l
Periodic cleaning of this workshop area is obligato-
ry, draughts, ventilation system and heating blow-
ers must be minimized.
Notes and measures for work place and tools in
the workshop
l
A special work place must be set up for work on dis-
assembled components.
l Clean disassembly and assembly tools at regular
intervals and keep these in a closed tool cabinet.
19
1.3 General repair instructions

l Remove loose parts (e.g. paint scales that may Fuel hoses
have come off during assembly work) with an indus-
trial vacuum cleaner or any means of extraction.
l Working means and tools must be cleaned before
being used for work. Use only tools without dam-
aged chromium coating, or tools without chromium
coating.

Fig. 2

! Caution
All fuel hoses have two layers of material, a rein-
forced rubber coating outside and an internal Vi-
ton hose. If a fuel hose has come loose one must
make absolutely sure that the internal Viton layer
has not been separated from the reinforced outer
layer. In case of a separation the hose needs to be
replaced.

20 BOMAG 008 911 57

General repair instructions 1.3
Gaskets and mating surfaces threads or splines. If no assembly sleeve is availa-
ble, you should use a plastic tube or adhesive tape to
Leaking or failing seals and gaskets can in most cases
prevent the sealing lip from being damaged.
be tracked down to careless assembly, causing dam-
age not only to the seal or gasket, but also to the mat-
ing surfaces. Careful assembly work is mandatory if
good results are to be achieved.
l Before assembling replacement seals make sure
that the running surface is free of pitting, flutes, cor-
rosion or other damage.
l
Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
l Sealing compound should only be used if specially
requested in the instructions. In all other cases
these joints should be assembled in dry condition.
l Sealing compound must be applied thin and evenly
on the corresponding surfaces; take care that the Fig. 4
compound does not enter into oil galleries or blind l Lubricate the outer rim 1 (Fig. 4) of the seal and
threaded bores.
press it flat on the housing seat.
l
Before assembly remove any residues of old seal-
ing compound. Do not use any tools that could dam-
age the sealing surfaces. i Note
If possible, use a "bell" 1 (Fig. 4), to make sure that
l
Examine the contact faces for scratches and burrs,
the seal will not skew. In some cases it may be ad-
remove these with a fine file or an oilstone; take
visable to assemble the seal into the housing first, be-
care that no grinding dust and dirt enters into
fore sliding it over the shaft. Under no circumstances
tapped bores or enclosed components.
should the full weight of the shaft rest on the seal.
l
Blow lines, ducts and gaps out with compressed air,
If you have no proper service tools at hand, use a suit-
replace any O-rings and seals that have been dis-
able drift punch with a diameter which is about 0.4mm
lodged by the compressed air.
smaller than the outer diameter of the seal. Use VERY
Assembly of radial seals LIGHT blows with the hammer if no press is available.
l
Press or knock the seal into the housing, until it is
flush with the housing surface.

Fig. 3
l
Lubricate sealing lips 1 (Fig. 3) with clean grease; in
case of double seals fill the space between the seal-
ing lips with a generous amount of grease.
l
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.

i Note
If possible, use an assembly sleeve 1 (Fig. 3), to pro-
tect the lip from being damaged by sharp edges,

008 911 57 BOMAG 21

1.3 General repair instructions

Feather keys and keyways Ball and roller bearings

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

Fig. 5
l Clean and thoroughly examine the feather key.
l Debur and thoroughly clean the edges of the key-
way with a fine file before reassembling.

Fig. 6
l Remove any lubricant residues from the bearing to
be examined by washing it with gasoline or any oth-
er appropriate degreasing agent. Cleanliness is of
utmost importance for all related work.
l
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. If necessary replace the bearing with
a new one, since these symptoms are first signs of
wear.
l
Hold the bearing with you thumb and the index fin-
ger by the inner race, rotate the outer race and
make sure that it runs without friction. Hold the
bearing by the outer race and repeat this test with
the inner race.
l
Move the outer race gently to and fro while holding
it by the inner race; check for resistance while rotat-
ing and replace the bearing if it does not work cor-
rectly.
l Lubricate the bearing with an appropriate lubricant
before reinstalling.

22 BOMAG 008 911 57

General repair instructions
l Check shaft and bearing housing for discolouration
or other signs of movement between bearing and
seats.
l Make sure that shaft and housing are free of burrs
before assembling the bearing.
l If a bearing of a pair of bearings shows any defects,
we highly recommend the replacement of both
bearings.
l On greased bearings (e.g. wheel bearings) fill the
space between bearing and outer seal with the rec-
ommended type of grease before assembling the
seal.
l Always mark the individual parts of separable bear-
ings (e.g. taper roller bearings) to enable correct re-
assembling. Never assemble the rollers to an outer
race that has already been used, replace the com-
plete bearing instead.
Fig. 7
Caution
!
When assembling the bearing to the shaft load
must only be applied to the inner race 1 (Fig. 7).
When fitting the bearing into the housing load
must only be applied to the outer race (2).
008 911 57 BOMAG
1.3
Screws and nuts
Tightening torque
!Caution
Always tighten nuts or screws to the specified
tightening torque. Tightening torques deviating
from the ones in the table are specially mentioned
in the repair instructions.
Damaged screws must under no circumstances
be used any longer. Recutting threads with thread
cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
roded thread pitches can cause incorrect torque
value readings.
Self-locking nuts must be generally renewed.
The use of screws with too high strength can
cause damage!
l Nut of a higher strength can generally be used in-
stead of nuts of a lower strength classification.
l When checking or retightening screw joints to the
specified tightening torque you should first relieve
by a quarter turn and then tighten to the correct
torque.
l Before tightening you should lightly oil the thread, in
order to ensure low friction movement. The same
applies for self-locking nuts.
l Make sure that no oil or grease will enter into tapped
bores. The hydraulic power generated when turning
in the screw could cause breakage of the effected
part.
23
1.3
Strength classes of metric screws
The strength classes (from 3.6 to 12.9) are specified
for all strength classes from a nominal diameter of
5mm. The corresponding identification can be found
where allowed for by the shape of the screw.
Fig. 8 Identification of screws
Example: A screw is identified with 12.9.
The first number corresponds with 1/100 of the nomi-
nal tensile strength (minimum tensile strength) in N/
mm2.
l
The nominal tensile strength is 12 X 100N/mm2 =
1200 N/mm2.
The second number specifies 10-times the ration be-
tween lower yield point and nominal tensile strength
(yield point ratio).
i Note
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas-
tic deformation).
When exceeding the upper yield point the material will
not restore its original shape after being relieved.
l The lower tensile strength is 9/10 X 1200 N/mm2 =
1080 N/mm2.
i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.
24 BOMAG
General repair instructions
Strength classes of metric nuts
Nuts are differentiated by three load groups. Each
load group has a special designation system for the
strength class assigned, so that the load group can be
clearly identified.
Nuts for screw joints with full load capability (4, 5,
6, 8, 10, 12)
Fig. 9 Identification of nuts
In a connection with a screw, these nuts 1 (Fig. 9)
must be able to bear the full pre-load at the yield point.
Nut height above 0.8 d (d = nominal dimension).
Strength class of Strength class of associated
nut screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
6 6.8
8 8.8
9 9.8
10 10.8
12 12.8
Nuts for screw joints with limited load factor (04,
05)
The preceding "0" indicates that, due to their low
height, nuts 2 (Fig. 9) in this group are only able to
withstand the force of a screw to a limited extent.
Nut height below 0.8 d (d = nominal dimension).
Nuts for screw joints without specified load factor
(11H, 14H, 17H, 22H)
This standard contains strength classes (hardness
classes) for nuts 3 (Fig. 9), for which no load values
can be specified, e.g. because of their shape and di-
mensions, but which can only be classified by their
hardness.
Nut height below 0,5 d (d = nominal dimension).
008 911 57
General repair instructions 1.3
Identification in clock system

Fig. 10 Identification of nuts in clock system

For small nuts (Fig. 10) the clock system can be used
for identification.
l The 12 o'clock position is identified by a dot or the
manufacturer's symbol.
l
The strength class is identified by a dash (b).

008 911 57 BOMAG 25

1.4 Tightening torques

The values specified in the table apply for screws:

1.4 Tightening torques

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

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

Tightening torques for screws with metric unified thread1

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

Tightening torques for screws with metric unified fine thread1

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

26 BOMAG 008 911 57

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

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

Tightening torques for wheel nuts (fine thread) 1 2

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

008 911 57 BOMAG 27

1.4 Tightening torques

The values specified in the table apply for screws:

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

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

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

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

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

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

28 BOMAG 008 911 57

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

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

008 911 57 BOMAG 29

1.4 Tightening torques

30 BOMAG 008 911 57

 2 Technical data

008 911 57 BOMAG 31

2.1 Technical data

2.1 Technical data

Fig. 11

Dimensions in A B B2 B3 D H H2 H4 K L
mm
BC 972 RB-2 4100 5200 4500 4260 2200 4845 4400 2225 765 9425
BC 1172 RB-2 4100 5200 4500 4260 2200 4845 4400 2225 765 9425

1
BC 972 RB-2 BC 1172 RB-2

Weights
Operating weight CECE kg 46500 54500
Front axle load CECE kg 22850 26850
Rear axle load CECE kg 23650 27650

Engine
Engine manufacturer Deutz Deutz
Type TCD 2015 V08 TCD 2015 V08
Cooling Water Water
Number of cylinders 8 8
Rated power ISO 9249 kW 400 440
Rated speed rpm 1900 1900
Electric equipment, oper- V 24 24
ating voltage
Batteries, 2 pcs. V/AH 12/200 12/200
Drive system hydrostatic hydrostatic
Driven compactor wheels 4 4

Travel characteristics

Speed
Travel range I km/h 0 to 3 forward, reverse 0 to 3 forward, reverse
Travel range II km/h 0 to 5 forward, reverse 0 to 5 forward, reverse
Travel range III km/h 0 to 12 forward, reverse 0 to 12 forward, reverse
Gradability (soil depend- % 100 100
ent)
Steering angle +/-° degree 40 40
Oscillation angle +/-° degree 15 15
Inner track radius mm 3050 3050

32 BOMAG 008 911 57

Technical data 2.1
1
BC 972 RB-2 BC 1172 RB-2

Compactor wheels
Number of teeth, front pcs. 72 72
Number of teeth, rear pcs. 72 72
Compaction width per mm 1520 1520
wheel side

Brake
Service brake hydrostatic hydrostatic
Parking brake mech./hydrost. mech./hydrost.
Emergency brake, emer- mech./hydrost. mech./hydrost.
gency stop

Steering
Type of steering Oscill.-articul. Oscill.-articul.
Steering operation hydraulic hydraulic

Dozer blade
Height adjustment above mm 1375 1375
ground level
Height adjustment below mm 50 50
ground level

Filling capacities
Fuel (diesel) l 1000 1000
Hydraulic oil l 590 590
1 The right for technical modifications remains reserved

Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 700 - 750
High idle speed rpm 1900 - 1950
Specific fuel consumption g/kWh 227
Valve clearance intake mm 0,25
Valve clearance exhaust mm 0,3
Injection valves opening pressure bar Pump/nozzle
Starter power kW 6,6

Transfer box
Type HVP-C3
Reduction ratio of travel pump drive 0,74
Reduction ratio of working pump 1,023
drive
Pressure setting PRV coolant circuit bar 25
(high idle)

Travel pump
Manufacturer Bosch-Rexroth
Type front A4 VG 90 DA
Type rear A4 VG 90 DG
System Axial piston/swash plate
Max. displacement cm3/rev. 90
Max. flow capacity l/min 255,1
High pressure limitation bar 480 - 20

008 911 57 BOMAG 33

2.1 Technical data

Pressure override valve bar 430 + 10/-20

Charge pressure, high idle bar 30 ± 1
_Absolute pressure at control start bar 50 at 925 ± 55 rpm
__Corresponds with pump speed rpm 1250 ± 75

Travel motors
Manufacturer Bosch-Rexroth
Type A6VM 200 EPD
Quantity 4
System Axial piston – bent axle
Displacement (stage 1) cm3/rev. 200
Displacement (stage 2) cm3/rev. 140
Displacement (stage 3) cm3/rev. 65
Control start change-over bar 250 ± 5
Control end change-over bar 260 ± 5
Perm. leak oil rate l/min 10

Wheel drive
up to serial number 101 570 821 037 BC 972 RB-2
up to serial number 101 570 831 022 BC 1172 RB-2
Manufacturer Bosch-Rexroth
Type GFT 220 R3 9096
Reduction ratio 145,4

Wheel drive
from serial number 101 570 821 038 BC 972 RB-2
from serial number 101 570 831 023 BC 1172 RB-2
Manufacturer Bosch-Rexroth
Type GFT 220 R3 9184
Reduction ratio 145,4

Steering/working pump
Type A10VO 100/100 DFR
System Tandem/axial piston/swash plate
Max. displacement cm3/rev. 100 + 100
Stand-by pressure bar 30 ± 2
Max. working pressure bar 230 ± 10

Valve block, working hydraulics

Type 2M6-22
Max. steering pressure bar 230 + 10
Max. dozer plate pressure bar 230 + 10
LS-pressure limitation bar 210 + 10
Tank pre-loading valve bar 18

Charge circuit filter micron 12

Return flow filter micron 80

34 BOMAG 008 911 57

Technical data 2.1
The following noise and vibration values according to the EC-directive for machines, edition (98/37/EEC)
and the noise emission regulation 2000/14/EC were measured at nominal engine speed and with the vi-
bration switched on. The machine was standing on an elastic base.

During operation these values may vary because of the existing operating conditions.

Noise value
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is

sound pressure level at the work place of the operator (with cabin):
LpA =74 dB(A)
The nose emission value for the machine according to the noise emission regulation 2000/14/EG is

guaranteed sound capacity level of the machine:

LWA = 111 dB(A)
These sound values were determined according to ISO 3744 for the sound capacity level (LwA) and ISO 11204
for sound pressure level (LpA) at the place of the operator.

Vibration value
The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are:

Vibration of the entire body (driver’s seat)

The weighted effective acceleration value determined according to ISO 7096 is <= 0.5 m/sec2.

Hand-arm vibration values

The weighted effective acceleration value determined according to EN 500/ISO is <= 2.5 m/sec2.

008 911 57 BOMAG 35

2.1 Technical data

36 BOMAG 008 911 57

 3 Maintenance

008 911 57 BOMAG 37

3.1 General notes on maintenance

3.1 General notes on maintenance
When performing maintenance work always comply
with the appropriate safety regulations.
Thorough maintenance of the machine guarantees far
longer safe functioning of the machine and prolongs
the lifetime of important components. The effort need-
ed for this work is only little compared with the prob-
lems that may arise when not observing this rule.
l Always clean machine and engine thoroughly be-
fore starting maintenance work.
l
For maintenance work stand the machine on level
ground.
l Always remove the main battery switch for all main-
tenance work.
l Perform maintenance work only with the engine
shut down.
l Relieve hydraulic pressures before working on hy-
draulic lines.
l
Before working on electric parts of the machine dis-
connect the battery and cover it with insulation ma-
terial.
The terms right/left correspond with travel direction
forward.
l
When working in the area of the articulated joint at-
tach the articulation lock (transport lock).
l
During maintenance work catch all oils and fuels
and do not let them seep into the ground or into the
sewage system. Dispose of oils and fuels environ-
mentally.
l
Catch and dispose of biodegradable oils separately.
Frequent causes of faults
l
Operating errors
l
Incorrect, insufficient maintenance
If you cannot locate the cause of a fault or rectify it
yourself by following the trouble shooting chart, you
should contact the service departments at our branch
offices or dealers.
l Do not draw off fuel from near the bottom of the
drum.
l Fuel residues in the drum are not suitable for the en-
gine.
Notes on the performance of the engine
On diesel engines both combustion air and fuel injec-
tion quantities are thoroughly adapted to each other
and determine power, temperature level and exhaust
gas quality of the engine.
If your engine has to work permanently in "thin air" (at
higher altitudes) and under full load, you should con-
sult the customer service of BOMAG or the customer
service of the engine manufacturer.
Notes on the hydraulic system
During maintenance work on the hydraulic system
cleanliness is of major importance. Make sure that no
dirt or other contaminating substances can enter into
the system. Small particles can produce flutes in
valves, cause pumps to seize, clog nozzles and pilot
bores, thereby making expensive repairs inevitable.
l
If, during the daily inspection of the oil level the hy-
draulic oil level is found to have dropped, check all
lines, hoses and components for leaks.
l
Seal external leaks immediately. If necessary in-
form the responsible customer service.
l
Clean fittings, filler covers and the area around such
parts before disassembly to avoid entering of dirt.
l
Do not leave the tank opening unnecessarily open,
but cover it so that nothing can fall in.
Welding work on the refuse compactor
l Disconnect the main battery switch
l
Pull the plugs off all control units, engine control unit
(EMR), travel control (ESX) and additional control
(DIOS).

Notes on the fuel system

The lifetime of the diesel engine depends to a great
extent on the cleanliness of the fuel.
l Keep fuel free of contaminants and water, since this
will damage the injection elements of the engine.
l
When choosing the storage place for fuel make
sure that spilled fuel will not harm the environment.
l Do not let the hose stir up the slurry at the bottom of
the drum.

38 BOMAG 008 911 57

Fuels and lubricants
3.2 Fuels and lubricants
Engine oil
l Use winter grade engine oil for winter operation!
In order to assure perfect cold starting it is import to
chose the viscosity (SAE-class) of the engine oil ac-
cording to the ambient temperature.
For winter operation below -10 °C the oil change inter-
vals must be shortened.
Fig. 12
Lubrication oil with a too high viscosity index causes
starting difficulties. The temperature when starting the
engine is therefore of highest importance when
choosing the viscosity of engine oil for winter opera-
tion.
Oil viscosity
Since lubrication oil changes its viscosity with the tem-
perature, the ambient temperature at the operating lo-
cation of the engine is of utmost importance when
choosing the viscosity class (SAE-class) (see dia-
gram).
Occasional falling short of the temperature limit (e.g.
use of SAE 10W/40 down to -20 °C) may effect the
cold starting ability of the engine, but will not cause
any engine damage.
Temperature related lubrication oil changes can be
avoided by using multi-purpose oils. The following oil
change intervals apply also when using multi-purpose
oils.
008 911 57
3.2
Regular lubrication oil changes
The longest permissible time a lubrication oil should
remain in an engine is 1 year. If the following oil
change intervals are not reached over a period of 1
year, the oil change should be performed at least once
per year, irrespective of the operating hours reached.
Oil quality
Use oil according to ACEA-classification E4-99/E6-04
(Deutz oil quality DQC III, DQC IV). This allows the uti-
lisation of the longest oil change intervals.
Lubrication oil change intervals
Oil change intervals with oil quality
Permitted ACEA-oil
E4-99/E6-04= 500 operating hours
Permitted Deutz oil
DQC III,DQC
IV = 500 operating hours
! Caution
These intervals apply only when using a diesel
fuel with maximum 0.5 % sulphur by weight and
for ambient temperatures higher than 10 °C.
When using fuels with a sulphur content of more
than 0,5% to 1% or under ambient temperatures
below -10 °C (10°C) the oil change intervals spec-
ified in the table must be halved.
When using oils with a sulphur content of more
than 1 % by weight and a permanent operating oil
temperature below 60°C consult the service de-
partment of the engine manufacturer.
Lubrication oil quality classes
The ACEA-classification is used to classify the oil
quality.
The oil manufacturer is solely responsible for assign-
ing a product to a certain quality class.
i Note
When changing to a higher alloyed oil quality after a
longer period of operation, it is recommended to per-
form the first oil change of the higher quality oil already
after 20 operating hours. The lubrication oil filter car-
tridge must be changed at the same time.
Fuels
Quality
You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% and en-
sure strict cleanliness when filling in. A higher sulphur
BOMAG 39
3.2
content has a negative effect on the oil change inter-
vals. Use only winter-grade diesel fuel under low am-
bient temperatures. The fuel level should always be
topped up in due time so that the fuel tank is never run
dry, as otherwise filter and injection lines need to be
bled.
The following fuel specifications are permitted:
l DIN/EN 590
l ASTM D 975, Grade No. 1-D and 2-D.
Winter fuel
Danger
!
Fire hazard!
Diesel fuels must never be mixed with gasoline.
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At very
low temperatures disturbing paraffin separation can
also be expected when using winter diesel fuel.
In most cases a sufficient cold resistance can also be
achieved by adding flow enhancing fuel additives.
Consult the engine manufacturer.
Winter fuel
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At very
low temperatures disturbing paraffin separation can
also be expected when using winter diesel fuel.
In most cases a sufficient cold resistance can also be
achieved by adding flow enhancing fuel additives.
Consult the engine manufacturer.
Mineral oil based hydraulic oil
The hydraulic system is operated with hydraulic oil HV
46 (ISO) with a kinematic viscosity of
46 mm2/s at 40 °C. For topping up or for oil changes
use only high-quality hydraulic oil, type HVLP accord-
ing to DIN 51524, part 3, or hydraulic oils type HV ac-
cording to ISO 6743/3. The viscosity index (VI) must
be at least 150. (Observe the information of the man-
ufacturer).
Bio-degradable hydraulic oil
The hydraulic system can also be operated with a syn-
thetic ester based biodegradable hydraulic oil.
The biologically quickly degradable hydraulic oil Pan-
olin HLP Synth.46 meets all demands of a mineral oil
based hydraulic oil according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.46
always use the same oil to top up.
When changing from mineral oil based hydraulic oil to
an ester based biologically degradable oil, you should
consult the lubrication oil service of the oil manufactur-
er for details.
40 BOMAG
Fuels and lubricants
Check the filter more frequently after this change.
Splitter gear oil / planetary gear oil
Quality
For splitter gear and planetary gears use only multi-
purpose gear oils of API-GL4- and API-GL5-class,
SAE 85W-90.
However, these oils must comply with the following
viscosity:
175 cSt - 250 cSt at 40°C
min. 16.5 cSt at 100°C
This is a hypoid lubricant of highest quality class for
extremely loaded transmissions.
The additives in this oil ensure low wear lubrication
under all operating conditions.
Lubrication grease
For lubrication purposes use an EP-high pressure
grease, calcium and/or lithium saponified (penetration
2), acc. to DIN 51502 KP 2G.
Coolant
High performance diesel engines require a well bal-
anced coolant mixture of water, anti-freeze and sup-
plementary coolant additives.
For coolant mixtures use only soft tap water with a wa-
ter hardness between 3 and 20 °dGH. The water
should not contain more than 100 mg/dm3 of chlorine
and sulphate.
Prepare and check coolant with highest care, since
otherwise the engine may be damaged by corrosion,
cavitation and freezing.
As a protection against frost and boiling point anti-
freeze agents must be used under any climatic condi-
tions.
Mixing of coolant water and cooling system protection
agent must be performed at a concentration level of
the cooling system protection agent of minimum 35%
and maximum 45%.
! Caution
Do not mix different coolants and additives of any
other kind.
Environment
Cooling system protection agents must be dis-
posed of environmentally.
008 911 57
Table of fuels and lubricants 3.3
3.3 Table of fuels and lubricants

Assembly Fuel or lubricant Quantity approx.

Summer Winter Attention

Observe the level marks

Engine Engine oil, ACEA E4-99 approx. 45 litres without

filter change, approx. 47
litres with filter change

SAE 10W/40

(-20 °C to +40 °C)

Coolant approx. 64 litres

Mixture of water and anti-freeze agent

Fuel Diesel Winter diesel fuel* (down 1000 litres

to -12 °C)

Hydraulic system Hydraulic oil (ISO), HV46, with viscosity index 150 or 590 litres
ester based biodegradable hydraulic oil

Splitter gear SAE 85W-90 EP, API GL5 9 litres

Planetary drives (Lohm- SAE 85W-90 EP, API GL5 12 litres

ann + Stolterfoht)

Central lubrication system High pressure grease (calcium and/or lithium saponi- 2.0 kg automatic lubrica-
fied) tion

DIN 51 502 KP 2G

Air conditioning system Refrigerant R 134 A approx. 1,9 kg

Cabin heater (diesel) as engine oil down to approx. -30 °C as required

use SAE 5W/30

- Oil bath air filter

008 911 57 BOMAG 41

3.4 Running-in instructions

3.4 Running-in instructions

The following service work must be performed
when taking new machines into operation.

! Caution
Up to approx. 250 operating hours check the en-
gine oil level twice every day.
Depending on the load the engine is subjected to,
the oil consumption will drop to the normal level
after approx. 100 to 250 operating hours.

After a running time of 15 minutes retighten the V-

belts for generator and compressor.

Maintenance after 50 operating hours

l Change the engine oil
l Change the engine oil filter
l Change the oil in the L + S planetary drives.
l Retighten bolted connections on intake and exhaust
tubes, oil sump and engine mounts.
l Retighten all bolted connections on the machine.

Maintenance after 500 operating hours

l Change the oil in splitter gear and oil filter.
l Change the oil in the planetary gear.

Special intervals
l Switch the heating system on every month for about
10 minutes.
l Switch the air conditioning on every month for about
10 minutes.

!Caution
After the installation of a new or a service ex-
change engine and after repair work on the cylin-
der head the valves clearance must be checked
after 50 operating hours.
After the installation of new or service exchange
gearboxes the specified service intervals start
again from the beginning.

42 BOMAG 008 911 57

Maintenance chart 3.5
3.5 Maintenance chart
With all maintenance intervals perform also the
work for shorter preceding service intervals.

No. Designation Note

Every 10 operating hours

5.6 Check the engine oil level SAE 10W/-40
5.7 Check the fuel level
5.8 Check the hydraulic oil level
5.9 Visual inspection of the machine for damage and
leaks
5.10 Check the coolant level
5.11 Check the oil level in the pump drive gear
5.12 Check/empty the fuel pre-cleaner (water separator)
Every 500 operating hours
5.13 Service the air conditioning summer operation
5.14 Check the fastening of the scrapers 628 Nm (463 ft lb)
5.15 Change the engine oil SAE 10W/-40, at least 1x per year
at a fuel consumption of >65l/h the oil change
must be performed every 250 operating hours
5.16 Change the engine oil filter
5.17 Changing the fuel precleaner
5.18 Change the fuel filter
5.19 Check the engine mounts
5.20 Check condition of radiator, intercooler and hydraulic
oil cooler, clean, clean the engine
5.21 Check the oil level in the planetary gears
5.22 Check the battery condition, greasing the poles
5.23 Check the central lubrication system, topping up
5.24 Check condition and tension of generator V-belt, re-
place the V-belt
5.25 Check the V-belt for refrigerant compressor, tighten,
if necessary replace the V-belt
5.26 Check, tighten the fan V-belt, replace if necessary replace every 2 years or 6000 operating hours
5.27 Replace the fresh air and circulation air filters
5.28 Check the anti-freeze concentration
Every 1000 operating hours
5.29 Oil change in planetary gear
5.30 Check, adjust the valve clearance Inlet valve 0.25 mm (0.009 inch) exhaust
valve 0.3 mm (0.012 inch)
5.31 Check fastening of engine / turbocharger / combus-
tion air hoses
5.32 Replace the fuel filter for the cabin heater (diesel)
5.33 Check, clean oil bath air filter for cabin heater (diesel)
5.34 Change the hydraulic oil fine filter**
Every 2000 operating hours
5.35 Changing hydraulic oil and breather filter ** at least every 2 years, only quality stage HV
46 VI150
5.36 Change oil and filter in the splitter gear

008 911 57 BOMAG 43

3.5 Maintenance chart

No. Designation Note

5.37 Change the coolant/vent the cooling system at least every 2 years
Every 4000 operating hours
5.38 Change the injection valve only by authorized service personnel
5.39 Check turbo charger compressor outlet, clean if nec- only by authorized service personnel
essary.
5.40 Change the crankcase ventilation valve only by authorized service personnel
Every 6000 operating hours
5.41 Change the coolant pump only by authorized service personnel
5.42 Change the fan V-belt at least every 2 years
5.43 Change the pressure retaining valve on the injection only by authorized service personnel
pump
As required
5.44 Clean the condenser (air conditioning)
5.45 Adjust scrapers and edge cutter
5.46 Check the condition of cutters, replacing the cutters if
necessary
5.47 Change the dry air filter cartridge at least every 2 years or when the indicator
lights up
5.48 Retighten bolted connections
5.49 Check the preheating system, maintenance in case
of frost
5.50 Fill the provision tank for the windscreen washer sys-
tem
5.51 Drain off dirty fluids from front and rear frame
5.52 Conservation

! Caution
**Also in case of major repairs in the hydraulic
system.

44 BOMAG 008 911 57

 4 Fundamental electrics

008 911 57 BOMAG 45

4.1 Understanding circuit diagrams

4.1 Understanding circuit diagrams

Wiring diagrams are graphical representations of circuitry conditions, related to the electrical system. They do
not contain any information about the actual type of wiring, they only serve the purpose of visualizing the circuitry
logics.
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system.
This plan provides the following information:
l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses,
switches, consumers, relays, ...
l The sequence in which current flows through the individual elements in the electric circuit.
l Connections between the examined, faulty electric circuit and other circuits in the vehicle wiring system.
l Pin assignment of plug-and-socket connections.

Structure
l Table of contents
l Function groups
l List of components

Table of contents
The table of contents lists all function groups.

Fig. 13 Table of contents

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

46 BOMAG 008 911 57

Understanding circuit diagrams 4.1
Function groups
On the individual pages the electric circuits are combined to function groups.

Arrangement of current paths

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

Fig. 14 Function groups

Potential cross references

Potential cross references serve the purpose of tracking signals, which are transmitted from one function group
to another.

Example:
Potential "15" on page no. 6 is continued to the left on page no. 4 in current path "10" and to the right on page
no. 8 in current path "1“.

Relay cross reference

Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing
contacts.
A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is
additionally attached to the bottom of each contactor coil.

Example:
The coil of relay (K99) is located on page no. 8 in current path "6".
The mimic diagram under the relay informs that a change-over switch with contact types 30, 87 and 87a is trig-
gered.
The changeover contact can be found on page no. 8 in current path "3".

008 911 57 BOMAG 47

4.1 Understanding circuit diagrams

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

Fig. 1 Current paths

48 BOMAG 008 911 57

Understanding circuit diagrams 4.1
List of components
Here you find all components used in alphabetical order, related to the name of the component (A01, A02....).

Fig. 1 List of components

Component cross references

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

008 911 57 BOMAG 49

4.1 Understanding circuit diagrams

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

Fig. 2 Graphic symbol

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

Fig. 3 Graphic symbol

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

50 BOMAG 008 911 57

Terminal designations 4.2
4.2 Terminal designations
For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a ter-
minal designation. In Germany the designation of the individual connection terminals is determined by the stand-
ard DIN 72552. The following table represents a section with the most important terminals from this standard.

Terminal designa- Meaning

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

2 Short circuit terminal (magneto ignition)

4 Ignition coil, ignition distributor high voltage

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

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

15a Output from dropping resistor to ignition coil and starter

17 Preheating starter switch, preheating

19 Preheating starter switch, starting

30 Battery plus direct

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

31 Battery minus direct or ground

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

32 Electric motors, return line

33 Electric motors, main connection

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

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

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

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

49 Input flasher relay

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

50 Starter, starter control

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

008 911 57 BOMAG 51

4.2 Terminal designations

Terminal designa- Meaning

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

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

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

52 Trailer signals: further signals from trailer to towing vehicle

53 Wiper motor input (+)

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

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

55 Fog light

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

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

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

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

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

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

61 Generator control

71 Intermittent tone control unit, input

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

72 Alarm switch (flashing beacon)

52 BOMAG 008 911 57

Terminal designations 4.2
Terminal designa- Meaning
tion
75 Radio, cigarette lighter

76 Loudspeaker

77 Door valve control

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

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

82 Switch (maker), input

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

83 Switch (multi-position switch), input

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

84 Current relay, input drive and relay contact

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

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

86 Switching relay, input drive winding start

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

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

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

88 Relay contact for maker

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

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

008 911 57 BOMAG 53

4.2 Terminal designations

Terminal designa- Meaning

tion
DF2 Dynamo field 2 (generator excitation current)

U Three-phase generator, three-phase terminal

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

C Travel direction indicator (flasher relay) control light 1

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

54 BOMAG 008 911 57

Battery ground and analog ground 4.3
4.3 Battery ground and analog 4.4 Current and voltage
ground
General
GND, battery ground If one wants to describe electric current, this can most
simply be accomplished by means of a comparison:
The term "ground" (abbreviated GND) describes a
conductive body which is normally defined with the One simply compares electric current with water.
potential of "Zero" Volt and represents the reference
potential for operating voltages. Voltage
The positive pole of the supply voltage (symbol + ) and
all other electric voltages and electical signals in an
electrical circuitry refer to the ground potential.
On motor vehicles and also on motorbikes and bicy-
cles the ground potential is represented by the chas-
sis or the frame. As a conductive part, which covers
the entire vehicle, it also serves a return conductor for
the vehicle wiring system - the consumers only need
to be wired up.

Terminal designation for GND = terminale 31

AGND, analog ground

Apart from the "normal" battery ground there is also
the analog ground, which is solely reserved for sen-
sors.

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

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

008 911 57 BOMAG 55

4.4
The following statements concerning electric volt-
age can be made
l electric voltage is the pressure or force applied to
free electrons.
l the electric voltage is the cause of electric current
l electric voltage is a result of the equalization at-
tempt of electric charges.
Voltage is measured with a Voltmeter.
Unit, Volt
The electric voltage (U) is measured in Volt (V).
56 BOMAG
Current and voltage
Current
Electric current generally describes the directed
movement of charge carriers.
l The charge carriers may either be electrons or ions.
l Electric current can only flow if there is a sufficient
amount of free moving charge carriers.
l The higher the number of electrons flowing through
a conductor per second, the higher the amperage.
Current is measured with an ammeter.
Unit, Ampere
The electric amperage (I) is measured in Ampere
(A).
The technical flow direction is specified from
PLUS to MINUS.
i Note
Current actually flows from minus to plus, because the
current flow is made up of negatively charged elec-
trons.
But since this was only discovered after the poles of a
current source had already been designated, the as-
sumption that current flows from plus to minus was
maintained for historic reasons.
Circuit
Fig. 3 Circuit
A simple circuit consists of a current source 1 (Fig. 3),
a consumer (3) and the connecting wiring.
When the circuit is closed, current can flow.
The circuit can be interrupted or closed with a switch
(2).
The system is protected by a fuse (4).
008 911 57
Current and voltage 4.4
Types of current Pulse width modulation (PWM)

Direct current (D.C.)

Fig. 1 Direct current (D.C.)

Direct current flows with steady voltage and amper-
age from the plus to the minus pole. Fig. 4 PWM
Pure D.C.-voltages are only delivered by accumula- The PWM signal is in most cases generated by a con-
tors or batteries. trol and can be used to trigger proportional valves.
The voltage in the vehicle wiring system is no pure The signal (square wave signal) is changed in its
D.C.-voltage. Even without the generator running, but pulse control factor, the period, however, remains un-
the consumers switched on, the voltage is not con- changed.
stant, but drops gradually according to the battery The following applies:
charge condition. l
The signal voltage cannot be measured.
The internal resistance of the battery also causes per- l
The current can be measured.
manent changes in the vehicle voltage, as soon as
consumers are switched on or off.
Caution
!
Alternating current (A.C.)
Solenoid valves must not be interference sup-
pressed with suppressor diodes.

Fig. 2 Alternating current (A.C.)

Alternating current not only changes its direction, but
also its amperage.

Pulsating direct current

Fig. 3 Pulsating direct current

Converting alternating current into a direct current sig-
nal by means of a rectifier results in an pulsating direct
current.

008 911 57 BOMAG 57

4.5 CAN-Bus

4.5 CAN-Bus

Controller Area Network

created by Bosch at the end of the eighties for automobile applications.

Development objectives:
Real-time critical, robust and low price communication of control units, such as transmission and engine control,
but also less time critical applications in the field of convenience electronics, such as air conditioning.

Fig. 1 CAN

Why CAN?
l
Networking of control units for the realization of complex functions.
l
Reduction of the extend of wiring and plug connections.
l Better diagnostic possibilities (central diagnostics socket).

Characteristics of CAN
It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are
required.
CAN lines are twisted together 30 to 40 times per metre. Electromagnetic interferences therefore always occur
simultaneously in both lines, the software is thus able to filter out interfering signals more easily.
Wire (+) = cable colour blue
Wire (-) = cable colour yellow

Measuring signals
Signals transmitted through the bus line can generally not be measured with simple measuring instruments.
Testing is therefore quite complicated for the user. Correct connection of lines can only be checked by means

58 BOMAG 008 911 57

CAN-Bus 4.5
of a continuity test. BOMAG display modules are connected to the BUS to give engineers and user the possibility
to detect faults or to receive information from the BUS.

008 911 57 BOMAG 59

4.6 Resistance

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

Bad

Fig. 1 Various size resistors

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

Fig. 2 Spring clamps

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

Symbol, R

Unit, Ohm Ω

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

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

60 BOMAG 008 911 57

Resistance 4.6
Sometimes the flanks of flat plugs bend open. If these
are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely
break sooner or later. It is better to place a small nail
under the bottom of the cable lug before bending.

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

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

Fig. 4 Balistol oil

008 911 57 BOMAG 61

4.7 Series / parallel connection

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

Fig. 1 Series connection

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

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

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

Series connection of batteries

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

62 BOMAG 008 911 57

Series / parallel connection
Parallel connection
In parallel connection all resistances (consumers) are
connected between feed and return line.
l All resistances (consumers) are supplied with the
same voltage.
l Each of the resistances (consumers) draws as
much current as required.
4.7
l In parallel connection the plus pole of the first bat-
tery is connected with the plus pole of the second
battery and the minus pole of the first battery with
the minus pole of the second battery.
l Plus and minus poles have the voltage of the single
battery applied.
l The total capacity (Ah) is identical with the sum of
all battery capacities.
The disadvantage of a parallel connection becomes
apparent, by equalizing currents flowing between par-
allel batteries, if the batteries have different states of
charging.

Fig. 3 Parallel connection

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

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

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

Parallel connection of batteries

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

008 911 57 BOMAG 63

4.8 Ohm's law

4.8 Ohm's law 4.9 Electrical energy

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

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

64 BOMAG 008 911 57

Formula diagram 4.10
4.10 Formula diagram
Description:
l Select the desired value from the inner circle.
l Determine the formula variables in the quarter circle
l Calculate

Example:
P = 150 Watt
U = 24 Volt
Sought for = Current in Ampere
I = P : U = 150 W : 24 Volt = 6.25 Ampere

Fig. 1 Formula diagram

Resistance, R Ohm Ω

Voltage, U Volt

Current, I Ampere

Power, P Watt

008 911 57 BOMAG 65

4.11 Metrology

4.11 Metrology Multimeter

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

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

Fig. 2 Diode test lamp

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

66 BOMAG 008 911 57

Metrology 4.11
Voltage and voltage drop measurement with mul- Clip-on measuring instrument
timeter
The clip-on measuring instrument can be used to
measure current, voltage and resistance.

Fig. 2 Voltage measurement

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

Current measurement with the multimeter

Fig. 1 Clip-on measuring instrument

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

Fig. 3 Current measurement

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

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

008 911 57 BOMAG 67

4.11 Metrology

Magnet tester Power measurement

The electric power of a module within a circuit can be
indirectly determined (calculated) by separate meas-
uring 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 per-
forming power measurements: Voltage or current path
may already be overloaded during the measurement,
even though the end stop in the meter has not yet
been reached.

Fig. 1 Magnet tester

The magnet tester is used to test solenoid valves and
magnetic coils.
The test lamp responds to the magnetic fields of A.C-
voltage, D.C.-voltage and permanent magnets.
l
The component to be tested does not need to be re-
moved.
l The magnetic coil can also be tested under a pro-
tective cap.

Fig. 2

68 BOMAG 008 911 57

Diodes, relays, fuses 4.12
4.12 Diodes, relays, fuses Diode logics and free-wheeling diode

Diodes

Fig. 1
A diode consists of two different semi-conductors,
which are connected by a separating layer. The max.
conducting state current must not be exceeded.
Plus-voltage on diode:
l At 0.6 – 0.7 Volt (silicium diode) the diode becomes
conductive.
Negative voltage on diode:
l The diode does not allow current to pass through.

Fig. 2 Marking of the cathode

Diodes are used:
l
For rectifying A.C. voltage.
l
For absorbing voltage peaks (free-wheeling diode).
l
For construction of logical circuits.

Fig. 3 Diode circuitry

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

008 911 57 BOMAG 69

4.12 Diodes, relays, fuses

Light emitting diodes Relays

Fig. 1 Relays
Relays are commonly used to realize switching proc-
esses.
Fig. 4 LED
A free-wheeling diode prevents induction voltage from
The light emitting diode, also referred to as LED, is a
flowing back from the coil into the vehicle wiring sys-
semi-conductor diode, which generates (emits) light
tem, which would cause interference with electronic
during operation in forward direction. A semi-conduc-
components (control units).
tor crystal thereby emits a light signal, which is con-
verged or scattered by the lenticular shape of the With the possibility of using breaker - maker contacts
head. Light emitting diodes are available in various the effect of an information can be reversed.
colours, sizes and shapes. They are for this reason
used as signal lamps. This component is constructed
of different semi-conductor crystals, depending on its
colour. It works like any other semi-conductor diode.

Fig. 2 Relay circuitry

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

70 BOMAG 008 911 57

Diodes, relays, fuses 4.12
85 = Ground supply for coil Fuses
30 = Supply voltage
87 = Normally open contact
87a= Normally closed contact

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

Caution
!

Fuses must not be repaired or bridged.

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

008 911 57 BOMAG 71

4.13 Batteries

4.13 Batteries Battery maintenance

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

Battery test in general

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

Testing batteries with screw plugs

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

72 BOMAG 008 911 57

Batteries 4.13
battery. The so-called acid tester (hydrometer) is
used for this purpose. In a battery of good condition
the acid density should be the same in all cells.

Acid density at 27 °C in kg/dm3

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

Fig. 4 Battery and generator tester

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

Fig. 3 Reading the acid level

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

Testing batteries without screw plugs

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

008 911 57 BOMAG 73

4.13 Batteries

Charge condition with hydrometer

Fig. 5 Charge condition

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

! Danger

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

low, the battery must no longer be charged.

74 BOMAG 008 911 57

Three-phase generator 4.14
4.14 Three-phase generator Design and function
In the generator the armature windings are located in-
General side the stationary stator, whereas the exciter winding
is arranged on the internally revolving rotor (Fig. 6).
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve-
hicle with electric current at a steady voltage already
at idling speed.

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

008 911 57 BOMAG 75

4.14 Three-phase generator

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

Charge control light

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

76 BOMAG 008 911 57

Three-phase generator
Fig. 9 Regulator with diode plate and rectifier diodes
In most cases voltage regulators (Fig. 9) with carbon
brushes form a compact component. The voltage reg-
ulator is maintenance free and the wear of carbon
brushes is only so little, that they hardly ever need to
be replaced during the lifetime of a machine.
The regulator has the following function:
l
To maintain the vehicle voltage under any operating
conditions below 14.4 V.
l
To match the regulator voltage to the temperature.
l
Smooth rising of generator current when switching
loads (convenience function to avoid jerking of the
engine).
008 911 57
4.14
Checking the generator
First one must check whether the generator is actually
defective.
l This can be easily found out by checking whether
the charge control light in the dashboard lights up. If
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula-
tor, the wiring or the V-belt.
l When the engine is at rest, the charge control light
must light up. If not, the lamp may probably be de-
fective. Defects on generator or wiring are obviously
also possible.
The following points allow to contain faults in the volt-
age supply within certain limits.
l Cable connections on the generator OK?
l V-belt OK?
l Generator ground (engine ground) OK?
l 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.
BOMAG 77
4.14 Three-phase generator

Checking the pre-excitation circuit Measuring the charge current

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

Fig. 10 Connections on the three-phase alternator (exemplary de-

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

78 BOMAG 008 911 57

Three-phase generator 4.14
Checking the rotor Checking the stator

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

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

008 911 57 BOMAG 79

4.14 Three-phase generator

Checking the regulator voltage with the generator Checking the regulator voltage with the multime-
tester ter
The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) thermal printer.

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

80 BOMAG 008 911 57

Three-phase generator 4.14
Checking the regulator in disassembled state
On a Bosch generator unscrew two fastening screws
for the regulator and lift the regulator off. For this work
the generator does not need to be removed.
The Delco-Remy generator needs to be removed
and partly dismantled, if the regulator needs to be dis-
assembled. Unscrew the housing screws to do so.
Pull rotor with drive bearing and V-belt pulley out of
the stator. Unscrew the ends of the stator winding
from the diode carrier and separate the stator from the
collector ring bearing. Disassemble exciter diodes and
brush holders and remove also the regulator. Fig. 16
E.g minus controlled regulator
i Note One connects the regulator (Fig. 16) with D+ and D- to
When testing the regulator one should be aware that the power source, as shown in the illustration, and the
there are 2 different types of regulators: lamp to both carbon brushes, instead of the exciter
winding. When slowly increasing the voltage the lamp
l If the carbon brush is not connected to ground the will first become brighter, because the regulator al-
regulator is a so-called minus controlled regulator. lows all lamp current (= exciter current) to flow at volt-
The exciter winding is positioned between D+ and age values up to 14.4V. Once the regulator voltage is
DF, the regulator therefore regulates the exciter reached, the regulator switches the lamp current off.
winding on the ground side. The other carbon brush When returning the voltage back below the control
is connected with the cathodes of the exciter di- voltage, the regulator will switch the lamp back on.
odes, terminal D+. This leaves one further terminal,
With this test the major difficulty is the problem to re-
this is DF.
move the regulator an identify terminals D+, DF and
D+ (vehicle wiring system) D-.
D- (ground contact, mostly located on one of the fas-
tening screws)
DF (Dynamo Field)

Fig. 17

Fig. 18
Fig. 15
The illustrations (Fig. 17) and (Fig. 18) show two dif-
l If the carbon brush is connected to ground the reg-
ferent regulator types.
ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
The basic function of a disassembled regulator can be
easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).

008 911 57 BOMAG 81

4.14 Three-phase generator

Replacing carbon brushes

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

82 BOMAG 008 911 57

Electric starter
4.15 Electric starter
The starter converts the electric energy stored in the
battery into mechanical energy. The starter can only
generate its power when a battery with appropriate
capacity is available.
Duties of the starter:
l to accelerate the combustion engine to start speed
with lowest possible current consumption.
4.15
l establish the gear connection between starter and
combustion engine.
l to maintain this connection.
l to switch on the starter current.
After starting the engine:
l to return the starter pinion to initial position.
l to switch off the starter current.

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

008 911 57 BOMAG 83

4.15 Electric starter

Function of pre-engaged-drive starting motor

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

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

84 BOMAG 008 911 57

Electric starter 4.15
Trouble shooting "Starter" Testing and measuring the electric starter
The most frequent fault is definitely a fully discharged
battery. i Note
If the starter rotates too slowly, either the brushes The highest current flows when the starter is blocked!
are partly worn off, or parts of the exciter or armature (Short circuit current in starter). This is the case when
winding is shorted. In some cases oxidized electric the pinion is engaged and the starter has the duty to
contacts or a soiled ground connection causing ex- accelerate the flywheel to starting speed.
tremely high voltage losses in the overall starter sys-
tem are the cause of problems. Function test with starter installed
If the starter only emits a clicking sound,- either
l Initiate the starting process and measure the volt-
the magnetic switch is defect / soiled (dismantle and age on the pickup solenoid switch (50a). At least
clean))- the main contacts on the magnetic switch are 10.8 Volt should be applied.
worn off / soiled (scrape off carefully with a file and l When operating the starter switch the magnetic
clean)- the starter motor is defective / soiled (remove switch must engage in the flywheel ring gear (no-
armature and clean), cover cleaned, moveable parts ticeable clicking sound) and release the starting
with grease. current to the starter. On most magnetic switches
the voltage can be measured with the multimeter. If
Frequently a jammed return mechanism is the reason
this does not happen even though voltage is ap-
for a starter failure.
plied, replace the magnetic switch.
Occasionally worn contacts are found on the magnetic
return switch Function tests with disassembled starter
Defects on the actual starter motor including pinion
and carbon brushes are very rare. !Caution
With a trouble shooting chart the faults in the starter Before removing the starter you must disconnect
system can be narrowed down. The starter system the ground cable from the minus pole of the bat-
can only work when many conditions are fulfilled at tery while the ignition is switched off.
the same time. l Check the wear on the carbon brushes and their
l
Immobilizer deactivated? contact pressure.
l
Ignition switch OK? l Check the collector, it must not have electrical con-
l
Travel lever in correct position? tact with the rotor shaft.
l
Emergency stop not actuated? l Check the drive pinion for excessive wear.
l
Battery sufficiently charged? l The return mechanism should not be tight, if neces-
l
Battery poles OK? sary grease amply with silicon grease (Bosch PZ 2
V3) or a comparable grease.
l
Main battery fuse OK?
l Measure the resistance of the magnetic switch main
l
Main battery switch closed?
contact in disengaged condition. Maximum value
l
Main starter cable (terminal 30) OK? 0.2 OHM Ω.
l
Starter control cable (terminal 50) OK, voltage
drop?
l
Ground cable OK?
l Switching of magnetic switches OK?
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
l
the experience of the specialist
l
the failure probability of the component to be tested
and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault
must be in the starter itself. In this case it can be re-
paired or replaced.

008 911 57 BOMAG 85

4.16 Telemecanique switch

4.16 Telemecanique switch

Example of terminal designations

Fig. 1 Terminal designations

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

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

86 BOMAG 008 911 57

Telemecanique switch 4.16
Disassembly

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

Fig. 4 Pulling out the front element

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

008 911 57 BOMAG 87

4.16 Telemecanique switch

Assembly

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

Fig. 7 Assemble the switch block

l Clip on the switch block (4).

Fig. 6 Observe the marks.

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

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

88 BOMAG 008 911 57

Inductive proximity switches 4.17
4.17 Inductive proximity switches NPN circuitry

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

Working principle

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

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

Fig. 9 PNP circuitry

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

008 911 57 BOMAG 89

4.18 Angle sensors

4.18 Angle sensors

Sensor with current output

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

90 BOMAG 008 911 57

Angle sensors 4.18
Sensor with voltage output
The design is almost identical with the angle sensor
on the new single drum rollers of generation -4 with
electronic steering wheel, where a sensor with a volt-
age output of 0-8.5 V is mounted on the articulated
joint. The potentiometer inside the sensor transmits a
variable voltage potential to the control. Due to the
short distance between articulated joint and central
electrics it is in this case possible to use a voltage sig-
nal.

Fig. 2 Connection diagram

The angle sensor has 3 electric connections (Fig. 2).
Ub, supply voltage (+ 8.5 Volt)
Gnd, ground
Out, output current 4-20 mA.
l at -35° = 4 mA output current
l
at 0° = 12 mA output current
l at +35° = 20 mA output current.

008 911 57 BOMAG 91

4.19 Plug connectors

4.19 Plug connectors 4.20 Deutsch plug, series DT and

Duties and requirements
DTM
Electric plug connectors must provide a reliable con-
nection between different system components and General
thus ensure the safe function of the systems under Plug connectors DT and DTM have a wedge to hold
any operating condition. There design ensures that the pins and sockets in their position. This wedge can
they will withstand the applied loads throughout the be removed and replaced, without having to cut any
lifetime of the machine. leads.
Examples for these loads are:
l Vibration acceleration
l
Temperature fluctuations, high and low tempera-
tures
l Dampness
l Micro movements of the contact with resulting fric-
tion corrosion.
These loads may increase the transition resistances
of the contacts, up to total interruption. Even the insu-
lation resistances may drop and thus cause short cir-
cuits in neighbouring lines. Electric plug connectors
must therefore have the following properties:
l
Low transition resistances of the conductive parts.
l
High insulation strength between conductive parts
with different voltage potentials. Fig. 3 Crimp connections
l
Excellent leak tightness against water and mois-
ture.
Caution
!

Do not crimp more than one lead per pin or per

socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).

Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
l
Perform a pull test on each lead, each of the termi-
nals and connections must withstand a pulling force
of 45 N without any difficulties.

92 BOMAG 008 911 57

Deutsch plug, series DT and DTM 4.20
DT Series

Fig. 1 DT plug connection

Fig. 2 DT Series

Fig. 3 Sectional drawing

008 911 57 BOMAG 93

4.20 Deutsch plug, series DT and DTM

Installing DT contacts

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

Caution
!

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

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

i Note
Use the same method when assembling the socket.

94 BOMAG 008 911 57

Deutsch plug, series DT and DTM 4.20
Disassembling DT contacts

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

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

008 911 57 BOMAG 95

4.20 Deutsch plug, series DT and DTM

DTM Series

Fig. 1 DTM plug connection

Fig. 2 DTM Series

Fig. 3 Sectional drawing

96 BOMAG 008 911 57

Deutsch plug, series DT and DTM 4.20
Installing DTM contacts

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

Caution
!

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

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

i Note
Use the same method when assembling the socket.

008 911 57 BOMAG 97

4.20 Deutsch plug, series DT and DTM

Disassembling DTM contacts

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

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

98 BOMAG 008 911 57

Plugs and terminals in spring clamping technology 4.21
4.21 Plugs and terminals in spring ventional copper conductors (single, multiple or fine
stranded) with or without wire and ferrule.
clamping technology
! Caution
General
The spring clamp technology is not suitable for
extra fine conductors. Extra fine conductors can
be easily pulled out of the spring clamp!

Fig. 1
Spring clamp technology (Fig. 1) for quick, vibration
resistant and maintenance-free connection of all con-

Connecting terminal for quick repairs

Fig. 2 That's how it works

BOMAG part-no.: 057 565 72

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

That's how it works

l Strip 9-10 mm of the lead. Fig. 3 Connecting clamp

l Open the actuating lever and insert the strand.

l Return the actuating lever to initial position.

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

008 911 57 BOMAG 99

4.21 Plugs and terminals in spring clamping technology

Series clamp

Fig. 4 That's how it works

That's how it works

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

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

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

Fig. 5 Test adapter

100 BOMAG 008 911 57

Plugs and terminals in spring clamping technology 4.21
X-COM System for universal system wiring, ever since it was intro-
The X-COM-SYSTEM, a synthesis of plug connector duced in 1997. All the familiar series clamping func-
and series clamp, has grown up to a construction kit tions have thus become pluggable.

X-COM plug clamp

Fig. 6 That's how it works Measuring signals

That's how it works
l
Insert a screw driver into the actuating opening until
it bottoms.
l
Strip 9-10 mm of the lead and insert it into the plug.
l
Pull out the screw driver.

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

Fig. 8 X-COM plug plugged onto the series clamp

Fig. 7 X-COM plug with measuring cable

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

008 911 57 BOMAG 101

4.22 Electric modules

4.22 Electric modules

In the latest generation of machines BOMAG uses machine programmable modules. A module mainly consists
of a programmable microprocessor with additional circuitry for inpiuts and outputs. With theses modules it is pos-
sible to cover the requirements of the individual machines.

Fig. 1
The modules have control lights on inputs and outputs to monitor the applied signals.

102 BOMAG 008 911 57

 5 Special tools, electrics

008 911 57 BOMAG 103

5.1 Special tools, electrics

5.1 Special tools, electrics

Measuring equipment
53. Electric test case

BOMAG part-no.: 057 505 70

Fig. 2
54. Multimeter

BOMAG part-no.: 057 509 91

Fig. 3
55. Test prod black, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.

BOMAG part-no.: 079 900 53

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

BOMAG part-no.: 079 900 54

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

BOMAG part-no.: 079 900 51

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

BOMAG part-no.: 079 900 52

Fig. 5

104 BOMAG 008 911 57

Special tools, electrics 5.1
59. Measuring and connecting lines with 4mm plug,
high flexible design, black, length 0.5 m.

BOMAG part-no.: 079 900 58

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

BOMAG part-no.: 079 900 59

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

BOMAG part-no.: 079 900 60

62. Measuring and connecting lines with 4mm plug,
Fig. 6 high flexible design, red, length 0.5 m.

BOMAG part-no.: 079 900 55

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

BOMAG part-no.: 079 900 56

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

BOMAG part-no.: 079 900 57

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

BOMAG part-no.: 079 900 63

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

BOMAG part-no.: 079 900 64

67. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, red, length 300 mm.
Fig. 7
BOMAG part-no.: 079 900 61
68. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, red, length 600 mm.

BOMAG part-no.: 079 900 62

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

BOMAG part-no.: 079 900 65

Fig. 8

008 911 57 BOMAG 105

5.1 Special tools, electrics

70. Magnetic coil tester

BOMAG part-no.: 057 555 54

Fig. 9
71. Clip-on measuring instrument

BOMAG part-no.: 079 900 50

Fig. 10
72. Battery - generator tester

BOMAG part-no.: 079 900 91

Fig. 11
Spring clamps (Wago or Weidmüller)
73. Cranked screwdriver (Fig. 12) to open spring
clamps (Fig. 13).

BOMAG part-no.: 972 024 68

Fig. 12

106 BOMAG 008 911 57

Special tools, electrics 5.1
74. Testing adapter to measure the signals from the
series spring clamps (Wago).

BOMAG part-no.: 057 564 26

Fig. 13
Deutsch contacts
75. Tool to disassemble the interlocking on Deutsch
plugs (series DT and DTM).

BOMAG part-no.: 079 900 84

Fig. 14
76. Crimping pliers for Deutsch contacts of series DT
and DTM, size AWG 20,16 and 12.
AWG 20 = 0.5 mm2 cable cross-section
AWG 16 = 1,5 mm2 cable cross-section
AWG 12 = 4,0 mm2 cable cross-section
BOMAG part-no.: 079 900 79

Fig. 15
77. Crimping pliers for Deutsch contacts of series
HDT, size AWG 6 and 8.
AWG 8 = 10,0 mm2 cable cross-section
AWG 6 = 16,0 mm2 cable cross-section
AWG 6 = 16,0 mm2 cable cross-section

BOMAG part-no.: 079 900 69

Fig. 16

008 911 57 BOMAG 107

5.1 Special tools, electrics

78. Disassembly tool for Deutsch contacts of series

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

Fig. 17
ITT contacts
79. Installation tool for ITT crimp contacts of series
CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 80

Fig. 18
80. Disassembly tool for ITT male contacts of series
CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 81

Fig. 19
81. Disassembly tool for ITT female contacts of se-
ries CA-COM, contact size 15S/16S/15/16.

BOMAG part-no.: 079 900 82

Fig. 20

108 BOMAG 008 911 57

Special tools, electrics 5.1
Schaltbau contacts
82. Disassembly tool for Schaltbau contacts of series
M1, M2.

BOMAG part-no.: 057 509 95

Fig. 21
83. Crimping pliers for Schaltbau contacts of series
M1, M2 with connecting cross-section 0.14 - 6.0
mm2.

BOMAG part-no.: 057 509 94

Fig. 22
FCI Burndy contacts
84. Disassembly tool for FCI Burndy contacts of se-
ries TRIM TRIO

BOMAG part-no.: 079 900 00

Fig. 23
AMP contacts
85. Crimping pliers for AMP-contacts of series FAS-
TIN-FASTON with a connecting cross-section of
1.0 - 2.5 mm2 (18 -14 AWG).

BOMAG part-no.: 079 900 35

Fig. 24

008 911 57 BOMAG 109

5.1 Special tools, electrics

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

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

BOMAG part-no.: 079 900 48

Fig. 25
87. Crimping pliers for AMP-contacts of series .070-
SERIES with a connecting cross-section of AWG
20 - 18 (0.5 - 0.9 mm2) and AWG 16 (1.25 - 1.5
mm2).

BOMAG part-no.: 079 900 23

Fig. 26
88. Crimping pliers for AMP-contacts of series FAS-
TON with connecting cross-section AWG 14 - 10.

BOMAG part-no.: 079 900 88

Fig. 27
89. Crimping pliers for AMP-contacts of series FAS-
TON with connecting cross-section AWG 16 - 14
and AWG 18.

BOMAG part-no.: 079 900 89

Fig. 28

110 BOMAG 008 911 57

Special tools, electrics 5.1
90. Crimping tool for Powertimer contacts with indi-
vidual strand sealing (example: ESX control)

BOMAG part-no.: 079 900 25

Fig. 29
91. Crimping jaws for Crimping tool 079 900 25

BOMAG part-no.: 079 900 27

Fig. 30
92. Disassembly tool for AMP-contacts of series CIR-
CULAR-CONNECTOR.
1.5 mm2, BOMAG part-no.: 079 900 74
2,5 mm2, BOMAG part-no.: 079 900 75
Spare sleeve 1.5 mm2, BOMAG part-no.: 079
900 76
Spare sleeve 2,5 mm2, BOMAG part-no.: 079
900 77

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

BOMAG part-no.: 972 038 47

Fig. 32

008 911 57 BOMAG 111

5.1 Special tools, electrics

94. Precision pressing pliers for non-insulated flat

male and female connectors0.5 - 6,0 mm2.

BOMAG part-no.: 079 900 70

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

BOMAG part-no.: 057 503 83

Fig. 34
96. Voltage measurement adapter for Deutsch plugs,
8-piece (2 to 12 pole).

BOMAG part-no.: 079 900 68

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

BOMAG part-no.: 079 900 83

Fig. 36

112 BOMAG 008 911 57

 6 Electronic control

008 911 57 BOMAG 113

114 BOMAG 008 911 57
 6.1 ESX control

008 911 57 BOMAG 115

6.1 ESX control

116 BOMAG 008 911 57

ESX control 6.1

Service Training
Electrics
BC572, 672, 772
BC972 ,1172

00809729 Version 7.00

Status: 16.02.2007 Page 1 of 67

Author: T.Löw / TE
Dateiname: c:\dokumente und einstellungen\nickb\lokale einstellungen\temp\schulung elektrik bc972_v7.00_gb.doc

008 911 57 BOMAG 117

6.1 ESX control

Service Training Refuse Compactor

Table of contents
1 Document alteration list.....................................................................................................................3
2 selected fault reactions of the ESX control .......................................................................................5
3 Known faults......................................................................................................................................6
4 Functions of the ESX control.............................................................................................................7
4.1 Description of the Display Module .............................................................................................7
4.2 Input of code numbers ...............................................................................................................7
4.3 Driving against the closed brake................................................................................................8
4.4 Enabling without the engine running..........................................................................................8
4.5 Enabling floating position ...........................................................................................................9
4.6 Showing stored faults...............................................................................................................10
4.7 Delete all stored faults .............................................................................................................10
4.8 Setting the machine type .........................................................................................................11
4.9 Parameter adjustment 2nd speed range (only BC972) ...........................................................12
4.10 Parameter setting steering system ..........................................................................................13
4.11 Travel pedal monitoring parameter setting ..............................................................................14
4.12 Dozer blade characteristics parameter setting ........................................................................14
4.13 Engine speed signal parameter setting ...................................................................................15
5 Block diagram normal operation BC972, 1172 ...............................................................................17
6 Block diagram normal operation BC 572/672/772 ..........................................................................18
7 Block diagram override operation BC972, 1172 .............................................................................19
8 Block diagram override operation BC 572/672/772 ........................................................................20
9 Description of the signals on the ESX-control.................................................................................21
10 Description of signals on the DIOS module (only with optional bucket)......................................26
11 Fault codes of the ESX control ....................................................................................................28
11.1 Overview ..................................................................................................................................28
11.2 Description of fault reactions ...................................................................................................29
11.3 Detailed description of fault codes and their possible causes................................................30
12 Input Codes for ESX Control .......................................................................................................53
12.1 Travel system...........................................................................................................................53
12.2 Steering....................................................................................................................................54
12.3 Working hydraulics...................................................................................................................56
12.4 Test functions...........................................................................................................................57
12.5 Diesel engine ...........................................................................................................................58
12.6 System information ..................................................................................................................59
12.7 Hydraulics ................................................................................................................................59
12.8 Parameter change ...................................................................................................................61
12.9 Fault log ...................................................................................................................................62
12.10 Setting the machine type......................................................................................................63
13 Terminology in connection with ESX...........................................................................................64

Status:16.02.2007
Author: T.Löw / TE

118 BOMAG 008 911 57

ESX control 6.1

Service Training Refuse Compactor

1 Document alteration list

No. Date Description of changes resp.

1 25.04.01 Creation of version 1.00 Löw
2 29.06.01 Creation of version 2.00: Löw
Pin assignment for dozer blade joystick changed
Fault "Hydr.Level1" eliminated
Fault and display codes changed

3 02.07.01 Pin 10 (open bucket) and Pin 17 (pressure differential switch) Löw
exchanged.
4 22.08.01 Inclusion of column "known faults" Löw

5 23.08.01 Creation of version 3.00: Löw

Parameter input "variable speed specification" eliminated
Code input "enter machine type" added
Block diagrams BC772 added
Fault description "travel speed range valve" added
Input codes "travel speed range valve" added
Cross references to wiring diagram deleted.

6 27.08.01 Voltage limits for bucket joystick changed. Löw

actuated to left: high voltage,
actuated to right: low voltage
PIN 17 open bucket, PIN 34 close bucket
7 13.09.01 Input code for "enable float position“ added Löw
8 01.10.01 Further point added under "known faults" Löw
9 09.10.02 Fault 475 "Fault when initializing the DIOS module" added Löw
10 25.02.02 Fault and input codes for travel pedal monitoring added Löw
(530..534), "Travel pedal monitoring parameter setting" added, list
of known faults extended.
11 18.03.02 Description of input code 452 adapted: Löw
max. closing = 1000
max. opening = -1000
12 10.06.02 Creation of version 4.00: Löw
Input codes for machine type BC572 added
Default setting 2nd gear changed to "FAST"
13 10.07.04 Creation of version 5.00 Löw
Input codes 271 / 272 changed to "steering valve right"
Input codes 276 / 277 changed to "steering valve left"
Comment concerning saving faults on page 29 added.
Explanation for input code 515 corrected (factor 10 added)
Number of pulses / engine revolutions on page 20 corrected
Speed data for 2nd gear on page 13 changed
Fault codes 053 and 063 added
Fault codes 052 and 062 added
Fault codes 045 and 046 deleted
Fault codes 045 and 046 deleted
Further point added under "known faults"
14 26.10.04 Creation of version 5.01 Löw
Machine codes 766 and 767 added
Description "Parameter setting for dozer blade characteristics"
added
Input codes 650..654 added

Status:16.02.2007
Author: T.Löw / TE

008 911 57 BOMAG 119

6.1 ESX control

Service Training Refuse Compactor

No. Date Description of changes resp.

15 24.01.06 Creation of version 6.0 Löw
Fault code 540 added
Input codes 540, 541, 685, 686, 687 added
Description "Parameter setting for engine speed signal" added

16 07.11.06 Creation of version 7.0 Löw

Item "4.10 Parameter setting steering system" extended,
Input codes 251, 252, 647, 648, 649 added,
Signal description X0:14 and X0:15 changed

Status:16.02.2007
Author: T.Löw / TE

120 BOMAG 008 911 57

ESX control 6.1

Service Training Refuse Compactor

2 selected fault reactions of the ESX control

Reaction Symbol in fault Warning Warning Engine stop

message display
Signal Code output Code output Code output
without buzzer with buzzer with buzzer

Engine oil pressure

(from EMR) 520 - -
after 2s

Coolant temperature
(from EMR) 522 - -
after 30s
Coolant level
(B55) 524 - 525
after 2s after 20s

Engine air filter

right or left 526 - -
(B03 or B116) after 2min

Contamination sensor
(B19) 570 - -
after 10s

Pressure differential switch

filter charge pump 1..4
1 572 - -
(B121, B122, B21, B22) after 10s
or
filter intermediate gear
(B42)
Hydraulic oil
Excessive temperature 574 - 575
(B20) after 10s after 2min

Filling level hydraulic oil

(B24) 578 - 579
after 2s after 20s

Return flow filter

(B25)
- 580 -
after 10s

Brake pressure
(B05)
- - -

1
BC572/772: only 2 pressure differential switches
Status:16.02.2007
Author: T.Löw / TE

008 911 57 BOMAG 121

6.1
Service Training Refuse Compactor
3 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
The ESX control detects several faults of engine
and hydraulic system monitoring at the same time
(524, 526, 570,...). However, the control
lights in the two fault indicators do not light. The
lamp test of the fault indicators is also out of
function.
The control detects line breakage on all 4 wheel
drive motors (100, 105, 110, 115) (only on
BC972).
Steering is very jerky, but no fault is detected.
All control lights in both fault indicators are
permanently on. The engine can be started, but
the machine will not move. The fault display of the
central electrics does not show a fault code.
The fault code 514 (Input engine speed:
no pulses from the resolver, even though the
engine is running) is already displayed while the
engine is at rest.
Machine is in override state and indicates fault
934.
Machine is in override state and indicates fault
960, 962.
Status:16.02.2007
Author: T.Löw / TE
122 BOMAG
ESX control
Possible cause
Fault indicators without voltage supply (F24
tripped). The ESX inputs are drawn to ground
through the LEDs of the fault indicators. For the
control this is the same as when a sensor (e.g. oil
pressure) delivers a ground signal.
) Check the voltage supply for the fault
indicators.
Missing / poor ground connection on ESX
housing.
) Check ground connection, renew if
necessary.
Terminal 15 signal for control and override relay
missing:
) Check fuse F25
Voltage is applied to input MD+ (PIN 36) on the
ESX control, even though the engine is not
running. This may occur when the link between
generator and central electrics is interrupted,
because in this case the potential at input MD+
will be raised to +24V through the resistor R10 or
the coil K61. The control then assumes that the
engine is running and thus expects pulses from
the speed sensor.
Up to software version 2.01 this fault was
displayed in addition to fault code 514 (see
above).
This means, that the machine has switched to
override state when a fault occurred at the rotation
sensor. This fault is a software fault, that has been
eliminated with version 3.00.
Intermittent contact on Pin 20, 42 or 43
Fault has been eliminated with software version
4.03
008 911 57
ESX control 6.1

Service Training Refuse Compactor

4 Functions of the ESX control

4.1 Description of the Display Module

The display module consists of a 3-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 ...9 9 9 are possible. Higher
values lead to the display "- - - ", negative values are indicated by the "minus dot" lighting up (see
illustration).

The following description describes the input of code numbers.

4.2 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
3rd 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 or switch the ignition
off.

Status: 16.02.2007 Functions of the ESX control Page 7 of 67

Author: T.Löw / TE

008 911 57 BOMAG 123

6.1 ESX control

Service Training Refuse Compactor

4.3 Driving against the closed brake

After entering code number 5 0 0 the brake will not be released. When opening the rotary switch
"Parking Brake" and actuating the travel lever, the travel pumps will be actuated in accordance with
the selected travel direction. At the same time a warning (fault code 5 0 0 ) appears on the display and
the warning buzzer is triggered, in order to keep the operator informed about the condition.

In order to terminate this function and release the brake you must either enter code number 5 0 I or
switch the ignition off.

Note: This function can only be activated / deactivated when the travel lever is in
neutral position.

4.4 Enabling without the engine running

The input of code number 5 0 2 simulates operation of the diesel engine, i.e. certain functions are
enabled which are normally only possible when the engine is running (power supply to brake valve,
wheel motors, steering valves etc.). For safety reasons the floating position cannot be enabled. For
this purpose an additional input code is required (see "Enabling floating position")

For safety reasons relay K22 (engine shut down) is energized when activating this function. This
results in the engine control unit (EMR) being switched off. The displays "Fault EMR", "Oil Pressure"
and "Excessive Temperature" will therefore light permanently.

Note: This function can only be activated / deactivated when the travel lever is in
neutral position.

NOTE! After the input of this function the starter can still be operated! However, the
engine will not start!

When actuating the travel lever a warning (fault code 5 0 2 ) appears on the display and the warning
buzzer is triggered, in order to keep the operator informed about the condition.

To terminate this function the ignition must be switched off.

NOTE! If the starter is to be actuated without starting the engine (e.g. during
commissioning of the hydraulic system), this can be accomplished by pressing
the EMERGENCY STOP button. In this condition the engine control unit EMR is
not supplied with voltage.

Status: 16.02.2007 Functions of the ESX control Page 8 of 67

Author: T.Löw / TE

124 BOMAG 008 911 57

ESX control 6.1

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4.5 Enabling floating position

This function is only available from software version 3.00!

NOTE: Since the dozer blade / bucket may drop down by its own weight when
activating the float position, the activation is only possible in normal operation
with the engine running.

By entering code 5 0 4 the float position can also be activated for testing without the engine running.
However, the input of this code is only possible after the input "Enable without engine running" (double
interlock).

ATTENTION: After the input of this code the dozer blade can be lowered, but not raised any
more (no hydraulic pressure without the engine running)! You must therefore
make sure that there are no persons in the vicinity of dozer blade or bucket!

Entercode number 5 0 2 . This code number activates the function "Enabling without engine
running“.

Entercode number 5 0 4 . This code number activates the function "Enabling float position“.

The display module now shows the flashing code 5 0 4 .

When float position is now activated (move joystick forward and press button), the two float position
valves will be energized and the warning buzzer will sound.

In order to cancel this function you must either enter code number 5 0 5 or switch the ignition off.

Status: 16.02.2007 Functions of the ESX control Page 9 of 67

Author: T.Löw / TE

008 911 57 BOMAG 125

6.1 ESX control

Service Training Refuse Compactor

4.6 Showing stored faults

Switch on function "Show stored faults":
Entercode number 7 0 0 . This code number enables the function „Show stored faults“.

The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are
successively displayed in cycles of 3 second. After the last fault has been displayed, the first fault will
appear again. If no faults are stored in the ESX the display remains dark.

Switch off function "Show stored faults":

Enter code number 7 0 I . This code number disables the function „Show stored faults“.

Note: Apart from the stored faults the current faults are also displayed.

4.7 Delete all stored faults

Execute the function "Delete all stored faults":
The engine must not be running!
Entercode number 7 1 0 .
Switch the ignition off and on again.

All stored faults are now deleted.

Note: The stored faults can only be deleted when the engine is not running.

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4.8 Setting the machine type

This function is only available from software version 3.00!

Since the same control is used for all refuse compactors with electronically controlled engine (EPA II),
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 these machines e.g. are fitted with different wheel drive motors
or are designed with different numbers of speed ranges, or are equipped with dozer blade or bucket.

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 by
entering code 720.

The following machine types can be adjusted:

Machine type Machine type code Available from software

BC972/1172 with dozer blade 760 1.00
BC672/772 with dozer blade 761 1.00
BC972 with bucket 762 Not available
BC672/772 with bucket 763 1.00
BC572 with dozer blade 764 4.00
BC572 with bucket 765 4.00
BC672 EB 766 5.00
BC672 EB with tilt function 767 5.00

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

Enter code number 7 2 5 . This code number activates the function "Adjusting machine type".

The display module now permanently shows the code 7 2 5 .

Select and enter the machine from the table above.

The display module now permanently shows the entered code. (e.g. 7 6 1 )

Enter code number 7 2 6 . This code number confirms the entered machine type.

After confirming the machine type the control switches off, the display module shows the flashing code
726.

Switch the ignition off and on again.

The display module shows the reading 8 8 8 for approx. 10 seconds. The new parameters are loaded
according to the machine type setting. Do not switch the ignition off during this time!

After this the newly adjusted machine type will be displayed for approx. 3 seconds.

Attention: A machine must not be operated with a wrong type setting, because in such a
case the correct function of the control cannot be assured!

New controls are delivered with the default machine type setting 7 6 0 .

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4.9 Parameter adjustment 2nd speed range (only BC972)

This function enables to choose from three different final speeds for the second travel range.

Note: Parameter adjustments can only be performed when the engine is not running!
This parameter adjustment is only possible on machines of type BC972

Enter code number 6 6 0 . This code number activates the function "Parameter input 2nd gear“.

The display module now permanently shows the code 6 6 0 .

At this point the input of following codes is possible:

Code number 6 6 1 ) Speed in speed range 2 SLOW (approx. 5 km/h)

Code number 6 6 2 ) Speed in speed range 2 MEDIUM (approx. 6
km/h)
Code number 6 6 3 ) Speed in speed range 2 FAST (approx. 7 km/h)

Upon delivery of the machine the final speed is preset to 6 km/h.

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4.10 Parameter setting steering system

This function enables the setting of various parameters for the steering system. A differentiation can
be made between e.g. electronic and mechanical end position damping.

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

Enter code number 6 4 0 . This code number activates the function "Parameter input steering“.

The display module now permanently shows the code 6 4 0 .

At this point the input of following codes is possible:

Code number 6 4 1 ) Steering joystick ON

Code number 6 4 2 ) Steering joystick OFF
Code number 6 4 3 ) Steering wheel ON
Code number 6 4 4 ) Steering wheel OFF
Code number 6 4 5 ) Arms rest contact ON
Code number 6 4 6 ) Arms rest contact OFF
Code number 6 4 7 ) mechanical end position damping OFF
Code number 6 4 8 ) mechanical end position damping ON
Code number 6 4 9 ) electronic end position damping OFF (see note!)

Note: The electronic end position damping is inactive after entering code 649. End
position damping is automatically reactivated when switching the ignition the
next time, in order to prevent the steering cylinders from being damaged!

ATTENTION During input make sure that at least one of the functions (steering wheel or
joystick) is active. If both are deactivated the control is no longer able to steer
the machine. This is indicated by the fault code 290. The control will then switch
to override condition. In this case enter one of the two code numbers (for
joystick or for steering wheel) and switch the ignition off and on again.

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4.11 Travel pedal monitoring parameter setting

This function is only available from software version 3.00!

This function provides the possibility to set the reaction to a cable breakage in the travel pedal. In case
of a cable breakage the engine is operated with a fixed speed of 1500 rpm, so that the machine can
still be moved.

If the fault monitoring system is active, the engine will be shut down when this engine fault occurs for
the first time while the travel lever is not in neutral position. This assures that the machine will not start
to move by itself.

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

Enter code number 6 9 0 . This code number activates the function "Parameter input for travel
pedal monitoring“.

The display module now permanently shows the code 6 9 0 .

At this point the input of following codes is possible:

Code number 6 9 1 ) Monitoring ON Engine is shut down (see above)

Code number 6 9 2 ) Monitoring OFF Engine is not shut down (see above)

The machine is delivered with this function enabled.

4.12 Dozer blade characteristics parameter setting

With this function one can pre-select one of three characteristics for the dozer blade function, or to
deactivate this characteristics function.

Note: Parameter adjustments can only be performed when the engine is not running!
This parameter adjustment is only possible on machines of type EB!

Enter code number 6 5 0 . This code number activates the function "Parameter input for dozer
blade characteristics“.

The display module now permanently shows the code 6 5 0 .

At this point the input of following codes is possible:

Code number 6 5 1 ) Characteristic 1 (slightly progressive)

Code number 6 5 2 ) Characteristic 2 (more progressive)
Code number 6 5 3 ) Characteristic 3 (highly progressive)
Code number 6 5 4 ) No characteristic

On machines of type BC672EB and BC772 EB no characteristic is selected by default!

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4.13 Engine speed signal parameter setting

This function is only available from software version 6.00!

On engines of TIER III and higher the speed signal from the engine control unit (EMR III) is evaluated.
On machines with EMR I and EMR II the signal from an additional BOMAG speed sensor was
evaluated instead. These two signals have different pulses per engine revolution.

The function described next will enable you to switch between the two signals.

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

Enter code number 6 8 5 . This code number activates the function "Parameter input for travel
pedal monitoring“.

The display module now permanently shows the code 6 8 5 .

At this point the input of following codes is possible:

Code number 6 8 6 ) Evaluation of EMR III sensor signal

Code number 6 8 7 ) Evaluation of BOMAG sensor signal

Upon delivery of the machine evaluation of the EMR III sensor is enabled.

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008 911 57
ESX control

5 Block diagram normal operation BC972, 1172

Motorsteuergerät Fahren A rbeitshydraulik Lenkung NOT Aus

Fahrpedal Schwimpos.
1 2 3 N
Heben STOP
24 V
analog
EMR Zu Auf
Solldrehzahl Senken

Öldruck Übertemp. Fahrstufen Fahrtrichtung Bremse Joystick Joystick Lenkrad Armlehne

Kontrolleuchte
CENTRY

digital
EMR

digital
digital
analog
analog
digital
analog/digital
analog/digital
analog/digital
digital
Dieselmotor

Pulse
Drehzahl
Drehzahl
CAN Bus
ESX
Hydraulik

BOMAG
digital
Druckschalter,
Füllstand, usw.
888
F1 F2

DIOS Modul Fehleranzeige

digital (auf /zu)

digital (vorwärts)
digital (rückwärts)
PWM (0..600mA)
PWM (0..600mA)
PWM (0..600mA)
PWM (0..600mA)
PWM (0..1000mA)
PWM (0..1000mA)
PWM (0..1000mA)
PWM (0..1000mA)
digital (ein/aus)
PWM (0..1000mA)
PWM (0..1000mA)

links rechts heben senken Schwimmpos. öffnen schließen

Bremse Fahrpumpen Radmotoren Lenkung Arbeitshydraulik Schaufel

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6 Block diagram normal operation BC 572/672/772

Motorsteuergerät Fahren A rbeitshydraulik Lenkung NOT Aus

Fahrpedal
Schwimpos.
1 2 N
Heben 24 V
analog STOP
EMR Zu Auf
Solldrehzahl Senken

Öldruck Übertemp. Fahrstufen Fahrtrichtung Bremse Joystick Joystick Lenkrad Armlehne

Kontrolleuchte
CENTRY

digital
EMR

digital
digital
analog
analog
digital
analog/digital
analog/digital
analog/digital
digital
Dieselmotor

Pulse
Drehzahl
Drehzahl
CAN Bus
ESX

BOMAG
Hydraulik

digital
Druckschalter,
Füllstand, usw.
888
F1 F2

DIOS Modul Fehleranzeige

digital (auf /zu)

digital (vorwärts)
digital (rückwärts)
PWM (0..1000mA)
PWM (0..1000mA)
PWM (0..1000mA)
PWM (0..1000mA)
digital (ein/aus)
PWM (0..1000mA)
PWM (0..1000mA)

digital (langsam/schnell)
links rechts heben senken Schwimmpos. öffnen schließen

Bremse Fahrpumpen Fahrstufen Lenkung Arbeitshydraulik Schaufel

Status: 16.02.2007 Block diagram Page 18 of 67

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008 911 57
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7 Block diagram override operation BC972, 1172

Motorsteuergerät Fahren Arbeitshydraulik Lenkung NOT Aus

Fahrpedal Schwimpos.
1 2 3 N 24 V
Heben ST OP
analog
EMR Zu Auf
Solldrehzahl Senken

Öldruck Übertemp. Fahrstufen Fahrtrichtung Bremse Joystick Joystick Lenkrad Armlehne

Kontrolleuchte
CENTRY

digital
EMR

digital
digital
digital
digital
digital
Dieselmotor

Override Relais
Drehzahl

Hydraulik

BOMAG
Druckschalter,
Füllstand, usw.
888
F1 F2

Leistungs- DIOS Modul Fehleranzeige

widerstände

digital (auf /zu)

digital (vorwärts)
digital (rückwärts)
konst. (ca.500mA)
konst. (ca.500mA)
konst. (ca.500mA)
konst. (ca.500mA)

links rechts heben senken Schwimmpos. öffnen schließen

Bremse Fahrpumpen Radmotoren (Qmax) Lenkung Arbeitshydraulik Schaufel

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8 Block diagram override operation BC 572/672/772

Motorsteuergerät Fahren A rbeitshy drau lik Lenkung NOT Aus

Fahrpedal Schwimpos.
1 2 N 24 V
Heben ST OP
analog
EMR Zu Auf
Solldrehzahl Senken

Öldruck Übertemp. Fahrstufen Fahrtrichtung Bremse Joystick Joystick Lenkrad Armlehne

Kontrolleuchte
CENTRY

digital
EMR

digital
digital
digital
digital
digital
Dieselmotor

Override Relais
Drehzahl

BOMAG
Hydraulik

Druckschalter,
Füllstand, usw.
888
F1 F2

Leistungs- DIOS Modul Fehleranzeige

widerstände

digital (auf /zu)

digital (vorwärts)
digital (rückwärts)
konst. (ca.500mA)
konst. (ca.500mA)
konst. (ca.500mA)
konst. (ca.500mA)

links rechts heben senken Schwimmpos. öffnen schließen

Bremse Fahrpumpen Fahrstufen (Qmax) Lenkung Arbeitshydraulik Schaufel

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9 Description of the signals on the ESX-control

Notes:
1. Wherever the value of 24 V is mentioned in the following text it refers to the current battery
voltage under due consideration of voltage drops in the lines.

ESX terminal Signal description Nominal values (voltage / current)

X0:1 AGND = Analogue ground: Ground potential for sensors (steering approx. 0 V measured against ground (terminal 31)
joystick, speed range switch etc.)
X0:2 Output Override (emergency operation) Control in operation, emergency operation not active) 24 V
Digital output (max. 2,5 A) Control not in operation, emergency operation active) approx.0 V
X0:3 Output indicator light 2nd gear Indicator light ON ) 24 V
Digital output (max. 2,5 A) Indicator light OFF ) approx.2 V
X0:4 Interface RS 232 RxD, not used for normal operation. Measurement not possible!

X0:5 Interface RS 232 TxD, not used for normal operation. Measurement not possible!

X0:6 Input drive pedal position Travel pedal not operated: ) approx. 0.5 V
Analog input / voltage input 0..5 V Travel pedal operated: ) Voltage > 0,5 V

BOMAG
X0:7 Input selector switch Speed ranges Position speed range selector switch (measured against AGND)
BC972/1172: 1st speed range ) 1,80..2,40 V
BC972/1172: (Step switch, 3 steps) 2nd speed range ) 3,70..4,70 V
BC572/672/772: (Step switch, 2 steps) 3rd speed range ) 5,60..7,00 V
BC572/672/772: 1st speed range ) approx. 0 V
Analogue input / voltage input 0..8.5 V 2nd speed range ) 7,65..9,35 V

X0:8 Input steering joystick Position steering joystick (measured against AGND)
Analogue input / voltage input 0..8.5 V maximum left ) 6,70..8,60 V
Neutral position ) 3,60..4,60 V
maximum right ) 0,50..1,00 V
X0:9 Input steering wheel (option) Position steering wheel (measured against AGND)
Analogue input / voltage input 0..8.5 V maximum left ) 5,70..7,10 V
Neutral position ) 3,70..4,60 V
maximum right ) 1,70..2,20 V

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ESX terminal Signal description Nominal values (voltage / current)

X0:10 Input Pressure differential switch filter charge pump 1..4, or 2 all filters ok )approx.5 V
and filter transfer box at least 1 filter soiled ) 0V
Digital input active low
X0:11 Input pressure differential switch engine air filter all air filters ok )approx.5 V
Digital input active low at least 1 filter soiled ) 0V
X0:12 Input push button float position Push button actuated ) 24 V
Digital input active high Push button not actuated )approx.2 V
X0:13 Input hydraulic oil return flow filter Return flow filter ok )approx.5 V
Digital input active low Return flow filter soiled ) 0V
X0:14 Input steering stop left Stop not reached ) 24 V
Digital input active high Stop reached )approx.2 V
X0:15 Input steering stop right Stop not reached ) 24 V
Digital input active high Stop reached )approx.2 V
X0:16 Input Diesel engine speed Transducer delivers square-wave pulses
Digital input active high 167 pulse / revolution or 129 pulses / revolution on BC572
X0:17 Input joystick bucket close (optional) Joystick actuated to the left ) 24 V

BOMAG
Digital input active high Joystick not actuated )approx.2 V
X0:18 Input excessive coolant temperature (from EMR) Temperature ok )approx.5 V
Digital input active low Temperature too high ) 0V
X0:19 Input coolant filling level Filling level ok )approx.5 V
Digital input active low Filling level too low ) 0V
X0:20 Output dozer blade up Dozer blade is moved ) 0,3..1 A
PWM digital output (max. 4 A) Dozer blade is not moved ) 0A
X0:21 Output travel pumps forward Travel pumps triggered ) 24 V
PWM digital output (max. 4 A) Travel pumps not triggered ) 0V
X0:22 Output travel pumps reverse Travel pumps triggered ) 24 V
PWM digital output (max. 4 A) Travel pumps not triggered ) 0V
X0:23 Output voltage supply for sensors Nominal voltage = 8,5 V
This output supplies steering joystick, travel speed range switch, etc. Permissible range: approx. 7,65..9,35 V
Without this voltage the control cannot work correctly and will switch to This voltage must be measured against AGND.
override mode (emergency function).
X0:24 Output engine shut down Engine shut down inactive ) 0V
Digital output (max. 2,5 A) Engine shut down active ) 24 V

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ESX terminal Signal description Nominal values (voltage / current)

X0:25 Output indicator light 1st speed range Indicator light OFF )approx.2 V
Digital output (max. 2,5 A) Indicator light ON ) 24 V
X0:26 Interface CAN-Bus Wire -, is used to trigger the fault display module. Measurement not possible!
On bucket option also to trigger the DIOS module.
X0:27 Interface CAN-Bus Wire +, is used to trigger the fault display module. Measurement not possible!
On bucket option also to trigger the DIOS module.

X0:28 Input potential terminal 15 Control switched on ) 24 V

Digital input active high Control switched off )approx.2 V
This signal must be present, so that the control can work.
X0:29 Input potentiometer speed range 2nd gear (optional) Position potentiometer (measured against AGND)
Analogue input / voltage input 0..8.5 V right hand stop ) 0,50..1,00 V (max. speed)
left hand stop ) 6,80..8,70 V (min. speed)
X0:30 Input joystick dozer blade up/down Position potentiometer (measured against AGND)
Analogue input / voltage input 0..8.5 V maximum up ) 6,70..8,60 V
Neutral position ) 3,60..4,60 V
maximum down ) 0,50..1,00 V

BOMAG
X0:31 Input joystick bucket open/close (optional) Position potentiometer (measured against AGND)
Analogue input / voltage input 0..8.5 V maximum close ) 6,70..8,60 V
Neutral position ) 3,60..4,60 V
maximum open ) 0,50..1,00 V
X0:32 Input selector switch travel direction Position selector switch (measured against AGND)
Analogue input / voltage input 0..8.5 V forward ) 4,10..5,20 V
neutral ) 5,70..7,20 V
reverse ) 3,20..4,10 V
X0:33 not used

X0:34 Input joystick bucket open (optional) Joystick actuated to the right ) 24 V
Digital input active high Joystick not actuated )approx.2 V
X0:35 Input joystick dozer blade up Joystick pulled back ) 24 V
Digital input active high Joystick not actuated )approx.2 V

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ESX terminal Signal description Nominal values (voltage / current)

X0:36 Input D+ generator Engine running / engine is started ) 24 V
Digital input active high Engine stopped ) 0V
X0:37 Input position arm rest (optional) Arm rest bottom position ) 24 V
Digital input active high Arm rest up )approx.2 V
X0:38 Input steering joystick left Joystick actuated to the left ) 24 V
Digital input active high Joystick not actuated )approx.2 V
X0:39 Input steering joystick right Joystick actuated to the right ) 24 V
Digital input active high Joystick not actuated )approx.2 V
X0:40 Input switch brake Open brake ) 24 V
Digital input active high Close brake )approx.2 V
X0:41 Input joystick dozer blade down Joystick pushed forward ) 24 V
Digital input active high Joystick not actuated )approx.2 V
X0:42 Output dozer blade down Dozer blade is moved ) 0,3..1 A
PWM digital output (max. 4 A) Dozer blade is not moved ) 0A
X0:43 Output wheel motor rear right permissible current range: approx. 0.. 0,6 A
PWM digital output (max. 4 A)

BOMAG
X0:44 Output warning buzzer Warning buzzer ON ) 24 V
PWM digital output (max. 4 A) Warning buzzer OFF )approx.2 V
X0:45 Input hydraulic oil level float Oil level ok )approx.5 V
Digital input active low Oil level too low ) 0V
X0:46 Output wheel motor front left permissible current range: approx. 0..0,6 A
PWM digital output (max. 4 A)
X0:47 Output wheel motor front right permissible current range: approx. 0..0,6 A
PWM digital output (max. 4 A)
X0:48 Output wheel motor rear left permissible current range: approx. 0..0,6 A
PWM digital output (max. 4 A)
X0:49 Output steering left Steering active ) 0,3..1 A
PWM digital output (max. 4 A) Steering not active ) 0A
X0:50 Input excessive hydraulic oil temperature Temperature ok )approx.5 V
Digital input active low Temperature too high ) 0V
X0:51 Input contamination sensor Filter ok )approx.5 V
Digital input active low Filter soiled ) 0V
X0:52 Input oil pressure (from EMR) Oil pressure ok )approx.5 V
Digital input active low Oil pressure too low ) 0V

Status: 16.02.2007 Signal Description ESX Control Page 24 of 67

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008 911 57
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ESX terminal Signal description Nominal values (voltage / current)

X0:53 not used -

X0:54 Voltage supply for electronics Emergency stop not actuated ) 24 V

Emergency stop actuated ) 0V
X0:55 Ground connection electronics 0 V measured against ground

X0:56 Voltage supply for outputs approx. 24 V measured against ground

X0:57 Voltage supply for outputs approx. 24 V measured against ground

X0:58 Voltage supply for outputs approx. 24 V measured against ground

X0:59 Voltage supply for outputs approx. 24 V measured against ground

X0:60 Voltage supply for outputs approx. 24 V measured against ground

X0:61 Output brake Open brake ) 24 V

BOMAG
Digital output (max. 4 A) Close brake ) 0V
X0:62 Output travel ranges (only BC772) Travel speed range: 2nd gear ) 24 V
Digital output (max. 4 A) Travel speed range: 1st gear ) 0V
X0:63 Output float position Float position active ) 24 V
Digital output (max. 4 A) Float position not active ) 0V
X0:64 Output steering right Steering active ) 0,3..1 A
PWM digital output (max. 4 A) Steering not active ) 0A
X0:65 Mouse port Baby Boards approx. 0 V

X0:66 Mouse port Baby Boards approx. 0 V

X0:67 Mouse port Baby Boards approx. 0 V

X0:68 Mouse port Baby Boards approx. 0 V

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10 Description of signals on the DIOS module (only with optional bucket)

DIOS terminal Signal description Nominal values (voltage / current)

X0/1:1 Interface CAN-Bus Wire +, is used to communicate with the ESX- Measurement not possible!
control.
X0/1:2 Interface CAN-Bus Wire -, is used to communicate with the ESX- Measurement not possible!
control.
X0/1:3 Voltage supply for electronics Ignition ON: ) 24 V
Ignition OFF: ) 0V
X0/1:4 Ground connection (Coding node address) 0 V measured against ground

X0/1:5 Output close valve Close bucket active ) 0,3..1 A

PWM digital output (max. 1 A) Bucket not active ) 0A
X0/1:6 Output open valve Open bucket active ) 0,3..1 A
PWM digital output (max. 1 A) Bucket not active ) 0A
X0/1:7 not used

X0/1:8 not used

BOMAG
X0/1:9 Voltage supply for outputs Ignition ON: ) 24 V
Ignition OFF: ) 0V
X0/1:10 Voltage supply for outputs Ignition ON: ) 24 V
Ignition OFF: ) 0V
X0/1:11 Ground connection 0 V measured against ground

X0/1:12 not used

X0/1:13 not used

X0/1:14 not used

X0/1:15 not used

X0/1:16 not used

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 Service Training Refuse Compactor Description of Signals on the DIOS Module

008 911 57
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BOMAG
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6.1 ESX control

Service Training Fault codes of the ESX control

11 Fault codes of the ESX control

11.1 Overview

Fault code Fault description

00I - 199 Fault in travel system
200 - 299 Fault in steering system
300 - 499 Fault in working hydraulics
500 - 509 Warning messages input codes
510 - 549 Fault diesel engine
560 - 562 Fault sensor voltage supply / override relays
570 - 599 Fault hydraulic system
800 - 899 Fault message „severe software fault"
900 - 919 Error message "Communication via CAN bus disturbed"
920 - 999 Fault message "Severe internal fault in control"

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008 911 57
ESX control

11.2 Description of fault reactions

Fault reaction Description of fault reaction

1 Warning.
Fault code is displayed.
Audible signal in 5 second intervals.2
Signal light in monitoring board lights in 5 second intervals.
2 Function affected, the faulty function is replaced by an emergency function.
Fault code is displayed.
Audible signal in 5 second intervals.
Signal light in monitoring board lights in 5 second intervals.
3 Partial function faulty, the partial function cannot be overridden by an emergency function.
After the occurrence of the fault the machine is stopped, after returning the travel lever to neutral the machine can move
again.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
Fault code is displayed.
Audible signal in 5 second intervals.
Signal light in monitoring board lights in 5 second intervals.

BOMAG
4 Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is no longer able to drive, e.g. because parts of the travel system are defective
) the diesel engine is shut down.
Fault code is displayed.
Audible signal in 1 second intervals.
Signal light in monitoring board lights in 1 second intervals.
5 Fatal fault. The function of the control can no longer be guaranteed.
Control is switched off.
The fault code is displayed, the signal light in the monitoring board is permanently on.
No audible signal!

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

2
audible signal not with all faults (see page 3: "selected fault reactions of the ESX control")

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11.3 Detailed description of fault codes and their possible causes

Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
00I Output brake ) Wire breakage in current path X0:61 001 5
No or too low current flow out of this output ) Current path connected to +24 V
002 Output brake ) Short circuit to ground in the current path X0:61 001 5
The current flow from this output is too high ) ) Coil from brake valve burned out
output was switched off!
003 Output brake ) Current path connected to +24 V X0:61 001 5
Although the output is switched off, voltage is
present
004 Output brake ) Excessive current flow in current path, probably because of a X0:61 - 5
The output switch was switched off because of a defective coil or a short circuit to ground
too high temperature. As soon as the switch has
cooled down the output will be switched on

BOMAG
again.

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
021 Input travel direction switch ) Wire breakage in current path X0:32 021 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 switch
) Fuse FM 6 has tripped or wire breakage in voltage supply
current path
) Switch defective
022 Input travel direction switch ) Current path connected to +24 V / +8,5 V X0:32 021 5
The voltage applied to the input is above the ) Switch not connected to ground
specified range (see signal description). ) Switch defective

025 Input travel direction switch ) Poor contact of plug-in connection (intermittent contact) in X0:32 021 5
The voltage applied to the input is excessively current path or in supply lines
fluctuating. ) Switch defective
040 Input travel range switch (only BC972) ) Wire breakage in current path X0:7 040 2
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 switch

BOMAG
) Fuse FM 1 has tripped or wire breakage in voltage supply
current path
) Switch defective
041 Input travel range switch (only BC972) ) Current path connected to +24 V / +8,5 V X0:7 040 2
The voltage applied to the input is above the ) Switch not connected to ground
specified range (see signal description). ) Switch defective

042 Input travel range switch (only BC972) ) Poor contact of plug-in connection (intermittent contact) in X0:7 040 2
The voltage applied to the input is excessively current path or in supply lines
fluctuating. ) Switch defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
050 Output travel pumps forward ) Current path connected to ground X0:21 050 2
The voltage on this output is too low

051 Output travel pumps forward ) Current path connected to +24 V X0:21 050 2
The voltage on this output is too high

052 Output travel pumps forward ) Line breakage in current path X0:21 052 2
No current flow out of this output
053 Output travel pumps forward ) Current path connected to ground X0:21 052 2
Too high current flow out of this output ) Magnetic coil defective

060 Output travel pumps reverse ) Current path connected to ground X0:22 060 2
The voltage on this output is too low

061 Output travel pumps reverse ) Current path connected to +24 V X0:22 060 2

BOMAG
The voltage on this output is too high

062 Output travel pumps reverse ) Line breakage in current path X0:22 062 2
No current flow out of this output
063 Output travel pumps reverse ) Current path connected to ground X0:22 062 2
Too high current flow out of this output ) Magnetic coil defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
070 Output valve speed ranges (only BC772) ) Current path connected to ground X0:62 070 2
The voltage on this output is too low

071 Output valve speed ranges (only BC772) ) Current path connected to +24 V X0:62 070 2
The voltage on this output is too high

072 Output valve speed ranges (only BC772) ) Line breakage in current path X0:62 070 2
No current flow out of this output
073 Output valve speed ranges (only BC772) ) Excessive current flow in current path, probably because of a X0:62 - 2
The output switch was switched off because of a defective coil or a short circuit to ground
too high temperature. As soon as the switch has
cooled down the output will be switched on
again.

BOMAG
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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
100 Output proportional solenoid (only BC972) ) Current path has short circuit to ground X0:46 100 2
Wheel motor front left ) Current path has non-permitted connection to another current 120
The specified current value is not reached path
) Current path is interrupted
) Interturn fault in proportional solenoid (measure resistance)
105 Output proportional solenoid (only BC972) ) Current path has short circuit to ground X0:47 105 2
Wheel motor front right ) Current path has non-permitted connection to another current 120
The specified current value is not reached path
) Current path is interrupted
) Interturn fault in proportional solenoid (measure resistance)
110 Output proportional solenoid (only BC972) ) Current path has short circuit to ground X0:48 110 2
Wheel motor rear left ) Current path has non-permitted connection to another current 120
The specified current value is not reached path
) Current path is interrupted
) Interturn fault in proportional solenoid (measure resistance)

BOMAG
115 Output proportional solenoid (only BC972) ) Current path has short circuit to ground X0:43 115 2
Wheel motor rear right ) Current path has non-permitted connection to another current 120
The specified current value is not reached path
) Current path is interrupted
) Interturn fault in proportional solenoid (measure resistance)

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
230 Input steering joystick ) One of the two switches is defective (permanently closed) X0:38, 230 2
Switch left / switch right ) Connection between both switches or inputs (probably a chafed X0:39
Plausibility problem on the switches; the signals through cable)
right and left were detected at the same time.
231 Input potentiometer steering joystick ) Steering joystick switch right defective (does not close) X0:8, 230 2
Input steering joystick switch right ) Wire breakage in current path for steering joystick switch right X0:39 231
The signal from the steering joystick switch right
was not detected, although the potentiometer is
actuated to the right
232 Input potentiometer steering joystick ) Steering joystick switch left defective (does not close) X0:8, 230 2
Input steering joystick switch left ) Wire breakage in current path for steering joystick switch left X0:38 231
The signal from the steering joystick switch left
was not detected, although the potentiometer is
actuated to the left
233 Input potentiometer steering joystick ) Current path connected to +24 V / +8,5 V X0:8 231 2
The voltage applied to the input is above the ) Potentiometer not connected to ground

BOMAG
specified range (see signal description). ) Potentiometer defective

234 Input potentiometer steering joystick ) Wire breakage in current path X0:8 231 2
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 4 has tripped or wire breakage in voltage supply
current path
) Potentiometer defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
240 Input steering wheel (optional) ) One of the two switches is defective (permanently closed) X0:14, 240 2
Switch left / switch right ) Connection between both switches or inputs (probably a chafed X0:15
Plausibility problem on the switches; the signals through cable)
right and left were detected at the same time.
241 Input steering wheel potentiometer (optional) ) Steering wheel switch right defective (does not close) X0:9, 240 2
Input steering wheel switch right ) Wire breakage in current path steering wheel switch right X0:15 241
The signal from the steering wheel switch right
was not detected, although the potentiometer is
actuated to the right
242 Input steering wheel potentiometer (optional) ) Steering wheel switch left defective (does not close) X0:9, 240 2
Input steering wheel switch left ) Wire breakage in current path for steering wheel switch left X0:14 241
The signal from the steering wheel switch left
was not detected, although the potentiometer is
actuated to the left
243 Input steering wheel potentiometer (optional) ) Current path connected to +24 V / +8,5 V X0:9 241 2

BOMAG
The voltage applied to the input is above the ) Potentiometer not connected to ground
specified range (see signal description). ) Potentiometer defective

244 Input steering wheel potentiometer (optional) ) Wire breakage in current path X0:9 241 2
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 3 has tripped or wire breakage in voltage supply
current path
) Potentiometer defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
271 Output proportional solenoid ) Current path has short circuit to voltage supply X0:64 271 2
Steering right ) Current path has non-permitted connection to another current 272
Output current too low. path
) Current path is interrupted
272 Output proportional solenoid ) Current path has short circuit to ground X0:64 271 2
Steering right ) Current path has non-permitted connection to another current 272
Output current too high. path

273 Output proportional solenoid ) Current path is interrupted X0:64 271 2

Steering right ) Current path has impermitted connection to another current path 272
Fault when calibrating the valve / ground

276 Output proportional solenoid ) Current path has short circuit to voltage supply X0:49 276 2
Steering left ) Current path has non-permitted connection to another current 277
Output current too low. path
) Current path is interrupted

BOMAG
277 Output proportional solenoid ) Current path has short circuit to ground X0:49 276 2
Steering left ) Current path has non-permitted connection to another current 277
Output current too high. path

278 Output proportional solenoid ) Current path is interrupted X0:49 276 2

Steering left ) Current path has short circuit to ground 277
Fault when calibrating the valve ) Current path has impermitted connection to another current path
/ ground

290 Incorrect parameter setting for steering ) Steering wheel AND steering joystick were both deactivated. - - 5
see description "parameter setting steering" (page 13)

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
400 Input dozer blade joystick ) One of the two switches is defective (permanently closed) X0:35, 400 2
Switch up / switch down ) Connection between both switches or inputs (probably a chafed X0:41
Plausibility problem on the switches; the signals through cable)
up and down were detected at the same time.
401 Input potentiometer for dozer blade joystick ) Dozer blade joystick switch up defective (does not close) X0:30, 400 2
Input dozer blade joystick switch up ) Wire breakage in current path dozer blade joystick switch up X0:35 401
The signal from the dozer blade joystick switch
up was not detected, although the potentiometer
is actuated to direction up
402 Input potentiometer for dozer blade joystick ) Dozer blade joystick switch down defective (does not close) X0:30, 400 2
Input dozer blade joystick switch down ) Wire breakage in current path dozer blade joystick switch down X0:41 401
The signal from the dozer blade joystick switch
down was not detected, although the
potentiometer is actuated to direction down
403 Input potentiometer for dozer blade joystick ) Current path connected to +24 V / +8,5 V X0:30 401 2

BOMAG
The voltage applied to the input is above the ) Potentiometer not connected to ground
specified range (see signal description). ) Potentiometer defective

404 Input potentiometer for dozer blade joystick ) Wire breakage in current path X0:30 401 2
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 5 has tripped or wire breakage in voltage supply
current path
) Potentiometer defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
411 Output proportional solenoid ) Current path has short circuit to voltage supply X0:20 411 2
Dozer blade up ) Current path has non-permitted connection to another current 412
Output current too low. path
) Current path is interrupted
412 Output proportional solenoid ) Current path has short circuit to ground X0:20 411 2
Dozer blade up ) Current path has non-permitted connection to another current 412
Output current too high. path

413 Output proportional solenoid ) Current path is interrupted X0:20 411 2

Dozer blade up ) Current path has impermitted connection to another current path 412
Fault when calibrating the valve / ground

421 Output proportional solenoid ) Current path has short circuit to voltage supply X0:42 421 2
Dozer blade down ) Current path has non-permitted connection to another current 422
Output current too low. path
) Current path is interrupted

BOMAG
422 Output proportional solenoid ) Current path has short circuit to ground X0:42 421 2
Dozer blade down ) Current path has non-permitted connection to another current 422
Output current too high. path

423 Output proportional solenoid ) Current path is interrupted X0:42 421 2

Dozer blade down ) Current path has impermitted connection to another current path 422
Fault when calibrating the valve / ground

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
430 Output float position valve ) Wire breakage in current path X0:63 430 2
No or too low current flow out of this output ) Current path connected to +24 V
431 Output float position valve ) Short circuit to ground in the current path X0:63 430 2
The current flow from this output is too high ) ) Coil from brake valve burned out
output was switched off!
432 Output float position valve ) Current path connected to +24 V X0:63 430 2
Although the output is switched off, voltage is
present
433 Output float position valve ) Excessive current flow in current path, probably because of a X0:63 - 2
The output switch was switched off because of a defective coil or a short circuit to ground
too high temperature. As soon as the switch has
cooled down the output will be switched on
again.

BOMAG
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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
450 Input bucket joystick (optional) ) One of the two switches is defective (permanently closed) X0:17, 450 2
Switch open / switch close ) Connection between both switches or inputs (probably a chafed X0:34
Plausibility problem on the switches; the signals through cable)
open and close were detected at the same time.
451 Input potentiometer bucket joystick (optional) ) Bucket joystick switch open defective (does not close) X0:31, 450 2
Input bucket joystick switch open ) Wire breakage in current path bucket joystick switch open X0:34 451
The signal from the bucket joystick switch open
was not detected, although the potentiometer is
actuated to direction open
452 Input potentiometer bucket joystick (optional) ) Bucket joystick switch close defective (does not close) X0:31, 450 2
Input bucket joystick switch close ) Wire breakage in current path bucket joystick switch close X0:17 451
The signal from the bucket joystick switch close
was not detected, although the potentiometer is
actuated to direction close
453 Input potentiometer bucket joystick (optional) ) Current path connected to +24 V / +8,5 V X0:31 451 2
The voltage applied to the input is above the ) Potentiometer not connected to ground

BOMAG
specified range (see signal description). ) Potentiometer defective

454 Input potentiometer bucket joystick (optional) ) Wire breakage in current path X0:31 451 2
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 7 has tripped or wire breakage in voltage supply
current path
) Potentiometer defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
461 Output proportional solenoid ) Current path has short circuit to voltage supply DIOS 461 2
Open bucket (optional) ) Current path has non-permitted connection to another current X0/1:6 462
Output current too low. path
) Current path is interrupted
462 Output proportional solenoid ) Current path has short circuit to ground DIOS 461 2
Open bucket (optional) ) Current path has non-permitted connection to another current X0/1:6 462
Output current too high. path

463 Output proportional solenoid ) Current path is interrupted DIOS 461 2

Open bucket (optional) ) Current path has impermitted connection to another current path X0/1:6 462
Fault when calibrating the valve / ground

471 Output proportional solenoid ) Current path has short circuit to voltage supply DIOS 471 2
Close bucket (optional) ) Current path has non-permitted connection to another current X0/1:5 472
Output current too low. path

BOMAG
) Current path is interrupted
472 Output proportional solenoid ) Current path has short circuit to ground DIOS 471 2
Close bucket (optional) ) Current path has non-permitted connection to another current X0/1:5 472
Output current too high. path

473 Output proportional solenoid ) Current path is interrupted DIOS 471 2

Close bucket (optional) ) Current path has impermitted connection to another current path X0/1:5 472
Fault when calibrating the valve / ground

475 DIOS module dozer blade
Fault when initializing the module
) Wire breakage in CAN bus lines - 2
) Short circuit between CAN bus lines
) One or both CAN bus line(s) has (have) connection to +12V or
ground
) DIOS module without voltage supply
) DIOS module defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
500 Warning „Drive against brake“ With the input of code 5 0 0 the function „Driving against brake“ - - 1
was activated. This messages is intended to remind you of this
condition. The function „Driving against brake“ can be disabled by
switching the ignition off and entering code 5 0 I .
502 Warning “Enable without the engine running” With the input of code 5 0 2 the function „Enable without engine - - 4
running” was activated. This messages is intended to remind you of
this condition. The function „Enable without engine running“ can be
disabled by switching the ignition off.
504 Warning „Enable float position“ With the input of code 5 0 4 the function „Enable float position” was - - 1
activated. This messages is intended to remind you of this
condition. The function „Enable float position“ can be disabled by
switching the ignition off and entering code 5 0 5 .

BOMAG
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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
510 Output engine shut down ) Current path connected to +24 V X0:24 510 2
Although the output is switched off, voltage is
present
511 Output engine shut down ) Short circuit to ground in the current path X0:24 510 2
Although the output is switched on, no voltage is
present
512 Output engine shut down ) Wire breakage in current path X0:24 510 2
Although the output is switched off, a voltage of
approx. 0.8 V is present.
513 Engine stalled or shut down by engine control ) Engine overloaded - - 2
unit (EMR)
514 Engine speed input: ) Wire breakage in current path X0:16 514 1
Although the engine is running, no pulses from ) Current path has short circuit to ground 515
the rotation sensor ) Wire breakage in current path for voltage supply 516
) Engine speed sensor B92 defective / incorrectly assembled

BOMAG
) see also under : "Known faults" on page 6
517 Input D+ generator ) Wire breakage in current path X0:36 517 1
Although the engine is running there is no ) Current path has short circuit to ground
voltage present at input D+ ) V-belt broken
) Connections on generator faulty
) Generator defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
520 Input engine oil pressure ) The engine control unit has measured a too low oil pressure. The X0:52 520 1
Engine control unit (EMR) delivers signal „no engine may be shut down.
engine oil pressure“
Should this message be displayed even though the engine is not
running, the following faults should be examined:
) Current path has short circuit to ground
) No voltage supply to EMR
521 Input engine oil pressure ) see fault code 5 2 0 X0:52 520 4
Fault 5 2 0 is present longer than 10 seconds
) Engine is shut down
522 Input coolant temperature )This message shows that the coolant temperature is too high. X0:18 522 1
Engine control unit (EMR) delivers signal The diesel engine control unit may reduce the engine power in
„excessive coolant temperature“ order to avoid a further temperature increase or may even shut
the engine down.

Should this message be displayed even though the coolant

BOMAG
temperature is in a non-critical range (e.g. machine is cold), you
should check the following faults:
) Current path has short circuit to ground
) No voltage supply to EMR
523 Input coolant temperature ) see fault code 5 2 2 X0:18 522 4
Fault 5 2 2 is present longer than 120 seconds
) Engine is shut down

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
524 Input coolant level float ) This message shows that the coolant level is too low. X0:19 524 1

Should this message be displayed even though the coolant level

is not critical, the following faults should be examined:
) Current path has short circuit to ground
) Float defective

525 Input coolant level float ) see fault code 5 2 4 X0:19 524 4
Fault 5 2 4 is present longer than 20 seconds
) Engine is shut down
526 Input pressure differential switch air filter diesel ) This message indicates that at least one of the two air filters is X0:11 526 1
engine dirty. (time delay 2 minutes)

Should this message be displayed even though both filters are

clean, the following faults should be examined:

BOMAG
) Current path has short circuit to ground
) Pressure switch defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
530 Input travel pedal potentiometer ) Wire breakage in current path X0:06 530 1
The voltage applied to the input is below the ) Current path has short circuit to ground
specified range (see signal description). ) No voltage supply to potentiometer
) No voltage supply for engine control unit (EMR)
) Potentiometer defective
531 Input travel pedal potentiometer ) Current path connected to +24 V / +5 V X0:06 530 1
The voltage applied to the input is above the ) Potentiometer not connected to ground
specified range (see signal description). ) Potentiometer defective

532 Input travel pedal potentiometer see Fault 5 3 0 / 5 3 1 X0:06 530 4

A travel pedal fault has occurred and the engine
runs with a speed of more than 1000 rpm, i.e. in
emergency mode the engine runs with a fixed
speed. Apart from that, the travel lever was NOT
in Neutral when the fault occurred.

BOMAG
) Engine is shut down
533 Input travel pedal potentiometer see Fault 5 3 0 / 5 3 1 X0:06 530 1
A travel pedal fault has occurred and the engine
runs with a speed of more than 1000 rpm, i.e. in
emergency mode the engine runs with a fixed
speed.

540 Engine speed signal ) Selection of incorrect parameter for "Engine speed signal X0:16 540 1
The engine speed is outside the permissible source"
range ) Speed sensor incorrectly installed
) Intermittent contact in current path
) Speed sensor defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
560 Output sensor voltage supply ) Current path connected to +24 V X0:23 560 5
The voltage applied to the output is higher than
10V.
561 Output sensor voltage supply ) Current path connected to ground X0:23 560 5
The voltage applied to the output is lower than
5V.
562 Output Override (emergency operation) )Fuse F67 has tripped or wire breakage in current path for X0:2 562 5
A voltage of 24V should be present at the output, voltage supply to control (56 - 60)
however, the measured voltage is lower than 5V. ) Current path has short circuit to ground

BOMAG
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Fault Fault description Possible cause Terminal Input - Fault -
ESX control

code on ESX code for reaction

diagnose
570 Input hydraulic oil contamination sensor ) This message shows that the hydraulic oil is contaminated. X0:11 570 1
(Time delay 10 seconds)

Should this message be displayed even though this is not true,

the following faults should be examined:
) Current path has short circuit to ground
) Sensor defective

571 Input hydraulic oil contamination sensor see fault code 5 7 0 X0:11 570 4
Fault 5 7 0 is present longer than 120 seconds
) Engine is shut down
572 Input pressure differential switch hydraulic filter ) At least one of the pressure differential switches shows a X0:10 572 1
charge pumps and intermediate gears pressure differential.

Should this message be displayed even though no differential

pressure has been measured, the following faults should be
examined:

BOMAG
) Current path has short circuit to ground
) one of the pressure switches are defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
573 Input pressure differential switch hydraulic filter see fault code 5 7 2 X1:13 572 4
charge pumps and intermediate gears
Fault 5 7 2 is present longer than 120 seconds
) Engine is shut down
574 Input excessive hydraulic oil temperature ) This message is a warning, giving the operator enough time to X0:50 574 1
move the machine out of the danger area before the engine is
automatically shut down after 120 seconds.

Should this message be displayed even though the hydraulic oil

temperature is ok (e.g. machine is cold), you should check the
following faults:
) Current path has short circuit to ground
) one of the 5 pressure switches is defective
575 Input excessive hydraulic oil temperature see fault code 5 7 4 X0:50 574 4
Fault 5 7 4 is present longer than 120 seconds

BOMAG
) Engine is shut down
578 Input hydraulic oil filling level ) This message shows that the hydraulic oil level is too low. X0:45 578 1
) This message is a warning, giving the operator enough time to
move the machine out of the danger area before the engine is
automatically shut down after 20 seconds.

Should this message be displayed even though the hydraulic oil

level is ok, the following faults should be examined:
) Current path has short circuit to ground
) Float defective

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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
579 Input hydraulic oil filling level see fault code 5 7 9 X0:45 578 4
Fault 5 7 9 is present longer than 20 seconds
) Engine is shut down
580 Input hydraulic oil return flow filter ) The return flow filter is dirty X0:13 580 1

Should this message be displayed even though no pressure has

581 The warning 5 8 0 was present for longer than
120 seconds, the engine was then automatically
shut down.
been measured, the following faults should be examined:
) Current path has short circuit to ground
) Pressure switch defective
)This message indicates that a pressure differential was detected X0:13 580 4
at the filter which lasted longer than 120 seconds (see message
5 8 0 ) and the engine was therefore automatically shut down.

BOMAG
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Fault Fault description Possible cause Terminal Input - Fault -

code on ESX code for reaction
diagnose
800 Fault message "severe software fault in control" - - - 5
- The machine can only be moved in emergency
899 mode. The control has automatically switched off.
This fault cannot be rectified on the machine. The
control must be immediately replaced.
900 Error message "Communication via CAN bus ) Wire breakage in CAN bus lines X0:26 - 2
- disturbed" ) Short circuit between CAN bus lines X0:27
919 The modules (DIOS module for bucket control) ) One or both CAN bus line(s) has (have) connection to +12V or
controlled via the CAN bus cannot be addressed ground
by the main control (ESX). The respective ) DIOS module without voltage supply
machine functions (e.g. bucket control) are not ) DIOS module defective
available

920 Fault message "Severe internal fault in control" - - - 5

- The machine can only be moved in emergency

BOMAG
999 mode. The control has automatically switched off.
This 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 X0:26 - -
control. ) Short circuit between CAN bus lines X0:27
) One or both CAN bus line(s) has (have) connection to +12V or
ground

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12 Input Codes for ESX Control
ESX control

12.1 Travel system

Input code Description of display function Display values

000 All display functions disabled. -
00I brake Display value / 10 = voltage in V
Show voltage on brake output.
003 brake 0 0 0 ) Switch position "brake OPEN"
Shows condition of brake switch 0 0 I ) Switch position "brake CLOSED"
020 Selector switch travel direction 1 0 0 ) actuated forward
Shows the travel direction. 0 0 0 ) Neutral position
0 0 I ) actuated to backward

021 Selector switch travel direction Display value / 100 = voltage in V

Shows the potentiometer voltage.
040 Selector switch travel speed range Display value / 100 = voltage in V
Shows the voltage on the input.

BOMAG
041 Selector switch travel speed range 0 0 I ) 1st gear
Shows the travel speed range. 0 0 2 ) 2nd speed range
0 0 3 ) 3rd speed range (only BC972)
050 Travel pump Display value / 10 = voltage in V
Show voltage on output “travel pump forward”
052 Travel pump Display value *10 = current in mA1
Show voltage on output “travel pump forward”
060 Travel pump Display value / 10 = voltage in V
Show voltage on output “travel pump reverse”
062 Travel pump Display value / 10 = current in mA1
Show current on output “travel pump reverse”

1
Current measurement with factor 10 only available from software version 4.03
(Up to and incl. version 4.02 the current output took place without this factor, i.e. only max. 999mA could be displayed)

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Input code Description of display function Display values

070 Speed range selector valve (only BC772) Display value / 10 = voltage in V
Shows the voltage on the output.
100 Wheel motor front left 3(only BC972) Display value = current in mA
Shows actual current value of proportional solenoid.
105 Wheel motor front right 1 (only BC972) Display value = current in mA
Shows actual current value of proportional solenoid.
110 Wheel motor front left 1 (only BC972) Display value = current in mA
Shows actual current value of proportional solenoid.
115 Wheel motor rear right 1 (only BC972) Display value = current in mA
Shows actual current value of proportional solenoid.
120 Wheel motors (only BC972) Display value = current in mA
Shows the current values.

12.2 Steering

BOMAG
Input code Description of display function Display values
230 Steering joystick I00 ) Switch left actuated
Shows the condition of the switches. 0 0 0 ) no switch actuated; neutral position
00I ) Switch right actuated
I0I ) Switches left and right actuated fault ) Fault
231 Steering joystick Display value / 100 = voltage in V
Shows the potentiometer voltage.
232 Steering joystick Value range: 1000...-1000
Shows the standardized position 1000 = max. actuation left
0 = zero position
-1000 = max. actuation right
Note: Due to the abilities of the display module only values from
9 9 9 . . . - 9 9 9 can be displayed. (See also description of
display module)

3
due to measuring inaccuracies the display values fluctuate slightly, e.g. actual current value 1st speed range: 0..15 mA

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Input code Description of display function Display values

240 Steering wheel (optional) I00 ) Switch left actuated
Shows the condition of the switches. 0 0 0 ) no switch actuated; neutral position
0 0 I ) Switch right actuated
I 0 I ) Switches left and right actuated fault ) Fault
241 Steering wheel (optional) Display value / 100 = voltage in V
Shows the potentiometer voltage.
242 Steering wheel (optional) Value range: 1000...-1000
Shows the standardized position 1000 = max. actuation left
0 = zero position
-1000 = max. actuation right
Note: Due to the abilities of the display module only values from
9 9 9 . . . - 9 9 9 can be displayed. (See also description of
display module)
250 Arm rest (optional) 0 0 0 ) Arm rest top position (joystick steering inactive)
Shows position determined by position switch 0 0 1 ) Arm rest bottom position
251 Limit switch steering left (only electronic end position damping) 0 0 0 ) End position reached
Shows position determined by position switch 001 )

BOMAG
252 Limit switch steering right (only electronic end position damping) 0 0 0 ) End position reached
Shows position determined by position switch 001 )
271 Steering valve right Display value = current in mA
Shows specified current value of proportional solenoid left.
272 Steering valve right Display value = current in mA
Shows actual current value of proportional solenoid left.
276 Steering valve left Display value = current in mA
Shows specified current value of proportional solenoid right.
277 Steering valve left Display value = current in mA
Shows actual current value of proportional solenoid right.

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12.3 Working hydraulics

Input code Description of display function Display values

400 Dozer blade joystick I00 ) Switch up actuated
Shows the condition of the switches. 0 0 0 ) no switch actuated; neutral position
0 0 I ) Switch down actuated
I 0 I ) Switches up and down actuated ) Fault
401 Dozer blade joystick Display value / 100 = voltage in V
Shows the potentiometer voltage.
402 Dozer blade joystick Value range: 1000...-1000
Shows the standardized position 1000 = max. actuation up
0 = zero position
-1000 = max. actuation down
Note: Due to the abilities of the display module only values from
9 9 9 . . . - 9 9 9 can be displayed. (See also description of
display module)
411 Valve up Display value = current in mA
Shows specified current value of proportional solenoid for lifting.

BOMAG
412 Valve up Display value = current in mA
Shows actual current value of proportional solenoid for lifting.
421 Valve down Display value = current in mA
Shows specified current value of proportional solenoid for lowering.
422 Valve down Display value = current in mA
Shows actual current value of proportional solenoid for lowering.
425 Push button float position 0 0 0 ) joystick not operated
Shows condition of push button 0 0 1 ) operated
426 Status float position 0 0 0 ) not active
0 0 1 ) active
430 Valve float position Display value / 10 = voltage in V
Shows the voltage on the output “float position”.

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Input code Description of display function Display values

450 Bucket joystick I00 ) Switch closing actuated
Shows the condition of the switches. 0 0 0 ) no switch actuated; neutral position
0 0 I ) Opening switch actuated
I 0 I ) Switches open and close actuated ) Fault
451 Bucket joystick Display value / 100 = voltage in V
Shows the potentiometer voltage.
452 Bucket joystick Value range: 1000...-1000
Shows the standardized position 1000 = max. actuation close
0 = zero position
-1000 = max. actuation open
Note: Due to the abilities of the display module only values from
9 9 9 . . . - 9 9 9 can be displayed. (See also description of
display module)
461 Valve open Display value = current in mA
Shows specified current value of proportional solenoid open.
462 Valve open Display value *100 = current in mA
Shows actual current value of proportional solenoid open.
471

BOMAG
Valve close Display value = current in mA
Shows specified current value of proportional solenoid close.
472 Valve close Display value *100 = current in mA
Shows actual current value of proportional solenoid close.

12.4 Test functions

Input code Description of display function Display values

500 Switch on function „Against brake“ see adjustment instructions (page 8 )!
50I Switch off function „Drive against brake“ see adjustment instructions (page 8 )!
502 Function “Enable without engine running” see adjustment instructions (page 8 )!
504 Switch on function „Enable float position" see adjustment instructions (page 9 )!
505 Switch off function „Enable float position" see adjustment instructions (page 9 )!

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12.5 Diesel engine

Input code Description of display function Display values

510 Engine shut down Display value / 10 = voltage in V
Shows the voltage on the output engine shut down.
511 Status diesel engine 0 0 0 ) Engine OFF
Shows the status of the diesel engine. Status is derived from MD+, oil 0 0 I ) Engine ON
pressure and engine speed. Running of engine is sensed if at least 2
signals are present.
514 Engine speed sensor Display value x 10 = engine speed in rpm
Shows the engine speed.
515 Engine speed sensor Display value x 10 = frequency in Hz
Shows the frequency at engine speed input.
516 Engine speed sensor Number of pulses; display jumps from 9 9 9 back to 0 0 0
Shows number of pulses on engine speed input.
517 D+ generator 0 0 0 ) MD+ not applied (input to ground)
Shows status of input MD+. 0 0 I ) MD+ present (input connected to +24 V)
520 Engine oil pressure 0 0 0 ) No engine oil pressure

BOMAG
Shows status of input engine oil pressure. 0 0 I ) Engine oil pressure OK
522 Coolant temperature 0 0 0 )Coolant temperature too high
Shows status of input coolant temperature. 0 0 I ) Coolant temperature OK
524 Coolant filling level 0 0 0 ) Filling level too low
Shows status of input coolant level. 00I ) Filling level OK
526 Air filter soiled 0 0 0 ) at least 1 filter soiled
Shows status of input air filter pressure differential switch. 00I ) both filters OK
530 Travel pedal potentiometer Display value / 100 = voltage in V
Shows the potentiometer voltage.
531 Travel pedal potentiometer Value range: 0..1000
Shows the standardized potentiometer voltage. Display value / 10 = voltage in % of the reference voltage from
EMR control unit (5 V)
532 Travel pedal potentiometer 0 0 I ) ok
Shows status. 0 0 2 ) Fault

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Input code Description of display function Display values

540 Engine speed measuring source
You may either evaluate the speed signal provided by the DEUTZ
engine control unit, or the signal from the BOMAG speed sensors.
541 Pulses / revolution engine speed signal
Number of pulses per revolution of the evaluated speed signal.
0 0 0 ) Evaluation of DEUTZ speed signal
0 0 I ) Evaluation of BOMAG speed signal
0 6 0 )DEUTZ speed signal
1 2 9 I )BOMAG speed signal (only BC572)
1 6 7 )BOMAG speed signal

12.6 System information

Input code Description of display function Display values

555 Software Version 3-digit version number
Shows the software version number.
560 Supply voltage 8.5V Display value / 100 = voltage in V
Shows the voltage value
56I Supply voltage 24 V Display value / 10 = voltage in V
Shows the voltage value

BOMAG
562 Override Display value / 10 = voltage in V
Shows the voltage on the output “override”.

12.7 Hydraulics

Input code Description of display function Display values

570 Hydraulic contamination sensor 000 ) Hydraulic oil contaminated
Shows status of input contamination sensor. 00I ) Hydraulic oil OK
572 Hydraulic oil filter 0 0 0 ) at least 1 hydraulic filter soiled
Shows the condition of input hydraulic oil filter for charge pumps and 00I ) all hydraulic oil filters OK
intermediate gear.
574 Hydraulic oil temperature 000 ) Temperature too high
Shows status of input oil temperature. 00I ) Temperature OK
578 Hydraulic oil filling level 0 0 0 ) Filling level too low

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Input code Description of display function Display values

Shows status of input hydraulic oil level float. 00I ) Filling level OK
580 Hydraulic return flow filter 0 0 0 )Hydraulic oil filter soiled
Shows status of input hydraulic return flow filter. 0 0 I ) Hydraulic oil filter OK

BOMAG
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12.8 Parameter change
ESX control

Input code Description of display function Display values

640 Activates function "parameter input steering" Display value 6 4 0
641 Activation of option "steering joystick" see adjustment instructions (page 13 )!
642 Deactivation of option "steering joystick" see adjustment instructions (page 13 )!
643 Activation of option "steering wheel" see adjustment instructions (page 13 )!
644 Deactivation of option "steering wheel" see adjustment instructions (page 13 )!
645 Activation of the arm rest initiator see adjustment instructions (page 13 )!
646 Deactivation of the arm rest initiator see adjustment instructions (page 13 )!
647 Deactivation of mechanical end position damping see adjustment instructions (page 13 )!
648 Activation of mechanical end position damping see adjustment instructions (page 13 )!
649 Deactivation of electronic end position damping see adjustment instructions (page 13 )!
650 Switch on function "parameter input setting dozer blade function" (only Display value 6 5 0
EB machines).
651 Activation "characteristic 1 (slightly progressive)" see adjustment instructions (page 14 )!
652 Activation "characteristic 2 (more progressive)" see adjustment instructions (page 14 )!
653 Activation "characteristic 3 (highly progressive)" see adjustment instructions (page 14 )!
654

BOMAG
Activation "no characteristic 1" see adjustment instructions (page 14 )!
660 Activates „parameter input 2nd speed range” (only BC972) Display value 6 6 0
661 Activation "slow speed" for 2nd speed range (only BC972). see adjustment instructions (page 12 )!
662 Activation "medium speed" for 2nd speed range (only BC972). see adjustment instructions (page 12 )!
663 Activation "high speed" for 2nd speed range (only BC972). see adjustment instructions (page 12 )!
685 Activation of "Parameter input diesel engine speed signal" see adjustment instructions (page 15 )!
686 Activation "DEUTZ engine speed signal" see adjustment instructions (page 15 )!
687 Activation "BOMAG engine speed signal" see adjustment instructions (page 15 )!
690 Activation "parameter input travel pedal monitoring" see adjustment instructions (page 14 )!
691 Activation "Monitoring ON" see adjustment instructions (page 14 )!
692 Activation "Monitoring OFF" see adjustment instructions (page 14 )!

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12.9 Fault log

Input code Description of display function Display values

700 Switch on function „Show stored faults“ see adjustment instructions (page 10 )!
701 Switch off function „Show stored faults“ see adjustment instructions (page 10 )!
710 Delete all stored faults see adjustment instructions (page 10 )!

BOMAG
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12.10 Setting the machine type

Input code Description of display function Display values

725 Switches on function „Set machine type“ see adjustment instructions (page 11 )!
726 Confirms entered machine type see adjustment instructions (page 11 )!
760 Pre-select machine type BC 972 dozer blade version see adjustment instructions (page 11 )!
761 Pre-select machine type BC 672/772 dozer blade version see adjustment instructions (page 11 )!
762 Pre-select machine type BC 972 bucket version see adjustment instructions (page 11 )!
763 Pre-select machine type BC 672/772 bucket version see adjustment instructions (page 11 )!
764 Pre-select machine type BC 572 dozer blade version see adjustment instructions (page 11 )!
765 Pre-select machine type BC 572 bucket version see adjustment instructions (page 11 )!
766 Pre-select machine type BC 672 EB see adjustment instructions (page 11 )!
767 Pre-select machine type BC 672 EB with tilt function see adjustment instructions (page 11 )!

BOMAG
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13 Terminology in connection with ESX

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

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

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

Terminal, cable lug

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

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Short circuit to ground

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

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

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

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

Closed loop control

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

Marking Closed loop control Control

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

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Current and voltage measurement

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

Override / emergency operation

In the event of a major fault the control will switch off and the override function will take over.
This has the effect that the machine can still be moved and steered with reduced speed.
Steering and dozer blade movements are only possible with a constant speed.
(see also: page 18, "")

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

PWM – digital output

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

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 7 Electronic modules

008 911 57 BOMAG 185

186 BOMAG 008 911 57
Blower monitoring module A53 7.1
7.1 Blower monitoring module
A53

Fig. 1
The module is located in the right hand cabin flap.
The module has the function:
To make a connection from terminal 30 to terminal
87a after 20 seconds if the blower speed drops below
a certain limit (1300 rpm) and after 8 seconds if the
speed signal fails.

i Note
In deenerized condition there is no connection be-
tween Pins 30 and 87a.

Fig. 1 Blower monitoring module

Module description blower monitoring

This module protects the fresh air blower in case of
overloads (contamination) against damage and thus
the machine against subsequent damage.

Switch position Dropping resistor Signal frequency Blower speed

Low speed 22 Ohm 73 Hz 2190 rpm
Mean speed 10 Ohm 89 Hz 2670 rpm
Max.speed No dropping resistor 113 Hz 3390 rpm

008 911 57 BOMAG 187

7.1 Blower monitoring module A53

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 8 Trouble shooting

008 911 57 BOMAG 189

8.1
General notes on trouble shooting in hy-
8.1 General
draulic systems
The following description of trouble shooting steps
contains a small selection of possible faults that may
occur during the operation of the machine. The fault
lists are by no means complete, but the fault tables
were compiled according to the experience gathered
by our central customer service, i.e. faults that have
occurred in the past have almost all been included.
Procedure:
On machines with electronic control (ESX) you should
first of all check the CAN-Bus module, to find out if
there is a error code and thus an electric fault present.
If a fault code is present, continue trouble shooting by
following the description of the ESX-control.
If no fault code is present, the fault may still be caused
by an electrical problem or an operating error. The
control will only report a fault if the current/voltage val-
ues are out of the nominal range. If e.g. a contact in a
switch is defective, the control will not always recog-
nize this. For this reason one can have the incoming
and outgoing signals for the control displayed by the
CAN-Bus module to compare these with the table of
nominal values.
Important points for trouble shooting and
fault rectification
Danger
! Hydraulic hoses must be visually inspected at
Danger of injury!
Do not touch rotating parts of the engine.
When working on the travel pump and performing
tests in the travel circuit block the wheels with
suitable wheel chocks.
Hydraulic oil escaping under pressure can pene-
trate the skin and cause severe injury. You should
therefore relieve the pressure in the system be-
fore disconnecting any lines. Before repressuriz-
ing the system make sure that all line connections
and ports are in perfect condition.
When being injured by hydraulic oil consult a phy-
sician immediately, as otherwise this may cause
severe infections.
Caution
! l
It is not recommended to open or repair hydraulic
units and components without comprehensive
knowledge.
Risk of damage to pressure gauges if incorrectly
connected.
When performing trouble shooting it is assumed that
the machine is correctly equipped and connected, that
connections and hoses are free of faults and that set-
screws have not been deadjusted without permission.
190 BOMAG
General
Progressive tests drawn up in the trouble shooting di-
agram lead to the detection of faults and their rectifi-
cation by trained personnel.
l Ensure strict cleanliness, clean ports and fittings
before disconnecting.
l Cover all openings and ports or close with plugs.
l Check the hydraulic oil level before and after the
work.
l Use only clean oil according to specification.
l
Check the hydraulic system for leaks, find and rec-
tify the cause.
l Ensure strict cleanliness, clean ports and fittings
before disconnecting.
l Fill new hydraulic units with hydraulic oil before
starting operation.
l After changing a component thoroughly flush and
bleed the hydraulic system.
l As far as possible conduct all measurements at op-
erating temperature 40 ... 50 °C.
l
After changing a component check charge and high
pressure, if necessary check the rotational speed.
Hydraulic hoses
Danger
!
Danger of injury
regular intervals.
Hydraulic hoses must be immediately replaced if:
l
the outer layer is damaged down to the inlay (e.g.
chafing, cuts, cracks, etc.)
l the outer layer is brittle (formation of cracks in the
hose material)
l the hose shows deformations in pressurized and
depressurized condition, which do not comply with
the genuine shape of the hydraulic hose
l
the hose shows deformations in bends, e.g.
squeezing, buckling, layer separation, formation of
blisters
l the hose is leaking
l the hydraulic hose has separated from the fitting
the fitting shows corrosion that impairs both function
and strength
l
the fitting is deformed in a way that both function
and strength are affected
l the storage time and utilization period has expired.
008 911 57
The machine drives with the travel lever in "NEUTRAL" 8.2
8.2 The machine drives with the travel lever in "NEUTRAL"

The machine drives with the travel lever in „NEUTRAL“

Check the control current to the sole-

noids
- Input module, enter PIN-CODE 500.

Perform
Machine yes trouble shoot-
stops? ing
in electric
no

Check the zero position of the pump

- Connect control chamber ports X3 and
X4 on
one pump with a hose
- Start the engine
- Repeat this test on all
pumps

no
Machine
stops?

yes

008 911 57 BOMAG 191

8.2 The machine drives with the travel lever in "NEUTRAL"

Adjust the mechanical 0-position

- Connect control chamber ports X3 and X4
with a hose
- Connect 600 bar pressure gauges to
MA and MB.
- Check which pump is delivering
- On this pump adjust the 0-position so that
the pressure reading is below 60 bar
- Repeat this test until the lowest pressure
value is reached
- Remove the connecting hose, repeat the
pressure test

Check the control unit

- Remove the control unit
- Check the smooth movement of the con-
trol piston

no
Control unit Replace the
OK? control unit

yes

Replace the
the travel
pump

192 BOMAG 008 911 57

The machine does not drive 8.3
8.3 The machine does not drive

008 911 57 BOMAG 193

8.3 The machine does not drive

The machine does not drive

Read fault code and proceed appropriately

Check the emergency stop switch
- Check whether the emergency stop switch was pressed
Note:
If necessary select the travel direction again after unlocking or
operate the brake

no Unlock the emergen-

Emergency
stop switch cy stop switch, re-
OK? place if necessary

yes

Check the electric control

- Input module, enter PIN-CODE
500.
- Switch the ignition on and select
the desired travel direction
- Check the voltage
Nominal value:
24V

no Perform trouble
Voltage shooting in electric
OK? system

yes

194 BOMAG 008 911 57

The machine does not drive 8.3

Check the solenoid

- Pull the plug off the solenoid
- Connect the adapter cable and measure
the current draw
Nominal value: approx. 2A

no
Current draw Replace the
OK? solenoid

yes

no Check the charge

Charge pres- pump, search for
sure OK? cause of pressure
drop
yes

Check the coupling on the engine

- Loosen the charge pump from the travel pump and pull it
off.
ATTENTION:
Do not loosen the hoses!
- Loosen the charge pump from the travel pump and pull it
off.
Nominal value:

008 911 57 BOMAG 195

8.4 Machine travels to one direction only or to one travel direction

8.4 Machine travels to one direction only or to one travel direction with
reduced power

196 BOMAG 008 911 57

Machine travels to one direction only or to one travel direction 8.4

Machine travels to one direction only or to one travel direction with reduced
power

Read fault code and proceed appropriately

Check the electric control
- Input module, enter PIN-CODE 500.
- Switch the ignition on and select the desired
travel direction
Check the voltage
Nominal value:

Perform
Voltage no trouble
OK? shooting in
the electric
yes

008 911 57 BOMAG 197

8.4 Machine travels to one direction only or to one travel direction

Check the high pressure relief valve

- Interchange the high pressure relief
valves

yes Replace the corre-

Travel direction sponding high pres-
changes sure relief valve

no

Check the swash time nozzles

- Unscrew the nozzles from ports
X1 and X2 and check for block-
age

no
Nozzles Clean/replace the
OK? nozzles

yes

198 BOMAG 008 911 57

Machine travels to one direction only or to one travel direction 8.4

Replace the control

Travel direction
changes?

no

Replace/repair
the travel pump

008 911 57 BOMAG 199

8.5 Hydraulic oil overheating

8.5 Hydraulic oil overheating

200 BOMAG 008 911 57

Hydraulic oil overheating 8.5

Hydraulic oil overheating

Check the engine cooling system

- Check the hydraulic oil cooler for dirt
- Check the engine cooling fan
- Inspect the air intake box on the cabin roof
for dirt

no Clean a dirty radiator

Radiator or repair the cooling
OK? system
yes

Check the high pressure limitation

- Pull the plug off the brake solenoid valve
- Start the engine
- Actuate the travel lever
- 2. Select the travel speed range
- Run the engine with maximum speed.
- Check whether the high pressure relief valves heat up
- Repeat this test to the opposite direction.

Check the pressure setting of high

pressure relief valves and pres-
Valve no sure override, adjust or replace as
heating up? necessary

yes

Check the thermostat

- Run the machine up to operating temperature (hydraulic oil
temperature55°C).
- Check, whether the hose to the hydraulic oil cooler warms up
at an hydraulic oil temperature of more than 70°C or becomes

Thermostat no Replace the

OK? thermostat

008 911 57 BOMAG 201

8.6 Insufficient travel power, max speed is not reached

8.6 Insufficient travel power, max speed is not reached

Insufficient travel power, max speed is not reached

Pressure and speed test

- Warm up machine to operating tem-
perature (approx. 50°C hydraulic oil
temperature)
- Input module, enter PIN-CODE 500.
- Connect 600 bar pressure gauges high pressure sides of
the travel pumps (pos. 1 to 4)
- Connect 60 bar pressure gauges for pilot pressure (Pos. 7
and 8)
- Connect 60 bar pressure gauges for charge pressure (Pos.
5 and 6)
- Start the engine, select 2nd speed range and switch to the
desired travel direction
- Watch the pressure gauges and accelerate the engine
slowly up to maximum speed
Nominal values:
Engine speed min. 2100 rpm; charge pressures must not
drop, min. 25 bar in idle speed, increasing to 30 bar; con-
trol chamber pressures must increase evenly; high pres-
sure must increase evenly up to approx. 430 bar.

no
Perform
Rated speed
trouble shooting
OK?
on engine
yes

no
Charge pres-
sure
in idle speed

yes

202 BOMAG 008 911 57

Insufficient travel power, max speed is not reached 8.6

Check the brake - Release the brake

- (only if pressure of left hand pump drops - Check charge pressure at idle
below 10 bar)
- Input module, enter PIN-CODE 500.

yes*
Charge pressure
OK?

no*

- * Inform the service department of

BOMAG

Check the charge pump

- Close the outlet port of the respective pump with
a 200 bar pressure relief valve
- Connect a 600 bar pressure gauge
- Crank the engine with the starter
Nominal value: 200 bar

yes
Pressure Replace the
OK? charge pump

no*

008 911 57 BOMAG 203

8.6 Insufficient travel power, max speed is not reached

Check the individual components

- Disconnect the high pressure hoses from one
pump
- Close the pump ports with plugs
- Repeat the pressure test
- Perform this test also on the other pump

yes Replace/repair
Charge pres- the correspond-
sure ing travel motor

no

Replace/repair
the correspond-
ing travel pump

Pilot pressure no
OK?

yes

Check and adjust the DA-control valve

- Unscrew and check the DA-control
valve, replace it if necessary
- Adjust the DA-control valve
Nominal value: 1220 rpm engine
speed
150 bar high pressure
1890 rpm engine speed
390 bar high pressure
Pilot pressure evenly increasing

Pilot pressure
OK?

no

204 BOMAG 008 911 57

Insufficient travel power, max speed is not reached 8.6

Checking the pressure override

- Turn the adjustment screw completely in
(block).
- Repeat the pressure test
Attention: Relieve through the high pressure
relief valves for max. 3 seconds!

Pilot pressure
OK?

no

Replace/repair the
travel pump

no
High pressure
OK?

yes

-
- Mechanical damage in travel
motors Check the swash time nozzles
- Engine power too low - Unscrew the swash time noz-
zles from X1 and X2 and check
them

008 911 57 BOMAG 205

8.6 Insufficient travel power, max speed is not reached

no
Nozzles Clean/replace the noz-
OK? zles

yes

Check the individual compo-

nents
- Disconnect the high pressure
hoses from one pump
- Close the pump ports with
plugs
- Repeat the pressure test
- Perform this test also on the
other pump

Replace/repair the
no travel pump with the
High pressure
OK? too low pressure

yes

Replace/repair the
corresponding travel
motor

206 BOMAG 008 911 57

No steering function / steering stiff, end stops are not reached 8.7
8.7 No steering function / steering stiff, end stops are not reached

008 911 57 BOMAG 207

8.7 No steering function / steering stiff, end stops are not reached

No steering function / steering stiff, end stops are not reached

Read fault code and proceed ap-

propriately
Check the steering/dozer blade
pump
- Connect a 600 bar pressure gauge
to the high pressure test port
- Start the diesel engine and turn the
steering wheel against an end stop
- Read the pressure gauge
Nominal value:
230 bar
Stand-by:

yes Replace the flow

High pressure booster
OK?

no

Check the load signal to the steering/dozer

blade pump
- Connect a 600 bar pressure gauge to pressure
test port X on the pump
- Operate the steering while the engine is run-
ning and read the pressure gauge. Depending

LS-signal yes Replace/repair the

OK? steering/dozer blade
pump
no

Replace/repair
the valve block

208 BOMAG 008 911 57

Failure of central lubrication system (grease emerges from re- 8.8
8.8 Failure of central lubrication system (grease emerges from relief
valve)

008 911 57 BOMAG 209

8.8 Failure of central lubrication system (grease emerges from re-

Central lubrication system not working

(lubricant emerging from the relief valve)

Check the grease pump

- Remove the lubrication hose
- Connect a 600 bar pressure gauge
- Close the lubrication hose with a
plug
- Switch the pump on and press the
push button several times
Nominal value:
Raise the pressure to approx. 350
bar, grease emerging from the relief

no
Pressure
OK?

yes

Check the pressure relief valve

no
Valve Replace the
OK? pressure relief
valve
yes

Replace the lubri-

cation pump

210 BOMAG 008 911 57

Failure of central lubrication system (grease emerges from re- 8.8

Check the main distributor

- Loosen the top and bottom lubrication
- Reconnect the lubrication hose hoses, one after the other
- Connect a grease gun to the grease - The hose from which grease comes
nipple and apply a pressure of 200 bar flowing out indicates in which branch
the blockage can be found
- Reconnect the hoses

none top
Changing/clean- Grease emerging
ing the main dis-
tributor
bottom

Check the sub-divider in Check the sub-distrib-

the front frame
- Generate a pressure of
200 bar with the grease
gun and loosen the lubri-
cation hoses one after the
other. The hose from
which grease comes flow-
ing out indicates the block-
utor in the rear frame
- Generate a pressure
of 200 bar with the
grease gun and loos-
en the lubrication hos-
es one after the other.
The hose from which
grease comes flowing
out indicates the

Replace, clean no yes

Repair the re-
the respective Grease emerging
spective bear-
sub-distributor ing location

008 911 57 BOMAG 211

8.9 Trouble shooting travel system

Travel drive The specified numbers in the table indicate the prob-
8.9 Trouble shooting travel system

ability of the fault cause and thus the recommended

The following trouble shooting chart lists electrical, but
trouble shooting sequence, based on our previous ex-
also mechanical and hydraulic faults.
perience.

Machine moves with travel direction switch in neutral

Machine does not travel (forward and reverse)

Left or right hand side blocked in 1 direction

Machine travels to one direction only

Max. travel speed is not reached

Trouble shooting

Travel drive

Hydraulic oil overheating

1 wheel blocked
Symptoms

Possible cause
Emergency stop push button 1
Brake switch open/defective/wiring 1
(fault code?)
ESX-control / electrics defective/wir- 2 2 3 2
ing (fault code?)
Travel direction switch defective/wir- 1 1 3
ing (fault code?)
Travel speed range selector switch 1
position/defective/wiring (fault code?)
Pump control (electric (fault code?) / 2 1 1 2
hydraulic)
Control start / DA-valve cartridge 3 2 1
dirty/deadjusted/defective
Pressure override / high pressure re- 2 2
lief valves in travel pump dirty/dead-
justed/defective
Charge pump(s) / charge pressure re- 3 3
lief valve(s) dirty/seized/defective
Travel pump(s) defective 3 2 1 1 2
Coupling / transfer box defective 3
Control start of travel motor deadjust- 2
ed
Travel motor flushing valve stuck 3
Travel motor(s) defective 1 2
Brake (mechanical/hydraulic) 2 3 2
Planetary wheel drive defective 2
Hydraulic oil cooler soiled (internally/ 1
externally)
Thermostat (hydraulics) dirty/seized/ 3
defective
Diesel engine 1

212 BOMAG 008 911 57

Trouble shooting working hydraulics 8.10
8.10 Trouble shooting working hy-
draulics

Working hydraulics
The following trouble shooting chart lists electrical, but
also mechanical and hydraulic faults.
The specified numbers in the table indicate the prob-
ability of the fault cause and thus the recommended
trouble shooting sequence, based on our previous ex-
perience.

No steering function (dozer blade/bucket function OK)

Dozer blade/bucket function only to one direction

individual work functions too slow / fast / jerky

No dozer blade/bucket function (steering OK)

No steering and dozer blade/bucket function

all work functions too slow / fast / jerky

Steering function only to one side
Trouble shooting

Working hydraulics
Symptoms

Possible cause
Steering joystick defective/wiring 1 3 1 2
(fault code?)
Dozer blade/bucket control lever de- 1 3 1 2
fective/wiring (fault code?)
ESX-control defective/wiring (fault 3 3 1 2 2 1* 2
code?)
Valve block defective/spool seized/ 2 2 3 1 1 1 1
wiring (fault code?)
Steering cylinders defective 3 3 3
Dozer blade/bucket cylinder defective 3 3 3
Pressure/flow control valve out of ad- 1 2
justment/dirty/defective
Working pump(s) defective 2 3

*Control in override mode

008 911 57 BOMAG 213

8.11 Fault diagnose TCD 2015

8.11 Fault diagnose TCD 2015 3a (red) flash-

Fig. 1
No. 7 = Fault indication, engine function
One of the red lights lighting up during operation indi-
cates and engine problem.
ing = external fault, the warning buzzer
sounds. The machine control has detect-
ed a fault.
4 (yellow)= Cabin dehumidifier switched on.
5 (yellow) = Air filter cartridges soiled, clean cartridg-
es, replace.
6 (red) = Coolant temperature too high. The en-
gine control unit shuts the engine down.
Clean the radiator.
7 (red) = Lack of coolant. The warning buzzer
sounds, the engine is shut down after 20
seconds. Fill up coolant, change if nec-
essary.
8 (yellow) = Failure of fresh air fan (depressed rotat-
ing speed). Clean the fresh air filter, re-
place if necessary, replace the fan if
damaged.

i Note
With the ignition switch in position "I" the control light
lights for about 4 seconds (function check)

Fig. 2

Fault monitoring board for engine functions (RB)

Control light
1 (yellow) = Preheating system (cold start) flashes
with ignition switch in position "I" after 30
seconds and goes out after starting.
2 (yellow) = Batteries are not being charged. Check
V-belt, if necessary repair the generator.
3 (red) = Engine oil pressure too low, the engine
control unit shuts the engine down.
Check the engine oil level, if necessary
have the engine repaired.
3a (red) per-
manent light= Fault in engine control. The engine con-
trol is switched off (emergency opera-
tion).

214 BOMAG 008 911 57

Fault diagnose TCD 2015 8.11

Fig. 3 Fig. 4
No. 1 = Control light for water separator in fuel No. 2 = Control light and diagnostic button for
pre-filter engine control (EMR III)
lights up = if the water proportion in the trans-
parent section of the fuel filter i Note
reaches the contacts. The diesel engine with EMR III (Electronic Engine
goes out = if fuel is clean. Control) inhibits protective functions for the engine.
Depending on the severity of the detected fault the en-
gine may continue operation with limitations (limp
home), whereby the control will permanently be on.
With flashing control light the engine is shut down. If
the fault indicator for engine oil pressure or coolant
level, coolant temperature light up as well, eliminate
the fault.
When the fault is eliminated the control light will go
out.
The diagnostic button provides the possibility to read
out existing faults in form of flashing codes.
With the ignition switch in position „I“ the control light
lights for about 2 seconds (function check)
permanent light = A fault message is present, the
engine can be started and the
refuse compactor is still operable
with limitations. Inform the service
department.
the control light flash-
es after 2 seconds= Severe fault, the engine cannot
be started, inform the service de-
partment.
goes out after 2 sec-
onds = the engine function is free of
faults.
does not light = Start the engine, press the diag-
nostic push button for 3 seconds.
Control light flashes 2x. EMR-con-
trol ok.

008 911 57 BOMAG 215

8.11 Fault diagnose TCD 2015

After output of fault

code = 5 seconds pause, the display by
i Note
flashing and permanent light.)
Depending on the significance of the detected fault
the engine may keep on running, however, with limita-
l If necessary repeat as described above to read out
tions (limp home), whereby the fault lamp will continu- the next fault code.
ally light, or the engine will be shut down and the fault
lamp will flash. If the warning lamps for engine oil
pressure control or coolant level also light up, correct
the fault (e.g. top up oil, let the engine cool down).
Once the fault is eliminated the fault lamp will go out.
The diagnostic button provides the possibility to read
out existing faults in form of flashing codes.

Example fault code 211

Fig. 5
l
Press the diagnose button (Fig. 5) for approx. 1 to 3
seconds, then release the button.

Fig. 6
After 2 seconds = 2 x short flashes of 0.4 seconds of
the first digit (recognition of the
EMR control) (Fig. 6).
after another 2 sec-
onds = 1 x long flash of 0.8 second of the
second digit for the stored fault
after another 2 sec-
onds = 1 x short flash of 0,4 second of the
third digit for the stored fault
l Write down the fault flash code.

216 BOMAG 008 911 57

List of fault flash codes TCD 2015 8.12

Flashing code
Short Long Short Function / component Fault
(0.4s) (0.8s) (0.4s)
1 2 6 Hand throttle Signal faulty / implausible
1 3 6 Air filter monitoring Air pressure after filter too low
1 4 4 Oil temperature monitoring Temperature outside nominal range
2 1 6 Fuel low pressure monitoring Fuel low pressure outside nominal
range
2 2 2 Throttle pedal input 1 (PWM) PWM signal faulty
2 2 3 Charge air pressure monitoring Charge air pressure outside nominal
range
2 2 6 Throttle pedal input 1 (analog) Signal faulty / implausible
2 2 8 Fuel filter water level monitoring Max. water level exceeded
2 3 1 Oil pressure monitoring outside nominal range
2 3 2 Coolant temperature monitoring Temperature above nominal range
2 3 3 Intake air temperature monitoring Temperature above nominal range
2 3 5 Coolant level monitoring Level below nominal range
2 3 7 Fuel temperature monitoring Temperature outside nominal range
2 3 8 Fan speed monitoring Speed outside nominal range
2 4 1 Combustion monitoring Misfiring detected in one or several
cylinders
2 7 1 CAN-Bus Time-Out for one or several sent
messages, bus inactive
3 1 4 Hydraulic oil temperature monitoring Temperature outside nominal range
3 1 8 Battery monitoring Voltage outside nominal range
5 1 4 Monitoring of terminal 15 No signal detected
5 1 5 Monitoring of terminal 50 Permanent signal detected

Behaviour in case of fault signal faulty / implausible:

Check function of affected parts; check wiring and
plugs for short circuit, breakage, corrosion.

008 911 57 BOMAG 217

8.13 General trouble shooting chart TCD 2015

8.13 General trouble shooting

chart TCD 2015

Faults Causes Action

Temperature below starting limit
Engine oil with wrong SAE viscosity class Change the lubrication oil
Fuel quality not as specified in the operating Change the fuel
Engine does not
instructions
start or starts
Air in the fuel system Bleed the fuel system
poorly
Battery defective or not charged Check the battery
Cable to starter loose or oxidized Check cable connection
Starter defective or pinion does not engage Check starter
Engine does not Engine electronics prevent starting Check fault by fault code, repair as necessary
start and diag-
nostic lamp flash-
ing
Engine starts, but Fuel quality not as specified in the operating Change the fuel
runs irregularly or instructions
misfires Injection line leaking Check the injection line
Injection valve defective Check the injection valve / replace if neces-
sary
Speed changes Engine electronics detected a system fault Check fault by fault code, repair as necessary
are possible and and activates a substitute speed
diagnostic lamp
lights
Oil level too low Fill up lubrication oil
Engine oil level too high Check oil level, drain off if necessary
Air filter clogged / exhaust turbocharger de- Check / replace if necessary
Engine overheat-
fective
ing. Temperature
Air filter service switch / indicator defective Check / replace if necessary
warning system
Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary
responds
Short circuit of heat in cooling system Check the cooling system
Resistance in cooling system too high / flow Check the cooling system
quantity too low
Engine oil level too high Check the oil level
Fuel quality not as specified in the operating Change the fuel
instructions
Air filter clogged / exhaust turbocharger de- Check / replace if necessary
Insufficient en-
fective
gine power
Air filter service switch / indicator defective Check / replace if necessary
Charge air pipe leaking Check the charge air pipe
Injection line leaking Check the injection line
Injection valve defective Check the injection valve
Insufficient en- Engine electronics reducing the output power Check fault by fault code, repair as necessary
gine power and
diagnostic lamp
lights
Engine does not Injection line leaking Check the injection valve / replace if neces-
work with all cyl- sary
inders Injection valve defective Check the injection valve / replace if neces-
sary

218 BOMAG 008 911 57

General trouble shooting chart TCD 2015 8.13
Faults Causes Action
Oil level too low Fill up lubrication oil
Engine has to low Extremely slanted position of engine Check engine pillow blocks / reduce the en-
or no oil pressure gine inclination
Engine oil of wrong SAE class or quality Change the lubrication oil
Engine has ex- Engine oil level too high Check oil level, drain off if necessary
cessive oil con- Extremely slanted position of engine Check engine pillow blocks / reduce the en-
sumption gine inclination
Blue engine ex- Engine oil level too high Check oil level, drain off if necessary
haust smoke Extremely slanted position of engine Check engine pillow blocks / reduce the en-
gine inclination
Temperature below starting limit
Fuel quality not as specified in the operating Change the fuel
White engine ex-
instructions
haust smoke
Injection valve defective Check the injection valve / replace if neces-
sary
Air filter clogged / exhaust turbocharger de- Check / replace if necessary
fective
Black engine ex- Air filter service switch / indicator defective Check / replace if necessary
haust smoke Charge air pipe leaking Check the charge air pipe
Injection valve defective Check the injection valve / replace if neces-
sary

008 911 57 BOMAG 219

8.13 General trouble shooting chart TCD 2015

220 BOMAG 008 911 57

 9 Installed components / connection overview

008 911 57 BOMAG 221

222 BOMAG 008 911 57
List of installed components 9.1

Fig. 1
(M) Diesel engine
1 Transfer box
2 Travel pump front right
3 Charge pump front right
4 Travel pump rear right
5 Charge pump rear right
6 Travel pump front left
7 Charge pump left front
8 Travel pump rear left
9 Charge pump rear left
10 Working pump 1
11 Working pump 2
12 Working hydraulics control block
13 Dozer blade cylinder
14 Steering cylinder, right
15 Steering cylinder, left
16 Central lubrication system
17 Hydraulic return flow filter
18 Hydraulic charge oil filter
19 Return flow filter from transfer case
20 Engine oil filter
21 Fuel pre-filter
22 Fuel filter
23 Travel motor front right with planetary gear
24 Dozer blade control lever
25 Steering joystick

008 911 57 BOMAG 223

9.2 Measuring and adjustment points on tandem travel pump unit

Measuring and adjustment points

9.2 Measuring and adjustment points on tandem travel pump unit

Fig. 2

224 BOMAG 008 911 57

Measuring and adjustment points on tandem travel pump unit 9.2

Pos. Designation Pos. in elec- Pos. in hy- Measuring value

tric wiring di- draulic dia-
agram gram
1 Port A, high pressure reverse, driven pump 08A, 11A
2 High pressure relief valves, driven pump 480 -20 bar
3 PS-line, pilot pressure supply to pressure over-
ride
4 Port A, high pressure reverse, dragged pump 09A, 12A
5 High pressure relief valves, dragged pump 480 -20 bar
6 Port B, high pressure forward, dragged pump
7 Plug T2, dragged pump T2
8 Port B, high pressure forward, driven pump B
9 Plug T2, driven pump T2
10 Plug a, solenoid valve forward Y 16 a 0 / 24V
11 Port T1, leak oil to return flow filter, driven pump, T1
with magnetic plug
12 Test port X1, control chamber pressure reverse M6, M16, X1 0 - 14 bar, **)
13 Port T1, leak oil to return flow filter, dragged T1
pump, with magnetic plug
14 Test port G, charge pressure M7, M17, G3 0 ± 2 bar in high idle
speed***)
15 Test port X2, control chamber pressure forward M5, M15, X2 0 - 14 bar **)
16 Port S, charge pressure from hydraulic oil filter
17 Plug b, solenoid valve reverse Y 17 b 0 / 24V
18 Charge pressure relief valve, driven pump 30 ± 2 bar in high idle
speed***)
19 DA-control valve *)
20 Pressure override, driven pump 430 +10/-20 bar
21 Test port MB, high pressure forward, driven M2, M12, MB 430 +10/-20 bar
pump
22 Charge pressure relief valve, dragged pump 30 ± 2 bar in high idle
speed***)
23 Pressure override, dragged pump 430 +10/-20 bar
24 Test port MB, high pressure forward, dragged M4, M14, MB 430 +10/-20 bar
pump
25 Port S1, suction connection charge pump from
tank
26 Port P, charge pump pressure port to filter
27 Test port MA, high pressure reverse, dragged M3, M13, MA 430 +10/-20 bar
pump
28 Test port MA, high pressure reverse, driven M1, M11, MA 430 +10/-20 bar
pump

*), **), ***); see adjustment instructions

008 911 57 BOMAG 225

9.3 Connection overview

Fig. 1 Travel pump

226 BOMAG 008 911 57

Connection overview
1 High pressure relief valve reverse, driven pump
2 Charge pressure test port, driven pump
3 Charge pressure relief valve, driven pump
4 DA-control valve
5 High pressure test port forward, driven pump
6 High pressure relief valve reverse, driven pump
7 High pressure test port forward, driven pump
8 Timing
9 High pressure test port forward, dragged pump
10 High pressure test port forward, dragged pump
11 Charge pressure relief valve, dragged pump
12 High pressure test port reverse, dragged pump
13 Charge pressure test port, dragged pump
14 High pressure relief valve reverse, dragged pump
15 Timing
16 PS-lines, control pressure connection for pressure
override
17 Test port and connection for control chamber
pressure, forward
008 911 57
9.3
18 Test port and connection for control chamber
pressure, reverse
19 Solenoid valve, reverse
20 Charge pressure outlet to filter, driven pump
21 Port B, high pressure forward, dragged pump
22 Charge pressure outlet to filter, dragged pump
23 Port B, high pressure forward, dragged pump
24 Solenoid valve, forward
25 Port T1, leak oil to return flow filter, dragged pump,
with magnetic plug
26 Pressure override, dragged pump
27 Pressure override, driven pump
28 Port T1, leak oil to return flow filter, driven pump,
with magnetic plug
29 Charge pressure inlet from filter, driven pump
30 Port A, high pressure reverse, driven pump
31 Port A, high pressure reverse, dragged pump
32 Charge pressure inlet from filter, dragged pump
BOMAG 227
9.4 Connection overview

Fig. 1

228 BOMAG 008 911 57

Connection overview 9.4
1 Setscrew, high pressure rear 25 Magnetic plug, wheel motor, front right
2 Setscrew, high pressure front 26 Leak oil port from travel pump, rear left
3 Setscrew, stand-by pressure front 27 Non-return valve (3 bar), to tank
4 LS-pressure test port 28 Connection to cooler
5 Setscrew, stand-by pressure rear 29 Thermostat (55°C...70°C)
6 High pressure test port 30 Connection to tank
7 31 Connection from solenoid valve for brake/travel
8 direction selector
9 32 Test port for case pressure
10 33 Pressure switch (3 bar), normally open
11 34 Contamination sensor
12 35 Magnetic plug, wheel motor, rear left
13 36 Magnetic plug, wheel motor, rear right
14 37 Leak oil port from travel pump, rear right
15 Active filter element 38 Leak oil port from travel pump, front right
16 By-pass filter element 39
17 Leak oil port from travel pump, front left 40 Pressure differential switch, charge pressure front
left
18 Magnetic plug, wheel motor, rear right
41 Pressure differential switch, charge pressure rear
19 Leak oil port, wheel motor, rear right
left
20 Leak oil port, wheel motor, rear left
42 Pressure differential switch, charge pressure rear
21 Leak oil port, steering/working pump right
22 Magnetic plug, steering/working pump 43 Pressure differential switch, charge pressure front
23 Leak oil port, wheel motor, front left right
24 Leak oil port, wheel motor, front right 44 Differential pressure switch, transfer box oil filter

008 911 57 BOMAG 229

9.5 Measuring and adjustment points on control valve block

Measuring and adjustment points

9.5 Measuring and adjustment points on control valve block

Fig. 2 Control valve block

Pos. Designation Pos. ii electric wir- Pos. in hydraulic Measuring

ing diagram diagram value
1 Proportional solenoid steering left Y93 0-1000 mA
- Proportional solenoid steering right (on oppo- Y92 0-1000 mA
site side)
2 Switching solenoid, float position Y102 24 Volt
- 2. Switching solenoid, float position (on oppo- Y102 24 Volt
site side)
3 Proportional solenoid, blade down Y109 0-1000 mA
- Proportional solenoid, blade up (on opposite Y108 0-1000 mA
side)
4 Pressure test port, steering left Ma2 0 -28 bar
- Proportional solenoid, steering right (on op- Mb2 0 -28 bar
posite side)
5 Pressure test port, blade up Ma1 0 -28 bar
- Proportional solenoid, blade down (on oppo- Mb1 0 -28 bar
site side)
6 Pressure test port, pre-loaded tank line Mt1 0 -18 bar
7 Pressure test port, pump pressure Mp 0-203 + 10
bar
8 LS-pressure limitation 3 210 ±10 bar
9 Tank pre-loading valve 6 18 bar

230 BOMAG 008 911 57

Cab electrics 9.6

1 P00, fuel gauge 19 S01, Emergency stop switch

2 P12, Volt meter 24V 20 A65, control unit for air conditioning
3 P03, engine RPM-meter with (P00) operating hour 21 S44, rotary switch for cabin fresh air ventilator
meter 22 S119, travel pedal for throttle control
4 P14, coolant temperature gauge 23 S71, steering lever
5 P02, hydraulic oil temperature gauge 24 S03, push button for warning horn
6 S00, ignition switch 25 Air distribution nozzles
7 A15, fault indicator, engine functions 26 S161, deceleration pedal with emergency braking
8 A15, fault indicator, machine functions kick-down
9 S70, lever for dozer blade / bucket control control 27 S160, rotary switch for activation of manual throt-
10 H04, warning light for engine control tle/deceleration pedal ON/OFF with indicator light,
H81
11 H70, control light for water separator in fuel pre-fil-
ter 28 S120, potentiometer for throttle control
12 XS, socket 24V (1600...2100 min-1)
13 S02, rotary switch, travel speed ranges
14 S31, travel lever (forward/0/reverse)
15 S04, rotary switch for parking brake
16 S25, rotary switch for seat heating
17 E20, cigarette lighter
18 S27, push button for central lubrication system

008 911 57 BOMAG 231

9.6 Cab electrics

1 Wiring loom, electrics box - engine control unit
(A48)
2 Wiring loom, electrics box - ESX control
3 Wiring loom, electrics box - module cockpit
4 A48, engine control unit
5 Wiring loom, electrics box - throttle pedal
6 ESX, electronic control
7 Wiring loom, electrics box - driver's seat

232 BOMAG 008 911 57

Cab electrics 9.6

Dashboard, cabin
a = S20, toggle switch for front windscreen
wipers Y138, solenoid valve for heating
b = S22, toggle switch for front washer
c = S21, toggle switch/push button for rear
windscreen wiper/washer
d = S45, toggle switch for inside lights
e = S16, toggle switch for front working head
lights
f = S53, toggle switch for working head
lights, sides
g = S26, toggle switch for working head
lights, rear
h = S128, toggle switch for rear view mirror
heating
i = S38, toggle switch for flashing beacon
j = S137, toggle switch for engine compart-
ment illumination
E37, radial twin blower
A53, blower module for radial twin blower

1 A53, fan module for fresh air fan

2 A57, pulse generator for windscreen wiper
3 K32, relay for cabin B117, thawing thermostat
4 U01, voltage transformer 24/12 Volt

008 911 57 BOMAG 233

9.6 Cab electrics

B29, room temperature sensor

B118, blow-off temperature sensor

234 BOMAG 008 911 57

Machine related electrics
1 Wiring loom, main battery switch - vehicle ground
2 Wiring loom, main fuse (F00) - electrics box
3 Wiring loom, fuse (F48) - engine control unit (A48)
4 Wiring loom, main fuse (F00) - fuse (F48)
5 Wiring loom, battery - starter (2 units)
008 911 57 BOMAG
9.7
6 Wiring loom, starter - generator
7 Wiring loom, main battery switch - battery
8 Wiring loom, battery (G01) - battery (G03)
9 Wiring loom, central electrics ground - vehicle
ground
235
9.7 Machine related electrics

10 Ground cable 16 G03, battery

11 Wiring loom, battery - main battery fuse 17 G01, battery
12 Wiring loom, engine ground - vehicle ground 18 S30, main battery switch
13 A48, engine control unit 19 M01, starter
14 F00, main battery fuse 20 G02, generator
15 F48, fuse for preheating system 21 B124, sensor for water separator

1 B88, oil pressure sensor

2 B126, fuel temperature sensor
3 B133, sensor for charge air temperature and
charge air pressure
4 A48, engine control unit
5 B113, coolant temperature sensor
6
7 X27.1, central engine plug
8 B114, crankshaft rotation speed sensor
9 B130, camshaft rotation speed sensor

236 BOMAG 008 911 57

Machine related electrics 9.7

1 Wiring loom, electrics box - front frame 5 Wiring loom, engine

2 Wiring loom, electrics box -central lubrication sys-
tem
3 Wiring loom, electrics box - solenoid valves for
travel
4 Wiring loom, electrics box - engine interface
6 M08, central lubrication system
7 B129, push button for transfer box
8 Y15, magnetic clutch for air conditioning system
9 R03, tank sensor

008 911 57 BOMAG 237

9.7 Machine related electrics

10 Y14, fuel pump for heating unit 13 B53, coolant temperature sensor
11 Y17, solenoid valves for reverse travel 14 Y133, solenoid valve wheel motor front right
12 Y16, solenoid valves for forward travel 15 Y132, solenoid valve wheel motor front left

B169, proximity switch steering stop left

B170, proximity switch steering stop right

238 BOMAG 008 911 57

Machine related electrics
1 Wiring loom, electrics box - rear frame
2 Wiring loom for light system
3 E57, headlight engine compartment left
4 E56, headlight engine compartment right
5 E27, working light rear left
008 911 57
9.7
6 E28, working light rear right
7 H14, backup alarm buzzer
8 B42, hydraulic oil differential pressure switch
9 B21, hydraulic oil filter differential pressure switch
10 B22, hydraulic oil filter differential pressure switch
BOMAG 239
9.7 Machine related electrics

11 B05, pressure switch for brake

12 Y04, brake solenoid valve
13 B122, hydraulic oil differential pressure switch
14 B75, pressure switch for refrigerant in air condi-
tioning
15 M26, cyclone separator
16 B55, coolant level sensor
17 B03, air filter vacuum switch
18 B116, air filter vacuum switch
19 R04, hydraulic oil temperature sensor
20 B20, hydraulic oil temperature switch
21 B19, magnetic dirt sensor
22 B25, pressure switch in return flow filter
23 B24, hydraulic oil float switch
24 Y135, solenoid valve wheel motor rear right
25 Y134, solenoid valve wheel motor rear left
26 Y93, solenoid valve steering front left
27 Y108, solenoid valve bucket up
28 Y102, solenoid valve for float position
29 B121, hydraulic oil differential pressure switch
30 Y92, solenoid valve steering front right
31 Y109, solenoid valve bucket down

240 BOMAG 008 911 57

 10 Air conditioning system

008 911 57 BOMAG 241

10.1 Physical basics

10.1 Physical basics A - heat absorption

In order to understand the working principle of an air B- Heat dissipation

conditioning system one must first become familiar
with the physical basics of such a system.
The four well known physical conditions of water apply
also for the refrigerant in the air conditioning system.

1. gaseous (invisible)

2. vaporous

3. liquid

4. solid

Fig. 2
Heat always flows from the warmer to the colder mat-
ter. Any matter consists of a mass of moving mole-
cules. The rapidly moving molecules or a warmer
matter dissipate part of their energy to the slower
moving molecules with less heat. The movement of
the molecules in the warmer matter becomes slower
and the molecules in the cooler matter are accelerat-
ed. This process continued, until all molecules in the
two matters move with identical speed. The matters
have then reached an identical temperature and the
transfer of heat stops.

Fig. 1
If the water in a container is heated up (absorption of
heat), the rising steam is visible. If the steam is heated
up further, due to the absorption of heat, the visible
steam will turn into invisible gas. This process is re-
versible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into
water and finally into ice.

242 BOMAG 008 911 57

Physical basics 10.1
Pressure and boiling point 4. If a fluid evaporates it requires a lot of heat, i.e. the
fluid thereby cools down the surrounding environment
The boiling point is the temperature at which fluid
(e.g. alcohol on skin)
changes to gaseous state.
Changing the pressure above a fluid also changes the
boiling point. It is a well known fact, that e.g. the lower i Note
the pressure applied to water, the lower the boiling At absolute pressure 0 bar correspond with an abso-
point. lute vacuum. The normal ambient pressure (overpres-
sure) corresponds with 1 bar absolute pressure. On
When looking at water, the following values do apply:
the scales of most pressure gauges 0 bar corre-
l Atmospheric pressure, boiling point 100°C sponds with an absolute pressure of 1 bar (indicated
l Overpressure 0.4 bar, boiling point 126°C by the statement -1 bar below the 0).
l Vacuum -0.6 bar, boiling point 71°C
For an optimal exchange of heat, liquid refrigerants
must have a low boiling point, so that they can absorb
and dissipate heat quickly.

Fig. 4 Pressure - Temperature Diagram

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

008 911 57 BOMAG 243

10.1 Physical basics

Excerpt from the wet steam table 1 R134a

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

244 BOMAG 008 911 57

Refrigerant R134a
10.2 Refrigerant R134a
General
The evaporation and condensation process is the
method commonly used in mobile air conditioning sys-
tems. The system in this case works with a substance
that boils at low temperature, a substance referred to
a refrigerant. The refrigerant used is tetrafluoroethane
R134a, which boils at a temperature of -26.5°C and
under a steam pressure of 1 bar.
Although the refrigerant circuit is a hermetically closed
loop, the system loses approx. 100g of refrigerant
over the course of 1 year by diffusion through hoses,
pipes and seals, even though the system is free of
leaks. If too much refrigerant is lost the cooling power
of the system will drop.
Physical data of the refrigerant R134a
Chemical formula:
CH2F-CF3 or CF3-CH2F
Chemical designation:
Tetrafluoroethane
Boiling point at 1 bar:
- 26.5 °C
Solidification point:
-101.6 °C
Critical temperature:
100,6 °C
Critical pressure:
40.56 bar (absolute)
Critical point:
Critical point (critical temperature and critical pres-
sure) means that above this point there is no separat-
ing interface between liquid and gas. Above its critical
point any substance is gaseous. At temperatures be-
low the critical point all refrigerant types in pressure
containers have a liquid and a gaseous phase, i.e. a
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature.
008 911 57 BOMAG
10.2
Characteristics of the refrigerant R134a:
Refrigerant R134a is currently available under the fol-
lowing trade marks.
H-FKW 134a
SUVA 134a
KLEA 134a
Colour:
Refrigerant in form of vapour or liquid is colourless as
water. The gas is invisible. Only the bordering layer
between gas and liquid is visible. (Fluid level in rising
pipe of filling cylinder or bubbles in inspection glass).
In the inspection glass the liquid refrigerant R134a
may appear coloured (milky). This turbidity results
from partially dissolved refrigeration oil and is no indi-
cator for a fault.
Steam pressure:
In an incompletely filled, closed container, vaporous
refrigerant will volatilize from the surface in the same
quantity that will turn liquid in combination with steam
particles. This state of equilibrium occurs under pres-
sure and is frequently referred to as steam pressure.
The steam pressure is independent from the temper-
ature.
Physical properties of R134a:
The steam pressure curves of R134a and other refrig-
erants are partly very similar, making a clear differen-
tiation solely by pressure impossible. With R 134a the
compressor is lubricated by special synthetic refriger-
ation oils, e.g. PAG-oils (polyalkylene glycol oils).
Behaviour with metals:
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
compounds, leads to aggressiveness against certain
metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.
Critical temperature / critical pressure:
Up to a gas pressure of 39.5 bar overpressure (this
corresponds with a temperature of 101 °C) the refrig-
erant R134a remains chemically stable, above this
temperature the refrigerant decomposes (see com-
bustibility).
Water content:
In liquid refrigerant water can only be dissolved in very
low quantities. In contrast to this refrigerant steam
mixes with water steam at any ratio. If the dryer in the
245
10.3
liquid container has absorbed approx. 8 gr. of water,
the refrigerant circuit transports possibly existing wa-
ter in form of droplets. This water flows to the nozzle
of the expansion valve and turns to ice. The air condi-
tioning system stops cooling. Water destroys the air
conditioning system, because under high pressures
and temperatures and in connection with other con-
taminants it forms acids.
Inflammability:
Refrigerant is not inflammable. On the contrary, it has
fire inhibiting or fire extinguishing properties. Refriger-
ant is decomposed by flames or glowing surfaces. Ul-
traviolet light also cracks refrigerant (caused by
electric welding). This results in toxic fission products,
these must not be inhaled. However, irritation of the
mucous membranes is an early and in-time warning.
Filling factor:
In a container there must be a steam space above the
liquid space. The liquid expands with increasing tem-
perature. The steam filled space becomes smaller.
From a certain time on the container will be filled with
just liquid. After this only a minor temperature in-
crease is enough to generate very high pressures in
the container, because the liquid would like to expand,
but there is no more room. The related forces are high
enough to cause the container to burst. In order to
avoid overfilling of a container the pressure gas direc-
tive clearly specifies how many kilograms of refriger-
ant may be filled into the container per litre volume.
Multiplied with the internal volume this "filling factor"
determines the permissible filling capacity For refrig-
erants used in motor vehicles it is 1.15 kg/l.
Environmental aspects
The contribution of R134a to the greenhouse effect is
by factor 10 smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for
newly produced construction equipment were succes-
sively converted to refrigerant R134a. This refrigerant
does not contain any chlorine and is thus harmless for
the ozone layer. Until approx. 1992 air conditioning
systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decompo-
sition potential and also a potential to amplify the
greenhouse effect. Conversion programs for existing
old systems with the ozone damaging R12 are in ef-
fect. For reasons of protecting the environment refrig-
erant must not be discharged into the atmosphere.
246 BOMAG
Compressor oil / refrigeration oil
10.3 Compressor oil / refrigeration
oil
The compressor oil lubricates the movable parts in the
compressor, seals e.g. the gap between piston and
cylinder inside the compressor to prevent refrigerant
loss and prevents other seals in the system from dry-
ing up.
Part of the compressor oil dissolves in the refrigerant
until saturation is reached, so that a gas mixture of re-
frigerant, water steam, compressor oil and contrast
agent circulates through the system.
Compressor oil (the oil quantity should be 10 % of the
refrigerant weight) mixes with the refrigerant and cir-
culates permanently through the system.
In connection with R134a- air conditioning systems
special synthetic compressor oils, e.g. polyalkylene
glycol (PAG) oils, are used. This is necessary, be-
cause e.g. mineral oil does not mix with R134a. Apart
from this, the materials in the R134a air conditioning
system may be attacked when the mixture is flowing
through the refrigerant circuit under high pressure and
at high temperatures or if the lubrication film in the
compressor tears off. The use of non-permitted oils
can cause damage to the air conditioning system, you
should therefore only used the approved oils.
Properties of compressor oil / refrigeration oil:
The most important properties are high solvency in
connection with refrigerants, good lubrication charac-
teristics, that they are free of acids and their low water
content. For this purpose only certain oils can be
used. PAG-oils suitable for use with refrigerant R134a
are highly hygroscopic and will not mix with other oil.
As a protection against the invasion of moisture drums
must immediately be closed again after they had been
opened. Compressor oil ages under the effect of
moisture and acids, becomes dark, viscous and ag-
gressive against metals.
008 911 57
Working principle of the air conditioning system
10.4 Working principle of the air
conditioning system
All air conditioning systems are based on the same
principle. They extract heat from the surrounding en-
vironment. Everybody knows the effect: if a sweating
body is exposed to wind it will cool down, because
heat is extracted. For this purpose a refrigerant circu-
lates in a closed circuit inside the vehicle. This refrig-
erant thereby continuously changes its physical state
between liquid and gaseous.
Fig. 1 Principle sketch of an air conditioning system
An engine driven compressor (1) draws in gaseous re-
frigerant from the evaporator (5) and compresses it.
During this process the temperature of the refrigerant
increases tremendously.
The refrigerant vapour is then pumped to the con-
denser (2). This condenser is arranged directly in front
of the vehicle radiator, so that a sufficient air flow is as-
sured. In the condenser (2) the gas is cooled down
and consequently liquefied.
In the dryer / liquid container (3) the refrigerant is then
collected and freed of moisture and contaminants.
The expansion valve (4) regulates the flow rate from
the dryer / liquid container (3) back to the evaporator
(5) and the circuit starts again.
008 911 57 BOMAG
10.4
10.5 Monitoring devices
Pressure switch
The pressure switch (8) is used as monitoring feature
for too high and too low pressures. The switching con-
tacts (4 and 5) effect the magnetic clutch of the com-
pressor via a relay (6).
If the system pressure increases excessively, e.g. be-
cause of a excessively soiled condenser, a failed fan
or a defective expansion valve, the high pressure con-
tact (5) will cut off the electric power supply to the
magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off
pressure by the set differential pressure, the magnetic
clutch of the compressor is switched on again.
The low pressure contact (4) interrupts the electric
power supply to the magnetic clutch when the set
pressure is fallen short of (possible causes: lack of re-
frigerant, defective expansion valve, too low heat
load, defective evaporator fan, ...). Since the refriger-
ant R134a has an evaporation temperature of 0 °C at
an overpressure of 2 bar, the low pressure contact (4)
is set to approx. 1.5 bar to avoid icing. The switch on
pressure is 0.5 to 2 bar higher than the shut-off pres-
sure (depending on system, see description of com-
ponents.)
Thermostat
A frost protection thermostat (3) protects the evapora-
tor against icing. Similar to the pressure switch, the
thermostat activates or deactivates the magnetic
clutch for the compressor. Depending on the design,
the feeler of the temperature control is mounted be-
tween the fins of the evaporator or attached to the
evaporator outlet (suction side). With fixed tempera-
ture controls the control switches the compressor off
at about 1 °C and back on again at about 2.5°C to 5.5
°C (depending on system, see description of compo-
nents.)
With adjustable temperature regulators the switching
point can be changed so that the compressor is al-
ready shut down at higher temperatures. This enables
regulation of the air temperature.
247
10.5 Monitoring devices

Monitoring chain

Fig. 2 Monitoring chain consisting of:

l 1 Switch
l 2 Fuse
l 3 Thermostat
l 4 Low pressure switch contact
l 5 High pressure switch contact
l
6 Relay
l
7 Connection for magnetic clutch
l
8 Pressure switch

248 BOMAG 008 911 57

Description of components 10.6
10.6 Description of components

Compressor

Fig. 1 Refrigerant compressor Oil: PAG SP-20 (H14-003-404)

The compressor is mounted to the engine and has the
duty to build up the refrigerant pressure required for
the function of the system. Coupling and decoupling is
accomplished by an electromagnetically controlled
mechanical clutch (Y15), which is integrated in the V-
belt pulley of the compressor.
The refrigerant compressor is a 7-cylinder compres-
sor in swash plate design.
The gaseous refrigerant enters into the compressor
through the cylinder heads at the end of the compres-
sor and is delivered to the condensers in desnified
state.
The oil sump of the compressor is filled with refrigera-
tion oil up to level of the filler and level inspection bore.
An internal gear pump at the end of the drive shaft de-
livers this oil to the bearing locations inside the com-
pressor for lubrication.

Compressor data
Displacement: 155 cm²
Weight: 6,9 kg
max. rpm: 6000
Sense of rotation: cw
Refrigerant: R134a
Oil quantity (scope of delivery): 207 gr

008 911 57 BOMAG 249

10.6 Description of components

Fig. 2 Compressor mounting, bottom view

Pos. Designation Pos. ii electric wiring diagram Measuring value

1 Pressure side filling
port
2 Suction side filling
port
3 Plug connection X14 0-24 Volt
4 Magnetic clutch Y15 24 Volt, 1.75 Amp.

The service valves are installed directly on the com-
pressor. These are used to e.g. evacuate and fill the
system.
Two manual shut-off valves are also installed here.
These valves can be used e.g. in case of a compres-
sor failure. The compressor can be replaced after
closing the valves. After completion of all repair work
the valves must be reopened, so that the system is
ready for operation without the need of refilling.
oil lost by exchanging the components, must be
replaced with fresh oil.
The actual quantity depends on the amount of oil
that may have been lost in connection with the
possible replacement of other components.
Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.

! Caution The following table shows how much compressor oil /

refrigeration oil will be lost in connection with various
The compressor oil level must be checked after
types of work on the air conditioning system.
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

250 BOMAG 008 911 57

Description of components 10.6
Reason of oil loss Amount of oil lost Condenser
Loss when emptying approx. 15 gr
Defective A/C hose approx. 30 gr
Hose change approx. 15 gr
Replacement of condens- approx. 30 gr
er
Replacement of evapora- approx. 30 gr
tor
Replacement of liquid con- approx. 30 gr
tainer
Replacement of expan- approx. 15 gr
sion valve

! Caution
Please bear in mind, that the new compressor is
delivered with a filling of 207 gr. compressor oil. Fig. 1 Condensers
To avoid excessive oil in the A/C-system and thus The 2 condensers are mounted on a foldable frame in
a poor cooling effect, the oil level in the A/C-sys- front of the combustion air intake opening on the
tem must be adjusted accordingly. ROPS. They dissipate heat energy from the system
The quantity depends on the amount of oil that into the surrounding air and liquefiy the gaseous re-
may have been lost in connection with the possi- frigerant.
ble replacement of other components.
The compressor oil quantity must be 10% of the i Note
refrigerant quantity in the complete system. The fins must be free of dirt and damage.
With a refrigerant filling of 1100 gr. the system re-
quires a compressor oil / refrigerant oil filling of ! Caution
100 gr.
When replacing a heat exchanger, e.g. evaporator
Procedure: or condenser, any compressor oil lost by ex-
Drain and measure the compressor oil from the changing the components, must be replaced with
old compressor. fresh oil.
Drain the compressor oil from the new compres-
sor and only fill in the exact quantity that had been
drained out of the old compressor. The compres-
sor oil from the new compressor can be used for
this purpose.

i Note
Topping up compressor oil / refrigeration oil is possi-
ble on a pressureless compressor directly into the oil
pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
into the pressure side of the refrigeration system dur-
ing the evacuation process.

008 911 57 BOMAG 251

10.6
Dryer / filter / fluid container / inspection
glass
Fig. 1
Dryer / filter
The fluid container collects the fluid drops and passes
these then as a constant flow to the expansion valve.
Moisture that has entered during assembly of the re-
frigerant circuit is absorbed by a dryer in the fluid con-
tainer.
At evaporation temperatures below zero the refriger-
ant will deposit previously absorbed moisture on the
expansion valve, where this water turns into ice and
thus adversely affects the controllability of the expan-
sion valve. Moreover, moisture in the refrigerant cir-
cuit causes corrosion, forms acids and enters into
chemical compositions.
Inside the refrigerant container the heavy liquid refrig-
erant collects in the lower part of the container, flows
through a rising pipe to the outlet marked "A" and thus
ensures bubble free operation of the expansion valve.
i Note
Since the absorbing capacity of this filter/dryer is lim-
ited, it must be changed within certain service inter-
vals. We recommend to replace it 1 x per years,
before the start of the season.
! Caution
The filter/dryer must generally be replaced when-
ever opening the refrigerant circuit, because
moisture will enter in such a case.
This requires emptying the air conditioning sys-
tem!
Installation position:
The arrow marks on the filter/dryer must point in
flow direction, i.e. towards the expansion valve.
Filter/dryer cannot be treated for further use!
252 BOMAG
Description of components
Safety valve
Fig. 2
The fluid container is equipped with a safety valve.
Response pressure 32 +/- 4 bar
Tightening torque 10 - 15 Nm
Inspection glass
Fig. 3
During operation the refrigerant must flow through the
inspection glass without air bubbles. In most cases
the presence of air bubbles is a sign for a too low re-
frigerant level in the system. Apart from this, the refrig-
erant may not sufficiently condense as a result of a
soiled evaporator or a defective condenser fan and
the fluid level in the refrigerant container may drop
down to a level, at which gaseous refrigerant could
flow through the rising tube to the inspection glass.
This results in abnormally high temperatures in and on
the fluid lines (between refrigerant container and ex-
pansion valve), as well as very high pressures in the
pressure side.
However, incorrect evacuation or filling may also be
the reason for air entering into the system and since
air cannot be condensed, one will not be able to get
rid of these bubbles by topping up refrigerant. In this
case the air conditioning system needs to be evacuat-
ed and refilled.
008 911 57
Description of components 10.6
i Note Pressure switch
Air in the system is characterized by high pressures
and temperatures.
On R134a refrigeration systems from KONVEKTA the
inspection glasses are equipped with moisture indica-
tors. In addition to the float, the dryer/collector/inspec-
tion glass combination has an indicator pearl
integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection
glass and should only be checked after approx. 5 min-
utes continuous operation, because the refrigerant
must first evenly distribute all over the system.

! Danger
In case of mechanical damage or corrosion on
this pressure container this collector unit must be
replaced, to avoid bursting and further damage.
Fig. 1
After a minimum pressure is reached in the low pres-
sure side or a maximum pressure in the high pressure
side, the pressure switch (B75) will switch of the mag-
netic clutch of the compressor, thus to avoid destruc-
tion of system components by excessive pressure or
drawing in external gases and foreign matter as a re-
sult 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
Overpressure on: 18,0 ±1,5 bar

008 911 57 BOMAG 253

10.6
Expansion valve
Fig. 1 Expansion valve
The expansion valve (1) is located inside the cab on
the blower box. The expansion valve always allows a
small amount of the high pressure liquefied refrigerant
to flow into the evaporator, which has a much lower
pressure. This lower pressure causes these liquid re-
frigerant to expand and to evaporate to gaseous state.
The heat required for this evaporation process is tak-
en from the ambient air through the lamellas and sup-
plied to the refrigerant. This is the so-called cooling
effect.
The thermostatic expansion valve operates with an
external pressure compensation. This type of expan-
sion valve works with high accuracy, because it uses
pressure and temperature at the evaporator outlet and
adjusts and overheating of approx. 7 K. The already
installed expansion valves and the ones delivered as
spare parts have this overheating value pre-set. In or-
der to prevent a loss in performance or compressor
damage you should only use original expansion
valves, because adjusting expansion valves takes a
lot of time and care.
i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+
254 BOMAG
Description of components
Evaporator
Fig. 1 Evaporator
The evaporator is located inside the cab in the blower
box. It consists of a heat exchanger (inside air - refrig-
erant), with refrigerant flowing to a pipe system with
cooling flanges.
As with the condenser, correct operation of all fans
and cleanliness of the fins must be assured.
Air conditioning systems have a circulation air filter
mounted in the air flow in front of the evaporator,
which should be cleaned or changed by the operator,
depending on the amount of dirt.
Fig. 2 Changing the circulation air filter
l
Remove the slotted cover from the console behind
the driver’s seat.
l Remove both circulation air filters and insert the
new circulation air filters (Fig. 2) .
l Fasten the slotted cover to the console.
A condensation water filter is mounted in the air flow
after the evaporator. This filter has the function to col-
lect the water that has condensed from the air in the
evaporator block and to discharge this water into the
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.
008 911 57
Description of components 10.6
! Caution Defroster thermostat
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.

Fig. 1 Defroster thermostat

The feeler of a defroster thermostat (B117) to switch
off the magnetic clutch in case of icing up or to switch
the clutch back on after defrosting, is mounted on the
evaporator. The correct adjustment of the defroster
thermostat as well as the correct feeler assembly
should be checked during maintenance.
Switching point on: + 1°C (± 1°C)
Switching point off: + 5,5°C (± 1°C)

i Note
It is very important that the feeler is mounted down-
stream of the evaporator, but before the pressure sen-
sor, in countercurrent direction, with full length and
insulated against the outside temperature.

008 911 57 BOMAG 255

10.6 Description of components

Blower with rotary speed module Solenoid valve, heating

The heating valve (Y138) is a black/white valve and is
opened by the Climatronic control with 24V. When the
voltage supply is switched off, the applied water pres-
sure will close the valve as a pilot controlled valve. It
is thus very important to maintain the prescribed flow
direction (arrow on housing).

Fig. 1 Radial twin blower

The radial twin blower (E37) draws in air from inside
the cabin through the circulation air filter. The drawn in
air is cooled down in the evaporator fins and guided
through air ducts and nozzles back into the cabin.
The rotary speed module (blower module, A53) is Fig. 2
mounted on the blower housing. This module serves
Intended intermediate positions are realized via tem-
the purpose of converting the PWM current signals
poral cycling. The length of the total interval is approx.
from the Climatronic control into corresponding volt-
10 seconds. The temporal proportion of "open" is be-
age signals for the blower motor. The fan voltage
tween 30-100%.
complies with the fan speed shown in the display.

Fig. 3 Solenoid valve for heating Y138

256 BOMAG 008 911 57

Description of components 10.6
Pipes and hoses
Pipes and hoses in air conditioning systems must
meet very high requirements with respect to resist-
ance against heat and pressure. The requirements
concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through
the hose material, are very high. Pipes and hoses to
be used must therefore be specially made for air con-
ditioning purposes. For this reason the hoses have an
inside lining of butyl rubber and an outside coating of
EDPM rubber. Hose sections exposed to heat are pro-
vided with a special heat insulation.
O-rings are made of a special type of chloroprene rub-
ber (neoprene). Before assembly of the air condition-
ing system these O-rings must be lubricated with
compressor oil / refrigeration oil. The O-rings must al-
ways be replaced when assembling A/C-components.

Recommended tightening torques for O-ring

sealed fittings

Thread Spanner width Torque

5/8“ 17 or 19 13,6 - 20,3 Nm
3/4“ 32,5 - 39,3 Nm
7/8“ 27 35,3 - 42,0 Nm
1 1/16“ 32 40,7 - 47,5 Nm
M30X2 36 105,0 - 115,0 Nm
M36X2 41 165,0 - 175,0 Nm
Bending radii for air conditioning hoses

Hose type Nominal width Bending radius

GH 134 NW8 min. 50 mm
GH 134 NW10 min. 65 mm
GH 134 NW12 min. 75 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm

008 911 57 BOMAG 257

10.7 Climatronic control

10.7 Climatronic control

The Climatronic control is integrated in the housing of
the control unit.

Fig. 3 Sensors
The two sensors are technically identical, they only
differ by their colour identification:
Room temperature sensor (B29): blue colour mark,
Fig. 1 Front view of Climatronic control
Blow out temperature sensor (B119): yellow colour
mark.
These sensors are NTC-elements, i.e. the electric re-
sistance drops with increasing temperature.

Designation Measuring value

Blow out tempera- B118 55kΩ at -10°C
ture sensor 32kΩ at 0°C
19kΩ at +10°C
Fig. 2 Backside with connection terminal
12kΩ at +20°C
When the ignition is switched on the Climatronic con-
10kΩ at +25°C
trol is supplied with vehicle voltage via terminal X26:1
Room temperature B29 55kΩ at -10°C
and can be switched on.
sensor 32kΩ at 0°C
As long as the engine is not running, no signal is ap-
plied to terminal X26:4 on the control. After a period of 19kΩ at +10°C
10 minutes without the engine running the Climatronic 12kΩ at +20°C
limits the blower speed to 30% to prevent unneces-
10kΩ at +25°C
sary discharging of the battery.
In automatic mode the control regulates the cabin
temperature. This is accomplished with the help of the
two sensors:
l Room temperature sensor B29 (Fig. 3) under the
circulation filters.
l
Blow out temperature sensor B118 (Fig. 3).
The two sensor signals are fault monitored, i.e. in
case of cable breakage, short circuit or disconnected
sensors a fault will be displayed and the Climatronic
will be out of servise.
The digital output signals for:
l the magnetic clutch of the compressor (Y15) and
l the solenoid valve for heating (Y138)
as well as the analog PWM-signal
l for the blower speed module
are generated from the sensor signals.

258 BOMAG 008 911 57

Climatronic control 10.7
Various functions of control logic
This point deals with special control steps, which are
not self explanatory, and with technical backgrounds
of Climatronic functions, which are worth knowing.

Automatic operation

Fig. 4
(LED under the hand 7 (Fig. 4) off, nominal tempera-
ture in display). In this position the Climatronic control
regulates the blower speed in dependence on the
temperature difference between nominal and actual
room temperature. Furthermore, heating valve and
compressor clutch (only in air conditioning operation)
are automatically switched on or off as required, in or-
der to achieve the desired room temperature. If the
engine is still cold while heating is required, the control
recognizes this fact by the blow out temperature on
the heater box; the control will then limit the blower
speed until the engine is warm, thus preventing that
too much cold air is blown into the cabin.

Fig. 5
Air conditioning operation: In order to achieve a
cooling effect, the compressor outlet of the control
must be manually released also in automatic opera-
tion by pressing button 3 (Fig. 5). (LED below crystal
(5) on!). The compressor outlet is in this case not per-
manently supplied with current (except REHEAT op-
eration), but only when the control supplies the output
(X26:8) due to the difference between nominal and
actual temperature. The compressor can only start
running when the thermostat (B117) and the pressure
switch (B75) are closed.

008 911 57 BOMAG 259

10.7 Climatronic control

Manual operation of heating Manual blower speed setting

Fig. 6 Fig. 7

The automatic control of the heating valve can be Automatic blower speed control can be disabled with
switched off with push button 12 (Fig. 6) (manual heat- button 10 (Fig. 7) (LED below hand (7) lights), temper-
er operation, the display shows ’H’ and the LED below ature is still displayed). However, the temperature
the hand lights). The automatic blower control is control remains active as long as air conditioning op-
switched off at the same time. In manual heater oper- eration and heater operation remain switched on. In
ation the heating valve is set to a opening interval as this operating mode the +/- buttons are used to set the
shown in the bar graph (13), which can be changed blower speed manually.
with the +/- buttons (2,4). The number of displayed
bars indicates the opening time in percent (e.g.
4 bars = 40%: approx. 4 seconds valve energized/
open, approx. 6 seconds valve dead/closed etc).
When operating the blower button (10) the ’H’ will dis-
appear in the display, the nominal temperature will ap-
pear, the LED below the hand stays on (as with
manual blower speed setting, see below), however,
the manual heating operation remains active. Manual
heater operation can only be switched over to auto-
matic heater operation by pressing the button (12)
again. In manual heater operation the compressor
control remains active, i.e. in summer the system will
continue to try to achieve the nominal temperature.

260 BOMAG 008 911 57

Climatronic control 10.7
REHEAT function (dehumidification function) Circulation air operation

Fig. 8 Fig. 9
When pressing button 11 (Fig. 8), the blower is fixed Button 9 (Fig. 9) can theoretically be used to toggle
to maximum speed and the compressor output is per- between circulation and fresh air operation, the button
manently switched (however, the compressor is is - except the LED display - ineffective, the machines
switched off by the thermostat if there is a risk of the are only prepared for this function electrically, but not
evaporator icing up). The display shows ’rH’. Howev- the air guidance.
er, the heater control function remains active in order
to maintain the previously set nominal temperature, if
this should be necessary. The REHEAT function is
mainyl used to dehumidify the cabin (steamed up win-
dows).

008 911 57 BOMAG 261

10.7
Error messages
Faulty room temperature sensor
Fig. 10
’F0’ flashes in display. The Climatronic is unable to
work without the actual temperature value and is
therefore out of function when this error message is
displayed. The Climatronic is only operable again af-
ter this fault (cable breakage, short circuit, sensor not
connected) has been rectified.
262
Climatronic control
Faulty blow out temperature sensor
Fig. 11
’F1’ flashes in the display. The Climatronic is unable
to work without the blow out temperature value and is
therefore out of function when this error message is
displayed. The Climatronic is only operable again af-
ter this fault (cable breakage, short circuit, sensor not
connected) has been rectified.
BOMAG 008 911 57
Checking the compressor oil level 10.8
10.8 Checking the compressor oil
level

Checking the compressor oil level / refrig-

eration oil level

!Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only compressor oil / re-
frigeration oil PAG SP-20 (H14-003-404).
l Run the compressor for 10 minutes at engine idle
speed.
l In order to avoid any compressor oil losses you
should slowly drain all refrigerant from the air condi- Fig. 2
tioning system. l Turn the nut that hold the armature clockwise with a
socket wrench, until the counterweight is correctly
positioned.

i Note
2 o'clock position with inclination to the right (Fig. 2).
10 o'clock position with inclination to the left
l Insert the oil dipstick.
l Pull out the dipstick and count the notches covered
by oil.
l Drain off oil or fill up as specified in the table.

Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
Fig. 1
Fastening angle (de- Oil dipstick in incre-
l Measure the fastening angle (Fig. 1) of the com- gree) ments
pressor (oil plug at top) 0 5-7
l
Remove the oil filler plug. 10 6-8
20 7-9
30 8-10
40 9-11
50 10-12
60 11-13
90 16-18
l
Screw the oil filler plug back in.

! Caution
The contact area must be clean and should be free
of damage.
Use a new O-ring.
Tightening torque 15 to 25 Nm
l Refill the air conditioning system.

008 911 57 BOMAG 263

10.9 Checking the magnetic clutch

10.9 Checking the magnetic clutch i Note

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

Cross-section of magnetic clutch

Fig. 3 shows a cross-section of the magnetic clutch. If
the coil (7) is not supplied with operating voltage,
there is no contact between the front plate of the
clutch (1) and the V-belt pulley (2). A spring presses
the front plate away from the belt pulley. The V-belt
pulley rotates with the bearing (3) in idle speed, the
compressor does not work. When the coil is supplied
with operating voltage (12 or 24 V), a magnetic field is
generated and pulls the front plate of the clutch. Both
front plate and compressor shaft (8) are then driven by
the V-belt pulley, the compressor works.

Fig. 1

i Note
at 12 Volt vehicle voltage approx. 3.5 Amp.
at 24 Volt vehicle voltage approx. 1.75 Amp.
Overcurrent indicates a short circuit inside the mag-
netic coil.
No current indicates an interrupted electric circuit.

Fig. 3 Cross-section of magnetic clutch

Fig. 2 Measuring the air gap

l Measure the air gap on the magnetic clutch be-
tween V-belt pulley (2) and thrust plate (1).

264 BOMAG 008 911 57

Inspection and maintenance work 10.10
10.10Inspection and maintenance 10.11Service the air conditioning
work (summer operation)
l Visual inspection of the complete system for dam- The air conditioning unit is attached to the ROPS
age. and can be access from outside for service work.
l Check the compressor mounting bracket on the ve-
hicle engine for tight fit and damage. !Caution
l Check the condition, alignment and tightness of the Under very dusty conditions clean every day in or-
V-belt. der to maintain the cooling power of the air condi-
l
Check the routing of refrigerant hoses and cables in tioning system.
the area of the vehicle engine and transmission, as
well as on the chassis for chafing and rectify any de- Danger
!
tected faults. Ensure sufficient clearance to hot
Danger of accident!
parts, such as the exhaust; install a protective
shield, if necessary. Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
l Check the routing of hoses and hoses on the at-
age or explosion of the system.
tachment box or in the cabin.
l Check all hose and screw fittings for leaks.
Cleaning the condenser
l Check the fastening of the condenser unit.
l
Clean the condenser fins, replace the condenser
block if damaged fins are found.
l
Check the fastening of the evaporator unit.
l
Check the function of evaporator and condenser
fans.
l
Check the electric control panel. If discolorations on
conductors are found, these should be replaced
and possibly also the corresponding relays.
l
Switch on the cooling system and check the refrig-
erant level.
l
Filter/dryer and filter/dryer/fluid container combina-
tions must always be replaced after opening the re- Fig. 4
frigerant circuit. If these are in service for more than l Fold the air intake grid (Fig. 4) back.
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.
l Measure the temperature on the evaporator: Meas-
ure the intake air temperature - Measure the blow
out air temperature - The temperature difference
should be at least 8-10 K.
l
Measuring the pressure in the refrigerant circuit

Fig. 5
l Clean the condenser fins on front and back with
compressed air or cold water (Fig. 5).

!Caution
During cleaning work do not damage the cooling
fins and realign bent fins.

008 911 57 BOMAG 265

10.11 Service the air conditioning (summer operation)

Checking the refrigerant level

l
Start the engine.

Fig. 9
l Check whether the white float (Fig. 9) inside the in-
spection glass of the drier/collector unit floats right
Fig. 6 at the top.
l Switching on the control unit (Fig. 6).
i Note
The refrigerant level is correct.

Fig. 7
l
Start operation of the air conditioning (Fig. 7).
Fig. 10
l
If the white float (Fig. 10) inside the inspection glass
of the drier/collector unit floats at the bottom, inform
the service department.

i Note
The refrigerant level is not correct.
l Refrigerant must be filled up, if necessary check the
air conditioning system for leaks.

Fig. 8
l Open the air outlet nozzles (Fig. 8).
l Check, whether the outflowing air is noticeably cool-
er.

i Note
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on.

266 BOMAG 008 911 57

Service the air conditioning (summer operation) 10.11
Checking the moisture level of the drying
agent

Fig. 12
l Check the drier/collector unit (Fig. 12) for mechani-
cal damage or rust.
Fig. 11
l Check the moisture indication pearl (Fig. 11) inside
the inspection glass of the drier/collector unit.
orange = drying agent o.k.
colorless = moisture level of drying agent too high.
l Inform the service department. Replace drier/col-
lector unit, check air conditioning system.

Caution
!

Have the drier/collector unit replaced by the serv-

ice department every year before the operating
season.

Checking the condition of the drier/col-

lector unit

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

! Danger

Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.

008 911 57 BOMAG 267

10.12 Check condition and tension of refrigerant compressor V-belt,

10.12Check condition and tension l Turn down tensioning screw (4) in direction of ar-
row, until the correct V-belt tension is reached.
of refrigerant compressor V- l Retighten screws and counter nut.
belt, replace the V-belt
Changing the V-belt
Danger
!

Danger of injury!
Work on the V-belt must only be performed with
the engine shut down.

Checking the V-belt

Fig. 13
l
Inspect the entire circumference of the V-belt (Fig.
13) visually for damage and cracks. Replace dam-
aged or cracked V-belts.
l
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 nec-
essary.
Fig. 15
l Remove the V-belt of the fan drive.
l Slacken the bearing screw 2 (Fig. 15) for the com-
pressor bracket.
l Slightly loosen the hexagon screw (1) on the slot for
the compressor bracket.
l Loosen the counter nut (3).
l Turn tensioning screw (4) in direction of arrow to the
stop.
l Take the old V-belt off the V-belt pulley.
l Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.
l
Reinstall and tension the fan drive V-belt.

Retightening the V-belt

i Note
Retighten new V-belts after a running time of 15 min-
utes.

Fig. 14
l Slacken the bearing screw 2 (Fig. 14) for the com-
pressor bracket.
l Slightly loosen the hexagon screw (1) on the slot for
the compressor bracket.
l Loosen the counter nut (3).

268 BOMAG 008 911 57

Drying and evacuation
10.13Drying and evacuation
Evacuation of air conditioning systems using R-type
refrigerants not only has the purpose of emptying the
system of all air before filling in refrigerant, but also to
verify the leak tightness over a longer lifetime in the
achieved vacuum. However, the most important factor
in this work step is the drying of the system.
Any water residues in the refrigerant circuit will com-
bine with the refrigerant, which will lead to the previ-
ously described consequential damage.
Vacuum pumps with a capacity of more than 100 l/min
and a final pressure of less than 30 micron, i.e. 0.039
mbar should be used to evacuate the refrigeration
system.
The refrigerant compressor is not suitable for the pur-
pose of evacuation, because it is not able to achieve
a sufficient final vacuum and, apart from this, may be
mechanically damaged because of a lack of lubrica-
tion when running empty during evacuation.
It is common practice to evacuate the refrigeration
system to a final vacuum of 1 Torr, i.e. 1.33 mbar.
An exact time for evacuation and drying cannot be
predicted. It can only be determined by means of a
vacuum meter. However, if there is no vacuum meter
at hand it is generally better to evacuate 1 hour longer
than 1 hour too less.
Function drying:
Under normal ambient pressure (1.013 mbar) evapo-
rates absolute at 100° C. If the pressure is reduced,
water will already evaporate, e.g. under a pressure of
10 mbar, at an ambient temperature of almost 7°C,
but the water will not evaporate all at once. Since it is
very difficult to separate the steam from the vacuum in
the system, the evacuation process is supported by
the co-called vacuum breaking (filling the circuit with
dried nitrogen). With vacuum breaking the filled in
dried nitrogen absorbs the moisture in the refrigerant
circuit, which can then be easily discharged together
with the nitrogen.
008 911 57 BOMAG
10.13
10.14Emptying in case of repair
For repair work the air conditioning systems must very
often be emptied of all refrigerant.
Especially with expensive refrigerants and larger
amounts of oil it may be necessary to keep the refrig-
erant for later use.
For later use these refrigerants must be drawn out
with suitable equipment and intermediately stored in
collecting containers.
Environment
Contaminated refrigerant must be disposed of en-
vironmentally
Releasing refrigerant into the atmosphere is pro-
hibited (see restrictive injunction concerning
CFC, day of enforcement 01. 08. 1991, § 8)
! Danger
For draining refrigeration systems you should not
simply use any delivery containers, but only ap-
propriate pressure bottles, which must be special-
ly marked and should comply with the pressure
gas directive.
When transferring refrigerant you must make sure
that the bottle does not contain more than the per-
mitted amount of refrigerant in litres and has suf-
ficient gas space for expansion (filling factor: 0,7).
In order to reduce the evacuation period in case of
short repairs, you may fill the refrigerant circuit with
approx. 0.5 bar nitrogen when opening. This ensures
that nitrogen will flow out of the refrigerant circuit while
it is open and no air or moisture can enter. However,
the necessity for vacuum generation and a dryer
change remains.
269
10.15 Leak test

10.15Leak test

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

Leak test with electronic leak tester

Fig. 1 Electronic leak tester

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

Leak test with soap bubbles

Fig. 2 Soap bubble test

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

270 BOMAG 008 911 57

Filling instructions 10.16
10.16Filling instructions

Filling of refrigerant into the dried, vented and oil filed

machines takes place under various conditions.
In most large series production facilities highly compli-
cated equipment is available for this purpose, where-
as individual machines at the place of installation must
be filled directly from the refrigerant container.
Liquid refrigerant is only used to pre-fill the pressure
side of the evacuated refrigeration system (protective
filling).
After switching the refrigeration system on and watch-
ing the inspection glass, gaseous refrigerant can be
filled into the system while the engine is running, if the
refrigerant level is found to be too low (gas bubbles in
the inspection glass).

! Caution
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from
the refrigerant bottle care must be taken not to overfill
the system. As an additional control and for statistical
purposes, e.g. for refilling, it is important to write down
the weight of the filled in refrigerant.
With correct operation of the air conditioning the re-
frigerant container should be about 1/3 filled with liq-
uid refrigerant, the evaporator should be maximally
filled at the calculated evaporation temperature, i.e.
the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the
pressure gauge.

i Note
White frost on the suction line is no measure for as-
sessing the filling.

008 911 57 BOMAG 271

10.16 Filling instructions

Fig. 1 10 Filter dryer

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

272 BOMAG 008 911 57

Filling instructions
19 Pressure reducing valve
20 Vacuum pump
21 Nitrogen bottle
22 Refrigerant bottle
23 Pressure gauge bar
Filling instructions
1 Connect the service adapter with the blue hand
wheel in the suction side.
2 Connect the service adapter with the red hand
wheel in the pressure side (the hand wheels on
the service adapters must be fully backed out - left
hand stop)
3 Connect the blue suction hose below the blue
hand wheel on the pressure gauge bar to the blue
service adapter.
4 Connect the red pressure hose below the red
hand wheel on the pressure gauge bar to the red
service adapter.
5 Connect the yellow hose below the yellow hand
wheel on the manometer bar to the 2-stage vacu-
um pump.
6 Connect the last hose below the black hand wheel
on the nitrogen bottle via the pressure reducing
valve.
7 Check on the pressure gauge bar that all hand
wheels are closed.
8 Turn the hand wheels on both service adapter
clockwise. This opens the valves (right hand
stop).
9 Open the valve on the nitrogen bottle (only via
pressure reducer); pressure approx. 20 bar.
10 Open the black and red hand wheels on the pres-
sure gauge bar and fill nitrogen into the system,
until a pressure of approx. 3.5 to 5.0 bar is indicat-
ed on the suction side.
11 Then open the blue hand wheel and raise the
pressure in the suction side (max. 10 bar). Check
for leaks with a leak detection fluid or soapsuds.
12 If the system is leak tight, release the nitrogen
from the system. For this purpose disconnect the
hose from the nitrogen bottle and open the red,
blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand
wheels on the pressure gauge bar. In case of a
leak no or only an insufficient vacuum will be
reached. In this case proceed as described under
point 9-12. Once the leak is sealed continue with
point 14.
15 Once a sufficient vacuum is reached, both pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.
008 911 57 BOMAG
10.16
16 Switch off the vacuum pump, watch the pressure
gauges to see whether the vacuum is maintained.
17 Open the valve on the refrigerant bottle and open
the black and red hand wheels on the pressure
gauge bar. Fill refrigerant into the system, until a
pressure equilibrium between suction and pres-
sure side is reached (reading of pressure gaug-
es).
18 Close the red hand wheel.
19 Perform a leak test with the electronic leak detec-
tor.
20 Start the engine and switch on the system.
21 Open the blue hand wheel and continue filling in
refrigerant until the inspection glass is free or air
bubbles (in fluid container/dryer combinations the
white pearl should float in the upper third of the in-
spection glass). Then close the refrigerant bottle.
22 Close the blue hand wheel on the pressure gauge
bar.
23 Preparing the test run: -Close windows and doors
-Fan on full speed stage -Mount measuring feel-
ers to air discharge and air intake.
24 Run the system for approx. 20 minutes with medi-
um engine speed.
25 The temperature difference between air discharge
and air intake should be (depending on type of air
condition) 8-10°C. The ambient temperature
thereby is approx. 20°C. (These data are only ref-
erence values, which may be influenced by possi-
ble insolation)
26 Switch off system and engine and check for leaks
again.
27 Turn out (left hand stop) and remove the hand
wheels on both service adapters.
28 Fit all valves with dust caps.
29 Perform a leak test.
30 Mark the system with the corresponding type
plates and information decals, such as type of oil
and refrigerant.
273
10.17 Trouble shooting in refrigerant circuit, basic principles

10.17Trouble shooting in refriger-

ant circuit, basic principles

Basic principles
Requirements
For trouble shooting two requirements must be ful-
filled:
l Expert knowledge
l technical equipment

Technical equipment
The most important aids for trouble shooting are pres-
sure gauges and thermometer. The refrigerant condi-
tions, like overheating and excessive cooling provide
important Information when searching for faults. Even
your own senses are important aids for trouble shoot-
ing. Bubbles in the sight glass, dirt and white frost can
be visibly perceived. If the compressor draws in wet
steam, this can be noticed by the suction line and it
may also be audibly detectable. An overloaded com- Fig. 2 Pressure gauge
pressor can even be smelled.
Example:
The following tools and auxiliary materials should be
A totally empty air conditioning system holds an at-
available for trouble shooting:
mospheric pressure of approx. Pamp = 1 bar.
l
Service station
Filling the system with refrigerant causes an excess
l
Pressure gauge pressure of Pe = 3 bar.
l
Thermometer
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
l
dry nitrogen
Evacuating the system down to Pe = -0.6 bar, creates
l
Refrigerant bottle for new refrigerant
a "vacuum" (negative excess pressure).
l
Container for old oil
l
Vacuum pump Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
l
Hoses
l Scales
l Suction station
l Leak detector
The measuring equipment must be checked at regular
intervals. Calibration can only be made by an ap-
proved testing authority.

Pressure gauge
Most pressure gauges used in practice are (for cost
reasons) excess pressure gauges. These pressure
gauges measure the excess pressure in relation to the
ambient pressure (air pressure). In order to achieve
the absolute (actual) pressure the ambient pressure
must be added to the pressure gauge reading. The
absolute pressure is needed for the calculation and
determination of material data.

Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = excess pressure (pressure gauge reading)

274 BOMAG 008 911 57

Trouble shooting in refrigerant circuit, basic principles
Pressure gauge with saturation temperature scale
Fig. 3 Absolute pressure gauge
Temperature scales on the pressure gauges always
refer to the absolute pressures Pabs. Please note that
it is not possible to measure a temperature directly
with a pressure gauge. The indicated temperatures
are just reference values. Only the saturation temper-
ature is assigned to the measured pressure.
If the refrigerant is fluid, the temperature is below the
saturation temperature.
If the refrigerant is gaseous, the temperature is above
the saturation temperature.
Pressure gauges must indicate 0 bar when not con-
nected to the system.
Low pressure gauges have a blue, high pressure
gauges a red border.
Thermometer
Normally digital thermometers with surface or contact
feelers are used. Especially for high temperature dif-
ferences excellent heat insulation of the measuring lo-
cation is of utmost importance. The sparing use of a
heat conducting paste is highly recommended. If the
measuring location is soiled, it needs to be cleaned
and probably treated with a fine emery cloth. Only the
temperature of the feeler is measured. Due to missing
heat insulation and insulating oxide layers on the line,
temperature differences of a few degrees Kelvin be-
tween the measured and the actual values may arise.
Overheating
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are
not compressible and must therefore not enter into the
compression chamber of the compressor.
008 911 57 BOMAG
10.17
If the suction condition of the compressor is directly on
the dew line, an e.g. incorrect evaporator load can
cause "wet suction". This can lead to two processes,
which are destructive for the compressor. The liquid
refrigerant washes off the lubricating film between pis-
ton and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in
the cylinder causes a direct energy transfer from pis-
ton to cylinder cover during compression. The valve
plate may then be damaged by so-called fluid strokes.
Apart from protecting the compressor against fluid,
overheating has further advantages. Since the fluid
proportions in the drawn in steam reduces the flow
rate of the compressor, it may be increased by a over-
heating. Overheating also improves the oil recircula-
tion.
Common overheating values
The optimal overheating value is approx. 5 - 8 Kelvin.
With this overheating the maximum system power is
reached. However, the thermostatic expansion valve
is unable to regulate this value exactly. Depending on
design and operating conditions overheating fluctu-
ates within a range between 4 and 12 Kelvin. The in-
fluence of the ambient air on the suction line causes
an additional overheating effect.
Overheating is calculated as follows:
Δ to2h = to2h - to
Δ to2h, overheating at evaporator outlet in K
to2h, temperature at evaporator outlet in °C
to, evaporation temperature in °C
„h“ represents "overheated"
Supercooling
It is the function of the expansion valve to reduce the
refrigerant to a lower pressure level (evaporation
pressure) after it has been liquefied. For an optimal
function of the valve pure fluid must be applied to its
inlet port.
The refrigerant must "squeeze" (literally speaking)
through a throttle gap inside the expansion valve.
When comparing a certain mass of refrigerant in fluid
and in vaporous state (with constant pressure), the
vaporous refrigerant requires a much higher volume.
That's why the vaporous refrigerant needs a much
longer time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
If the refrigeration system is operated with the "expan-
sion valve inlet" condition directly on the boiling curve,
slightest fluctuations in operating condition may cause
275
10.17 Trouble shooting in refrigerant circuit, basic principles

a formation of bubbles in front of the expansion ele-

ment.
For this reason one shifts the condition "Expansion
Valve Inlet" away from the boiling curve into the fluid
area and refers to this condition as Supercooling. This
supercooling ensures a fluid supply in front of the ex-
pansion valve.

Common supercooling values

In systems with fluid container the supercooling at the
fluid container outlet is approx. Zero "0" Kelvin (as-
sumed that the system is filled with the correct refrig-
erant quantity). In this case the fluid container
provides the required fluid supply.

Supercooling is calculated as follows:

Δ tc2u = tc - tc2u
Δ tc2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
„u“ represents "supercooled"

276 BOMAG 008 911 57

Trouble shooting in refrigerant circuit, basic principles 10.17

Fig. 1 Refrigerant circuit with t, h- diagram

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

008 911 57 BOMAG 277

10.18 Trouble shooting, refrigerant circuit diagram

10.18Trouble shooting, refrigerant

circuit diagram

Fig. 1 Refrigerant circuit diagram 13 Compressor

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

278 BOMAG 008 911 57

Trouble shooting procedure 10.19
10.19Trouble shooting procedure l Evaporator and heating (with highest fresh air fan
speed) do not draw leak air.
l The fresh air fan runs when the engine is running
Procedure
and the air conditioning system is set to max. cool-
Knowledge ing power.
Trouble shooting is not possible with exact knowledge
l Ambient temperature above 15 °C.
about the system design, the installed components l The thermostat is correctly installed and the switch-
and their function in the system trouble shooting is not ing temperatures are correct.
possible:

Visual inspection
With the appropriate experience some faults can be
visually detected or felt. Frequently occurring con-
denser soiling or formation of steam bubbles in the in-
spection glass can be quickly detected.
In case of unusual formation of hoarfrost on the evap-
orator the hoarfrost pattern provides useful informa-
tion. Hoarfrost only occurring at the inlet side is a clear
indication of insufficient refrigerant feed, which in turn
indicates an incorrectly working expansion valve or a
lack of refrigerant.. Complete hoarfrost covering indi-
cates load problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the
naked eye. At the end of the evaporator there should
be an area which is dry or at least drier at evaporator
temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a
local cooling can be felt or if condensation develops,
this is a clear indicator for an extreme pressure drop
in the line. Similar phenomena can be noticed in case
of blocked filters.
Unusually cold pressure lines indicate "wet" intake of
the compressor.
The oil level in the compressor sight glass provides in-
formation about the oil quantity and the oil recircula-
tion in the system. However, the oil level may also be
considerably influenced by condensing refrigerant.
Discoloration informs about the state of the oil.
Water in the system can simply be detected through
the inspection glass with moisture indicator.

i Note
The dangerous part of common rules is that they ap-
ply in most, but not in all cases. The refrigerant states
in the individual piping sections or components must
therefore be exactly determined by means of pressure
and temperature measurements.

Test prerequisites
l Cooler and condenser are clean, clean if neces-
sary.
l The ribbed belt for compressor and generator is
correctly tightened.
l All air ducts, covers and seals are OK and correctly
fitted. Flaps reach their end positions.
l The engine has operating temperature.

008 911 57 BOMAG 279

10.19
Fig. 2 Flow diagram with measuring points
l C, condenser measuring points
l E, expansion valve measuring points
l O, evaporator measuring points
l V, compressor measuring points
The flow diagram contains "Minimum Requirements"
which must be fulfilled to be able to check the system
or perform trouble shooting.
Temperature and pressure at the evaporator outlet
can be used to derive the overheating of the evapora-
tor. Overheating is a clear indicator for the evaporator
filling level. In case of excessive overheating the re-
frigerant quantity fed into the evaporator is too low, in
case of insufficient overheating it is too high. In indi-
vidual cases one must then check if this situation is
caused by the expansion element or by insufficient fill-
ing. A differentiation is only possible if there is a clear
indicator for the refrigerant filling quantity.
Pressure and temperature at the condenser outlet can
be used to derive the supercooling. This can be used
280 BOMAG
Trouble shooting procedure
Measuring points and measurements
to assess the filling quantity. In systems with fluid con-
tainer the inspection glass is most suitable to check
the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
The hot gas temperature can be used to check wheth-
er the compressor runs in the permissible operating
range.
Example: Measurement of overheating
l a) Which measuring equipment is required ?
l b) Where to measure with which size ?
l c) A pressure gauge connected to the evaporator
indicates "Peo2 = 1.7 bar". How high is the evapora-
tor pressure "Po" ?
l
d) How high is the evaporator temperature "to" ?
l e) A thermal sensor attached to the evaporator out-
let measures the temperature "to2h = +3 °C". How
high is the overheating „Δto2h“ ?
l
f) Evaluation of the measured overheating.
008 911 57
Trouble shooting procedure 10.19
Solution: be a defect in the expansion valve or problems in the
l a) Pressure gauge, thermometer, steam table oil recirculation.
l b) Evaporation pressure "Peo2" and temperature The following list contains pressure values in a sys-
"to2h" are measured at the same point on the evap- tem, that can be expected at various ambient temper-
atures (measured at medium speeds).
orator outlet.
l c) Po = Peo2 + Pamb, "Evaporation pressure = Suction pressure (low pressure gauge)
pressure on evaporator + atmospheric pressure" =
Ambient temperature in °C Excess pressure in bar
1.7 bar + 1 bar = 2.7 bar.
25 approx. 2,0
l
d) "Pc" = 2,7 bar can then be used to derive an con- 30 approx. 2,5
densing temperature "to" of -2,2 °C from the steam 35 approx. 3
table for R134a. High pressure (high pressure gauge)
l e) Δto2h = to2h - to, „Overheating at evaporator out-
Ambient temperature in °C Excess pressure in bar
let = evaporator outlet temperature - evaporation
temperature" = 3 °C - (-2.2 °C) = 5.2 Kelvin. 25 approx. 8,0
35 approx. 13
l f) The determined overheating is within the usual
40 approx. 16
range of 4 - 12 Kelvin.
45 approx. 18
Example: Measuring supercooling
l a) Which measuring equipment is required ?
l
b) Where to measure with which size ?
l
c) A pressure gauge connected to the condenser in-
dicates "Pec2 = 15 bar". How high is the condensing
pressure "Pc" ?
l
d) How high is the condensing temperature "tc" ?
l
e) A thermal sensor attached to the condenser out-
let measures the temperature "tc2u = 58 °C". How
high is the supercooling "Δtc2u" ?
l
f) Evaluation of the measured supercooling.

Solution:
l
a) Pressure gauge, thermometer, steam table
l
b) Condensing pressure "Pec2" and temperature
"tc2u" are measured at the same point on the con-
denser.
l c) Pc = Pec2 + Pamb, "Evaporation pressure =
pressure on evaporator + atmospheric pressure" =
15 bar + 1 bar = 16 bar.
l d) "Pcc = 16 bar can then be used to derive an con-
densing temperature "tc" of 57.9 °C from the steam
table for R134a.
l e) Δtc2u = tc - tc2u, "Supercooling at condenser out-
let = condensing temperature - condenser outlet
temperature" = 57.9°C - 58 °C) = -0.1 Kelvin.
l f) The determined overheating is within the usual
range of approx. "0" Zero Kelvin.

Typical faults and possible causes

Most faults in the refrigerant side of the system can be
clearly assigned with the help a checklist. r Occur-
ring faults frequently have a similar appearance, but
different causes. An evaporator showing hoarfrost
may be quite normal. However, there may also

008 911 57 BOMAG 281

10.19 Trouble shooting procedure

Values effecting the operating pressures tions, it is mandatory to know these dependencies.
Since the pressures occurring in a refrigeration sys- The following table contains some of these dependen-
tem are highly dependent on environmental condi- cies.
Measuring value Suction pressure High pressure
increases drops increases drops
Compressor speed increases X X
drops X X
Vehicle interior tempera- increases X X
ture drops X X
Ambient temperature increases X X
drops X X
Humidity increases X X
drops X X

282 BOMAG 008 911 57

Trouble shooting procedure 10.19
Suction pressure too low (1), high pressure too
low to normal (2)

Fig. 3

Cause Possible effect Remedy

Lack of refrigerant no supercooling, bubbles in inspec- Check for leaks, refill
tion glass, high overheating, hoar-
frost on evaporator
Evaporator fins or air filter soiled Cooling power too low clean
Evaporator fan failed Low pressure shut off Repair the fan
Expansion valve defective Suction pressure gauge shows vac- Replace the valve
uum, because the valve has closed
Screen or nozzle in expansion valve high overheating clean
clogged
Filter dryer clogged Bubbles in inspection glass, high Change filter dryer
overheating, filter dryer cold
Heat power too low Frequent low pressure shut off, Check the control
thawing thermostat / rotary thermo-
stat switching too frequently

008 911 57 BOMAG 283

10.19 Trouble shooting procedure

Suction pressure normal (1), high pressure too

high (2)

Fig. 4

Cause Possible effect Remedy

Condenser dirty high hot gas temperature, low cool- clean
ing power
Condenser fan failed high hot gas temperature, high pres- repair
sure shut down
overfilled high hot gas temperature, low su- Correct the filling capacity
percooling, low cooling power
Leak gas (air) high hot gas temperature, low renew filling
measured supercooling, low cooling
power
Restriction between compressor and high hot gas temperature, low cool- Check lines and valves
condenser ing power

284 BOMAG 008 911 57

Trouble shooting procedure 10.19
Suction pressure too high (1), high pressure too
low to normal (2)

Fig. 5

Cause Possible effect Remedy

Compressor defective Cooling power too low Replace the compressor

008 911 57 BOMAG 285

10.19 Trouble shooting procedure

Suction pressure too high (1), high pressure too

high (2)

Fig. 6

Cause Possible effect Remedy

Expansion valve defective overheating too low, wet operation Replace the valve
of compressor

286 BOMAG 008 911 57

Trouble shooting procedure 10.19
Other faults

Symptom Cause Possible effect Remedy

Hot gas temperature too Lack of refrigeration oil increased compressor Refill refrigeration oil
high, the hot gas line be- wear
comes so hot that it cannot
be touched long with a
hand
Compressor does not start Pressure switch or any oth- System stopped Check the control units,
er safety feature has trig- check cause for switching
gered, electrical fault, and rectify
cylinder filled with liquid re-
frigerant
Compressor switches con- Switching difference too Cycling of compressor, in- Check the control units,
tinuously small, triggering of a creased wear, too low cool- check cause for switching
switching element (over- ing power and rectify
pressure switch, low pres-
sure switch), lack of
refrigerant, fan defective,
overfilled
Excessive overheating Expansion valve deadjust- low cooling power, hot gas Replace the expansion
ed or screen blocked, lack temperatures too high valve, clean the screen, fill
of refrigerant in refrigerant, leak test
Hoarfrost on inlet side of incorrectly working expan- too low infeed of refrigerant Check the expansion
evaporator sion valve, lack of refriger- into the evaporator valve, check the refrigerant
ant filling
Evaporator fully covered Load problem, too low air low cooling power of sys- Clean the evaporator,
with hoarfrost flow volume tem check the evaporator fan
Fluid line is warm and Pressure drop in fluid line, low cooling power Eliminate the pressure
shows condensation filter dryer clogged drop, replace the filter dryer
Exceptionally cold pres- "Wet intake" of the com- low cooling power, exces- Clean the compressor, re-
sure lines pressor due to insufficient sive wear of compressor place if necessary, replace
overheating of evaporator the expansion valve if nec-
essary

Noise in system

Faults Possible cause Remedy

V-belt loose or excessively worn
Magnetic clutch loud
Refrigerant compressor is loud
Fan is loud, fan motor excessively
worn
Whistling and rattling noise in opera- V-belt pulley and bearing worn
tion, noticeable unevenness when
turning by hand
Rattling noise or vibration of high
pressure line, knocking noise in
compressor, ball in inspection glass
floating at the top
Expansion valve loud
Hissing noise in evaporator housing, refrigerant level in system too low
on expansion valve, turbidity in in-
spection glass or ball does not float
V-belt slips and generates noise Retention or renew the V-belt
Magnetic clutch runs until high pres- Repair or replace the magnetic
sure builds up, then the clutch starts clutch
to slip
Mounting bracket is loose, internal Repair the mounting bracket, re-
parts worn, low oil level in compres- place the compressor, renew the re-
sor frigeration oil
Replace the fan motor
Replace the bearing, check V-belt
pulley for wear
System overfilled Draw out refrigerant
excessive moisture in system Replace the dryer
Perform a leak test, fill up the system

008 911 57 BOMAG 287

10.19 Trouble shooting procedure

Inspection glass

Faults Possible cause Remedy

Steam bubbles in inspection glass
Discolouration of inspection glass
(black from inside)
Moisture indicator changes to pink
Ball floats at bottom
No supercooling before expansion
valve, lack of refrigerant in system,
pressure loss in system, supercool-
ing caused by excessively soiled fil-
ter dryer
Lubricant destroyed by excessive
operating temperatures
Moisture level of drying agent too
high
lack of refrigerant
Fill up the system, replace the filter
dryer, perform a leak test
Replace the refrigeration oil, exam-
ine the temperature increase
Replace the filter dryer
Fill the system

Monitoring devices

Faults Possible cause Remedy

The high pressure contact has
switched off the magnetic clutch
The low pressure contact has
switched off the magnetic clutch
The thermostat has switched off the Ambient temperature below 1°C, Check the thermostat switching
magnetic clutch
System pressure exceeded, con- Clean the condenser, replace the
denser excessively soiled, condens- expansion valve, check the con-
er fan defective, expansion valve denser fan
defective
System pressure fallen short of, re- Clean the evaporator, replace the
frigerant level too low, expansion expansion valve, check the evapora-
valve defective, evaporator fan de- tor fan
fective, heat load too low, ambient
temperature below 1.5 °C
expansion valve defective, thermo- point, replace the expansion valve,
stat defective, air flow volume too clean the evaporator, check the
low evaporator fan

288 BOMAG 008 911 57

Steam table for R134a 10.20

Tempera- Pres- Density spec. volume spec. enthalpy Evapora-

ture sure tion heat
of the fluid of the of the fluid of the of the fluid of the
steam steam steam

008 911 57 BOMAG 289

10.20 Steam table for R134a

290 BOMAG 008 911 57

Steam table for R134a 10.20

008 911 57 BOMAG 291

10.20 Steam table for R134a

292 BOMAG 008 911 57

Steam table for R134a 10.20

008 911 57 BOMAG 293

10.20 Steam table for R134a

294 BOMAG 008 911 57

 11 Central lubrication system

008 911 57 BOMAG 295

11.1 System layout

11.1 System layout

The sanitary landfill compactors are equipped with an
automatically working central lubrication system.

Fig. 1 Lubrication system RB machine

Fig. 2 Lubrication system RS machine 6 Main distributor in rear frame

1 Ignition switch 7 Piston detector, monitors and ends duty cycle
2 Fuse F16 8 Sub-distributor in front frame
3 Push button with control light
4 Lubrication pump with integrated control
5 Main distributor

296 BOMAG 008 911 57

Description of components
11.2 Description of components
Technical description
When switching the ignition on, the automatic lubrica-
tion system is supplied with voltage via fuse F16. At
the same time the system performs a function test for
drive motor and control light.
During this function test the motor is activates for 0,1
seconds (short movement of stirring blade) and the
control light lights up for 2 seconds. In case of a fault
the control light will flash. If the control light does not
light up, the light is defective.
The system is equipped with an electronic control and
a monitoring device for the function of the lubricant
distributor.
The electronic control is integrated in the pump case
and controls the lubrication cycle automatically. One
lubrication cycle consists of a pumping period and a
pause.
Duty cycle
The duty cycle is aprox. 45 seconds. It depends on the
grease used for lubrication and the operating temper-
ature. It is monitored by a piston detector mounted to
the sub-distributor (rear frame). The piston detector
terminates its working cycle after all pistons have
ejected their quantity of grease. The duty cycle is indi-
cated by the control light in the cabin.
Pause
The pause starts when the lubrication interval is fin-
ished. After this pause a new lubrication cycle will
start.
! Caution
Set the pause time to 1 hour (position "1") (Fig. 3).
008 911 57
11.2
Fig. 3 Setting the pause time
l Bridge right
l Rotary switch to position "1".
Remark
When switching the ignition off, all times (duty cycles
and pause times) as well as the present operating
conditions (faults) are stored in an electronic memory.
When switching the ignition back on, the control will
start exactly at the same point where it stopped before
the ignition was switched off.
Test run
To check the function of the system you can perform
a test run. For this purpose press the push button for
approx. 2 seconds after switching the ignition on. This
triggers a normal lubrication cycle.
Lubrication process
During a duty cycle the lubricant pump delivers the lu-
bricant to the main distributor. This distributor delivers
the grease quantity to the sub-distributors in front and
rear frames . These sub-distributors press the grease
to the individual lubrication points.
Lubrication points
The sub-distributor in the rear frame supplies the fol-
lowing points in the rear frame with grease:
l
the rocker bearings (4 pieces) on both steering cyl-
inders
l
top and bottom bearings on the articulated joint
The sub-distributor in the front frame supplies the fol-
lowing points in the rear frame with grease:
l
the live ring bearing in the oscillating joint
l
all bucket bearings
l the upper rocker bearing on the bucket cylinder
BOMAG 297
11.2 Description of components

Monitoring the function

Main distributor and sub-distributors are connected by
a main grease line. This results in a positive connec-
tion between the pump and the connected progres-
sive system.
If one of the pistons in any of the distributors does not
move or if one of the pistons is not able to push out the
grease through the corresponding outlet, the distribu-
tor will block itself.
If one of the sub-distributors is blocked, the positive
connection of the system will also block the main dis-
tributor. The complete progressive system will stop.
The fundamental internal structure of the progres-
sivbe distributor ensures a self-monitoring of the work-
ing cycle in the distributor.
The cross-linking of this system enables monitoring of
the complete system.
Due to the use of the piston detector functional faults
are immediately detected and indicated by a flashing
sequence of the control light.
The complete system can be visually monitored on
the pressure relief valve of the pump. If grease emerg-
es from this pressure relief valve during the pumping
process, there must be a blockage in the system.

298 BOMAG 008 911 57

Description of components 11.2
Indication of faults

Fig. 4 Indication of faults The control lamp shows the following flashing se-
A = Motor defective quence
If the motor does not start when operating the starter l
0.5 second ”ON” - 1 second ”OFF”
switch or the machine contact, or if the cable of the C = Fault in lubrication circuit 2 (not appli-
motor is defective, the control lamp will flash after 2 cable)
seconds as follows:
D = Fault in lubrication circuit 1 + 2 (not
l
A= 1 second ”ON” - 1 second ”OFF” applicable)
B = Fault in lubrication circuit 1 E = Empty signal: Container empty
e.g.: The control lamp shows the following flashing se-
l
blocked lubrication point(s) quence
l
blocked distributor
l
0.5 second ”ON” - 0.5 second ”OFF”
l
main hose to distributor with piston detector inter-
rupted i Note
l
air in system. After 6 motor revolutions the empty signal will be con-
verted to a flashing signal with the above mentioned
The above faults mean that the piston in the moni- frequency.
tored distributor cannot move any more.

008 911 57 BOMAG 299

11.2 Description of components

In case of a system fault the piston detector (initiator) Central lubrication pump
Z

cannot register any piston movement and therefore The pump is a compact multiple-line pump and con-
the pump will not switch off. sists of:
With the help of the parallel running monitoring time l container with stirring blade
the controls switch the pump off at the end of the mon-
itoring time (5 minutes). l housing with built-in motor
l This is followed by a fault signal l control unit
l The contact lamp flashes l Pump element
l
The pump does no longer start automatically. l safety valve and
F = Acknowledgement of fault (permanent l
filler nipple
light)
Pressing the button (< 1 second) acknowledges the
fault signal, i.e the flashing of the control lamp chang-
es to a permanent light.

i Note
An acknowledged fault also remains stored after
switching the drive switch or the machine contact off.
When switching on again the control lamp flashes
again, according to the respective fault.

Rectify the fault and release additional lubrication

l In the event of a fault check the central lubrication
pump and the connected system for faults.
Rectify the cause of the fault.
l Switch the pump on again by triggering an addition-
al lubrication cycle. Keep the button slightly longer
depressed (> 2 seconds). If the fault is eliminated,
the control lamp will go out at the end of the lubrica-
tion process.
Fig. 5 Lubrication pump
1 transparent container
2 connecting fitting for manual filling gun
3 Grease emerging from the opening indicates that
one of the lubrication points is clogged.
Pump element

!Caution
In case of a malfunction the pump will not auto-
matically start to run again after rectification of
the fault. The pump must be switched on.

Fig. 6 Pump element

1 Piston
2 Push back spring
3 Check valve
The electric motor drives the eccentric 1 (Fig. 7).
During operation the piston 2 (Fig. 6) draws lubricant
out of the grease container and delivers it via the dis-
tributor to the connected lubrication points in front and
rear frames.

300 BOMAG 008 911 57

Description of components 11.2
Check valve
The check valve serves the function of the pump ele-
ment. It prevents the back flow of lubricant to the
housing, i.e. to the container.

Fig. 7 Pump element drawing in grease

1 Eccentric
2 Piston
3 Spring
4 Check valve

Fig. 9 Hydraulic diagram of pump

Fig. 8 Pump element pumping
1 Eccentric 1 container with stirring blade
2 Piston 2 Pump
3 Spring 3 Check valve, spring loaded
4 Check valve 4 Pressure relief valve
5 Pressure line

Pressure relief valve

The pressure relief valve limits the pressure in the
system to the adjusted value.
The valve opens at a pressure of 305 bar.
Lubricant escaping from the pressure relief valve indi-
cates a fault in the system.

008 911 57 BOMAG 301

11.2 Description of components

Progressive distributor

Fig. 11
1 Inlet fitting
2 Supply bore from piston
3 Fitting, assembled
4 Plug, piston
Fig. 10 Checking the pressure relief valve 5 Check valve, complete
1 Hose, at least 1 m long 6 Clamping ring (brass)
2 T-piece 7 Valve body
3 Pressure gauge 8 Cutting ring
4 Relieve cock 9 Spigot nut
10Connecting channel
i Note 11Copper sealing ring
When checking the system it is necessary to run one 12Plug
or more additional lubrication cycles.
Features of a progressive distributor
The term ”progressive” refers to the special processes
!Caution which occur in the distributor during the supply of lu-
Do not connect the pressure gauge directly to the bricant, e.g.
pump element. Very high pressure peaks, exceed- l
successive movement of the individual pistons in
ing the measuring range of the gauge, will occur.
the distributor caused by the supplied pressurized
l Connect the pressure gauge (0 - 600 bar; 0 - 8708 lubricant.
psi) to the valve. l The pistons move in a preset sequence and in con-
l Start an additional lubrication cycle. stantly repeated cycles.
l
Each piston must have fully completed its move-
i Note ment before the movement of the next piston can
The engine will stop. It can be blocked for up to 30 take place, irrespective of whether the supply of lu-
minutes without any harm. bricant is constant or intermittant.
l The pistons work in dependence on each other.
None of the connected lubrication points will be
missed out.
Progressive distributors of type SSV are piston distrib-
utors.
l
They control the distribution of the lubricant (pro-
gressively) to the connected lubrication points.
l
Per outlet and piston stroke a quantity of 0.2 cm3 of
lubricant is supplied.

302 BOMAG 008 911 57

Description of components 11.2
l By closing single outlets it is possible to deliver the Phase 2
double or multiple amounts of lubricant.
l This distributor provides the possibility to connect
several lubrication points to one central lubrication
point.

Description of function
The following five illustrations show how the individual
outlets are supplied with the proper amount of lubri-
cant.

i Note
For simplification we only show the delivery details for
the outlets 2, 7, 5, 3 and 1. All other processes result
from the logic pumping sequence.

Phase 1 Fig. 13 Phase 2

When piston A (Fig. 13) reaches its left hand stop po-
sition it opens the connecting passage at the right
hand end of channel B.
The lubricant flowing in from above (vertical arrow)
likewise moves piston B (horizontal arrow) to the left
and presses the confined lubricant from the left hand
end of piston B to outlet 7.

Phase 3

Fig. 12 Phase 1
The lubricant enters from above (vertical arrow) into
the lubricant distributor and flows to the right end of
piston A (Fig. 12).
The lubricant pressure moves piston A (horizontal ar-
row) to the left and presses the confined lubricant from
the left hand end of piston A to outlet 2.

Fig. 14 Phase 3
When piston B (Fig. 14) reaches its left hand stop po-
sition it opens the connecting passage at the right
hand end of piston C.
The lubricant flowing in from above (vertical arrow)
likewise moves piston C (horizontal arrow) to the left
and presses the confined lubricant from the left hand
end of piston C to outlet 5.

008 911 57 BOMAG 303

11.2 Description of components

Phase 4 When lubricant flows through the distributor again, the

cycle starts exactly at the point where it was interrupt-
ed.

Fig. 15 Phase 4
The connecting passage at the right hand end of pis-
ton D (Fig. 15) is now open (bottom horizontal arrow).
Lubricant flowing in from above (vertical arrow) press-
es piston D to the left hand side, thus the confined lu-
bricant from the left hand end of piston D leaves the
distributor through outlet 3.

Phase 5

Fig. 16 Phase 5
In phase 4 piston D (Fig. 16) opens the connecting
passage to the left end of piston A.
The flowing lubricant (vertical arrow) pushes piston A
to the right (upper horizontal arrow) and conveys the
confined lubricant to outlet 1.
In the subsequent sequence of delivery the pistons B
– D move in succession from left to right.
Thus one complete revolution has come to an end and
a new cycle can start.
If the flow of lubricant is interrupted the piston will stop.
In this case there is no conveyance of lubricant to the
lubrication points.

304 BOMAG 008 911 57

Check the central lubrication system, topping up
11.3 Check the central lubrication
system, topping up
!Caution
When using an external heavy duty lubrication de-
vice lubricate slowly and with interruptions.
The following lubrication points are effectively
and reliably supplied with lubricant by the central
lubrication system.
l 2 x on bearing block at bottom of dozer blade,
l 1 x eye for dozer blade cylinder,
l 4 x steering cylinder eyes,
l 2 x articulated joint,
l 4 x live ring of articulated joint
A differentiation is made between the time cycles for
pause and duty.
Pause: No lubrication over a period of 60 minutes.
Duty cycle: Factory set.
Check
Fig. 17
l Switch on the ignition.
l
Actuate push button (Fig. 17) for 2 seconds.
008 911 57
11.3
Fig. 18
l The agitator in the transparent container 1 (Fig. 18)
moves and presses the grease to the lubrication
points.
i Note
Use the push button only to check the system.
Failure of a lubrication point
(e.g. a clogged lubrication point)
l
Grease emerging from opening 3 (Fig. 18) indicates
that one of the lubrication points is clogged.
l
Identify and rectify the cause.
Filling through the grease nipple
Caution
!
Ensure strict cleanliness, as otherwise the distrib-
utors may seize.
Do not fill the grease container by removing the
cover.
Fill the grease container if it is only 1/4 filled.
l
Clean the grease nipple.
l
Fill the grease container through the grease nipple
(2) up to the "Max"-mark.
For quality and quantity of grease refer to the ta-
ble of fuels, lubricants and filling capacities.
l Switch on the ignition, actuate the push button (Fig.
17) for two seconds, the system will start.
Filling with the hand pump
! Caution
Ensure strict cleanliness, as otherwise the distrib-
utors may seize.
For quality and quantity of grease refer to the ta-
ble of fuels, lubricants and filling capacities.
BOMAG 305
11.3 Check the central lubrication system, topping up

Fig. 19
l Remove both lids from the cartridge 1 (Fig. 19).
l Unscrew the connecting fitting from the hand pump
(2).
l Pull the actuator rod completely out.
l Slide the cartridge into the hand pump with the tri-
angle mark to the front.
l Check whether the seal ring has been inserted into
the connecting fitting.
l Screw the connecting fitting onto the hand pump.

Fig. 20
l
Clean the area around the locking cap on the cen-
tral lubrication system.
l
Unscrew the locking cap from the central lubrication
system and the locking plug from the hand pump
(Fig. 20).
l Screw the hand pump onto the socket on the central
lubrication system.
l Push the grease into the transparent container by
operating the actuating rod.
l
Unscrew the hand pump, insert a new cartridge and
repeat the pumping procedure until the transparent
container is filled up to the "Max"-mark.

Caution
!

After filling screw locking cap and locking plug

back on.

306 BOMAG 008 911 57

 12 Engine

008 911 57 BOMAG 307

12.1 Diesel engine

12.1 Diesel engine The engines are characterized by the following posi-
tive features:
Refuse compactors of series BC 772 RB-2 are pow- l compact design
ered by 6-cylinder Deutz diesel engines type TCD
2015 and the BC 972/1172 RB-2 by an 8-cylinder en-
l low noise level
gine type TCD 2015. l almost vibration free operation
These engines are V-type engines with water cooling,
l low fuel consumption
whereby the cylinder banks are arranged to each oth- l low exhaust emission EPA/COM IIl
er under a 90° angle. l high power density
The engines are designed in four-valve technology l excellent access to all service locations.
with turbo charging and intercooler. They are ex- l high reliability
tremely compact and are fitted with a solenoid valve
controlled electronic injection system (MVS).
l low running costs,
l long lifetime
Emission limit values acc. to EPA/ COM/ Tier/ stage lll

Fig. 1 Deutz diesel engine TCD 2015

308 BOMAG 008 911 57

Engine description TCD 2015 V 6 cylinder 12.2
12.2 Engine description TCD 2015
V 6 cylinder

Fig. 1 Deutz diesel engine TCD 2015 V06 right hand side 15 Connection to EMR3 system
16 Connection to MVS system
1 Crankcase ventilation 17 Connection from air filter
2 Connection to coolant heat exchanger 18 Cylinder head cover
3 Pre-heating plug 19 Connection to exhaust silencer
4 Connection from intercooler 20 Exhaust turbo charger
5 Connection to intercooler 21 Charge air suction line
6 Connection from coolant heat exchanger 22 Transport device
7 Lubrication oil filter cartridge
8 Coolant pump
9 Connection from separate lubrication oil tank
10 Connection to separate lubrication oil tank
11 Vibration damper / V-belt pulley
12 Generator
13 Engine type plate (company plate)
14 Exhaust manifold

008 911 57 BOMAG 309

12.2 Engine description TCD 2015 V 6 cylinder

Fig. 2 Deutz diesel engine TCD 2015 V06 left hand side

23. Auxiliary drive

24. Engine suspension
25. Transmission connection (SAE)
26. Flywheel
27. free auxiliary drive
28. Crankcase ventilation line
29. Lubrication oil cooler
30. Injection pump (plug-type pump)
31. Injection line

310 BOMAG 008 911 57

Engine description TCD 2015 V 8 cylinder 12.3
12.3 Engine description TCD 2015
V 8 cylinder

Fig. 1 Deutz diesel engine TCD 2015 V08 right hand side 16 Connection from air filter
1 Crankcase ventilation 17 Exhaust turbo charger
2 Connection to coolant heat exchanger 18 Connection to exhaust silencer
3 Charge air duct
4 Coolant pump
5 Connection from coolant heat exchanger
6 Vibration damper / V-belt pulley
7 Lubrication oil sump
8 Generator
9 Oil drain plug
10 Fuel lift pump
11 Connection from intercooler left (optional: right)
12 Connection to intercooler
13 Cylinder head cover
14 Transport angle
15 Exhaust manifold

008 911 57 BOMAG 311

12.3 Engine description TCD 2015 V 8 cylinder

Fig. 2 Deutz diesel engine TCD 2015 V08 left hand side

19 Injection pump (plug-type pump)

20Transmission connection (SAE)
21Flywheel
22Starter
23 Lubrication oil filter cartridge
24 Injection line
25 Lubrication oil cooler

312 BOMAG 008 911 57

Lubrication oil circuit TCD 2015 12.4
12.4 Lubrication oil circuit TCD
2015

Fig. 1 Lubrication oil schematic 16 Plunger with rocker arm pulse lubrication
17 Push rod, oil supply to rocker arm lubrication
1 Lubrication oil sump 18 Rocker arm
2 Lubrication oil suction pipe 19 Oil return bore in cylinder head leading to crank-
3 Lubrication oil pump case
4 Pressure relief valve 20 Oil pressure sensor / oil pressure switch
5 Lubrication oil cooler 21 Oil line to exhaust turbo charger
6 Lubrication oil filter 22 Exhaust turbo charger
7 Main oil galleries 23 Oil line to crankshaft and camshaft, compressor /
hydraulic pump
8 Crankshaft bearings
24 Compressor (optional)
9 Conrod bearings
25 Hydraulic pump (optional)
10 Camshaft bearings
26 Pressure retaining valve (adjustable)
11 Oil flow to individual injection pumps
27 Return flow from compressor / hydraulic pump to
12 Injection pump with injection valve
crankcase
13 Camshaft lubrication
28 Return flow from exhaust turbo charger
14 Line to spray nozzle
15 Spray nozzle with pressure retaining valve for pis-
ton cooling

008 911 57 BOMAG 313

12.5 Coolant circuit TCD 2015

12.5 Coolant circuit TCD 2015

Fig. 1 Coolant diagram

1 Coolant pump
2 Lubrication oil cooler
3 Coolant channel
4 Cooling of cylinder liner/cylinder head (number-
ing/arrangement of cylinders depending on en-
gine series)
5 Compressor (optional)
6 Transmission oil cooler (optional)
7 Additional cooler (optional)
8 Temperature sensor
9 Thermostat
10 Compensation tank
11 Filler socket
12 Heat exchanger
13 Cabin heater (optional)

314 BOMAG 008 911 57

Fuel circuit TCD 2015 12.6
12.6 Fuel circuit TCD 2015

Fig. 1 Fuel diagram

1 Fuel tank
2 min. distance 500 mm
3 Fuel supply line from tank
4 Manual priming pump for bleeding
5 Fuel pre-filter (example)
6 Fuel priming pump
7 Fuel twin filter
8 Fuel supply line to injection pumps
9 Injection pump
10 Injection line
11 Injection valves
12 Fuel supply line to injection pumps
13 Fuel return line from injection pumps
14 Pressure retaining valve
15 Fuel return line to fuel tank

008 911 57 BOMAG 315

12.6 Fuel circuit TCD 2015

Fuel pre-filter

Fig. 2 Fuel pre-filter

1 Filter bracket
2 Filter cartridge
3 Water collecting bowl
4 Electric connection
5 Drain plug
6 Manual fuel pump
7 Bleeding screw
8 Sealing face
A Electric water level sensor

316 BOMAG 008 911 57

Fuel circuit TCD 2015 12.6
Fuel filter system

2
2

4
4
1 11 3
1
4
2

Fig. 3 Fuel pre-filter

1 Fuel pressure filter min. 3µm
2 Bleeding screws
3 Fuel pre-filter
4 additional hand pump

008 911 57 BOMAG 317

12.7
12.7 Injection system (MVS) TCD
2015
The solenoid valve system (MVS) is a new fully elec-
tronically controlled diesel injection system without
mechanical link to the operator (no governor rod). In
contrast to conventional injection systems the MVS
enables an absolutely unrestricted control of delivery
period (injection quantity) and start of delivery (injec-
tion timing) and thus ensures reliable compliance with
current emission regulations.
The MVS consists of a pump with solenoid valve and
injection nozzle for each individual cylinder.
Overview of electronic diesel fuel control
Sensors Control unit (EMR3)
Fig. 1 MVS - Injection system TCD 2015
318 BOMAG
Injection system (MVS) TCD 2015
The solenoid valve closes the fuel bypass in the
plunger chamber, thus causing an increase in injec-
tion pressure and finally triggers the injection when
the nozzle opening pressure is reached. If injection is
to be ended, the valve will open the bypass, the sys-
tem pressure drops and the spring force closes the
nozzle needle.
The solenoid valves are triggered by the electronic
control unit in dependence on the operatig parame-
ters. The system is capable of providing a wide range
of limp-home functions, should any of the sensors fail.
This ensures a reliable and safe completion of travel
and work.
Actuators
008 911 57
Injection system (MVS) TCD 2015 12.7

Fig. 2 Electrics of TCD 2015 18 Diagnostics push button

19 Fault lamp with flashing code
1 Oil pressure sensor 20 Diagnostics interface/CAN-Bus
2 Fuel temperature sensor
3 Sensor for charge air temperature and charge air
pressure
4 Engine control unit
5 Coolant temperature sensor
6 Oil level sensor
7 Central plug
8 Rotary speed sensor for crankshaft
9 Rotary speed sensor for camshaft
10 Power supply
11 Multi-function display
12 Outputs (configurable)
13 Inputs (configurable) (PWM/Digital/Analog)
14 Travel pedal
15 Manual throttle (optional)
16 Changeover function
17 Key switch Start/Stop

008 911 57 BOMAG 319

12.7 Injection system (MVS) TCD 2015

Injection pump with solenoid valve

Fig. 3 Pump/solenoid valve TCD 2015

Pump

Nozzle

Fig. 4 Injection pump and nozzle

320 BOMAG 008 911 57

Sensors TCD 2015 12.8
12.8 Sensors TCD 2015

10

Fig. 1 Sensors TCD 2015

1 Oil pressure sensor

2 Fuel temperature sensor
3 Sensor for charge air temperature and charge air
pressure
4 Engine control unit
5 Coolant temperature sensor
6 Oil level sensor
7 Central plug
8 Rotary speed sensor for crankshaft
9 Rotary speed sensor for camshaft
10 Travel pedal

008 911 57 BOMAG 321

12.8 Sensors TCD 2015

Fig. 2 Sensors TCD 2015

Fig. 3 Wiring loom TCD 2015

322 BOMAG 008 911 57

Sensors TCD 2015 12.8
Rotary speed sensor for camshaft
l Inductive sensor
l Determination of TDC
l Limp-home function in case of crankshaft sensor
failure

Rotary speed sensor for crankshaft

l Inductive sensor
l Exact determination of engine speed
l Limp-home function in case of camshaft sensor fail-
ure

Charge pressure sensor

l Pressure sensor
l Avoidance of smoke development
l Adaptation of injection pump in case of too low
charge pressure
l Determination of air mass for cylinder

Oil pressure sensor

l
Pressure sensor
l
Monitors the oil pressure
l
Engine protection by switching of in case of too low
oil pressure

Charge air temperature sensor

l
Temperature sensor
l
Temperature correction of air mass
l
Optimized injection quantity during cold start

Fuel temperature sensor

l
Temperature sensor
l
Temperature correction for injection quantity

Coolant temperature sensor

l Temperature sensor
l Engine protection in case of excessive temperature
by reduction of injection quantity
l Optimized injection quantity during cold start

Travel potentiometer
l
Potentiometer
l
Specification of nominal value (e.g. rotary speed)

008 911 57 BOMAG 323

12.8 Sensors TCD 2015

Crankshaft speed sensor

Fig. 4 Crankshaft speed sensor TCD 2015 Adjustment measurement or sensor gap meas-
urement
1 Flywheel
2 Speed sensor

Gap measurement C = 1mm +/- 0.5mm

Fig. 5 Crankshaft speed sensor

324 BOMAG 008 911 57

Sensors TCD 2015 12.8
Camshaft speed sensor

Fig. 6 Camshaft speed sensor TCD 2015 Adjustment measurement or sensor gap meas-
urement
1 Camshaft sprocket
2 Speed sensor

Gap measurement C = 1mm +/- 0.5mm

Fig. 7 Camshaft speed sensor

008 911 57 BOMAG 325

12.9 Exhaust gas recirculation TCD 2015

12.9 Exhaust gas recirculation TCD

2015
In order to be able to meet the exhaust gas stand-
ards EC and stage/Tier3, all engines are designed
with exhaust gas recirculation.

On 6 and 8 cylinder engines TCD 2015 the exhaust

gas recirculation has been realized internally
through the exhaust valves. For this purpose the
camshaft has been manufactured with an addi-
tional cam for short-term opening of the exhaust
valve

Exhaust valves

Camshaft

Fig. 1 Exhaust valve control TCD 2015

326 BOMAG 008 911 57

Engine control EDC 7 with EMR 3 TCD 2015 12.10
12.10Engine control EDC 7 with l Working range 9-31 V
EMR 3 TCD 2015
l Engine start possible from 6 V

Control unit EDC 7 - EMR 3

l Operating voltage 12 V DC and 24 V DC

Engine side Vehicle side

Fig. 1 EDC 7 - EMR 3 TCD 2015

008 911 57 BOMAG 327

12.10 Engine control EDC 7 with EMR 3 TCD 2015

EMR 3 - interface description

Engine side
XD2.2:01 - 2:36
XD2.3:03 - 3:16

Vehicle side
XD2.1:02 - 1:89

Electric wiring diagram, page

Fig. 2 EMR 3 - connecting plug TCD 2015

Fig. 3 Electric wiring diagram, page 004

328 BOMAG 008 911 57

Engine control EDC 7 with EMR 3 TCD 2015 12.10
Interface, engine side XD2.2 and XD2.3

Fig. 4 Electric wiring diagram, page 004

008 911 57 BOMAG 329

12.10 Engine control EDC 7 with EMR 3 TCD 2015

Interface, vehicle side XD2.1

Fig. 5 Electric wiring diagram, page 004

330 BOMAG 008 911 57

Engine control EDC 7 with EMR 3 TCD 2015 12.10
Engine control EDC7 / EMR3

Fig. 6 EMR position in the machine

008 911 57 BOMAG 331

12.11 Fan V-belt tension TCD 2015

12.11Fan V-belt tension TCD 2015

Fig. 1 V-belt tension

i Note
The V-belt is tightened by shifting the two hexagon
nuts accordingly.

332 BOMAG 008 911 57

Fan V-belt tension TCD 2015 12.11

Fig. 4
Fig. 2 l
Read the V-belt tension where the upper edge of
l Press the indicator arm of the tester a (Fig. 2) into the indicating arm intersects with the measuring
the gap of the measuring scale. scale (Fig. 4).
l
Lay the measuring unit loosely onto the back of the First installation = approx. 1900N
fan V-belt.
after 20 minutes of
operation = approx. 1400N
i Note at minimum 1100N
To measure the V-belt tension a free length of at least (retightening limit)= tension to approx. 1400N (opera-
200 mm is required. tion value)

Fig. 3
l Operate measuring unit b (Fig. 3) with a finger (I or
II or II), until the pressure spring disengages audibly
or noticeably.

i Note
The indicator arm remains in the measured position.
l take the measuring unit carefully off, without moving
the indicating arm.

008 911 57 BOMAG 333

12.12 Valve adjustment TCD 2015

12.12Valve adjustment TCD 2015

Fig. 1 TCD 2015 - 8 cylinder Sense of rotation

General defination Viewd on drive side
Cylinder arrangement, engine side and sense of rota- turning ccw: counter-clockwise (see example)
tion Viewed on power take-off side.
Cylinder arrangement left = links
The cylinders must be successively numbered, start- right = rechts
ing with 1 at the flywheel .

Fig. 1 TCD 2015 - 8 cylinder Remove valve cover 2 with gasket 3

Adjusting the valve clearance Fasten the cranking device with fastening screws to
the flywheel.
Before adjusting the valve clearance: Allow the engine
to cool down for at least 30 minutes: Crank the engine, until the valves on cylinder 1 over-
lap.
Oil temperature below 80 °C.
(Exhaust valve not yet closed, intake valve starts to
Crankshaft position as per "valve adjustment sche-
open)
matic".
further procedure as per table
Loosen the screws 1

334 BOMAG 008 911 57

Valve adjustment TCD 2015 12.12

008 911 57 BOMAG 335

12.12 Valve adjustment TCD 2015

Fig. 2 TCD 2015 valves 6-cylinder: During the intake cycle the exhaust
Loosen the counter nut (1). valve opens for a short moment.
Attach the rotation angle disc (4) and the spanner 8-cylinder: During the exhaust cycle the intake
socket to the valve clearance adjustment screw (2). valve opens for a short moment.
Fix the magnet of the rotation angle disc (4). This must not be mistaken as overlapping of
valves!
Turn the rotation angle disc (4) clockwise against the
stop (rocker arm no clearance) and set the scale to ze-
ro.
Turn the rotation angle disc (4) anti-clockwise, until TCD 2015 - 6 cylinder
the specified turning angle is reached: Overlapping of valves adjustment
IN = Intake valve 90 ° +10 ° A1 B2
B1 A2
EX = Exhaust valve 108 ° +10° A3 B1
Hold the rotation angle disc (4) tight to prevent it from B2 A1
turning. A2 B3
Tighten the counter nut 1 (tightening torque 20 Nm ). B1 A3
Then adjust the second valve on the rocker arm as de-
TCD 2015 - 8 cylinder
scribed above.
Overlapping of valves adjustment
Repeat the adjustment procedure on each cylinder.
A1 B3
Reassemble the valve cover with a new gasket in re- B4 A3
verse order. A4 B2
Reassemble the screws (tightening torque 22 Nm). B1 A2
B3 A1
The valve clearance can also be adjusted with a feeler
A3 B4
gauge. Use 0.25mm or 0.09in feeler gauges for the in-
B2 A4
take valves.
A2 B1
Use 0.30mm or 0.12in feeler gauges for the exhaust
valves.

Valve clearance adjustment schematic

Overlapping of valves: Exhaust valve not yet closed,
intake valve starts to open.

! Caution
This engine is equipped with an internal exhaust
recirculation system.

336 BOMAG 008 911 57

Fault diagnose TCD 2015 12.13
12.13Fault diagnose TCD 2015 3a (red) flash-
ing = external fault, the warning buzzer
sounds. The machine control has detect-
ed a fault.
4 (yellow)= Cabin dehumidifier switched on.
5 (yellow) = Air filter cartridges soiled, clean cartridg-
es, replace.
6 (red) = Coolant temperature too high. The en-
gine control unit shuts the engine down.
Clean the radiator.
7 (red) = Lack of coolant. The warning buzzer
sounds, the engine is shut down after 20
seconds. Fill up coolant, change if nec-
essary.
Fig. 1 8 (yellow) = Failure of fresh air fan (depressed rotat-
ing speed). Clean the fresh air filter, re-
No. 7 = Fault indication, engine function
place if necessary, replace the fan if
One of the red lights lighting up during operation indi- damaged.
cates and engine problem.

i Note
With the ignition switch in position "I" the control light
lights for about 4 seconds (function check)

Fig. 2

Fault monitoring board for engine functions (RB)

Control light
1 (yellow) = Preheating system (cold start) flashes
with ignition switch in position "I" after 30
seconds and goes out after starting.
2 (yellow) = Batteries are not being charged. Check
V-belt, if necessary repair the generator.
3 (red) = Engine oil pressure too low, the engine
control unit shuts the engine down.
Check the engine oil level, if necessary
have the engine repaired.
3a (red) per-
manent light= Fault in engine control. The engine con-
trol is switched off (emergency opera-
tion).

008 911 57 BOMAG 337

12.13 Fault diagnose TCD 2015

Fig. 3 Fig. 4
No. 3 = Control light for water separator in fuel No. 4 = Control light and diagnostic button for
pre-filter engine control (EMR III)
lights up = if the water proportion in the trans-
parent section of the fuel filter i Note
reaches the contacts. The diesel engine with EMR III (Electronic Engine
goes out = if fuel is clean. Control) inhibits protective functions for the engine.
Depending on the severity of the detected fault the en-
gine may continue operation with limitations (limp
home), whereby the control will permanently be on.
With flashing control light the engine is shut down. If
the fault indicator for engine oil pressure or coolant
level, coolant temperature light up as well, eliminate
the fault.
When the fault is eliminated the control light will go
out.
The diagnostic button provides the possibility to read
out existing faults in form of flashing codes.
With the ignition switch in position „I“ the control light
lights for about 2 seconds (function check)
permanent light = A fault message is present, the
engine can be started and the
refuse compactor is still operable
with limitations. Inform the service
department.
the control light flash-
es after 2 seconds= Severe fault, the engine cannot
be started, inform the service de-
partment.
goes out after 2 sec-
onds = the engine function is free of
faults.
does not light = Start the engine, press the diag-
nostic push button for 3 seconds.
Control light flashes 2x. EMR-con-
trol ok.

338 BOMAG 008 911 57

Fault diagnose TCD 2015 12.13
After output of fault
code = 5 seconds pause, the display by
i Note
flashing and permanent light.)
Depending on the significance of the detected fault
the engine may keep on running, however, with limita-
l If necessary repeat as described above to read out
tions (limp home), whereby the fault lamp will continu- the next fault code.
ally light, or the engine will be shut down and the fault
lamp will flash. If the warning lamps for engine oil
pressure control or coolant level also light up, correct
the fault (e.g. top up oil, let the engine cool down).
Once the fault is eliminated the fault lamp will go out.
The diagnostic button provides the possibility to read
out existing faults in form of flashing codes.

Example fault code 211

Fig. 5
l
Press the diagnose button (Fig. 5) for approx. 1 to 3
seconds, then release the button.

Fig. 6
After 2 seconds = 2 x short flashes of 0.4 seconds of
the first digit (recognition of the
EMR control) (Fig. 6).
after another 2 sec-
onds = 1 x long flash of 0.8 second of the
second digit for the stored fault
after another 2 sec-
onds = 1 x short flash of 0,4 second of the
third digit for the stored fault
l Write down the fault flash code.

008 911 57 BOMAG 339

12.14 List of fault flash codes TCD 2015

Flashing code
Short Long Short Function / component Fault
(0.4s) (0.8s) (0.4s)
1 2 6 Hand throttle Signal faulty / implausible
1 3 6 Air filter monitoring Air pressure after filter too low
1 4 4 Oil temperature monitoring Temperature outside nominal range
2 1 6 Fuel low pressure monitoring Fuel low pressure outside nominal
range
2 2 2 Throttle pedal input 1 (PWM) PWM signal faulty
2 2 3 Charge air pressure monitoring Charge air pressure outside nominal
range
2 2 6 Throttle pedal input 1 (analog) Signal faulty / implausible
2 2 8 Fuel filter water level monitoring Max. water level exceeded
2 3 1 Oil pressure monitoring outside nominal range
2 3 2 Coolant temperature monitoring Temperature above nominal range
2 3 3 Intake air temperature monitoring Temperature above nominal range
2 3 5 Coolant level monitoring Level below nominal range
2 3 7 Fuel temperature monitoring Temperature outside nominal range
2 3 8 Fan speed monitoring Speed outside nominal range
2 4 1 Combustion monitoring Misfiring detected in one or several
cylinders
2 7 1 CAN-Bus Time-Out for one or several sent
messages, bus inactive
3 1 4 Hydraulic oil temperature monitoring Temperature outside nominal range
3 1 8 Battery monitoring Voltage outside nominal range
5 1 4 Monitoring of terminal 15 No signal detected
5 1 5 Monitoring of terminal 50 Permanent signal detected

Behaviour in case of fault signal faulty / implausible:

Check function of affected parts; check wiring and
plugs for short circuit, breakage, corrosion.

340 BOMAG 008 911 57

SerDia Service-Software TCD 2015 12.15
12.15SerDia Service-Software TCD
2015

EDC7
EMR3

Fig. 1 Service-Software TCD 2015 Representation of measuring values: There is a vast

SerDIA is a software program from Deutz which ena- variety of measuring values available for selection
bles the use of a laptop computer to run a more de- which can even be used if no EMR-fault is present
tailed fault analysis and to read out the error log in (start behaviour, engine sawing, lack of power).
particular.
Connection
This procedure displays information like:
For this purpose the PC or laptop is connected to the
Location of fault (e.g. ’pedal value transducer’, ’cool- diagnostic interface by means of an interface cable.
ant temperature sensor’)
Work with SERDIA is described in separate operating
Type of fault (e.g. 'bottom limit value fallen short of', instructions.
'sporadic fault')
Environmental data/operating data (speed and oper-
ating hours at the time of the last occurrence of the
fault).
Number of fault locations.
Frequency of fault
Fault status (active - fault present / passive - fault no
longer present).
Fault messages for faults that are no longer active or
have been rectified can be deleted with SERDIA.
Other possible displays:
Function test: Control outputs and governor rod travel
can be activated with the engine stopped.
Assignment of inputs / outputs: Display of the current
assignment of inputs and outputs on the EMR-control

008 911 57 BOMAG 341

12.15 SerDia Service-Software TCD 2015

SerDia connection
SerDia
Connection

Fig. 2 Electric junction box

Replacement of the EMR III control unit

Each control unit is firmly assigned to the engine, ac-
cording to its application. In case of replacement the
control unit must therefore be completed with an en-
gine specific data set. When ordering a new control
unit the engine serial number (sticker on EMR control
unit) must be specified alongside the part number.
Note: The Deutz part number specified on the EMR
control unit is the part number without engine specific
software. The correct part number is to be taken from
the spare parts catalogue.

Replacing the pump with solenoid valve

On engines of type 2015 both injection pump and so-
lenoid valve form one unit and can only be replaced
together. In case of replacement the pump needs to
be calibrated with the EMR control unit. The calibra-
tion must be made with the help of SERDIA (Level II-
Ia). (see also SERDIA manual).

Replacement of other EMR components

Any other EMR components (sensors etc) must under
no circumstances be repaired, but must be replaced if
they are defective.

342 BOMAG 008 911 57

SerDia Service-Software TCD 2015 12.15
SerDia screen shot

Fig. 3 Error log

008 911 57 BOMAG 343

12.16 EMR3 List of fault codes

344 BOMAG 008 911 57

EMR3 List of fault codes 12.16

008 911 57 BOMAG 345

12.16 EMR3 List of fault codes

346 BOMAG 008 911 57

EMR3 List of fault codes 12.16

008 911 57 BOMAG 347

12.16 EMR3 List of fault codes

348 BOMAG 008 911 57

EMR3 List of fault codes 12.16

008 911 57 BOMAG 349

12.16 EMR3 List of fault codes

350 BOMAG 008 911 57

EMR3 List of fault codes 12.16

008 911 57 BOMAG 351

12.16 EMR3 List of fault codes

352 BOMAG 008 911 57

EMR3 List of fault codes 12.16

008 911 57 BOMAG 353

12.17 General trouble shooting chart TCD 2015

12.17General trouble shooting

chart TCD 2015

Faults Causes Action

Temperature below starting limit
Engine oil with wrong SAE viscosity class Change the lubrication oil
Fuel quality not as specified in the operating Change the fuel
Engine does not
instructions
start or starts
Air in the fuel system Bleed the fuel system
poorly
Battery defective or not charged Check the battery
Cable to starter loose or oxidized Check cable connection
Starter defective or pinion does not engage Check starter
Engine does not Engine electronics prevent starting Check fault by fault code, repair as necessary
start and diag-
nostic lamp flash-
ing
Engine starts, but Fuel quality not as specified in the operating Change the fuel
runs irregularly or instructions
misfires Injection line leaking Check the injection line
Injection valve defective Check the injection valve / replace if neces-
sary
Speed changes Engine electronics detected a system fault Check fault by fault code, repair as necessary
are possible and and activates a substitute speed
diagnostic lamp
lights
Oil level too low Fill up lubrication oil
Engine oil level too high Check oil level, drain off if necessary
Air filter clogged / exhaust turbocharger de- Check / replace if necessary
Engine overheat-
fective
ing. Temperature
Air filter service switch / indicator defective Check / replace if necessary
warning system
Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary
responds
Short circuit of heat in cooling system Check the cooling system
Resistance in cooling system too high / flow Check the cooling system
quantity too low
Engine oil level too high Check the oil level
Fuel quality not as specified in the operating Change the fuel
instructions
Air filter clogged / exhaust turbocharger de- Check / replace if necessary
Insufficient en-
fective
gine power
Air filter service switch / indicator defective Check / replace if necessary
Charge air pipe leaking Check the charge air pipe
Injection line leaking Check the injection line
Injection valve defective Check the injection valve
Insufficient en- Engine electronics reducing the output power Check fault by fault code, repair as necessary
gine power and
diagnostic lamp
lights
Engine does not Injection line leaking Check the injection valve / replace if neces-
work with all cyl- sary
inders Injection valve defective Check the injection valve / replace if neces-
sary

354 BOMAG 008 911 57

General trouble shooting chart TCD 2015 12.17
Faults Causes Action
Oil level too low Fill up lubrication oil
Engine has to low Extremely slanted position of engine Check engine pillow blocks / reduce the en-
or no oil pressure gine inclination
Engine oil of wrong SAE class or quality Change the lubrication oil
Engine has ex- Engine oil level too high Check oil level, drain off if necessary
cessive oil con- Extremely slanted position of engine Check engine pillow blocks / reduce the en-
sumption gine inclination
Blue engine ex- Engine oil level too high Check oil level, drain off if necessary
haust smoke Extremely slanted position of engine Check engine pillow blocks / reduce the en-
gine inclination
Temperature below starting limit
Fuel quality not as specified in the operating Change the fuel
White engine ex-
instructions
haust smoke
Injection valve defective Check the injection valve / replace if neces-
sary
Air filter clogged / exhaust turbocharger de- Check / replace if necessary
fective
Black engine ex- Air filter service switch / indicator defective Check / replace if necessary
haust smoke Charge air pipe leaking Check the charge air pipe
Injection valve defective Check the injection valve / replace if neces-
sary

008 911 57 BOMAG 355

12.18 Check the engine oil level

12.18Check the engine oil level

i Note
The machine must be in horizontal position. Just be-
fore testing run the engine approx. 2 minutes with idle
speed. Shut the engine down.

Fig. 4
l
Pull the dipstick (Fig. 4) out, wipe it off with a lint-
free, clean cloth and reinsert it until it bottoms.
l Pull the dipstick back out again.
l
The oil level must be near the ”Max”-mark.
l
If the oil level is too low top up oil immediately.

For quality of oil refer to the table of fuels, lubri-

cants and filling capacities.

356 BOMAG 008 911 57

Change the engine oil 12.19
12.19Change the engine oil

i Note
Drain the engine oil only when the engine is warm.
Preferably use oils of ACEA-classification E4-99. This
enables utilization of the longest oil change intervals.

Oil change intervals (operating hours) for ACEA

quality
E4-99 = 500 operating hours

Danger
!
Fig. 6
Danger of scalding!
l Fill in new engine oil (Fig. 6) through the oil filler
Danger of scalding when draining off hot oil! neck.

For quality and quantity of oil refer to the table of

Environment fuels, lubricants and filling capacities.
Environmental damage! l Screw the cap back on again.
Do not let old oil seep into the ground, but dispose
off environmentally.

Fig. 7
l
After a short test run check the oil level on the dip-
Fig. 5 stick (Fig. 7), if necessary top up to the top mark
l Remove the rear service door. ("Max").
l
Unscrew the safety cap 2 (Fig. 5) from the oil drain
socket (1).
l Take the oil drain hose (3) out of the right hand stor-
age compartment and screw it on, drain the engine
oil off and collect it.
l Once the old oil has run out remove the drain hose
and screw the safety cap back on.

008 911 57 BOMAG 357

12.20 Changing the engine oil filter

12.20Changing the engine oil filter 12.21Change the fuel pre-filter car-
tridge
! Danger

Danger of scalding! Danger

!

There is a danger of scalding by hot oil when un- Fire hazard!

screwing the engine oil filter.
When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Environment Catch running out fuel, do not let it seep into the
Environmental hazard! ground.
Catch running out oil and dispose of environmen- Do not inhale any fuel fumes.
tally together with the engine oil filter cartridge.

Fig. 9
Fig. 8 l
Pull off the cable and unscrew the fuel filter car-
l
Loosen the engine oil filter (Fig. 8) with a suitable fil- tridge (Fig. 9) using an appropriate filter wrench.
ter wrench and screw it off. l
Clean the sealing face on the filter carrier from any
l
Wipe the sealing face clean. dirt.
l
Apply a thin film of clean oil to the rubber seal of the
new engine oil filter.
l
Screw the new engine oil filter on hand-tight.
l Perform a short test run, inspect the engine for
leaks and check the oil level, top up oil if necessary.

Fig. 10
l Unscrew the water separator from the filter car-
tridge (Fig. 10).

358 BOMAG 008 911 57

Change the fuel pre-filter cartridge 12.21

Fig. 11 Fig. 12
l Apply a thin coat of oil to the rubber seal of the water l Operate the hand pump (Fig. 12) manually, until
separator 1 (Fig. 11). fuel flows out of the bleeding screw without air bub-
bles.
l Screw the water separator on by hand (2), until the
seal contacts. l Then tighten the bleeding screw while pumping.
l Tighten the water separator for another half turn (3).
l Fill the filter cartridge with clean diesel fuel (4).
l Apply some oil to the rubber seal of the filter ele-
ment (5) and screw it on by hand, until the seal con-
tacts.
l Tighten the filter element for another half turn (6).
l Plug the water sensor cable back on.
l Check the filter cartridge for leaks after a short test
run.

i Note
Air in the fuel system causes irregular running of the
engine, a drop in engine power, stalls the engine and
makes starting impossible.
Therefore bleed the fuel system after changing the
fuel pre-filter.

Environment
Catch running out fuel and dispose of environ-
mentally.

008 911 57 BOMAG 359

12.22 Changing the fuel filter cartridge

12.22Changing the fuel filter car- 12.23Checking condition of radia-

tridge tor, intercooler and hydraulic
oil cooler, clean, cleaning the
Danger
! engine
Fire hazard!
No open fire, do not smoke, do not spill any fuel. i Note
Do not inhale any fuel fumes. Dirty operating conditions, particularly lubrication oil
and fuel deposits on the cooling fins reduce the cool-
ing effect. You should therefore immediately seal any
Environment oil or fuel leaks near cooling fan, cylinder or oil cooler
Catch running out fuel, do not let it seep into the and subsequently clean the cooling fins.
ground.
l Open the left hand engine compartment doors. ! Danger

Danger of injury!
Perform cleaning work only after the engine has
cooled down and with the engine stopped!

Fig. 13
l
Loosen both fuel filters (Fig. 13) using a suitable fil-
ter wrench and screw it off.
l
Clean the sealing face on the filter carriers from any Fig. 15
dirt. l Remove the service covers on left (Fig. 15) and

Fig. 14
Fig. 16
l Slightly oil the rubber seal on the new filter cartridge
(Fig. 14).
l right hand side (Fig. 16) of the air duct housing.
l Fill the filter cartridge with clean diesel fuel.
Caution
!
l
Turn the new filter cartridge on by hand, until the
seal contacts. During cleaning take care not to damage the fins
on hydraulic oil cooler, intercooler and radiator.
l Then tighten hand-tight. Keep a safe distance with the spray nozzle.
l Check for leaks after a short test run.

360 BOMAG 008 911 57

Checking condition of radiator, intercooler and hydraulic oil 12.23
i Note
Clean the coolers in the correct sequence.
l
Clean hydraulic oil cooler, intercooler and radiator
from the air duct side first.

Fig. 18
l Blow the engine dry with compressed air. Flush lose
dirt with a water jet out of the V-shaped space be-
tween the cylinders.
l The drain bore (Fig. 18) must be free, remove
Fig. 17 blockage if necessary.
l Remove the service door (Fig. 17).
l
Clean all coolers from the air intake side.
l
Remove dried on dirt with a suitable brush.
l Blow the cooling air channels out with compressed
air.
l
In case of oily contamination spray the parts with
cold cleansing agent and spray it off with a water jet
after s sufficient soaking time.
l
If steam cleaning equipment is available, this
should preferably be used.

Cleaning the engine Fig. 19

l In case of oily contamination spray the engine with
!Caution cold cleansing agent and spray it off with a water jet
After cleaning the coolers it is mandatory to clean after s sufficient soaking time.
the engine. l
Drain bores (Fig. 19) and (Fig. 18) must be free, re-
Cover all parts of the electrical system, do not move blockage if necessary.
subject to the direct water jet. l
After wet cleaning run the engine warm to evapo-
rate all water residues and to avoid corrosion.
l Reinstall the service covers.

008 911 57 BOMAG 361

12.24 Changing the coolant, venting the cooling system

12.24Changing the coolant, venting

the cooling system

Danger
!

Danger of scalding!
Change the coolant only when the engine is cold.

!Caution
Do not start the engine after draining off the cool-
ant.
When changing the coolant without any signs of Fig. 22
contamination, cleaning of the cooling system is l
Fill coolant in through the opening in the compensa-
not necessary. tion tank (Fig. 22).

For coolant quantity refer to the table of fuels, lu-

Environment bricants and filling capacities.
Catch coolant and dispose of environmentally. l Close the compensation tank. For bleeding start the
engine and run it warm.

Fig. 20
l
Unscrew the cap (Fig. 20). Fig. 23
l Check the coolant level, top up if necessary (Fig.
23).

Fig. 21
l Connect the drain hose to the drain cock (Fig. 21).
l Guide the drain hose into a vessel of appropriate
size.
l Open the drain cock and let the coolant run out.
l After the coolant has run out close the drain cock,
remove the drain hose.

362 BOMAG 008 911 57

Checking the anti-freeze concentration 12.25
12.25Checking the anti-freeze con- 12.26Checking the condition and
centration tension of the generator V-
belt, replacing the V-belt
!Caution
In order to avoid damage to the engine e.g. by cor- Danger
!
rosion, cavitation and freezing, particular atten-
Danger of injury!
tion must be paid to the inspection of the coolant.
Work on the generator V-belt must only be per-
formed with the engine shut down.
Danger
!

Danger of scalding!
Checking the V-belt
Check the anti-freeze concentration only when the
engine is cold.
l
Perform the inspection with conventional test equip-
ment.
l The anti-freeze concentration (additive) must be at
least 35 Vol% and maximum 45 Vol%.

! Danger

Health hazard!
The mixing of nitrite based anti-freeze agents with
amine based agents results in the formation of
health affecting nitrosamines.
Fig. 24

Environment l
Inspect the entire circumference of the V-belt (Fig.
24) visually for damage and cracks. Replace dam-
Catch all anti-freeze agent and dispose of environ-
aged or cracked V-belts.
mentally.
l
Check with thumb pressure whether the V-belt can
be depressed more than 5 to 10 mm between the V-
belt pulleys, retighten if necessary.

Retightening the V-belt

Fig. 25
l Slacken the fastening screws 3 and 4 (Fig. 25)
slightly.
l Loosen the counter nut (2).
l Turn down tensioning screw (1) in direction of ar-
row, until the correct V-belt tension is reached.
l
Retighten hexagon screws and counter nut.

008 911 57 BOMAG 363

12.27 Check the engine mounts

Changing the V-belt 12.27Check the engine mounts

l
Remove the V-belt of the fan drive.

Fig. 27
Fig. 26 l Check all fastening screws on the engine mounts
l Slacken the fastening screws 3 and 4 (Fig. 26) for tight fit, tighten if necessary (Fig. 27).
slightly.
l Loosen the counter nut (2).
l Turn tensioning screw (1) in direction of arrow to the
stop.
l Take the old V-belt off the V-belt pulley.
l Fit the new V-belt to the V-belt pulleys.
l Tension the V-belt as previously described.
l Reinstall and tension the fan drive V-belt.

i Note
Retighten new V-belts after a running time of 15 min-
utes.

364 BOMAG 008 911 57

Check fastening of engine / turbocharger / combustion air hos- 12.28
12.28Check fastening of engine / 12.29Checking the preheating sys-
turbocharger / combustion air tem. Maintenance in case of
hoses frost.

Danger
!

Fire hazard!
When working on the fuel system do not use open
fire, do not smoke, do not spill any fuel.

Environment
Catch running out fuel.

Fig. 28
l Check charge air line (Fig. 28) and intercooler for
tight fit and leaks.
l Check exhaust pipe and lubrication oil line to and
from the exhaust turbo charger for tight fit and
leaks.
l Check connecting sockets for tight fit.

Fig. 30

i Note
If the system works correctly suction pipe 3 (Fig. 30)
must become hand-warm near the glow plug (1) dur-
ing preheating. Otherwise perform the test in the fol-
lowing sequence:

Test step 1

Fig. 29
l Check combustion air pipe and connecting sockets
for tight fit (Fig. 29).

Fig. 31
l Turn the ignition key to position "I", the control light
"preheating" 1 (Fig. 31) mus flash.
Otherwise the glow plug is defective or the line is in-
terrupted.

008 911 57 BOMAG 365

12.29 Checking the preheating system. Maintenance in case of frost.

Test step 2

Danger
!

Danger of injury!
Keep clear of rotating parts.
l Loosen the pipe fitting (2) on the glow plug for a few
turns.

Fig. 32
l
Press the button of the emergency stop switch in
(Fig. 32).
l
Hold the ignition key in position „I“, until the „pre-
heating“ control light goeas out.
l
Turn the ignition key further to position "II" against
the resistance and crank the engine with the starter.
l
Fuel must run out of the loosened pipe fitting. Oth-
erwise have the system (solenoid valve) checked.

Test step 3
l
Remove the glow plug and connect the fuel line.
l Crank the engine with the starter, see test step 2.
l
Fuel must run out of the glow plug. Otherwise re-
place the clogged glow plug.
l
Reinstall the disassembled parts.

366 BOMAG 008 911 57

Special tools, Deutz engine (TCD 2015) 12.30
12.30Special tools, Deutz engine
(TCD 2015)

TCD 2015 Standard tools

8005
Compression pressure tester 057 250 67
for diesel engines
10 - 40 bar
Checking compression pressure

© 35410-2

8008
Nozzle tester
with spray mist collecting vessel
Check injection nozzles

© 35411-2

8011
Hose clip pliers
Loosen and fasten hose clips
e. g. fuel return pipe

© 39426-1

008 911 57 BOMAG 367

12.30 Special tools, Deutz engine (TCD 2015)

Standard tools TCD 2015

8015
Socket wrench insert
SW 14, reinforced
Unscrew and tighten big end bearing screws.

© 37503-1

8016
Socket wrench insert
SW 17, reinforced
Unscrew and tighten flywheel screws.

© 37504-1

8018
Claw wrench
SW 17, reinforced
Unscrew and tighten union nuts of the injection pipes.

© 37506-1

368 BOMAG 008 911 57

Special tools, Deutz engine (TCD 2015) 12.30

TCD 2015 Standard tools

8024
Assembly pliers 057 250 68
e. g. removing valve stem seals

© 37509-4

8115
V-belt tension measuring device
150 to 600 N
079 947 09
Check V-belt tension

© 35416-3

8189
Pricker 057 250 76
Removing rotary shaft lip seal

© 43206-3

008 911 57 BOMAG 369

12.30 Special tools, Deutz engine (TCD 2015)

Standard tools TCD 2015

8190
Rotation angle disc
with magnet (e. g. setting valve clearance)
057 250 72

© 42528-1

7
8191
Socket wrench insert 057 250 74
with slotted screwdriver insert (8x1.6)
(e. g. setting valve clearance)

© 43060-0

8196
Open end wrench adapter 057 250 71
Size 13,
for torque wrench
Tighten lock nut of the valve clearance setting screw.

© 43197-0

© 06/2006 6/8 8248-001

370 BOMAG 008 911 57

Special tools, Deutz engine (TCD 2015) 12.30

TCD 2015 Standard tools

9017
Assembly lever
057 250 78
e. g. removing and installing valves

© 37511-1

008 911 57 BOMAG 371

12.30 Special tools, Deutz engine (TCD 2015)

TCD 2015 Special tools

6066
Assembly block 079 947 30
Engine clamping, double-sidedmaximum load capacity
at middle centre of gravity approx. 1200 kg

© 35451-2

6066/151
Clamping bracket
(in conjunction with assembly block 6066)
Engine clamping, double-sided

© 37601-1

100130
Connector
(in conjunction with compression pressure tester 8005)

© 37602-1

372 BOMAG 008 911 57

Special tools, Deutz engine (TCD 2015) 12.30

Special tools TCD 2015

100300
Turning gear
with mechanical TDC transmitter and degree scale for 079 947 11
start of pumping check
Turn crankshaft,
block engine

© 37603-1

100350
Turning gear
Turn crankshaft on the V-belt pulley.

© 37604-1

100400
Dial gauge with fixing wheel
Measuring range 0 - 10 mm / 0.01 mm
057 250 81

© 37605-1

008 911 57 BOMAG 373

12.30 Special tools, Deutz engine (TCD 2015)

TCD 2015 Special tools

100410
Digital gauge
Measuring range 0 - 30 mm / 0.01 mm 057 250 82

© 43205-0

100850
Measuring instrument with measuring plate 8
Checking piston overhang

© 37606-1

101830
Dial gauge adapter
Measuring installation depth for impulse transmitter

© 45906-0

© 06/2006 5/16 8249-001

374 BOMAG 008 911 57

Special tools, Deutz engine (TCD 2015) 12.30

Special tools TCD 2015

102560
Tester
Basic device with two dipsticks
Check radiation position of the piston cooling nozzle
(old version)

© 37608-1

102565
Dipstick
(in connection with tester 102560)
Check radiation position of the piston cooling nozzle
(new version)

© 37628-1

103240
Dial gauge holder
with stylus extension (diameter 5/95 mm)
Checking plunger lift of injection pumps

© 43927-3

008 911 57 BOMAG 375

12.30 Special tools, Deutz engine (TCD 2015)

TCD 2015 Special tools

110030
Puller
(in connection with sliding hammer 150800) 079 947 61
Removing fuel injector

© 35433-2

110110
Holder
SW11,
Clamp fuel injector in the vice

© 35434-2

110130
Slotted nut wrench
Unscrew and tighten union screw on the fuel injector.

© 37610-1

376 BOMAG 008 911 57

Special tools, Deutz engine (TCD 2015) 12.30

Special tools TCD 2015

110500
Special wrench 057 250 86
Size 17
Removing and installing injection pipes

© 35436-1

110510
Special wrench
Removing and installing charge air pipe

© 43928-3

110700
Socket wrench insert
Size 27
057 250 87
long
Removing and installing oil pressure transmitter

© 42341-2

008 911 57 BOMAG 377

12.30 Special tools, Deutz engine (TCD 2015)

TCD 2015 Special tools

110901
Disassembly tool
Removing O-ring

© 45950-1

120660
Puller
(in connection with sliding hammer 150800)
Removing jammed fuel injector sealing ring

© 45421-0

120900
Support bracket
pivoting
057 250 90
Clamping cylinder head

© 35438-2

378 BOMAG 008 911 57

Special tools, Deutz engine (TCD 2015) 12.30

Special tools TCD 2015

120910
Base plate 057 250 91
(in conjunction with support bracket 120900 if support
bracket is not screwed tightly)

© 35439-2

121410
Assembly tool
057 250 92
Assembling valve stem gasket

© 37614-1

121420
Assembly sleeves
057 250 93
Set of assembly sleeves for valve stem gasket

© 43210-0

008 911 57 BOMAG 379

12.30 Special tools, Deutz engine (TCD 2015)

TCD 2015 Special tools

130300
Universal piston ring pliers
Removing and installing the piston rings
057 250 94

© 35441-2

130400
Trapezoidal groove wear gauge
Testing piston ring groove

© 36461-1

130650
Piston ring compressor
Removing and installing the piston rings

© 35443-2

380 BOMAG 008 911 57

Special tools, Deutz engine (TCD 2015) 12.30

Special tools TCD 2015

131200
Base plate
(in connection with assembly tool kit 131210)
Pressing small end bush out and in

© 37616-1

131210
Assembly tool kit
(in connection with base plate 131200)
Pressing small end bush out and in

© 37617-1

142640
Assembly tool
Installing crankshaft sealing ring
(opposite side to flywheel)

© 37618-1

008 911 57 BOMAG 381

12.30 Special tools, Deutz engine (TCD 2015)

TCD 2015 Special tools

142650
Assembly tool
Installing crankshaft sealing ring
(flywheel side)

© 37619-1

143830
Assembly tool
Removing and installing camshaft bearing

© 37621-1

144150
Counter support
Blocking camshaft gear wheel

© 37622-1

382 BOMAG 008 911 57

Special tools, Deutz engine (TCD 2015) 12.30

Special tools TCD 2015

150030
Tool kit
Repairing the collar rest of the cylinder liner

© 40221-0

150120
Assembly device
Installing cylinder liner

© 37624-1

150130
Puller
Removing cylinder liner

© 37625-1

008 911 57 BOMAG 383

12.30 Special tools, Deutz engine (TCD 2015)

TCD 2015 Special tools

150800
Slide hammer 079 947 18
Removing fuel injector

© 35449-2

170050
Special wrench 079 947 28
Unscrewing the filter cartridges

© 37629-1

170100
Special wrench
Removing and installing lubricating oil pipe turbocharg-
er

© 37626-1

384 BOMAG 008 911 57

Special tools, Deutz engine (TCD 2015) 12.30

Special tools TCD 2015

170120
Disassembly and assembly tool
Pressing the ball stud of the rocker arm shaft out and in

© 37627-1

170160
Stoppers/caps 079 947 29
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system

© 43663-0

008 911 57 BOMAG 385

12.30 Special tools, Deutz engine (TCD 2015)

386 BOMAG 008 911 57

 13 Working hydraulics

008 911 57 BOMAG 387

13.1
Hydraulic system
13.1 Hydraulic system
Travel system as well as steering and dozer blade on
these machines are hydraulically operated.
This guarantees an almost loss-free transfer of engine
output power to compactor wheels, steering cylinders
and dozer blade/bucket control.
The pumps for the corresponding circuits are driven
by the engine via a transfer box and convert the me-
chanical energy provided by the engine into hydraulic
energy.
Inside the motors or the cylinders for steering or dozer
blade actuation this hydraulic energy is then convert-
ed back to mechanical energy.
Since the medium oil is used for this transfer of power,
any losses in power are only of minor significance.
All hydraulic circuits are protected against contamina-
tion by charge oil filters and a hydraulic oil return flow
filter.
Safety elements in pumps and hydraulic control units
protect the hydraulic system and the drive engine
against overloads and damage resulting from such
excessive loads.
To ensure quick heating of the hydraulic oil up to op-
erating temperature the return flow from the hydraulic
system flows directly back to the hydraulic oil tank, un-
til the operating temperature is reached. When the oil
temperature comes close to operating temperature a
thermostat valve will start to open and guide the oil
flow through the hydraulic oil cooler back to the tank.
This ensures that the operating temperature is quickly
reached, particularly during the cold season, and that
the hydraulic system can be operated without any
risks.
388 BOMAG
Hydraulic system
13.2 Working hydraulics
The working hydraulics on sanitary landfill compactors
BC 972/1172 RB cover the hydraulic systems for
steering and dozer blade control.
The working hydraulics mainly consist of 2 axial piston
pumps (tandem unit), the control valve block for the
functions dozer blade up / down and steering control,
the 2 steering cylinder and the dozer blade cylinder
and the electrical parts (control potentiometer for
steering and dozer blade control and ESX-control).
Tow swash plate type axial piston pumps supply the
system with pressure oil.
The movement of the dozer blade is controlled by a
joystick beside the driver’s seat. The control is ex-
tremely light moving and sensitive.
When shifting the control lever forward and pressing
the top push button at the same time the dozer blade
can be held in floating position (piston and piston rod
sides of the lift cylinders are open to the tank). In this
operating mode the dozer blade can be used to level
the landfill site surface while driving in reverse. The
electro-hydraulic operation of the working hydraulics
is similar to the system used in machines of series BC
671/771-RS. The joystick units are potentiometers,
the signals of which are converted to dedicated cur-
rent pulses in the ESX-control, to operate the corre-
sponding valves in the valve block.
Steering control and operation on machines BC 972/
1172 RB are based on the principle of the dozer blade
control. The potentiometer in the steering joystick
transmits signals to the ESX-control, where these sig-
nals are processed and send on to the steering valve
in the control valve block.
008 911 57
Steering and working pump 13.3
Steering and working pump use in open hydraulic circuits. Both pumps are ar-
13.3 Steering and working pump

ranged hydraulically parallel, LS-line as well as pres-

The tandem pump for the working hydraulics consists
sure line are connected by a T-fitting or in the control
of two identical swash-plate operated axial piston
block. The pump speed is slightly lower than the
pumps with variable displacement. However, the
speed of the travel pumps, because the working pump
pumps deliver oil only to one direction, i.e. the swash
transfer box ratio i = 1, 023 differs slightly from the
plate moves out of neutral position only to one direc-
travel pump ratio of i = 0,740.
tion. They are therefore particularly suitable for the

Fig. 33 Hydraulic pump for working hydraulics the engine the swash plate will move immediately
1 Working pump back towards zero, until the stand-by pressure adjust-
2 Flow control valve ed on valve 2 (Fig. 33) is reached.
3 Pressure control valve As long as the steering system or the bucket hydrau-
lics do not require any oil, the pumps will maintain the
4 Resetting piston
so-called ”Stand-by pressure” (30 ±1 bar). Due to the
5 Control piston flow control in the working hydraulics the engine has
(B) to dozer blade control and steering to supply power only when it is actually needed.
(L) to hydraulic oil tank Working principle
(S) from hydraulic oil tank When looking at the working hydraulics, for better un-
(X) LS, load signal from steering and dozer blade derstanding one must always consider two different
operating conditions:
When the engine is not running the swash plate is in
max. displacement position, however, when starting

008 911 57 BOMAG 389

13.3 Steering and working pump

l Engine not running

l Engine running
When the engine is not running the swash plate in the
steering and working pump is at maximum displace-
ment position. The spring of the smaller control piston
in the pump holds the swash plate in this position.
When starting the engine pressure builds up between
the outlet on the steering and working pump and the
inlet ”P” (front pump) and "P2" (rear pump) on the
valve block. These two ports are connected inside the
control block. This pressure increase is possible, be-
cause all three 8/3-way valves in the valve block are
closed in neutral position (all consumers in neutral po-
sition).
The now increasing pressure moves the flow control
valve spools on the pumps and opens a connection
between the pump flow and the bigger control piston
(reversing piston) for the pump swash plate.
Since the effective area of this piston is much bigger
than the area of the counter piston, the increasing
pressure moves the swash plates towards zero (de-
spite the spring force supporting the counter piston).
The setting of the flow control valves ensures a so-
called ”stand-by pressure” in the system.
The pressure control valve on the working pump limits
the high pressure in the working hydraulics to 230 bar.
If the system pressure increases up to the adjusted
value because of steering or dozer blade operation,
this pressure will move the spool inside the pressure
control valve. This guides high pressure on the piston
area of the reversing pistons inside the pumps and the
swash plates are thereby moved towards zero posi-
tion.
If the pressure drops below the adjusted value, the
spring is able to close the pressure control valve and
the pumps return to the previous displacement.

390 BOMAG 008 911 57

Control valve block, steering and dozer blade
Control valve block
13.4 Control valve block, steering and dozer blade
Fig. 34 Control valve block
(A) LS signal to the working pumps
(P) from rear working pump
(P2) from front working pump
Pst1, Pst2) from rear right hand charge pump
The function of the control valve block is based on the
principle of load pressure independent flow distribu-
tion. This concept enables quick and precise working
with overlapping movements of several consumers
under different load pressures.
The operator controls the speed for steering and doz-
er blade proportional to the deflection of the joystick or
the dozer blade control lever, irrespective of the load
pressure. The control valve spools in the individual
008 911 57
13.4
sections of the control block are perfectly adapted to
the individual requirements for steering or dozer blade
control by the geometry of their measuring orifices.
The control valve block is located in the hydraulic con-
nection from steering and working pump to the con-
sumers (steering and dozer blade cylinders). Both
work functions are integrated in the control block
housing.
Pump, tank and LS-lines are internally linked and
combined as central connections on the control block.
In the control block all consumers are arranged in par-
allel mode.
The geometry of the fine control grooves in the control
pistons is specially adapted to the characteristics of
BOMAG 391
13.4 Control valve block, steering and dozer blade
the corresponding consumer. The control pistons for
the individual axes can thus be interchanged. The pis-
tons must not be turned by 180°.
Besides the piston axes to control the consumer
movements, the control block also contains compo-
nents serving necessary system functions:
l Stabilizing the system
l Securing the primary and secondary pressure
l
Limiting the permissible LS-pressure
l Avoiding cavitation caused by external loads or de-
celeration
The optimal adjustment of pump and control block en-
sures quick response with high stability.
392 BOMAG
Load-Sensing
If the working hydraulics (steering and dozer blade
control) does not demand any power, the load signal
(load sensing line ”LS”) for all consumers is dumped
into the tank, in this case the load signal is 0 bar.
If one of the consumers requires hydraulic oil, the ac-
tuation of the steering or bucket hydraulics will gener-
ate a load signal.
Example steering
In neutral position the steering valve is ”closed”, i.e.
there is no connection between the valve inlet ”P” and
one of the outlets ”A2” or ”B2” to the steering cylin-
ders. The load signal line is directly connected with
the tank return line.
When operating the steering joystick the valve inlet
port ”P” is connected with one of the outlets ”A2” or
”B2” and with the load sensing line ”LS”.
The pressure, which is now increasing because of the
load resistance, is applied to the back of the flow con-
trol valve on the steering and working pump through
the ”LS”-line. The spool in the flow control valve
moves and interrupts the oil flow to the reversing pis-
ton for the swash plate.
The spring loaded counter piston actuates the swash
plate and the pump delivers oil to the steering system.
When stopping the steering joystick movement after
this steering operation, the 8/3-way valve in the steer-
ing valve block will automatically return to neutral po-
sition. The connection between valve inlet port ”P” and
the valve outlets ”A2” or ”B2” and the load signal line
”LS” is interrupted again. The LS-drain valve in the
valve block connects the load signal line ”LS” with the
return flow to the tank, the pump returns immediately
towards zero and the pressure drops to the stand-by
pressure value.
008 911 57
Control valve block, steering and dozer blade
Steering control
The steering movements are controlled by means of
the "steering joystick" in the left hand arm rest of the
operator's seat. The steering speed is proportional to
the displacement of the joystick.
Due to the electronic control via the ESX-control the
solenoid valves of the steering valve are triggered in
pulses. With each pulse a minimum oil quantity is
guided to the control piston of the steering spool (in-
crease of steering angle) or relieved. This increases
the opening cross-sections of the 8/3-way valve in
both positions ”left” and ”right” very sensitively propor-
tional to the actuation of the steering joystick. This en-
ables very sensitive steering of the machine.
008 911 57 BOMAG
13.4
Dozer blade control
The dozer blade movements (up, down and float posi-
tion) are controlled by means of a ”joystick” on the
right hand side of the driver’s seat.
With this joystick the ESX-control is electrically pro-
portionally triggered via a potentiometer.
The lowering speed is proportional to the displace-
ment of the joystick.
When operating the joystick forward and pressing the
push button at the same time, the 2/2-way valve for
float position will switch to ”float position”, i.e. both pis-
ton and piston rod sides of the lifting cylinders are con-
nected with the tank. This position is particularly
suitable for levelling the landfill site surface during re-
verse travel.
When the joystick is pulled back, the valve is switched
to position ”up”. Oil flows from the working pump
through the valve block to the piston rod sides of the
lifting cylinders and the dozer blade moves up.
The lifting speed is proportional to the displacement of
the joystick.
393
13.4 Control valve block, steering and dozer blade
Description of individual components
LS drain valve
The LS drain valve relieves the LS line to the tank,
when all work functions are in neutral position (no
function operated). When operating steering / dozer
blade, the flow control valve will regulate the flow vol-
ume from the LS line to the tank, irrespective of the
load pressure.
Fig. 35 LS drain valve
1 Spring
2 Control piston
3 Control orifice
The 2-way flow limiting valve in cartridge design con-
sists of housing, control piston with control orifice and
spring. The control piston maintains the pressure drop
across the orifice constant, irrespective of the LS
pressure and the outflowing LS flow volume.
394 BOMAG
LS shuttle valve
The LS signal reported by the pressure balance with
the highest pressure reaches the pump control
through orifice 1 (Fig. 36). In neutral position the LS
pump control is relieved to the tank through orifice (2)
and the LS drain valve.
Fig. 36 LS shuttle valve
1 Orifice
2 Orifice
3 LS signal to pump control
4 LS signal in control block
5 effective to the valve block
6 effective to the pump
The cooperation of various orifices in the LS shuttle
valve with the capacity of the LS hose between control
block and pump (defined oil volume / line cross-sec-
tion) leads to the damping of excessive pressure puls-
es in the system. Short and strong pressure pulses in
the system will thus not cause immediate undesired
reactions of the pump.
008 911 57
Control valve block, steering and dozer blade 13.4
LS-pressure limitation Primary pressure relief valve
The LS pressure limitation limits the maximum LS
pressure in the system. Once the LS pressure reach-
es the value set by the spring, the valve seat will open
a connection to the tank and maintain the max. LS
pressure at a constant level.
The cartridge type valve is screwed into the control
block and factory set to a specific value.

Fig. 38 Primary pressure relief valve

1 Consumer port
2 Orifice D1
3 Spring 1
4 Main taper
5 Area A2
6 Orifice D2
Fig. 37 LS-pressure relief valve 7 Counter nut
1 Counter nut 8 Protective cap
2 Basic housing 9 Adjustment spindle
3 Valve seat 10Adjustment spring
4 High pressure setting 11Pilot control taper
5 Spring 12Spring 2
6 Tank 13Tank port
7 LS system pressure 14Area A3
15Volume C
16Area A1
The pilot controlled primary pressure relief valve is
screwed into the side of the control block and, in its
function of a safety valve, it limits the maximum pump
pressure to the adjusted value (approx. 260 bar).
Pressure peaks may be experienced in the pump line,
e.g. if the pump does not regulate the flow volume
down quick enough or a malfunction occurs in the sys-
tem. The supplier of the valve block has set the pres-
sure and sealed the block. Primary pressure relief
valve (pump side) and secondary relief valves (cylin-
der side) are identical in design and function. System
pressure p is applied to chamber C through orifice D1.
As the area A2 is bigger than the area A1, the main ta-
per remains closed. Spring 1 in chamber C ensures a
stable installation position.
As long as the system pressure p is lower than the val-
ue adjusted with the adjustment spindle, the valve will
remain closed. If pressure p exceeds the adjusted val-
ue, the pilot control taper will open and allow oil to flow
from chamber C through orifice D2 into the tank. The
pressure in chamber C collapses, because the flow
through the smaller cross-section of orifice D1 is
smaller than the drain through the opened pilot control
taper. The higher pressure p on the area A1 opens the

008 911 57 BOMAG 395

13.4 Control valve block, steering and dozer blade

main taper against the spring 1 and links the pump line
with the tank. The feed function is not used on the pri-
mary side.
Secondary / consumer valves
Shock valve
The cartridge type pilot controlled pressure/feed
valves in the individual consumer ports A and B are
screwed into the individual sections, above the control
pistons. The valve protects the consumer circuit
against overloads or damage caused e.g. by external
forces or sudden decelerations (control piston in neu-
tral), by relieving pressure peaks to the tank.
As a safety valve it limits the maximum pressure in the
consumer and in the connecting line to the way valve
to the adjusted value. The pressure has been adjust-
ed and the blocked sealed by the manufacturer before
delivery.

Fig. 39 Shock valve

1 Consumer port
2 Orifice D1
3 Spring
4 Main taper
5 Area A2
6 Orifice D2
7 Counter nut
8 Protective cap
9 Adjustment spindle
10Adjustment spring
11Pilot control taper
12Spring 2
13Tank port
14Area A3
15Volume C
16Area A1

Function
The corresponding load pressure of the consumer
port is applied to chamber C through orifice D1. Spring
1 in chamber C only ensures a stable installation po-
sition. As long as the consumer pressure p is lower
than the value adjusted with the adjustment spindle,
the valve will remain closed. If pressure in the con-
sumer port A or B exceeds the adjusted value, the pi-
lot control taper will open and allow oil to flow from
chamber C through orifice D2 into the tank. The pres-

396 BOMAG 008 911 57

Control valve block, steering and dozer blade
sure in chamber C collapses, because the flow
through the smaller cross-section of orifice D1 is
smaller than the drain through the opened pilot control
taper. The higher pressure p on area A1 opens the
main taper and links the pump line with the tank.
008 911 57 BOMAG
13.4
Pre-tensioning valve
The valve block has two internal tank channels. The
first one connects the shock valve for steering to the
right and the outlet of a floating position valve directly
with the tank. The second tank line is pre-tensioned by
a 18 bar valve. Here all consumer outlets are closed.
This protects the cylinders against cavitation, which
could be caused e.g. by abrupt lowering of the. Fur-
thermore, the shock valve for steering to the left and
for lifting the dozer blade as well as the other float po-
sition valve, are connected to this pre-tensioned chan-
nel for reasons of design.
397
13.4 Control valve block, steering and dozer blade

Float position valves Function of the control valve block

When switching the solenoids Y102, the float position
valves connect both sides of the hydraulic cylinder
with the tank return line.
(General description, the components may vary in de-
tail from the BOMAG version. For better understand-
ing the pressure balances, in particular, are shown as
3/3-way proportional valves, instead of 2 individual
valves, as shown in the original hydraulic diagram.
However, the function is absolutely identical).

Neutral position

Fig. 40 Neutral position 6 Control piston

1 Lift limitation 7 Infeed measuring orifice p –› A
2 Secondary pressure relief/boost check valve 8 Infeed measuring orifice p –› B
3 Load retaining valve 9 Outlet orifice B –› T
4 LUDV- pressure balance 10Outlet orifice A –› T
5 11Passage p –› A

398 BOMAG 008 911 57

Control valve block, steering and dozer blade
12Passage p –› B
13Control piston
14Pressure balance
15Pressure spring, pressure balance
With the control piston in neutral position (no control
current applied to the proportional solenoids connec-
tions a or b) the connection between pump and p’-
channel (after measuring orifice) is blocked by the
spool. Load retaining valves and pressure balance are
closed. The pressure in the p’- channel and behind the
008 911 57 BOMAG
13.4
load retaining valves is in this situation relieved to tank
pressure through the piston clearance. The consumer
ports are blocked by the overlapping of the control pis-
ton in the housing. The consumer is thus locked and
fixed between two oil columns.
The pressure balances for the individual functions
(steering / dozer blade) are arranged downstream of
the control piston measuring orifice. They consists of
a control piston (13) and a pressure spring (15), which
ensures a stable initial position.
399
13.4 Control valve block, steering and dozer blade
Individual operation or consumer with highest
load
Fig. 41
The force of the pilot pressure, which is released by
the control solenoids, shifts the control piston (6) pro-
portionally against spring pressure. In this illustration
the solenoid on connection "a" shifts the piston to the
right against the spring in the control cover on side B.
The inlet orifice (7) of the control piston opens a pas-
sage from pump port P to channel p’. The pressure in
this chamber opens the pressure balance (14) and is
applied up to the load retaining valves (3).
The consumer pressure pc in port A keeps the left
hand load retaining valve (3) closed through the pas-
sages in control piston (11). As p’ increases higher
than pc, the non-return valve will open. The connec-
tion between pump and consumer is opened and the
400 BOMAG
movement is initiated. The oil displaced from the con-
sumer flows from B through the outlet orifice (9) back
to the tank. The secondary pressure relief valves (2)
remain closed as long as the pressure in the consum-
er connection is lower than the adjusted pressure. In
case of cavitation in the consumer connection the
main taper of the combined pressure relief/boost
check valve in the infeed line (side A) opens, e.g.
caused by extern negative forces, and enables the in-
feed from the pre-tensioned tank channel into the
block.
In case of individual movements or if the load pres-
sure of the consumer pc is the highest in the system,
the LS pressure is generated from the p'-channel
through the bore in the pressure balance and fed back
008 911 57
Control valve block, steering and dozer blade
to the pump control and to the section pressure bal-
ances with lower load pressure.
Feeding the LS-signal from the p’-channel, before the
load retaining valves, ensures blocking of the con-
sumer port, until the required working pressure is
reached. This prevents short-term dropping of the
consumer by removing oil volume from the consumer
lines to feed the LS-system.
The pressure balance is completely open and the p’-
channel is connected with the consumer port pc with-
out any pressure drop.
008 911 57 BOMAG
13.4
Overlapping of movements
System saturated
In saturated operation of the system the quantity re-
quested through the measuring orifices is smaller than
or identical with the pump flow.
Σ Q consumer <= maximum Q pump (within the output
control)
Δpmeasuring orifice approximately corresponds with the
ΔpLS control adjusted on the pump flow control.
The difference between both values results from the
losses in the supply line between pump and measur-
ing orifices.
401
13.4 Control valve block, steering and dozer blade

Overlapping with a consumer with higher load

pressure

Fig. 42 regulating position the control edge of the pressure

A typical example for this is lifting the dozer blade balance generates a pressure drop from channel p’ to
while steering. The higher load pressure in the dozer pc of the consumer port. The Δp across the measuring
blade circuit reduces the cross-section of the orifice in orifice (7) is identical and the consumer speed thus
the pressure balance for the steering section. In this depends on the difference of the load pressures.

402 BOMAG 008 911 57

Control valve block, steering and dozer blade 13.4
Subsaturation / priority function

Fig. 43 Function of pressure balance under different load pressures blade pressure balance is already closed. This gives
(A) Load pressure low the steering function priority.
(B) Load pressure high If the speed of one consumer is reduced during the
overlapping of movements in subsaturation, i.e. the
1 Spring chamber
measuring orifice is closed, the degree of subsatura-
2 Control orifice tion will drop. The Δp measuring orifice of the still actuat-
In case of subsaturation of the system the oil quantity ed section will increase and the speed of the
demanded by the sum of the open measuring orifice corresponding movement will follow proportionally.
cross-sections exceeds the maximum flow rate of the
pump. The flow control valve no longer is able to gen-
erate the required system pressure by operating the
pump to a higher displacement. The pump pressure
drops, because the pump has already reached its
maximum displacement, as specified by the perform-
ance characteristic.
In case of subsaturation the pump flow rate is solely
determined by the power controller.
Σ Q Consumer > Maximum Q Pump
In case of subsaturation of the system the pressure
balances of both consumers are wide open and the
LS pressure corresponds with the pressure p' behind
the measuring orifice. However, the system/pump
pressure drops with every degree of subsaturation
and this applies also for the Δp measuring orifice and the
section quantity.
The pressure springs in the pressure balances for
steering and dozer blade are of different designs
(steering 1-2.5 bar, dozer blade 58 bar). This has the
effect, that the steering pressure balance will stay
open in case of subsaturation, whereas the dozer

008 911 57 BOMAG 403

13.4 Control valve block, steering and dozer blade

404 BOMAG 008 911 57

 14 Tests and adjustments in working hydraulics

008 911 57 BOMAG 405

14.1 Tests and adjustments on the steering/working pump

Measuring and adjustment points

14.1 Tests and adjustments on the steering/working pump

Fig. 44 Tandem working pump with pressure/flow control valve

Pos. Designation Pos. in hydraulic dia- Measuring value

gram
1 Stand-by pressure adjustment screw 30 ± 1 bar at Pos. 3
2 High pressure adjustment screw 230 +10 bar at Pos. 3
3 High pressure test port 0 - 230 +10 bar
4 LS-pressure test port X 0 - 210 +10 bar

406 BOMAG 008 911 57

Tests and adjustments on the steering/working pump 14.1
Tests and adjustments Checking/adjusting high pressure

Checking/adjusting stand-by pressure

Fig. 46
l Connect a 600-bar pressure gauge to high pressure
Fig. 45
test port (Fig. 46).
l
Connect a 60-bar pressure gauge to high pressure
test port (Fig. 45).
l Connect a 600-bar pressure gauge to LS pressure
test port 4 (Fig. 44).
l
Connect a 60-bar pressure gauge to LS pressure
test port 4 (Fig. 44).
Caution
!

! Caution
Do not operate the steering and the dozer blade,
since this would destroy the pressure gauge.
l Start the engine and run it at low idle speed.
l Read high and LS pressure values in unoperated
state.
Nominal value:
30 ± 2 bar high pressure (stand-by pressure)
approx. 0 bar LS-pressure
Adjustment procedure
l
Block the rear pump by backing the adjustment
screw (Pos. 1 rear) (Fig. 44) out.
l Correct the stand-by pressure on the flow control
valve of the front pump (Pos. 1 front) (Fig. 44).
l Set the stand-by pressure on the flow control valve
of the rear pump 0.5 to 1 bar higher than on the front
pump.
Danger of squashing!
Make sure nobody is near the dozer blade.
l Start the engine and run it with high idle speed.
l Raise the dozer blade and hold the control lever
against the end stop.
Nominal value:
230 +10 bar on the high pressure test port
LS-pressure 210 + 10 bar.
Adjustment procedure
l Block the rear pump by backing the high pressure
adjustment screw (Pos. 2 rear) (Fig. 44) out.
l
Correct the high pressure on the flow control valve
of the front pump (Pos. 2 front) (Fig. 44).
l Set the stand-by pressure on the flow control valve
of the rear pump 0.5 to 1 bar higher than on the front
pump.

008 911 57 BOMAG 407

14.1 Tests and adjustments on the steering/working pump

Checking/adjusting the LS-pressure for the work-

ing pumps

Fig. 47
l Connect a 600-bar pressure gauge to high pressure
test port (Fig. 47).
l Connect a 600-bar pressure gauge to LS pressure
test port (4) (Fig. 44).
l
Operate the steering/dozer blade slowly from neu-
tral to end stop, read both pressure gauges.

Nominal value:
As long as the working cylinders are moving the LS-
value should always be approx. 30 bar lower than the
actual high pressure. When holding the control levers
against the end stop the LS-pressure should increase
to 210 + 10 bar.
l
If there is no or a too low LS-signal, you should first
check the electric triggering of the control valves. If
the electrical system is Ok, you should check the
LS-system (valve block, hoses).
l
If both pressures are too low at the same level, the
fault is caused by the pump. The pump high pres-
sure can be corrected on the lower adjustment
screw. Should this not be possible, either the pres-
sure/flow control valve or the pump itself is defec-
tive.

408 BOMAG 008 911 57

Measuring and adjustment points on control valve block 14.2
Measuring and adjustment points
14.2 Measuring and adjustment points on control valve block

Fig. 48 Control valve block

Pos. Designation Pos. ii electric wir- Pos. in hydraulic Measuring

ing diagram diagram value
1 Proportional solenoid steering left Y93 0-1000 mA
- Proportional solenoid steering right (on oppo- Y92 0-1000 mA
site side)
2 Switching solenoid, float position Y102 24 Volt
- 2. Switching solenoid, float position (on oppo- Y102 24 Volt
site side)
3 Proportional solenoid, blade down Y109 0-1000 mA
- Proportional solenoid, blade up (on opposite Y108 0-1000 mA
side)
4 Pressure test port, steering left Ma2 0 -28 bar
- Proportional solenoid, steering right (on op- Mb2 0 -28 bar
posite side)
5 Pressure test port, blade up Ma1 0 -28 bar
- Proportional solenoid, blade down (on oppo- Mb1 0 -28 bar
site side)
6 Pressure test port, pre-loaded tank line Mt1 0 -18 bar
7 Pressure test port, pump pressure Mp 0-203 + 10
bar
8 LS-pressure limitation 3 210 ±10 bar
9 Tank pre-loading valve 6 18 bar

008 911 57 BOMAG 409

14.2 Measuring and adjustment points on control valve block

410 BOMAG 008 911 57

 15 Travel hydraulics

008 911 57 BOMAG 411

15.1 Hydraulic system

Hydraulic system
15.1 Hydraulic system

Travel system as well as steering and dozer blade on

these machines are hydraulically operated.
This guarantees an almost loss-free transfer of engine
output power to compactor wheels, steering cylinders
and dozer blade/bucket control.
The pumps for the corresponding circuits are driven
by the engine via a transfer box and convert the me-
chanical energy provided by the engine into hydraulic
energy.
Inside the motors or the cylinders for steering or dozer
blade actuation this hydraulic energy is then convert-
ed back to mechanical energy.
Since the medium oil is used for this transfer of power,
any losses in power are only of minor significance.
All hydraulic circuits are protected against contamina-
tion by charge oil filters and a hydraulic oil return flow
filter.
Safety elements in pumps and hydraulic control units
protect the hydraulic system and the drive engine
against overloads and damage resulting from such
excessive loads.
To ensure quick heating of the hydraulic oil up to op-
erating temperature the return flow from the hydraulic
system flows directly back to the hydraulic oil tank, un-
til the operating temperature is reached. When the oil
temperature comes close to operating temperature a
thermostat valve will start to open and guide the oil
flow through the hydraulic oil cooler back to the tank.
This ensures that the operating temperature is quickly
reached, particularly during the cold season, and that
the hydraulic system can be operated without any
risks.

412 BOMAG 008 911 57

Travel system (general description) 15.2
Travel drive
15.2 Travel system (general description)

Fig. 49 Schematic, front right hand travel circuit All four pumps are simultaneously controlled by pilot
1 Diesel engine pressure. The pilot oil needed to control the travel
2 Transfer case pumps is supplied by four charge pumps. The pump
flow from the charge pumps is also used to feed the
3 3.1 Travel pump front right, 3.2 Charge pump front closed travel circuits and to compensate leak oil and
right, 3.3 Travel pump rear right, 3.4 Charge pump flushing quantities.
rear right
The end of each tandem pump unit carries a charge
4 Control piston
pump. The charge pumps are gear pumps which are
5 Travel direction valve driven by through-shafts with the output speed of the
6 Travel direction switch transfer box.
7 DA-control valve The charge pumps draw the hydraulic oil out of the hy-
8 Speed range selector switch draulic oil tank and deliver it through a 12 µ fine filters
to serve the individual functions (control of travel
9 ESX control
pumps, boost check valves). The charge oil flow from
10Charge pressure limitation the rear right charge pump (when looking in travel di-
11Travel motor rection forward) is additionally used to open the multi-
12Planetary drive disc parking brakes in the planetary gears on the com-
pactor wheels. All leak oil and flushing oil quantities
13Solenoid valve for brake
are returned to the hydraulic oil tank through a central
14Brake switch return flow filter block, a temperature controlled 3/2-
15Emergency stop way valve and the hydraulic oil cooler.
16Throttle pedal The travel pumps are equipped with all control and
The travel system of the sanitary landfill compactor safety elements needed for operation in a closed hy-
works with four closed hydraulic circuits. Each of draulic circuit, such as servo control unit, combined
these circuits consists of a travel pump (variable dis- high pressure relief and boost check valves, charge
placement pump) and a travel motor (variable dis- pressure relief valve and pressure override valve. At
placement motor). Always two travel pumps are joined this point it must be mentioned that each of the pumps
together to a tandem unit. is fitted with a pressure override valve.
Both tandem units are driven by the diesel engine via All travel motors can be operated with three different
a transfer box. This transfer box is flanged to the fly- displacements and therefore with three different travel
wheel side of the engine. speed ranges. The highest speed range is used as

008 911 57 BOMAG 413

15.2 Travel system (general description)

transport speed, whereas the slow speed range is

used as working speed. Since the travel motors have
the possibility to adjust themselves towards the slow
travel speed range whenever demanded by the load,
it is possible to operate the machine solely in high
speed range. However, in such a case it must be not-
ed that the motors will immediately change back to the
higher speed range when the load is relieved (when
pushing the refuse over the tipping edge).
All planetary gears are equipped with integrated multi-
disc brakes.
These multi-disc brakes are opened by charge pres-
sure and will close automatically when the charge
pressure supply is interrupted. This can be accom-
plished by shutting the engine down, by a fault in the
hydraulic system (travel system), by the brake switch
or the emergency stop via one of the 4/2-way valves.

414 BOMAG 008 911 57

Travel pump 15.3
Travel pump pump) and one pump of series A4VG 90 DG (dragged
15.3 Travel pump

pump) are connected. The end of each tandem pump

The travel pumps are swash plate controlled HYDRO-
unit carries a charge pump. The charge pump is a
MATIK axial piston pumps with variable displacement.
gear pump with fixed displacement.
Always one pump of series A4VG 90 DA (driven

Fig. 1 Hydraulic diagram of travel pump bles an infinite alteration of the pump flow rate and
1 Travel pump therefore an infinite adjustment of the travel speed
2 4/3-way valve (travel direction) within the chosen travel speed range.
3 Control piston The pump is equipped with all control and safety ele-
ments needed for operation in a closed hydraulic cir-
4 High pressure relief valves with boost check
cuit, such as
valves
5 Charge pressure relief valve
l
High pressure relief valves
6 DA-control valve l Boost check valves
7 Pressure override valve l Charge pressure relief valve
8 Shuttle valve l Pressure override valve and
9 Charge pump l Servo control
10 Charge pressure filter
.
(A) to / from travel motor
(B) to / from travel motor
(PS) to PS pump 2
(X1) to X1 on pump 2
(X2) to X2 on pump 2
The flow rate of the travel pump is determined by the
displacement and the actual drive speed of the pump.
It is proportional to drive speed and displacement. The
possibility of the infinite swash plate adjustment ena-

008 911 57 BOMAG 415

15.3 Travel pump

Fig. 2 Cross-section of travel pump
The spherical valve plate centres the cylinder block,
which is tightly connected with the drive shaft, and
avoids the appearance of unwanted transverse forc-
es.
Belleville springs hold the complete drive section
(valve plate, cylinder block, swash plate) together and
eliminate appearing wear in axial direction immediate-
ly. Due to this design principle the pump has a very
high rate of efficiency over the entire lifetime.

416 BOMAG 008 911 57

Travel pump 15.3
Pump control

Fig. 3 Travel pump control 7 Inlet orifice

1 Control valve cartridge 8 Charge pump
2 Charge pressure relief valve (A) High pressure port
3 Pressure override valve (B) High pressure port
4 Control
5 4/3-way valve (travel direction)
6 Outlet orifice

008 911 57 BOMAG 417

15.3 Travel pump

Fig. 4 DA-control valve 12Circlip

1 Charge pump 13Threaded pin
2 Circlip 14Controller screw
3 Controller tube 15Locking nut
4 Stepped piston 16Charge pressure valve
5 Ring 17Housing channel
6 Circlip 18Pilot pressure channel
7 Nut 19Control edge
8 Washer 20Control edge
9 Pressure spring 21Measuring orifice
10O-ring 22Bore
11Spring cup

418 BOMAG 008 911 57

Travel pump 15.3
The pump is infinitely controlled with pilot pressure
from neutral position to the desired flow direction and
to the desired displacement.
The necessary hydraulic oil for the pump control is
provided by the charge circuit of the respective tan-
dem pump. The oil supplied by the charge pump flows
to the DA-control valve.
At an engine speed between low idle speed and con-
trol start (for values refer to the technical data) the
pump flow rate is so low, that almost all oil can flow
through the inside of the control valve cartridge to the
charge system for the travel pumps. The static pres-
sure in front of the orifice (ø 7,9 mm) in the control
valve cartridge is not yet high enough to be able to dis-
place the inner spool against the spring force.
When raising the engine speed beyond the control
start, the flow rate from the charge pump will also in-
crease. This higher oil flow rate causes a far higher
pressure drop at the orifice and pushes the inner
spool against the spring. The movement of the spool
opens four bores, which are arranged in a ring around
the circumference of the spool, and connects them
with the ¾-way solenoid valve on the pump control.
The opening cross-section of these bores depends on
the pressure drop at the inlet orifice on the control
valve cartridge and therefore from the rotary speed of
the engine. It increases with raising engine speed or
with increasing oil flow.
At control end (for values refer to the technical data)
the bores are fully open.
Since the bores have a considerable throttle effect
even when they are fully open, the pilot pressure will
never be higher than max. 14 bar.
At control start (bores are beginning to open) the static
pressure is approx. 6 bar.
If the solenoid valve is now actuated to one of the two
possible directions, the pilot pressure is high enough
to actuate the pump slowly out of neutral position. The
pump starts to deliver oil to the respective travel mo-
tor.
Raising the engine speed will also increase the oil flow
from the charge pump, the bores around the control
valve spool (orifice) will open further and the pilot
pressure will gradually increase. The displacement in-
creases and the pump delivers a larger oil volume to
the motor per unit of time. The machine drives faster.
The rest of the oil flows through the DA-control valve
to the charge pressure relief valves in the travel
pumps. The setting of these valves (see technical da-
ta) determines the charge pressure.

008 911 57 BOMAG 419

15.3
Fig. 5 Arrangement of valves
1 DA-control valve
2 Charge pressure valve
3 High pressure relief valve
4 Pressure override valve
5 Travel direction valve
6 High pressure relief valve
7 Inlet orifice
420
Travel pump
8 Charge pump
9 Travel pump
(A) High pressure port
(B) High pressure port
The charge circuit is necessary for the compensation
of leaks and flushing quantities in a closed hydraulic
circuit and for controlling the pump.
BOMAG 008 911 57
Travel pump 15.3
Pilot controlled high pressure relief valve

Fig. 6 Pilot controlled high pressure relief valve

1 Valve sleeve
2 Pressure spring
3 Piston
4 O-ring
5 Pilot valve
6 Valve body
7 Valve body
Fig. 7 High pressure relief valve, boost check valve function
8 O-ring
(A) Low pressure side
9 Pressure spring (high pressure)
(B) Charge circuit
10Locking nut
11Setscrew Boost check valve function
12High pressure circuit The charge oil (charge oil circuit) from the charge
13Charge circuit pressure relief valve acts on the ring area A1 of piston
(3).
The charge oil flow is now available at the boost check
valves for the closed hydraulic circuit. The boost The piston is lifted off because the force (P x A1) is
check valves are non-return valves, which are inte- higher than the sum of spring force (2) and counter-
grated in the high pressure relief valves. Their back is acting force (P x A2).
always loaded with the actual pressure in the closed Charge oil can now flow into the low pressure side of
circuit (high pressure or low pressure). Since the the closed hydraulic circuit.
charge pressure is not able to open the boost check
This ensures permanent filling of the closed circuit.
valve against the high pressure, fresh oil can only be
fed in through the boost check valve in the low pres-
sure side.

008 911 57 BOMAG 421

15.3 Travel pump

High pressure relief valve

Fig. 8 Valve settings The connection between high pressure side and
(A) HPRV closed charge pressure side opens, whereby the high pres-
sure value set by the high pressure spring (9) is main-
(B) HPRV open
tained.
(C) Charge circuit
(D) Pressure relief
(E) High pressure side

High pressure relief valve closed (A)

High pressure acts on area A3 and tries to lift the pis-
ton (3) of its seat. High pressure is guided through
valve sleeve (1) to the back of piston (3). The effective
area A2 is bigger than A3, the piston is therefore
pressed down in its seat and seals the high pressure
side to the charge pressure side.

High pressure relief valve open (B)

If the high pressure exceeds the value adjusted on pi-
lot (5) with the high pressure spring (9), the pilot will
open against the high pressure spring (9). Oil will now
flow through valve sleeve (1) and pilot (5) to the
charge pressure side.
This causes a pressure drop at piston (3) and the pis-
ton is lifted off its seat.

422 BOMAG 008 911 57

Travel pump 15.3
Charge pressure relief valve

Fig. 9 Charge pressure relief valve 8 O-ring

1 Plug 9 Collar nut
2 Setscrew The charge oil coming from the DA-control valve en-
3 Valve piston ters the charge pressure relief valve through the
4 Spring cup charge oil channel and acts against area A1 on the
valve cone.
5 Pressure spring
If the force acting against the valve cone exceeds the
6
force of the pressure spring, the valve cone will be lift-
7 ed off its seat in the valve body and charge oil can flow
into the housing channel.

008 911 57 BOMAG 423

15.3 Travel pump

The closed circuit

As soon as the swash plate inside the travel pump is
displaced out of neutral position, the pump will start to
deliver oil to the respective travel motor.
In dependence on the speed of the diesel engine the
swash plate can be infinitely displaced out of neutral
position up to maximum displacement position.
Immediately after the swash plate has been moved
out of neutral the pressure in the hoses from pump to
motor will increase. This pressure is higher than the
pressure in the hose from the motor to the pump. The
pressure in the hose from pump to motor depends on
the actual load condition of the motor. Under normal
conditions this pressure may increase up to the set-
ting of the pressure override (for pressure values refer
to the technical data).
The high pressure relief valves protect the closed hy-
draulic circuit and the combustion engine against
overloads (e.g. short pressure peaks). In such a case
the valve on the high pressure side will open and re-
lieve oil through the boost check valve into the low
pressure side.
Since permanent responding of the high pressure re-
lieve valves would cause extreme overheating of the
hydraulic oil and quickly lead to serious damage, this
system is protected by another kind of primary pres-
sure limitation, the pressure override. Each of the trav-
el pumps is equipped with a pressure override valve.
The high pressure in the system is permanently re-
ported to the pressure override valve via a shuttle
valve between both sides of the closed hydraulic trav-
el circuit. The pressure override valve itself is connect-
ed with the pilot oil flow from the DA-control valve to
the 4/3-way valve for the travel direction.
If the high pressure in the travel system increases up
to the setting of the pressure override, this high pres-
sure will push the valve spool in the pressure override
against the pressure spring. This guides part of the pi-
lot oil flow between DA-control valve and 4/3-way so-
lenoid valve through the now open spool to the valve.
The pressure drop in the pilot oil supply reduces the
force acting on the control piston and the pump
swashes back towards neutral. This reduces the
pump displacement, until the pump pressure is in ac-
cordance with the value adjusted with the pressure
spring.
If the pressure drops below the setting of the pressure
override, the pilot oil flow is opened again and the
pump will return to the previously chosen displace-
ment.
As a measure to avoid any reaction of the high pres-
sure relief valves, the pressure override is adjusted to
a lower value than the high pressure relief valves.

424 BOMAG 008 911 57

Travel pump 15.3
Pressure override valve

Fig. 10 Pressure override valve The minimum difference between high pressure relief
1 Valve piston valve and pressure override is 30 bar.
2 Bore
3 Valve seat
4 Piston
5 Valve bushing
6 Control piston
7 Spring cup
8 Pressure spring
9 Setscrew
10Pilot pressure channel
11Housing channel
12High pressure circuit
13High pressure circuit
14Valve seat
Adjustment values see next page.

008 911 57 BOMAG 425

15.4
Travel motors
15.4 Travel motors
Each wheel of the sanitary landfill compactor is driven
by a HYDROMATIK bent axle motor A6VM 200
EP2D. The motors are designed with variable dis-
placement and can be adjusted electro-proportionally.
Fig. 1 Travel motor A6VM 200 EP2D
1 Setscrew for electric control start
2 Setscrew for hydraulic control start
Caution
! ment of the connected output shaft.
Do not turn setscrew 1 (Fig. 1)!
The motors are connected to the associated travel
pumps via the high pressure ports A and B. The high
426 BOMAG
Travel motors
The y can thus be operated in different travel speed
ranges, as desired. On the BC 972/1172 three fixed
displacements are specified by three programmed
control currents, which results in three travel speed
ranges.
pressure hydraulic oil flows through the respective
high pressure port to the back of the working pistons.
Since these pistons are arranged under an angle to
the output shaft, the pressurized pistons perform an
axial movement, thereby generating the rotary move-
Once a piston has passed through its dead centre
(max. extension), the piston will change to the low
pressure side. The continuing rotation presses the
piston back into the cylinder. This forces the hydraulic
008 911 57
Travel motors
oil from the cylinder chamber through the low pres-
sure side back into the pump.
Changing the control current on the proportional sole-
noid of the motor (0-200 mA Qmax, 200-600 mA Qmin
- Qmax) also changes the angle position of the piston
block to the output shaft.
In this context a large angle means high displace-
ment. In low speed range the motor works with a high
15.4
torque. With a small angle these conditions are exact-
ly opposite.
When the refuse compactor is operated in second or
third speed range and a certain pressure is reached,
the travel motors will automatically regulate hydrauli-
cally back towards high displacement, irrespective of
the control current. At the same time the torque in-
creases accordingly.

Fig. 2 Hydraulic diagram travel motor Motor works in speed range 1

(A) from / to travel pump If travel range 1 (slow) is pre-selected, the proportion-
(B) from / to travel pump al solenoid on the electrically controlled pre-control
valve (bottom valve) is supplied with a minimal control
(G1) connection front and rear motor
current of approx. 0 mA. This has the effect that the
1 Engine movement of the pre-control piston (4) out of its rest
2 Check valve position against the spring forces F2 + F4 is only mi-
3 Check valve nor.
4 Pre-control piston The valve (4) thus only allows a low pressure Pmin,
which works through the upper control valve on the
5 Control valve
control piston area A2.
6 Control piston
If high pressure increases beyond the control start
7 Pressure relief valve pressure, the hydraulically operated control valve (up-
8 Flushing valve per valve) will also close. The passage to the control
9 Planetary gear with brake piston area A2 is then interrupted and the area is com-
pletely depressurized.
The high pressure Phigh in A or B is guided through the
corresponding non-return valve via the pilot control
piston to the control piston area A1.
The resulting force F1 (F1 = (A1xPhigh - A2x Pmin or 0)
regulates the motor to the large swashing angle or
keeps it in this position (max. torque and lowest
speed).

008 911 57 BOMAG 427

15.4 Travel motors

Motor works in speed range 2 or 3 when the charge pressure drops below the brake re-
leasing pressure (when shutting the engine down,
Pilot pressure below control start when actuating the parking brake etc.).
In speed ranges 2 and 3 the proportional solenoid is
controlled with 400 or 600 mA respectively. The creat-
ed force of the magnetic coil opens the lower pre-con- i Note
trol piston against the spring force, as appropriate for The brake is designed as parking/emergency brake.
the amperage. The valve therefore allows a certain Unnecessary use of the emergency stop during travel
pressure PI to flow through the open upper control reduces the lifetime of the brake and should therefore
valve to the control piston area A2. be avoided!
The high pressure Phigh in A or B is guided through the
corresponding non-return valve via the pilot control
piston to the control piston area A1. The resulting
force F1 (F1 = (A1xPhigh - A2x PI) controls the motor
to a smaller swashing angle (min. torque and highest
speed).
The actuated control piston presses the spring F2
against the back of the pre-control piston. This spring
force holds the pre-control piston in balance against
the force of the magnetic coil.

Operating pressure within the control range

If the operating pressure increases beyond the control
start, the upper control valve will close against the
force of the adjustable control start spring F3. This in-
terrupts the connection between the pressure outlet
on the lower pre-control valve and the control piston
area F2. The control piston area is relieved to the tank
and is thus depressurized. Since the opposite side A1
is always loaded with high pressure, the motor will au-
tomatically swash back towards high displacement.
This process occurs continuously.
The two motors on one side of the machine are linked
via the ports ”G”. Through these ports the pressure in
the travel circuit with the highest pressure is reported
to the other motor. The motor with the lower pressure
thereby responds exactly in the same way as the mo-
tor with the higher pressure. This installation synchro-
nizes the motor controls of the two motors on one side
of the machine.
This type of control ensures that both motors on one
machine side work with almost the same displace-
ment / speed. This prevents the unloaded motor from
changing to max. speed, if one of the wheels is un-
loaded (e.g. when raising the wheels with the dozer
blade).
Since the output speed of the motors is too high for di-
rect driving of the wheels, the motor output speed is
reduced to final working speed by planetary gears.
Each wheel unit therefore consists of a hydraulic mo-
tor with a planetary gear.
The motors are directly connected to the planetary
gears via splined shafts.
The housings of the planetary gears also contain the
multi-disc brakes. The brakes run in an oil bath and
are therefore almost wear-free. The brakes are re-
leased by charge pressure and close automatically

428 BOMAG 008 911 57

Filtration 15.5
Filtration Charge circuit filtration
15.5 Filtration

Function and lifetime of a hydraulic system depend
decisively on the cleanliness of the power transmis-
sion medium (hydraulic oil).
For this reason it is mandatory to filter the hydraulic oil
permanently while the machine is working. In closed
hydraulic circuits the full flow filtration of the charge
circuit and the return flow from the individual compo-
nents has been found very beneficial.
All four charge circuits are fitted with one 12 µm fine
filter each. The oil flows through these filters to the in-
dividual consumers and functions.
The filters are fitted with by-pass valves. These open
at a pressure differential (pressure difference between
filter inlet and filter outlet) of 3.5 bar. This pressure dif-
ferential depends on the filter contamination and the
viscosity of the hydraulic oil.
Pressure differential switches on the filters report any
increase of the pressure differential into the cabin.
These switches are designed for a pressure differen-
tial of 2.5 bar. The respective information will therefore
already be available before the by-pass valve opens.

Fig. 3

Pos. Designation Pos. in elec- Pos. in hy- Measuring value

tric wiring di- draulic dia-
agram gram
1 Pressure differential switch, charge pressure B122 > 3.5 bar Δp open
front left
2 Pressure differential switch, charge pressure B121 > 3.5 bar Δp open
rear left
3 Pressure differential switch, charge pressure B22 > 3.5 bar Δp open
rear right
4 Pressure differential switch, charge pressure B21 > 3.5 bar Δp open
front right
5 Differential pressure switch, transfer box oil filter B42 > 3.5 bar Δp open

008 911 57 BOMAG 429

15.5 Filtration

Return flow filter block

As a second measure to keep the oil free of any impu-
rities, all leaks, flushing quantities and return flows are
guided back to the tank through a central return flow
filter block.
The return flow filter block contains two 80 µ filters,
two dirt sensors, one pressure switch and a tempera-
ture controlled 3/2-way valve.
All return flows pass through the primary filter, fol-
lowed by a temperature controlled valve (thermostat).
This valve guides the oil flow directly back to the 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.
If the primary filter is dirty, the oil flow is guided
through the secondary filter. The oil can only pass
through this filter when the static pressure in front of
the primary filter is higher than 2 bar. In this case the
oil is no longer cooled. The pressure switch reports a
too high static pressure in front of the primary filter and
informs the operator via the fault indicator module.
In addition to this the dirt sensor (permanent magnet)
reports any metallic contamination in the oil via a vis-
ual indicator in the cabin.

430 BOMAG 008 911 57

Transfer box filter unit 15.6
Oil circuit A pressure relief valve is installed in front of the filter
15.6 Transfer box filter unit

inlet. It limits the pressure to 12 bar in low and 25 bar

A pump inside the transfer box pumps the oil in the
in high idle speed of the engine, at a gear oil temper-
transfer box through a cooling circuit and finally
ature of min. 40°C.
through a filter.

Fig. 1 4 Pressure relief to gearbox

1 Filter unit 5 filtered oil to transfer box
2 Pressure relief valve 6 from cooling circuit
3 Differential pressure switch 7 Separation PRV-setting

Pos. Designation Measuring value

1 Filter unit
2 Pressure relief valve 25 bar in high idle and min. 40°C oil temperature
3 Differential pressure switch 2.4 bar

008 911 57 BOMAG 431

15.6 Transfer box filter unit

432 BOMAG 008 911 57

 16 Tests and adjustments in travel hydraulics

008 911 57 BOMAG 433

16.1 Measuring and adjustment points on tandem travel pump unit

Measuring and adjustment points

16.1 Measuring and adjustment points on tandem travel pump unit

Fig. 2

434 BOMAG 008 911 57

Pressure tests in the travel circuit 16.2

Pos. Designation Pos. in elec- Pos. in hy- Measuring value

tric wiring di- draulic dia-
agram gram
1 Port A, high pressure reverse, driven pump 08A, 11A
2 High pressure relief valves, driven pump 480 -20 bar
3 PS-line, pilot pressure supply to pressure over-
ride
4 Port A, high pressure reverse, dragged pump 09A, 12A
5 High pressure relief valves, dragged pump 480 -20 bar
6 Port B, high pressure forward, dragged pump
7 Plug T2, dragged pump T2
8 Port B, high pressure forward, driven pump B
9 Plug T2, driven pump T2
10 Plug a, solenoid valve forward Y 16 a 0 / 24V
11 Port T1, leak oil to return flow filter, driven pump, T1
with magnetic plug
12 Test port X1, control chamber pressure reverse M6, M16, X1 0 - 14 bar, **)
13 Port T1, leak oil to return flow filter, dragged T1
pump, with magnetic plug
14 Test port G, charge pressure M7, M17, G3 0 ± 2 bar in high idle
speed***)
15 Test port X2, control chamber pressure forward M5, M15, X2 0 - 14 bar **)
16 Port S, charge pressure from hydraulic oil filter
17 Plug b, solenoid valve reverse Y 17 b 0 / 24V
18 Charge pressure relief valve, driven pump 30 ± 2 bar in high idle
speed***)
19 DA-control valve *)
20 Pressure override, driven pump 430 +10/-20 bar
21 Test port MB, high pressure forward, driven M2, M12, MB 430 +10/-20 bar
pump
22 Charge pressure relief valve, dragged pump 30 ± 2 bar in high idle
speed***)
23 Pressure override, dragged pump 430 +10/-20 bar
24 Test port MB, high pressure forward, dragged M4, M14, MB 430 +10/-20 bar
pump
25 Port S1, suction connection charge pump from
tank
26 Port P, charge pump pressure port to filter
27 Test port MA, high pressure reverse, dragged M3, M13, MA 430 +10/-20 bar
pump
28 Test port MA, high pressure reverse, driven M1, M11, MA 430 +10/-20 bar
pump

*), **), ***); see adjustment instructions 16.2 Pressure tests in the travel circuit

! Danger
Whenever performing tests make sure you
direct visual contact with the driver.
1. Run the machine warm to operating tempera-
ture (approx. 40°C hydraulic oil temperature).

008 911 57 BOMAG 435

16.2 Pressure tests in the travel circuit

Fig. 1
2. Connect the following pressure gauges (Fig. 1):
1 High pressure (5), travel pump forward 600
bar.
2 High pressure (6), travel pump reverse 600
bar.
3 High pressure, travel pump front right, 600
bar.
4 High pressure, travel pump rear right, 600
bar.

436 BOMAG 008 911 57

Pressure tests in the travel circuit 16.2

Fig. 2
3. Connect the following pressure gauges (Fig. 2):
1 Charge pressure (2), left hand tandem
pump 60 bar.
2 Charge pressure (13), right hand tandem
pump 60 bar.

008 911 57 BOMAG 437

16.2 Pressure tests in the travel circuit

Fig. 3
4. Connect the following pressure gauges (Fig. 3):
1 Control chamber pressure (17), left hand
tandem pump 60 bar.
2 Control chamber pressure (18), left hand
tandem pump 60 bar.

Danger
!

Make sure there are no persons in front of or

behind the machine.

438 BOMAG 008 911 57

Pressure tests in the travel circuit 16.2

Fig. 4
5. Input module (Fig. 4) enter PIN-CODE 500.
6. Start the engine, select 2nd speed range and
switch to travel direction reverse.

i Note
Do not actuate the emergency stop.
7. Accelerate the engine slowly up to full speed
and watch the pressure gauges.

Nominal values:
High pressures must increase evenly to 430
+10/-20 bar. The charge pressures must not
drop considerably (<28 bar). At least 28 bar at
idle speed, increasing to 30 bar.
Control chamber pressures must increase
evenly to approx. 14 bar.

008 911 57 BOMAG 439

16.3 Checking high pressure relief valves and pressure override

16.3 Checking high pressure relief valves

and pressure override
1. Run the machine up to operating temperature
(40°C hydraulic oil temperature).

Fig. 1
2. Input module (Fig. 1) enter PIN-CODE 500.

440 BOMAG 008 911 57

Checking high pressure relief valves and pressure override 16.3

Fig. 2
3. Connect a 600 bar pressure gauge to both high
pressure ports (Fig. 2) of a tandem pump.

Fig. 3
4. Turn the adjustment screw of the pressure
override (Fig. 3) completely in (block).

008 911 57 BOMAG 441

16.3 Checking high pressure relief valves and pressure override

! Danger
Make sure there are no persons in front of or
behind the machine.
5. Start the engine, select 2nd speed range and
shift the travel lever to the desired travel direc-
tion
! Caution
Perform the following test for max. 3 sec-
onds, as otherwise the pump may be de-
stroyed by overheating!
6. Accelerate for a moment (max. 3 seconds) to
full speed and read the pressure gauges.

Nominal value:
i Note 480 -20 bar
Do not actuate the emergency stop.

Fig. 4
7. If necessary adjust the high pressure relief
valves (Fig. 4).
8. Repeat this test to the opposite travel direction.
9. Repeat these tests for the rear pump.

442 BOMAG 008 911 57

Checking high pressure relief valves and pressure override 16.3

Fig. 5
10. Adjust the pressure override (Fig. 5) on the
front pump to 430 bar (high pressure measure-
ment on front pump!).
11. Adjust the pressure override on the rear pump
to 430 bar (high pressure measurement on rear
pump).

! Caution
If the pressure override is not correctly ad-
justed on one of the pumps (remains
blocked) the high pressure in the respective
circuit may increase up to the setting of the
high pressure relief valves.
12. Perform the same tests for the second tandem
pump.

008 911 57 BOMAG 443

16.4 Travel pump high pressure test (individual test)

16.4 Travel pump high pressure test (in-

dividual test)

Fig. 1
1. Close the high pressure ports (Fig. 1) on one
travel pump with plugs.

Fig. 2

444 BOMAG 008 911 57

Travel pump high pressure test (individual test) 16.4
2. Input module (Fig. 2) enter PIN-CODE 500.

Fig. 3
3. Connect a 600 bar pressure gauge to the high
pressure test port of the pump (Fig. 3).

i Note
Do not actuate the emergency stop.
4. Start the engine, select 2nd speed range and
shift the travel lever to the desired travel direc-
tion
5. Raise the engine speed for a moment and read
the pressure gauge.

Nominal value:
460 to 480 bar
6. If the nominal value is not reached, check pres-
sure override and high pressure relief valves. If
the valves are o.k., replace or repair the travel
pump.

008 911 57 BOMAG 445

16.5 Check charge pressure

16.5 Check charge pressure

1. Run the machine until operating temperature is
achieved, then shut down the engine.

Fig. 1
2. Block the front charge pressure relief valve
(Fig. 1) on a tandem pump, turn the setscrew
completely in to do so.
3. Connect a 60 bar pressure gauge to the charge
pressure test port.
4. Start the engine and run it with half speed.
5. Set the rear charge pressure relief valve (2) to
30 bar.
6. Run the engine with maximum speed (the
charge pressure increases).
7. Loosen the blocked valve until the charge pres-
sure of 30 bar is reached again.
8. Check the charge pressure again at idle speed.

Nominal value:
min. 28 +/- 2 bar
9. Should the pressure of 28 bar not be reached,
repeat the basic adjustment with a pressure
higher than 30 bar, but on both valves identical.
10. Check and adjust the other tandem pump ac-
cordingly.

446 BOMAG 008 911 57

Adjusting the DA-control valve 16.6
16.6 Adjusting the DA-control valve
1. Warm the machine up to operating tempera-
ture.

Fig. 1
2. Input module (Fig. 1) enter PIN-CODE 500.
3. Select 2nd speed range.

008 911 57 BOMAG 447

16.6 Adjusting the DA-control valve

Fig. 2
4. Connect 600 bar pressure gauges to both high
pressure test ports (MA or MB) of both tandem
pumps (1) / (2) and (3) / (4) (Fig. 2).
5. Start the engine and raise the engine speed to
925 +/- 55 rpm.
6. Select the travel direction in accordance with
the chosen high pressure test port (in this illus-
tration reverse) and read the pressure gauge.

i Note
Do not operate foot brake and emergency stop.

Nominal value:
High pressure 50 bar as mean value
7. Raise the engine speed to 1700 rpm.

Nominal value:
High pressure 400 bar

448 BOMAG 008 911 57

Adjusting the DA-control valve 16.6

Fig. 3
8. If deviations from the nominal value for control
start are found the pressure must be adjusted
on the corresponding DA-control valve (Fig. 3).

! Caution
The control end can only be adjusted on a
pump test bench

i Note
Turn clockwise = control start at higher engine
speed.
Turn anti-clockwise = control start at lower en-
gine speed.
Both tandem pumps must be equalized, i.e. for
a synchronous operation the adjustment values
of right and left hand pumps should be almost
identical.

008 911 57 BOMAG 449

16.7 Checking the control chamber pressure

16.7 Checking the control chamber pres-

sure
1. Warm the machine up to operating tempera-
ture.

Fig. 1
2. Input module (Fig. 1) enter PIN-CODE.
3. Select 2nd speed range.

450 BOMAG 008 911 57

Checking the control chamber pressure 16.7

Fig. 2
4. Connect one 60 bar pressure gauge each to the
test ports (X1 and X2) (Fig. 2) for control cham-
ber pressure.
5. Start the engine.

i Note
Do not operate foot brake and emergency stop.

Nominal value:
Engine speed 925 ± 50 rpm: approx. 6 bar
Engine speed 1700 ± 50 rpm: approx. 12...14
bar

i Note
The measurement of control start and control
end under high pressure are much more mean-
ingful than the control chamber pressure, be-
cause these measurements actually measure
the effective pressure to the wheels.

008 911 57 BOMAG 451

16.8 Measuring and adjustment points on travel motors

Measuring and adjustment points on

16.8 Measuring and adjustment points on travel motors

travel motors

Fig. 3 Travel motor with gearbox rear right

Pos. Designation Pos. in elec- Pos. in hy- Measuring value

tric wiring di- draulic dia-
agram gram
1 Control pressure test port M1 0 - 250 bar*
2 Control start adjustment screw pressure de-
pendent (shows direction of wheel reduction
gear)
3 Proportional solenoid Y135 0-200 mA - Vgmax
600 mA - Vgmin
4 High pressure test port G 0-430 bar (actual
high pressure)
5 Control start adjustment screw, electric (behind do not turn!
solenoid)

452 BOMAG 008 911 57

Measuring and adjustment points on travel motors 16.8
Adjust the control start (pressure depend-
ent) of the travel motors

!Caution
Adjustments may only be made on the ad-
justment screws for the pressure depend-
ent control start. The adjustment screw for
the electric control start has been adjusted
on the motor test bench (Hydromatik) and
must not be changed.
l Run the machine up to operating tempera-
ture (min. 40°C hydraulic oil temperature).
l Install 600 bar pressure gauges to both test
ports on the corresponding travel motor.
l Use input code 500 on the CAN-Bus input
module to block the brake.
l Choose 3rd speed range and any travel di-
rection and slowly increase the engine
speed while keeping an eye on the pres-
sure gauges.

Nominal value:
until 250 bar high pressure can be read on the
lower test port (G), the upper test port (M1)
should also show approximately the current
high pressure.
At approx. 250 bar high pressure, the pressure
gauge on M1 should drop to about 0 bar (tank
pressure).
l If necessary correct the setting with adjust-
ment screw 2 (Fig. 3).

i Note
1 revolution of the control start adjustment
screw causes a difference of approx. 100 bar!

008 911 57 BOMAG 453

16.9 Checking the displacement setting of the travel motors

Fig. 1

454 BOMAG 008 911 57

Checking the displacement setting of the travel motors
1 Pilot pressure port (pressure in swashing zylinder)
2 High pressure port „G“
Special tools:
2 x 600 bar pressure gauges
2 pressure test hoses
i Note
Always perform this test after replacing one or
several motors.
If a new motor was installed, fill, bleed and, if
necessary, flush the hydraulic system as de-
scribed.
16.9
3 Electric plug, brake solenoid valve
4 Setscrew, displacement adjustment
Once the pressure on pressure gauge (2) ex-
ceeds 280 bar, the pressure on pressure gauge
(1) also starts to increase.
When pressure gauge (2) reaches 330 bar,
pressure gauge (1) must also reach 380 bar.
At pressure above 380 bar both pressure gaug-
es (2 and 1) must have identical readings.
Evaluation of test:
If the specified values are not reached adjust
the pilot pressure on screw (4).

1. Run the machine warm in the first speed range,

until the hydraulic oil has a reached a tempera- i Note
ture of approx. 50 °C. If pressure gauge (2) shows 380 bar, while
pressure gauge (1) shows less than 380 bar,
2. Connect a high pressure gauge 2 (Fig. 1) to
turn the adjustment screw in anti-clockwise di-
port “G“ on the respective motor.
rection.
If pressure gauges (2) and (1) show identical
i Note pressure values before reaching 380 bar, turn
This pressure gauge shows the load dependent the adjustment screw in clockwise direction.
high pressure in travel operation.
6. Repeat this test on all other travel motors.
3. Connect a high pressure gauge (1) to the pilot
pressure test port on the motor to be tested.

iNote
This pressure gauge shows the pressure in the
swashing cylinder.

! Danger
Input module, enter PIN-CODE 500.
Secure all wheels with wedges.

i Note
The adjustments can be made in any travel di-
rection.
4. Start the engine and let it run in idle speed, se-
lect second speed range and the respective
travel direction.

! Caution
Do not actuate the emergency stop switch.
5. Slowly raise the engine speed, read both pres-
sure gauges.

Nominal value:
As the engine speed increases, the pressure on
pressure gauge (2) port “G“ will increase.
The pressure on pressure gauge (2) increases
from approx. 29 bar to 280 bar, while pressure
gauge (1) does not indicate any pressure.

008 911 57 BOMAG 455

16.10 Filter unit for transfer box / pressure relief valve

Filter unit
16.10 Filter unit for transfer box / pressure relief valve

Fig. 1 4 Pressure relief to gearbox

1 Filter unit 5 filtered oil to transfer box
2 Pressure relief valve 6 from cooling circuit
3 Differential pressure switch 7 Separation PRV-setting

Pos. Designation Measuring value

1 Filter unit
2 Pressure relief valve 25 bar in high idle and min. 40°C oil temperature
3 Differential pressure switch 2.4 bar

456 BOMAG 008 911 57

Filter unit for transfer box / pressure relief valve 16.10
Adjusting the pressure relief valve
l Run the machine warm (min. 40°C gear oil
temperature) and shut the engine down.
l Unscrew the pressure relief valve from the
filter inlet port (Fig. 1).
l Close the outlet towards the filter on the dis-
connected T-fitting with a plug (P/N 055 427
05).
l Close the filter inlet with plug (P/N 055 427
05) and nut (P/N 055 450 25).
l Start the engine and adjust the pressure re-
lief valve to 25 bar in high idle speed / 12
bar in low idle speed; then shut the engine
down again.
l Reconnect the PRV to the filter.

008 911 57 BOMAG 457

16.10 Filter unit for transfer box / pressure relief valve

458 BOMAG 008 911 57

 17 Special tools, tests and adjustments

008 911 57 BOMAG 459

17.1 Special tools, tests and adjustments

17.1 Special tools, tests and adjustments

1. Vibration reed frequency meter
1000 - 4000 rpm
17 - 67 Hz
BOMAG part-no.: 300 120 80

Fig. 1
2. Sirometer (frequency meter)
800 - 50.000 rpm
14 - 750 Hz
BOMAG part-no.: 059 710 02

Fig. 2
3. Anti-freeze tester, quick and accurate measuring,
sturdy plastic housing, automatic temperature
correction, no after-dripping, instructions for use
on unit, reading down to -40 °C. Material: Plastic,
Temperature range: down to -40 °C

BOMAG part-no.: 050 100 75

Fig. 3
4. Digital rpm-meter for petrol engines

BOMAG part-no.: 079 948 99

Fig. 4

460 BOMAG 008 911 57

Special tools, tests and adjustments 17.1
5. Digital rpm-meter for petrol engines

BOMAG part-no.: 059 711 12

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

BOMAG part-no.: 079 948 98

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

BOMAG part-no.: 057 668 06

Fig. 7
8. Hydraulic test case, large

BOMAG part-no.: 007 610 03

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

Fig. 8

008 911 57 BOMAG 461

17.1 Special tools, tests and adjustments

9. Hydraulic test case, small

BOMAG part-no.: 079 930 01

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

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

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

Fig. 11
12. Adapter for pressure test hose

BOMAG part-no.: 055 439 02

Fig. 12

462 BOMAG 008 911 57

Special tools, tests and adjustments 17.1
13. Gear pump testing device

BOMAG part-no.: 007 610 05

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

Fig. 14

008 911 57 BOMAG 463

17.1 Special tools, tests and adjustments

464 BOMAG 008 911 57

 18 Oscillating articulated joint

008 911 57 BOMAG 465

18.1 Articulated joint, repair overview

466 BOMAG 008 911 57

Articulated joint, repair overview 18.1

1 Cover 5 Taper roller bearing

2 Sleeve 6 Upper bolt
3 Flanged cover 7 Central block
4 Dirt scraper 8 Lower bolt

008 911 57 BOMAG 467

18.2 Disassembling and assembling the top bolt

18.2 Disassembling and assembling the

top bolt
Securing the machine
1. Drive the machine on a level base of sufficient
load bearing capacity.
2. Swing the articulation lock 1 (Fig. 1) forward out
of its holding bracket and fasten with bolt (2) to
the eye on the front frame. Secure the bolt with
the cotter pin (3).

Fig. 1
3. Push the lever for dozer blade control (Fig. 2) for-
ward to position "I" and lower the dozer blade
slowly ........

Fig. 2
4. .... and rest it on the ground (Fig. 3).

Fig. 3

468 BOMAG 008 911 57

Disassembling and assembling the top bolt 18.2
5. Press button "a" (Fig. 4).
6. Shift the dozer blade control lever to float position
"I".
7. Shut down the engine.

Fig. 4
Disassembling the upper bolt
8. Disassemble the covering from the front frame
(Fig. 5).

Fig. 5
9. Remove the hose bracket (Fig. 6), pull the hy-
draulic hoses up and tie them to the machine.

Fig. 6

! Danger
Remove the joint bolt only if the bottom bear-
ing of the articulated joint is still fully func-
tional.
10. Unscrew the hexagon screws and remove the top
cover (Fig. 7).

Fig. 7

008 911 57 BOMAG 469

18.2 Disassembling and assembling the top bolt

! Danger

Secure the joint bolt, the bolt has a weight of

27 kg!
11. Screw an eye bolt (thread M20) (Fig. 8) into the
central bore.
12. Use appropriate lifting tackle to secure the joint
bolt against dropping down.

Fig. 8
13. Place one 20 tonne hydraulic jack (Fig. 9) each
centrally under the front and rear frames.

! Danger

Make sure that persons are not endangered

by the machine tipping or sliding off.
14. Slightly raise both hydraulic jacks, so that the up-
per joint bolt is relieved from any strain.

Fig. 9
15. Unscrew the screw (Fig. 10) from the upper joint
bolt.

Fig. 10

!Danger
Danger of squashing!
16. Screw an impact puller (thread size M20) 1 (Fig.
11) into the thread and knock out the joint down-
wards. Thereby....
17. ...... keep paying off lifting tackle (2).

i Note
If the joint bolt is under strain, relieve this strain by
carefully raising or lowing the hydraulic jacks.

Fig. 11

470 BOMAG 008 911 57

Disassembling and assembling the top bolt 18.2
18. Remove the joint bolt, disassemble eye bolt and
lifting tackle 1 (Fig. 12).

Fig. 12

! Danger
Do not reach with your hands into the bore,
the articulated joint could be under tension.
19. Knock the sleeve with a suitable drift punch or flat
chisel carefully upwards out (Fig. 13).

! Caution
Make sure that the dirt scraper (see sectional
drawing or articulated joint, Pos. 4) is not
damaged.

Fig. 13
20. Lift out the sleeve (Fig. 14).

Fig. 14

008 911 57 BOMAG 471

18.2 Disassembling and assembling the top bolt

Assembling the new joint bolt

21. Place the joint bolt into the articulated joint (Fig.
15).
22. Screw an eye bolt (thread M20) into the central
bore and secure the bolt with lifting tackle.

iNote
Apply some oil to the bolt.

Fig. 15
23. Guide the bolt upwards into the receiving bore
and ...... (Fig. 16).
24. .... secure it with the lifting tackle against dropping
down.

Fig. 16

i Note
Make sure that the oil bores of the bolt face in di-
rection of travel.
25. Press the bolt with a hydraulic jack carefully into
the joint, until it bottoms (Fig. 17).

Fig. 17

i Note
Assemble the bushing with the grooves facing
downwards.
26. Remove eye bolt and lifting tackle.
27. Slightly oil the sleeve (Fig. 18) and drive it in with
a plastic hammer.

Fig. 18

472 BOMAG 008 911 57

Disassembling and assembling the top bolt 18.2
28. Attach the cover (Fig. 19).
29. Turn in three fastening screws (1) and tighten
these hand-tight.
30. Insert two fastening screws (2) into the bore.
31. Use an open end spanner to turn the cover with
the joint bolt to left or right, until the screw (3) can
be threaded in.

Fig. 19
32. Insert the screws 1 (Fig. 20) with LOCTITE 243
and tighten with 200 Nm.
33. Tighten the screws (2) (123 Nm).

Fig. 20
34. Turn the screw (Fig. 21) into the joint bolt and
tighten it.
35. Assemble hose bracket and hydraulic hoses (Fig.
6).
36. Assemble the covering to the front frame (Fig. 5).

Fig. 21

008 911 57 BOMAG 473

18.3 Removing and installing the steering cylinders

18.3 Removing and installing the steering

cylinders
Securing the machine
1. Drive the machine on a level base of sufficient
load bearing capacity.
2. Swing the articulation lock 1 (Fig. 1) forward out
of its holding bracket and fasten with bolt (2) to
the eye on the front frame. Secure the bolt with
the cotter pin (3).

Fig. 1
3. Push the lever for dozer blade control (Fig. 2) for-
ward to position "I" and lower the dozer blade
slowly ........

Fig. 2
4. .... and rest it on the ground (Fig. 3).

Fig. 3

474 BOMAG 008 911 57

Removing and installing the steering cylinders 18.3
5. Press button "a" (Fig. 4).
6. Shift the dozer blade control lever to float position
"I".
7. Shut down the engine.

Fig. 4
Removing the steering cylinders
8. Disassemble the covering from the front frame
(Fig. 5).

Fig. 5

Environment
Catch running out hydraulic oil and dispose
of environmentally.

! Danger

Before disconnecting any hydraulic connec-

tions you must make sure that the engine has
been shut down and the system pressure has
been relieved.
9. Disconnect the hydraulic hoses (Fig. 6) and (Fig.
7) from the steering cylinders.

Fig. 6
10. Close connections and hoses with plugs.

Fig. 7

008 911 57 BOMAG 475

18.3 Removing and installing the steering cylinders

11. Disassemble lubrication grease hoses 1 (Fig. 8),

screws (2) and washers from the steering bolts
on the articulated joint.
12. Unscrew screws (3) from the articulated joint.
13. Remove the flat steel bars (4).
14. Knock out steering bolts (5).

Fig. 8

Environment
Catch running out hydraulic oil and dispose
of environmentally.
15. Retract the piston rods into the steering cylinders
(Fig. 9).

i Note
The cylinders may be carefully retracted with
compressed air or by pressing manually.
Remove the plugs beforehand.

Fig. 9
16. Disassemble lubrication grease hoses 1 (Fig. 10),
screws (2) and washers from the front steering
bolts.
17. Unscrew screws (3) from both cylinders.
18. Remove plates (4) and axle holders (5).

! Danger
Danger of squashing!
The steering cylinders have a weight of ap-
prox. 100 kg.
Attach the lifting tackle to the steering cylin-
Fig. 10 der.
19. Knock out steering bolts (6).
20. Lift the steering cylinders out of the machine and
lay them down safely (Fig. 11).

Fig. 11

476 BOMAG 008 911 57

Removing and installing the steering cylinders 18.3
Assembling the steering cylinders
1. Position the steering cylinders in the front frame
(Fig. 1).

Fig. 1
2. Check the rocker bearing, replace if necessary
(Fig. 2).

Fig. 2
3. Grease the steering bolts and drive them in (Fig.
3).
4. Reassemble plates, axle holders and lubrication
grease hoses.

Fig. 3
5. Extend the piston rods (Fig. 4).

i Note
The cylinders may be carefully extended with
compressed air or by pressing manually.
Remove the plugs beforehand.

Fig. 4

008 911 57 BOMAG 477

18.3 Removing and installing the steering cylinders

6. Insert steering cylinders and spacer rings 1 (Fig.

6) into the articulated joint.
7. Grease the steering bolts (2) and drive them in .

Fig. 5
8. Assemble flat bars and lubrication grease hoses
(Fig. 6).

Fig. 6

i Note
Assemble the lubrication grease hoses under an
angle of approx. 30° (Fig. 6).

Fig. 7
9. Connect the hydraulic hoses (Fig. 8) and (Fig. 9)
again.

Fig. 8

478 BOMAG 008 911 57

Removing and installing the steering cylinders 18.3

Fig. 9
10. Loosen the articulation lock (Fig. 10) again and
fasten it in the holder.

Fig. 10
Bleeding
1. Check the hydraulic oil level (Fig. 1).

! Danger
Do not step or stand in the articulation area of
the machine when the engine is running.

i Note
Steer the machine several times to right and left
with the engine running at idle speed.
Due to trapped air hydraulic cylinders may initially
Fig. 1 perform erratically, but normally vent themselves
after a few stroked
2. Check hydraulic connections for leaks.
3. Check the hydraulic oil level once again.

008 911 57 BOMAG 479

18.3 Removing and installing the steering cylinders

Adjusting the electric steering dampening

i Note
Steer the machine fully to the left to adjust the
right hand initiator.
Steer the machine fully to the right to adjust the
left hand initiator.
1. Turn the initiators 1 (Fig. 1) as far out as possible.
2. Steer the machine against the end stop.
3. Turn the initiator in against the stop (2).
4. Back the initiator one revolution out and fasten it
Fig. 1 with the counter nut.
5. Reassemble the covering from the front frame
(Fig. 2).

Fig. 2

480 BOMAG 008 911 57

 19 Suppliers documentation

008 911 57 BOMAG 481

482 BOMAG 008 911 57
 19.1 Travel pump

008 911 57 BOMAG 483

19.1 Travel pump

484 BOMAG 008 911 57

Travel pump 19.1
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

RDE 92 003-02-R/03.03
Verstellpumpe A4VG 71-180 ersetzt/replaces 01.02

Variable Pump A4VG 71-180

Baureihe/Series 32

Reparaturanleitung / Repair Instructions

008 911 57 BOMAG 485

19.1 Bosch Rexroth AG | Mobile Hydraulics
2 A4VG | RDE 92Travel
003-02-R/03.03
pump

Hinweis / Inhalt
Notice / Contents

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

INHALT CONTENTS
Seite/
Page

A4VG A4VG

Schnittbild 3-4 Sectional view

Allgemeine Reparaturhinweise 5 General repair instructions
Dichtsätze und Baugruppen 6-9 Seal kits and sub assembly groups
Triebwelle abdichten 10 Sealing of the drive shaft
Hilfspumpe abdichten 11 Sealing of the boost pump
Stellkolbendeckel abdichten 12-13 Sealing of the control piston cover
Speisedruckventil abdichten 14 Sealing of the boost pressure valve
Druckbegrenzungsventil abdichten 15 Sealing of the pressure relief valve HD
Druckabschneidung abdichten 16 Sealing of the pressure cut-off valve
Ansteuergerät abdichten 17 Sealing of the control device
Ansteuergerät HW 18 Control device HW
Ansteuergeräte EP - HD 19-22 Control devices EP - HD
4/3 Wegeventil DA 23 Control device DA
Regelventil abdichten / überprüfen 24 Sealing of the regulator valve
Pumpe demontieren 25-29 Pump disassembly
Verstellung demontieren 30-31 Dismantling of the control
Zylinder demontieren 32 Dismantling of the cylinder
Überprüfungshinweise 33-34 Inspection notes
Stellkolben, Triebwerk montieren 35-37 Positioning piston, rotary group assembly
Triebwerk einbauen 38-41 Installation of the rotary group
Pumpe montieren 42-44 Assembly of the pump
Montageanweisung für Anziehdrehmomente 45-48 Assembly guidelines for tightening torques
Sicherheitsbestimmungen 49-50 Safety regulations
Einstellhinweise 51-57 Adjustment instructions

486 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.13
Schnittbild
Sectional view

HW/D

EP/D HD/D

008 911 57 BOMAG 487

19.1 Bosch Rexroth AG | Mobile Hydraulics
4 A4VG | RDE 92Travel
003-02-R/03.03
pump

Schnittbild
Sectional view

DA/D

488 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.15
Allgemeine Reparaturhinweise
General repair instructions

Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!

Attention!
Observe the following notices when carrying
out repair work at hydraulic aggregates!

Alle Öffnungen der Hydraulikaggregate

verschließen.

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.

Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.

Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.

Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen.

Fill the hydraulic units with the operating medium

before commissioning.

008 911 57 BOMAG 489

19.1 Bosch Rexroth AG | Mobile Hydraulics
6 A4VG | RDE 92Travel
003-02-R/03.03
pump

Dichtsätze und Baugruppen

Seal kits and sub assembly groups

Dichtsatz für Triebwelle.

Seal kit for drive shaft.

Äußerer Dichtsatz.

Peripheral seal kit.

Triebwerk komplett.

Complete rotary group.

Stellkolben

Positioning piston

490 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.17
Stellkolben - Turcon-Glyd-Ring Dichtung
Positioning piston - Turcon-Glyd-ring seal

Deckel Stelldruck

Führungsbuchse
Stellzylinder
Turcon-Glyd-Ring
Lecköl
Pumpengehäuse

Bei den Verstellpumpen A4VG erfolgt zur Zeit die Umstellung
der Verstellung auf Turcon-Dichtungen.
Die Stückliste der kompletten Einheit erhält dabei eine neue
Ident.- Nummer.
Typenschlüssel, Typnummer und Außenabmeßungen bleiben
dabei unverändert. (Pumpengehäuse ändert sich nur im Bereich
vom Stellkolben. Stellkolben ändert sich in eine angefaste
Ausführung).
At present the change of the control into Turcon seal is made
for A4VG.
The parts list of the complete unit will receive a new identification
number.
Type reference and outside dimensions remain unchanged
(pump housing will change at the area of the positioning piston.
Positioning piston will change into chamfering design).

Pumpengehäuse / Pump housing Pumpengehäuse / Pump housing

mit Lagerbuchse / with bush ALT / OLD mit Turcon-Dichtung / with Turcon seal NEU / NEW

* *

Die Umstellung der Verstellung auf Turcon-Dichtung ist The change of the control into Turcon seal design
im allgemeinen mit einer Funktionsverbesserung improves in general the function (DA-behaviour, lower
verbunden (DA-Verhalten, geringerer Temperatureinfluß temperature-influence on control times).
auf Stellzeiten).

Bei gleicher Düsenbestückung können sich die Stellzeiten The control times will slightly change with the same throttle
geringfügig verändern. sections. Therefore our customers have to be informed
about this change.

008 911 57 BOMAG 491

19.1 Bosch Rexroth AG | Mobile Hydraulics
8 A4VG | RDE 92Travel
003-02-R/03.03
pump

Baugruppen
Sub assemblies

Anschlußplatte

Valve plate

Ansteuergerät HW
Hinweis:
NG 71 wie NG 40 - 56 mit Flachdichtung.

Control device HW
Note:
Size 71 control device as size 40 - 56 with flat seal.

alt / old Ansteuergerät HD

Hinweis:
NG 71 wie NG 40 - 56 mit Flachdichtung.

Control device HD
Note:
neu / new Size 71 control device as size 40 - 56 with flat seal.

Ansteuergerät EP
Hinweis:
NG 71 wie NG 40 - 56 mit Flachdichtung.

alt / old Control device EP

Note:
Size 71 control device as size 40 - 56 with flat seal.

neu / new

4/3 Wegeventil DA
Hinweis:
NG 71 wie NG 40 - 56 mit Flachdichtung.
alt / old
Control device DA
Note:
neu / new Size 71 control device as size 40 - 56 with flat seal.

492 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.19
Baugruppen
Sub assemblies

Hilfspumpe

Boost pump

Regelventil

Control valve

HD - Ventil

High pressure valve

ND - Ventil

Low pressure valve

Druckabschneidung

Pressure cut-off

008 911 57 BOMAG 493

19.1 Bosch Rexroth AG | Mobile Hydraulics
10 A4VG | RDE 92Travel
003-02-R/03.03
pump

Triebwelle abdichten
Sealing of the drive shaft

Triebwelle abkleben.
Sicherungsring ausbauen.

Protecting the drive shaft.

Remove retaining ring.

Blechschraube in die mit Gummi gefüllten

Löcher eindrehen.
Mit Zange WDR herausziehen.

Screw in sheet metal screw into the holes fitted

with rubber.
Pull out shaft seal with pliers.

Wellendichtring mit Buchse auf Anschlag

einpressen.
Zwischen Dicht- und Staublippe, Wellendichtring
leicht einfetten.

Press-in shaft seal with bush to stop.

Lightly grease the seal, dust lips and shaft seal ring.

494 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
11

Hilfspumpe abdichten
Sealing of the boost pump

*
*
Achtung!
* Angefaste "Seite" zum Deckel montieren.

Note!
* Mount chamfered side facing cover.

Lage kennzeichnen,
Befestigungsschrauben ausbauen.

Mark position,
remove fixing screws.

Deckel abdrücken.

Pry-off cover.

Kontrolle:
O-Ring, Nut, Lauffläche, Anschlußplatte.

Check:
O-ring, groove, gliding surface, connection plate.

008 911 57 BOMAG 495

19.1 Bosch Rexroth AG | Mobile Hydraulics
12 A4VG | RDE 92Travel
003-02-R/03.03
pump

Stellkolbendeckel abdichten
Sealing of the control piston cover

Achtung!
Korrekt mechanische 0-Lageneinstellung
überprüfen

Attention!
Check correct mechanical 0-position.

Lage kennzeichnen.

Mark position.

Deckel verdrehen und mit leichten

Hammerschlägen lösen.

Rotate cover and release by tapping gently

with hammer.

496 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
13

Stellkolbendeckel abdichten
Sealing of the control piston cover

Deckel kennzeichnen. Maß X festhalten, Konter-

mutter lösen, Stellschraube gegenhalten.

Mark cover. Must be fixed, loosen counter nut,

hold adjustment screw.
X

Deckel demontieren.

Remove cover.

Deckel von Stellschraube "abschrauben".

Lift off by turning the setting screw.

Kontrolle!
O-Ring (1), Nut (2), Gehäuse (3).

Check!
O-ring (1), groove (2), housing (3).

Achtung!
Korrekte mechanische Nullageneinstellung muß
nach Einbau im Gerät bzw. Prüfstand erfolgen.
(siehe Einstellhinweise Seite 54)

Attention!
Adjustment of the correct zero position to be carried
out after installation into the machine or on the test
bench.
(see adjustment instructions on page 54)

008 911 57 BOMAG 497

19.1 Bosch Rexroth AG | Mobile Hydraulics
14 A4VG | RDE 92Travel
003-02-R/03.03
pump

Speisedruckventil abdichten
Sealing of the boost pressure valve

Ventil komplett ausbauen.

Hinweis:
Einstellschraube nicht verändern.
Achtung!
Nach Einbau Ventileinstellung überprüfen!

Remove valve completely:

Note:
Do not change adjustment screw.
Attention!
Check valve setting after installation.

498 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
15

Druckbegrenzungsventil abdichten
Sealing of the pressure relief valve HD

Ventil komplett ausbauen.

Kontrolle: O-Ring, Gehäuse.
Wechsel der Dichtmutter - Einstellmaß (*)
festhalten.
Achtung!
Nach Einbau "Ventileinstellung" überprüfen.

Remove valve completely.

Control: O-ring, housing.
Replacement of the tightening nut, record
measure (*).
Attention!
After assembly check "valve setting".
*

008 911 57 BOMAG 499

19.1 Bosch Rexroth AG | Mobile Hydraulics
16 A4VG | RDE 92Travel
003-02-R/03.03
pump

Druckabschneidung abdichten
Sealing of the pressure cut-off valve

Einstellteil komplett ausschrauben.

Kontrolle: O-Ring, Gehäuse.
Wechsel der Dichtmutter - Einstellmaß (*)
festhalten.
Achtung!
Nach Einbau "Ventileinstellung" überprüfen.

Unscrew setting cartridge completely.

Control: O-ring, housing.
Replacement of the tightening nut, record
measure (*).
Attention!
After assembly check "valve setting".

500 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
17

Ansteuergerät abdichten
Sealing of the control device

DA
DA alt / old
HD
alt / old

DA
neu / new
HD
neu / new EP
alt / old

HW

EP
neu / new
NG 71 ... 125

NG 180

Ansteuergerät abbauen. Remove control device.

NG 71: Abdichtung der Ansteuergeräte wie NG 40 - 56 Size 71: Sealing of control device as size 40 - 56
mit Flachdichtung. with flat seal.
Achtung! Korrekte hydraulische Nullageneinstellung überprüfen. Attention! Check correct hydraulic 0-position.

Befestigungsschrauben demontieren.

Remove fixing screws.

Ansteuergerät abdrücken.

Pry-off the control unit.

Kontrolle
Dichtfläche (1), Flachdichtung (2), O-Ringe (3).

Check
Sealing surface (1), gasket (2), O-rings (3).

008 911 57 BOMAG 501

19.1 Bosch Rexroth AG | Mobile Hydraulics
18 A4VG | RDE 92Travel
003-02-R/03.03
pump

Ansteuergerät HW
Control device HW

NG 90-180
Size 90-180

Kontrolle:
O-Ringe und Dichtung.

Check:
O-rings, gasket.

502 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
19

Ansteuergeräte EP - HD
EP - HD Control devices

Ansteuergerät HD - EP alt (NG 90 - 180)

HD - EP (Size 90 - 180) control unit old

HD alt / old

EP alt / old HD alt / old

EP alt / old

Neues Ansteuergerät HD - EP (NG 71)

New HD - EP (Size 71) control unit alt / old

131,0 mm
neu / new

77,4 mm
202,0 mm

alt / old
214,4 mm

neu / new

008 911 57 BOMAG 503

19.1 Bosch Rexroth AG | Mobile Hydraulics
20 A4VG | RDE 92Travel
003-02-R/03.03
pump

Ansteuergeräte EP - HD
EP - HD Control devices

Ansteuergerät HD neu (NG 90 - 180)

HD - control unit new (Size 90 - 180)

Ansteuergerät EP neu (NG 90 - 180)

EP - control unit new (Size 90 - 180)

504 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
21

Ansteuergeräte EP - HD
EP - HD Control devices

* Markierung Montageposition HD *
* Marking the assembly position HD
*

* *

* Markierung
Montageposition HD * Assembly position marker HD

Wird von EP- auf HD-Ausführung umgebaut - Is converted from EP into the HD version -
Deckelposition beachten siehe Markierung take note of the cover position, see marker

Leckölkanal offen wird geschlossen. The open leakage port is plugged

Zugfeder tauschen! Exchange the tension spring!

008 911 57 BOMAG 505

19.1 Bosch Rexroth AG | Mobile Hydraulics
22 A4VG | RDE 92Travel
003-02-R/03.03
pump

Ansteuergeräte EP - HD
EP - HD Control devices

Markierung Montageposition EP Die neuen Proportionalmagnete müssen bei der Inbe-

Assembly position marker EP triebnahme entlüftet werden. Wird die Luft nicht aus
* dem Ankerraum entfernt, kann es zum Schwingen der
Hydraulische Nullage
Ansteuerung kommen.
Hydraulic zero position
Zum Entlüften ist am Ende des Magneten, im Messing-
Klemmschraube teil, ein kleiner Gewindestift M4, SW 2 vorhanden.
Clamping screw Dieser Gewindestift ist max. 2 Umdrehungen heraus-
* zudrehen und nach dem Entlüften mit 1 Nm wieder
festzuziehen.
Bei der Ausführung mit Nothand mit Federrückzug muß
zum Entlüften die Kunststoffmutter mit Gummibalg
entfernt und nach dem Entlüften mit 5+1 Nm wieder
angeschraubt werden.

Entlüftungsschraube * max. 2 Umdrehungen herausdrehen. The new proportional solenoids must be bled during
Bleed screw *. Unscrew by commissioning. If the air is not removed from the
a max. of 2 turns armature chamber oscillations at the control can occur.
* For bleeding purposes there is, on the end of the sole-
* noid, in the brass component a small set screw M4,
2A/F. This can be unscrewed by a maximum of 2 turns
and then after completion of the bleeding tightened to
a maximum of 2 Nm.
For the version with hand override and spring return
the plastic nut with rubber coating has to be removed
for bleeding. After bleeding it has to be replaced and
tightened with 5+1 Nm.

Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm

* *
Markierung
Klemmschraube 6,1 Nm Anziehmoment 5+1 Nm
Montageposition EP
Clamping screw 6,1 Nm Steckschlüssel SW 26
Assembly position
marker EP Tightening torque 5+1 Nm
26 A/F socket spanner
Hydraulische Nullage
Exzenterstift
Hydraulic
zero point
Eccentric pin
Beim Lösen der Klemmschraube
Exzenterstift - Hydraulische Nullage festhalten.

When loosening the clamping screw

Hold the eccentric pin - hydraulic zero point

506 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
23

4/3 Wegeventil DA
Control device DA

4/3 Wegeventil DA alt (NG 90 - 180)

DA - control unit old (Size 90 - 180)

Ablaufdrossel

4/3 Wegeventil DA neu (NG 90 - 180)

DA - control unit new (Size 90 - 180)

Anziehmoment 5+1 Nm
Steckschlüssel SW 26
Tightening torque 5+1 Nm
26 A/F socket spanner

Polrohr
Anziehmoment 19 Nm
Pole tube
Tightening torque 19 Nm

008 911 57 BOMAG 507

19.1 Bosch Rexroth AG | Mobile Hydraulics
24 A4VG | RDE 92Travel
003-02-R/03.03
pump

Regelventil abdichten/überprüfen
Sealing of the regulator valve

Blende überprüfen.
Keine Beschädigung.

Inspect orifice.
No damage.

Gewinde abkleben.
O-Ring einsetzen.

Cover threads.
Insert O-ring.

508 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
25

Pumpe demontieren
Removing of the pump

EP, HD, HW
Verschlußschraube / Stift
Locking screw / pin

DA
Verdrillschraube /
Timing adjustment screw

Ansteuergerät abbauen.

Remove control device.

Hilfspumpe ausbauen.
Hinweis:
Einbaulage kennzeichnen.

Remove auxiliary pump.

Note:
Mark assembly position previously.

008 911 57 BOMAG 509

19.1 Bosch Rexroth AG | Mobile Hydraulics
26 A4VG | RDE 92Travel
003-02-R/03.03
pump

Pumpe demontieren
Removing of the pump

Anschlußplatte mit Hilfspumpe

Achtung: Drehrichtung wird immer mit Blick

auf die Triebwelle angegeben.

Port plate with auxiliary pump

Attention: Direction of rotation is always

indicated with view on the drive shaft.

z.B. Drehrichtung "Rechts"

e.g. "clockwise" direction of rotation

Drehrichtung "rechts"
2 1
Breite Seite zur Sichel "rechts".

1. O-Ring,
2. Entlastungskanal

Direction of rotation "clockwise"

2
Broadside to the crescent "clockwise"

1. O-ring
2. Discharge channel

510 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
27

Pumpe demontieren
Removing of the pump

Drehrichtung "links"

"Counterclockwise" direction of rotation

2 1 1. O-Ring,
2. Entlastungskanal

1. O-ring
2. Discharge channel

Verschleißplatte 71 - 180

Wear plate 71 - 180

008 911 57 BOMAG 511

19.1 Bosch Rexroth AG | Mobile Hydraulics
28 A4VG | RDE 92Travel
003-02-R/03.03
pump

Pumpe demontieren
Pump disassembly

Lage der Verdrillschraube markieren (1).

Einstellmaß festhalten.
Verdrillschraube auf Demontageposition stellen (2).

Mark the position of the indexing screw (1).

Record setting measure.
Set the indexing screw to disassembly position (2).
X

Lage der Hilfspumpe und Anschlußplatte

markieren.
Anschlußplattenbefestigung lösen.

Mark position of the connection plate.

Loosen connection plate fixation.

Anschlußplatte und Steuerplatte abheben.

Lift off port plate and control plate.

1. Zylinder nach unten drücken, nicht beschädigen.

2. Verdrillschraube herausdrehen.

1. Press the cylinder to the bottom, do not damage.

2. Remove fixing indexing screw.

Zylinder komplett mit Kolben und

Rückzugeinrichtung ausbauen.

Push off hydraulic section of rotary group.

512 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
29

Pumpe demontieren
Pump disassembly

WDR / Sicherungsring ausbauen.

Remove radial seal ring and retaining ring.

Triebwelle mit leichten Hammerschlägen austreiben.

Remove drive shaft with slide hammer strokes.

Schwenkwiege / Lager komplett ausbauen.

Remove swash plate / bearing cups.

Gelenkstift ausbauen.

Remove joint pin.

008 911 57 BOMAG 513

19.1 Bosch Rexroth AG | Mobile Hydraulics
30 A4VG | RDE 92Travel
003-02-R/03.03
pump

Verstellung demontieren
Dismantling of the control

Alt / Old
Neu / New

Alt / Old

Neu / New

Lage vom Deckel markieren, Maß "Nullage" fest-

halten - Mutter lösen.

Mark position of the cover, note measure of

"zero position" - loosen nut.

Deckel abdrehen.

Remove cover.

514 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
31

Verstellung demontieren
Dismantling of the control

Lage des Deckels markieren.

Befestigungsschrauben lösen, abbauen.

Mark position of the cover.

Loosen locking screw, remove cover.

Stellzylinder ausbauen.

Remove positioning ring.

Vorrichtung aufsetzen und Feder vorspannen.

Aufnahmering ausbauen.

Fit tool device and preload spring.

Remove take-off ring.

Ringe ausbauen.
Sicherungsring ausbauen.
Achtung: Teile stehen unter Federvorspannung.

Remove rings.
Remove safety ring.
Attention: Parts are under spring load.

008 911 57 BOMAG 515

19.1 Bosch Rexroth AG | Mobile Hydraulics
32 A4VG | RDE 92Travel
003-02-R/03.03
pump

Zylinder demontieren
Dismantling of the cylinder

Kolben mit Rückzugeinrichtung ausbauen.

Tragkugel mit Tellerfedersäule abheben.

Remove piston with retaining plate.

Remove retaining ball with spring cup assembly.

Sicherungsring ausbauen.

Remove safety ring.

Scheibe 1, 2

Disc 1, 2

1 2

516 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
33

Überprüfungshinweise
Inspection notes

Lager Lagerschalen Kontrolle!

Bearing Bearing cup Käfig-Paar (1),
Lagerschalenpaar (2).
2
Check!
Cage set (1),
Bearing cup set (2).

Kontrolle!
Lagerbahnen (1)

Check!
Bearing surfaces (1)

Kontrolle!
Gleitfläche riefenfrei.

Check!
Sliding surface free from scoring.

Kontrolle!
Rückzugeinrichtung riefenfrei.

Check!
Check that return device is free of scoring.

Kontrolle!
1 1. Verzahnung "ausgeschlagen", Passungsrost.
2 2. Laufflächen.
1 3. Lauffläche - Wellendichtring.
3
1
Check!
1. Splines for damage or fretting.
2. Running surfaces.
3. Groove cut by shaft seal.

008 911 57 BOMAG 517

19.1 Bosch Rexroth AG | Mobile Hydraulics
34 A4VG | RDE 92Travel
003-02-R/03.03
pump

Überprüfungshinweise
Inspection notes

Kontrolle!
Lauffläche (1) keine Kratzer, keine Metall-
einlagerungen, kein Axialspiel (2), (Kolben nur
satzweise tauschen).

Check!
Check that there are no scratches or metal deposits
on sliding surface (1), and there is no axial play (2),
(otherwise: pistons must be replaced in sets).

Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).

Check!
Cylinder bores (1), splines (2).

Kontrolle!
Zylindergleitfläche (1) riefenfrei.
Steuerplatte (2) nicht riefig.

Check!
Cylinder surface (1) free of scoring.
Control plate (2) without scoring.

Kontrolle!
Stellkolben - Schwenkwiegenverbindung
Gleitstein (1), Nut im Stellkolben (2), Stellkolben.

Check!
Positioning piston - cradle linkage
Gliding stone (1), groove at the positioning piston
(2).
Positioning piston.

518 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
35

Stellkolben, Triebwerk montieren

Positioning piston, rotary group assembly

Stellkolben montieren.
Hinweis:
Auf korrekten Sitz der geteilten Ringe "achten".

Assemble positioning piston.

Instruction:
Observe correct fit of the divided rings.

Gehäuse - Turcon-Glyd-Ring montieren / Assemble housing - Turcon-Glyd-ring

Hilfswerkzeuge / Auxiliary tools:
Montagezange / Assembly pliers: B+S x M22

Montage / Assembly A4VG

2
3

3
2
Pos. / Pos. / Pos. / Pos. /
1
Item 1 Item 2 / 3 Item 2 / 3 Item 1

Pos. / Item 1: Stangenführungsring montieren.

Install barguide ring.

Pos. / Item 3: O-Ring montieren.

Install O-ring.

008 911 57 BOMAG 519

19.1 Bosch Rexroth AG | Mobile Hydraulics
36 A4VG | RDE 92Travel
003-02-R/03.03
pump

Stellkolben, Triebwerk montieren

Positioning piston, rotary group assembly

Gehäuse - Turcon-Glyd-Ring montieren / Assemble housing - Turcon-Glyd-ring

Dichtring (Pos. 2) in die Montagezange einlegen.

Fit the seal ring (Item 2) into the assembly tool.

Dichtring mit Zangenschenkel nierenförmig zu-

sammendrücken. Die Verformung von Turcon-Dich-
tungen ist sorgfältig vorzunehmen, damit die Dicht-
kanten nicht beschädigt werden.

Press the seal ring into the kidney shape using the
assembly tool. The deformation of the Turcon seal
has to be done with care so as not to damage the
sealing edges.

Dichtring ins Gehäuse einführen und in der

Aufnahmenut plazieren. Dann Spannung lösen und
Montagezange herausziehen. Lage des Dicht-
ringes prüfen - eventuell mit dem Finger
egalisieren.

Position the seal ring into the housing and place it

into the groove. Release the tension and withdraw
the assembly tool.
Check the position of the seal ring if necessary
straighten using a finger.

Führungsdorn in Stellkolben einbauen.

Insert guide thorn into the positioning piston.

Führungsdorn / A4VG28 I: 277 5 017

Guide thorn: A4VG40 I: 277 5 017
A4VG56 I: 277 5 018
A4VG71 I: 277 5 019
A4VG90 I: 277 5 020
A4VG125 I: 277 5 021
A4VG180 I: 277 5 022
A4VG250 I: 277 5 023

Führungsdorn leicht einfetten.

Stellkolben mit Führungsdorn einbauen.

Grease slightly guide thorn.

Install positioning piston with guide thorn.

520 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
37

Stellkolben, Triebwerk montieren

Positioning piston, rotary group assembly

Stellkolben ins Gehäuse einsetzen.

Hinweis:
Stellkolben vor Einbau einölen.

Insert positioning piston into the housing.

Instruction:
Oil positioning piston before assembly.

Stellkolben mit Hebel (Id.Nr. 2774491) ausrichten.

* Führung für Gleitstein - Schwenkwiege

Position stroke piston with lever (Id.No. 2774491).

* Sliding stone guidance in the piston.

Lagerschalenpaar einsetzen.

Insert bearing cup set.

Lager, Draht, Gleitstein und Gelenkstift montieren.

Montagehilfe: z.B. - Klammer / Gummiringe / Fett

Assemble bearing, wire, gliding stone and

articulating pin.
Assistance: Devices e.g. - Clamp / rubber rings /
grease

Schwenkwiege komplett ins Gehäuse einsetzen.

Auf korrekten Sitz der Schwenklager im Gehäuse
"achten".
Montagehilfe ausbauen.

Insert completely swivel cradle into the housing.

Pay attention for correct seat of the swivel cradle in
the housing.
Remove auxiliary device.

008 911 57 BOMAG 521

19.1 Bosch Rexroth AG | Mobile Hydraulics
38 A4VG | RDE 92Travel
003-02-R/03.03
pump

Triebwerk einbauen
Installation of the rotary group

Kontrolle: Sitz der Schwenklager in der

Lagerbahn.
Schwenkwiege mittig stellen mit Meßvorrichtung
(Uhr oder Tiefenmaß)
Punkt 1 und 2 kontrollieren - gleiches Maß.

Check: Location of the swivel-bearing

in the bearing.
Centralise by using a measuring device (dial gauge
or depth measurement).
Check points 1 and 2 - they should have the same
dimension.

Gelenkstift montieren.

Fit joint pin.

522 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
39

Triebwerk einbauen
Installation of the rotary group

Haltevorrichtung montieren.
Mit Gewindestift Schwenkwiege festhalten.
Keine Gewaltanwendung.

Fit holding device.

Hold swash plate in position utilising the set screw.
Do not use force.

Haltevorrichtung "Schwenkwiege" A4V

Holding device "swivel cradle" A4V

Teil/Part 3 Teil/Part 4

∅ ∅
6, 7, 8, 9
∅ ∅
3, 4, 5

∅ ∅

Teil/Part 5
∅
2
∅
1

Pos./Item Benennung/Designation Stck./Qty.

1 Winkel/Angle 2
2 Gewindestift/Threaded pin 2
3 Scheibe/Shim 2
4 Scheibe/Shim 2
5 Scheibe/Shim 2
6 Zyl. Schraube/Cyl. screw M12 x 25 DIN 912 2
7 Zyl. Schraube/Cyl. screw M14 x 25 DIN 912 2
8 Zyl. Schraube/Cyl. screw M16 x 30 DIN 912 2
9 Zyl. Schraube/Cyl. screw M20 x 35 DIN 912 2

008 911 57 BOMAG 523

19.1 Bosch Rexroth AG | Mobile Hydraulics
40 A4VG | RDE 92Travel
003-02-R/03.03
pump

Triebwerk einbauen
Installation of the rotary group

Neue Montageposition!
Triebwelle mit Lager und Wellendichtring
einbauen (siehe Seite 10).

Assemble drive shaft with bearings and radial

seal rings (see at page 10).

Kolben mit Rückzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einölen.

Assemble piston with retaining plate.

Note:
Oil piston and piston pad.

524 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
41

Triebwerk einbauen
Installation of the rotary group

Vorrichtung ausbauen.
Zylinder mit Kolben und Rückzugeinrichtung
einbauen.

Remove holding device.

Fit cylinder complete with pistons and retaining device.

Montagehilfe:
Mit O-Ring Kolben festhalten.

Assembly aid:
Hold the pistons by using an O-ring.

008 911 57 BOMAG 525

19.1 Bosch Rexroth AG | Mobile Hydraulics
42 A4VG | RDE 92Travel
003-02-R/03.03
pump

Triebwerk montieren DA
Assembly of the rotary group DA

Steuerplatte Rechtslauf - in Drehrichtung verdreht.

Achtung! Geräuschkerben sind drehrichtungs-
bezogen eingeschliffen.

Control plate clockwise rotation - indexed in the

R direction of rotation.
Note! Noise grooves are machined - in based on
directionof rotation.

Steuerplatte Linkslauf - in Drehrichtung verdreht.

Achtung! Geräuschkerben sind drehrichtungs-
bezogen eingeschliffen.
L
Control plate counter clockwise rotation - indexed
in the direction of rotation.
Note! Noise grooves are machined - in based on
direction of rotation.

Bei Ausführung mit Verdrillschraube:

Zylinder nach unten drücken - Verdrillschraube
auf Maß x einschrauben.
* Kerbe in Montageposition.

For the version with eccentric screw:

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

Maß X mit Vorrichtung neu ermitteln.

Zylinder mit Vorrichtung nach unten drücken.
Verdrillschraube bis Anschlag einschrauben -
Maß X - Kerbe in Montageposition drehen.

Re-identify dimension X with device.

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

Hilfsvorrichtung: / A4VG71 I: 277 5 088

X Auxiliary device: A4VG90 I: 277 5 089
A4VG125 I: 277 5 090
A4VG180 I: 277 5 091
A4VG250 I: 277 5 092

Steuerplatte einsetzen - Rechtslauf.

Insert the control plate - clockwise rotation.

526 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
43

Triebwerk montieren DA
Assembly of the rotary group DA

Steuerplatte einsetzen - Linkslauf.

Insert the control plate - Counter- clockwise

rotation.

Anschlußplatte aufbauen.
Achtung! Federvorspannung!
Mit zwei Befestigungsschrauben überkreuz An-
schlußplatte in Gehäuseführung einsetzen -
Fertigmontage!

Assemble connection plate.

Attention! Spring preloaded!
Insert control plate into housing, guidance with two
locking screws crossing over -Finish assembly!

Verdrillschraube - Nach Markierung ausrichten.

Locking screw - Observe adjusting measure.

1. Deckel montieren.
2. Nullage nach Maß einstellen.

1. Assemble cover
2. Adjust zero position according to measure.

008 911 57 BOMAG 527

19.1 Bosch Rexroth AG | Mobile Hydraulics
44 A4VG | RDE 92Travel
003-02-R/03.03
pump

Triebwerk montieren EP, HD, HW

Assembly of the rotary group EP, HD, HW

Steuerplatte Rechtslauf - in Drehrichtung verdreht.

Achtung! Pos.1 Fixierstift
Geräuschkerben sind drehrichtungsbezogen
eingeschliffen.

Control plate clockwise rotation - indexed in the

direction of rotation.
R Pos.1
Note! Pos.1 Fixing pin
Noise grooves are machined - in based on direction
of rotation.

Steuerplatte Linkslauf - in Drehrichtung verdreht.

Achtung! Pos.1 Fixierstift
Geräuschkerben sind drehrichtungsbezogen
eingeschliffen.

Control plate counter clockwise rotation - indexed

L Pos.1
in the direction of rotation.
Note! Pos.1 Fixing pin
Noise grooves are machined - in based on direction
of rotation.

Zylinderflächen und DU-Lager einölen, neue

O-Ringe mit Fett einreiben und einsetzen.

Oil the running surfaces of the cylinder barrel and

the DU- bearing. Grease the O-rings and insert
in grooves.

Verschlußschraube

Plug

528 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
45

Triebwerk montieren EP, HD, HW

Assembly of the rotary group EP, HD, HW

Verschlußschraube einbauen.

Screw in the plug.

Anschlußplatte mit Steuerplatte lagerichtig aufset-

zen.
Hinweis:
EP, HD, HW -Steuerplatte mit Fett einsetzen.

Place port block with control plate in correct

position.
Note:
EP, HD, HW - Put control plate with grease.

1. Deckel montieren.
2. Nullage nach Maß einstellen.

1. Assemble cover
2. Adjust zero position according to measure.

008 911 57 BOMAG 529

19.1 Bosch Rexroth AG | Mobile Hydraulics
46 A4VG | RDE 92Travel
003-02-R/03.03
pump

Pumpe montieren
Assembly of the pump

Achtung!
Korrekte mechanische Nullageneinstellung muß nach
Einbau im Gerät bzw. Prüfstand erfolgen.

Attention!
Adjustments of the correct zero position to be carried out
after installation into the machine or on the bench test.

Hilfspumpe montieren.
Hinweis: Drehrichtung beachten. (Siehe Seite 26, 27)

Assemble auxiliary pump.

Note: Take care of direction of rotation. (See page 26, 27)

Dichtung mit zwei Befestigungschrauben zentrieren und

NG 71 Ansteuergerät einbauen.
Alle vier Schrauben mit halbem Drehmoment anziehen.

Centre the seal using two fixing screws and fit

the control unit.
Tighten all four screws to half of specified torque.

Fünfte Schraube einsetzen und mit Drehmoment = 10,4 Nm

festziehen.
Restliche vier Schrauben nach Drehmoment festziehen.

Fit the fifth screw and tighten to a torque of 10,4 Nm.

Then tighten the other four screws to there correct torque.

Ansteuergerät montieren.

Assemble control device.

530 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
47

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)

Die Werte gelten für Schaftschrauben mit metrischem
ISO-Gewinde nach DIN 13 Teil 13, sowie Kopfauflagemaßen
nach DIN 912 Zylinderschrauben,
DIN 931 Sechskantschrauben mit Schaft bzw.
DIN 933 Sechskantschrauben mit Gewinde bis Kopf.
The values stated are valid for bolts with metric ISO threads
to DIN 13 part 13, as well as head areas to DIN 912 socked
head cap screws,
DIN 931 hexagon bolt or
DIN 933 hexagon bolts with threads up to the head.

Festigkeitsklassen / Tensile strength class

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

008 911 57 BOMAG 531

19.1 Bosch Rexroth AG | Mobile Hydraulics
48 A4VG | RDE 92Travel
003-02-R/03.03
pump

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).

G
EOLASTIC-
Dichtung / Seal

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

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

532 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
49

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

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

G
O-Ring / O-ring seal
Dichtung / Thread

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
7/16 - 20 UNF 15 M12 x 1,5 10
1/2 - 20 UNF 20 M14 x 1,5 30
9/16 - 18 UNF 25 M27 x 1,5 35
3/4 - 16 UNF 72
7/8 - 14 UN 127
1 1/16 -12 UN 147
1 3/16 -12 UN 173
1 5/16 -12 UN 198
1 5/8 -12 UN 320
1 7/8 -12 UN 390

6. SEAL-LOCK-Dichtmuttern (nach N 02.100) 6. SEAL-LOCK - sealing nuts (to N 02.100)

Gewinde / Anziehdrehmoment MA in Nm
Thread Tightening torque MA in Nm

M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180

008 911 57 BOMAG 533

19.1 Bosch Rexroth AG | Mobile Hydraulics
50 A4VG | RDE 92Travel
003-02-R/03.03
pump

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

A4V - Düsen / orifices

Gewinde / Anziehdremomente Nm /
Thread Tightening torques Nm
bisher / up to neu / new
M6 6,5 3
M10 28 12

534 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG
Sicherheitsbestimmungen
Safety regulations
Allgemein
● Machen Sie sich mit der Ausstattung der Maschine
vertraut.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den
Bedien- und Steuerelementen sowie der Arbeitsweise der
Maschine vertraut gemacht haben.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm,
Sicherheitsschuhe und Gehörschutz.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut.
● Benutzen Sie die Maschine nur für den ihr zugedachten
Zweck.
Beachten Sie bitte die Richtlinien der Berufsgenossenschaft
und des Maschinenherstellers
Vor dem Start
● Beachten Sie die Bedienungshinweise vor dem Starten.
● Prüfen Sie die Maschine auf auffällige Fehler.
● Fahren Sie die Maschine nicht mit defekten Instrumenten,
Kontrolleuchten oder Steuerorganen.
● Alle Schutzvorrichtungen müssen fest auf ihrem Platz sein.
● Nehmen Sie keine losen Gegenstände mit bzw. befestigen
Sie diese an der Maschine.
● Halten Sie die Maschine von öligem und zündfähigem
Material frei.
● Prüfen Sie vor dem Besteigen der Maschine, ob sich
Personen oder Hindernisse neben oder unter der Maschine
befinden.
● Vorsicht beim Besteigen der Maschine, benützen Sie
Treppen und Griffe.
● Stellen Sie vor dem Start Ihren Sitz ein.
008 911 57 BOMAG
Mobile Hydraulics | Bosch Rexroth AG 19.1
51
General advice
● Make yourself familiar with the equipment of the
machine.
● Only operate the machine if your are completely familiar with
the operating and control elements as well as the functioning
of the machine.
● Use your safety equipment like helmet, safety shoes and
hearing protection.
● Make yourself familiar with your working field.
● Only operate the machine for its intended purpose.
Please observe the guidelines of the Professional
Association and the machine manufacturer.
Before starting
● Observe the operating instructions before starting.
● Check the machine for remarkable faults.
● Do not operate the machine with defective instruments,
warning lights or control elements.
● All safety devices must be in a secure position.
● Do not carry with you movable objects or secure them to the
machine.
● Keep oily and inflammable material away from the machine.
● Before entering thc driver s cabin, check if personsor
obstacles are beside or beneath the machine.
● Be careful when entering the driver s cabin, use stairs and
handles.
● Adjust your seat before starting.
535
19.1 Bosch Rexroth AG | Mobile Hydraulics
52
Sicherheitsbestimmungen
Safety regulations
Starten
● Beim Starten müssen alle Bedienhebel in “Neutralstellung”
stehen.
● Die Maschine nur vom Fahrersitz aus Starten.
● Prüfen Sie die Anzeigeinstrumente nach dem Start, um
sicher zu gehen, daß alles ordnungsgemäß funktioniert.
● Lassen Sie die Maschine nicht unbewacht, während
der Motor läuft.
● Beim Start mit Batterieverbindungskabeln verbinden Sie Plus
mit Plus und Minus mit Minus. Massekabel (Minus) immer
zuletzt anschliesen und zuerst abtrennen.
Vorsicht
● Auspuffgase sind lebensgefährlich. Bei Start in
geschlossenen Räumen für ausreichende Luftzufuhr
sorgen!
Hydraulikanlage
1. Hydraulikanlage steht unter hohem Druck!
Unter hohem Druck austretende Hochdruck- Flüssig-
keiten (Kraftstoff, Hydrauliköl) können die Haut durch-
dringen und schwere Verletzungen verursachen. Daher
sofort einen Arzt aufsuchen, da anderenfalls schwere
Infektionen entstehen können!
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr
geeignete Hilfsmittel verwenden!
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt
drucklos machen und angebaute Geräte absenken!
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor
abstellen und Traktor gegen Wegrollen sichern
(Feststellbremse, Unterlegkeil)!
5. Beim Anschließen von Hydraulikzylindern und -motoren ist
auf vorgeschriebenen Anschluß der Hydraulikschläuche zu
achten!
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen
(z.B. Heben/Senken) - Unfallgefahr!
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und bei
Beschädigung und Alterung austauschen! Die Austausch-
schlauchleitungen müssen den technischen Anforderungen
des Geräteherstellers entsprechen!
Öle, Kraftstoffe und Filter ordnungsgemäß
entsorgen!
536 BOMAG
A4VG | RDE 92Travel
003-02-R/03.03
pump
Start
● When starting all operating levers must be in “neutral position”.
● Only start the machine from the driver s seat.
● Check the indicating instruments after start to assure that all
functions are in order.
● Do not leave the machine unobserved when the motor is
running.
● When starting with battery connection cables connect plus
with plus and minus with minus. Always connect mass cable
(minus) at last and cut off at first.
Attention
● Exhaust gas is dangerous. Assure sufficient fresh air when
starting in closed rooms!
Hydraulic equipment
1. Hydraulic equipment is standing under high pressure.
High pressure fluids (fuel, hydraulic oil) which escape
under high pressure can penetrate the skin and cause
heavy injuries. Therefore immediately consult a doctor as
otherwise heavy infections can be caused.
2. When searching leakages use appropriate auxiliary devices
because of the danger of accidents.
3. Before working at the hydraulic equipment, lower pressure
to zero and lower working arms of the rnachine.
4. When working at the hydraulic equipment, absolutely stop
motor and secure tractor against rolling away (parking brake,
shim)!
5. When connecting hydraulic cylinders and motor pay attention
to correct connection of hydraulic flexible hoses.
6. In case of exchanging the ports, the tunctions are vice versa
(f. ex. lift-up/lower) - danger of accidents!
7. Check hydraulic flexible hoses regularly and replace them in
case of dammage or wear! The new hose pipes must comply
with the technical requirements of the machine manufacturer!
Orderly disposal or recycling of oil, fuel and
filters!
008 911 57
RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
53

Einstellhinweise - ND-Ventil (Speisedruck)

Adjustment instructions - Low pressure valve (Boost pressure)

Achtung! Attention!
Sicherheitsbestimmungen beachten! Observe safety regulations!

Hinweis: Note:
Nachjustierung nur bei Betriebstemperatur. Readjusting only at operating temperature.

Manometer an "G" anschließen. Connect pressure gauge to "G".

Achtung! Attention!
* Speisedruckeinstellung! * Boost pressure setting!
Nenndruck pH - 20 bar Nominal pressure pH - 20 bar
Höchstdruck pH - 40 bar Peak pressure pH - 40 bar
Bei Max.-Drehzahl. at max. speed.

Hinweis: Note:
Einstelldaten nach Werksauftrag. Setting data is in accordance to the works order.

* bei DA-Ausführung * with the DA version

"G"

008 911 57 BOMAG 537

19.1 Bosch Rexroth AG | Mobile Hydraulics
54 A4VG | RDE 92Travel
003-02-R/03.03
pump

Einstellhinweise - Mechanische "Nullage"

Adjustment instructions - Mechanical "zero position"

HW HD EP DA

Achtung!
Sicherheitsbestimmungen beachten!
Mit Schlauch NW6 beide Stellkammern
verbinden. Vermeidung von Restsignal
aus hydraulischer Nullage.
Manometer an MA und MB anschließen.
Nullage so einstellen, daß bei blockiertem Antrieb
beide Manometer auf gleichem Druckwert stehen.
Hinweis:
Totband der Nullage - vermitteln.

Attention!
Observe safety regulations!
Connect both control chambers with a nominal size
6 hose. Avoidance of residual signals from hydraulic
zero position.
Connect pressure gauges to MA and MB. Adjust
the zero position so that with at blocked drive both
pressure gauges indicate the same pressure valve.
Note:
Ascertain the zero position dead band.

538 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
55

Einstellhinweise - Hydraulische "Nullage"

Adjustment instructions - Hydraulic "zero position"

* *
*

HW HD EP
Achtung!
Sicherheitsbestimmungen beachten!

Attention!
Observe safety regulations!

Manometer an X1 und X2 anschließen.

* Nullage so einstellen, daß bei blockiertem Antrieb
beide Manometer auf gleichem Druckwert stehen.
Hinweis:
Excenterjustierung - nicht über ± 90° verdrehen.

Connect pressure gauges to X1 and X2.

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

008 911 57 BOMAG 539

19.1 Bosch Rexroth AG | Mobile Hydraulics
56
Einstellhinweise - HD- Ventile (Hochdruck) und Druckabschneidung
Adjustment instructions - HP- valves (High pressure) and pressure cut-off
Druckabschneidung
Pressure cut-off
Zum Blockieren der Druckabschneidung beim Überprüfen
der Hochdruckventile die Einstellschraube Pos. 1 mit gelöster
Kontermutter Pos. 2 bis zum Anschlag mit
max. 2 Nm im drucklosen Zustand eindrehen!
Bei größerem Kraftaufwand als 2 Nm werden sonst Federteller
und Feder verbogen. Druckabschneidungseinstellung ist nicht
mehr gewährleistet.
To block the pressure cut-off when testing the high pressure
valves, the adjustment screw (item 1), with the lock-nut (item 2)
loosened, has to be screwed in
with a max. torque of 2 Nm in the depressurised condition
until the end stop is reached.
Forces larger than 2 Nm bends the spring and spring plate.
The pressure cut-off setting can then no longer be guaranteed.
HD- Ventile
HP- valves
540 BOMAG
A4VG | RDE 92Travel
003-02-R/03.03
pump
Achtung!
Sicherheitsbestimmungen beachten!
HD-Ventil ohne Bypass
1. HD-Ventile sind immer 10% höher eingestellt als die
Druckabschneidung.
Bei Veränderung eines Einstellwertes immer beide
kontrollieren.
2. Nachjustierung nur bei Betriebstemperatur
Manometer an MA und MB anschließen.
Druckabschneidung: Maß X Einstellschrauben notieren!
Einstellschraube auf Block drehen.
HD-Ventile: Mit geringer Pumpenmenge über Ventile fahren.
Einstellwert kontrollieren.
(Nur kurzzeitig "Temperatur“.)
Drucklos "Einstellwert“ verändern - Kontrolle
Druckabschneidung:
Einstellschraube auf Maß (*) zurückdrehen.
Druckwert kontrollieren bzw. nachjustieren.
Achtung! Differenz von 10% HD-Ventile und
Druckabschneidung beachten!
Hinweis: Einstelldaten nach Werksauftrag.
Pos.1
Item 1
Pos.2
Item 2
Attention!
Observe safety regulations.
HP valve without bypass-function
1. HP valves are always adjusted 10% higher than the
pressure cut-off.
If one setting value is changed, always check both values.
2. Readjusting only at operating temperature.
Connect pressure gauge MA and MB.
Pressure cut-off: Note measurement X for setting screw!
Turn setting screw to the blocked position.
HP valves: Operate the valves with small pump flow over the
valves.
Check setting value. (only for a short time "temperature“).
Change zero pressure "setting value“ - then check.
Pressure cut-off:
Turn back setting screw to measurement (*).
Check pressure value and readjust if necessary.
Attention! Observe the 10% pressure difference
between the HP valves and the pressure cut-off!
Note: Setting data is in accordance with the works order.
008 911 57
RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
57

Einstellhinweise - Bypassventil
Adjustment instructions - Bypass valve

A4VG 71 - 90 Pos.1
ca. 2 Umdrehungen
10 Nm

Pos.1
Anziehdrehmoment /
Tightening torque
20 Nm

150 Nm

100 Nm

Pos.1 Neu / New Alt / Old

Fahrzeuge mit rein-hydrostatischem Fahrantrieb bzw. mit Vehicle with hydrostatic transmission and gear shift without idling
hydrostatischem Fahrantrieb und Schaltgetriebe ohne Leerlauf- setting position (free wheeling).
stellung (Freilauf).

Hydrostatischer Antrieb / Bypaß-Schaltung Hydrostatic transmission / Bypass-switching

In diesem Fall wird der Fahrantrieb auf freien Umlauf geschaltet.
Zu diesem Zweck haben die in der Verstellpumpe integrierten
Hochdruckbegrenzungsventile eine sogenannte Bypaß-Funktion.
D.h. durch Drehen der entsprechenden Schraube (Pos.1) wird
der Ventil-Einsatz so entspannt, daß ein freier Öl-Umlauf möglich
ist.
In this case the travel transmission is switched on to free
wheeling.For this purpose the variable displacement pump has
incorporated high pressure relief valves with bypass function.
The screw (item 1) is unscrewed to such an extent, that the valve
cartridge is released and free oil circulation is possible.

A4VG 125 - 250

Bypass-Schaltung
ca. 2 Umdrehungen
Pos.1 200 ± 10 Nm

008 911 57 BOMAG 541

19.1 Bosch Rexroth AG | Mobile Hydraulics
58 A4VG | RDE 92Travel
003-02-R/03.03
pump

Einstellhinweise - DA- Regelung

Adjustment instructions - DA control

Achtung!
Sicherheitsbestimmungen beachten!

Überprüfung der Einstelldaten

Betriebstemperatur soll während des Über-
prüfungsvorgangs weitgehend konstant
gehalten werden.
Antriebsmotor starten, Leerlaufdrehzahl

Blockzustand
Fahrtrichtungsschalter "0“
Motordrehzahl langsam steigern bis zur max.
Motordrehzahl, dabei Meßgeräte beobachten.
Speisedruck:
Leerlaufdrehzahl
Psp = ca. 15-20 bar
max. Motordrehzahl
Psp = . . . . . . . . bar*

Blockzustand
Fahrtrichtungsschalter - vorwärts
(Straßengang und Festgebremst)

Einstelldaten Pumpe A4V/DA überprüfen

Regelbeginn
HD 40 - 50 bar
Motordrehzahl . min.1 * Psp . . . . . bar*
HD . . . . . . bar
Nachjustierung - Regelbeginnschraube
Verdrillung
Regelende
Regelbeginn HD . . . . . bar*
Motordrehzahl . . . . . min.1 * Psp . . . . . bar*
Nachjustierung - Verdrillschraube

Hinweis:
Excenterjustierung - Drehrichtung beachten

Hinweis: * Einstelldaten nach Werksauftrag!

542 BOMAG 008 911 57

RDE 92 003-02-R/03.03
Travel pump | A4VG Mobile Hydraulics | Bosch Rexroth AG 19.1
59

Einstellhinweise - DA- Regelung

Adjustment instructions - DA control

Attention!
Observe safety regulations!

Check setting data.

Operating temperature should be kept largely
constant during the check procedure.
Start prime mover, idle speed.

Block position
Drive direction switch - "0“.
Slowly increase motor speed up to the max.
motor speed and thereby observe measuring
instruments.

Boost pressure:
Idle speed of prime mover
Psp = approx. 15 - 20 bar
max. motor speed
Psp = . . . . . . . . . bar*

Block position
Drive direction switch - forward
(Road gear and fully applied brake)

Check setting data pump A4VIDA

Begin of control:
Timing HD 40 - 50 bar
adjustment screw
Motor speed . . . . . rpm* Psp . . . . . . . bar*
HD . . . . . . . bar*
Begin of control Readjusting - control start screw

End of control
HD . . . . . . . . bar
Motor speed . . . . . . rpm* Psp . . . . . . . bar*
Readjusting timing adjustment screw

Note:
Eccentric adjusting - observe direction of
rotation

* Setting data according to order!

008 911 57 BOMAG 543

19.1
© 2003 by Brueninghaus Hydromatik
GmbH, 89275 Elchingen
All rights reserved. No part of this
document may be reproduced or
stored, processed, duplicated or
circulated using electronic systems, in
any form or by any means, without the
prior written authorization of Bosch
Rexroth AG. In the event of
contravention of the above provisions,
the contravening party is obliged to
pay compensation.
The data specified above only serve to
describe the product. No statements
concerning a certain condition or
suitability for a certain application can
be derived from our information. The
given information does not release the
user from the obligation of own
judgement and verification. It must be
remembered that our products are
subject to a natural process of wear
and aging.
544 BOMAG
Travel pump
Brueninghaus Hydromatik GmbH
Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
info.brm@boschrexroth.de
www.boschrexroth.com/brm
© 2003 by Brueninghaus Hydromatik
GmbH, 89275 Elchingen
Alle Rechte vorbehalten. Kein Teil des
Werkes darf in irgendeiner Form ohne
vorherige schriftliche Zustimmung der
Brueninghaus Hydromatik GmbH
reproduziert oder unter Verwendung
elektronischer Systeme gespeichert,
verarbeitet, vervielfältigt oder verbreitet
werden. Zuwiderhandlungen
verpflichten zu Schadensersatz.
Die angegebenen Daten dienen allein
der Produktbeschreibung. Eine
Aussage über eine bestimmte
Beschaffenheit oder eine Eignung für
einen bestimmten Einsatzzweck kann
aus unseren Angaben nicht abgeleitet
werden. Die Angaben entbinden den
Verwender nicht von eigenen
Beurteilungen und Prüfungen. Es ist zu
beachten, dass unsere Produkte einem
natürlichen Verschleiß- und
Alterungsprozess unterliegen.
Printed in Germany
RDE 92 003-02-R/03.03
008 911 57
 19.2 Steering/working pump

008 911 57 BOMAG 545

19.2 Steering/working pump

546 BOMAG 008 911 57

Steering/working pump 19.2

Brueninghaus Hydromatik

R
Reparaturanleitung
Repair Instructions

A10VSO*
Baureihe 31 / Series 31
Nenngrößen 18...140
Sizes 18...140

* auch für
A10 VO ( s. S.2 )/
if its A10 VO see
page 2

RDE 92 711-02-R 01.95

008 911 57 BOMAG 547

RDE 92 711-02-R 01.95
19.2
Inhaltsverzeichnis
Steering/working pump
Reparaturanleitung A10 VSO/31
Contens Repair Instruction A10 VSO/31

HINWEIS NOTE

Teilgeprüfte und vormontierte Original Pretested and preassembled Original

Brueninghaus Hydromatik, Werk Horb-Bau- Brueninghaus Hydromatik, plant Horb -
gruppen ermöglichen bei kürzestem Zeitauf- subassemblies make quick and successful
wand erfolgreiche Reparaturen. repairs possible

Besonders rasch erhalten Sie die richtigen
Ersatzteile, wenn Sie uns bei der Bestellung
Typ- und Fabriknummer mit angeben. ( Für
den A 10-Ersatzteilservice wurde ein Schnell-
versand eingeführt, bitte ggf RD 90124 anfor-
dern.)
Delivery of the correct spare parts will be
especially quick if you state the type and the
serial number when orderring. ( We created a
A 10-spare part - quick shipping - service,
order RE 90 124 if necessary.)

Die Reparaturarbeiten sind einfach, trotzdem
sollten Sie unser Angebot zur Schulung nut-
zen und sich bei uns das notwendige Spezial-
wissen aneignen.
Although repairs are simple, you are
encouraged to enroll in the repair training
classes offered by Brueninghaus Hydromatik,
plant Horb. This will give you the proper
experience and specialized knowledge to make
your own repairs.

Die vorliegende Rep.Anleitung kann auch als
Grundlage für die A10VO (Mobilan-
wendungen) verwendet werden. Sie unter-
scheidet sich nicht in den Einstellwerten von
der im Stationärsektor verwendeten A10VSO.
This repairing manual also can be used to
repair the mobile A 10 VO. Adjustments of the
mobile pump are the same like the adjustments
of the stationary units A 10 VSO.

INHALT Seite CONTENTS

Page

Inhaltsverzeichnis 2 Contents

Schnittbild / Hinweise 3 Cross Sectional Diagram / Notes

Ersatzteil kits 4 - 5 spare parts kits

Abtriebswelle abdichten 6 - 7 Sealing the drive shaft

Demontage und Montage der 8 - 14 Disassembly and re-assembly

kompletten Einheit of the complete unit

Hinweise zum Steuerventil 15 - 17 control valve instructions

Zerlegen und Reinigen des 18 - 21 Disassembling and cleaning the control

Steuerventils valve

Montage-Abstimmung 22 Specification tolerance lists

Einstellhinweise und Prüfung 23 set up and testing instruction

Werkzeuge und Anziehdrehmomente 24 Tools and tightening torques

2 Brueninghaus Hydromatik
548 BOMAG 008 911 57
 RDE 92 711-02-R 01.95
Steering/working pump
Schnittbild
19.2
Reparaturanleitung A10 VSO/31
Section Repair Instruction A10 VSO/31

X
NG 100 und 140 mit mechan.
einstellbarem Q min - Anschlag

Size 100 and 140 with stopper

min flow adjustable mechanically

Brueninghaus Hydromatik 3
008 911 57 BOMAG 549
RDE 92 711-02-R 01.95
19.2
Ersatzteil - Kits
Steering/working pump
Reparaturanleitung A10 VSO/31
Spare part kits Repair Instruction A10 VSO/31

K1
Kompletter Dichtsatz ( Dichtsätze sind typenbezogen
festgelegt, Foto z. B. A 10 VSO 28 DFR, ohne
Steuerventildichtelemente), Werkstoff der Dicht-
elemente: Wellendichtring in FPM übrige in NBR

Sealing set complelely( sealing sets are based on

the type of the pump, picture shows for example A
10 VSO DFR, without pilot valve seals). Sealing
material: drive shaft sealing ring FPM, others NBR.

K2

Wie K 1, s. o., jedoch Werkstoff aller Dichtelemente

in FKM.

Same like K 1, see picture on top. Only difference: all

material FKM

K3
Antriebswelle: im Ersatzteilverkauf werden folgende
Ausführungen angeboten:
ISO - Paßfeder, SAE - Paßfeder, SAE - Zahnwelle

Drive shaft: our spare part supply offers you the

following drive shaft types:
ISO - key design, SAE - key design, SAE - splined
design

K4 Die Gruppe "Lagersatz Kleinteile" beinhaltet: 2

Kegelrollenlager, 2 Gleitlagerschalen, Abstimm-
scheibe, Distanzscheibe, Befestigungsschrauben,
diverse Stopfen und Zy-linderstift für Fixierung der
Verteilerplatte.

Contents of kit "bearing set / miscellaneous parts":

2 tapered roller bearings, 2 bearing shells,
adjustment shim, spacer shim, plugs, cylindric pin to
fix the valve plate.

K5

Die komplette Rotationsgruppe mit montierten

Hakenstiften im Zylinder wird für Drehrichtung rechts
oder links angeboten.

We offer the rotary group completely with its cylinder

with mounted pressure - pins for cw or ccw rotating
units ( pls order your direction of rotation ).

4 Brueninghaus Hydromatik
550 BOMAG 008 911 57
 RDE 92 711-02-R 01.95
Steering/working pump
Dichtelemente / Ersatzteil-Kits
19.2
Reparaturanleitung A10 VSO/31
sealing kits / spare parts kits Repair Instruction A10 VSO/31

K6 Schwenkwiegen in Standard - Ausführung stehen für

rechte oder linke Antriebsdrehrichtung zur Verfü-
gung. Ebenso wird zusätzlich für leistungsgeregelte
Pumpen die rechte und linke Schwenkwiege angebo-
ten.

We offer swash plates for cw or ccw rotating units

in the serial design or for horse power controlled
pumps by our spare part service.(Order your
direction of rotation)

K7
Die Abb. li zeigt die Verstellteile ohne Anschläge.
Ggf können auch Verstellteile mit Anschlägen bezo-
gen werden ( s. dazu auch RD 90 124)

Picture leftt shows the control device parts without

the stopper parts. Order with stopper parts if
necessary ( see RE 90 124 ).

K8 Als geprüftes und voreingestelltes Ventil kann das Steuer-

ventil für p- und Q-Regelung bezogen werden. Wenige Hand-
griffe ermöglichen ggf. Modifikationen in der Steuerventilaus-
führung. (Abb. li zeigt Steuerventil für A10 NG 18 bis100;
NG 140 mit Ventil-NG 6 - s. Titelbild bzw. Abb 10* S. 5)

Order a checked and preadjusted pilot valve to control the

pump for pressure compensator and flow control. Easy
handling is possible to convert the design of the pilot valve.
(Picture left shows valve of pump size 18 ..100; size 140 must
have valve size 6 - see cover picture or 10*this page)

9*
Steuerventilausführung für NG 18 bis 100:
X-Adapter am DFR-Steuerventil für metrische
Verrohrung des Steueranschlußes X (ohne Blende).

Pilot valve design 18 to 100:

Adapter without orifice of the DFR - pilot valve, if you
use a metric pilot pipe connection X.

10* Die Abb. zeigt den zerlegten Druckregler als

Zwischenplat-tenventil (NG 140). Als zweite Ventil-
achse wird der Förder-stromregler außen am Druck-
regler angeflanscht.

Picture left shows the pressure compensator

disassembled as a sandwich valve
(of pump size 140). Mount on top of the pressure
compensator housing the valve housing for the flow
control.

Brueninghaus Hydromatik 5
008 911 57 BOMAG 551
RDE 92 711-02-R 01.95
19.2
Antriebswelle abdichten
Steering/working pump
Reparaturanleitung A10 VSO/31
Sealing the drive shaft Repair Instruction A10 VSO/31

1 Die hier beschriebene Möglichkeit zum Wechsel der

Antriebswellen - Abdichtung stellt nicht die serien-
mäßige Montage dar. Für sicheres Dichtungs-
verhalten ist eine Montage des Dichtringes gemein-
sam mit dem Kegelrollenlager von innen her durch
Hinweis ! das Pumpengehäuse durchzuführen. Soll aus Grün-
den der Vereinfachung im Reparaturfall die folgend
beschriebene Vorgehensweise durchgeführt wer-
Note ! den, so ist beim Ausbau der Dichtung besonders
darauf zu achten, daß die Antriebswelle nicht beschä-
digt wird.

2
This discription showes how to change the drive shaft
sealing ring but it isn`t the way of serial assembly.
The sealing ring is assembled together with the taper
roller bearing from inside the pump housing normally
to get a secure sealing condition. If you decide to
repair the pump in the shown way be very careful
while handling so that the drive shaft wouldn`t be
damaged during disassembly of the shaft sealing
ring.

Entfernen der Paßfeder.

Disassemble of the key.

4
Sicherungsring ausbauen.

Remove the retaining ring.

5
Ausbau des WDR mit spitz angeschliffenem Schrau-
bendreher. Achtung: Beschädigung der Welle führt
o. Abb. zur Undichtheit.

Grind screwdriver to disassemble the shaft sealing

no picture
ring carefully. Pay attention: Damages of the drive
shaft indicate leakage.

6 Brueninghaus Hydromatik
552 BOMAG 008 911 57
 RDE 92 711-02-R 01.95
Steering/working pump
Antriebswelle abdichten
19.2
Reparaturanleitung A10 VSO/31
Sealing the drive shaft Repair Instruction A10 VSO/31

Bevor der neue eingefettete WDR montiert wird ist

eine Kontrolle der Lauffläche, Welle und Gehäuse
vorzunehmen.

Change the shaft seal and check the contact surfaces

( drive shaft and housing ), grease sealing ring
before mounting.

7 Einführhülse für die Montage des WDR aufsetzen:

Hülse 74.0.0655 ( NG 18 )
Angaben für
Hülse 74.0.0656 ( NG 28 )
ISO - Wellen /
Hülse 74.0.0657 ( NG 45 )
List shows ISO-
Hülse 74.0.0658 ( NG 71 )
drive shaft standard
Hülse 74.0.0659 ( NG 100 )
only
Hülse 74.0.0660 ( NG 140 )

Use installation tool for the sealing ring ( see tool list
on top ).

8 Mit geeignetem Rohr oder größerem Verstellkolben

wird über die Einführhülse der WDR nur so tief mon-
tiert, daß der Sicherungsring montierbar ist ( zu tiefes
Montieren führt zum Ausfall: Berührung mit dem
Wellenlager ! )
Use a suitable pipe or use the control piston of a
bigger pump size to mount the shaft seal ring via the
installation tool, but don't push it too deap. If the shaft
seal ring touches the bearing ring you will damage
the seal ring.

Sicherungsring einsetzen.

Assemble the retaining ring.

10
Sicherungsring ganz einrasten. Anschließend Montie-
render Paßfeder mit Hilfe eines Kunststoffhammers.
(o. Abb.)

Assemble the retaining ring. Assemble the key next

by using a plastic hammer. This handling isn't shown
in pictures.

Brueninghaus Hydromatik 7
008 911 57 BOMAG 553
RDE 92 711-02-R 01.95
19.2
Demontage und Montage der kompl. Einheit
Steering/working pump
Reparaturanleitung A10 VSO/31
Disassembly and re-assembly of the complete unit Repair Instruction A10 VSO/31

11
Die folgenden Arbeiten sind beispielhaft an einer NG
45 durchgeführt. Abweichungen für andere NG sind
im Bedarfsfall extra angeführt.
Abbau des Steuerventils.

This manual shows the handling of size 45. If

necessary changes to the other pump sizes are
shown separately.
Disassemble the pilot valve.

12

Markieren der Anschlußplatte zum Pumpengehäuse

und Lösen der Befestigungsschrauben.

Mark position of the port plate to pump housing and

remove socket screws of the port plate.

13

Abheben der Anschlußplatte und Verteilerplatte mit

Verstellteilen ( Herunterfallen der Verteilerplatte
durch Festhalten vermeiden).

Remove the port plate together with the valve plate

and control device parts (hold the valve plate so
that the plate can´t fall down ) .

14

Abheben des Kegelrollenlagers und Abstimmscheibe.

Disassemble taper roller bearing and adjustment

shim.

15

Triebwerk herausziehen.

Disassemble the rotary group.

8 Brueninghaus Hydromatik
554 BOMAG 008 911 57
 RDE 92 711-02-R 01.95
Steering/working pump
Demontage und Montage der kompl. Einheit
19.2
Reparaturanleitung A10 VSO/31
Disassembly and re-assembly of the complete unit Repair Instruction A10 VSO/31

16

O - Ring entfernen.

Remove the O - ring.

17

Lagerschalen herausheben.

Disassemble beaaring shells.

18

Kugellager Ab- und Auszieher ( handelsüblich ) für

Kegelrollenlager - Außenring ( antriebswellenseitig ).

Use bearing puller to remove outer bearing race of

front bearing.

19

Steuerplatte abheben.

Remove the control plate.

20

Kugellager Ab- und Auszieher ( handelsüblich ) des

Kegelrollenlager - Außenringes (anschlußplattenseitig )

Use bearing puller to remove outer bearing race of rear

bearing.

Brueninghaus Hydromatik 9
008 911 57 BOMAG 555
RDE 92 711-02-R 01.95
19.2
Demontage und Montage der kompl. Einheit
Steering/working pump
Reparaturanleitung A10 VSO/31
Disassembly and re-assembly of the complete unit Repair Instruction A10 VSO/31

21

O - Ringe entfernen.

Remove the O - rings

22

Demontage der Hutmutter für Gewindestift.

Disassemble the head nut of threaded pin.

23

Demontage der Fixiermutter und des Gewindestiftes.

Disassemble the hexagon fixing nut and the

threaded pin.

24

Kolbenführung des Verstellkolbens (Einbau

"ventilseitig") ausbauen.

Disassemble the guide of control piston (Mounting

position: pilot valve side).

25

Kolbenführung des Gegenkolbens ausbauen.

Disassembly the guide of opposite piston.

1 0 Brueninghaus Hydromatik
556 BOMAG 008 911 57
 RDE 92 711-02-R 01.95
Steering/working pump
Demontage und Montage der kompl. Einheit
19.2
Reparaturanleitung A10 VSO/31
Disassembly and re-assembly of the complete unit Repair Instruction A10 VSO/31

26

Antriebswelle aus der Rotationsgruppe herausziehen.

Pull out the drive shaft.

27

Kolben und Rückzugplatte entfernen.

Remove the pistons and the retaining plate.

28

Rückzugkugel entfernen.

Remove the retaining ball.

29

Vorspannung der Feder für Ausbau des Sicherungs-

rings erhöhen (mit Hilfsschraube und Scheiben).

Compress the center spring in order to disassemble

the retaining ring (easy handling by a helping bolt
and shims).

30

Sicherungsring ausbauen.

Disassemble the retaining ring.

Brueninghaus Hydromatik 11
008 911 57 BOMAG 557
RDE 92 711-02-R 01.95
19.2 Steering/working pump
Reparaturanleitung A10 VSO/31
Demontage und Montage der kompl. Einheit
Disassembly and re-assembly of the complete unit Repair Instruction A10 VSO/31

31

Restliche Einzelteile des Zylinders:Zylinderstifte,

Zylinder, Scheibe, Feder und Sicherungsring.

Remaining parts of the cylinder: pins, cylinder, shim,

spring and retaining ring.

32

Beim Zusammenbau der Pumpe in umgekehrter

Hinweis ! Reihenfolge ist auf die folgeden Punkte zu achten
( 33 - 42 ).

Note ! Assemble the pump in reverse order and note the

following ( 33 - 42 ).

33
Im Graugußgehäuse werden die Kegelrollenlager
mit einer Vorspannung von 0.....0,05 abgestimmt
s.a. S 22.

Taper roller bearing in the cast iron pump housing

must have a initial tension with 0.....0,05 mm ( see
page 22 ).

34
Drehrichtung: rechts
Vorbereiten der Anschlußplatte : Führung für Verstell-
und Gegenkolben mit Loctite einkleben.

- Lagerichtiges Verdrillen der Verteilerplatte in Dreh-

richtung 4 ° .(Verteilerplatte bei BR 31 nur noch in
Originallage montierbar)
- Befetten der O - Ringe.

35
Port plate ( direction of rotation clockwise ) : Both
piston guides are glued with Loctite.

See picture 34 - Correct position of the valve plate ( clockwise 4 ° ):

In case of series 31 the valve plate only can be
installed into the correct position.
- Grease O - rings prior assembly.

1 2 Brueninghaus Hydromatik
558 BOMAG 008 911 57
 RDE 92 711-02-R 01.95
Steering/working pump
Demontage und Montage der kompl. Einheit
19.2
Reparaturanleitung A10 VSO/31
Disassembly and re-assembly of the complete unit Repair Instruction A10 VSO/31

36
Drehrichtung: links
Vorbereiten der Anschlußplatte: Führung für Verstell-
und Gegenkolben mit Loctite einkleben.

- Lagerichtiges Verdrillen der Verteilerplatte in Dreh-

richtung 4°. (Verteilerplatte bei BR 31 nur noch in
Originallage montierbar)
- Befetten der O - Ringe

37
Port plate ( direction of rotation anti-clockwise ): Both
piston guides are glued with Loctite.

- Correct position of the valve plate ( anti-clockwise

See picture 36
4 ° ): In case of series 31 the valve plate only can be
installed into the correct position.
- Grease O - rings prior assembly

38
Lagerichtiger Einbau der Schwenkwiege mit großer
Schmiertasche auf der Hochdruckseite, Schwenk-
wiege für Drehrichtung rechts oder Schwenkwiege für
Drehrichtung links verwenden.

Correct position of cradle ( lubrication bore relief on

the high pressure side ), use cradle for clockwise
rotation, if counter clockwise use cradle for counter
clockwise rotation ( two different sub - assemblies ).

39 U. U. Nacharbeit der Schwenkwiege im Laufbereich

durch Läppen möglich( Läppdorn zentriert ), jedoch
Auspressen der Anschläge ( Kugelzapfen mit
Gleitschuh ) nicht zulässig ( Riefenbildung beim
Wiedereinbau ).
If it is possible to lap the cradle (sliding area of the
piston shoes ) it can be possible to use the cradle
again. Notice: It isn't allowed to press out the piston
connection parts out of the cradle ( scorings while
fitting ! ).

40 Falls Zylinder u. Verteilerplatte wiederverwendet

werden ggf. Kontaktstelle Verteilerplatte / Zylinder
nachläppen mit anschließendem Abziehen auf
ebener Unterlage mit 1000er Läpp-Papier.

Connection surfaces between valve plate and

cylinder: if lapping is possible use parts again, but
after lapping procedure use a lapping paper No.1000
to plan the cylinder and valve plate ( plain
underground totally is a must ).

Brueninghaus Hydromatik 13
008 911 57 BOMAG 559
RDE 92 711-02-R 01.95
19.2
Demontage und Montage der kompl. Einheit
Steering/working pump
Reparaturanleitung A10 VSO/31
Disassembly and re-assembly of the complete unit Repair Instruction A10 VSO/31

41

Überprüfung der Laufeigenschaft des Verstellkolbens.

Check running conditions of the control piston.

42

Überprüfung der Laufeigenschaft des Gegenkolbens.

Check running conditions of the opposite piston.

43

1 4 Brueninghaus Hydromatik
560 BOMAG 008 911 57
 RDE 92 711-02-R 01.95
Steering/working pump
Ersatzteil kit: A 10 Steuerventil DFR
19.2
Reparaturanleitung A10 VSO/31
Spare parts kit: A 10 control valve DFR Repair Instruction A10 VSO/31

Vorderseite des Beipackzettels aus dem Cover page of the pamphlet out of the
Ersatzteilpäckchen Steuerventil: spare part kit control valve:
( für NG 18... 100 ) ( pump size 18 to 100 )

1.Allgem eine Hinweise 1.Generaldirections

Zurwesentlichen Erleichterung derErsatzteilbeschaffung hat
Brueninghaus den ErsatzteildienstfürA10-Produkte m oder-
nisiert.Hinweise dazu finden Sie in derDruckschriftRD
90124 "A10-Ersatzteilversorgung ".Dervorliegende
Beipackzettelaus dem Ersatzteil-Päckchen des DFR Steuer-
ventils zeigtaufseinerRückseite wie die ausgelieferte
Ausführung einfach um gebautwerden kann,in andere ,
gängige Ausführungen .
Bitte beachten :beiÄnderung derAusführung m uß das
Ventilum gestem peltwerden .
Die gelieferte Ausführung m itderTeile Nr.942 581 wird nur
in Viton-Ausführung verschickt.
Brueninghaus m odernized the spare parts service ofA10
products so thatyou willgetspare parts m uch m ore easyly .
The advertizing folderRD 90124 "A10-spare part-service "
gives you m ore inform ation .This pam fletoutofthe spare
partkit"controlvalve :pressure com pensatorand flow
controlDFR "show on its backside:how to change the design
to the m ostcom m en typs ofthe controlvalve in an easy way .
Please note :The valve m ustbe m arked with the original
num berafterits change .
This valve willbe delivered only in the Viton-execution (
spare part No.942 581 ).

Pre-adjustm ents :
Voreinstelldaten :
DR-pressure com penator:approx 280 bar
DR:ca.280 bar FR-flow control:Δp approx 14 bar
FR:Δp ca.14 bar

2.Ersatzteil-Lieferung / spare partkit

Pos.5 :Stopfen fürBypaßdüse (Um bau in Pos.4 :2 Stopfen /plugs 7/16-20 UNF
DFR1)/plug in frontofthe decom pression -764 647 - M A /tightening torque :
orifice ifits type DFR1 (reversion kit). 20 Nm .
M 4x4 DIN 913 -914 741 -2erSteck- Steckschlüssel/offsethex.box
schlüssel/offsethex. box spannersize X spanner:3/16".
2m m .
(M itLoctite gesichert/use Loctite :Nr.
242 )

Pos.2 :3 O-Ringe /O-rings

Pos.3 :4 Befestigungsschrauben
PRP 011-19459 /screws
-514 497 - M 6x30 DIN 912 -900 443 -M A /
tightening torque :12 Nm .
Steckschlüssel/offsethex.box
spanner:5m m

W erkzeuge gehören nichtzum Lieferum fang /The tools are notincluded in the supply .

Brueninghaus Hydromatik 15
008 911 57 BOMAG 561
RDE 92 711-02-R 01.95
19.2
Ersatzteil kit: A 10 Steuerventil DFR (Rückseite Beipackzettel)
Steering/working pump
Reparaturanleitung A10 VSO/31
Spare parts kit: A 10 control valve DFR ( pamphlets reverse page ) Repair Instruction A10 VSO/31

M ontagehinweise fürdie Steuerventilausführungen

Fitting note ofthe controlvalve -devices
gelieferte Ausführung /supply
MA:21Nm
1 X MA:30Nm 1 X

Teile Nr.: 942 581

Ersetzt /substitutes
MA:70Nm
Teile Nr.: 942 581 Perbunan 908 241
Ersetzt/substitutes Viton
Perbunan 907 094
Viton 907 371
SteuerventilDFR-SO74
Blende /orifice 0,6m m
SteuerventilDFR pressure com pensatorand flow
Einbaulage
pressure com pensator and flow control controlDFR-SO74
der Blende /
DFR Ein X -Anschluß m it
posi-
Ein X -Anschluß m itPos.4 verschließen. Pos.4 verschließen .
tion of
the orifice One X -portis pluged by Pos.4 . Blende 0,6 m m um 90° verdrehen .
One X -portis pluged by
Pos.4 .Orifice 0,6m m in closed
position .

Teile Nr.: 942 581

Ersetzt:/substitutes
Perbunan 907 096
Viton 908 384

SteuerventilDFR 1
pressure com pensatorand flow controlDFR 1
Ein X -Anschluß m itPos.4 verschließen .
Bypaßdüse X -T m itPos.5 verschließen .
One X -portis pluged by Pos.4 .De-
com pression orifice X-T is pluged by Pos.5.

X 1 X

Teile Nr.: 942 581

Teile Nr.: 942 581
Ersetzt/substitutes
Perbunan 907 095
Viton 907 370
SteuerventilDR
pressure com pensatorDR
Beide X -Anschlüsse m it
Pos.4 verschließen
Förderstrom reglerblockieren .
Both X-ports are pluged by
Pos.4 .Flow control blocked.
1 6 Brueninghaus Hydromatik
562
Ersetzt /substitutes
Perbunan 908 242
Viton 939 705
SteuerventilDR-SO74
pressure com pensatorDR-SO74
Beide X -Anschlüsse m it
Pos.4 verschließen ;FR blockieren,
Blende 0,6 m m um 90° verdrehen .
Both X -ports are pluged by
Pos.4 ;Flow controlblocked,
orifice 0,6 m m in closed position (turn 90° )
BOMAG 008 911 57
 RDE 92 711-02-R 01.95
Steering/working pump
A 10 Steuerventil DFR für NG 140
19.2
Reparaturanleitung A10 VSO/31
A 10 control valve DFR of pump size 140 Repair Instruction A10 VSO/31

Teile-Nr.
FR NBR 920 184
FPM 931 668

Abb. zeigt Zwischenplattenventil (Option) Teile-Nr.

DR Shown as sandwich valve (option) NBR 920 180
FPM 924 992

Brueninghaus Hydromatik 17
008 911 57 BOMAG 563
RDE 92 711-02-R 01.95
19.2
Zerlegen und Reinigen des Steuerventils
Steering/working pump
Reparaturanleitung A10 VSO/31
Disassembling and cleaning the control valve Repair Instruction A10 VSO/31

46

Lösen der Befestigungsschrauben ( siehe S. 15 ).

Loosen socket screws ( see page 15 ).

47

Entfernen der O - Ringe.

Remove the O - rings.

48 Am komplett montierten Ventil wird mit Hilfe der

Druckluft die Puls.-Blende herausgeblasen: Druckluft
über Bohrung A, T verschlossen. Zur Vermeidung
von Hautkontakt Bewegungsrichtung der Blende
vorher beachten!
Blow out the pulsations orifice by air pressure out of
the complete valve: pressure at drilling A, close
drilling T. Note that there is no skin connection
during blowing,look how the orifice comes out before
blowing!

49

Entfernen der Hutmuttern. Die folgenden Arbeiten

werden erst beim Druckregler, dann beim Förderst-
romregler durchgeführt.

Remove the hexagon nuts. First disassemble

pressure control, afterwards flow control.

50

Kontermutter lösen und Gewindestift herausdrehen.

Loosen the lock nut and unscrew threaded pin.

1 8 Brueninghaus Hydromatik
564 BOMAG 008 911 57
 RDE 92 711-02-R 01.95
Steering/working pump
Zerlegen und Reinigen des Steuerventils
19.2
Reparaturanleitung A10 VSO/31
Disassembling and cleaning the control valve Repair Instruction A10 VSO/31

51

Verschlußschraube demontieren.

Disassemble the plug.

52

Herausnehmen des Federtellers.

Remove the spring collar.

53

Herausnehmen der Federn.

Remove the springs.

54

Herausnehmen des Federtellers.

Remove the spring cup.

55

Verschlußschraube entfernen.

Disassemble the plug.

Brueninghaus Hydromatik 19
008 911 57 BOMAG 565
RDE 92 711-02-R 01.95
19.2
Zerlegen und Reinigen des Steuerventils
Steering/working pump
Reparaturanleitung A10 VSO/31
Disassembling and cleaning the control valve Repair Instruction A10 VSO/31

56

Sorgfältiger Ausbau des Kolbens.

Be careful while disassembling the piston.

57

Demontage des Stopfens bzw. der Entlastungsdüse

(im Förderstromregler - Federraum ).

Disassemble the plug or orifice ( spring area of flow

control ).

58

Auswaschen des Steuerventilgehäuses und Einzel-

teile mit gründlichem Beseitigen des Waschmittels
durch Ausblasen.

Clean housing and parts with clean fluid and dry

with air carefully.

59

Zusammenbau des Steuerventils in umgekehrter

Reihenfolge. Dabei ist auf folgende Punkte zu ach-
Hinweis ! ten ( 60 bis 63 ).

Assemble pilot valve in reverse order and note the

Note ! following ( 60 to 63 ).

60

Kontrolle der Düsendurchlässigkeit.

Check the opening of the orifice.

2 0 Brueninghaus Hydromatik
566 BOMAG 008 911 57
 RDE 92 711-02-R 01.95
Steering/working pump
Zerlegen und Reinigen des Steuerventils
19.2
Reparaturanleitung A10 VSO/31
Disassembling and cleaning the control valve Repair Instruction A10 VSO/31

61

Einkleben der Düse ( auf verstopfte Düse ist beim

Klebevorgang zu achten ).

Be careful when loctiting the orifice.

62

Laufeigenschaft der Reglerkolben prüfen, keine

Beschädigungen der Kolben und der Bohrungen.

Check the movement of the pilot valve spools, and

drillings should not be damaged.

63
Einstellungen der Bypaßblende (s. auch S. 16):
1) Schlitz in Längsrichtung ( entspr. der Abb. ):
Blende geöffnet.
2) Schlitz quergestellt: Blende geschlossen

Adjustments of the bypass orifice (see page 16, too ):

1) open position of the orifice: like shown on the
picture
2) turn the orifice 90 ° to close it.

64

Einstellen des Steuerventils siehe Einstellhinweise

( s. S. 23 ).

For adjustment of the pilot valve see set up

instructions ( page 23 ).

65

Für die Steuerventilausführung der Pumpen NG 140

sind keine weiteren Angaben gemacht. Sinngemäß
Siehe S. 17.
sind die o. a. Hinweise zu beachten.

see page 17. Pilot valve of pump size 140 doesn't have own
instructions. However see the given hints on top.

Brueninghaus Hydromatik 21
008 911 57 BOMAG 567
RDE 92 711-02-R 01.95
19.2
Tabelle / Montage - Abstimmung
Steering/working pump
Reparaturanleitung A10 VSO/31
List / Adjustment of taper roller bearing set Repair Instruction A10 VSO/31

T a b e l l e " mechanische Förderstrombegrenzung" (gültig für Anschlag Q min und Q max )

L i s t mechanical flow limiter (both stopper max. and min. flow)

NG / Size 18 28 45 71 100* 140*

1,09 1,58 3,23 4,69 6,16 7,06

Volumenänderung ( in cm3 ) pro Gewindestiftumdrehung / Differential volume ( cm3 ) if

you are rotating the threaded pin - each rotation.
* mit vorhandenem einstellbaren Anschlag Q min /
mech. stopper min. flow adjustable

Montage - Abstimmung ( Kegelrollenlager ) / taper roller bearing initial tension

A10VSO Baureihe 31
A10VSO series 31 Hinweis zu den NG 18 und 28/
Note for size 18 and 28:
Die Ausmessung muß mit einer
Nullscheibe -Pos. 12- (1,5 ±
0,01 breit) erfolgen, s. u. Ein-
zelheit X. Diese Scheibe wird
nach der Messung entnommen.
Meßwert, Scheibenstärke der
Nullscheibe und erforderliche
Vorspannung ergibt die Stärke
der Abstimmscheibe (Pos. 12).
The smal pump sizes have to
be measured by using a spezial
shim -Pos. 12- with its
tolerance of 1,5 ± 0,01, see
detail X. This shim will be
disassembled after the
measurement. Measurement,
thickness of the spezial shim
and necessary pretention all
together makes the thickness of
the adjustment shim (Pos. 12).

Nullscheibe /

spezial shim

Einzelheit X/ detail X
Abstimmung der Triebwerkslagerung
Die Vorspannung der Triebwerkslagerung muß im Gußgehäuse von 0 bis 0,05 mm durch Abschlei-
fen der Abstimmscheibe Pos. 12 hergestellt werden.
Cast iron housing must have initial tension of the bearings : 0........0,05 mm , grind Pos. 12 if
necessary.

2 2 Brueninghaus Hydromatik
568 BOMAG 008 911 57
 RDE 92 711-02-R 01.95
Steering/working pump
Einstellhinweise
19.2
Reparaturanleitung A10 VSO/31
Testing and set up instuctions Repair Instruction A10 VSO/31

DR: bei geschlossener Verbraucherleitung wird der

Regler auf Sollwert eingestellt ( bei DFR einstellbare
Drossel offen, FR-Feder vorgespannt )

DR: When pressure line is closed adjust the

pressure of the controller ( if it's DFR design then
open the adjustable orifice and increase force of the
FR - spring).

FR: Differenzdruck 14 bar wird eingestellt bei halbem

Schwenkwinkel der Pumpe ( einstellbare Drossel in
der Systemdruckleitung teilweise geschlossen ).

FR: If swivel angle is in the mid position adjust diffe-

rential pressure 14 bar ( adjustable orifice in the
system pressure line is partly closed).

Mechanische Förderstrombegrenzung: Durch

Drehen am Gewindestift kann der Förderstrom der
Pumpe abhängig von der NG um min. 35% von V gmax
reduziert werden. (Soll jedoch eine größere Re-
duzierung des Förderstromes erforderlich werden,
kann auf den Einbau der Kontermutter verzichtet
werden. Bemerkung: Einstellung der Gewinde-
spindel ohne Kontermutter erfolgt unter Betriebs-
druck) Einstellwerte siehe Tabelle Seite 22.

Mechanical flow limiter: While screwing in the

threaded pin you will be able to reduce the flow from
Vg max to 35% reduction of V gmax dependent on the
size of the pump (If you need more reducton of the
flow, don´t mount the fixing hexagon nut. Note: to
adjust the threaded pin without the fixing hexagon
nut do it by the existence of the working pressure.)
Adjustment list see page 22.

Brueninghaus Hydromatik 23
008 911 57 BOMAG 569
RDE 92 711-02-R 01.95
19.2
Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente
Steering/working pump
Reparaturanleitung A10 VSO/31
Tools / auxiliary tools / tightening torques Repair Instruction A10 VSO/31

Verwendete Loctite-Sorten/ Loctite used :

alle Abreißstopfen/ for break-off plugs Nr. 601

sonst / normaly Nr. 242

Anziehdrehmomente / Tightening torques

Festigkeitsklassen / bolt hardness grade : 8,8; 10,9; 12,9

M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M30

8,8 2,3 5,0 8,5 21 41 72 115 176 240 350 600 1220

Ma 10,9 3,2 7,2 12 29 58 100 165 250 350 490 840 1670

12,9 4,1 8,5 14,5 35 70 121 195 300 410 590 990 2000

Ma (Nm) = max. Anziehdrehmoments (geölte Schrauben μ = 0,125)

Ma (Nm) = max. tightening torques (screws lubricated μ = 0,125)

Brueninghaus Hydrom atik Gm bH,W erk Horb,An den Kelterwiesen 14,D-72160 Horb 1,Telefon (0 74 51)9 20,Telefax (0 74 51)82 21

2 4 Brueninghaus Hydromatik
570 BOMAG 008 911 57
 19.3 Travel motor

008 911 57 BOMAG 571

19.3 Travel motor

572 BOMAG 008 911 57

Travel motor 19.3
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

RDE 91 604-01-R/03.03
Verstellmotor A6VM 28...200 ersetzt/replaces 08.01

Variable Displ. Motor A6VM 28...200

Reparaturanleitung / Repair Instructions

008 911 57 BOMAG 573

19.3 Bosch Rexroth AG | Mobile Hydraulics
2 A6VM | RDE 91 604-01-R/03.03
Travel motor

Typschlüssel
Typschlüssel A6V M / 6 3 W
Axialkolbenmaschine
Schrägachsenbauart, verstellbar A6V
Betriebsart
Motor (Einschubmotor A6VE siehe RD 91606) M
Nenngröße
≅ Schluckvolumen Vg max (cm3) 28 55 80 107 140 160 200
NG 28...200: Fertigung Werk Elchingen
Regel- und Verstelleinrichtung 28 55 80 107 140 160 200
Hydraulische Verstellung Steuerdruckanstieg 10 bar HD1 HD1 *
steuerdruckabhängig 25 bar HD2 HD2 *
35 bar HD3 – – – – – – – HD3 *
Hydraulische Zweipunktverstellung HZ – – – – – – – HZ .
HZ1 – – – HZ1 *
HZ3 – – – – HZ3
Elektrische Verstellung, Steuerspannung 12 V EP1 EP1 *
mit Proportionalmagnet 24 V EP2 EP2 *
Elektrische Steuerspannung 12 V EZ1 – – – EZ1 *
Zweipunktverstellung, 24 V EZ2 – – – EZ2 *
mit Schaltmagnet 12 V EZ3 – – – – EZ3
24 V EZ4 – – – – EZ4
Automatische Verstellung, ohne Druckanstieg HA1 HA1 *
hochdruckabhängig mit Druckanstieg Δp = 100 bar HA2 HA2 *
Hydraulische Verstellung, drehzahlabhängig DA – – – – – – – DA *
pSt/pHD = 5/100, hydraulisches Fahrtrichtungsventil DA1 DA1 *
elektrisches Fahrtrichtungsventil 12 V DA2 DA2 *
+ elektrische Vg max-Schaltung 24 V DA3 DA3 *
pSt/pHD = 8/100, hydraulisches Fahrtrichtungsventil DA4 DA4 *
elektrisches Fahrtrichtungsventil 12 V DA5 DA5 *
+ elektrische Vg max-Schaltung 24 V DA6 DA6 *
Druckregelung (nur für HD, EP) 28 55 80 107 140 160 200
ohne Druckregelung (kein Zeichen)
Druckregelung, direktgesteuert D
direktgesteuert, mit 2. Druckeinstellung E
fernsteuerbar – – – – – – – G
Übersteuerung der HA-Verstellung (nur für HA1, HA2)
ohne Übersteuerung (kein Zeichen)
hydraulische Übersteuerung T
elektrische Übersteuerung Steuerspannung 12 V U1
24 V U2
elektrische Übersteuerung Steuerspannung 12 V R1
+ elektrisches Fahrtrichtungsventil 24 V R2

* Differentialkolben Gleichgangkolben

574 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.33
Type code
Type code A6V M / 6 3 W
Axial piston unit
Bent axis design, variable displacement A6V
Mode of operation
Motor (plug-in motor A6VE see RE 91606) M
Size
≅ Displacement Vg max (cm3) 28 55 80 107 140 160 200
Sizes 28...200: production plant Elchingen
Control device 28 55 80 107 140 160 200
Hydraulic control pilot pressure increase 10 bar HD1 HD1 *
pilot pressure related 25 bar HD2 HD2 *
35 bar HD3 – – – – – – – HD3 *
Hydraulic two-position control HZ – – – – – – – HZ .
HZ1 – – – HZ1 *
HZ3 – – – – HZ3
Electrical control, control voltage 12 V EP1 EP1 *
with proportional solenoid 24 V EP2 EP2 *
Electrical control voltage 12 V EZ1 – – – EZ1 *
two-position control, 24 V EZ2 – – – EZ2 *
with switching solenoid 12 V EZ3 – – – – EZ3
24 V EZ4 – – – – EZ4
Automatic control, without pressure increase HA1 HA1 *
high pressure related with pressure increase Δp = 100 bar HA2 HA2 *
Hydraulic control, speed related DA – – – – – – – DA *
pSt/pHD = 5/100, hydraulic valve for travel direction DA1 DA1 *
electrical valve for travel direction 12 V DA2 DA2 *
+ electrical Vg max-switch 24 V DA3 DA3 *
pSt/pHD = 8/100, hydraulic valve for travel direction DA4 DA4 *
electrical valve for travel direction 12 V DA5 DA5 *
+ electrical Vg max-switch 24 V DA6 DA6 *
Pressure control (only for HD, EP) 28 55 80 107 140 160 200
without pressure control (no code)
Pressure control, direct control D
direct control, with 2nd pressure setting E
remote control – – – – – – – G
Override of HA-control (only for HA1, HA2)
without override (no code)
Hydraulic override T
Electrical override control voltage 12 V U1
24 V U2
Electrical override control voltage 12 V R1
+ el. valve for travel direction 24 V R2

* Differential piston Synchronizing piston

008 911 57 BOMAG 575

19.3 Travel motor

576 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.35
Schnittbild
Sectional drawing

A6VM 55-107 HZ3

A B

max. min.

X T

A6VM 55-107 EZ3

A B

max. min.

A6VM 55-107 HA3

A B

max. min.

A6VM 55-107 HA3U

A B

max. min.

008 911 57 BOMAG 577

19.3 Bosch Rexroth AG | Mobile Hydraulics
6 A6VM | RDE 91 604-01-R/03.03
Travel motor

Schnittbild
Sectional drawing

A6VM 28-200 HD

A B

max min

X
G

M1 T(T1)

A6VM 28-200 HD
mit Spülventil / with flushing valve

A B

max min

M1 T(T1)

A6VM 28-200 HD1D

mit Druckregelventil / with pressure
control valve

A B

max min

X
G

M1 T(T1)

578 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.37
Schnittbild
Sectional drawing

A6VM 28-200 EP

A B

max min

M1 T(T1)

A6VM 28-200 EP./..A

A B

max min

T(T1) M1

A6VM 28-200 EP./..A

A B

max min

Sa

T(T1) M1

008 911 57 BOMAG 579

19.3 Bosch Rexroth AG | Mobile Hydraulics
8 A6VM | RDE 91 604-01-R/03.03
Travel motor

Schnittbild
Sectional drawing

A6VM ... DA1

A B X1 X2

max min
G
X3

M1 T(T1)

A6VM ... DA3 A B

X1

X3
max min
G

M1 T(T1)

580 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.39
Schnittbild
Sectional drawing

A6VM 28-200 HA2U

mit Bremsventil / with braking valve

A
S

max min

T(T1) M1

A6VM 28-200 HA1R

mit Spülventil / with flushing valve

A B

max min

T(T1) M1

A6VM ... HA1U

mit Spülventil / with flushing valve

A B

max min

T(T1) M1

008 911 57 BOMAG 581

19.3 Bosch Rexroth AG | Mobile Hydraulics
10 A6VM | RDE 91 604-01-R/03.03
Travel motor

Allgemeine Reparaturhinweise
General repair instructions

Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!

Attention!
Observe the following notices when carrying out
repair work at hydraulic aggregates!

Alle Öffnungen der Hydraulikaggregate

verschließen.

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.

Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.

Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.

Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen.

Fill up hydraulic aggregates with medium

before start- up.

582 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
11

Dichtsätze und Baugruppen

Seal kits and sub assembly groups

Dichtsatz für Triebwelle.

Seal kit for drive shaft.

Äußerer Dichtsatz.

External seal kit.

Gehäuse

Housing

Triebwerk komplett
Hinweis: Pos. 1 - Für Anschlußplatte mit
Pos. 2 Differentialkolben
Pos. 2 - Für Anschlußplatte mit
Gleichgangkolben

Complete rotary group

Note: Pos. 1 - For port plate with differential
piston
Pos. 2 - For port plate with
synchronizing piston
Pos. 1

Pos. 1 Pos. 2 Anschlußplatte mit Stellkolben

Hinweis: Pos. 1 - Für Anschlußplatte mit
Differentialkolben
Pos. 2 - Für Anschlußplatte mit
Gleichgangkolben

Port plate with control piston

Note: Pos. 1 - For port plate with differential
piston
Pos. 2 - For port plate with
synchronizing piston

008 911 57 BOMAG 583

19.3 Bosch Rexroth AG | Mobile Hydraulics
12 A6VM | RDE 91 604-01-R/03.03
Travel motor

Dichtsätze und Baugruppen

Seal kits and sub assembly groups

Schaltmagnet / Proportionalmagnet

Solenoid

Deckel mit * Drosselstift.

* Drosselstift "Auftragsbezogen".
* Cover with * throttle pin.
* Throttle pin "as to order requirement".
*
*

*
*
Deckel mit Spül- und Speisedruckventil
* und * Drosselstift
* Drosselstift "Auftragsbezogen".
Cover with flushing and boost pressure valve
and * throttle pin.
* Throttle pin "as to order requirement".

584 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
13

Baugruppen / Steuerteile
Component groups / Control components

z. B. HA EP

HA2
Auftrags-
bezogen *
"as to order
DA
requirement".

HD

008 911 57 BOMAG 585

19.3 Bosch Rexroth AG | Mobile Hydraulics
14 A6VM | RDE 91 604-01-R/03.03
Travel motor

Baugruppen / Steuerteile
Component groups / Control components

z. B. HZ3 / EZ3

HA3 / HA3U

586 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
15

Dichtmutter austauschen
Replace seal nut

Dichtmutter austauschen.
Zuerst Maß X messen und festhalten.

Replace seal nut.

First measure and record setting height.

Maß X

Beim Anziehen Einstellschraube gegenhalten,

anschließend Einstellhöhe kontrollieren.

When tightening, counterhold setting screw, then

check setting height.

008 911 57 BOMAG 587

19.3 Bosch Rexroth AG | Mobile Hydraulics
16 A6VM | RDE 91 604-01-R/03.03
Travel motor

Triebwelle abdichten
Sealing of the drive shaft

Triebwelle abkleben.
Sicherungsring und Scheibe ausbauen.

Protecting the drive shaft.

Remove retaining ring and shim.

Blechschraube in die mit Gummi gefüllten

Löcher eindrehen.
Mit Zange WDR herausziehen.

Screw in sheet metal screw into the holes

fitted with rubber.
Pull out seal with pliers.

Wellendichtring und Scheibe mit Montagehülse

einpressen.
Zwischen Dicht- und Staublippe, Wellendichtring
* leicht einfetten
Einpresstiefe beachten! * Marke für Einpresstiefe.
Sicherungsring einbauen.

Press in shaft seal ring and shim with bush to stop.

Take note of press-in depth!
Lightly grease the seal, dust lips and shaft seal ring.
Install * mark for press-in depth of safety ring.

588 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
17

Steuerteile abdichten
Sealing of the control parts

Achtung!
Federvorspannung

1 Attention!
Spring load

1. Deckel / Cover
2. Steuerteil / Control part
1
Kontrolle
Bohrung im Gehäuse, O-Ring, Nut.

Inspect
Drilling in housing, O-ring, groove.

Einstellschraube nicht ausbauen.

2 Kontrolle
O-Ring, O-Ring-Nut, Gehäuse

Do not remove adjustment screw.

Inspect
O-ring, O-ring groove, housing

Montagehilfe
Stift mit Fett einkleben.

2 Assembly aid
Insert pin with grease.

008 911 57 BOMAG 589

19.3 Bosch Rexroth AG | Mobile Hydraulics
18 A6VM | RDE 91 604-01-R/03.03
Travel motor

Verstellung abdichten
Sealing the hydraulic control

Beispiel: A6VM ... HD Verstellung

Demontageposition:
Deckel Pos. 1 abbauen.

Example: A6VM ... HD control

Pos.1 Disassembly position:
Remove cover pos. 1

1
1. O-Ring
2
2. Stellölzulauf
3. Drosselstift
Einbaulage je nach Steuerteil verschieden.

1. O-ring
2. Input flow of oil control
3. Throttle pin
Installation position differs according to the
3 control components

1
5
1. Stellölzulauf / Input flow of oil control
2 3 2. Hochdruck bzw. Niederdruck / High pressure /
low pressure
3. Hochdruck bzw. Niederdruck / High pressure /
low pressure
4. Lecköl / Leckage oil
4 5. Stellkolben / Control piston

590 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
19

Verstellung abdichten
Sealing the hydraulic control

Pos. 2

Beispiel: A6VM ... Verstellung - Differentialkolben

Demontageposition: Deckel Pos. 2 abbauen.
Achtung! Federvorspannung.
Maß x: Maß festhalten (Regelbeginn).
x
Example: A6VM... control - differential piston
Disassembly position: Remove cover pos. 2.
Attention! Spring load.
Dimension x: Note dimension (begin of regulation).

1. O-Ring Kontrolle

1. Check of O-ring

1
2 1. Hochdruck - kleine Stellkolbenseite
* 2. Stelldruck
3. Hochdruck - Rückschlagventil
4. Hochdruck - Rückschlagventil
* siehe Serviceinfo

1. High pressure - small control piston side

2. Control pressure
3
4 3. High pressure - check valve
4. High pressure - check valve
* see serviceinfo

008 911 57 BOMAG 591

19.3 Bosch Rexroth AG | Mobile Hydraulics
20 A6VM | RDE 91 604-01-R/03.03
Travel motor

Abschlußplatte demontieren
Disassembly of the port plate

x Differentialkolben:
Maß X festhalten.

Differential piston:
Note dimension x

Bei "Demontage" der Anschlußplatte

"Triebwerk" immer auf Null schwenken.
Kolbenringe hängen aus der Zylinder-
bohrung aus.

For disassembly of the port plate, swivel

always rotary group to zero position.
Piston rings to hang out of the cylinder
boring.
Qmin-Schraube
Qmin-screw

Qmin-Schraube ausbauen.
Triebwerk auf 0o schwenken.

Remove Qmin-screw.
Swivel rotary group to 0o.

592 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
21

Abschlußplatte demontieren
Disassembly of the port plate

x Gleichgangkolben:
Maß X festhalten.

Synchronizing piston:
Note dimension x.

Bei "Demontage" der Anschlußplatte "Triebwerk"

immer auf Null schwenken.
* Kolbenringe hängen sonst aus der Zylinder-
bohrung aus.
Qmin-Schraube
For disassembly of the port plate, swivel always
Qmin-screw
rotary group to zero position.
* Piston rings to hang out of the cylinder boring.

Qmin-Schraube und Verschlußschraube ausbauen.

Remove Qmin-screw and plug.

Mit Schraube Qmin Triebwerk auf 0o schwenken.

Swivel rotary group to zero position with screw Qmin

.

008 911 57 BOMAG 593

19.3 Bosch Rexroth AG | Mobile Hydraulics
22 A6VM | RDE 91 604-01-R/03.03
Travel motor

Abschlußplatte demontieren
Disassembly of the port plate

Anschlußplatte
Lage markieren. Schrauben lösen.
Abbauen

Port plate
Mark position. Loosen screws.
Removal

O-Ring austauschen.
Neuer O-Ring mit etwas Fett einkleben.
Triebwerk nicht ausschwenken.
Kolbenringe hängen aus der Zylinderbohrung aus.

Check O-ring.
Stick new O-ring with some grease.
Do not swivel rotary group.
Piston rings to hang out from the cylinder boring.

Steuerlinse in Gleitbahn mit Fett einkleben.

Fertigmontage in umgekehrter Reihenfolge.
Anschlußplatte aufsetzen.
Triebwerk senkrecht.

Stick control lens in sliding surface with grease.

Assembly in reversal order.
Mount port plate.
Rotary group vertical.

594 BOMAG 008 911 57

Travel motor 19.3

008 911 57 BOMAG 595

19.3 Travel motor

596 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
25

Triebwerk ausbauen
Remove rotary group

Gewindestift in Mittelzapfen einschrauben,

mit Schutzscheibe und Mutter Zylinder befestigen.
Qmax - Anschlagschraube ausbauen.

Screw in threaded pin into center pin.

Fix the cylinder with disc and locknut.
Remove Qmax -stop screw.

Nenngröße / Size 28 : M4 x 60 mm
55 : M5 x 80 mm
80 : M6 x 90 mm
107 : M6 x 100 mm
140 : M8 x 110 mm
160 : M8 x 110 mm
200 : M8 x 110 mm

Triebwerk auspressen!
Bei Wiederverwendung der Lager nicht schlagen.

Press out rotary group!

If the bearings are used again do not hit on the drive
shaft.

008 911 57 BOMAG 597

19.3 Bosch Rexroth AG | Mobile Hydraulics
26 A6VM | RDE 91 604-01-R/03.03
Travel motor

Triebwerk ausbauen
Remove rotary group

Oder mit Abziehvorrichtung ausdrücken.

Or press-out with extraction device.

598 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
27

Triebwerk austauschen
Exchanging of the rotary group

eingepresst
pressed in
Triebwerk komplett
Abstimmung hydraulischer
Teil notwendig.

Complete rotary group

Setting of hydraulic part
necessary.

Triebwerk Baugruppe
1.Mechanischer Teil: Triebwelle mit Lager abgestimmt.
2.Hydraulischer Teil: Abstimmung notwendig *.

Rotary group
1. Mechanical part: Adjust drive shaft with bearing.
2. Hydraulic part: Adjustment necessary *.

Triebwerk: Alle Bauteile

* Abstimmung
Abstimmwerte, Drehmomente siehe Serviceinfo.

Rotary group: All parts

* Setting
Setting value, torque see service information.

008 911 57 BOMAG 599

19.3 Bosch Rexroth AG | Mobile Hydraulics
28 A6VM | RDE 91 604-01-R/03.03
Travel motor

Triebwerk austauschen
Exchanging of the rotary group

Befestigungsschraube (Zylinder) ausbauen.

Zylinder abheben.

Remove fixing screw (cylinder).

Remove cylinder.

Rückzugplatte demontieren.
Schrauben sind eingeklebt. Nach Erwärmen auf
max 120o C mit Torx-Werkzeug demontieren.

Disassemble retaining plate.

Screws are glued. Warm it up to max. 120o C
and remove with Torx-tools.

600 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
29

Überprüfungshinweise
Inspection notes

Kein Passungsrost, nicht ausgeschlagen.

Free of corrosion, erosion or fretting;

no damage to splines or keyways.

Kolben
Riefenfrei und keine Pittings.

Pistons
No scoring and no pittings.

1 2

Mittelzapfen
Riefenfrei und keine Pittings.

Center pin
No scoring and no pittings.

Rückzugplatte
Riefenfrei und keine Ausbrüche.

Retaining plate
No scoring and no evidence of wear

Zylinder / Steuerlinse
1 Bohrungen riefenfrei, nicht ausgelaufen.
2 Gleichmäßiges Tragbild, riß- und riefenfrei.

Cylinder block / control lens

1 Bores free of scoring, no evidence of wear.
2 Faces smooth and even, free of cracks
and scoring.

008 911 57 BOMAG 601

19.3 Bosch Rexroth AG | Mobile Hydraulics
30 A6VM | RDE 91 604-01-R/03.03
Travel motor

Überprüfungshinweise
Inspection notes

Reglergehäuse
Gleitbahn und Seitenführung riefenfrei,
nicht ausgelaufen.

Control housing
Sliding surface and side guides free of scoring
and no wear.

Sichtkontrolle:
Im Lagerbereich riefenfrei und keine Einlaufspuren.

Visual check:
Bearing areas free of scoring and no evidence
of wear.

602 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
31

Triebwerk montieren / siehe Serviceinformation

Rotary group assembly / see service information

Triebwelle: mechanischer Teil

Rotary group: mechanical part

1 Abstimmung Maß * und Lagerdrehmomente

siehe Serviceinfo.

2
* Adjustment dimension * and bearing torque
see service infoprmation.

Lager aufpressen.
Beim Aufpressen Lagerdrehmoment nicht
überschreiten.

Press on bearing.
Do not exeed bearing torque during press-on.

BOJH
GG
DRTT
GHE

000
000
BOJH
GG
DRTT
GHE

Lager mit Montagehülse vorspannen und laufende Drehmomentenkontrolle.

Preload bearing with assembly sleeve and steady control of the torque.

008 911 57 BOMAG 603

19.3 Bosch Rexroth AG | Mobile Hydraulics
32 A6VM | RDE 91 604-01-R/03.03
Travel motor

Triebwerk montieren
Rotary group assembly

Sicherungsring 1 montieren.
Maß * für Abstimmscheibe mit Endmaß ermitteln
(überkreuz).
Abstimmscheibe einbauen.
Sicherungsring montieren.

1 Assemble safety ring.

Determine dimension * for adjustment disc with fi-
* nal dimensions (crossover)
Install adjustment shim.
Assemble safety ring.

Triebwelle einbaufertig.

Drive shaft ready for assembly.

604 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
33

Triebwerk montieren
Rotary group assembly

Rückzugplatte mit Kolben und Mittelzapfen

einsetzen.
Schrauben mit Precote-Beschichtung verwenden.
(Anziehdremoment siehe Seite 42).

Insert retaining plate with piston and center pin.

Use screw with Precote-coating.
(Tightening torque see page 42).

Auf richtige Schichtung aller Teile achten.

Make sure all parts are fitted in correctly.

Triebwerk auf Null schwenken und Zylinder mit

Gewindestift befestigen. (siehe Seite 25)

Swivel cylinder block to zero position and fix the

cylinder with a threaded pin (see page 25)

008 911 57 BOMAG 605

19.3 Bosch Rexroth AG | Mobile Hydraulics
34 A6VM | RDE 91 604-01-R/03.03
Travel motor

Triebwerk montieren
Rotary group assembly

Triebwerk komplett zum Einbau fertig.

Rotary group completely assembled ready

for assembly.

Montagehülse montieren.

Place assembly sleeve.

Gehäuse auf 80oC erwärmen.

Warm up housing to 80oC.

606 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
35

Triebwerk montieren
Rotary group assembly

Triebwerk ins Gehäuse auf Anschlag einsetzen.

Insert rotary group into housing to seat position.

Nach Einbau des Triebwerks im Gehäuse ist die

Triebwelle bis auf Anschlag nach vorne zu ziehen.

Pull the drive shaft after rotary groupassembly into

housing to seat position.

2 1

Zylinder in Nullposition
ausrichten.
1. Zylinderbefestigungsschraube
demontieren.
2. O-Ring einsetzen.

Fix zero position of cylinder

with Qmax-screw.
1. Disassemble cylinder
fixing screw.
2. Insert O-ring.

008 911 57 BOMAG 607

19.3 Bosch Rexroth AG | Mobile Hydraulics
36 A6VM | RDE 91 604-01-R/03.03
Travel motor

Triebwerksabstimmung (siehe Serviceinfo)

Rotary group adjustment (see service information)

Mit Schraube Zylinderausschwenkung

vermitteln.

Determine cylinder swivel range to

max. angle with screw.

* * Scheibe
* Disc

Zentrierscheibe aufsetzen.

Place centering disc.

Meßvorrichtung aufbauen.

Mount measuring device.

Maß X überprüfen.

Check dimension X.

608 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
37

Abschlußplatte montieren
Assembly of the port plate

1. Anschlußplatte mit Differential-

* kolben montieren.
Montageausführung beachten!
Befestigungsschrauben mit
Drehmoment anziehen.
2. Triebwerk in "Ausgangsstellung"
schwenken.
3. Qmin -Schraube auf
Maß * einstellen.
4. Verschlußschraube einbauen.
5. Montagehülse demontieren.

1. Assemble port plate with

differential piston.
Take care of assembly design!
Tighten fixing screws
with torque.
2. Swivel rotary group to "starting
position".
3. Set Qmin -screw to
dimension*.
4. Assemble plug.
5. Remove assembly sleeve.

Deckel montieren.

Assemble cover.

Steuerteil montieren.
x
Assemble control components.

008 911 57 BOMAG 609

19.3 Bosch Rexroth AG | Mobile Hydraulics
38 A6VM | RDE 91 604-01-R/03.03
Travel motor

Anschlußplatte montieren
Assembly of the port plate

1. Anschlußplatte mit Gleichgang-

kolben montieren.
Montageausführung beachten!
Befestigungsschrauben mit
* Drehmoment anziehen.
2. Triebwerk in "Ausgangsstellung"
schwenken.
3. Qmin -Schraube auf Maß * einstellen.
4. Verschlußschraube einbauen.
5. Montagehülse demontieren.

1. Assemble port plate with

synchronizing piston.
Take care of assembly design!
Tighten fixing screws
with torque.
2. Swivel rotary group to "starting
position".
3. Set Qmin -screw to dimension*.
4. Assemble plug.
5. Remove assembly sleeve.

Wellendichtring, Scheiben und Sicherungsring

montieren.
Mit Montagehülse einpressen.
Dicht- und Staublippe, Wellendichtring leicht
einfetten.
Einpresstiefe beachten!

Assemble shaft seal, disc and safety ring.

Press-in with assembly sleeve.
Lightly grease the seal, dust lips and shaft seal ring.
Take care of press-in depth.

610 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
39

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)

Die Werte gelten für Schaftschrauben mit metrischen
ISO-Gewinde nach DIN 13 Teil 13, sowie Kopfauflage-
maßen nach DIN 912 Zylinderschrauben, DIN 931
Sechskantschrauben mit Schaft bzw.
DIN 933 Sechskantschrauben mit Gewinde bis Kopf.
The values stated are valid for bolts with metric ISO threads
to DIN 13 part 13, as well as head areas to DIN 912 socked
head cap screws, DIN 931 hexagon bolt or
DIN 933 hexagon bolts with threads up to the head.

Festigkeitsklassen / Tensile strength class

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

008 911 57 BOMAG 611

19.3 Bosch Rexroth AG | Mobile Hydraulics
40 A6VM | RDE 91 604-01-R/03.03
Travel motor

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).

G
EOLASTIC-
Dichtung / Seal

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

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

612 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
41

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

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

G
O-Ring / O-ring seal
Dichtung / Thread

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
7/16 - 20 UNF 15 M12 x 1,5 20
1/2 - 20 UNF 20 M14 x 1,5 30
9/16 - 18 UNF 25 M27 x 1,5 90
3/4 - 16 UNF 72
7/8 - 14 UN 127
1 1/16 -12 UN 147
1 3/16 -12 UN 173
1 5/16 -12 UN 198
1 5/8 -12 UN 320
1 7/8 -12 UN 390

008 911 57 BOMAG 613

19.3 Bosch Rexroth AG | Mobile Hydraulics
42 A6VM | RDE 91 604-01-R/03.03
Travel motor

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

6. Linsenschrauben mit Innen-TORX, Gewindevor- 6. Oval head screw with inner TORX, thread precoated with
beschichtung mit "precote" "precote"

precote 80 - Rot / Red

Standard / Standard

precote 86 - Blau / Blue

Variante / Variant
* * mit Unterkopfbeschichtung - farblos
Ι 2602493 M5 x 16
Ι 2602395 M6 x 20
* with head bottom coating - colorless
siehe Stückliste / as to parts list

Festigkeitsklassen / Tensile strength class

Gewinde / Thread 10.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 2,1
M4 4,7
M5 9,1
M6 15,8
M8 37,7

7. SEAL-LOCK-Dichtmuttern (nach N 02.100) 7. SEAL-LOCK - sealing nuts (to N 02.100)

Gewinde / Anziehdrehmoment MA in Nm
Thread Tightening torque MA in Nm

M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180

614 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
43

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

A6V - Stellkolben / positioning piston

für / for A6V / A7V / A7F / A8V)

Anziehdrehmoment MA für Gewindestift (1) / Anziehdrehmoment MA für Schraube (2) /

Tightening torque MA for threaded pin (1) Tightening torque MA for shaft bolts (2)
(Verbindung: Stellkolben und Stellzapfen / (Verbindung: Stellkolben und Stellzapfen für A6V
Connection: Positioning piston and positioning trunnion Connection: Positioning piston and piston for A6V

M6 : 8,5 Nm M14 x 1,5 : 120 Nm

M8 : 14,0 Nm
M10 : 30,0 Nm
M12 : 52,0 Nm

008 911 57 BOMAG 615

19.3 Bosch Rexroth AG | Mobile Hydraulics
44
Sicherheitsbestimmungen
Safety regulations
Allgemein
● Machen Sie sich mit der Ausstattung der Maschine
vertraut.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den
Bedien- und Steuerelementen sowie der Arbeitsweise der
Maschine vertraut gemacht haben.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm,
Sicherheitsschuhe und Gehörschutz.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut.
● Benutzen Sie die Maschine nur für den ihr zugedachten
Zweck.
Beachten Sie bitte die Richtlinien der Berufsgenossenschaft
und des Maschinenherstellers
Vor dem Start
● Beachten Sie die Bedienungshinweise vor dem Starten.
● Prüfen Sie die Maschine auf auffällige Fehler.
● Fahren Sie die Maschine nicht mit defekten Instrumenten,
Kontrolleuchten oder Steuerorganen.
● Alle Schutzvorrichtungen müssen fest auf ihrem Platz sein.
● Nehmen Sie keine losen Gegenstände mit bzw. befestigen
Sie diese an der Maschine.
● Halten Sie die Maschine von öligem und zündfähigem
Material frei.
● Prüfen Sie vor dem Besteigen der Maschine, ob sich
Personen oder Hindernisse neben oder unter der Maschine
befinden.
● Vorsicht beim Besteigen der Maschine, benützen Sie
Treppen und Griffe.
● Stellen Sie vor dem Start Ihren Sitz ein.
616 BOMAG
A6VM | RDE 91 604-01-R/03.03
Travel motor
General advice
● Make yourself familiar with the equipment of the
machine.
● Only operate the machine if your are completely familiar with
the operating and control elements as well as the functioning
of the machine.
● Use your safety equipment like helmet, safety shoes and
hearing protection.
● Make yourself familiar with your working field.
● Only operate the machine for its intended purpose.
Please observe the guidelines of the Professional
Association and the machine manufacturer.
Before starting
● Observe the operating instructions before starting.
● Check the machine for remarkable faults.
● Do not operate the machine with defective instruments,
warning lights or control elements.
● All safety devices must be in a secure position.
● Do not carry with you movable objects or secure them to the
machine.
● Keep oily and inflammable material away from the machine.
● Before entering thc driver s cabin, check if personsor
obstacles are beside or beneath the machine.
● Be careful when entering the driver s cabin, use stairs and
handles.
● Adjust your seat before starting.
008 911 57
RDE 91 604-01-R/03.03
Travel motor | A6VM
Sicherheitsbestimmungen
Safety regulations
Starten
● Beim Starten müssen alle Bedienhebel in “Neutralstellung”
stehen.
● Die Maschine nur vom Fahrersitz aus Starten.
● Prüfen Sie die Anzeigeinstrumente nach dem Start, um
sicher zu gehen, daß alles ordnungsgemäß funktioniert.
● Lassen Sie die Maschine nicht unbewacht, während
der Motor läuft.
● Beim Start mit Batterieverbindungskabeln verbinden Sie Plus
mit Plus und Minus mit Minus. Massekabel (Minus) immer
zuletzt anschliesen und zuerst abtrennen.
Vorsicht
● Auspuffgase sind lebensgefährlich. Bei Start in
geschlossenen Räumen für ausreichende Luftzufuhr
sorgen!
Hydraulikanlage
1. Hydraulikanlage steht unter hohem Druck!
Unter hohem Druck austretende Hochdruck- Flüssig-
keiten (Kraftstoff, Hydrauliköl) können die Haut durch-
dringen und schwere Verletzungen verursachen. Daher
sofort einen Arzt aufsuchen, da anderenfalls schwere
Infektionen entstehen können!
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr
geeignete Hilfsmittel verwenden!
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt
drucklos machen und angebaute Geräte absenken!
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor
abstellen und Traktor gegen Wegrollen sichern
(Feststellbremse, Unterlegkeil)!
5. Beim Anschließen von Hydraulikzylindern und -motoren ist
auf vorgeschriebenen Anschluß der Hydraulikschläuche zu
achten!
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen
(z.B. Heben/Senken) - Unfallgefahr!
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und bei
Beschädigung und Alterung austauschen! Die Austausch-
schlauchleitungen müssen den technischen Anforderungen
des Geräteherstellers entsprechen!
Öle, Kraftstoffe und Filter ordnungsgemäß
entsorgen!
008 911 57 BOMAG
Mobile Hydraulics | Bosch Rexroth AG 19.3
45
Start
● When starting all operating levers must be in “neutral position”.
● Only start the machine from the driver s seat.
● Check the indicating instruments after start to assure that all
functions are in order.
● Do not leave the machine unobserved when the motor is
running.
● When starting with battery connection cables connect plus
with plus and minus with minus. Always connect mass cable
(minus) at last and cut off at first.
Attention
● Exhaust gas is dangerous. Assure sufficient fresh air when
starting in closed rooms!
Hydraulic equipment
1. Hydraulic equipment is standing under high pressure.
High pressure fluids (fuel, hydraulic oil) which escape
under high pressure can penetrate the skin and cause
heavy injuries. Therefore immediately consult a doctor as
otherwise heavy infections can be caused.
2. When searching leakages use appropriate auxiliary devices
because of the danger of accidents.
3. Before working at the hydraulic equipment, lower pressure
to zero and lower working arms of the rnachine.
4. When working at the hydraulic equipment, absolutely stop
motor and secure tractor against rolling away (parking brake,
shim)!
5. When connecting hydraulic cylinders and motor pay attention
to correct connection of hydraulic flexible hoses.
6. In case of exchanging the ports, the tunctions are vice versa
(f. ex. lift-up/lower) - danger of accidents!
7. Check hydraulic flexible hoses regularly and replace them in
case of dammage or wear! The new hose pipes must comply
with the technical requirements of the machine manufacturer!
Orderly disposal or recycling of oil, fuel and
filters!
617
19.3 Bosch Rexroth AG | Mobile Hydraulics
46 A6VM | RDE 91 604-01-R/03.03
Travel motor

Inbetriebnahme
Operating instruction

Einstellüberprüfung Setting test

(Regelbeginn von Vg max - Vg min ) (Begin of regulation of Vg max - Vg min )
z.Beispiel HD e.g HD

X - 10 bar

Einstellschraube - Regelbeginn / P
Set screw - begin of control
Vg min

G
X
Betriebsdruck /
Operating
pressure

~ P/2

1:2

M1

Stelldruck /
Control pressure
Sicherheitsbestimmungen beachten! Observe safety regulations!
Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake).

A6VM - HD Vg max - Vg min A6VM - HD Vg max - Vg min

● Manometer "G" = 600 bar ● Pressure gauge "G" = 600 bar

● Manometer "M1" = 600 bar ● Pressure gauge "M1" = 600 bar
● Manometer "X" = 60 bar ● Pressure gauge "X" = 60 bar

Regelbeginn / Einstellung Begin of regulation / Setting

Beispiel: 10 bar Steuerdruck an X Example: 10 bar pilot pressure at X

Manometer an M1 beachten! Observe pressure gauge at M1!

Druckwert an X erhöhen bis an M1 die Hälfte Increase pressure value at X till half the pressure is generated
des Druckes von G ansteht ♦ Regelbeginn from G ♦ Begin of regulation

Einstellschraube im Uhrzeigersinn ♦ Regelbeginn Setscrew turned clockwise ♦ Begin of regulation earlier

früher
Setscrew turned anti-clockwise ♦ Begin of regulation later
Einstellschraube gegen Uhrzeigersinn ♦ Regelbeginn
später

618 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
47

Inbetriebnahme
Operating instruction

Einstellüberprüfung Setting test

(Regelbeginn von Vg max - Vg min ) (Begin of regulation of Vg max - Vg min )
z.Beispiel EP e.g EP

Einstellschraube - Regelbeginn /
Set screw - Begin of control
P

Vg min

Betriebsdruck /
Operating pressure

~ P/2

1:2

M1

Stelldruck /
Control pressure

Sicherheitsbestimmungen beachten! Observe safety regulations!

Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake).

A6VM - EP Vg max - Vg min A6VM - HD Vg max - Vg min

● Manometer "G" = 600 bar ● Pressure gauge "G" = 600 bar

● Manometer "M1" = 600 bar ● Pressure gauge "M1" = 600 bar
● Magnet = Multimessgerät ● Solenoid = multi measuring device

Regelbeginn / Einstellung Begin of regulation / Setting

Beispiel: 200/400 mA Example: 200/400 mA

Manometer an M1 beachten! Observe pressure gauge at M1!

Strom erhöhen bis an M1 die Hälfte Increase current till half the pressure is generated
des Druckes von G ansteht ♦ Regelbeginn from G ♦ Begin of regulation

Einstellschraube im Uhrzeigersinn ♦ Regelbeginn Setscrew turned clockwise ♦ Begin of regulation earlier

früher
Setscrew turned anti-clockwise ♦ Begin of regulation later
Einstellschraube gegen Uhrzeigersinn ♦ Regelbeginn
später

008 911 57 BOMAG 619

19.3 Bosch Rexroth AG | Mobile Hydraulics
48 A6VM | RDE 91 604-01-R/03.03
Travel motor

Inbetriebnahme
Operating instruction

Einstellüberprüfung Setting test

(Regelbeginn von Vg min - Vg max ) (Begin of regulation of Vg min - Vg max )
z.Beispiel HA z.Beispiel HA

Vg min X M1

Stelldruck /
Control
pressure
1:2

Einstellschraube - Regelbeginn / G
Set screw - Begin of control Betriebsdruck /
Operating
pressure
Sicherheitsbestimmungen beachten! Observe safety regulations!
Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake)
Manometer 600 bar an G und M1 anschließen. Connect pressure gauge 600 bar at G and M1
Beispiel 1: Example 1:
Regelbeginn 200 bar, Begin of regulation 200 bar
Betriebsdruck langsam erhöhen bis Manometer an G 200 bar Increase service pressure slowly till pressure gauge at
Stelldruck Manometer M1 G = 200 bar
1 /2 des Betriebsdruckes = ca. 100 bar Positioning pressure gauge M1
♦ Regelbeginn 1/2 of the sevice pressure = approx. 100 bar.
Nachjustierung des Stelldruckes an ♦ Begin of control
Einstellschraube - Regelbeginn Readjust positioning pressure at set screw - start of control
Hinweis: Note:
Drehen im Uhrzeigersinn - Regelbeginn früher. Clockwise turning - begin of regulation earlier
Drehen gegen Uhrzeigersinn - Regelbeginn später. Anti-clockwise turning - begin of regulation later
Beispiel 2: Example 2:
Bei Anlagen mit zwei oder mehr Motoren z. B. Raupenfahrzeuge In systems with two or more motors, e.g. tracked vehicles,
kann folgende Einstellung zusätzlich erfolgen. the following setting may be carried out additionally.
Kontermutter von Einstellschraube Vgmin lösen - Remove safety cap from the setscrew Vg min - do not disturb
Einstellschraube nicht verdrehen. Maß X festhalten. setscrew.
Betriebsdruck langsam erhöhen bis Manometer an G 200 bar Increase service pressure slowly till pressure gauge is indicating
anzeigt. 200 bar at G.
Kontrolle: Einstellschraube Vg min "fest" (Steuerlinse wird gegen Verification: Vg min "fixed" (lens plate is pressed against setscrew).
die Einstellschraube gedrückt). Up from 200 bar service pressure the screw is becoming
Ab 200 bar Betriebsdruck wird die Schraube "lose" "movable".
(Steuerlinse schwenkt Richtung Vg max). (lens plate is stroking to direction Vg max).
♦ Regelbeginn ♦ Begin of control
Achtung! Attention
Einstellwert Vg min -Schraube nicht verändern. Do not modify setting data of Vg min screw.
Hinweis: Nachjustierung an Einstellschraube- Regelbeginn Note: Readjustment at the set screw - begin of regulation

620 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
49

Inbetriebnahme
Operating instruction

Einstellüberprüfung (Regelbeginn) G1
DA1/4, DA2,3,4,5,6 X3 Einstellschraube - Regelbeginn
Vg min
5/8

100

1:2

M1
DA1, DA2, DA3 = PST / PHD 5 / 100
DA4, DA5, DA6 = PST / PHD 8 / 100 Stelldruck

Beispiel: Betriebsdaten nach Geräteblatt

Verstellbeginn Vg min - Vg max bei 20 bar Steuerdruck X3
und 220 bar Betriebsdruck

● Manometer G = 600 bar Betriebsdruck

● Manometer X3 = 60 bar Steuerdruck
● Manometer M1 = 600 bar Stelldruck G
Fahrzeug beladen, Straßengang, Fahren (max. Geschwindigkeit
= max. Steuerdruck)
Manometer M1 beobachten, anbremsen für Druckaufbau an
"G", ab 220 bar Betriebsdruck baut sich Druck an M1 ab.
♦ Regelbeginn P/2.

DA1, DA2, DA3 PSt / PSt 5/100

X3 G M1 = 1/2 Betriebsdruck (Regelbeginn)

20 bar 200 bar 200 bar = Vg min
20 bar 220 bar 110 bar = Regelbeginn Vg min ♦ Vg max
20 bar 240 bar 0-50 bar = Vg max
* Einstellschraube - Regelbeginn - Drehen im Uhrzeigersinn - Regelbeginn später

nur 1/8 Umdrehung verstellen ♦ kontrollieren

DA4, DA5, DA6 PSt / PSt 8/100

X3 G M1
20 bar 207,5 bar 207,5 bar = Vg min M1
20 bar 220 bar 110 bar = Vg min ® Vg max
20 bar 225 bar 0 bar = Vg max Stelldruck

008 911 57 BOMAG 621

19.3 Bosch Rexroth AG | Mobile Hydraulics
50 A6VM | RDE 91 604-01-R/03.03
Travel motor

Inbetriebnahme
Operating instruction

Setting test (Begin of Regulation) G1

DA1/4, DA2,3,4,5,6 X3
Setscrew - Begin of control
Vg min
5/8

100

1:2

M1
DA1, DA2, DA3 = PST / PHD 5 / 100
DA4, DA5, DA6 = PST / PHD 8 / 100 Control
pressure
X3
Example: Operation data as to machine specification sheet
Begin of regulation Vg min - Vg max at 20 bar pilot pressure
and 220 bar service pressure
G
● Pressure gauge G = 600 bar service pressure
● Pressure gauge X3 = 60 bar pilot pressure
● Pressure gauge M1 = 600 bar positioning pressure
Load vehicle, travel mode, travel (max. speed = max. pilot pressure
Observe pressure gauge M1, declarate at "G" for pressure generation,
up from 220 bar service pressure pressure at M1 is dropping.
♦ begin of regulation P/2.

DA1, DA2, DA3 PSt / PSt 5/100

X3 G M1 = 1/2 service pressure (begin of regulation)
20 bar 200 bar 200 bar = Vg min
20 bar 220 bar 110 bar = begin of regulation Vg min ♦ Vg max
20 bar 240 bar 0-50 bar = Vg max
* Setscrew - begin of regulation - turn clockwise - begin of regulation later

displace by 1/8 turn only ♦ verification

DA4, DA5, DA6 PSt / PSt 8/100

X3 G M1
20 bar 207,5 bar 207,5 bar = Vg min M1
20 bar 220 bar 110 bar = Vg min ♦ Vg max
20 bar 225 bar 0 bar = Vg max Control
pressure

622 BOMAG 008 911 57

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 19.3
51

008 911 57 BOMAG 623

19.3
© 2003 by Brueninghaus Hydromatik
GmbH, 89275 Elchingen
All rights reserved. No part of this
document may be reproduced or
stored, processed, duplicated or
circulated using electronic systems, in
any form or by any means, without the
prior written authorization of Bosch
Rexroth AG. In the event of
contravention of the above provisions,
the contravening party is obliged to
pay compensation.
The data specified above only serve to
describe the product. No statements
concerning a certain condition or
suitability for a certain application can
be derived from our information. The
given information does not release the
user from the obligation of own
judgement and verification. It must be
remembered that our products are
subject to a natural process of wear
and aging.
624 BOMAG
Travel motor
Brueninghaus Hydromatik GmbH
Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
info.brm@boschrexroth.de
www.boschrexroth.com/brm
© 2003 by Brueninghaus Hydromatik
GmbH, 89275 Elchingen
Alle Rechte vorbehalten. Kein Teil des
Werkes darf in irgendeiner Form ohne
vorherige schriftliche Zustimmung der
Brueninghaus Hydromatik GmbH
reproduziert oder unter Verwendung
elektronischer Systeme gespeichert,
verarbeitet, vervielfältigt oder verbreitet
werden. Zuwiderhandlungen
verpflichten zu Schadensersatz.
Die angegebenen Daten dienen allein
der Produktbeschreibung. Eine
Aussage über eine bestimmte
Beschaffenheit oder eine Eignung für
einen bestimmten Einsatzzweck kann
aus unseren Angaben nicht abgeleitet
werden. Die Angaben entbinden den
Verwender nicht von eigenen
Beurteilungen und Prüfungen. Es ist zu
beachten, dass unsere Produkte einem
natürlichen Verschleiß- und
Alterungsprozess unterliegen.
Printed in Germany
RDE 91 604-01-R/03.03
008 911 57
 19.4 Wheel drive gear up to S/N

008 911 57 BOMAG 625

19.4 Wheel drive gear up to S/N

626 BOMAG 008 911 57

Wheel drive gear up to S/N
Electric Drives Linear Motion and
19.4
and Controls Hydraulics Assembly Technologies Pneumatics Service

Demontage- Montageanleitung
Disassembly- Assembly Instructions RDE 77972-01-R/09.07
12.09.2007
Planetengetriebe / Planetary Gearbox
HYDROTRAC

GFT 220 R3 9096

008 911 57 BOMAG 627

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 2/45

Inhaltsverzeichnis • Table of Contents

1. Einleitung 1. Preliminary Notes

1.1 Allgemeines 1.1 Generally
1.2 Anziehdrehmomente 1.2 Tightening Torques
1.3 Schmieröl; Gewicht 1.3 Lube Oil; Weight

2. Zeichnungen 2. Drawings
Einbauzeichnung Getriebe Installation Drawing
Ersatzteilzeichnung Getriebe Spare Parts Drawing
Explosionszeichnung Getriebe Exploded View of Gearbox

3. Teilelisten 3. Parts Lists

Teileliste Getriebe Parts List Gearbox

4. Demontage 4. Disassembly
4.1 Demontage Allgemein 4.1 Disassembly General
4.2 Demontage Bremse 4.2 Disassembly Brake
4.3 Demontage Abtrieb 4.2 Disassembly Output
4.3.1 Demontage Planetenstufen 4.2 Disassembly Planet Stage
4.3.2 Demontage Planetenstege 4.2 Disassembly Planet Carrier
4.3.3 Demontage Wellenmutter 4.2 Disassembly Shaft Nut
4.3.4 Demontage Abtriebslagerung 4.2 Disassembly Output bearings

5. Montage 5. Assembly
5.1 Montage Allgemein 5.1 Assembly General
5.2 Montage Abtrieb 5.2 Assembly Output
5.2.1 Montage Abtriebslagerung 5.2.1 Assembly Output bearings
5.2.2 Montage Wellenmutter 5.2.2 Assembly Shaft Nut
5.2.3 Montage Planetenräder / Planetenstege 5.2.3 Assembly Planet Carrier / Planet Wheels
5.2.4 Montage Planetenstufen 5.2.4 Assembly Planet Stage
5.2.5 Montage Deckel 5.2.5 Assembly Cover
5.3 Montage Bremse 5.3 Assembly Brake

6. Probelauf 6. Test Run

6.1 Prüfstandsaufbau 6.1 Test set-up
6.2 Ölversorgung 6.2 Lubrication
6.3 Drehzahl, Laufzeit und Prüflast 6.3 Speed, Running Time, Test Load
6.4 Thermische Werte 6.4 Thermal Parameters
6.5 Laufgeräusch 6.5 Running Noise
6.6 Dichtigkeitsprüfung 6.6 Leakage Testing
6.7 Funktionsprüfung der Bremsen 6.7 Functional Test of Hydraulic Brakes
6.8 Fremdkörper 6.8 Oil Contamination Test

628 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096
1. Einleitung • 1. Preliminary Notes
1.1 Einführung
Mit diesem Symbol sind Gefahren für das
Produkt und die Gesamtanlage gekenn-
zeichnet.
Dieses Symbol kennzeichnet Hinweise.
Zur Demontage; Montage des Getriebes
werden die Ersatzteilzeichnung und die
Teileliste der entsprechenden Getriebe-
ausführung benötigt.
Beachten Sie unbedingt die Sicherheitsbe-
stimmungen und die einschlägigen Unfallver-
hütungsvorschriften!
Bauen Sie nur Originalersatzteile ein.
Lassen Sie das Öl ab.
Verwenden Sie dabei geeignete Auffanggefäße.
Achten Sie darauf, dass kein Schmutz oder Fremdkör-
per in das Getriebe gelangt.
Beschädigte Teile, sowie Dichtringe, durch neue Teile
ersetzen.
Vor dem Einbau sind alle beweglichen Teile sowie
Dichtringe einzuölen.
Unter Umständen ist der Farbanstrich des Getriebes
durch das Zerlegen und Zusammenbauen beschädigt.
Erneuern Sie deshalb den Farbanstrich, um das Getrie-
be gegen Korrosion zu schützen.
Führen Sie einen Probelauf des Getriebes durch.
¤Alle Rechte bei Bosch Rexroth AG, auch für den Fall von
Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie
Kopier- und Weitergaberecht, bei uns.
Die angegebenen Daten dienen allein der Produktbe-
schreibung. Eine Aussage über eine bestimmte Beschaf-
fenheit oder eine Eignung für einen bestimmten Einsatz-
zweck kann aus unseren Angaben nicht abgeleitet wer-
den. Die Angaben entbinden den Verwender nicht von
eigenen Beurteilungen und Prüfungen. Es ist zu beachten,
dass unsere Produkte einem natürlichen Verschleiß- und
Alterungsprozess unterliegen.
Hinweis!
Die verwendeten Bilder müssen nicht der beschriebe-
nen Getriebetype entsprechen.
008 911 57 BOMAG
Bosch Rexroth AG 19.43/45
1.1 Introduction
This symbol signifies danger to the prod-
uct and the overall plant.
This symbol calls attention to notes.
For disassembly; assembly procedure of
the gearbox, spare parts drawing and
parts list of the respective gearbox-type is
required.
The safety instructions and the appropriate accident
prevention instructions have absolutely to be ob-
served!
Exclusively install original spares.
Drain the oil from the gearbox.
For this purpose use suitable containers.
Make sure that no dirt or foreign bodies are allowed to
enter the gear box.
Replace damaged parts and all seals with new L+S
parts.
Oil all moving parts and seals prior to assembly.
In the event the paint coat of the gear-box has been
damaged as a result of disassembly / assembly work
touch up or renew the paint coat as necessary to protect
the gear against corrosion.
Carry out a test run of the gearbox.
¤This document, as well as the data, specifications and
other information set forth in it, is the exclusive property
of Bosch Rexroth AG. It may not be reproduced or given
to third parties without its consent.
The data specified above only serve to describe the
product. No statements concerning a certain condition
or suitability for a certain application can be derived from
our information. The information given does not release
the user from the obligation of own judgment and verifi-
cation. It must be remembered that our products are
subject to a natural process of wear and aging.
Note!
The photos may show other drive types than the de-
scribed one.
629
19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 4/45

1. Einleitung • 1. Preliminary Notes

1.2 Anziehdrehmomente 1.2 Tightening Torques

Standard-Anziehdrehmomente MA in Nm für ungeschmierte Schaftschrauben (μ = 0,13 bis 0,17) mit Regelgewinde ohne zusätz-
liche Einzelangaben (s. LSN 945 0201)
Standard-tightening torque MA in Nm for unlubricated shoulder stud (μ = 0,13 bis 0,17) with standard thread without additional details
(LSN 945 0201)
Schraube M6 M8 M 10 M 12 M 14 M 16 M 20 M 24 M 27 M 30 M 33 M 36 M 39 M 42
screw

8.8 Dr. 8,5 21,1 42,2 73,6 114,8 176,6 358 618 903 1216 1687 2129 2757 3394

10.9 Dr. 12,4 30,4 60,8 104,0 166,8 255,1 510 873 1285 1736 2364 3021 3924 4836

Dr. = Drehmomentschlüssel (torque wrench)

1.3 Schmieröl; Gewicht 1.3 Lube Oil; Weight

Gewicht ca. 850 kg Weight approx. 1874 lbs

Getriebeölmenge ca. 14 Liter Gear lube oil volume approx. 3,7 gall

Schmieröl CLP 220 oder Lube oil CLP 220 or

SAE 85 W-90 API GL-4 SAE 85 W-90 API GL-4

630 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG 19.45/45
2. Zeichnungen • 2. Drawings

Zeichnungen Drawings
Einbauzeichnung Installation Drawing
0/6137/5096/4 0/6137/5096/4
Ersatzteilzeichnung Spare Parts Drawing
0/6137/1096/2 0/6137/1096/2

Explosionszeichnung Exploded View

008 911 57 BOMAG 631

19.4 Wheel drive gear up to S/N

632 BOMAG 008 911 57

Wheel drive gear up to S/N 19.4

008 911 57 BOMAG 633

19.4 Wheel drive gear up to S/N

634 BOMAG 008 911 57

Wheel drive gear up to S/N 19.4

008 911 57 BOMAG 635

19.4 Wheel drive gear up to S/N

636 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 19.46/45
Bosch Rexroth AG

3. Teileliste • 3. Parts List

Teileliste Partslist
Teileliste Parts List
16218480 16218480

008 911 57 BOMAG 637

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 7/45

3. Teileliste • 3. Parts List

10.09.2007 Teileliste / Parts List

Matnr./Material No : 16218480
Auftrag/Order :
Produkt/Product : GFT 220 R3 9096 i=145,4
Zeichnungs-Nr./Drawing No : 0 6137/1096 2

Menge Pos. Benennung Bestell-Nr.

Quantity Item Designation Part-No

1,000 001 Hohlrad GFT 220

Ring gear

1,000 003 Stuetzring GFT 220 R3 9096

Supporting ring

1,000 005 Sonnenradwelle z=24 GFT 220 R3 9096

Sun gear shaft

1,000 006 Sonnenrad GFT 220

Sun gear
9098016/3

1,000 007 Planetensteg GFT 220 W3

Planet carrier

1,000 008 Planetensteg GFT 220

Planet carrier

3,000 010 Planetenrad GFT 220 W3

Planet gear

5,000 011 Planetenrad GFT 220

Planet gear

1,000 014 Wellenmutter M 280 x 3

Shaft nut

2,000 015 Zylinderstift 8 m6x18 B

Cylindrical dowel pin
ISO 8734

1,000 017 Zylinderrolle GFT330

Cylindrical roller

1,000 018 Hohlraddeckel GFT 220 R3 9096

Ring gear cover

10,000 020 Zylinderrollenlager RSL 183018

Cylindrical roller bearing
DIN 5412

6,000 021 Zylinderrollenlager RSL 182211

Cylindrical roller bearing
DIN 5412

2,000 022 Kegelrollenlager 32956 J

Tapered roller bearing
DIN 720

638 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 19.48/45
Bosch Rexroth AG

3. Teileliste • 3. Parts List

10.09.2007 Teileliste / Parts List

Matnr./Material No : 16218480
Auftrag/Order :
Produkt/Product : GFT 220 R3 9096 i=145,4
Zeichnungs-Nr./Drawing No : 0 6137/1096 2

Menge Pos. Benennung Bestell-Nr.

Quantity Item Designation Part-No

1,000 023 Zwischenring GFV 177X

Spacer ring

1,000 026 Sicherungsring 100x3

Snap ring
DIN 471

10,000 027 Anlaufscheibe F 91544

Locating ring

6,000 028 Anlaufscheibe F 91915

Locating ring

1,000 029 Sicherungsring 160x4

Snap ring
DIN 471

3,000 030 Sicherungsring 88x3

Snap ring
DIN 472

5,000 031 Sicherungsring 130x4

Snap ring
DIN 472

3,000 032 Sicherungsring 55x2

Snap ring
DIN 471

5,000 033 Sicherungsring 90x3

Snap ring
DIN 471

1,610 034 Rundschnur 5 mm

Chord

1,000 035 Gleitringdichtung 366x394x38 B

Face seal

1,000 036 Sprengring SW 220

Snap ring

24,000 038 6kt-Schraube M 12x40

Hex head bolt
DIN 933

1,000 039 Verschlussschraube M 18x1,5 m. Mag.

Screw plug

008 911 57 BOMAG 639

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 9/45

3. Teileliste • 3. Parts List

10.09.2007 Teileliste / Parts List

Matnr./Material No : 16218480
Auftrag/Order :
Produkt/Product : GFT 220 R3 9096 i=145,4
Zeichnungs-Nr./Drawing No : 0 6137/1096 2

Menge Pos. Benennung Bestell-Nr.

Quantity Item Designation Part-No

36,000 041 Zylinderschraube M 27x2x70

Socket head cap screw
DIN 912

2,000 042 Verschlussschraube M 30x1,5

Screw plug
DIN 908

2,000 043 Dichtring A 30x36x2

Seal ring
DIN 7603

1,000 044 Dichtring A 18x22x1,5

Seal ring
DIN 7603

1,000 045 O-Ring 530x4

O-ring
DIN 3771

1,000 050 Tragachse GFT 220 T3

Spindle

1,000 051 Mitnehmer GFT 220 T3

Coupler

1,000 052 Passscheibe GFT 60/130/220

Shim

1,000 053 Lamellentraeger GFT 220

Disk housing

1,000 054 Mitnehmer GFT 220

Coupler

1,000 055 Kolben GFT 220

Piston

9,000 056 Innenlamelle 3070-740-23-004

Inner disk

10,000 057 Aussenlamelle 3070-636-33-001

Outer disk

18,000 058 Druckfeder 1,6x6,5x54

Pressure spring
DIN 2098

640 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 19.410/45
Bosch Rexroth AG

3. Teileliste • 3. Parts List

10.09.2007 Teileliste / Parts List

Matnr./Material No : 16218480
Auftrag/Order :
Produkt/Product : GFT 220 R3 9096 i=145,4
Zeichnungs-Nr./Drawing No : 0 6137/1096 2

Menge Pos. Benennung Bestell-Nr.

Quantity Item Designation Part-No

18,000 059 Druckfeder 2,5x11,5x54

Pressure spring
DIN 2098

1,000 060 Quadring 4364 446 A

Piston seal

2,000 061 Stuetzring 168,5x178x1,4 P

Supporting ring

1,000 062 Quadring 4358 446 A

Piston seal

2,000 063 Stuetzring 142x151,4x1,4 P

Supporting ring

1,000 064 Stuetzring 163,9x168,5x1,4 P

Supporting ring

1,000 065 O-Ring 160x3

O-ring
DIN 3771

1,000 067 Sicherungsring 180x4

Snap ring
DIN 472

1,000 068 Sicherungsring 135x4

Snap ring
DIN 472

1,000 069 Rillenkugellager 6011 J

Ball bearing
DIN 625

1,000 070 Sicherungsring 135x4

Snap ring
DIN 471

1,000 071 Stopfen GPN 700 M 18x1,5

Plug

2,000 073 Expander MB 700-050

Expander

1,000 075 Verschlussschraube M 18x1,5

Screw plug
DIN 908

008 911 57 BOMAG 641

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 11/45

3. Teileliste • 3. Parts List

10.09.2007 Teileliste / Parts List

Matnr./Material No : 16218480
Auftrag/Order :
Produkt/Product : GFT 220 R3 9096 i=145,4
Zeichnungs-Nr./Drawing No : 0 6137/1096 2

Menge Pos. Benennung Bestell-Nr.

Quantity Item Designation Part-No

1,000 076 Dichtring A 18x22x1,5

Seal ring
DIN 7603

1,000 087 Sonnenradwelle GFT 220 R3 9096

Sun gear shaft

1,000 089 Planetensteg GFT 220 R3 9096

Planet carrier

3,000 090 Planetenrad GFT 220 R3 9096

Planet gear

3,000 091 Zylinderrollenlager RSL 182211

Cylindrical roller bearing
DIN 5412

6,000 094 Anlaufscheibe F 91915

Locating ring

3,000 095 Sicherungsring 55x2

Snap ring
DIN 471

6,000 096 Sicherungsring 88x3

Snap ring
DIN 472

1,000 097 Wellenscheibe * GFT220

Thrust washer

1,000 098 Zwischenring GFT 220 R3 9096

Spacer ring

1,000 099 Verschlussstopfen KAS00121 (D=200)

Cap plug

2,000 121 6kt-Schraube M 12x20

Hex head bolt
DIN 933

1,000 066 O-Ring 192x4

O-ring
DIN 3771

642 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG 19.412/45
4. Demontage • 4. Disassembly

4.1 Demontage Allgemein 4.1 Disassembly General

Getriebe nur im ausgebauten Zustand de- Make sure to remove the gearbox from the
montieren. machine frame before disassembling it.

Für die Demontage des Getriebes sind folgende Vorar- Prior to disassembly prepare the drive as follows:
beiten erforderlich:

Beachten Sie hierzu auch Kapitel 8 der Also observe chapter 8 „Operating In-
entsprechenden Betriebsanleitung für die structions" in according of the gearbox
Getriebetype. type.

• Getriebeöl ablassen. Lösen Sie dafür Ver-

schlussschrauben (Pos. 69). Verwenden • Remove screw plugs (items 69) and drain
oil. Use suitable oil drain pan.
Sie dabei geeignete Auffanggefäße.
Ölinhalt: Gear lube oil volume:
ca. 14 Liter approx. 14 liters

Achten Sie beim Transport auf eine aus- When handling the equipment make sure
reichende Tragkraft des Kranes. the carrying capacity of the crane is ade-
quate.
Getriebegewicht: ca. 850 kg. Gearbox Weight approx 850 kg.

• Stellen Sie sicher, dass das abgesetzte

Getriebe seine Lage nicht ändern kann. • Make sure the set down gearbox rests
immovably.

008 911 57 BOMAG 643

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 13/45

4. Demontage • 4. Disassembly

4.2 Demontage Bremse 4.2 Disassembly Brake

Lassen Sie das Öl ab. Entfernen Sie die Ölablass-
schraube (Pos. 42, 43).
Fangen Sie Altöl in geeigneten Behältern auf und ent-
sorgen Sie es unter Beachtung der entsprechenden
Vorschriften.

Remove screw plugs (item 42, 43) and drain oil.

Collect spent oil in suitable containers and dispose of
the oil line with the respective regulations.

Bild / fig 1

Drehen Sie das Getriebe um 180°.

Gear box rotated 180°.

Bild / fig 2

Entfernen Sie den Mitnehmer (Pos. 51).

Remove coupler (item 51).

Bild / fig 3

Betätigen Sie die Bremse über Bremslüftanschluss, sie-

he Einbauzeichnung 0/6137/5096/4, mit 50 bar.

Impinge pressure on brake at brake release point

approx. 50 bar. (See installation drawing
0/6137/5096/4).

Bild / fig 4

644 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG 19.414/45
4. Demontage • 4. Disassembly

Entfernen Sie den Sicherungsring (Pos. 68).

Remove snap ring (item 68).

Bild / fig 5

Entfernen Sie die Scheibe (Pos. 52).

Remove pressure springs (item 52).

Bild / fig 6

Entfernen Sie die Lamellen (Pos. 56, 57).

Remove brake disks (item 56, 57).

Bild / fig 7

Entlüften Sie die Bremse.

Bleed brake.

Bild / fig 8

008 911 57 BOMAG 645

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 15/45

4. Demontage • 4. Disassembly

Pressen Sie mit geeigneter Vorrichtung die Bremse ge-

gen die Federn (Pos. 56, 57)) und entfernen Sie den
Sicherungsring (Pos. 67).

Press gear box with suitable fixture against springs (item

56, 57) and remove snap ring (item 67).

Bild / fig 9

Entfernen Sie den Kolben (Pos. 55, 53) mit Quad- und
Stützringen. Beaufschlagen Sie den Kolben. mit Luft-
druck. Benutzen Sie hierzu Anschluss BR (siehe Ein-
bauzeichnung).
Quad- und Stützringe aus Tragachse (Pos. 50) entfer-
nen.

Remove piston (item 55, 53) with piston seals and

supporting rings. Pressurize piston with air. For this pur-
pose, use port BR (see installation drawing)
Remove piston seals as well as supporting rings out off
spindle (item 50).

Bild / fig 10

Entfernen Sie die Federn (Pos. 58, 59).

Remove pressure springs (item 58, 59).

Bild / fig 11

Entfernen Sie das Rillenkugellager (Pos. 69).

Remove ball bearing (item 69).

Bild / fig 12

646 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG 19.416/45
4. Demontage • 4. Disassembly

4.3 Demontage Abtrieb 4.2 Disassembly Output

Entfernen Sie den Sicherungsring (Pos. 70). Heben Sie
hierfür die Sonnenradwelle (Pos. 87) an und lösen den
Sicherungsring (Pos. 70).

Lift up sun gear shaft (item 87) and loose the snap ring
(item 70).

Bild / fig 13

Drehen Sie das Getriebe um 180°.

Gear box rotated 180°.

Bild / fig 14

Lösen Sie die Schrauben (Pos. 38) und entfernen Sie

den Deckel (Pos. 18) mit O-Ring (Pos. 45).

Remove bolts (item 38) and remove cover (item 18) with
o-ring (item 45).

Bild / fig 15

008 911 57 BOMAG 647

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 17/45

4. Demontage • 4. Disassembly

4.3.1 Demontage Planetenstufen 4.3.2 Disassembly Planet Stages

Heben Sie die kompletten Stege (Pos. 7+6 und 89+5 mit
Rädern (Pos. 10, 90)) der 3. und 2. Stufe zusammen mit
der Sonnenradwelle (Pos. 87) aus dem Getriebe.

rd nd
Remove complete 3 and 2 planet stage (with items
7+6+10 and 89+5+90) with sun gear shaft (item 87).

Bild / fig 16

Heben Sie die 1. Planetenstufe (Pos. 54, 8, 11) aus dem

Getriebe.

st
Remove complete 1 planet stage (with items 87+95).

Bild / fig 17

648 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG 19.418/45
4. Demontage • 4. Disassembly

4.3.2 Demontage Planetenstege 4.3.2 Disassembly Planet Carrier

Entfernen Sie die Sicherungsringe (Pos. 95, 32, 33) von

den drei Planetenstufen.

Remove snap rings (item 95, 32, 33).

Bild / fig 18

Entfernen Sie die Planetenräder der drei Planetenstufen

(Pos. 11, 10, 90) mit Hilfe einer Vorrichtung von den
Planetenstegen (Pos. 8, 7, 89).

Pull planet wheels (item 11, 10, 90) from planet carrier
(item 8, 7, 89).

Bild / fig 19

Achtung!
Beim lösen der Planetenräder der 1. Planetenstufe (Pos.
11) fällt der Planetensteg (Pos. 8) automatisch nach
unten.

Attention!
During loosing planet wheels 8item 11) the planet carrier
(item 8) will fall down automatically.

Bild / fig 20

Lösen Sie den Sicherungsring (Pos. 29) der 2. Plane-

tenstufe vom Sonnenrad (Pos. 6) und entfernen Sie den
Planetensteg (Pos. 7).

Remove snap ring (item 29) and lift off planet carrier
(item 7).

Bild / fig 21

008 911 57 BOMAG 649

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 19/45

4. Demontage • 4. Disassembly

Entfernen Sie die Wellenscheibe (Pos.97) von der 3.

Planetenstufe (Pos. 89, 5).

Remove thrust washer (item 97).

Bild / fig 22

Lösen Sie den Sicherungsring (Pos. 26) und entfernen

den Planetensteg (Pos. 89) von der Sonnenradwelle
(Pos. 5).

Loosen snap ring (item 26) and disassemble planet car-

rier (item 89) from sun gear shaft (item 5).

Bild / fig 23

650 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG 19.420/45
4. Demontage • 4. Disassembly

4.3.3 Demontage Wellenmutter 4.3.3 Disassembly Shaft Nut

Entfernen Sie die Wellenmutter (Pos. 14).

Hierzu sind folgende Arbeitsschritte erforderlich:
ACHTUNG!
Schutzbrille tragen.

Remove shaft nut (item 14). To accomplish this you

would do the following:
ATTENTION!
Wear suitable protective goggles.

Bild / fig. 24

Decken Sie den Bauraum zum Kegelrollenlager (Pos.

22) hin ab. Entfernen Sie während des Bohrvorganges
die Metallspäne um sicherzustellen, dass keine Metall-
reste im Getriebe verbleiben.

Cover the area towards to the tapered roller bearing

(item 22). Clean away metal scrap from drilling as you
drill to ensure no material gets lost within drive.

Bild / fig. 25

1.)
Bohren Sie im Bereich der Zylinderstifte (Pos. 15) ent-
14 sprechend der beiliegenden Skizze (Bild 26) ein Loch in
die Wellenmutter (Pos. 14).
ACHTUNG!
Nicht den Innenring des Kegelrollenlagers (Pos. 9)
beschädigen! Späne entfernen!

Start drilling one side of the shaft nut (item 145) close to
one of the dowel pins (item 15) according to the
attached sketch (fig. 26).
ATTENTION!
20 Do not damage the bearing inner ring of tapered
roller bearing (item 9), carefully remove metal
scraps!
Bild / fig. 26

008 911 57 BOMAG 651

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 21/45

4. Demontage • 4. Disassembly

2.)
Setzen Sie neben diese Bohrung eine weitere und wie-
derholen Sie den Vorgang zum AußenØ der Wellenmut-
ter (Pos. 14) hin, bis diese Seite ausgebohrt ist.

Drill another hole next to the one you just completed and
keep working your way towards the shaft nut (item 14)
outside diameter until that side is drilled out.

Bild / fig. 27

Wiederholen Sie die Arbeitsschritte 1.) und 2.) um 180°

versetzt an der Wellenmutter.

Go 180° degrees around the shaft nut and start the

process over again.

Bild / fig. 28

Wellenmutter (Pos. 14) mit Hilfe eines Meißels im Be-

reich der beiden Bohrungen sprengen und von der
Tragachse (Pos. 50) entfernen.
ACHTUNG!
Nicht den Lagerkäfig des Lagers (Pos. 22) beschädi-
gen!
ACHTUNG!
Die Wellenmutter darf sich hierbei nicht drehen!

Use a chisel to open up the shaft nut (item 14) where

you completed your drilling and remove it from the spin-
dle (item 50).
ATTENTION!
Do not damage the bearing cage of bearing (item
22)!
ATTENTION!
Do not turn the shaft nut – possibility of spindle
thread damage!
Bild / fig. 29

652 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG 19.422/45
4. Demontage • 4. Disassembly

4.3.4 Demontage Abtriebslagerung 4.3.4 Disassembly Output Bearings

Heben Sie das Hohlrad (Pos. 1, 3) und den O-Ring

(Pos. 34) ab.

Remove ring gear (item 1, 3) and O-ring (item 34).

Bild / fig 30

Entfernen Sie das Rollenlager (Pos.22) aus Getriebe.

Remove bearing cage of upper tapered roller bearing

(item 22).

Bild / fig 31 (Abb. Ähnlich)

Demontieren Sie die Gleitringdichtung (Pos.35) aus der

Aufnahmebohrung des Stützringes (Pos. 98).
Achtung!
Keine scharfkantigen Werkzeuge benutzen.

Remove the axial face seal half (item 35) out of the cav-
ity of support ring (item 98).
Attention!
Do not use a tool with a sharp edge!

Bild / fig 32

Demontieren Sie die Lageraußenringe (Pos. 22).

Remove rings of tapered roller bearing (item 9).

Bild / fig 33

008 911 57 BOMAG 653

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 23/45

4. Demontage • 4. Disassembly

Demontieren Sie den Zwischenring (Pos. 23) von der

Tragachse (Pos. 50).

Disassemble spacer ring (item 23) from spindle (item

50).

Bild / fig 34

Entfernen Sie das Rollenlager (Pos. 22) von der Trag-

achse (Pos. 50).

Remove roller bearing (item 22) from spindle (item 50).

Bild / fig 35

Demontieren Sie die Gleitringdichtung (Pos.35) aus der

Tragachse (Pos. 50).
Achtung!
Keine scharfkantigen Werkzeuge benutzen.

Remove the axial face seal half (item 35) out of the spin-
dle (item 50).
Attention!
Do not use a tool with a sharp edge!

Bild / fig 36

Deformiertes Gewinde der Tragachse (Pos. 60) im Be-

reich der Kugelsicherung mit Hilfe einer Gewindefeile -
Steigung 3mm- nacharbeiten.

Repair deformed threads on the spindle (item 60) in the

area of the ball detent with a thread file of 3mm pitch.

Bild / fig 37

654 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 19.424/45
Bosch Rexroth AG

5. Montage • 5. Assembly

5.1 Montage Allgemein 5.1 Assembly General

Vor der Montage sind folgende Ver- Prior to assembly the following inspec-
schleißprüfungen erforderlich: tions of wear and tear are required:

• Prüfen Sie auf Verschleiß:

- axiale Anlaufflächen
• Check for wear:
- axial contact faces
- Passsitze - machined seats
- Gewindebohrungen - threaded holes

• Prüfen Sie alle Dichtflächen auf:

- Beschädigung • Check all sealing faces for:
- damage

• Prüfen Sie die Lager auf:

- Verwendbarkeit (Spiel übermäßig)
• Check the bearings for:
- usability (excessive clearance)
- visuelle Prüfung - visual appearance

• Prüfen Sie die Verzahnung auf:

- Zahnausbrüche
• Check the gear teeth for:
- tooth breakage
- Pittings - pitting
- Rissbildung - cracks
- Gratbildung - burrs
- Verschleiß - wear

MET-L-CHEK / Rissprüfung: MET-L-CHEK /

check for cracks
Entfetten und reinigen der Prüfteile Degrease and clean the parts to be
1. (z.B. Spezialreiniger NPU).
1. checked (e.g. special cleaner NPU).

Aufbringen des Eindringmittel Apply penetrant fluid (e.g. DYE VP 30).

2. (z.B. DYE VP 30).
2. Reaction time approx. 5-30 minutes de-
Einwirkzeit ca. 5-30 Min. je nach Tempera- pending on temperature and material.
tur und Werkstoff.

Werkstück von Eindringmittel reinigen. Clean off penetrant fluid from work piece
3. (z.B. mit Spezialreiniger NPU oder Wasser)
3. (e.g. with special cleaner NPU or water).
Oberfläche trocknen lassen. Allow surface to dry.

Den Entwickler „weiß“, hauchdünn auftra-
4. gen. Nach einer kurzen Trockenzeit tritt
4.
aus den Fehlstellen das Eindringmittel
(z.B. DYE VP 30) aus und bildet mit dem
weißen Entwickler einen roten Kontrast.
Apply a very thin layer of developer
„white“. After a short drying time, the
penetrant fluid (e.g. DYE VP 30) emerges
from the defective spots and creates a red
contrast to the white developer.

Inspektion – rote Linien im weißen Ent-
5. wicklerfeld zeigen Risse oder Überlap-
5.
pungen an, während punktförmige Farb-
austritte als Poren zu werten sind.
Inspection – red lines on the white devel-
oper field indicate cracks or overlapping,
while point shaped color patterns can be
rated as blowholes and pores.

008 911 57 BOMAG 655

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 25/45

5. Montage • 5. Assembly

5.2 Montage Abtrieb 5.2 Assembly Output

Entfetten Sie die Aufnahmebohrung für die Gleitring-
dichtung (Pos. 43) in Tragachse (Pos. 1) und Stützring
(Pos. 2). (z.B. LOCTITE 7061)

Degrease and dry the cavities for the face seal (item 43)
in the spindle (item 1) and in the supporting ring (item 2)
(e.g. with LOCTITE 7061).

Bild / fig. 38

Kühlen Sie die Außenringe der Kegelrollenlager (Pos.

30) in flüssigem Stickstoff auf –180°C ab.

Use nitrogen to cool down the outer rings of tapered

roller bearings (item 30) to approx. –180°C.

Bild / fig. 39

5.2.1 Montage Abtriebslagerung 5.2.1 Assembly Output Bearings

Setzen Sie die in Stickstoff abgekühlten Außenringe von

den Kegelrollenlagern (Pos. 22) in den Stützring (Pos. 3)
ein. (Prüfen Sie auf richtige axiale Anlage).

After cooling-off with nitrogen, insert outer rings of ta-

pered roller bearings (item 30) into supporting ring (item
2). (Check for proper axial seat).

Bild / fig 40

Montieren Sie die beiden Kegelrollenlager (Pos. 22) in

den Stützring (Pos. 3).

Mount both tapered roller bearing (item 22) into support-

ing ring (item 3).

Bild / fig 41

656 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG 19.426/45
5. Montage • 5. Assembly

Belasten Sie die beiden Kegelrollenlager (Pos. 22) axial

mit Hilfe einer Vorrichtung mit 150 kp.
Lagerung durch 20 Drehungen in einer Richtung eindre-
hen.

Apply axial load of 150 kp to both bearings (item 22).

Make use of a device.

Bild / fig 42

Messen Sie das Maß zwischen den beiden Innenringen

der Kegelrollenlager (Pos. 22) mittels einer Messvorrich-
tung.

Determine dimensions between inner rings of bearing

(item 22) with measuring device.

Bild / fig 43

Schleifen Sie den Zwischenring(Pos. 23) auf Maß. (Er-

mitteltes Maß -0,25 mm).

Grind spacer ring (item 23) to measure, i.e. calculated

dimension -0,25 mm.

Bild / fig 44

Schlagen Sie den Expander (Pos. 73) in die entspre-

chende Aufnahmebohrung der Tragachse (Pos. 50).

Stamp expander (item 73) into locating hole of spindle

(item 50).

Bild / fig 45

008 911 57 BOMAG 657

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 27/45

5. Montage • 5. Assembly

Benetzen Sie den Gleitringdichtungs– O-Ring (Pos. 8)

und die Aufnahmebohrung der Tragachse (Pos. 50) mit
Spiritus.

Wet face seal o- ring (item 8) and cavity on spindle (item

50) with spirit of wine cleaner.

Bild / fig 46

Drücken Sie die untere Gleitringsichtungshälfte (Pos.

35) in die entsprechende Aufnahmebohrung der Trag-
achse (Pos. 50).
Achtung!
Keine scharfkantigen Werkzeuge benutzen.

Install face seal ring half (item 35) into spindle (item 50)
under even pressure on the seal surface.
Attention!
Do not use a tool with a sharp edge
Bild / fig 47

Schneiden Sie eine Rundschnur (Pos. 34) auf Maß und

kleben Sie die Enden mit LOCTITE 480 zusammen.

Cut chord (item 34) to mesure and glue it with LOCTITE

480.

Bild / fig 48

Setzen Sie die gefettete Rundschnur (Pos. 34) in die

entsprechende Nut im Stützring (Pos. 3) ein.

Insert chord (item 34) into the o-ring groove of support-

ing ring (item 3).
Grease chord.

Bild / fig 49

658 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG 19.428/45
5. Montage • 5. Assembly

Setzen Sie den Stützring (Pos. 3) auf das Hohlrad

(Pos. 1).

Mount supporting ring (item 3) onto ring gear (item 1).

Bild / fig 50

Gewinde der Zylinderschrauben (Pos. 41) gleichmäßig

mit LOCTITE 638 bestreichen.

Evenly apply coat of LOCTITE 638 to threads of socket

head cap screws (item 41).

Bild / fig 51

Zylinderschrauben (Pos. 70) in entsprechende Gewin-

debohrungen von Hohlrad (Pos. 1 einsetzen und mit
einem Anzugsdrehmoment von 1650 Nm anziehen.

Install socket head cap screws (item 70) into threaded

holes of ring gear (item 1) and tighten them to a required
torque of 1650 Nm.

Bild / fig 52

Benetzen Sie den Gleitringdichtungs– O-Ring (Pos. 8)

und die Aufnahmebohrung des Stützringes (Pos. 3) mit
Spiritus.

Wet axial face seal o- ring (item 8) and cavity on sup-

porting ring (item 3) with spirit of wine cleaner.

Bild / fig 53

008 911 57 BOMAG 659

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 29/45

5. Montage • 5. Assembly

Drücken Sie die obere Gleitringsichtungshälfte (Pos. 35)

in die entsprechende Aufnahmebohrung des Stützringes
(Pos. 3).
Achtung!
Keine scharfkantigen Werkzeuge benutzen.

Install face seal ring half (item 35) into supporting ring
(item 3) under even pressure on the seal surface.
Attention!
Do not use a tool with a sharp edge
Bild / fig 54

Montieren Sie den unteren Innenring mit Rollenkranz

von Kegelrollenlager (Pos. 22) auf Tragachse (Pos. 50).

Mount upper inner ring with roller cage of double ta-

pered roller bearing (item 22) onto spindle (item 50).

Bild / fig 55

Setzen Sie den auf Maß geschliffenen Zwischenring

(Pos. 23), auf die Tragachse auf.

Mount the grounded spacer ring (item 23) on the spindle

(item 50).

Bild / fig 56

Versehen Sie die Gleitflächen der Gleitringdichtung

(Pos. 35) mit einem Ölfilm.

Wet the sliding surfaces of the face seal (item 35) with
oil.

Bild / fig 57

660 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG 19.430/45
5. Montage • 5. Assembly

Montieren Sie das vormontierte Hohlrad/ Stützring (Pos.

1, 3) auf die vormontierte Tragachse (Pos. 50).

Install pre-assembled ring gear/ supporting ring (item 1,

3) on spindle (item 50).

Bild / fig 58

Montieren Sie den oberen Innenring mit Rollenkranz von

Kegelrollenlager (Pos. 22) in das Hohlrad (Pos. 1).

Mount upper inner ring with roller cage of double ta-

pered roller bearing (item 20) into ring gear (item 1).

Bild / fig 59

008 911 57 BOMAG 661

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 31/45

5. Montage • 5. Assembly

5.2.2 Montage Wellenmutter 5.2.2 Assembly Shaft Nut

Gewinde der Tragachse (Pos. 1) und der Wellenmut-

ter (Pos. 18) entfetten (z.B. mit LOCTITE 7061).

Degrease threads of spindle (item 1) and shaft nut

(item 18) (e.g. with LOCTITE 7061).

Bild / fig. 60

Bestreichen Sie das Gewinde der Wellenmutter (Pos.

14) gleichmäßig mit LOCTITE 638.

Evenly apply coat of LOCTITE 638 to thread of shaft nut

(item 14).

Bild / fig 61

Montieren Sie die Wellenmutter (Pos. 14) mit Ringkerbe

nach oben (sichtbar).

Mount shaft nut (item 14) with groove on upper side

(visible).

Bild / fig 62

ACHTUNG!
Beim Einstellen der Kegelrollenlager ist der Stütz-
ring mehrfach in eine Richtung zu drehen.
- Wellenmutter (Pos. 14) – mittels einer Vorrichtung
mit einem Anziehdrehmoment von 27000 Nm an-
ziehen.

ATTENTION!
Rotate the supporting ring repeatedly in one direc-
tion only when setting the tapered roller bearing
Tighten shaft nut (item 14) – by using an adequate de-
vice with a tightening torque of 27000 Nm.
Bild / fig 63

662 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG 19.432/45
5. Montage • 5. Assembly

Setzen Sie die Zylinderstifte (Pos. 15) ein.

Insert cylindrical dowel pins (item 15).

Bild / fig 64

008 911 57 BOMAG 663

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 33/45

5. Montage • 5. Assembly

5.2.3 Montage Planetenräder 5.2.3 Assembly Planet Carrier /

Planet Wheels

st
1. Stufe 1 Stage

1.1 Montieren Sie den 1.1 Mount snap ring (i-

Sprengring (Pos. 36) auf tem 36) onto coupler
den Mitnehmer (Pos. 54). (item 54).
1.2 Montieren Sie den 1.2 Mount coupler (item
Mitnehmer (Pos. 54) in 54) into planet carrier
den Planetensteg (item 8).
(Pos.8).
1.1 1.2
2. Montage der Zylin- 2. Assembly of cylin-
derrollenlager drical roller bearing
2.1 Drücken Sie das Zy- 2.1 Push cylindrical roller
linderrollenlager (Pos. bearing (item 20) directly
20) aus der Transport- out of transport packing
verpackung direkt in die into the locating hole of
Aufnahmebohrung von the planet gear (item 11).
2.1 2.2 Planetenrad (Pos. 11).
2.2 Setzen Sie die An- 2.2 Insert locating ring
laufscheibe (Pos. 27) (item 27).
ein.
2.3 Setzen Sie den Si- 2.3 Insert a new snap
cherungsring (Pos. 31) ring (item 31).
ein.
nd
2.4 Setzen Sie die zweite 2.4 Insert 2 locating
Anlaufscheibe (Pos. 27) ring (item 27).
2.3 2.4
ein.
nd
2.5 Drücken Sie das 2.5 Push 2 cylindrical
zweite Zylinderrollenla- roller bearing (item 20)
ger (Pos. 20) aus der directly out of transport
Transportverpackung packing into the locating
direkt in die Aufnahme- hole of the planet gear
bohrung von Planetenrad (item 11).
(Pos. 11).
2.4
3. 3.
Erwärmen Sie vormon- Heat pre-assembled
tiertes Planetenrad (Pos. planet gear (item 11) to
11) auf ca. 120°-130°C. approx. 120°-130°C.
3.1 Montieren Sie das 3.1 Mount pre-
vormontierte Planetenrad assembled planet gear
auf den Planetenbolzen onto the planetary pin of
3.1 3.2 von Planetensteg (Pos. planet carrier (item 8).
8).
3.2 Sichern Sie die Pla- 3.2 Secure the planet
netenräder mit den Si- gears with snap ring
cherungsringen (Pos. (item 33).
33).
Bild / fig 65

664 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG 19.434/45
5. Montage • 5. Assembly

nd
2. Stufe 2 Stage

1.1 Setzen Sie den Pla- 1.1 Insert planet carrier

netensteg (Pos. 7) auf (item 7) into internal
die Verzahnung des teeth of sun gear (item
Sonnenrades (Pos. 6) 6).
ein.
1.2 Sichern Sie das Son- 1.2 Secure sun gear with
nenrad mit dem Siche- a new snap ring (item
1.1 1.2 rungsring (Pos. 29). 29).

2. Montage der Zylin- 2. Assembly of cylin-

derrollenlager drical roller bearing
2.1 Drücken Sie das Zy- 2.1 Push cylindrical roller
linderrollenlager (Pos. bearing (item 21) directly
21) aus der Transport- out of transport packing
verpackung direkt in die into the locating hole of
2.1 2.2 Aufnahmebohrung von the planet gear (item 10).
Planetenrad (Pos. 10).
2.2 Setzen Sie die An- 2.2 Insert locating ring
laufscheibe (Pos. 28) (item 28).
ein.
2.3 Setzen Sie den Si- 2.3 Insert a new snap
cherungsring (Pos. 30) ring (item 30).
ein.
nd
2.3 2.4 2.4 Setzen Sie die zweite 2.4 Insert 2 locating
Anlaufscheibe (Pos. 28) ring (item 28).
ein.
nd
2.5 Drücken Sie das 2.5 Push 2 cylindrical
zweite Zylinderrollenla- roller bearing (item 21)
ger (Pos. 21) aus der directly out of transport
Transportverpackung packing into the locating
direkt in die Aufnahme- hole of the planet gear
bohrung von Planetenrad (item 10).
2.5 3.1
(Pos. 10).

3. 3.
Erwärmen Sie vormon- Heat pre-assembled
tiertes Planetenrad (Pos. planet gear (item 10) to
10) auf ca. 120°-130°C. approx. 120°-130°C.
3.1 Montieren Sie das 3.1 Mount pre-
vormontierte Planetenrad assembled planet gear
3.2
auf den Planetenbolzen onto the planetary pin of
von Planetensteg (Pos. planet carrier (item 7).
7).
3.2 Sichern Sie die Pla- 3.2 Secure the planet
netenräder mit den Si- gears with snap ring
cherungsringen (Pos. (item 38).
38).
Bild / fig 66

008 911 57 BOMAG 665

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 35/45

5. Montage • 5. Assembly

rd
3. Stufe 3 Stage

1.1 Setzen Sie den Pla- 1.1 Insert planet carrier

netensteg (Pos. 89) auf (item 89) into internal
die Verzahnung des Son- teeth of sun gear (item
nenrades (Pos. 5) ein. 5).
1.2 Sichern Sie das Son- 1.2 Secure sun gear with
nenrad mit dem Siche- a new snap ring (item
rungsring (Pos. 26). 26).
1.1 1.2 1.3 Setzen Sie Scheibe 1.3 Mount thrust washer
(Pos. 97) auf das Son- (item 97) onto sun gear
nenrad (Pos. 5). shaft (item 5).

2. Montage der Zylin- 2. Assembly of cylin-

derrollenlager drical roller bearing
2.1 Setzen Sie den Si- 2.1 Insert a snap ring
cherungsring (Pos. 96) (item 96).
1.3 2.1 ein.
2.2 Setzen Sie die An- 2.2 Insert locating ring
laufscheibe (Pos. 94) (item 94).
ein.
2.3 Drücken Sie das Zy- 2.3 Push cylindrical roller
linderrollenlager (Pos. bearing (item 91) directly
91) aus der Transport- out of transport packing
verpackung direkt in die into the locating hole of
2.2 2.3 Aufnahmebohrung von the planet gear (item 90).
Planetenrad (Pos. 90).
nd
2.4 Setzen Sie die zweite 2.4 Insert 2 locating
Anlaufscheibe (Pos. 94) ring (item 94).
ein.
nd
2.5 Setzen Sie den Si- 2.5 Insert a 2 snap ring
cherungsring (Pos. 96) (item 96).
ein.
2.4 2.5
3. 3.
Erwärmen Sie vormon- Heat pre-assembled
tiertes Planetenrad (Pos. planet gear (item 90) to
90) auf ca. 120°-130°C. approx. 120°-130°C.
3.1 Montieren Sie das 3.1 Mount pre-
vormontierte Planetenrad assembled planet gear
auf den Planetenbolzen onto the planetary pin of
3.1 3.2 von Planetensteg (Pos. planet carrier (item 89).
89).
3.2 Sichern Sie die Pla- 3.2 Secure the planet
netenräder mit den Si- gears with snap ring
cherungsringen (Pos. (item 95).
95).
Bild / fig 67

666 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG 19.436/45
5. Montage • 5. Assembly

5.2.4 Montage Planetenstufen 5.2.4 Assembly Planet Stage

Setzen Sie den komplett montierten Planetensteg der 1.

Stufe (Pos. 54, 8, 11) in das Getriebe ein.

st
Install completely pre-assembled 1 planet stage (item
54, 8, 11) into gear box.

Bild / fig 68

Setzen Sie den komplett montierten Planetensteg der 2.

Stufe (Pos. 6, 7, 10) in das Getriebe ein.

nd
Install completely pre-assembled 2 planet stage (item
6, 7, 10) into gear box.

Bild / fig 69

Setzen Sie den komplett montierten Planetensteg der 3

Stufe (Pos. 5, 89, 90) in das Getriebe ein.

rd
Install completely pre-assembled 3 planet stage (item
5, 89, 90) into gear box.

Bild / fig 70

Setzen Sie die Sonnenradwelle (Pos. 87) in das Getrie-

be ein.

Install sun gear shaft (item 87).

Bild / fig 71

008 911 57 BOMAG 667

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 37/45

5. Montage • 5. Assembly

5.2.5 Montage Deckel 5.6 Assembly Cover

Zylinderrolle (Pos. 17) in Deckel (Pos. 18) einsetzen.

Install cylindrical roller (item 17) into cover (item 18).

Bild / fig 72

Axialspiel prüfen:
Spiel zwischen Anlauffläche der Sonnenradwelle (Pos.
87) und der Zylinderrolle (Pos. 17) vor der Montage des
Deckels (Pos. 18) prüfen. (Sollwert 1-2 mm).

Checking of axial clearance:

Determine clearance between contact face of sun gear
shaft (item 87) and cylindrical roller (item 17) by measur-
ing parts prior to assembly of cover (item 18). (Recom-
mended clearance 1-2 mm).
Bild / fig. 73

Montieren Sie den O-Ring (Pos. 45) in die entsprechen-

de Nut des Deckels (Pos. 18).

Insert (item 45) into the o-ring groove of cover (item 18).

Bild / fig 74

Fetten Sie den O- Ring (Pos. 45) ein.

Grease o-ring (item 45).

Bild / fig 75

668 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG 19.438/45
5. Montage • 5. Assembly

Setzen Sie den vormontierten Deckel (Pos. 18) mit neu-

em O-Ring (Pos. 45) in den Einpass des Hohlrades
(Pos. 1) ein und befestigen ihn mit den Schrauben (Pos.
38).
Ziehen Sie die Schrauben (Pos. 38) mit erforderlichem
Anzugsmoment an. (Siehe Ersatzteilzeichnung
0/6137/1096/2)

Mount the cover (item 18) with o-ring (item 45) to the
ring gear (item 1).
Tighten screws (item 38) to a proper torque.
(See spare part drawing 0/6137/1096/2).
Bild / fig 76

Schrauben Sie die Verschlussschrauben (Pos. 39, 44

und 42, 43) in den Deckel ein.

Screw the screw plugs (item 39, 44 and 42, 43) into the
cover (item 18).

Bild / fig 77

008 911 57 BOMAG 669

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 39/45

5. Montage • 5. Assembly

5.3 Montage Bremse 5.3 Assembly Brake

Drehen Sie das Getriebe um 180°.

Gear box rotated 180°.

Bild / fig 78

Montieren Sie den Sicherungsring (Pos. 70). Heben Sie

hierfür die Sonnenradwelle (Pos. 87) mit Hilfe eines
Kranes an und setzen den Sicherungsring ein.

Lift up sun gear shaft (item 87) and mount the snap ring
(item 70).

Bild / fig 79

Rillenkugellager (Pos. 69) in Einpass von Mitnehmer

(Pos. 54) bis zum Anschlag einsetzen.
Achtung, beim Einbau darf nur auf den Außenring des
Lagers Druck ausgeübt werden.

Insert grooved ball bearing (item 69) into fitting of cou-

pler (item 54) up to stop point.
Attention, when inserting the bearing, pressure may only
be exerted onto the outer ring of the bearing.

Bild / fig 80

Setzen Sie die Federn (Pos. 58, 59) ein.

Mount pressure springs (item 58, 59).

Bild / fig 81

670 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG 19.440/45
5. Montage • 5. Assembly

Montieren Sie die Quad- und Stützringe (Pos. 62, 63) in

den Kolben (Pos. 55).

Mount supporting rings and piston seal (Pos, 62, 63) into
the piston (Pos. 55).

Bild / fig 82

Ölen Sie die Dichtfläche ein.

Lubricate the sealing surface.

Bild / fig 83

Montieren Sie die Quad- und Stützringe (Pos. 64, 65) in

den Lamellenträger (Pos. 53).

Mount supporting rings and piston seal (item 64, 65) into
the disk housing (item 53).

Bild / fig 84

Montieren Sie den Lamellenträger (Pos. 53) auf den

Kolben (Pos. 55).

Mount the disk housing (item 53) onto the piston (item
55).

Bild / fig 85

008 911 57 BOMAG 671

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 41/45

5. Montage • 5. Assembly

Ölen Sie die Einbauflächen des vormontierten

Kolben / Lamellenträger (Pos. 53, 55) ein.

Lubricate the installation area of piston / disk housing

(item 53, 55).

Bild / fig 86

Setzen Sie den vormontierten Kolben/ Lamellenträger

(Pos. 53, 55) in die Tragachse (Pos. 50) ein.

Mount piston/ disk housing (item 53, 55) into spindle

(item 50).

Bild / fig 87

Pressen Sie mit geeigneter Vorrichtung den vormontier-

ten Kolben/ Lamellenträger (Pos. 53, 55) gegen die Fe-
dern (Pos. 56, 57) und montieren Sie den Sicherungs-
ring (Pos. 67).

Press piston/ disk housing (item 53, 55) with suitable

fixture against springs (item 56, 57) and mount snap ring
(item 67).

Bild / fig 88

Legen Sie die Lamellen (Pos. 56+57) in richtiger Rei-

henfolge ein. (siehe Ersatzteilzeichnung 0/6137/1096/2)

Insert brake disks (item 56+57) in correct order.

(note spare part drawing 0/6137/1096/2 )

Bild / fig 89

672 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096 Bosch Rexroth AG19.442/45
5. Montage • 5. Assembly

Betätigen Sie die Bremse über Bremslüftanschluss, sie-

he Einbauzeichnung 0/6137/5096/4, mit 50 bar.

Impinge pressure on brake at brake release point

approx. 50 bar. (See installation drawing
0/6137/5096/4).

Bild / fig 90

Setzen Sie die Scheibe (Pos. 52) ein.

Insert disk (item 52).

Bild / fig 91

Sichern Sie das Lamellenpaket mit dem Sicherungsring

(Pos. 52).

Secure brake disks (item 56, 57) with snap ring (item
68).

Bild / fig 92

Setzen Sie den Mitnehmer (Pos. 51)ein.

Mount coupler (item 51).

Bild / fig 93

008 911 57 BOMAG 673

19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 43/45

5. Montage • 5. Assembly

Messen Sie wie auf der Einbauzeichnung bemaßt den

Abstand (41mm) zwischen Anlagefläche Hydromotor
und Stirnfläche Mitnehmer (Pos.51).

Measure distance (41 mm) between contact surface of

hydraulic motor and front surface of coupler (item 51) as
scaled on the installation drawing.

Bild / fig 94

674 BOMAG 008 911 57

Wheel drive gear up toGFT
RDE 77972-01-R/09.07 S/N220 R3 9096
6. Probelauf • 6. Test Run
6.1 Prüfstandsaufbau
Das Getriebe wird in der vorgesehenen Einbaulage auf-
gebaut und mit einem geeigneten Antriebsmotor angetrie-
ben. Wenn das Betriebsverhalten des Getriebetyps be-
kannt ist, kann eine andere Prüflage gewählt werden, wo-
bei die Radialwellendichtringe, bzw. Gleitringdichtungen
unter Öl stehen müssen (Luftkammerbildung beachten!).
6.2 Ölversorgung
Die Getriebe werden wie in der Einbauzeichnung vorge-
sehen mit Öl gefüllt. Bremsen mit separater Ölfüllung sind
vor dem Probelauf gemäß Einbauzeichnung ebenfalls mit
Öl zu befüllen.
Zur Ölbefüllung verwenden Sie bitte die in der Betriebsan-
leitung angebenden Schmierstoffe.
6.3 Drehzahl, Laufzeit und
Prüflast
Die Getriebe sind mit Höchstdrehzahl (nmax Getriebe bzw.
nmax Prüfstand) über 1 Stunde (je ½ Stunde pro Drehrich-
tung bei Getrieben mit wechselnder Drehrichtung) ohne
Last zu fahren.
Hierbei ist die Ölsumpftemperatur am Außendurchmesser
des Hohlrades nach 30, 45 und 60 Minuten zu messen
und zu protokollieren.
6.4 Thermische Werte
Die Ölsumpftemperatur soll nach Abschluss des
1-stündigen Probelaufs 70°C nicht übersteigen. Die Tem-
peratur nach 30 Minuten bei reduzierter Laufzeit soll die
Temperatur der Temperaturaufschreibung des ersten Ge-
triebes um nicht mehr als 4°C überschreiten.
Die Temperaturen an außenliegenden Lagerstellen (so-
weit zutreffend) sollen die Ölsumpftemperaturen um nicht
mehr als 10°C übersteigen.
6.5 Laufgeräusch
Das Laufgeräusch soll weich und gleichmäßig sein.
Es dürfen keine harten, schlagenden oder pfeifende Ge-
räusche vorhanden sein.
6.6 Dichtigkeitsprüfung
Während des Probelaufs sind alle Dichtungen auf Undich-
tigkeiten hin zu beobachten, z.B.:
- Ein- und Auslassschrauben
- Entlüfter
- Dichtflächen an Hohlrädern und Deckeln
- Wellendichtungen
008 911 57 BOMAG
Bosch Rexroth AG 19.444/45
6.1 Test set up
The gearbox shall be mounted in its intended installation
position and connected to a suitable driving motor. If the
operating performance of the gearbox type is known, it
is possible to mount the gearbox in another test position
under the condition that the radial face seals and the
axial seal are submerged in oil (check for air cham-
bers!).
6.2 Lubrication
The gear units are to be filled with oil as shown on the
installation drawing. Brakes which have separate oil
fillings shall be filled with oil before test run.
For oil fill, please use the lubricants listed in the operat-
ing instructions.
6.3 Speed, Running Time,
Test Load
The gear units are to be operated at max. speed (nmax of
gearbox or nmax test bed) under no load for one hour
(half an hour in each direction of rotation in case of re-
verse gears).
Measure oil sump temperatures at outside diameter of
ring gear and note them down after 30, 45 and 60 min-
utes of operation.
6.4 Thermal Parameters
The oil sump temperature measured after the 1-hour
test run shall not exceed 70°C.
The temperature measured after 30 minutes reduced
operating time shall not exceed the temperature records
of the first gearbox by more than 4°C.
The temperatures measured at the external bearing
areas (if applicable) must be not exceed the oil sump
temperature by more than 10°C.
6.5 Running Noise
The running noise under test conditions should be
smooth and steady.
Hard, knocking or howling noise produced by the unit is
inadmissible.
6.6 Leakage Testing
During the test run, make sure to check all seals for
leakages, e.g.:
- Inlet and drain plugs
- Vent
- Sealing faces at ring gears and covers
- Shaft seals
675
19.4
RDE 77972-01-R/09.07 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 45/45

6. Probelauf • 6. Test Run

6.7 Funktionsprüfung der 6.7 Functional Test of

Bremsen Hydraulic Brakes
Rexroth Bremsen werden durch eine pulsierende Prüfung A pulsating pressure test shall be performed on the
auf Funktion und Dichtigkeit geprüft: Rexroth brakes to check the tightness and function:
- Prüfdruck: 60-80 bar - Test pressure: 60-80 bar
- Lüftzeit: 6-10 sek pro Kolbenhub - Releasing time: 6-10 sec. per piston stroke
- Prüfdauer: min. 15 Minuten - Testing time: 15 minutes minimum

Die hier beschriebene Funktionsprüfung gilt nicht für in The described functional test of hydraulic brakes is not
Motoren integrierte Bremsen. valid for motor integrated brakes.

6.8 Fremdkörper 6.8 Oil Contamination Test

Nach Durchführung des Probelaufs ist das ablaufende After completing the test run, the oil shall be inspected
Getriebeöl auf Späne, Zunder, übermäßigen Abrieb zu for scraps, scales and wear particles and other impuri-
beobachten. Auf Fremdkörper an Magnetstopfen und ggf. ties. The magnetic plug and, if necessary, the oil filter
am Ölfilter ist zu achten. shall be checked.

676 BOMAG 008 911 57

Wheel drive gear up to S/N
Electric Drives Linear Motion and
19.4
and Controls Hydraulics Assembly Technologies Pneumatics Service

Betriebsanleitung / Operating Instructions BDA 16218480 00

Planetengetriebe / Planetary Gearbox 24.11.2006

HYDROTRAC

GFT 220 R3 9096

Made in Germany
Ident.-Nr. / ident.-no. 05901801
Type / product GFT 220 R3 9096
Serial-Nr. / serial-no. Imprint on Rating Plate
Auftrags-Nr. / order-no. 372999.010
Baujahr / produced in 2006
Abtriebsdrehmoment / output torque max. 184950 Nm
-1
Antriebsdrehzahl / input speed max. 3901 min
Übersetzung / ratio 145,4
Schmiergruppe / lubr. group CLP 220 oder / or
SAE 85 W-90 API GL-4
MNR 16218480

008 911 57 BOMAG 677

19.4
BDA 16218480 00 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 2/31

Inhaltsverzeichnis • Table of Contents

1. Einleitung 1. Preliminary Notes

1.1 Einführung 1.1 Introduction
1.2 Sicherheitshinweise 1.2 Notes on Safety

2. Produktbeschreibung 2. Product Description

2.1 Einführung 2.1 Introduction
2.2 Beschreibung 2.2 Description
2.3 Beschreibung der Bremse 2.3 Description of Brake
2.4 Lieferumfang 2.4 Scope of Supply
2.5 Technische Daten 2.5 Technical Data
2.6 Zeichnungen und Listen 2.6 Drawings and Lists
2.7 Betriebsmittel 2.7 Operating Media

3. Transport / Lagerung 3. Handling / Storage

3.1 Einführung 3.1 Introduction
3.2 Hinweise zu Transport und Lagerung 3.2 Notes on Handling and Storing
3.3 Verpackung 3.3 Packing
3.4 Konservierung 3.4 Preservation
3.4.1 Lagerung in gelüfteten Räumen 3.4.1 Storage in Ventilated Rooms
3.4.2 Lagerung im Freien 3.4.2 Storage Outdoors
3.4.3 Lagerung in klimatisierten Räumen 3.4.3 Storage in Air-Conditioned Rooms
3.4.4 Lagerung von teilgeschlossenen Getrieben 3.4.4 Storage of part closed Gearboxes
3.4.5 Langzeitkonservierung 3.4.5 Long-Term Preservation

4. Einbau 4. Mounting
4.1 Einführung 4.1 Introduction
4.2 Handlungsschritte zum Einbau 4.2 Mounting Work to be Performed

5. Inbetriebnahme 5. Commissioning
5.1 Einführung 5.1 Introduction
5.2 Handlungsschritte zur Inbetriebnahme 5.2 Commissioning Activities

6. (in diesem Handbuch nicht enthalten) 6. (does not form part of this manual)

7. Pflege / Wartung 7. Maintenance / Care

7.1 Einführung 7.1 Introduction
7.2 Handlungsschritte zu Pflege und Wartung 7.2 Maintenance and Care Activities
7.3 Wartungsplan 7.3 Maintenance Schedule
7.4 Wartungsplan Bremse 7.4 Maintenance Schedule Brake

8. Ausbau 8. Dismantling
8.1 Einführung 8.1 Introduction
8.2 Handlungsschritte zum Ausbau 8.2 Dismantling Work to be Performed

9. (in diesem Handbuch nicht enthalten) 9. (does not form part of this manual)

10. Ersatzteilbestellung 10. Spare Parts Ordering

678 BOMAG 008 911 57

Wheel drive gear
BDA 16218480 up 220
00 GFT to S/N
R3 9096 19.43/31
Bosch Rexroth AG

Inhaltsverzeichnis • Table of Contents

Anhang Appendix

B. Schmieröle B. Lube Oils

C. (in diesem Handbuch nicht enthalten) C. (does not form part of this manual)

Änderungsverzeichnis • Table of Modification

Ersetzt Ausgabe: Substitutes Issue:

4/6137/4096/0 4/6137/4096/0

1 Getriebe überarbeitet / revised gearbox 24.11.2006 Winkler Winkler

Nr. / No. Änderung / Modification Tag / Date geändert / geprüft /

modified by checked by

008 911 57 BOMAG 679

19.4
BDA 16218480 00 GFT 220 R3 9096
1. Einleitung • 1. Preliminary Notes
1.1 Einführung
In der vorliegenden Betriebsanleitung finden Sie Infor-
mationen zum Einbau, zur Inbetriebnahme, zur Pflege
und Wartung und zur Ersatzteilbestellung.
Beachten Sie unbedingt die Sicherheitshinweise
dieser Dokumentation.
- Allgemeine Sicherheitshinweise finden Sie in diesem
ersten Kapitel.
- Besondere Hinweise finden Sie jeweils am Anfang
eines Kapitels.
- Auf eine Handlung bezogene Sicherheitshinweise
finden Sie vor der Beschreibung des Handlungs-
schrittes.
Die Seitenzahl finden Sie am äußeren Seitenrand.
Die Bereiche des Anhanges sind durch Zwischenblätter
voneinander getrennt und ggf. versehen mit Hinweisen
auf den angesprochenen Leserkreis.
1.2 Sicherheitshinweise
Die Produkte von BOSCH-REXROTH sind nach dem
aktuellen Stand von Wissenschaft und Technik ausge-
legt und hergestellt. Dennoch können Gefahren auftre-
ten für:
- Körper und Gesundheit,
- das Produkt und die Gesamtanlage,
- sonstige Werte.
Mit diesem Symbol sind Gefahren für Kör-
per und Gesundheit gekennzeichnet.
Mit diesem Symbol sind Gefahren für das
Produkt und die Gesamtanlage gekenn-
zeichnet.
Mit diesem Symbol sind Gefahren für
sonstige Werte gekennzeichnet.
Dieses Symbol kennzeichnet Hinweise.
680 BOMAG
Wheel drive gear
Bosch up to
Rexroth AGS/N 4/31
1.1 Introduction
The present operating instructions contain information
on installation, start-up, care and maintenance as well
as spare parts ordering.
Make sure the safety instructions in this documenta-
tion are carefully observed.
- General notes on safety are listed in this first chap-
ter.
- Special instructions are given at the beginning of the
individual chapter.
- Safety instructions referring to actions are given
before the action itself is described.
Page numbers are shown at the outer bottom margin.
The various areas of the Appendix have been separated
by sheets and, where considered expedient, provided
with notes on the relevant persons.
1.2 Notes on Safety
The products of BOSCH-REXROTH have been de-
signed and manufactured so as to reflect the state of the
scientific and technical knowledge. Nevertheless, it
cannot be ruled out that danger may arise to:
- life and limb,
- the product and overall plant,
- other assets.
This symbol signifies danger to life and
limb.
This symbol signifies danger to the prod-
uct and the overall plant.
This symbol signifies danger to other
assets.
This symbol calls attention to notes.
008 911 57
Wheel drive gear
BDA 16218480 up 220
00 GFT to S/N
R3 9096
1. Einleitung • 1. Preliminary Notes
Gefahren können insbesondere dann auftreten:
- wenn unzureichend ausgebildetes Personal am
Produkt tätig ist,
- wenn das Produkt unsachgemäß installiert, bedient
und instand gehalten wird,
- wenn das Produkt zu nicht bestimmungsgemäßem
Gebrauch eingesetzt wird.
Alle Personen, die mit dem Betrieb der Anlage oder des
Produktes befaßt sind, müssen:
- unbedingt das Kapitel "Sicherheitshinweise" gelesen
und verstanden haben,
- diese Betriebsanleitung zumindest in den Teilen
kennen, in denen die jeweilige Tätigkeit und zugehö-
rige Gefahrenhinweise beschrieben sind,
- mit Abschaltprozeduren, z.B. "NOT-AUS", der gan-
zen Anlage oder den für die jeweilige Tätigkeit wich-
tigen Teilen der Anlage vertraut sein,
- technisch ausreichend ausgebildet und zu der jewei-
ligen Tätigkeit befugt sein,
- ihre Aufgaben und Befugnisse kennen.
Sie müssen unbedingt:
- alle Handlungen unterlassen, die Gefahren für Kör-
per und Gesundheit, Gefahren für das Produkt oder
Gefahren für andere Werte bedeuten könnten,
- alle an dem Produkt vorgenommenen Veränderun-
gen dem zuständigen Vorgesetzten oder Betreiber
mitteilen,
- alle Veränderungen beim Betrieb des Produkts, z.B.
unübliche Laufgeräusche, dem zuständigen Vorge-
setzten oder Betreiber mitteilen.
An dem Produkt dürfen keine Veränderungen vor-
genommen werden, die nicht zuvor von BOSCH -
REXROTH genehmigt worden sind.
Der Anwender verpflichtet sich:
- am und um das Produkt für Sauberkeit und Ordnung
zu sorgen,
- das Produkt nur in einwandfreiem Zustand zu betrei-
ben,
- das Produkt nur zum bestimmungsgemäßen
Gebrauch einzusetzen,
- das Produkt nur im Rahmen der unter 2.5 aufgeführ-
ten technischen Daten einzusetzen,
- umlaufende Teile durch geeignete Schutzvorrichtun-
gen abzusichern,
- das Personal soweit wie nötig zum Tragen von
Schutzkleidung zu verpflichten,
- dem zuständigen Personal diese Betriebsanleitung
auszuhändigen.
Zum bestimmungsgemäßen Gebrauch gehört auch die
Beachtung aller Angaben dieser Betriebsanleitung.
Beachten Sie ergänzend zur Betriebsanleitung alle
allgemein gültigen gesetzlichen und sonstigen Regelun-
gen zur Unfallverhütung.
008 911 57 BOMAG
Bosch Rexroth AG 19.45/31
In particular, hazards may occur:
- if insufficiently trained personnel manipulates the
product,
- if the product is inexpertly installed, operated and
serviced,
- if the product is used for other than the intended
purposes.
All persons responsible for the operation of the plant or
product must:
- have definitely read and understood the chapter
"Notes on Safety",
- know these Operating Instructions or at least be
familiar with those parts where the respective activity
and associated dangers are described,
- be familiar with shut-down procedures, e.g. "Emer-
gency-OFF", relating to the entire plant or to plant
items important to the relevant activity,
- have adequate technical qualifications and be au-
thorized to perform the relevant activity,
- know their specific duties and authority.
Moreover, it is mandatory that these persons:
- refrain from doing anything that might cause bodily
harm or constitute a danger to health, the product or
other assets,
- inform their superiors in charge or the Operator of
any modifications made to the product,
- inform their superiors in charge or the Operator of
any changes detected in the operational behaviour
of the product, e.g. unusual running noise.
No modifications to the product are permitted un-
less the prior approval of BOSCH - REXROTH has
been obtained.
The User shall undertake to:
- ensure that the product and its surroundings are kept
clean and in good order,
- operate the product only when in perfect condition,
- use the product exclusively for the intended purpose,
- use the product only in the framework of the techni-
cal characteristics listed under 2.5,
- safeguard rotating parts by means of suitable protec-
tive systems,
- instruct the personnel to wear protective clothing, to
the extent deemed necessary,
- distribute these operating instructions among the
personnel in charge.
Using the equipment for the intended purpose as set out
above also includes observing the instructions given in
this operating manual.
In addition to the procedures and instructions outlined in
this operating manual all generally applicable statutory
and other accident prevention rules and provisions must
be observed.
681
19.4
BDA 16218480 00 GFT 220 R3 9096
1. Einleitung • 1. Preliminary Notes
Die Gewährleistung durch
BOSCH - REXROTH erlischt:
- wenn das Produkt ohne unsere Zustimmung geöff-
net oder verändert wird,
- bei Nichtbeachtung der Instruktionen dieser Be-
triebsanleitung,
- bei Ein- und Anbau nicht von uns gelieferter oder
genehmigter Ersatzteile und Zusatzgeräte,
- bei Überlastung des Produktes von besonderer Art,
wie z.B. Drehschwingungen, Drehmomentstößen,
Fundamentverwindungen oder sonstigen unzulässi-
gen Einflüssen,
- wenn die in Kapitel 2.5 aufgeführten technischen
Daten über- oder unterschritten werden,
- bei unsachgemäßer Handhabung des Produktes.
Technische Änderungen, die der Verbesserung des
Produktes dienen, behalten wir uns vor.
Die Abbildungen in dieser Betriebsanleitung können von
der tatsächlichen Ausführung geringfügig abweichen.
Soweit vertraglich nichts anderes vereinbart ist, richten
sich die Gewährleistungsansprüche nach den zum Zeit-
punkt des Vertragsabschlusses geltenden "Allgemeinen
Bedingungen für Lieferungen und Leistungen" von
BOSCH - REXROTH.
Urheberrecht
Das Urheberrecht an Zeichnungen verbleibt bei uns.
Eine Zeichnung darf nur zu den Zwecken benutzt wer-
den, zu denen sie dem Empfänger anvertraut ist. Ohne
unsere ausdrückliche schriftliche Genehmigung dürfen
Zeichnungen nicht an Dritte weitergegeben oder diesen
zugänglich gemacht werden.
Jede Vervielfältigung - auch von Einzelheiten - ist unter-
sagt.
Zuwiderhandlungen werden gerichtlich verfolgt.
682 BOMAG
Wheel drive gear
Bosch up to
Rexroth AGS/N 6/31
The warranty obligations of
BOSCH - REXROTH will become void:
- if the product is opened or modified without our con-
sent,
- in the event the instructions in this manual are disre-
garded,
- if spare parts and auxiliary items are built in or at-
tached which have not been supplied or approved by
us,
- if the product is subjected to overloads caused for
example by torsional vibrations, torque impacts,
distorted or deformed foundations or other imper-
missible influences,
- if the technical characteristics specified under pt. 2.5
are exceeded or fallen short of,
- if the product is improperly handled or manipulated.
We reserve the right to implement technical changes for
product improvement purposes.
The photos and figures shown in this manual may slight-
ly deviate from the actual design.
Unless otherwise stipulated in the contract, any warranty
claims shall be dealt with in accordance with BOSCH -
REXROTH`s "General Terms and Conditions of Sup-
plies and Services" applicable at the time the contract
has been concluded.
Copyright
The copyright on drawings remains with us. A drawing
must only be used for the purposes it has been trans-
ferred to the recipient. Drawings must not be handed
over disclosed to third parties without our express con-
sent in writing.
Any reproduction of a drawing in whole or part is prohib-
ited.
Contraventions will be prosecuted.
008 911 57
Wheel drive gear
BDA 16218480 up 220
00 GFT to S/N
R3 9096
2. Produktbeschreibung • 2. Product Description
2.1 Einführung
In diesem Kapitel finden Sie eine Beschreibung des
Getriebes GFT 220 R3 9096. Diese wird ergänzt durch
Angaben zum Lieferumfang, durch eine Auflistung der
technischen Daten und durch Angaben zu den Be-
triebsmitteln.
2.2 Beschreibung
Das Getriebe HYDROTRAC GFT 220 R3 9096 ist ein
dreistufiges Planetengetriebe. Zur Ausstattung gehört
eine integrierte, hydraulisch lüftbare Lamellenhalte-
bremse.
Um einen optimalen Lastausgleich zu gewährleisten,
enthält jede Planetenstufe satzweise sortierte Planeten-
räder. Die außenverzahnten Räder sind einsatzgehärtet.
Das komplett wälzgelagerte Getriebe ist mit einer Öl-
tauchschmierung ausgestattet.
Eine spezielle Gleitringdichtung sorgt für den
optimalen Schmutz- und Staubschutz der Felgen- bzw.
der Turaslagerung.
Der mitgelieferte O-Ring (motorseitig) ermöglicht eine
statische Abdichtung des Hydromotors.
Das Getriebe ist ausschließlich zum Einsatz als Fahrge-
triebe für einen Müllverdichter vorgesehen.
Für Schäden, die aus nicht bestimmungsgemäßem
Gebrauch entstehen, haftet BOSCH-REXROTH nicht.
Das Risiko trägt in einem solchem Fall ausschließlich
der Anwender.
2.3 Beschreibung der
Bremse
Die im Getriebe integrierte, naßlaufende, hydraulisch
lüftbare Lamellenbremse ist eine Haltebremse. Sie ist
durch Federkraft ständig geschlossen und wird durch
Zufuhr von Drucköl geöffnet.
2.4 Lieferumfang
Zum Lieferumfang gehört:
- Getriebe mit integrierter Lamellenhaltebremse.
- Technische Dokumentation.
Der gesetzlich vorgeschriebene Berührungsschutz an
umlaufenden Teilen gehört nicht zum Lieferumfang.
Überprüfen Sie alle Anlieferungen nach Erhalt unverzüg-
lich auf Vollständigkeit. Teilen Sie Abweichungen und
Transportschäden sofort BOSCH - REXROTH mit.
008 911 57 BOMAG
Bosch Rexroth AG 19.47/31
2.1 Introduction
This chapter contains a description of the propel gear
GFT 220 R3 9096. The description is supplemented by
information on the scope of supply, a list of technical
data and details of operating media.
2.2 Description
The planetary gearbox HYDROTRAC GFT 220 R3 9096
is of 3-stage design complete with an integrated, hy-
draulically released multi-plate parking brake.
To ensure an optimum balancing of loads, each plane-
tary stage comprises of planet gears in sets. The exter-
nally toothed wheels are case-hardened.
The gearbox runs in antifriction bearings exclusively and
has a splash lubrication system.
A special mechanical seal reliably protects the rim- resp.
the tumbler bearing system against the ingress of dirt
and dust.
The o-ring (motor side) included in the supply enables
the unit to be reliably sealed statically.
The gearbox is exclusively intended for use as a propel
drive in a garbage compressor.
BOSCH-REXROTH shall not be liable for any damage
arising as a result of the gearbox being used for pur-
poses other than originally intended. In such a case, the
risk lies solely with the User.
2.3 Description of Brake
The hydraulically released, wet-running, multi-plate
brake, integrated in the gearbox, is a parking brake. It is
normally closed by spring force and released when
pressurized by hydraulic oil.
2.4 Scope of Supply
The supply scope includes:
- Gearbox with integrated multiple disk holding brake.
- Technical documentation.
Means of protection against accidental contact with
rotating parts as prescribed by statutory provisions do
not form part of the supply scope.
Please check all equipment supplies for completeness
immediately upon receipt. Any deviations and transit
damage must be reported to BOSCH - REXROTH right
away.
683
19.4
BDA 16218480 00 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 8/31

2. Produktbeschreibung • 2. Product Description

2.5 Technische Daten 2.5 Technical Data

Antriebsdrehzahl max. 3901 min-1 Input speed max. 3901 rpm
Antriebsdrehmoment max. 1272 Nm Input torque max. 938 ft.lbs
Übersetzung 145,4 Transmission ratio 145,4
Abtriebsdrehzahl max. 26,8 min-1 Output speed max. 26,8 rpm
Abtriebsdrehmoment max. 184950 Nm Output torque max. 136401 ft.lbs
Federdruck-Lamellenbremse Spring-applied, multi-disk brake
Bremsmoment, statisch 1360 Nm Static brake torque 1003 ft.lbs
Lüftdruck 20 bar Release pressure 290 psi
max. Lüftdruck 50 bar max. release pressure 725 psi
Betriebstemperatur max. 90°C Operating temperature max. 90°C
Gewicht ca. 850 kg Weight approx. 1874 lbs
Getriebeölmenge ca. 14 Liter Gear lube oil volume approx. 3,7 gall
Schmieröl CLP 220 oder Lube oil CLP 220 or
SAE 85 W-90 API GL-4 SAE 85 W-90 API GL-4
Konservierung innen: SHELL S. 7294 Preservation inside: SHELL S. 7294
SAE 50 SAE 50
Konservierung außen: TECTYL 502 C Preservation outside: TECTYL 502 C

2.6 Zeichnungen und 2.6 Drawings and Lists

Listen
Anhang Appendix
Einbauzeichnung 0/6137/5096/4 D Installation drawing 0/6137/5096/4 D
Ersatzteilzeichnung 0/6137/1096/2 D Spare parts drawing 0/6137/1096/2 D
Teileliste Getriebe 16218480 E Parts list gear drive 16218480 E

2.7 Betriebsmittel 2.7 Operating Media

Beachten Sie die Auflistung der ausgewählten Schmier- The list of recommended lube oils given in Appendix B
öle im Anhang B. shall be observed.

684 BOMAG 008 911 57

Wheel drive gear
BDA 16218480 up 220
00 GFT to S/N
R3 9096 Bosch Rexroth AG 19.49/31
3. Transport / Lagerung • 3. Handling / Storage

3.1 Einführung 3.1 Introduction

Dieses Kapitel gibt Ihnen Hinweise auf die sichere Vor- This chapter describes how the handling and storing of
bereitung und Durchführung von Transport und Lage- the products of BOSCH-REXROTH are safely prepared
rung der Produkte von BOSCH-REXROTH. and carried through.

3.2 Hinweise zu Transport 3.2 Notes on Handling and

und Lagerung Storing
Achten Sie beim Transport auf eine aus- When handling the equipment make sure
reichende Tragkraft des Kranes. the carrying capacity of the crane is
adequate.

• Benutzen Sie nur zugelassene Transport-

elemente. • Use exclusively
equipment.
approved handling

• Befestigen Sie das Getriebe sorgfältig am

Kranhaken und benutzen Sie in Abhängig- • Carefully attach the gearbox to the crane
hook, using the lifting points provided.
keit von der Getriebegröße vorgesehene
Anhängevorrichtungen.

Stellen Sie sicher, daß beim Anheben des When lifting the gearboxes make sure that
Getriebes Anbauteile durch Transportele- the handling elements do not cause dam-
mente nicht beschädigt werden können. age to attachment parts.

• Lagern Sie die Getriebe nur in trockenen

und temperierten Räumen. • Store the gearboxes in dry and moderately
heated rooms only.

• Lagern Sie Getriebe nur in Einbaulage. • Store the gearboxes only in their intended
mounting position.

• Stellen Sie sicher, daß abgesetzte Getriebe

ihre Lage nicht ändern können. • Make sure that set down gearboxes rest
immovably.

BOSCH-REXROTH entsorgt mitgeliefertes BOSCH-REXROTH will dispose of any

Verpackungsmaterial, wenn dies kosten- packing material supplied with the gear-
frei zurückgesandt wird. boxes when this is returned to the Factory
free of charge.

3.3 Verpackung 3.3 Packing

Getriebe bis zur Größe 1200 x 1200 mm werden auf Up to dimensions of 1200 x 1200 mm the gearboxes will
einer Palette in Folie verschweißt. be welded with foil on a pallet.

Überseetransporte erfolgen vorwiegend in geschlosse- For oversea transports seaworthy packed wooden cases
nen, seemäßig verpackten Holzkisten bzw. in geschlos- respectively closed containers are used.
senen Containern.

008 911 57 BOMAG 685

19.4
BDA 16218480 00 GFT 220 R3 9096
3. Transport / Lagerung • 3. Handling / Storage
3.4 Konservierung
BOSCH-REXROTH liefert die Getriebe ohne Ölfüllung
aus.
Die Getriebe sind mit SHELL Öl S. 7294 SAE 50 innen-
konserviert.
Außenliegende Flansche, Wellenenden und Anflansch-
flächen sind mit TECTYL 502 C flächenkonserviert.
3.4.1 Lagerung in gelüfteten
Räumen
Die Getriebe sind in gelüfteten Räumen bis zu
24 Monate nach Lieferung ab unserem Werk gegen
Korrosion geschützt.
Wird die Verpackung entfernt, so ist die Außenkonser-
vierung zu prüfen und bei Bedarf fachgerecht zu erneu-
ern.
3.4.2 Lagerung im Freien
Bei einer Lagerung im Freien ist unbedingt sicherzustel-
len, daß kein Spritzwasser o.ä. die äußere Konservie-
rung beschädigen bzw. ins Getriebe eindringen kann
(Getriebe abgeplant; Spritzwasser geschützt unter
Schleppdach).
In diesen Fällen ist die Innen- und Außenkonservierung
regelmäßig alle 6 Monate zu überprüfen und evtl. zu
erneuern. Unter diesen Bedingungen besteht Korrosi-
onsschutz bis zu max. 24 Monate nach Lieferung ab
unserem Werk.
3.4.3 Lagerung in klimatisier-
ten Räumen
Ein Korrosionsschutz für max. 36 Monate ist nur mög-
lich, wenn die Lagerung in geschlossenen, klimatisierten
Lagerräumen erfolgt. Kondensation und hohe Luftfeuch-
tigkeit sind unbedingt auszuschließen.
Wird die Verpackung vorher entfernt, ist eine Kontrolle
der freiliegenden blanken Teile und eine evtl. Nachkon-
servierung mit TECTYL 502 C unerläßlich.
686 BOMAG
Wheel drive gear
Bosch up to
Rexroth AGS/N 10/31
3.4 Preservation
The gearboxes supplied by BOSCH-REXROTH are not
filled with oil.
The interior of the gearboxes has been protected with
SHELL oil S. 7294 SAE 50.
The surfaces of external flanges, ends of shafts and
flange attachment faces are preserved with TECTYL
502 C.
3.4.1 Storage in Ventilated
Rooms
In ventilated localities the gearboxes are protected
against corrosion up to 24 month after delivery ex works.
If the packing material is removed the outer preservation
must be checked and -if necessary- skillfully renewed.
3.4.2 Storage Outdoors
If the gearboxes are stored outdoors it must be made
safe that no splash water can enter the gearbox or can
do any harm to the outer preservation (Gearboxes can-
vas covered or splash proofed by a movable hood).
In such cases the inner and outer preservation has to be
checked every 6 months and -if necessary- to be
renewed. Under this condition the protection against
corrosion will last max. 24 months after delivery ex
works.
3.4.3 Storage in Air-
Conditioned Rooms
A protection against corrosion for max. 36 months is
only possible, if the storage is done in air-conditioned
localities. Condensation and high atmospheric humidity
must be avoided.
If the packing material will be removed all bare parts
have to be checked and the preservation with TECTYL
502 C has to be renewed.
008 911 57
Wheel drive gear
BDA 16218480 up 220
00 GFT to S/N
R3 9096 Bosch Rexroth AG 19.411/31
3. Transport / Lagerung • 3. Handling / Storage

3.4.4 Lagerung von teilge- 3.4.4 Storage of part-closed

schlossenen Getrieben
Getriebe oder Getriebeöffnungen, die nur mit Ölpapier
und einem Holzdeckel oder mit einem ölbeständigen
Kunststoffdeckel verschlossen sind, dürfen nur in ge-
schlossenen Räumen, max. 3 Monate gelagert werden.
Gearboxes
Gearboxes or gearbox orifices that are protected/closed
off only by oil paper and a wooden cover or by an oil
resistant plastic cover, must exclusively be stored in
enclosed rooms for a maximum period of 3 months.

3.4.5 Langzeitkonservierung 3.4.5 Long-Term Preservation

Bei einer Zwischenlagerung von mehr als 36 Monaten In the event the gearboxes are stored for a period ex-
bedarf es einer speziellen Nachkonservierung und die ceeding 36 months, they must receive a special preser-
Einhaltung verschiedener Auflagen. vation treatment. Furthermore various special directions
have to be executed.

In solchen Fällen sind die Getriebe vor dem Einsatz In such cases the gearboxes have to undergo a com-
einer gründlichen Inspektion und einem Probelauf zu plete inspection and a new test run.
unterziehen.

Einzelheiten hierzu erfragen Sie bitte bei unserer For details in this respect please contact our Service
Service-Abteilung. Department.

008 911 57 BOMAG 687

19.4
BDA 16218480 00 GFT 220 R3 9096
4. Einbau • 4. Mounting
4.1 Einführung
Das Kapitel beschreibt den Einbau des Fahrgetriebes in
den Fahrwerksrahmen.
Beachten Sie unbedingt die vorangestell-
ten Sicherheitshinweise.
Beachten Sie die Hinweise in der Einbauzeichnung:
0/6137/5096/4
4.2 Handlungschritte zum
Einbau
Achtung!
Beim Abbau des Hydromotors kann je
nach Ausführung des Getriebes der Mit-
nehmer aus dem Eingriff der Lamellenver-
zahnung gezogen werden!
Achten Sie beim Einbau des Mitnehmers
auf dessen richtige Einbaulage.
Siehe Ersatzteilzeichng.: 0/6137/1096/2
Befestigen Sie das Getriebe sicher am
Fahrwerksrahmen, bevor Sie die An-
schlagmittel entfernen.
• Vermeiden Sie beim Einbau unbedingt
grobe Schläge.
Vermeiden Sie unbedingt Axialkräfte.
• Vermeiden Sie unbedingt hohe Druckkräf-
te auf das Getriebegehäuse.
• Beachten Sie die Einbauzeichnung und die
zugehörigen Daten.
Hängen Sie das Getriebe an den Kran.
Heben Sie das Getriebe in den Fahrwerksrahmen.
Ziehen Sie die Befestigungsschrauben (Qualität min.
10.9 DIN / ISO) mit einem Drehmomentschlüssel an.
Entnehmen Sie die Anzugsmomente der Rahmenzeich-
nung.
Entfernen Sie die Transportmittel.
Entfernen Sie den Schutzstopfen (motorseitig) am Ge-
triebe vor dem Anschrauben des Hydromotors.
Achten Sie darauf, daß kein Schmutz oder
Fremdkörper in das Getriebe gelangt.
688 BOMAG
Wheel drive gear
Bosch up to
Rexroth AGS/N 12/31
4.1 Introduction
This chapter describes the installation of the propel gear
into the bogie frame.
The preceding safety notes must be care-
fully observed.
Carefully follow the instructions given on the installation
drawing: 0/6137/5096/4
4.2 Mounting Work to be
Performed
Caution!
Depending on the gearbox design, the
coupler can be disengaged from the inner
gearing of the disks when disassembling
the hydraulic motor!
Make sure to observe its correct installa-
tion position when mounting the coupler.
See spare part drawing: 0/6137/1096/2
Secure the gearbox safely before remov-
ing the lifting straps or ropes.
• Avoid heavy blows when mounting the
equipment.
Make sure that axial forces are not exerted
during mounting.
• Make sure high compressive forces do not
act on the gearbox housing.
• During this work observe installation dra-
wing as well as pertinent data.
Attach the gearbox to a crane.
Lift the gear into the bogie frame.
Tighten the screws (quality nom. 10.9 DIN / ISO) using
a torque wrench.
The relevant tightening torques shall be taken from the
frame drawing.
Remove the lifting straps or ropes.
Remove the plug (motor side) at the gearbox before
connecting the hydraulic motor.
Make sure that no dirt or foreign bodies
are allowed to enter the gearbox.
008 911 57
Wheel drive gear
BDA 16218480 up 220
00 GFT to S/N
R3 9096 Bosch Rexroth AG 19.413/31
4. Einbau • 4. Mounting

Bauen Sie den Hydromotor an. Beachten Sie unbedingt Mount the hydraulic motor. Carefully observe the re-
die Angaben des Herstellers. spective instructions given by the manufacturer.

• Achten Sie beim Anbau des Motors auf

sorgfältige Abdichtung (O-Ring Pos. 66). • When mounting the hydraulic motor make
sure that it is properly sealed off (O-ring
item 66).

Beachten Sie unbedingt die Sicher- The preceding safety notes of manufac-
heitshinweise des Herstellers. turer must be carefully observed.

Entfernen Sie die Schutzstopfen vor dem Anschrauben Remove the plugs before connecting the hydraulic oil
der Hydraulikölleitungen. lines.

Achten Sie darauf, daß kein Schmutz oder Make sure that no dirt or foreign bodies
Fremdkörper in die Hydraulikanlage ge- are allowed to enter the hydraulic system.
langen.

• Schließen Sie den Hydromotor an. • Connect the hydraulic motor.

Beachten Sie unbedingt die Sicher- The preceding safety notes of manufac-
heitshinweise des Herstellers. turer must be carefully observed.

• Schließen Sie die Lamellenhaltebremse

an. • Connect the multi-plate parking brake.

Die Lamellenhaltebremse ist eine Sicher- The multi-plate parking brake is a safety
heitseinrichtung des Getriebes. device of the gearbox.

• Schließen Sie die Bremslüftleitung an.

Entfernen Sie dafür den Schutzstopfen • Connect the brake release line after re-
moving the plug (item 71).
(Pos. 71).

Achten Sie darauf, daß kein Schmutz oder Make sure that no dirt or foreign bodies
Fremdkörper in den Bremslüftanschluß are allowed to enter the brake release port.
gelangt.

Sorgfältige Abdichtung des Brems- Make sure that the brake release port is
lüftanschlusses beachten. properly sealed.

• Es darf kein Staudruck in der Brems-

leitung vorhanden sein. • Back pressure is not allowed in the brake
release line.

Überprüfen Sie noch einmal den ordnungsgemäßen Sitz Check once again tight fit of all joining elements.
und die Festigkeit aller Verbindungselemente.

008 911 57 BOMAG 689

19.4
BDA 16218480 00 GFT 220 R3 9096
7. Pflege / Wartung • 7. Maintenance / Care
5.1 Einführung
Dieses Kapitel beschreibt die Handlungsschritte zur
Inbetriebnahme des Getriebes. Beachten Sie die ent-
sprechenden Sicherheitshinweise.
5.2 Handlungsschritte zur
Inbetriebnahme
Betätigen Sie im Gefahrenfall NOT-AUS.
• Berühren Sie keine umlaufenden Teile.
Bei der Befüllung dürfen keine Schmier-
stoffe in die Umwelt gelangen.
Führen Sie die Ölwechsel nur im be-
triebswarmen Zustand unmittelbar nach
dem Stillstand des Getriebes durch.
Hierdurch ist sichergestellt, daß kein Ab-
setzen der Feststoffpartikel stattgefunden
hat.
Befüllen Sie gemäß der Schmierölangabe das Getriebe
mit sauberem Öl.
Bei der Erstölbefüllung können Ölmenge und Ölmen-
genangabe durch im Getriebe vorhandenes Konservie-
rungsöl voneinander abweichen.
Vermeiden Sie Verunreinigungen des Ge-
triebes.
Eine Liste der von BOSCH-REXROTH zu-
gelassenen Öle finden Sie im Anhang B.
Zusätzlich freigegeben:
SAE 85 W-90 API GL-4
min. Viskosität 175 cSt - 250 cSt bei 40°C
min. Viskosität 16,5 cSt bei 100°C
Füllen Sie das Öl durch die in der Einbauzeichnung
gekennzeichnete Schraube ein.
Überprüfen Sie den Ölstand, bevor Sie das Getriebe
anfahren.
Den korrekten Ölstand erkennen Sie bei Stillstand des
Getriebes durch die Öffnung im Getriebegehäuse.
Die max. Betriebstemperatur beträgt 90°C.
Überprüfen Sie nach Erreichen der Betriebstemperatur
das Getriebe auf Dichtigkeit.
Diese Prüfung können Sie während des Betriebes
durchführen.
690 BOMAG
Wheel drive gear
Bosch up to
Rexroth AGS/N 14/31
5.1 Introduction
This chapter describes the course of action to be fol-
lowed when taking the gearbox into service. The respec-
tive notes on safety shall be duly observed.
5.2 Commissioning Activties
In cases of emergency actuate
EMERGENCY-OFF.
• Do not touch any rotating parts.
When filling the gearbox take care that
lubricants are not allowed to pollute the
environment.
Make sure to perform oil changes
immediately after standstill with the
gearbox still being warm, to avoid any
setting of solid particles.
Fill the gearbox with clean oil as specified under the
heading lubrication.
At first oil fill, actual oil volume and specified oil volume
may vary due to preservation oil remains in the gearbox.
Ensure that no dirt or other contaminants
are allowed to enter the gearbox.
A list of oils approved by BOSCH-
REXROTH is given in Appendix B.
Additional released:
SAE 85 W-90 API GL-4
min. viscosity 175 cSt - 250 cSt at 40°C
min. viscosity 16,5 cSt at 100°C
Fill in oil through the screw indicated in the installation
drawing.
Check the oil level before starting up the gearbox.
The correct oil level can be ascertained through the
opening in the gearbox housing, when the gearbox is
not operating.
The maximum operating temperature is 90°C.
When the operating temperature has been
reached, check the entire gearbox for tightness.
This check can be performed while the gearbox is run-
ning.
008 911 57
Wheel drive gear
BDA 16218480 up 220
00 GFT to S/N
R3 9096 Bosch Rexroth AG 19.415/31
7. Pflege / Wartung • 7. Maintenance / Care

Die folgenden Überprüfungen dürfen Sie The following checks must only be carried
nur bei Stillstand des Getriebes durchfüh- out when the gearbox is at a standstill.
ren.

Überprüfen Sie nach ca. 10 Stunden Vollastbetrieb After 10 hours of full load operation check all fastening
sämtliche Befestigungsschrauben auf festen Sitz. screws and boltings for tightness.

Überprüfen Sie den festen Sitz aller Schrauben des Check whether all bolts of the gearbox are tight as re-
Getriebes. quired.

Erster Ölwechsel nach ca. 50 Motorbetriebsstunden First oil change is to be made after approx. 50 motor
durch BOMAG - Personal. operating hours, by BOMAG - personnel.

Weitere Ölwechsel sind entsprechend den im Further oil changes are to be made at intervals as per
Wartungsplan (Kapitel 7.3) angegebenen Intervallen the Maintenance Schedule given in Chapter 7.3.
durchzuführen.

Bei jedem Ölwechsel sind die Magnetverschlußschrau- Make sure that the magnetic screw plugs must be
ben zu reinigen. cleaned at each oil change.

008 911 57 BOMAG 691

19.4
BDA 16218480 00 GFT 220 R3 9096
7. Pflege / Wartung • 7. Maintenance / Care
7.1 Einführung
Dieses Kapitel zeigt Wartungsschritte und die zugehöri-
gen Sicherheitsmaßnahmen auf.
Berühren Sie keine umlaufenden Teile.
• Setzen Sie zu Wartungsarbeiten das Ge-
triebe still.
7.2 Handlungsschritte zu
Pflege und Wartung
Durch entsprechende Pflege und Wartung können Sie
die Lebensdauer von Maschinen und Anlagen wesent-
lich verlängern.
Führen Sie wöchentlich Sichtkontrollen durch. Überprü-
fen Sie dabei insbesondere die Dichtigkeit des Getrie-
bes.
Führen Sie regelmäßig Geräuschkontrollen durch.
Führen Sie regelmäßig Ölstandskontrollen durch
(Ölstandskontrolleinrichtung, Markierungen, Ölstands-
kontrollschrauben).
Führen Sie die Ölwechsel nur im be-
triebswarmen Zustand unmittelbar nach
dem Stillstand des Getriebes durch.
Hierdurch ist sichergestellt, daß kein Ab-
setzen der Feststoffpartikel stattgefunden
hat.
Führen Sie nach Angaben des Wartungsplanes Öl-
wechsel durch.
Fangen Sie Altöl in geeigneten Behältern
auf und entsorgen Sie es unter Beachtung
der entsprechenden Vorschriften.
Alle Stundenangaben zu den Ölwechseln
beziehen sich auf Motorbetriebsstunden.
Erster Ölwechsel nach ca. 50 Motorbetriebsstunden
durch BOMAG - Personal.
Zweiter Ölwechsel nach 500 Motorbetriebsstunden.
Führen Sie weitere Ölwechsel nach jeweils 1000 Motor-
betriebsstunden durch, spätestens jedoch nach
12 Monaten.
Bei jedem Ölwechsel sind die Magnetverschlußschrau-
ben zu reinigen.
692 BOMAG
Wheel drive gear
Bosch up to
Rexroth AGS/N 16/31
7.1 Introduction
This chapter indicates maintenance routines and related
safety measures.
Do not touch rotating components.
• If you intend to perform maintenance work
shut down the unit.
7.2 Maintenance and Care
Activities
The service life of machinery and equipment can be
considerably increased by taking appropriate mainte-
nance and care steps.
Perform visual inspections on a daily basis. In particular,
check the tightness of the gear.
Check the equipment regularly for unusual noise.
Make oil level checks at regular intervals (oil level moni-
toring device, markers, oil level plug).
Make sure to perform oil changes
immediately after standstill with the
gearbox still being warm, to avoid any
setting of solid particles.
Make oil changes as prescribed in the Maintenance
Schedule.
Collect spent oil in suitable containers and
dispose of the oil in line with the respec-
tive regulations.
All user specifications concerning oil
change intervals refer to motor operating
hours.
First oil change is to be made after approx. 50 motor
operating hours, by BOMAG - personnel.
Second oil change is to be made after 500 motor operat-
ing hours.
Change the oil every 1000 motor operating hours or
after 12 months wichever is earlier.
Make sure that the magnetic screw plugs must be
cleaned at each oil change.
008 911 57
Wheel drive gear
BDA 16218480 up 220
00 GFT to S/N
R3 9096 Bosch Rexroth AG 19.417/31
7. Pflege / Wartung • 7. Maintenance / Care

Überprüfen Sie mindestens einmal monatlich den festen Check the tightness of all screws and bolts at least once
Sitz aller Schrauben. a month.

7.3 Wartungsplan Getriebe 7.3 Maintenance Schedule

Gearbox
Nach 50 - erster Ölwechsel durch After 50 - First oil change by
Motorbetriebsstunden BOMAG - Personal motor operating hours BOMAG - personnel

- Magnetverschlußschrauben - Clean the magnetic screw

reinigen plugs

Nach 500 - zweiter Ölwechsel After 500 - Second oil change

Motorbetriebsstunden - Magnetverschlußschrauben motor operating hours - Clean the magnetic screw

reinigen plugs

Wöchentlich: - Sichtkontrolle Weekly: - Inspect visually

- Geräuschkontrolle - Check for unusual noise

- Ölstandskontrolle - Check oil level

Monatlich: - Schraubenverbindungen Monthly: - Check the tightness of all

kontrollieren* screws and bolts*

Halbjährlich: - Ölqualitätskontrolle Semi-annually: - Check oil quality

Jährlich: - Ölwechsel Annually: - Change oil

(spätestens jedoch - Magnetverschlußschrauben (or after 1000 motor - Clean the magnetic screw

nach jeweils 1000 reinigen operating hours whi- plugs

Motorbetriebsstunden) chever is earlier)

* Beachten Sie unbedingt die in der Einbau- * Observe the tightening torques indicated in the
zeichnung angegebenen Anzugsdrehmomente. installation drawing.

7.4 Wartungsplan Bremse 7.4 Maintenance

Schedule Brake
Die Bremse ist wartungsfrei. The brake is maintenance-free.

Bei Funktionsstörungen, thermischer Ü- In case of malfunctions, excessive thermal

berlastung und bei sämtlichen Reparatur- stress and all repair works on the multi-
arbeiten an der Lamellenhaltebremse plate parking brake, make sure to always
müssen immer: replace:
- Lamellen - disks
- Federn - springs
- Dichtelemente - seals.

ausgetauscht werden.

008 911 57 BOMAG 693

19.4
BDA 16218480 00 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 18/31

8. Ausbau • 8. Dismantling

8.1 Einführung 8.1 Introduction

Dieses Kapitel beschreibt den Ausbau des Getriebes In this chapter the procedure of dismantling the propel
aus dem Fahrwerksrahmen. Beachten Sie unbedingt die gear is described. It is mandatory to observe the safety
Sicherheitshinweise. Der Einbau ist im Kapitel 4 be- notes. A gearbox mounting description is given in Chap-
schrieben. ter 4.

Die Anlage ist nicht in Betrieb. The plant has been taken out of service.

• Sichern Sie die Anlage zuverlässig gegen

unbeabsichtigtes Einschalten. • Make sure reliable measures are taken to
prevent the plant from being activated
inadvertently.

• Stellen Sie sicher, daß die Tragkraft des

Kranes zur Aufnahme des Getriebes aus- • Make sure the crane carrying capacity is
adequate for gearbox lifting.
reicht.

Sichern Sie das Getriebe gegen unkontrol- Safeguard the gearbox against uncon-
lierte Bewegungen, z.B. Verrutschen. trolled movements, e.g. sliding.

• Vermeiden
Schläge.
Sie beim Ausbau grobe
• Avoid heavy blows when dismantling the
equipment.

• Vermeiden Sie Axialkräfte. • Make sure that axial forces are not
exerted.

8.2 Handlungsschritte zum 8.2 Dismantling Work to be

Ausbau Performed
Lassen Sie das Öl ab. Drain the oil from the gearbox.
Verwenden Sie dabei geeignete Auffanggefäße. For this purpose use suitable containers.

Fangen Sie evtl. auslaufendes Öl in geeig- Any oil spillage must be collected in
neten Gefäßen auf. suitable containers.

Achten Sie beim Transport auf eine aus- For gearbox handling make sure that the
reichende Tragkraft des Kranes. carrying capacity of the crane is sufficient.

• Benutzen Sie nur zugelassene Transport-

elemente. • Use approved handling elements only.

• Befestigen Sie das Getriebe sorgfältig am

Kranhaken. • Attach the gearbox carefully to the lifting
hook.

Straffen Sie die Anschlagmittel, ohne jedoch das Ge- Tighten the lifting straps or ropes without lifting up the
triebe anzuheben. gearbox.

Stellen Sie sicher, daß das Getriebe nicht Make sure that the gearbox is not canted.
verkantet.

694 BOMAG 008 911 57

Wheel drive gear
BDA 16218480 up 220
00 GFT to S/N
R3 9096
8. Ausbau • 8. Dismantling
Lösen Sie die Versorgung des Hydromotors.
Verschließen Sie die Hydraulikleitungen mit Stopfen.
Achten Sie darauf, daß kein Schmutz oder
Fremdkörper in die Hydraulikanlage ge-
langen.
Achtung!
Beim Abbau des Hydromotors kann je
nach Ausführung des Getriebes der Mit-
nehmer aus dem Eingriff der Lamellenver-
zahnung gezogen werden!
Achten Sie beim Einbau des Mitnehmers
auf dessen richtige Einbaulage.
Siehe Ersatzteilzeichng.: 0/6137/1096/2
Lösen Sie die Bremslüftleitung.
Verschließen Sie den Bremslüftanschluß mit einem
Stopfen.
Achten Sie darauf, daß kein Schmutz oder
Fremdkörper in den Bremslüftanschluß
gelangt.
Lösen Sie die Befestigungsschrauben des Getriebeflan-
sches.
Das Getriebe hängt nun am Kran.
Führen Sie das Getriebe vorsichtig aus dem Fahrwerks-
rahmen und legen Sie es ab.
008 911 57
Bosch Rexroth AG 19.419/31
Disconnect the hydraulic motor from the supply system.
Close off the hydraulic lines by means of plugs.
Make sure that no dirt or foreign bodies
are allowed to enter the hydraulic system.
Caution!
Depending on the gearbox design, the
coupler can be disengaged from the inner
gearing of the disks when disassembling
the hydraulic motor!
Make sure to observe its correct installa-
tion position when mounting the coupler.
See spare part drawing: 0/6137/1096/2
Disconnect the brake release line.
Close off the brake release port by means of a plug.
Make sure that no dirt or foreign bodies
are allowed to enter the brake release port.
Remove the fastening screws of the gearbox flange.
The gearbox is now suspended from the crane.
Move the gearbox carefully out of the bogie frame and
lay it down.
BOMAG 695
19.4
BDA 16218480 00 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 20/31

10. Ersatzteilbestellung • 10. Spare Parts Ordering

Die im Anhang „E“ aufgeführten Positio- Some of the parts list items listed in ap-
nen der Teileliste können zum Teil nur als pendix „E“ can only be purchased as spa-
Ersatzteil-Kits wie z.B.: re parts kits, e.g.:
• Dichtsatz • sealing kit
• Bremsen Reparatur-Satz • brake repair kit
• Planetensteg komplett • planet carrier complete.
bezogen werden. Please address your enquiries for the
Fragen Sie die entsprechenden Kits über required kits to our spare parts sales de-
unseren Verkauf-Ersatzteile an. partment.

Das Anschriftenverzeichnis finden Sie im For list of addresses, see appendix A.

Anhang A.

Ersatzteile müssen den von BOSCH-REXROTH festge- Spare parts must satisfy the technical requirements
legten technischen Anforderungen genügen. Dies ist bei stipulated by BOSCH-REXROTH. Original spares sup-
Original BOSCH-REXROTH Ersatzteilen immer gewähr- plied by BOSCH-REXROTH always meet these de-
leistet. mands.

Geben Sie Ersatzteilbestellungen schriftlich auf. In drin- Please submit your spare parts orders in writing. In
genden Fällen können Sie auch telefonisch oder über urgent cases, the order can also be placed via phone or
Telefax bestellen, wenn Sie dies umgehend schriftlich fax; however, such orders must be confirmed in writing
bestätigen. without delay.

Richten Sie Ersatzteilbestellungen an die in Ihrer Nähe Please send your spare parts order to an agency of
niedergelassene Außenstelle von BOSCH-REXROTH BOSCH-REXROTH located in your area or send it di-
oder direkt an das Stammhaus (siehe angefügtes Ver- rectly to our main offices (see attached list of ad-
zeichnis der Anschriften). dresses).

Geben Sie bei einer Bestellung folgende Daten an: Spares orders should specify the following details:

- die Serialnummer - the serial number

- die Auftragsnummer - the order number
Sie finden diese Nummern auf dem Typenschild, das These numbers are given on the nameplate attached
an jedem Produkt angebracht ist. to each product.

- die Zeichnungsnummer - the drawing number

- die Positionsnummer - the item number
- die genaue Benennung - the exact designation
- die Teil-Nr. - the part-no.
Sie finden diese Nummern in der Teileliste. These numbers are included in the parts list.

- die Stückzahl der gewünschten Ersatzteile - the required spare parts quantity
- die gewünschte Versandart (z.B. Expressgut, - the type of shipment desired (e.g. by express,
Frachtgut, Luftfracht, Kurierdienst, usw.). freight, air freight, messenger etc.).

Bei Ersatzbestellung des kompletten Please advise control data specified on

Hydraulikverstellmotors sind die auf der the installation drawing when submitting a
Einbauzeichnung aufgeführten Einstellda- spare order for the complete hydraulic
ten mit anzugeben. variable displacement motor.

696 BOMAG 008 911 57

Wheel drive gear
BDA 16218480 up 220
00 GFT to S/N
R3 9096 19.421/31
Bosch Rexroth AG

Anhang • Appendix

008 911 57 BOMAG 697

19.4
BDA 16218480 00 GFT 220 R3 9096 Wheel drive gear
Bosch up to
Rexroth AGS/N 23/31

B. Schmieröle • B. Lube Oils

Inhaltsverzeichnis Table of Contents

1. Schmierölempfehlung 1. Recommendation on Lube Oils
Übersicht RNM 17420-000 Overview RNM 17420-000

2. Schmierölempfehlung 2. Recommendation of Lube Oils

CLP 220 RNM 17421-005 CLP 220 RNM 17421-005

698 BOMAG 008 911 57

 Wheel
Industrial drive
Hydraulics
gear
Electric Drives up to
and Controls
S/N
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics
19.4

BRM-GT / Werknorm
Schmierölempfehlung RNM 17420-000
Übersicht 2004-10-01

Sachgebiet 17: Schmierstoffempfehlungen Ersatz für

LSN 935 1400: 2003-05-02

Änderungen

x Reda ktionelle Überarbeitung und Umwandlung der LSN-Nummern in RNM-Nummern

(Rexroth Norm Mobile Hydraulics)

1. Zweck

Diese Norm legt empfohlene Schmieröle für den Einsatz in Bosch Rexroth–Getriebe für mobile und industrielle
Anwendungen fest.
Für Schmieröle in Windkraftanlagen gelten Sonderempfehlungen!

2. Anwendungsbereich

Diese Norm ist für den Produktbereich BRM-GT gültig.

(Bosch Rexroth, Mobile Hydraulics, Produktbereich Getriebetechnik)

3. Zuständigkeit
© Bosch Rexroth AG 2004

Für die Pflege dieser Norm ist BRM-GT/NOR zuständig.

4. Allgemeines

Die in der RNM 17421 und RNM 17422 aufgeführten Öle sind eine Auswahl der von BRM-GT empfohlenen
Schmieröle für Stirnrad,- Kegelrad- und Planetengetriebe. Es sind CLP-Industriegetriebeöle und
Kfz-Getriebeöle, die die von BRM-GT zwingend vorgeschriebenen Anforderungen erfüllen. Die
Empfehlungen basieren auf einschlägigen Produktinformationen sowie einer zum Teil jahrelangen
Erfahrung.

Die Auswahl der Ölsorte, (Mineralöl, Synthetiköl oder Kfz-Getriebeöl) wird primär durch den Anwender
vorgenommen. Hierbei spielt unter anderem die Logistik eine wesentliche Rolle. Eine qualitative Bewertung
zwischen diesen Ölen kann hieraus nicht abgeleitet werden.

Alle aufgeführten Öle sind mit dem bei BRM-GT eingesetzten Einkomponentenlack (kein Nitrolack) als
Innenanstrich sowie den standardmäßigen Elastomeren aus NBR und FPM (einsatztemperaturabhängig)
verträglich. Bei den mineralölbasischen Getriebeölen sollte eine Ölbaddauertemperatur von +85°C nicht
überschritten werden. Kurzfristig sind Spitzentemperaturen von +100°C zulässig, wobei diese die
Gebrauchsdauer des Schmiermittels erheblich herabsetzen können. Höhere Dauertemperaturen führen zu
einer erheblichen Herabsetzung der Betriebsviskosität und zum frühzeitigen Altern des Schmierstoffes. Das
Überschreiten einer zulässigen Grenztemperatur bewirkt eine chemischen Zersetzung der Ölmoleküle, die
RNM-17420_000_NOR_N_DE_2004-10-01.doc

sich durch Geruch, Ablagerungen und Rückstände im System bemerkbar machen. Sind höhere
Temperaturen zu erwarten oder zeigt die Praxis höhere Dauertemperaturen, so sind synthetische Öle auf
Basis von Polyalphaolefinen (POA) vorzusehen, da diese einen erheblich flacheren Temperatur-
Viskositätsverlauf aufweisen.

Bosch Rexroth AG erstellt: BRM-GT/NOR, Moormann

Mannesmannstraße 29 • D-58455 Witten geprüft:
Tel. +49 2302 877-167 • Fax +49 2302 877 478 freigegeben:
Seite 1 / 5
008 911 57 BOMAG 699
19.4 Wheel drive gear up to S/N
Seite 2 / 5
Schmierölempfehlung, Übersicht RNM 17420-000 : 2004-10-01

Eine, für den Anwender bindende Vorgabe ist die auf dem Typenschild und /
Achtung! oder in der Bedienungsanleitung angegebene Viskosität sowie Sonderhinweise.

Bei Verwendung einer anderen Viskosität oder eines anderen als hier
empfohlenen Getriebeöles übernimmt der Betreiber die Verantwortung für die
technische Eignung des Schmierstoffes. Die Benutzung von Schmierstoffen, die
nicht den nachfolgend spezifizierten Qualitätsanforderungen entsprechen, kann
unter Umständen die BRM-GT-Gewährleistungsbedingungen außer Kraft setzen.
Es wird ausdrücklich darauf hingewiesen, daß jeder Ölhersteller
beziehungsweise Öllieferant für die Qualität seines Produktes verantwortlich ist,
zum Beispiel Verunreinigungen oder Chargenunterschiede.

Hinweis: Bei der BRM-GT Verzahnungsberechnung nach DIN 3990 mit zusätzlicher
Graufleckenberechnung nach FVA-Nr. 54 wird die erforderliche Schadenkraftstufe
(SKS) für das Öl ausgewiesen. Sollte hier eine SKS > 9 errechnet werden, muss in
der Bedienungsanleitung ein Hinweis auf eine eingeschränkte Ölauswahl mit der
Grauflecken-Tragfähigkeitsklasse „hoch“ erscheinen!

Hinweis: Die oberen und unteren Gebrauchstemperaturen einzelner Getriebeöle können zu den
technischen Kennwerten „Flammpunkt und Pourpoint“ stark abweichen. Diese sowie
weitere Daten und Eigenschaften der Getriebeöle sind stets den technischen
Datenblättern der Ölhersteller zu entnehmen.

Nach Angaben der Schmierstoffhersteller sind die aufgeführten Produkte weltweit unter dem selben
Handelsnamen verfügbar und weisen vergleichbare technologische Eigenschaften auf.

4.1 Synthetische Öle auf Basis von Polyalphaolefinen PAO

Synthetische Öle haben einen höheren Viskositätsindex (VI) als Mineralöle und vermindern somit die
Viskositätsabhängigkeit von der Temperatur. Die aufgelisteten synthetischen Öle auf Basis von
Polyalphaolefinen (Spalte LS 3) sind zwar in jedem Verhältnis mit Mineralölen mischbar, um jedoch
Eintrübungen und Additivausfällungen zu vermeiden, sollten nicht mehr als 5 bis 10% Restöl im Gehäuse
verbleiben.

4.2 Synthetische Öle auf Basis von Polyglykolen PG (zur Zeit nicht zulässig für BR-Getriebe)

Hinweis: Synthetische Öle auf Basis von Polyglykolen sind aufgrund eventueller Unverträglichkeiten
mit dem Anstrich, den Standarddichtungen und den eingesetzten Ölschauglasmaterialien
ohne vorherige Rücksprache mit dem Getriebehersteller nicht zugelassen!

Eine Vermischung von Mineralölen mit Polyglykolen muss unter allen

Achtung! Umständen vermieden werden!

4.3 Biologisch schnell abbaubare Öle auf Basis synthetischer Ester HEES

Unter bestimmten Umständen können auch, hier nicht aufgeführte, biologisch schnell abbaubare Schmieröle
(synthetische Ester HEES) eingesetzt werden. Die Ergebnisse diverser Forschungsvorhaben, zum Beispiel
FKM-Nr. 051950, das VDMA-Arbeitsblatt 24 569 sowie auch einschlägige Erfahrungen von
Dichtungsherstellern und Ölfirmen zeigen bei Einsatz von biologisch schnell abbaubaren Ölen mögliche
Unverträglichkeiten mit bestimmten Dichtungsmaterialien und Anstrichstoffen sowie Reibwertminderungen
bei Lamellen. Für den Einsatz dieser Öle werden unter Umständen Sondermaterialien (nicht standardmäßige
BRM-GT-Materialien) notwendig, die Verträglichkeitsuntersuchungen erfordern.

Hinweis: Vor Einsatz eines biologisch schnell abbaubaren Öles, (Erstbefüllung oder Umstellung) ist
Rücksprache mit dem Getriebehersteller zu nehmen!

700 BOMAG 008 911 57

 Wheel drive gear up to S/N 19.4
Seite 3 / 5
Schmierölempfehlung, Übersicht RNM 17420-000 : 2004-10-01

5. RNM 17421 „Schmierölempfehlung CLP ISO VG 46 – 680“

In dieser Werknorm sind Mineralöle aufgeführt, die nach DIN 51517 T.3 die Mindestanforderungen für
CLP-Öle erfüllen. Sie enthalten Wirkstoffe zur Erhöhung des Korrosionsschutzes und der
Alterungsbeständigkeit sowie zur Herabsetzung des Verschleißes im Mischreibungsgebiet
(Hochdruckzusätze, sogenannte Extrem-Pressure Additives). Die Schadenkraftstufe im FZG-Normaltest
A/8,3/90 nach DIN 51354 T.2 beträgt mindestens 12. Im FZG-Graufleckentest gemäß FVA-Nr. 54/I-IV
erreichen diese Öle eine Graufleckentragfähigkeit „hoch“ (SKS 10) oder aber mindestens „mittel“ (SKS 9).

Andere Öle, wie zum Beispiel Hydrauliköle HLP oder synthetische Öle HC, die die CLP-Bedingungen
erfüllen oder übertreffen, sind hier integriert.

Die RNM 17421 ist nach ISO Viskositätsklassen abgestuft. Die niedrig viskosen Öle werden fast
ausschließlich für den Einsatz in Lamellenbremsen benötigt.

Nicht alle in dieser Werknorm aufgeführten Öle eignen sich für jeden Anwendungsfall. Aus diesem Grund
wurden die Gruppenbezeichnungen LS 1 und LS 3 festgelegt.

Hinweis: Die erforderliche LS-Gruppe ist von der Konstruktion vorzugeben! Sie ist in der
Betriebsanleitung und / oder auf dem Typschild genannt. Bei der Auswahl eines Öles ist
darauf zu achten, daß alle von der Konstruktion angegebenen LS Gruppen erfüllt werden.
ƎSchutzvermerk DIN 34 beachtenƎ - ƎCopyright reservedƎ

LS 1: Verschärfter FZG-Test

Diese Öle haben auch beim verschärften FZG-Test A / 16,6 / 90 (doppelte Umfangsgeschwindigkeit) die
Schadenkraftstufe 12 erreicht.

Bezeichnung für ein Schmieröl mit verschärftem FZG-Test der Viskosität ISO VG 100 CLP 100 LS 1

LS 3: Vollsynthetische Öle (Polyalphaolefine PAO)

Bei der Umstellung von Mineralöl auf Polyalphaolefinöl können 5 bis zu 10% des Mineralöles nach dem
Ablassen im Gehäuse verbleiben. Eine Vermischung beider Ölsorten in dieser Größenordnung kann
bedenkenlos vorgenommen werden.

Hinweis: Bei einer Vermischung mit Resten des von BRM-GT eingesetzten Konservierungsöles
neigen PAO jedoch zur Schaumbildung. Daher ist bei der Erstbefüllung eines konservierten
Getriebes ein Spüllauf durchzuführen oder ein Mineralöl als Einlauföl zu verwenden.

Bezeichnung für ein synthetisches Schmieröl der Viskosität ISO VG 100 CLP 100 LS 3

6. RNM 17422 „Schmierölempfehlung Kfz-Getriebeöl HYP SAE

In dieser Werknorm sind Ein- und Mehrbereichsöle für Kfz-Getriebe nach DIN 51512 aufgeführt und der API-
Klassifikation GL 4 und / oder GL 5 zugeteilt. Sie sind unter anderem unter dem Gesichtspunkt einer
definierten Ist-Viskosität (ISO-Viskosität) ausgewählt, da die bei Kfz-Getriebeölen übliche SAE-Viskosität in
mehrere ISO-Viskositätsklassen fallen kann (siehe nachfolgendes Schaubild). Für diese Öle liegen noch
keine Grauflecken-Testergebnisse vor, weshalb sie ausschließlich für Mobilgetriebe zur Anwendung
kommen dürfen.

Hinweis: Für die Auswahl einer HYP-Ölsorte ist die Viskositätsangabe auf dem Typenschild und/oder
in der Bedienungsanleitung mit der Ölspezifikation der Bedienungsanleitung abzugleichen.

Bezeichnung für ein Kfz-Getriebeöl der Viskosität SAE 80W-90 HYP SAE 80W-90

008 911 57 BOMAG 701

19.4 Wheel drive gear up to S/N
Seite 4 / 5
Schmierölempfehlung, Übersicht RNM 17420-000 : 2004-10-01

7. Vergleich der Viskositäts-Einteilung verschiedener Öle

8. Ölwechsel / Ölauffüllung

Die Lebensdauer und Betriebssicherheit eines Getriebes wird wesentlich beeinflusst von dem Reinheitsgrad
des verwendeten Öles. Für den ersten Ölwechsel nach der Inbetriebnahme des Getriebes sowie die
weiteren Ölwechsel sind die Vorschriften in den Betriebsanleitungen zu beachten. Die beim Ölwechsel im
Getriebe verbleibenden Restmengen sollten so gering wie möglich gehalten werden.

Hinweis: Beim Nachfüllen oder Mischen von Ölen sollten unbedingt die Qualitäts- und
Viskositätsanforderungen beachtet werden. Ein Vermischen von Ölen unterschiedlicher
Hersteller bei gleicher Viskosität kann zu Qualitätsminderungen führen. Hier sollte vorher
der Schmierstofflieferant auf mögliche Verträglichkeitsprobleme angesprochen werden.

Die aufgeführten Schmierstoffe dürfen auf keinen Fall mit anderen Stoffen
Achtung! vermischt werden. Nach dem Spülen sowie Reinigen mit Petroleum oder
anderen Reinigungsmitteln muss das Getriebe vollkommen rückstandsfrei von
den zuvor genannten Mitteln sein. Vor Inbetriebnahme ist ein zusätzlicher
Spüllauf durchzuführen.

702 BOMAG 008 911 57

Wheel drive gear up to S/N 19.4
Seite 5 / 5
Schmierölempfehlung, Übersicht RNM 17420-000 : 2004-10-01

9. Verwendete Abkürzungen und Kurzzeichen

AGMA American Gear Manufacturers Association

API American Petroleum Institute

DIN Deutsches Institut für Normung

EP Extrem Pressure

FKM Forschungskuratorium Maschinenbau e.V.

FVA Forschungsvereinigung Antriebstechnik

FZG Forschungsstelle für Zahnräder und Getriebebau, TU München

GfT Gesellschaft für Tribologie

GL Gear Lubricant

HD Heavy Duty

HYP Hypoidöl

SAE Society of Automotive Engineers

VDMA Verband Deutscher Maschinen- und Anlagenbau e.V.

VG Viskositätsgrad (Viskosität bei 40°C in mm²/s)

VI Viskositätsindex

10. Literaturangaben, mitgeltende DIN-Normen

DIN 51502 Kurzbezeichnung der Schmierstoffe

DIN 51512 SAE-Viskositätsklassen für Kraftfahrzeuggetriebe

DIN 51517 T3 Schmieröle CLP „Mindestanforderungen“

DIN 51354 T2 FZG-Zahnrad-Verspannungs-Prüfmaschine „Prüfverfahren“

FVA-Nr.54/I-IV Graufleckentragfähigkeit

008 911 57 BOMAG 703

 19.4 Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Wheel drive gear up to S/N
Mobile
Hydraulics

BRM-GT / Werknorm
Schmierölempfehlung RNM 17421-005
Viskositätsklasse ISO VG 220 bei 40°C mm² / s (cST) DIN 51519 2004-10-01

Sachgebiet 17: Schmierstoffempfehlungen Ersatz für

LSN 935 1410-7: 2003-05-02

Änderungen

x Redaktionelle Überarbeitung und Umwandlung der LSN-Nummern in RNM-Nummern

(Rexroth Norm Mobile Hydraulics)

1. Zweck

Diese Norm legt empfohlene Schmieröle für den Einsatz in Bosch Rexroth–Getrieben für mobile und industrielle
Anwendungen fest.
Für Schmieröle in Windkraftanlagen gelten Sonderempfehlungen!

2. Anwendungsbereich

Diese Norm ist für den Produktbereich BRM-GT gültig.

3. Zuständigkeit
© Bosch Rexroth AG 2004

Für die Pflege dieser Norm ist BRM-GT/NOR zuständig.

4. Schmieröle

Ölfirma Ölsorte Kennz. n. Pourp. 1) GFT 2) Gruppenbezeichn. 3)

DIN 51502 in °C LS1 LS3
ADDINOL ECO GEAR 220 M CLP -15 hoch x
ECO GEAR 220 S CLP HC -45 hoch x x
Agip BLASIA 220 CLP -20 x
ARAL Degol BG 220 Plus CLP -15 hoch x
Degol PAS 220 CLP HC -42 hoch x x
Degol ESG 220 CLP HC -45 hoch x
BECHEM ECOGEAR 220 M CLP -15 hoch x
ECOGEAR 220 S CLP HC -45 hoch x x
BP Energol GR-XF 220 CLP -21 hoch x
Enersyn HTX 220 CLP HC -40 x x
Castrol Alpha SP 220 CLP -21 hoch x
Alphasyn T 220 CLP HC -45 x
Tribol 1100/220 CLP -24 hoch
Tribol 1510/220 CLP HC -42 hoch x
OPTIGEAR BM 220 CLP -15 hoch
OPTIGEAR SYNTHETIC A 220 CLP HC -36 hoch x x
RNM-17421_005_NOR_N_DE_2004-10-01.doc

ESSO SPARTAN EP 220 CLP -24

FUCHS RENOLIN CLP 220 PLUS CLP -24 hoch x
RENOLIN UNISYN CLP 220 CLP HC -54 hoch x x
KLÜBER Klüberoil GEM 1 – 220 N CLP -10 hoch
Kuwait Q8 Goya NT 220 CLP -12 hoch
Q8 El Greco 220 CLP HC -24 hoch x

Bosch Rexroth AG erstellt: BRM-GT/NOR, Moormann

Mannesmannstraße 29 • D-58455 Witten geprüft:
Tel. +49 2302 877-167 • Fax +49 2302 877 478 freigegeben:
Seite 1 / 2
704 BOMAG 008 911 57
 Wheel drive gear up to S/N 19.4
Seite 2 / 2
Schmierölempfehlung, ISO VG 220 RNM 17421-005 : 2004-10-01

Mobil Mobilgear XMP 220 CLP -24 hoch x

Mobilgear SHC XMP 220 CLP HC -45 hoch x x
MOTOREX GEAR COMPOUND 220 PLUS CLP -21 hoch
GEAR SINTEC CLP 220 CLP HC -51 hoch x
Shell Omala Oil F 220 CLP -18 hoch x
Omala Oil HD 220 CLP HC -48 hoch x x
TOTAL CARTER EP 220 CLP -12
CARTER SH 220 CLP HC -39 hoch x

1) Der Pourpoint ist nicht gleichzusetzen mit der niedrigsten Temperatur des Einsatzbereiches!
2) Graufleckentragfähigkeit GFT gem. FVA Nr. 54 / I – IV
3) Fehlt auf dem Typenschild und / oder in der Betriebsanleitung die Angabe einer bestimmten Gruppenbezeichnung, so
kann jedes der hier aufgeführten Öle eingesetzt werden.

LS1: Verschärfter FZG-Test:

Diese Öle haben auch im verschärften FZG-Test A/16,6/90 die Schadenskraftstufe • 12

LS3: Vollsynthetische Öle ( Polyalphaolefine POA )

Diese Öle sind mit Mineralölen mischbar.
PAO-Öle neigen bei einer Vermischung mit Resten von Konservierungsöl zur Schaumbildung!
Es sollte ein Spüllauf mit geeignetem Spülöl durchgeführt oder ein Mineralöl als Einlauföl verwendet werden.
ƎSchutzvermerk DIN 34 beachtenƎ - ƎCopyright reservedƎ

5. Hinweise

Die aufgelisteten Informationen sind Auszüge aus den aktuellen Produktdatenblätter zum
Zeitpunkt der Erstellung dieser Werknorm.

Bestandteil dieser Schmierölempfehlung ist die allg. Übersicht RNM 17420-000

Ölwechsel nach Betriebsanleitung !

Bosch Rexroth übernimmt für die empfohlenen Öle keine Gewähleistung!

Die Produktverantwortung für die aufgelisteten Öle liegt ausschließlich beim Ölhersteller.

Vor Einsatz einer bestimmten Ölsorte sind die technischen Produktdatenblätter und
die entsprechenden Sicherheitsdatenblätter zu beachten.

008 911 57 BOMAG 705

 19.4 Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Wheel drive gear up to S/N
Mobile
Hydraulics

BRM-GT / Company standard

Recommendation on Lube Oils RNM 17420-000
Overview 2004-10-01

Subject group 17: Lubricant Recommendations Replacement for

LSN 935 1400-EN: 2003-05-02

Modifications

Ɣ Editorial revision and transformation of the LSN numbers in RNM numbers

(Rexroth standard mobile Hydraulics)

1. Purpose

This standard specifies recommended lubricating oils to be applied in Bosch Rexroth-Gears for mobile and
industrially applications.
For wind turbine application please refer to specific lube oil recommendations.

2. Application

The standard is valid for the product unit BRM-GT.

(Bosch Rexroth, Mobile Hydraulics, Product Unit of Gear Technology)

3. Responsibility
© Bosch Rexroth AG 2004

Responsible for this standards is BRM-GT/NOR

4. General

The oils listed in RNM 17421 and RNM 17422 are a selection of lube oils recommended by BRM-GT for use
in cylindrical, bevel and planetary gearboxes. CLP industrial gear oils and motorcar transmission oils meet
the requirements specified by BRM-GT as mandatory. These recommendations are based on applicable
product information and many years of experience in this field.

The lube oil brands (mineral oil, synthetic oil or motorcar transmission oil) are primarily selected by the
Operator. In this context, logistics play an important role. The recommendations are not meant to provide
quality standards for the individual lube oils.

All oils listed are compatible with one-pot paint material (not nitrocellulose lacquer) BRM-GT uses for inside
paint coatings as well as the standard elastomers of NBR and FPM (depending on application temperature).
As regards mineral-oil based gearbox lube oils an oil bath temperature of +85°C should not be exceeded.
For short operating periods peak temperatures of +100°C are admissible, but it should be noted that these
may considerably reduce the useful life of the lubricant. Continuously prevailing higher temperatures will
reduce the operating viscosity significantly and lead to premature ageing of the lubricant. If an admissible
temperature limit is exceeded the oil molecules chemically decompose and cause smell, deposits and
residues in the system. If higher temperatures are to be expected or higher continuous temperatures are
RNM-17420_000_NOR_N_EN_2004-10-01.doc

experienced in operating practice, synthetic oils based on polyalphaolefins (PAO) are to be used that feature
a considerably flatter temperature-viscosity characteristic curve.

Bosch Rexroth AG prepared: BRM-GT/NOR, Moormann

Mannesmannstraße 29 • D-58455 Witten checked:
Tel. +49 2302 877-167 • Fax +49 2302 877 478 released:
Page 1 / 5
706 BOMAG 008 911 57
Wheel drive gear up to S/N 19.4
Page 2 / 5
Recommendation on Lube Oils ,Overview RNM 17420-000 : 2004-10-01

A mandatory requirement specified on the nameplate and/or in the operating

Attention! manual are the viscosity indication and the special notes.

If the viscosity requirements are not met or a gearbox lube oil other than listed
is used the responsibility for technical suitability of the lubricant lies solely
with the Operator. The use of lubricants not meeting the quality standards
described below may result in BRM-GT‘ warranty obligations becoming
forfeited. It is expressly pointed out that any lubricant manufacturer or
supplier is responsible for the quality of its product, eg with respect to
impurities or differences between individual batches.

Note: BRM-GT‘ gearteeth calculation according to DIN 3990 (including micro-pitting

determination to FVA No. 54) shows the required breakdown-load stage (SKS) for the
oil. If a breakdown-load stage SKS of > 9 is determined here, a note must be included
in the operating manual saying that the lubricant selection is restricted to brands
featuring a „high“ micro-pitting (frosting) load carrying property.

Note: The maximum and minimum application temperatures of individual gear oils may
deviate significantly with regard to the technical parameters of „flashpoint and pour
point“. Relevant data and properties of the gear oils must always be taken from the
technical data sheets issued by the oil producers.

As pointed out by the lubricant producers, the products listed are available under the same tradename on a
worldwide basis and have comparable technological characteristics.

4.1 Synthetic oils on polyalphaolefin basis - PAO

Synthetic oils have a higher viscosity index (VI) than mineral oils and are thus able to reduce the influence of
temperature on viscosity. Although the polyalphaolefin-based synthetic oils listed (Column LS 3) can be
mixed with mineral oil at any desired ratio, care should nevertheless be taken to limit the amount of residual
mineral oil in the gearbox casing to 5 to 10% to avoid clouding and additive precipitation.

4.2 Synthetic oils on polyglycols basis - PG (presently not permissible for BR gearboxes)

Note: In view of the fact that synthetic oils on polyglycol basis may be incompatible with the
paint coat, standard seals and oil sightglass materials employed, these lubricants
must not be used without prior consent obtained from the gearbox maker!

Attention! Mixing polyglycols with mineral oils is strictly prohibited!

4.3 Quickly biodegradable oils on synthetic-ester basis - HEES

Under certain conditions, quickly biodegradable lubricant oils (synthetic ester – HEES) not listed here may
also be employed. Results of various research projects, for example FKM No. 051950, VDMA Data Sheet
24 569 as well as applicable experience gained by seal manufacturers and oil companies indicate that
quickly biodegradable oils may be incompatible with certain seal and gasketing materials and paint materials
or may reduce the friction characteristics of multiple plates. If such oils are to be used, special materials
(not BRM-GT standard materials) may be needed that have to be tested to ensure they are compatible with
the oil.

Note: Before using quickly biodegradable oil (first filling or brand change) consult with the
gearbox manufacturer!

008 911 57 BOMAG 707

19.4 Wheel drive gear up to S/N
Page 3 / 5
Recommendation on Lube Oils ,Overview RNM 17420-000 : 2004-10-01

5. RNM 17421 „Lube Oil Recommendation CLP ISO VG 46 – 680“

The mineral oils listed in this company standard specification meet the minimum requirements given in
DIN 51517 T.3 for CLP oils. They contain constituents that improve corrosion protection and ageing
resistance as well as reduce wear in the mixed friction range (extreme pressure additives). When subjected
to normal FZG testing A/8,3/90 to DIN 51354 T.2 a breakdown-load stage of min. 12 is achieved. When
subjected to a FZG micro-pitting test as per FVA No. 54/I-IV these oils reach the micro-pitting (frosting)
load-carrying property category „high“ (SKS 10) or at least „medium“ (SKS 9).

Other oil brands meeting or exceeding CLP requirements are included such as hydraulic oils HLP or
synthetic oils HC.

The specification RNM 17421 describes ISO viscosity categories. Low-viscosity oils are almost exclusively
needed for use with multiplate brakes. They have been tested by the multiple-plate manufacturer for
compatibility and friction behavior.

Not all of the lubricants listed in this standard are suited for any conceivable application. For that reason,
LS Groups LS 1, LS 3 were established.

Note: The Design Department hast to specify the required LS Group! This group will be indicated
in the operating manual and/or on the nameplate. When selecting an oil brand care must be
taken to ensure that all the requirements of a given LS Group are met. In the event an oil
meets requirements of additional LS Groups this lubricant can be used as well.

LS 1: Aggrevated FZG test:

Even when FZG tested under aggravated conditions (test A / 16,6 / 90 – double peripheral speed) these oils
have reached the properties of breakdown-load stage 12.

Identification for a lube oil passed aggravated FZG testing of viscosity ISO VG 100 CLP 100 LS1

LS 3: Fully synthetic oils (polyalphaolefins PAO)

When replacing mineral oil by polyalphaolefin-based oil 5 to 10% of the mineral oil are allowed to remain in
the casing after draining. Mixing both lube oil types is perfectly allowable if this mixing ratio is observed.

Note: However, PAO oils tend to foaming when mixed with residues of preservation oil as
used by L+S. Therefore, prior to initial filling of a preserved gearbox the unit must
either be flushed out or a mineral oil is to be used as running-in oil.

Identification for a synthetic lube oil of viscosity ISO VG 100 CLP 100 LS 3

6. RNM 17422 „Recommendation for Motorcar Transmission Oil HYP SAE”

This company standard specification lists unigrade and multigrade lube oils for motorcar transmission units
to DIN 51512 and assigns them to API classification GL 4 and/or GL 5. The selection of these lube oils is
based, inter alia, on a defined ‚actual‘ viscosity (ISO viscosity) because the SAE viscosity parameter
commonly applied to motorcar transmission units may appear in several ISO viscosity categories (see
following diagram). It is to be noted that micro-pitting (frosting) test results are not yet available for these oils
so that they must exclusively be used for mobile gears.

Note: When selecting a HYP lubricant brand the viscosity specification on the nameplate
and/or in the operating manual is to be compared and adapted to the lubricant
specification included in the operating manual.

Identification for a motorcar transmission oil of viscosity SAE 80W-90 HYP SAE 80W-90

708 BOMAG 008 911 57

 Wheel drive gear up to S/N 19.4
Page 4 / 5
Recommendation on Lube Oils ,Overview RNM 17420-000 : 2004-10-01

7. Viscosity Classification Comparison of Various Lubricants

ƎSchutzvermerk DIN 34 beachtenƎ - ƎCopyright reservedƎ

8. Oil Change / Topping up Oil

The life and operational safety of a gear unit is greatly dependent on the purity of the oil employed for
lubrication. For the first oil change after commissioning of the gearbox as well as further oil changes the
instructions given in the relevant operating manuals are to be followed. The oil volume remaining in the
gearbox should be kept to a minimum.

Note: When topping up oil or if oils are to be mixed the quality and viscosity requirements
have to be carefully observed. Mixing lubricants of different makers may bring down
the quality standard even if the viscosity properties coincide. In such a case the
lubricant supplier should be consulted in advance to check if there are compatibility
problems.

The lubricants listed must never be mixed with other substances.

Attention! Flushing/purging media or petroleum or other agents used for cleaning the
gearbox have to be thoroughly removed without residues left. The unit must
again be flushed out before it is commissioned.

008 911 57 BOMAG 709

19.4 Wheel drive gear up to S/N
Page 5 / 5
Recommendation on Lube Oils ,Overview RNM 17420-000 : 2004-10-01

9. Abbreviations and Symbols Used

AGMA American Gear Manufacturers Association

API American Petroleum Institute

DIN Deutsches Institut für Normung

EP Extreme pressure

FKM Forschungskuratorium Maschinenbau e.V.

FVA Forschungsvereinigung Antriebstechnik

FZG Forschungsstelle für Zahnräder und Getriebebau, TU München

GfT Gesellschaft für Tribologie

GL Gear lubricant

HD Heavy duty

HYP Hypoid oil

SAE Society of Automotive Engineers

VDMA Verband Deutscher Maschinen- und Anlagenbau e.V.

VG Degree of viscosity (viscosity at 40°C in mm²/s)

VI Viscosity index

10. References, Co-applicable DIN Standards

DIN 51502 Abbreviation used for the lubricants

DIN 51512 SAE- viscosity categories for motorcar transmission lube oils

DIN 51517 T3 Lube oils „minimum requirements“

DIN 51354 T2 FZG- gear test rig „method“

FVA-Nr.54/I-IV Micro-pitting (frosting) load-carrying property category

710 BOMAG 008 911 57

 Wheel
Industrial drive
Hydraulics
gear
Electric Drives up to
and Controls
S/N
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics
19.4

BRM-GT / Company standard

Recommendation of Lube Oils RNM 17421-005
Viscosity Class ISO VG 220 at 40°C mm² / s (cSt) DIN 51519 2004-10-01

Subject group 17: Lubricant Recommendations Replacement for

LSN 935 1410-7-EN: 2003-05-02

Modifications

Ɣ Editorial revision and transformation of the LSN numbers in RNM numbers

(Rexroth standard mobile Hydraulics)

1. Purpose

This standard specifies recommended lubricating oils to be applied in Bosch Rexroth-Gears for mobile and
industrially applications.
For wind turbine application please refer to specific lube oil recommendations.

2. Application

The standard is valid for the product unit BRM-GT.

(Bosch Rexroth, Mobile Hydraulics, Product Unit of Gear Technology)

3. Responsibility
© Bosch Rexroth AG 2004

Responsible for this standards is BRM-GT/NOR

4. Lube Oils

Supplier Oil Brand Identific. Pourp. 1) GFT 2) Group designation

DIN 51502 in °C LS1 LS3
ADDINOL ECO GEAR 220 M CLP -15 high x
ECO GEAR 220 S CLP HC -45 high x x
Agip BLASIA 220 CLP -20 x
ARAL Degol BG 220 Plus CLP -15 high x
Degol PAS 220 CLP HC -42 high x x
Degol ESG 220 CLP HC -45 high x
BECHEM ECOGEAR 220 M CLP -15 high x
ECOGEAR 220 S CLP HC -45 high x x
BP Energol GR-XF 220 CLP -21 high x
Enersyn HTX 220 CLP HC -40 x x
Castrol Alpha SP 220 CLP -21 high x
Alphasyn T 220 CLP HC -45 x
Tribol 1100/220 CLP -24 high
Tribol 1510/220 CLP HC -42 high x
OPTIGEAR BM 220 CLP -15 high
RNM-17421_005_NOR_N_EN_2004-10-01.doc

OPTIGEAR SYNTHETIC A 220 CLP HC -36 high x x

ESSO SPARTAN EP 220 CLP -24
FUCHS RENOLIN CLP 220 PLUS CLP -24 high x
RENOLIN UNISYN CLP 220 CLP HC -54 high x x
KLÜBER Klüberoil GEM 1 – 220 N CLP -10 high
Kuwait Q8 Goya NT 220 CLP -12 high
Q8 El Greco 220 CLP HC -24 high x

Bosch Rexroth AG prepared: BRM-GT/NOR, Moormann

Mannesmannstraße 29 • D-58455 Witten checked:
Tel. +49 2302 877-167 • Fax +49 2302 877 478 released:
Page 1 / 2
008 911 57 BOMAG 711
 19.4 Wheel drive gear up to S/N
Page 2 / 2
Recommendation of Lube Oils, ISO VG 220 RNM 17421-005 : 2004-10-01

Mobil Mobilgear XMP 220 CLP -24 hoch x

Mobilgear SHC XMP 220 CLP HC -45 hoch x x
MOTOREX GEAR COMPOUND 220 PLUS CLP -21 hoch
GEAR SINTEC CLP 220 CLP HC -51 hoch x
Shell Omala Oil F 220 CLP -18 hoch x
Omala Oil HD 220 CLP HC -48 hoch x x
TOTAL CARTER EP 220 CLP -12
CARTER SH 220 CLP HC -39 hoch x

1) The pour point is not to be confused with the lowest application range temperature!
2) Micro-pitting (frosting) load-carrying property GFT as per FVA-Nr. 54 / I – IV.
3) If a gearbox lube oil specified for use lacks an indication of a certain L+S group, any of the lube oils listed here can be
used.

LS1: Aggravated FZG test:

Even when FZG tested (A/16,6/90) under aggravated conditions these oils reach the properties of
breakdown-load stage • 12.

LS3: Fully synthetic oils (polyalphaolefins PAO)

These oils can be mixed with mineral oils.
PAO oils tend to foaming when mixed with residues of preservation oil!
The unit must either be flushed out using a suitable purge oil or a mineral oil must be used as running-in oil.
?Schutzvermerk DIN 34 beachten? - ?Copyright

5. Note

The listed information are excerpts from current product data sheets at the time this company standard
was drawn up.

The generall overview RNM 17420-000 is part of this recommendation on lube oils.

Change of oil as prescribed in the service manual!

Bosch Rexroth does not accept any warranty for the recommended oils!
The product responsibility for the listed oils is exclusively with the oil manufacturer.

Before using a certain type of oil the technical product data sheets and the respective safety data sheets
are to be considered.

712 BOMAG 008 911 57

 Wheel
Industrial drive
Hydraulics
gear
Electric Drives up to
and Controls
S/N
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics
19.4

BRM-GT / Company standard Appendix 1

Recommendation of Lube Oils RNM 17421-005
Viscosity Class ISO VG 220 bei 40°C mm² / s (cST) DIN 51519 2004-10-01

Subject group 17: Recommendation of lubricant Replacement for

-----

Besides the oils in our lubricant recommendations RNM 17421 and RNM 17422 we can release the following oils.
Only lubrication oils with viscosity 220 are released for our mobile gearboxes.
These types of oil are preferably available over the indicated suppliers on the North American market.

Supplier Oil Brand Pourpoint °C

American Agip Blasia 220 - 20

Industrial Gear Lubricant 5 EP - 15

JAX-Behnke Lubricants HP INDUSTRIAL GEAR OIL 220 -14

SYNAX-EP INDUSTRIAL GEAR OIL 220 - 38

BENZ OIL, Inc. GEAROL 220 -7

SYN-TECH PAO 220 - 40
© Bosch Rexroth AG 2004

BEL-RAY SYNTHETIC GEAR OIL 6690 -40

Etna Products, Inc. ECOGEAR 220 M - 15

ECOGEAR 220 S - 45
BERUGEAR GS 220 BM - 24

Lubrication Engineers, Inc. ALMASOL 5 EP - 24

Petro-Canada Lubricants ULTIMA EP 220 - 27

ULTIMA SYNTHETIC EP 220 - 45

Imperial Oil Mobilgear SHC 220 - 37

Spartan EP 220 - 15

BP Lubricants Energol PM 220 -6

Energol GR-XP 220 -9

Texas Refinery Corp. INDUSTRIAL GEAR LUB 5 EP -9

Chevron Texaco TEXACO PINNACLE EP 220 - 51

TEXACO MEROPA 220 - 21
RNM-17421_005_ANH_N_EN_2004-10-01.doc

Chevron Gear Compound EP 220 - 21

Chevron Tegra Synthetic Gear Lub 220 - 51
Chevron Ultra Gear Lub 220 - 18

Bosch Rexroth AG prepared: BRM-GT/NOR, Moormann

Mannesmannstraße 29 • D-58455 Witten checked:
Tel. +49 2302 877-167 • Fax +49 2302 877 478 released:
Page 1 / 1
008 911 57 BOMAG 713
19.4 Wheel drive gear up to S/N

714 BOMAG 008 911 57

 19.5 Wheel drive gear from S/N

008 911 57 BOMAG 715

19.5 Wheel drive gear from S/N

716 BOMAG 008 911 57

Wheel drive gear from S/N
Electric Drives Linear Motion and
19.5
and Controls Hydraulics Assembly Technologies Pneumatics Service

Demontage- Montageanleitung
Disassembly- Assembly Instructions RDE 77978-01-R/01.08
05.02.2008
Planetengetriebe / Planetary Gearbox
HYDROTRAC

GFT 220 R3 9184

008 911 57 BOMAG 717

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 2/43

Inhaltsverzeichnis • Table of Contents

1. Einleitung 1. Preliminary Notes

1.1 Allgemeines 1.1 Generally
1.2 Anziehdrehmomente 1.2 Tightening Torques
1.3 Schmieröl; Gewicht 1.3 Lube Oil; Weight

2. Zeichnungen 2. Drawings
Einbauzeichnung Getriebe Installation Drawing
Ersatzteilzeichnung Getriebe Spare Parts Drawing
Explosionszeichnung Getriebe Exploded View of Gearbox

3. Teilelisten 3. Parts Lists

Teileliste Getriebe Parts List Gearbox

4. Demontage 4. Disassembly
4.1 Demontage Allgemein 4.1 Disassembly General
4.2 Demontage Bremse 4.2 Disassembly Brake
4.3 Demontage Abtrieb 4.2 Disassembly Output
4.3.1 Demontage Planetenstufen 4.2 Disassembly Planet Stage
4.3.2 Demontage Planetenstege 4.2 Disassembly Planet Carrier
4.3.3 Demontage Wellenmutter 4.2 Disassembly Shaft Nut
4.3.4 Demontage Abtriebslagerung 4.2 Disassembly Output Bearings

5. Montage 5. Assembly
5.1 Montage Allgemein 5.1 Assembly General
5.2 Montage Abtrieb 5.2 Assembly Output
5.2.1 Montage Abtriebslagerung 5.2.1 Assembly Output Bearings
5.2.2 Montage Wellenmutter 5.2.2 Assembly Shaft Nut
5.2.3 Montage Planetenräder / Planetenstege 5.2.3 Assembly Planet Carrier / Planet Wheels
5.2.4 Montage Planetenstufen 5.2.4 Assembly Planet Stage
5.2.5 Montage Deckel 5.2.5 Assembly Cover
5.3 Montage Bremse 5.3 Assembly Brake

6. Probelauf 6. Test Run

6.1 Prüfstandsaufbau 6.1 Test set-up
6.2 Ölversorgung 6.2 Lubrication
6.3 Drehzahl, Laufzeit und Prüflast 6.3 Speed, Running Time, Test Load
6.4 Thermische Werte 6.4 Thermal Parameters
6.5 Laufgeräusch 6.5 Running Noise
6.6 Dichtigkeitsprüfung 6.6 Leakage Testing
6.7 Funktionsprüfung der Bremsen 6.7 Functional Test of Hydraulic Brakes
6.8 Fremdkörper 6.8 Oil Contamination Test

Verkauf Ersatzteile / Sales Spare Parts Kundendienst / Service

Bosch Rexroth AG Bosch Rexroth AG

PO Box 18 60 PO Box 18 60
D - 58408 Witten D - 58408 Witten
Tel. (02302) 877-170 Tel. (02302) 877-183
Telefax (02302) 887-300 Telefax (02302) 877-409
Hotline +49 173-2569948

718 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184
1. Einleitung • 1. Preliminary Notes
1.1 Einführung
Mit diesem Symbol sind Gefahren für das
Produkt und die Gesamtanlage gekenn-
zeichnet.
Dieses Symbol kennzeichnet Hinweise.
Zur Demontage; Montage des Getriebes
werden die Ersatzteilzeichnung und die
Teileliste der entsprechenden Getriebe-
ausführung benötigt.
Beachten Sie unbedingt die Sicherheitsbe-
stimmungen und die einschlägigen Unfallver-
hütungsvorschriften!
Bauen Sie nur Originalersatzteile ein.
Lassen Sie das Öl ab.
Verwenden Sie dabei geeignete Auffanggefäße.
Achten Sie darauf, dass kein Schmutz oder Fremdkörper
in das Getriebe gelangt.
Beschädigte Teile, sowie Dichtringe, durch neue Bosch
Rexroth Teile ersetzen.
Vor dem Einbau sind alle beweglichen Teile sowie Dicht-
ringe einzuölen.
Unter Umständen ist der Farbanstrich des Getriebes
durch das Zerlegen und Zusammenbauen beschädigt.
Erneuern Sie deshalb den Farbanstrich, um das Getrie-
be gegen Korrosion zu schützen.
Führen Sie einen Probelauf des Getriebes durch.
¤Alle Rechte bei Bosch Rexroth AG, auch für den Fall von
Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie
Kopier- und Weitergaberecht, bei uns.
Die angegebenen Daten dienen allein der Produktbe-
schreibung. Eine Aussage über eine bestimmte Beschaf-
fenheit oder eine Eignung für einen bestimmten Einsatz-
zweck kann aus unseren Angaben nicht abgeleitet werden.
Die Angaben entbinden den Verwender nicht von eigenen
Beurteilungen und Prüfungen. Es ist zu beachten, dass
unsere Produkte einem natürlichen Verschleiß- und Alte-
rungsprozess unterliegen.
Hinweis!
Die verwendeten Bilder müssen nicht der beschriebenen
Getriebetype entsprechen.
008 911 57 BOMAG
Bosch Rexroth AG 19.53/43
1.1 Introduction
This symbol signifies danger to the prod-
uct and the overall plant.
This symbol calls attention to notes.
For disassembly; assembly procedure of
the gearbox, spare parts drawing and
parts list of the respective gearbox-type is
required.
The safety instructions and the appropriate accident
prevention instructions have absolutely to be ob-
served!
Exclusively install original spares.
Drain the oil from the gearbox.
For this purpose use suitable containers.
Make sure that no dirt or foreign bodies are allowed to
enter the gear box.
Replace damaged parts and all seals by new Bosch
Rexroth parts.
Oil all moving parts and seals prior to assembly.
In the event the paint coat of the gear-box has been
damaged as a result of disassembly / assembly work
touch up or renew the paint coat as necessary to protect
the gear against corrosion.
Carry out a test run of the gearbox.
¤This document, as well as the data, specifications and
other information set forth in it, is the exclusive property
of Bosch Rexroth AG. It may not be reproduced or given
to third parties without its consent.
The data specified above only serve to describe the
product. No statements concerning a certain condition or
suitability for a certain application can be derived from
our information. The information given does not release
the user from the obligation of own judgment and verifi-
cation. It must be remembered that our products are
subject to a natural process of wear and aging.
Note!
The photos may show other drive types than the de-
scribed one.
719
19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 4/43

1. Einleitung • 1. Preliminary Notes

1.2 Anziehdrehmomente 1.2 Tightening Torques

Standard-Anziehdrehmomente MA in Nm für ungeschmierte Schaftschrauben (μ = 0,13 bis 0,17) mit Regelgewinde ohne zusätz-
liche Einzelangaben (s. LSN 945 0201)
Standard-tightening torque MA in Nm for unlubricated shoulder stud (μ = 0,13 bis 0,17) with standard thread without additional details
(LSN 945 0201)
Schraube M6 M8 M 10 M 12 M 14 M 16 M 20 M 24 M 27 M 30 M 33 M 36 M 39 M 42
screw

8.8 Dr. 8,5 21,1 42,2 73,6 114,8 176,6 358 618 903 1216 1687 2129 2757 3394

10.9 Dr. 12,4 30,4 60,8 104,0 166,8 255,1 510 873 1285 1736 2364 3021 3924 4836

Dr. = Drehmomentschlüssel (torque wrench)

1.3 Schmieröl; Gewicht 1.3 Lube Oil; Weight

Gewicht ca. 850 kg Weight approx. 1874 lbs

Getriebeölmenge ca. 14 Liter Gear lube oil volume approx. 3,7 gall

Schmieröl CLP 220 oder Lube oil CLP 220 or

SAE 85 W-90 API GL-4 SAE 85 W-90 API GL-4

720 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 Bosch Rexroth AG 19.55/43
2. Zeichnungen • 2. Drawings

Zeichnungen Drawings
Einbauzeichnung Installation Drawing
0/6137/5184/0 0/6137/5184/0
Ersatzteilzeichnung Spare Parts Drawing
0/6137/1184/2 0/6137/1184/2

Explosionszeichnung Exploded View

102
101

008 911 57 BOMAG 721

19.5 Wheel drive gear from S/N

722 BOMAG 008 911 57

Wheel drive gear from S/N 19.5

008 911 57 BOMAG 723

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 6/43

3. Teileliste • 3. Parts List

Teileliste Partslist
Teileliste Parts List
16633700 16633700

724 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 19.57/43
Bosch Rexroth AG

3. Teileliste • 3. Parts List

15.01.2008 Teileliste / Parts List

Matnr./Material No : 16633700
Auftrag/Order :
Produkt/Product : GFT 220 R3 9184 i=145,4 KDN-K
Zeichnungs-Nr./Drawing No : 0 6137/1184 1

Menge Pos. Benennung Bestell-Nr.

Quantity Item Designation Part-No

1,000 001 Hohlrad GFT 220

Ring gear

1,000 003 Stuetzring GFT 220 R3 9096

Supporting ring

1,000 005 Sonnenradwelle z=24 GFT 220 R3 9096

Sun gear shaft

1,000 006 Sonnenrad GFT 220

Sun gear
9098016/3

1,000 007 Planetensteg GFT 220 W3

Planet carrier

1,000 008 Planetensteg GFT 220

Planet carrier

3,000 010 Planetenrad GFT 220 W3

Planet gear

5,000 011 Planetenrad GFT 220

Planet gear

1,000 014 Wellenmutter M 280x3 GFT 220 R3

Shaft nut

2,000 015 Zylinderstift 8 m6x18 B

Cylindrical dowel pin
ISO 8734

1,000 017 Zylinderrolle GFT330

Cylindrical roller

1,000 018 Hohlraddeckel GFT 220 R3 9096

Ring gear cover

10,000 020 Zylinderrollenlager RSL 183018

Cylindrical roller bearing
DIN 5412

6,000 021 Zylinderrollenlager RSL 182211

Cylindrical roller bearing
DIN 5412

2,000 022 Kegelrollenlager 32956 J

Tapered roller bearing
DIN 720

008 911 57 BOMAG 725

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 8/43

3. Teileliste • 3. Parts List

15.01.2008 Teileliste / Parts List

Matnr./Material No : 16633700
Auftrag/Order :
Produkt/Product : GFT 220 R3 9184 i=145,4 KDN-K
Zeichnungs-Nr./Drawing No : 0 6137/1184 1

Menge Pos. Benennung Bestell-Nr.

Quantity Item Designation Part-No

1,000 023 Zwischenring GFV 177X

Spacer ring

1,000 026 Sicherungsring 100x3

Snap ring
DIN 471

10,000 027 Anlaufscheibe F 91544

Locating ring

6,000 028 Anlaufscheibe F 91915

Locating ring

1,000 029 Sicherungsring 160x4

Snap ring
DIN 471

3,000 030 Sicherungsring 88x3

Snap ring
DIN 472

5,000 031 Sicherungsring 130x4

Snap ring
DIN 472

3,000 032 Sicherungsring 55x2

Snap ring
DIN 471

5,000 033 Sicherungsring 90x3

Snap ring
DIN 471

1,610 034 Rundschnur 5 mm

Chord

1,000 035 Gleitringdichtung 366x394x38 B

Face seal

1,000 036 Sprengring SW 220

Snap ring

24,000 038 6kt-Schraube M 12x40

Hex head bolt
DIN 933

1,000 039 Verschlussschraube M 18x1,5 m. Mag.

Screw plug

726 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 19.59/43
Bosch Rexroth AG

3. Teileliste • 3. Parts List

15.01.2008 Teileliste / Parts List

Matnr./Material No : 16633700
Auftrag/Order :
Produkt/Product : GFT 220 R3 9184 i=145,4 KDN-K
Zeichnungs-Nr./Drawing No : 0 6137/1184 1

Menge Pos. Benennung Bestell-Nr.

Quantity Item Designation Part-No

36,000 041 Zylinderschraube M 27x2x70

Socket head cap screw
DIN 912

2,000 042 Verschlussschraube M 30x1,5

Screw plug
DIN 908

2,000 043 Dichtring A 30x36x2

Seal ring
DIN 7603

1,000 044 Dichtring A 18x22x1,5

Seal ring
DIN 7603

1,000 045 O-Ring 530x4

O-ring
DIN 3771

1,000 050 Tragachse GFT 220 R3 9184

Spindle

1,000 051 Mitnehmer GFT 220 R3 9184

Coupler

1,000 052 Scheibe GFT 220 R3 9184

Disk

1,000 053 Scheibe GFT 9 W2 9022

Disk

1,000 054 Mitnehmer GFT 220 R3 9184

Coupler

1,000 055 Kolben GFT 220 R3 9184

Piston

9,000 056 Innenlamelle 3070-740-23-004

Inner disk

10,000 057 Aussenlamelle 3070-636-33-001

Outer disk

18,000 058 Druckfeder 1,6x6,5x54

Pressure spring
DIN 2098

008 911 57 BOMAG 727

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 10/43

3. Teileliste • 3. Parts List

15.01.2008 Teileliste / Parts List

Matnr./Material No : 16633700
Auftrag/Order :
Produkt/Product : GFT 220 R3 9184 i=145,4 KDN-K
Zeichnungs-Nr./Drawing No : 0 6137/1184 1

Menge Pos. Benennung Bestell-Nr.

Quantity Item Designation Part-No

18,000 059 Druckfeder 2,5x11,5x54

Pressure spring
DIN 2098

1,000 060 Quadring 4364 446 A

Piston seal

2,000 061 Stuetzring 168,5x178x1,4 P

Supporting ring

1,000 062 Quadring 4368 446 A

Piston seal

2,000 063 Stuetzring 192,6x202x1,4 P

Supporting ring

1,000 067 Sicherungsring 195x4

Snap ring
DIN 472

1,000 069 Rillenkugellager 6011 J

Ball bearing
DIN 625

1,000 070 Sicherungsring 145x4

Snap ring
DIN 471

1,000 071 Stopfen GPN 700 M 18x1,5

Plug

1,000 075 Verschlussschraube M 18x1,5

Screw plug
DIN 908

1,000 076 Dichtring A 18x22x1,5

Seal ring
DIN 7603

1,000 087 Sonnenradwelle GFT 220 R3 9096

Sun gear shaft

1,000 089 Planetensteg GFT 220 R3 9096

Planet carrier

3,000 090 Planetenrad GFT 220 R3 9096

Planet gear

728 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 19.511/43
Bosch Rexroth AG

3. Teileliste • 3. Parts List

15.01.2008 Teileliste / Parts List

Matnr./Material No : 16633700
Auftrag/Order :
Produkt/Product : GFT 220 R3 9184 i=145,4 KDN-K
Zeichnungs-Nr./Drawing No : 0 6137/1184 1

Menge Pos. Benennung Bestell-Nr.

Quantity Item Designation Part-No

3,000 091 Zylinderrollenlager RSL 182211

Cylindrical roller bearing
DIN 5412

6,000 094 Anlaufscheibe F 91915

Locating ring

3,000 095 Sicherungsring 55x2

Snap ring
DIN 471

6,000 096 Sicherungsring 88x3

Snap ring
DIN 472

1,000 097 Wellenscheibe * GFT220

Thrust washer

1,000 098 Zwischenring GFT 220 R3 9096

Spacer ring

1,000 099 Verschlussstopfen KAS00121 (D=200)

Cap plug

1,000 101 6kt-Schraube M 10x30

Hex head bolt
DIN 933

1,000 102 Scheibe GFT 220 R3 9184

Disk

2,000 121 6kt-Schraube M 12x20

Hex head bolt
DIN 933

1,000 066 O-Ring 192x4

O-ring
DIN 3771

008 911 57 BOMAG 729

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 12/43

4. Demontage • 4. Disassembly

4.1 Demontage Allgemein 4.1 Disassembly General

Getriebe nur im ausgebauten Zustand de- Make sure to remove the gearbox from the
montieren. machine frame before disassembling it.

Für die Demontage des Getriebes sind folgende Vorar- Prior to disassembly prepare the drive as follows:
beiten erforderlich:

Beachten Sie hierzu auch Kapitel 8 der Also observe chapter 8 „Operating Instruc-
entsprechenden Betriebsanleitung für die tions" in according of the gearbox type.
Getriebetype.

• Getriebeöl ablassen. Lösen Sie dafür Ver-

schlussschrauben (Pos. 42). Verwenden • Remove screw plugs (items 42) and drain
oil. Use suitable oil drain pan.
Sie dabei geeignete Auffanggefäße.
Ölinhalt: Gear lube oil volume:
ca. 14 Liter approx. 14 liters

Achten Sie beim Transport auf eine aus- When handling the equipment make sure
reichende Tragkraft des Kranes. the carrying capacity of the crane is ade-
quate.
Getriebegewicht: ca. 850 kg. Gearbox Weight approx 850 kg.

• Stellen Sie sicher, dass das abgesetzte

Getriebe seine Lage nicht ändern kann. • Make sure the set down gearbox rests im-
movably.

730 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 Bosch Rexroth AG 19.513/43
4. Demontage • 4. Disassembly

4.2 Demontage Bremse 4.2 Disassembly Brake

Lassen Sie das Öl ab. Entfernen Sie die Ölablass-
schraube (Pos. 42, 43).
Fangen Sie Altöl in geeigneten Behältern auf und ent-
sorgen Sie es unter Beachtung der entsprechenden Vor-
schriften.

Remove the screw plugs (item 42, 43) and drain oil.
Collect spent oil in suitable containers and dispose of the
oil line with the respective regulations.

Bild / fig. 1

Demontieren Sie die Schraube (Pos. 101) und die

Scheibe (Pos. 102) aus dem Mitnehmer (Pos. 51).

Remove the screw (item 101) and the disk (item 102) out
off coupler (item 51).

Bild / fig. 2

Entfernen Sie den Mitnehmer (Pos. 51).

Remove the coupler (item 51).

Bild / fig. 3

008 911 57 BOMAG 731

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 14/43

4. Demontage • 4. Disassembly

Pressen Sie mit geeigneter Vorrichtung die Bremse ge-

gen die Federn (Pos. 58,59) und entfernen Sie den Si-
cherungsring (Pos. 67).

Press the gear box with suitable fixture against the

springs (item 58, 59) and remove the snap ring (item 67).

Bild / fig. 4

Entfernen Sie die Scheibe (Pos. 52).

Remove the disk (item 52).

Bild / fig. 5

732 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 Bosch Rexroth AG 19.515/43
4. Demontage • 4. Disassembly

Entfernen Sie die Federn (Pos. 58, 59).

Remove the pressure springs (item 58, 59).

Bild / fig. 6

Entfernen Sie den Kolben (Pos. 55) mit Quad- und Stütz-
ringen. Beaufschlagen Sie den Kolben. mit Luftdruck.
Benutzen Sie hierzu Anschluss BR (siehe Einbauzeich-
nung).
Entfernen Sie die Quad- und Stützringe (Pos. 60, 61, 62,
63) aus Tragachse und Kolben (Pos. 50, 55).

Remove the piston (item 55) with piston seals and sup-
porting rings. Pressurize piston with air. For this purpose,
use port BR (see installation drawing)
Remove piston seals as well as supporting rings (item
60, 61, 62, 63) out off spindle and coupler (item 50, 55).

Bild / fig. 7

Entfernen Sie die Lamellen (Pos. 56, 57).

Remove the brake disks (item 56, 57).

Bild / fig. 8

008 911 57 BOMAG 733

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 16/43

4. Demontage • 4. Disassembly

Entfernen Sie die Scheibe (Pos. 53).

Remove the disk (item 53).

Bild / fig. 9

Entfernen Sie das Rillenkugellager (Pos. 69).

Remove the ball bearing (item 69).

Bild / fig. 10

4.3 Demontage Abtrieb 4.2 Disassembly Output

Entfernen Sie den Sicherungsring (Pos. 70). Heben Sie
hierfür die Sonnenradwelle (Pos. 87) an und lösen den
Sicherungsring (Pos. 70).

Lift up the sun gear shaft (item 87) and loose the snap
ring (item 70).

Bild / fig. 11

Drehen Sie das Getriebe um 180°.

Gear box rotated 180°.

Bild / fig. 12

734 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 Bosch Rexroth AG19.517/43
4. Demontage • 4. Disassembly

Lösen Sie die Schrauben (Pos. 38) und entfernen Sie

den Deckel (Pos. 18) mit O-Ring (Pos. 45).

Remove the bolts (item 38) and remove the cover (item
18) with o-ring (item 45).

Bild / fig. 13

4.3.1 Demontage Planetenstufen 4.3.2 Disassembly Planet Stages

Heben Sie die kompletten Stege (Pos. 7+6 und 89+5 mit
Rädern (Pos. 10, 90)) der 3. und 2. Stufe zusammen mit
der Sonnenradwelle (Pos. 87) aus dem Getriebe.

Remove the complete 3rd and 2nd planet stage (with

items 7+6+10 and 89+5+90) with the sun gear shaft (i-
tem 87).

Bild / fig. 14

Heben Sie die 1. Planetenstufe (Pos. 54, 8, 11) aus dem

Getriebe.

Remove the complete 1st planet stage (with items

87+95).

Bild / fig. 15

008 911 57 BOMAG 735

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 18/43

4. Demontage • 4. Disassembly

4.3.2 Demontage Planetenstege 4.3.2 Disassembly Planet Carrier

Entfernen Sie die Sicherungsringe (Pos. 95, 32, 33) von

den drei Planetenstufen.

Remove the snap rings (item 95, 32, 33).

Bild / fig. 16

Entfernen Sie die Planetenräder der drei Planetenstufen

(Pos. 11, 10, 90) mit Hilfe einer Vorrichtung von den Pla-
netenstegen (Pos. 8, 7, 89).

Pull the planet wheels (item 11, 10, 90) from planet car-
rier (item 8, 7, 89).

Bild / fig. 17

Achtung!
Beim lösen der Planetenräder der 1. Planetenstufe (Pos.
11) fällt der Planetensteg (Pos. 8) automatisch nach un-
ten.

Attention!
During loosing the planet wheels (item 11) the planet
carrier (item 8) will fall down automatically.

Bild / fig. 18

Lösen Sie den Sicherungsring (Pos. 29) der 2. Planeten-

stufe vom Sonnenrad (Pos. 6) und entfernen Sie den
Planetensteg (Pos. 7).

Remove the snap ring (item 29) and lift off the planet
carrier (item 7).

Bild / fig. 19

736 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 Bosch Rexroth AG 19.519/43
4. Demontage • 4. Disassembly

Entfernen Sie die Wellenscheibe (Pos.97) von der 3.

Planetenstufe (Pos. 89, 5).

Remove the thrust washer (item 97).

Bild / fig. 20

Lösen Sie den Sicherungsring (Pos. 26) und entfernen

den Planetensteg (Pos. 89) von der Sonnenradwelle
(Pos. 5).

Loosen the snap ring (item 26) and disassemble the

planet carrier (item 89) from the sun gear shaft (item 5).

Bild / fig. 21

4.3.3 Demontage Wellenmutter 4.3.3 Disassembly Shaft Nut

Entfernen Sie die Wellenmutter (Pos. 14).

Hierzu sind folgende Arbeitsschritte erforderlich:
ACHTUNG!
Schutzbrille tragen.

Remove the shaft nut (item 14). To accomplish this you

would do the following:
ATTENTION!
Wear suitable protective goggles.

Bild / fig. 22

Decken Sie den Bauraum zum Kegelrollenlager (Pos.

22) hin ab. Entfernen Sie während des Bohrvorganges
die Metallspäne um sicherzustellen, dass keine Metall-
reste im Getriebe verbleiben.

Cover the area towards to the tapered roller bearing

(item 22). Clean away metal scrap from drilling as you
drill to ensure no material gets lost within drive.

Bild / fig. 23

008 911 57 BOMAG 737

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 20/43

4. Demontage • 4. Disassembly

1.)
Bohren Sie im Bereich der Zylinderstifte (Pos. 15) ent-
14 sprechend der beiliegenden Skizze (Bild 26) ein Loch in
die Wellenmutter (Pos. 14).
ACHTUNG!
Nicht den Innenring des Kegelrollenlagers (Pos. 9)
beschädigen! Späne entfernen!

Start drilling one side of the shaft nut (item 145) close to
one of the dowel pins (item 15) according to the
attached sketch (fig. 26).
ATTENTION!
20 Do not damage the bearing inner ring of tapered
roller bearing (item 9), carefully remove metal
scraps!
Bild / fig. 24

2.)
Setzen Sie neben diese Bohrung eine weitere und wie-
derholen Sie den Vorgang zum AußenØ der Wellenmut-
ter (Pos. 14) hin, bis diese Seite ausgebohrt ist.

Drill another hole next to the one you just completed and
keep working your way towards the shaft nut (item 14)
outside diameter until that side is drilled out.

Bild / fig. 25

Wiederholen Sie die Arbeitsschritte 1.) und 2.) um 180°

versetzt an der Wellenmutter.

Go 180° degrees around the shaft nut and start the

process over again.

Bild / fig. 26

Wellenmutter (Pos. 14) mit Hilfe eines Meißels im Be-

reich der beiden Bohrungen sprengen und von der Trag-
achse (Pos. 50) entfernen.
ACHTUNG!
Nicht den Lagerkäfig. des Lagers (Pos. 22) beschä-
digen!
ACHTUNG!
Die Wellenmutter darf sich hierbei nicht drehen!

Use a chisel to open up the shaft nut (item 14) where

you completed your drilling and remove it from the spin-
dle (item 50).
ATTENTION!
Do not damage the bearing cage of bearing (item 22)!
ATTENTION!
Do not turn the shaft nut – possibility of spindle
thread damage!

738 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 Bosch Rexroth AG 19.521/43
4. Demontage • 4. Disassembly

Bild / fig. 27

4.3.4 Demontage Abtriebslagerung 4.3.4 Disassembly Output Bearings

Heben Sie das Hohlrad (Pos. 1, 3) und den O-Ring (Pos.

34) ab.

Remove the ring gear (item 1, 3) and the o-ring (item

34).

Bild / fig. 28

Entfernen Sie das Rollenlager (Pos.22) aus Getriebe.

Remove the bearing cage of the upper tapered roller

bearing (item 22).

Bild / fig. 29 (Abb. Ähnlich)

Demontieren Sie die Gleitringdichtung (Pos.35) aus der

Aufnahmebohrung des Stützringes (Pos. 98).
Achtung!
Keine scharfkantigen Werkzeuge benutzen.

Remove the axial face seal half (item 35) out of the cav-
ity of support ring (item 98).
Attention!
Do not use a tool with a sharp edge!

Bild / fig. 30

Demontieren Sie die Lageraußenringe (Pos. 22).

Remove the rings of tapered roller bearing (item 9).

Bild / fig. 31

008 911 57 BOMAG 739

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 22/43

4. Demontage • 4. Disassembly

Demontieren Sie den Zwischenring (Pos. 23) von der

Tragachse (Pos. 50).

Disassemble the spacer ring (item 23) from the spindle

(item 50).

Bild / fig. 32

Entfernen Sie das Rollenlager (Pos. 22) von der Trag-

achse (Pos. 50).

Remove the roller bearing (item 22) from the spindle

(item 50).

Bild / fig. 33

Demontieren Sie die Gleitringdichtung (Pos.35) aus der

Tragachse (Pos. 50).
Achtung!
Keine scharfkantigen Werkzeuge benutzen.

Remove the axial face seal half (item 35) out of the spin-
dle (item 50).
Attention!
Do not use a tool with a sharp edge!

Bild / fig. 34

Deformiertes Gewinde der Tragachse (Pos. 60) mit Hilfe

einer Gewindefeile -Steigung 3mm- nacharbeiten.

Repair deformed threads on the spindle (item 60) with a

thread file of 3mm pitch.

Bild / fig. 35

740 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 19.523/43
Bosch Rexroth AG

4. Demontage • 4. Disassembly

008 911 57 BOMAG 741

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 24/43

5. Montage • 5. Assembly

5.1 Montage Allgemein 5.1 Assembly General

Vor der Montage sind folgende Ver- Prior to assembly the following inspec-
schleißprüfungen erforderlich: tions of wear and tear are required:

• Prüfen Sie auf Verschleiß:

- axiale Anlaufflächen
• Check for wear:
- axial contact faces
- Passsitze - machined seats
- Gewindebohrungen - threaded holes

• Prüfen Sie alle Dichtflächen auf:

- Beschädigung • Check all sealing faces for:
- damage

• Prüfen Sie die Lager auf:

- Verwendbarkeit (Spiel übermäßig)
• Check the bearings for:
- usability (excessive clearance)
- visuelle Prüfung - visual appearance

• Prüfen Sie die Verzahnung auf:

- Zahnausbrüche
• Check the gear teeth for:
- tooth breakage
- Pittings - pitting
- Rissbildung - cracks
- Gratbildung - burrs
- Verschleiß - wear

MET-L-CHEK / Rissprüfung: MET-L-CHEK /

check for cracks
Entfetten und reinigen der Prüfteile Degrease and clean the parts to be
1. (z.B. Spezialreiniger NPU). 1. checked (e.g. special cleaner NPU).

Aufbringen des Eindringmittel Apply penetrant fluid (e.g. DYE VP 30).

2. (z.B. DYE VP 30). 2. Reaction time approx. 5-30 minutes de-
Einwirkzeit ca. 5-30 Min. je nach Tempera- pending on temperature and material.
tur und Werkstoff.

Werkstück von Eindringmittel reinigen. Clean off penetrant fluid from work piece
3. (z.B. mit Spezialreiniger NPU oder Wasser) 3. (e.g. with special cleaner NPU or water).
Oberfläche trocknen lassen. Allow surface to dry.

Den Entwickler „weiß“, hauchdünn auftra-
4. gen. Nach einer kurzen Trockenzeit tritt
aus den Fehlstellen das Eindringmittel
(z.B. DYE VP 30) aus und bildet mit dem
weißen Entwickler einen roten Kontrast.
Apply a very thin layer of developer
4. „white“. After a short drying time, the
penetrant fluid (e.g. DYE VP 30) emerges
from the defective spots and creates a red
contrast to the white developer.

Inspektion – rote Linien im weißen Ent- Inspection – red lines on the white devel-
5. wicklerfeld zeigen Risse oder Überlappun- 5. oper field indicate cracks or overlapping,
gen an, während punktförmige Farbaustrit- while point shaped color patterns can be
te als Poren zu werten sind. rated as blowholes and pores.

742 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 Bosch Rexroth AG 19.525/43
5. Montage • 5. Assembly

5.2 Montage Abtrieb 5.2 Assembly Output

Entfetten Sie die Aufnahmebohrung für die Gleitringdich-
tung (Pos. 43) in Tragachse (Pos. 1) und Stützring (Pos.
2). (z.B. LOCTITE 7061)

Degrease and dry the cavities for the face seal (item 43)
in the spindle (item 1) and in the supporting ring (item 2)
(e.g. with LOCTITE 7061).

Bild / fig. 36

Kühlen Sie die Außenringe der Kegelrollenlager (Pos.

30) in flüssigem Stickstoff auf –180°C ab.

Use nitrogen to cool down the outer rings of tapered

roller bearings (item 30) to approx. –180°C.

Bild / fig. 37

5.2.1 Montage Abtriebslagerung 5.2.1 Assembly Output Bearings

Setzen Sie die in Stickstoff abgekühlten Außenringe von

den Kegelrollenlagern (Pos. 22) in den Stützring (Pos. 3)
ein. (Prüfen Sie auf richtige axiale Anlage).

After cooling-off with nitrogen, insert the outer rings of

tapered roller bearings (item 30) into the supporting ring
(item 2). (Check for proper axial seat).

Bild / fig. 38

Montieren Sie die beiden Kegelrollenlager (Pos. 22) in

den Stützring (Pos. 3).

Mount both tapered roller bearing (item 22) into the sup-
porting ring (item 3).

Bild / fig. 39

008 911 57 BOMAG 743

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 26/43

5. Montage • 5. Assembly

Belasten Sie die beiden Kegelrollenlager (Pos. 22) axial

mit Hilfe einer Vorrichtung mit 150 kp.
Lagerung durch 20 Drehungen in einer Richtung eindre-
hen.

Apply axial load of 150 kp to both bearings (item 22).

Make use of a device.

Bild / fig. 40

Messen Sie das Maß zwischen den beiden Innenringen

der Kegelrollenlager (Pos. 22) mittels einer Messvorrich-
tung.

Determine dimensions between the inner rings of bear-

ing (item 22) with measuring device.

Bild / fig. 41

Schleifen Sie den Zwischenring(Pos. 23) auf Maß. (Er-

mitteltes Maß -0,25 mm).

Grind spacer ring (item 23) to measure, i.e. calculated

dimension -0,25 mm.

Bild / fig. 42

Schlagen Sie den Expander (Pos. 73) in die entspre-

chende Aufnahmebohrung der Tragachse (Pos. 50).

Stamp the expander (item 73) into locating hole of spin-

dle (item 50).

Bild / fig. 43

744 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 Bosch Rexroth AG 19.527/43
5. Montage • 5. Assembly

Benetzen Sie den Gleitringdichtungs-– O-Ring (Pos. 8)

und die Aufnahmebohrung der Tragachse (Pos. 50) mit
Spiritus.

Wet the face seal o- ring (item 8) and cavity on the spin-
dle (item 50) with spirit of wine cleaner.

Bild / fig. 44

Drücken Sie die untere Gleitringsichtungshälfte (Pos. 35)

in die entsprechende Aufnahmebohrung der Tragachse
(Pos. 50).
Achtung!
Keine scharfkantigen Werkzeuge benutzen.

Install face seal ring half (item 35) into spindle (item 50)
under even pressure on the seal surface.
Attention!
Do not use a tool with a sharp edge
Bild / fig. 45

Schneiden Sie eine Rundschnur (Pos. 34) auf Maß und

kleben Sie die Enden mit LOCTITE 480 zusammen.

Cut the chord (item 34) to measure and glue it with

LOCTITE 480.

Bild / fig. 46

Setzen Sie die gefettete Rundschnur (Pos. 34) in die

entsprechende Nut im Stützring (Pos. 3) ein.

Insert the chord (item 34) into the o-ring groove of sup-
porting ring (item 3).
Grease the chord.

Bild / fig. 47

008 911 57 BOMAG 745

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 28/43

5. Montage • 5. Assembly

Setzen Sie den Stützring (Pos. 3) auf das Hohlrad

(Pos. 1).

Mount the supporting ring (item 3) onto the ring gear

(item 1).

Bild / fig. 48

Gewinde der Zylinderschrauben (Pos. 41) gleichmäßig

mit LOCTITE 638 bestreichen.

Evenly apply coat of LOCTITE 638 to threads of socket

head cap screws (item 41).

Bild / fig. 49

Zylinderschrauben (Pos. 70) in entsprechende Gewinde-

bohrungen von Hohlrad (Pos. 1 einsetzen und mit einem
Anzugsdrehmoment von 1650 Nm anziehen.

Install the socket head cap screws (item 70) into the
threaded holes of the ring gear (item 1) and tighten them
to a required torque of 1650 Nm.

Bild / fig. 50

Benetzen Sie den Gleitringdichtungs-– O-Ring (Pos. 8)

und die Aufnahmebohrung des Stützringes (Pos. 3) mit
Spiritus.

Wet the axial face seal o- ring (item 8) and cavity on

supporting ring (item 3) with spirit of wine cleaner.

Bild / fig. 51

746 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 Bosch Rexroth AG 19.529/43
5. Montage • 5. Assembly

Drücken Sie die obere Gleitringsichtungshälfte (Pos. 35)

in die entsprechende Aufnahmebohrung des Stützringes
(Pos. 3).
Achtung!
Keine scharfkantigen Werkzeuge benutzen.

Install face seal ring half (item 35) into supporting ring
(item 3) under even pressure on the seal surface.
Attention!
Do not use a tool with a sharp edge
Bild / fig. 52

Montieren Sie den unteren Innenring mit Rollenkranz von

Kegelrollenlager (Pos. 22) auf Tragachse (Pos. 50).

Mount the upper inner ring with roller cage of double

tapered roller bearing (item 22) onto the spindle (item
50).

Bild / fig. 53

Setzen Sie den auf Maß geschliffenen Zwischenring

(Pos. 23), auf die Tragachse auf.

Mount the grounded spacer ring (item 23) on the spindle

(item 50).

Bild / fig. 54

Versehen Sie die Gleitflächen der Gleitringdichtung

(Pos. 35) mit einem Ölfilm.

Wet the sliding surfaces of the face seal (item 35) with
oil.

Bild / fig. 55

008 911 57 BOMAG 747

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 30/43

5. Montage • 5. Assembly

Montieren Sie das vormontierte Hohlrad/ Stützring (Pos.

1, 3) auf die vormontierte Tragachse (Pos. 50).

Install the pre-assembled ring gear/ supporting ring (item

1, 3) on the spindle (item 50).

Bild / fig. 56

Montieren Sie den oberen Innenring mit Rollenkranz von

Kegelrollenlager (Pos. 22) in das Hohlrad (Pos. 1).

Mount the upper inner ring with roller cage of double

tapered roller bearing (item 20) into the ring gear (item
1).

Bild / fig. 57

5.2.2 Montage Wellenmutter 5.2.2 Assembly Shaft Nut

Gewinde der Tragachse (Pos. 1) und der Wellenmut-

ter (Pos. 18) entfetten (z.B. mit LOCTITE 7061).

Degrease threads of spindle (item 1) and shaft nut

(item 18) (e.g. with LOCTITE 7061).

Bild / fig. 58

Bestreichen Sie das Gewinde der Wellenmutter (Pos.

14) gleichmäßig mit LOCTITE 638.

Evenly apply coat of LOCTITE 638 to thread of shaft nut

(item 14).

Bild / fig. 59

748 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 Bosch Rexroth AG 19.531/43
5. Montage • 5. Assembly

Montieren Sie die Wellenmutter (Pos. 14) mit Ringkerbe

nach oben (sichtbar).

Mount the shaft nut (item 14) with groove on upper side
(visible).

Bild / fig. 60

ACHTUNG!
Beim Einstellen der Kegelrollenlager ist der Stütz-
ring mehrfach in eine Richtung zu drehen.
- Wellenmutter (Pos. 14) – mittels einer Vorrichtung
mit einem Anziehdrehmoment von 27000 Nm anzie-
hen.

ATTENTION!
Rotate the supporting ring repeatedly in one direc-
tion only when setting the tapered roller bearing
Tighten shaft nut (item 14) – by using an adequate de-
vice with a tightening torque of 27000 Nm.
Bild / fig. 61

Setzen Sie die Zylinderstifte (Pos. 15) ein.

Insert the cylindrical dowel pins (item 15).

Bild / fig. 62

008 911 57 BOMAG 749

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 32/43

5. Montage • 5. Assembly

5.2.3 Montage Planetenräder 5.2.3 Assembly Planet Carrier /

Planet Wheels

1. Stufe 1st Stage

1.1 Montieren Sie den 1.1 Mount the snap ring

Sprengring (Pos. 36) auf (item 36) onto the coupler
den Mitnehmer (Pos. 54). (item 54).
1.2 Montieren Sie den 1.2 Mount the coupler
Mitnehmer (Pos. 54) in (item 54) into the planet
den Planetensteg carrier (item 8).
(Pos.8).
1.1 1.2
2. Montage der Zylin- 2. Assembly of cylin-
derrollenlager drical roller bearing
2.1 Drücken Sie das Zy- 2.1 Push the cylindrical
linderrollenlager (Pos. roller bearing (item 20)
20) aus der Transport- directly out of transport
verpackung direkt in die packing into the locating
Aufnahmebohrung von hole of the planet gear
2.1 2.2 Planetenrad (Pos. 11). (item 11).
2.2 Setzen Sie die An- 2.2 Insert the locating
laufscheibe (Pos. 27) ein. ring (item 27).
2.3 Setzen Sie den Si- 2.3 Insert a new snap
cherungsring (Pos. 31) ring (item 31).
ein.
nd
2.4 Setzen Sie die zweite 2.4 Insert the 2 locating
Anlaufscheibe (Pos. 27) ring (item 27).
2.3 2.4 ein.
2.5 Drücken Sie das 2.5 Push the 2nd cylindri-
zweite Zylinderrollenlager cal roller bearing (item
(Pos. 20) aus der Trans- 20) directly out of trans-
portverpackung direkt in port packing into the lo-
die Aufnahmebohrung cating hole of the planet
von Planetenrad (Pos. gear (item 11).
11).
2.4
3. 3.
Erwärmen Sie vormon- Heat the pre-assembled
tiertes Planetenrad (Pos. planet gear (item 11) to
11) auf ca. 120°-130°C. approx. 120°-130°C.
3.1 Montieren Sie das 3.1 Mount the pre-
vormontierte Planetenrad assembled planet gear
auf den Planetenbolzen onto the planetary pin of
von Planetensteg (Pos. planet carrier (item 8).
3.1 3.2
8).
3.2 Sichern Sie die Pla- 3.2 Secure the planet
netenräder mit den Si- gears with snap ring
cherungsringen (Pos. (item 33).
33).
Bild / fig. 63

750 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 Bosch Rexroth AG 19.533/43
5. Montage • 5. Assembly
2. Stufe 2nd Stage
1.1 Setzen Sie den Pla-
netensteg (Pos. 7) auf
die Verzahnung des
Sonnenrades (Pos. 6)
ein.
1.2 Sichern Sie das Son-
nenrad mit dem Siche-
1.1 1.2 rungsring (Pos. 29).
2. Montage der Zylin-
derrollenlager
2.1 Drücken Sie das Zy-
linderrollenlager (Pos.
21) aus der Transport-
verpackung direkt in die
2.1 2.2 Aufnahmebohrung von
Planetenrad (Pos. 10).
2.2 Setzen Sie die An-
laufscheibe (Pos. 28) ein.
2.3 Setzen Sie den Si-
cherungsring (Pos. 30)
ein.
2.4 Setzen Sie die zweite
2.3 2.4 Anlaufscheibe (Pos. 28)
ein.
2.5 Drücken Sie das
zweite Zylinderrollenlager
(Pos. 21) aus der Trans-
portverpackung direkt in
die Aufnahmebohrung
von Planetenrad (Pos.
2.5 3.1 10).
3.
Erwärmen Sie vormon-
tiertes Planetenrad (Pos.
10) auf ca. 120°-130°C.
3.1 Montieren Sie das
vormontierte Planetenrad
3.2 auf den Planetenbolzen
von Planetensteg (Pos.
7).
3.2 Sichern Sie die Pla-
netenräder mit den Si-
cherungsringen (Pos.
32).
Bild / fig. 64
008 911 57 BOMAG
1.1 Insert the planet car-
rier (item 7) into the in-
ternal teeth of sun gear
(item 6).
1.2 Secure the sun gear
with a new snap ring
(item 29).
2. Assembly of cylin-
drical roller bearing
2.1 Push the cylindrical
roller bearing (item 21)
directly out of transport
packing into the locating
hole of the planet gear
(item 10).
2.2 Insert the locating
ring (item 28).
2.3 Insert a new snap
ring (item 30).
2.4 Insert the 2nd locating
ring (item 28).
2.5 Push the 2nd cylindri-
cal roller bearing (item
21) directly out of trans-
port packing into the lo-
cating hole of the planet
gear (item 10).
3.
Heat the pre-assembled
planet gear (item 10) to
approx. 120°-130°C.
3.1 Mount the pre-
assembled planet gear
onto the planetary pin of
planet carrier (item 7).
3.2 Secure the planet
gears with snap ring
(item 32).
751
19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 34/43

5. Montage • 5. Assembly

3. Stufe 3rd Stage

1.1 Setzen Sie den Pla- 1.1 Insert the planet car-
netensteg (Pos. 89) auf rier (item 89) into internal
die Verzahnung des Son- teeth of sun gear (item
nenrades (Pos. 5) ein. 5).
1.2 Sichern Sie das Son- 1.2 Secure the sun gear
nenrad mit dem Siche- with a new snap ring
rungsring (Pos. 26). (item 26).
1.1 1.2 1.3 Setzen Sie Scheibe 1.3 Mount the thrust
(Pos. 97) auf das Son- washer (item 97) onto the
nenrad (Pos. 5). sun gear shaft (item 5).

2. Montage der Zylin- 2. Assembly of cylin-

derrollenlager drical roller bearing
2.1 Setzen Sie den Si- 2.1 Insert the snap ring
cherungsring (Pos. 96) (item 96).
1.3 2.1 ein.
2.2 Setzen Sie die An- 2.2 Insert the locating
laufscheibe (Pos. 94) ein. ring (item 94).
2.3 Drücken Sie das Zy- 2.3 Push the cylindrical
linderrollenlager (Pos. roller bearing (item 91)
91) aus der Transport- directly out of transport
verpackung direkt in die packing into the locating
Aufnahmebohrung von hole of the planet gear
2.2 2.3 Planetenrad (Pos. 90). (item 90).
nd
2.4 Setzen Sie die zweite 2.4 Insert the 2 locating
Anlaufscheibe (Pos. 94) ring (item 94).
ein.
2.5 Setzen Sie den Si- 2.5 Insert the 2nd snap
cherungsring (Pos. 96) ring (item 96).
ein.

2.4 2.5 3. 3.
Erwärmen Sie vormon- Heat the pre-assembled
tiertes Planetenrad (Pos. planet gear (item 90) to
90) auf ca. 120°-130°C. approx. 120°-130°C.
3.1 Montieren Sie das 3.1 Mount the pre-
vormontierte Planetenrad assembled planet gear
auf den Planetenbolzen onto the planetary pin of
von Planetensteg (Pos. planet carrier (item 89).
3.1 3.2 89).
3.2 Sichern Sie die Pla- 3.2 Secure the planet
netenräder mit den Si- gears with snap ring
cherungsringen (Pos. (item 95).
95).
Bild / fig. 65

752 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 19.535/43
Bosch Rexroth AG

5. Montage • 5. Assembly

5.2.4 Montage Planetenstufen 5.2.4 Assembly Planet Stage

Setzen Sie den komplett montierten Planetensteg der 1.

Stufe (Pos. 54, 8, 11) in das Getriebe ein.

Install the completely pre-assembled 1st planet stage

(item 54, 8, 11) into the gear box.

Bild / fig. 66

Setzen Sie den komplett montierten Planetensteg der 2.

Stufe (Pos. 6, 7, 10) in das Getriebe ein.

Install the completely pre-assembled 2nd planet stage

(item 6, 7, 10) into the gear box.

Bild / fig. 67

Setzen Sie den komplett montierten Planetensteg der 3

Stufe (Pos. 5, 89, 90) in das Getriebe ein.

Install the completely pre-assembled 3rd planet stage

(item 5, 89, 90) into the gear box.

Bild / fig. 68

Setzen Sie die Sonnenradwelle (Pos. 87) in das Getriebe

ein.

Install the sun gear shaft (item 87).

Bild / fig. 69

008 911 57 BOMAG 753

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 36/43

5. Montage • 5. Assembly

5.2.5 Montage Deckel 5.6 Assembly Cover

Zylinderrolle (Pos. 17) in Deckel (Pos. 18) einsetzen.

Install the cylindrical roller (item 17) into the cover (item
18).

Bild / fig. 70

Axialspiel prüfen:
Spiel zwischen Anlauffläche der Sonnenradwelle (Pos.
87) und der Zylinderrolle (Pos. 17) vor der Montage des
Deckels (Pos. 18) prüfen. (Sollwert 1-2 mm).

Checking of axial clearance:

Determine clearance between contact face of the sun
gear shaft (item 87) and the cylindrical roller (item 17) by
measuring parts prior to assembly of cover (item 18).
(Recommended clearance 1-2 mm).
Bild / fig. 71

Montieren Sie den O-Ring (Pos. 45) in die entsprechen-

de Nut des Deckels (Pos. 18).

Insert the o-ring (item 45) into the o-ring groove of cover
(item 18).

Bild / fig. 72

Fetten Sie den O- Ring (Pos. 45) ein.

Grease the o-ring (item 45).

Bild / fig. 73

754 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 Bosch Rexroth AG 19.537/43
5. Montage • 5. Assembly

Setzen Sie den vormontierten Deckel (Pos. 18) mit neu-

em O-Ring (Pos. 45) in den Einpass des Hohlrades
(Pos. 1) ein und befestigen ihn mit den Schrauben (Pos.
38).
Ziehen Sie die Schrauben (Pos. 38) mit erforderlichem
Anzugsmoment an. (Siehe Ersatzteilzeichnung
0/6137/1184/2)

Mount the cover (item 18) with the o-ring (item 45) to the
ring gear (item 1).
Tighten the screws (item 38) to a proper torque.
(See spare part drawing 0/6137/1184/2).
Bild / fig. 74

Schrauben Sie die Verschlussschrauben (Pos. 39, 44

und 42, 43) in den Deckel ein.

Screw the screw plugs (item 39, 44 and 42, 43) into the
cover (item 18).

Bild / fig. 75

5.3 Montage Bremse 5.3 Assembly Brake

Drehen Sie das Getriebe um 180°.

Gear box rotated 180°.

Bild / fig. 76

Montieren Sie den Sicherungsring (Pos. 70). Heben Sie

hierfür die Sonnenradwelle (Pos. 87) mit Hilfe eines Kra-
nes an und setzen den Sicherungsring ein.

Lift up the sun gear shaft (item 87) and mount the snap
ring (item 70).

008 911 57 BOMAG 755

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 38/43

5. Montage • 5. Assembly

Bild / fig. 77

756 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 Bosch Rexroth AG 19.539/43
5. Montage • 5. Assembly

Setzen Sie das Rillenkugellager (Pos. 69) in Einpass bis

zum Anschlag ein.
Achtung, beim Einbau darf nur auf den Außenring des
Lagers Druck ausgeübt werden.

Insert the grooved ball bearing (item 69) into fitting up to

stop point.
Attention, when inserting the bearing, pressure may only
be exerted onto the outer ring of the bearing.

Bild / fig. 78

Setzen Sie die Scheibe (Pos. 53) ein.

Insert the disk (item 53).

Bild / fig. 79

Legen Sie die Lamellen (Pos. 56+57) in richtiger Reihen-

folge ein. (siehe Ersatzteilzeichnung 0/6137/1184/2)

Insert the brake disks (item 56+57) in correct order.

(Note spare part drawing 0/6137/1184/2).

Bild / fig. 80

Montieren Sie die Quad- und Stützringe (Pos. 60, 61, 62,
63).

Mount the supporting rings and piston seal (item 60, 61,
62, 63).

Bild / fig. 81

008 911 57 BOMAG 757

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 40/43

5. Montage • 5. Assembly

Ölen Sie die Einbauflächen des Kolben (Pos. 55) ein.

Lubricate the installation area of piston (item 55).

Bild / fig. 82

Setzen Sie den Kolben (Pos. 55) in die Tragachse (Pos.

50) ein.

Mount the piston (item 55) into the spindle (item 50).

Bild / fig. 83

Setzen Sie die Federn (Pos. 58, 59) ein.

Mount the pressure springs (item 58, 59).

Bild / fig. 84

Setzen Sie die Scheibe (Pos. 52) ein.

Insert the disk (item 52).

Bild / fig. 85

758 BOMAG 008 911 57

Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 Bosch Rexroth AG19.541/43
5. Montage • 5. Assembly

Legen Sie die Sicherungsring (Pos. 67) ein.

Insert the snap ring (item 67).

Bild / fig. 86

Pressen Sie mit geeigneter Vorrichtung den vormontier-

ten Kolben (Pos. 55) gegen die Federn (Pos. 58, 59) und
montieren Sie den Sicherungsring (Pos. 67).

Press the piston (item 55) with suitable fixture against

the springs (item 58, 59) and mount the snap ring (item
67).

Bild / fig. 87

Setzen Sie die Scheibe (Pos. 102) in den Mitnehmer

(Pos. 51) ein. Bestreichen Sie die Schraube (Pos. 101)
mit LOCTITE 270. Ziehen Sie die Schraube (Pos. 101)
mit einem Anziehdrehmoment von 51 Nm an. (Siehe
Ersatzteilzeichnung 0/6137/1184/2)

Mount the disc (item 102) into the coupler (item 51).
Evenly apply coat of LOCTITE 270 to thread of screws
(item 101).
Tighten the screws (item 101) to the torque 51 Nm.
(See spare part drawing 0/6137/1184/2).

Bild / fig. 88

008 911 57 BOMAG 759

19.5
RDE 77978-01-R/01.08 GFT 220 R3 9184
6. Probelauf • 6. Test Run
6.1 Prüfstandsaufbau
Das Getriebe wird in der vorgesehenen Einbaulage aufge-
baut und mit einem geeigneten Antriebsmotor angetrieben.
Wenn das Betriebsverhalten des Getriebetyps bekannt ist,
kann eine andere Prüflage gewählt werden, wobei die Ra-
dialwellendichtringe, bzw. Gleitringdichtungen unter Öl
stehen müssen (Luftkammerbildung beachten!).
6.2 Ölversorgung
Die Getriebe werden wie in der Einbauzeichnung vorgese-
hen mit Öl gefüllt. Bremsen mit separater Ölfüllung sind
vor dem Probelauf gemäß Einbauzeichnung ebenfalls mit
Öl zu befüllen.
Zur Ölbefüllung verwenden Sie bitte die in der Betriebsan-
leitung angebenden Schmierstoffe.
6.3 Drehzahl, Laufzeit und
Prüflast
Die Getriebe sind mit Höchstdrehzahl (nmax Getriebe bzw.
nmax Prüfstand) über 1 Stunde (je ½ Stunde pro Drehrich-
tung bei Getrieben mit wechselnder Drehrichtung) ohne
Last zu fahren.
Hierbei ist die Ölsumpftemperatur am Außendurchmesser
des Hohlrades nach 30, 45 und 60 Minuten zu messen
und zu protokollieren.
6.4 Thermische Werte
Die Ölsumpftemperatur soll nach Abschluss des
1-stündigen Probelaufs 70°C nicht übersteigen. Die Tem-
peratur nach 30 Minuten bei reduzierter Laufzeit soll die
Temperatur der Temperaturaufschreibung des ersten Ge-
triebes um nicht mehr als 4°C überschreiten.
Die Temperaturen an außenliegenden Lagerstellen (soweit
zutreffend) sollen die Ölsumpftemperaturen um nicht mehr
als 10°C übersteigen.
6.5 Laufgeräusch
Das Laufgeräusch soll weich und gleichmäßig sein.
Es dürfen keine harten, schlagenden oder pfeifende Ge-
räusche vorhanden sein.
6.6 Dichtigkeitsprüfung
Während des Probelaufs sind alle Dichtungen auf Undich-
tigkeiten hin zu beobachten, z.B.:
- Ein- und Auslassschrauben
- Entlüfter
- Dichtflächen an Hohlrädern und Deckeln
- Wellendichtungen
760 BOMAG
Wheel drive gear
Bosch from
Rexroth AGS/N 42/43
6.1 Test set up
The gearbox shall be mounted in its intended installation
position and connected to a suitable driving motor. If the
operating performance of the gearbox type is known, it is
possible to mount the gearbox in another test position
under the condition that the radial face seals and the
axial seal are submerged in oil (check for air chambers!).
6.2 Lubrication
The gear units are to be filled with oil as shown on the
installation drawing. Brakes which have separate oil fill-
ings shall be filled with oil before test run.
For oil fill, please use the lubricants listed in the operat-
ing instructions.
6.3 Speed, Running Time,
Test Load
The gear units are to be operated at max. speed (nmax of
gearbox or nmax test bed) under no load for one hour
(half an hour in each direction of rotation in case of re-
verse gears).
Measure oil sump temperatures at outside diameter of
ring gear and note them down after 30, 45 and 60 min-
utes of operation.
6.4 Thermal Parameters
The oil sump temperature measured after the 1-hour test
run shall not exceed 70°C.
The temperature measured after 30 minutes reduced
operating time shall not exceed the temperature records
of the first gearbox by more than 4°C.
The temperatures measured at the external bearing ar-
eas (if applicable) must be not exceed the oil sump tem-
perature by more than 10°C.
6.5 Running Noise
The running noise under test conditions should be
smooth and steady.
Hard, knocking or howling noise produced by the unit is
inadmissible.
6.6 Leakage Testing
During the test run, make sure to check all seals for
leakages, e.g.:
- Inlet and drain plugs
- Vent
- Sealing faces at ring gears and covers
- Shaft seals
008 911 57
Wheel drive gear fromGFT
RDE 77978-01-R/01.08 S/N220 R3 9184 Bosch Rexroth AG 19.543/43
6. Probelauf • 6. Test Run

6.7 Funktionsprüfung der 6.7 Functional Test of

Bremsen Hydraulic Brakes
Rexroth Bremsen werden durch eine pulsierende Prüfung A pulsating pressure test shall be performed on the
auf Funktion und Dichtigkeit geprüft: Rexroth brakes to check the tightness and function:
- Prüfdruck: 60-80 bar - Test pressure: 60-80 bar
- Lüftzeit: 6-10 sek pro Kolbenhub - Releasing time: 6-10 sec. per piston stroke
- Prüfdauer: min. 15 Minuten - Testing time: 15 minutes minimum

Die hier beschriebene Funktionsprüfung gilt nicht für in The described functional test of hydraulic brakes is not
Motoren integrierte Bremsen. valid for motor integrated brakes.

6.8 Fremdkörper 6.8 Oil Contamination Test

Nach Durchführung des Probelaufs ist das ablaufende After completing the test run, the oil shall be inspected
Getriebeöl auf Späne, Zunder, übermäßigen Abrieb zu for scraps, scales and wear particles and other impuri-
beobachten. Auf Fremdkörper an Magnetstopfen und ggf. ties. The magnetic plug and, if necessary, the oil filter
am Ölfilter ist zu achten. shall be checked.

008 911 57 BOMAG 761

19.5 Wheel drive gear from S/N

762 BOMAG 008 911 57

Wheel drive gear from S/N
Electric Drives Linear Motion and
19.5
and Controls Hydraulics Assembly Technologies Pneumatics Service

Betriebsanleitung / Operating Instructions BDA 16633700 00

Planetengetriebe / Planetary Gearbox 12.07.2007

HYDROTRAC

GFT 220 R3 9184

Made in Germany
Ident.-Nr. / ident.-no.
Type / product GFT 220 R3 9184
Serial-Nr. / serial-no. Imprint on Rating Plate
Auftrags-Nr. / order-no. 376402.010
Baujahr / produced in 2007
Abtriebsdrehmoment / output torque max. 184950 Nm
Antriebsdrehzahl / input speed max. 3901 min-1
Übersetzung / ratio 145,4
Schmiergruppe / lubr. group CLP 220
MNR 16633700

008 911 57 BOMAG 763

19.5
BDA 16633700 00 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 2/32

Inhaltsverzeichnis • Table of Contents

1. Einleitung 1. Preliminary Notes

1.1 Einführung 1.1 Introduction
1.2 Sicherheitshinweise 1.2 Notes on Safety

2. Produktbeschreibung 2. Product Description

2.1 Einführung 2.1 Introduction
2.2 Beschreibung 2.2 Description
2.3 Beschreibung der Bremse 2.3 Description of Brake
2.4 Lieferumfang 2.4 Scope of Supply
2.5 Technische Daten 2.5 Technical Data
2.6 Zeichnungen und Listen 2.6 Drawings and Lists
2.7 Betriebsmittel 2.7 Operating Media

3. Transport / Lagerung 3. Handling / Storage

3.1 Einführung 3.1 Introduction
3.2 Hinweise zu Transport und Lagerung 3.2 Notes on Handling and Storing
3.3 Verpackung 3.3 Packing
3.4 Konservierung 3.4 Preservation
3.4.1 Lagerung in gelüfteten Räumen 3.4.1 Storage in Ventilated Rooms
3.4.2 Lagerung im Freien 3.4.2 Storage Outdoors
3.4.3 Lagerung in klimatisierten Räumen 3.4.3 Storage in Air-Conditioned Rooms
3.4.4 Lagerung von teilgeschlossenen Getrieben 3.4.4 Storage of part closed Gearboxes
3.4.5 Langzeitkonservierung 3.4.5 Long-Term Preservation

4. Einbau 4. Mounting
4.1 Einführung 4.1 Introduction
4.2 Handlungsschritte zum Einbau 4.2 Mounting Work to be Performed

5. Inbetriebnahme 5. Commissioning
5.1 Einführung 5.1 Introduction
5.2 Handlungsschritte zur Inbetriebnahme 5.2 Commissioning Activities

6. (in diesem Handbuch nicht enthalten) 6. (does not form part of this manual)

7. Pflege / Wartung 7. Maintenance / Care

7.1 Einführung 7.1 Introduction
7.2 Handlungsschritte zu Pflege und Wartung 7.2 Maintenance and Care Activities
7.3 Wartungsplan 7.3 Maintenance Schedule
7.4 Wartungsplan Bremse 7.4 Maintenance Schedule Brake

8. Ausbau 8. Dismantling
8.1 Einführung 8.1 Introduction
8.2 Handlungsschritte zum Ausbau 8.2 Dismantling Work to be Performed

764 BOMAG 008 911 57

Wheel drive gear
BDA 16633700 from
00 GFT 220S/N
R3 9184 19.53/32
Bosch Rexroth AG

Inhaltsverzeichnis • Table of Contents

Anhang Appendix

A. Anschriften A. Addresses
B. Schmieröle B. Lube Oils
C. (in diesem Handbuch nicht enthalten) C. (does not form part of this manual)
D. Zeichnungen D. Drawings
E. Teilelisten E. Parts Lists

Änderungsverzeichnis • Table of Modification

Ersetzt Ausgabe: Substitutes Issue:

Nr. / Änderung / Modification Tag / Date geändert / geprüft /

No. modified by checked by

008 911 57 BOMAG 765

19.5
BDA 16633700 00 GFT 220 R3 9184
1. Einleitung • 1. Preliminary Notes
1.1 Einführung
In der vorliegenden Betriebsanleitung finden Sie Infor-
mationen zum Einbau, zur Inbetriebnahme, zur Pflege
und Wartung und zur Ersatzteilbestellung.
Beachten Sie unbedingt die Sicherheitshinweise
dieser Dokumentation.
- Allgemeine Sicherheitshinweise finden Sie in diesem
ersten Kapitel.
- Besondere Hinweise finden Sie jeweils am Anfang
eines Kapitels.
- Auf eine Handlung bezogene Sicherheitshinweise
finden Sie vor der Beschreibung des Handlungs-
schrittes.
Die Seitenzahl finden Sie am äußeren Seitenrand.
Die Bereiche des Anhanges sind durch Zwischenblätter
voneinander getrennt und ggf. versehen mit Hinweisen
auf den angesprochenen Leserkreis.
1.2 Sicherheitshinweise
Die Produkte von BOSCH-REXROTH sind nach dem
aktuellen Stand von Wissenschaft und Technik ausge-
legt und hergestellt. Dennoch können Gefahren auftreten
für:
- Körper und Gesundheit,
- das Produkt und die Gesamtanlage,
- sonstige Werte.
Mit diesem Symbol sind Gefahren für Kör-
per und Gesundheit gekennzeichnet.
Mit diesem Symbol sind Gefahren für das
Produkt und die Gesamtanlage gekenn-
zeichnet.
Mit diesem Symbol sind Gefahren für
sonstige Werte gekennzeichnet.
Dieses Symbol kennzeichnet Hinweise.
766 BOMAG
Wheel drive gear
Bosch from
Rexroth AGS/N 4/32
1.1 Introduction
The present operating instructions contain information on
installation, start-up, care and maintenance as well as
spare parts ordering.
Make sure the safety instructions in this documenta-
tion are carefully observed.
- General notes on safety are listed in this first chapter.
- Special instructions are given at the beginning of the
individual chapter.
- Safety instructions referring to actions are given
before the action itself is described.
Page numbers are shown at the outer bottom margin.
The various areas of the Appendix have been separated
by sheets and, where considered expedient, provided
with notes on the relevant persons.
1.2 Notes on Safety
The products of BOSCH-REXROTH have been de-
signed and manufactured so as to reflect the state of the
scientific and technical knowledge. Nevertheless, it can-
not be ruled out that danger may arise to:
- life and limb,
- the product and overall plant,
- other assets.
This symbol signifies danger to life and
limb.
This symbol signifies danger to the prod-
uct and the overall plant.
This symbol signifies danger to other
assets.
This symbol calls attention to notes.
008 911 57
Wheel drive gear
BDA 16633700 from
00 GFT 220S/N
R3 9184
1. Einleitung • 1. Preliminary Notes
Gefahren können insbesondere dann auftreten:
- wenn unzureichend ausgebildetes Personal am Pro-
dukt tätig ist,
- wenn das Produkt unsachgemäß installiert, bedient
und instand gehalten wird,
- wenn das Produkt zu nicht bestimmungsgemäßem
Gebrauch eingesetzt wird.
Alle Personen, die mit dem Betrieb der Anlage oder des
Produktes befaßt sind, müssen:
- unbedingt das Kapitel "Sicherheitshinweise" gelesen
und verstanden haben,
- diese Betriebsanleitung zumindest in den Teilen
kennen, in denen die jeweilige Tätigkeit und zugehö-
rige Gefahrenhinweise beschrieben sind,
- mit Abschaltprozeduren, z.B. "NOT-AUS", der gan-
zen Anlage oder den für die jeweilige Tätigkeit wich-
tigen Teilen der Anlage vertraut sein,
- technisch ausreichend ausgebildet und zu der jewei-
ligen Tätigkeit befugt sein,
- ihre Aufgaben und Befugnisse kennen.
Sie müssen unbedingt:
- alle Handlungen unterlassen, die Gefahren für Kör-
per und Gesundheit, Gefahren für das Produkt oder
Gefahren für andere Werte bedeuten könnten,
- alle an dem Produkt vorgenommenen Veränderun-
gen dem zuständigen Vorgesetzten oder Betreiber
mitteilen,
- alle Veränderungen beim Betrieb des Produkts, z.B.
unübliche Laufgeräusche, dem zuständigen Vorge-
setzten oder Betreiber mitteilen.
An dem Produkt dürfen keine Veränderungen vorge-
nommen werden, die nicht zuvor von BOSCH -
REXROTH genehmigt worden sind.
Der Anwender verpflichtet sich:
- am und um das Produkt für Sauberkeit und Ordnung
zu sorgen,
- das Produkt nur in einwandfreiem Zustand zu betrei-
ben,
- das Produkt nur zum bestimmungsgemäßen
Gebrauch einzusetzen,
- das Produkt nur im Rahmen der unter 2.5 aufgeführ-
ten technischen Daten einzusetzen,
- umlaufende Teile durch geeignete Schutzvorrichtun-
gen abzusichern,
- das Personal soweit wie nötig zum Tragen von
Schutzkleidung zu verpflichten,
- dem zuständigen Personal diese Betriebsanleitung
auszuhändigen.
Zum bestimmungsgemäßen Gebrauch gehört auch die
Beachtung aller Angaben dieser Betriebsanleitung.
Beachten Sie ergänzend zur Betriebsanleitung alle all-
gemein gültigen gesetzlichen und sonstigen Regelungen
zur Unfallverhütung.
008 911 57 BOMAG
Bosch Rexroth AG 19.55/32
In particular, hazards may occur:
- if insufficiently trained personnel manipulates the
product,
- if the product is inexpertly installed, operated and
serviced,
- if the product is used for other than the intended
purposes.
All persons responsible for the operation of the plant or
product must:
- have definitely read and understood the chapter
"Notes on Safety",
- know these Operating Instructions or at least be
familiar with those parts where the respective activity
and associated dangers are described,
- be familiar with shut-down procedures, e.g. "Emer-
gency-OFF", relating to the entire plant or to plant
items important to the relevant activity,
- have adequate technical qualifications and be author-
ized to perform the relevant activity,
- know their specific duties and authority.
Moreover, it is mandatory that these persons:
- refrain from doing anything that might cause bodily
harm or constitute a danger to health, the product or
other assets,
- inform their superiors in charge or the Operator of
any modifications made to the product,
- inform their superiors in charge or the Operator of
any changes detected in the operational behaviour of
the product, e.g. unusual running noise.
No modifications to the product are permitted unless
the prior approval of BOSCH - REXROTH has been
obtained.
The User shall undertake to:
- ensure that the product and its surroundings are kept
clean and in good order,
- operate the product only when in perfect condition,
- use the product exclusively for the intended purpose,
- use the product only in the framework of the technical
characteristics listed under 2.5,
- safeguard rotating parts by means of suitable protec-
tive systems,
- instruct the personnel to wear protective clothing, to
the extent deemed necessary,
- distribute these operating instructions among the
personnel in charge.
Using the equipment for the intended purpose as set out
above also includes observing the instructions given in
this operating manual.
In addition to the procedures and instructions outlined in
this operating manual all generally applicable statutory
and other accident prevention rules and provisions must
be observed.
767
19.5
BDA 16633700 00 GFT 220 R3 9184
1. Einleitung • 1. Preliminary Notes
Die Gewährleistung durch
BOSCH - REXROTH erlischt:
- wenn das Produkt ohne unsere Zustimmung geöffnet
oder verändert wird,
- bei Nichtbeachtung der Instruktionen dieser Be-
triebsanleitung,
- bei Ein- und Anbau nicht von uns gelieferter oder
genehmigter Ersatzteile und Zusatzgeräte,
- bei Überlastung des Produktes von besonderer Art,
wie z.B. Drehschwingungen, Drehmomentstößen,
Fundamentverwindungen oder sonstigen unzulässi-
gen Einflüssen,
- wenn die in Kapitel 2.5 aufgeführten technischen
Daten über- oder unterschritten werden,
- bei unsachgemäßer Handhabung des Produktes.
Technische Änderungen, die der Verbesserung des
Produktes dienen, behalten wir uns vor.
Die Abbildungen in dieser Betriebsanleitung können von
der tatsächlichen Ausführung geringfügig abweichen.
Soweit vertraglich nichts anderes vereinbart ist, richten
sich die Gewährleistungsansprüche nach den zum Zeit-
punkt des Vertragsabschlusses geltenden "Allgemeinen
Bedingungen für Lieferungen und Leistungen" von
BOSCH - REXROTH.
Urheberrecht
Das Urheberrecht an Zeichnungen verbleibt bei uns.
Eine Zeichnung darf nur zu den Zwecken benutzt wer-
den, zu denen sie dem Empfänger anvertraut ist. Ohne
unsere ausdrückliche schriftliche Genehmigung dürfen
Zeichnungen nicht an Dritte weitergegeben oder diesen
zugänglich gemacht werden.
Jede Vervielfältigung - auch von Einzelheiten - ist unter-
sagt.
Zuwiderhandlungen werden gerichtlich verfolgt.
768 BOMAG
Wheel drive gear
Bosch from
Rexroth AGS/N 6/32
The warranty obligations of
BOSCH - REXROTH will become void:
- if the product is opened or modified without our con-
sent,
- in the event the instructions in this manual are disre-
garded,
- if spare parts and auxiliary items are built in or at-
tached which have not been supplied or approved by
us,
- if the product is subjected to overloads caused for
example by torsional vibrations, torque impacts,
distorted or deformed foundations or other impermis-
sible influences,
- if the technical characteristics specified under pt. 2.5
are exceeded or fallen short of,
- if the product is improperly handled or manipulated.
We reserve the right to implement technical changes for
product improvement purposes.
The photos and figures shown in this manual may slight-
ly deviate from the actual design.
Unless otherwise stipulated in the contract, any warranty
claims shall be dealt with in accordance with BOSCH -
REXROTH`s "General Terms and Conditions of Supplies
and Services" applicable at the time the contract has
been concluded.
Copyright
The copyright on drawings remains with us. A drawing
must only be used for the purposes it has been trans-
ferred to the recipient. Drawings must not be handed
over disclosed to third parties without our express con-
sent in writing.
Any reproduction of a drawing in whole or part is prohib-
ited.
Contraventions will be prosecuted.
008 911 57
Wheel drive gear
BDA 16633700 from
00 GFT 220S/N
R3 9184
2. Produktbeschreibung • 2. Product Description
2.1 Einführung
In diesem Kapitel finden Sie eine Beschreibung des
Getriebes GFT 220 R3 9184. Diese wird ergänzt durch
Angaben zum Lieferumfang, durch eine Auflistung der
technischen Daten und durch Angaben zu den Be-
triebsmitteln.
2.2 Beschreibung
Das Getriebe HYDROTRAC GFT 220 R3 9184 ist ein
dreistufiges Planetengetriebe. Zur Ausstattung gehört
eine integrierte, hydraulisch lüftbare Lamellenhaltebrem-
se.
Um einen optimalen Lastausgleich zu gewährleisten,
enthält jede Planetenstufe satzweise sortierte Planeten-
räder. Die außenverzahnten Räder sind einsatzgehärtet.
Das komplett wälzgelagerte Getriebe ist mit einer Öl-
tauchschmierung ausgestattet.
Eine spezielle Gleitringdichtung sorgt für den
optimalen Schmutz- und Staubschutz der Felgen- bzw.
der Turaslagerung.
Der mitgelieferte O-Ring (motorseitig) ermöglicht eine
statische Abdichtung des Hydromotors.
Das Getriebe ist ausschließlich zum Einsatz als Fahrge-
triebe für einen Müllverdichter (BC 50 RB) vorgese-
hen.
Für Schäden, die aus nicht bestimmungsgemäßem
Gebrauch entstehen, haftet BOSCH-REXROTH nicht.
Das Risiko trägt in einem solchem Fall ausschließlich
der Anwender.
2.3 Beschreibung der
Bremse
Die im Getriebe integrierte, naßlaufende, hydraulisch
lüftbare Lamellenbremse ist eine Haltebremse. Sie ist
durch Federkraft ständig geschlossen und wird durch
Zufuhr von Drucköl geöffnet.
2.4 Lieferumfang
Zum Lieferumfang gehört:
- Getriebe mit integrierter Lamellenhaltebremse.
- Technische Dokumentation.
Der gesetzlich vorgeschriebene Berührungsschutz an
umlaufenden Teilen gehört nicht zum Lieferumfang.
Überprüfen Sie alle Anlieferungen nach Erhalt unverzüg-
lich auf Vollständigkeit. Teilen Sie Abweichungen und
Transportschäden sofort BOSCH - REXROTH mit.
008 911 57 BOMAG
Bosch Rexroth AG 19.57/32
2.1 Introduction
This chapter contains a description of the propel gear
GFT 220 R3 9184. The description is supplemented by
information on the scope of supply, a list of technical
data and details of operating media.
2.2 Description
The planetary gearbox HYDROTRAC GFT 220 R3 9184
is of 3-stage design complete with an integrated, hydrau-
lically released multi-plate parking brake.
To ensure an optimum balancing of loads, each plane-
tary stage comprises of planet gears in sets. The exter-
nally toothed wheels are case-hardened.
The gearbox runs in antifriction bearings exclusively and
has a splash lubrication system.
A special mechanical seal reliably protects the rim- resp.
the tumbler bearing system against the ingress of dirt
and dust.
The o-ring (motor side) included in the supply enables
the unit to be reliably sealed statically.
The gearbox is exclusively intended for use as a propel
drive in a garbage compressor (BC 50 RB).
BOSCH-REXROTH shall not be liable for any damage
arising as a result of the gearbox being used for pur-
poses other than originally intended. In such a case, the
risk lies solely with the User.
2.3 Description of Brake
The hydraulically released, wet-running, multi-plate
brake, integrated in the gearbox, is a parking brake. It is
normally closed by spring force and released when pres-
surized by hydraulic oil.
2.4 Scope of Supply
The supply scope includes:
- Gearbox with integrated multiple disk holding brake.
- Technical documentation.
Means of protection against accidental contact with rotat-
ing parts as prescribed by statutory provisions do not
form part of the supply scope.
Please check all equipment supplies for completeness
immediately upon receipt. Any deviations and transit
damage must be reported to BOSCH - REXROTH right
away.
769
19.5
BDA 16633700 00 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 8/32

2. Produktbeschreibung • 2. Product Description

2.5 Technische Daten 2.5 Technical Data

Die Liste der technischen Daten finden Sie im The technical data are given in Appendix „D“.
Anhang „D“.
Beachten Sie die Daten auf der Einbauzeichnung: Please note the details on the installation drawing
0/6137/5184/0. 0/6137/5184/0.

2.6 Zeichnungen und 2.6 Drawings and Lists

Listen
Anhang Appendix
Einbauzeichnung 0/6137/5184/0 D Installation drawing 0/6137/5184/0 D
Ersatzteilzeichnung 0/6137/1184/1 D Spare parts drawing 0/6137/1184/1 D
Teileliste Getriebe 16633700 E Parts list gear drive 16633700 E

2.7 Betriebsmittel 2.7 Operating Media

Beachten Sie die Auflistung der ausgewählten Schmier- The list of recommended lube oils given in Appendix B
öle im Anhang B. shall be observed.

770 BOMAG 008 911 57

Wheel drive gear
BDA 16633700 from
00 GFT 220S/N
R3 9184 19.59/32
Bosch Rexroth AG

3. Transport / Lagerung • 3. Handling / Storage

3.1 Einführung 3.1 Introduction

Dieses Kapitel gibt Ihnen Hinweise auf die sichere Vor- This chapter describes how the handling and storing of
bereitung und Durchführung von Transport und Lage- the products of BOSCH-REXROTH are safely prepared
rung der Produkte von BOSCH-REXROTH. and carried through.

3.2 Hinweise zu Transport 3.2 Notes on Handling and

und Lagerung Storing
Achten Sie beim Transport auf eine aus- When handling the equipment make sure
reichende Tragkraft des Kranes. the carrying capacity of the crane is
adequate.

• Benutzen Sie nur zugelassene Transport-

elemente. • Use exclusively
equipment.
approved handling

• Befestigen Sie das Getriebe sorgfältig am

Kranhaken und benutzen Sie in Abhängig- • Carefully attach the gearbox to the crane
hook, using the lifting points provided.
keit von der Getriebegröße vorgesehene
Anhängevorrichtungen.

Stellen Sie sicher, daß beim Anheben des When lifting the gearboxes make sure that
Getriebes Anbauteile durch Transportele- the handling elements do not cause dam-
mente nicht beschädigt werden können. age to attachment parts.

• Lagern Sie die Getriebe nur in trockenen

und temperierten Räumen. • Store the gearboxes in dry and moderately
heated rooms only.

• Lagern Sie Getriebe nur in Einbaulage. • Store the gearboxes only in their intended
mounting position.

• Stellen Sie sicher, daß abgesetzte Getriebe

ihre Lage nicht ändern können. • Make sure that set down gearboxes rest
immovably.

BOSCH-REXROTH entsorgt mitgeliefertes BOSCH-REXROTH will dispose of any

Verpackungsmaterial, wenn dies kosten- packing material supplied with the gear-
frei zurückgesandt wird. boxes when this is returned to the Factory
free of charge.

3.3 Verpackung 3.3 Packing

Getriebe bis zur Größe 1200 x 1200 mm werden auf Up to dimensions of 1200 x 1200 mm the gearboxes will
einer Palette in Folie verschweißt. be welded with foil on a pallet.

Überseetransporte erfolgen vorwiegend in geschlosse- For oversea transports seaworthy packed wooden cases
nen, seemäßig verpackten Holzkisten bzw. in geschlos- respectively closed containers are used.
senen Containern.

008 911 57 BOMAG 771

19.5
BDA 16633700 00 GFT 220 R3 9184
3. Transport / Lagerung • 3. Handling / Storage
3.4 Konservierung
BOSCH-REXROTH liefert die Getriebe ohne Ölfüllung
aus.
Die Getriebe sind mit SHELL Öl S. 7294 SAE 50 innen-
konserviert.
Außenliegende Flansche, Wellenenden und Anflansch-
flächen sind mit TECTYL 502 C flächenkonserviert.
3.4.1 Lagerung in gelüfteten
Räumen
Die Getriebe sind in gelüfteten Räumen bis zu
24 Monate nach Lieferung ab unserem Werk gegen
Korrosion geschützt.
Wird die Verpackung entfernt, so ist die Außenkonser-
vierung zu prüfen und bei Bedarf fachgerecht zu erneu-
ern.
3.4.2 Lagerung im Freien
Bei einer Lagerung im Freien ist unbedingt sicherzustel-
len, daß kein Spritzwasser o.ä. die äußere Konservie-
rung beschädigen bzw. ins Getriebe eindringen kann
(Getriebe abgeplant; Spritzwasser geschützt unter
Schleppdach).
In diesen Fällen ist die Innen- und Außenkonservierung
regelmäßig alle 6 Monate zu überprüfen und evtl. zu
erneuern. Unter diesen Bedingungen besteht Korrosi-
onsschutz bis zu max. 24 Monate nach Lieferung ab
unserem Werk.
3.4.3 Lagerung in klimatisier-
ten Räumen
Ein Korrosionsschutz für max. 36 Monate ist nur mög-
lich, wenn die Lagerung in geschlossenen, klimatisierten
Lagerräumen erfolgt. Kondensation und hohe Luftfeuch-
tigkeit sind unbedingt auszuschließen.
Wird die Verpackung vorher entfernt, ist eine Kontrolle
der freiliegenden blanken Teile und eine evtl. Nachkon-
servierung mit TECTYL 502 C unerläßlich.
772 BOMAG
Wheel drive gear
Bosch from
Rexroth AGS/N 10/32
3.4 Preservation
The gearboxes supplied by BOSCH-REXROTH are not
filled with oil.
The interior of the gearboxes has been protected with
SHELL oil S. 7294 SAE 50.
The surfaces of external flanges, ends of shafts and
flange attachment faces are preserved with TECTYL 502
C.
3.4.1 Storage in Ventilated
Rooms
In ventilated localities the gearboxes are protected
against corrosion up to 24 month after delivery ex works.
If the packing material is removed the outer preservation
must be checked and -if necessary- skillfully renewed.
3.4.2 Storage Outdoors
If the gearboxes are stored outdoors it must be made
safe that no splash water can enter the gearbox or can
do any harm to the outer preservation (Gearboxes can-
vas covered or splash proofed by a movable hood).
In such cases the inner and outer preservation has to be
checked every 6 months and -if necessary- to be
renewed. Under this condition the protection against
corrosion will last max. 24 months after delivery ex
works.
3.4.3 Storage in Air-
Conditioned Rooms
A protection against corrosion for max. 36 months is only
possible, if the storage is done in air-conditioned locali-
ties. Condensation and high atmospheric humidity must
be avoided.
If the packing material will be removed all bare parts
have to be checked and the preservation with TECTYL
502 C has to be renewed.
008 911 57
Wheel drive gear
BDA 16633700 from
00 GFT 220S/N
R3 9184 Bosch Rexroth AG 19.511/32
3. Transport / Lagerung • 3. Handling / Storage

3.4.4 Lagerung von teilge- 3.4.4 Storage of part-closed

schlossenen Getrieben
Getriebe oder Getriebeöffnungen, die nur mit Ölpapier
und einem Holzdeckel oder mit einem ölbeständigen
Kunststoffdeckel verschlossen sind, dürfen nur in ge-
schlossenen Räumen, max. 3 Monate gelagert werden.
Gearboxes
Gearboxes or gearbox orifices that are protected/closed
off only by oil paper and a wooden cover or by an oil
resistant plastic cover, must exclusively be stored in
enclosed rooms for a maximum period of 3 months.

3.4.5 Langzeitkonservierung 3.4.5 Long-Term Preservati-

Bei einer Zwischenlagerung von mehr als 36 Monaten
bedarf es einer speziellen Nachkonservierung und die
Einhaltung verschiedener Auflagen.
on
In the event the gearboxes are stored for a period ex-
ceeding 36 months, they must receive a special preser-
vation treatment. Furthermore various special directions
have to be executed.

In solchen Fällen sind die Getriebe vor dem Einsatz In such cases the gearboxes have to undergo a com-
einer gründlichen Inspektion und einem Probelauf zu plete inspection and a new test run.
unterziehen.

Einzelheiten hierzu erfragen Sie bitte bei unserer For details in this respect please contact our Service
Service-Abteilung. Department.

008 911 57 BOMAG 773

19.5
BDA 16633700 00 GFT 220 R3 9184
4. Einbau • 4. Mounting
4.1 Einführung
Das Kapitel beschreibt den Einbau des Fahrgetriebes in
den Fahrwerksrahmen.
Beachten Sie unbedingt die vorangestell-
ten Sicherheitshinweise.
Beachten Sie die Hinweise in der Einbauzeichnung:
0/6137/5184/0
4.2 Handlungschritte zum
Einbau
VORSICHT !
Gefahr von Personen- oder Sachschäden!
Durch das Verwenden von metrischen und
amerikanischen Gewinden wie z.B. UN oder
UNF Gewinden an unseren Produkten kann
es zu Verwechslungen und somit zu Be-
schädigungen des Produkts und/oder zu
Verletzungen von Personen kommen.
• Stellen Sie sicher, dass das Pro-
dukt/die Anlage durch qualifizier-
tes Personal korrekt montiert
wurde, bevor Sie das Produkt/die
Anlage in Betrieb nehmen.
• Das Produkt darf nur montiert und
in Betrieb genommen werden
wenn Dokumente wie z.B das
Technische Datenblatt oder die
Einbauzeichnung des Produkts
vorliegen aus denen die Gewinde-
arten und -größen ersichtlich sind.
Achtung!
Beim Abbau des Hydromotors kann je
nach Ausführung des Getriebes der Mit-
nehmer aus dem Eingriff der Lamellenver-
zahnung gezogen werden!
Achten Sie beim Einbau des Mitnehmers
auf dessen richtige Einbaulage.
Siehe Ersatzteilzeichng.: 0/6137/1184/1
Befestigen Sie das Getriebe sicher am
Fahrwerksrahmen, bevor Sie die An-
schlagmittel entfernen.
• Vermeiden Sie beim Einbau unbedingt
grobe Schläge.
774 BOMAG
Wheel drive gear
Bosch from
Rexroth AGS/N 12/32
4.1 Introduction
This chapter describes the installation of the propel gear
into the bogie frame.
The preceding safety notes must be care-
fully observed.
Carefully follow the instructions given on the installation
drawing: 0/6137/5184/0
4.2 Mounting Work to be
Performed
CAUTION!
Risk of Personal Injury or Damage to Proper-
ty!
As both metric and US threads, such as UN or
UNF threads, are used on our products, there
is a risk of confusion that may lead to damage
to equipment and/or personal injury.
• Prior to starting up the pro-
duct/equipment, make sure that it
has been correctly assembled and
installed by qualified personnel.
• The product/equipment must not
be assembled/installed and star-
ted up, unless documents are a-
vailable, e.g. technical datasheets
or installation drawings, which
clearly show the thread types and
sizes.
Caution!
Depending on the gearbox design, the
coupler can be disengaged from the inner
gearing of the disks when disassembling
the hydraulic motor!
Make sure to observe its correct installa-
tion position when mounting the coupler.
See spare part drawing: 0/6137/1184/1
Secure the gearbox safely before removing
the lifting straps or ropes.
• Avoid heavy blows when mounting the
equipment.
008 911 57
Wheel drive gear
BDA 16633700 from
00 GFT 220S/N
R3 9184 19.513/32
Bosch Rexroth AG

4. Einbau • 4. Mounting

Vermeiden Sie unbedingt Axialkräfte. Make sure that axial forces are not exerted
during mounting.

• Vermeiden Sie unbedingt hohe Druckkräf-

te auf das Getriebegehäuse. • Make sure high compressive forces do not
act on the gearbox housing.

• Beachten Sie die Einbauzeichnung und die

zugehörigen Daten. • During this work observe installation dra-
wing as well as pertinent data.

Hängen Sie das Getriebe an den Kran. Attach the gearbox to a crane.

Heben Sie das Getriebe in den Fahrwerksrahmen. Lift the gear into the bogie frame.

Ziehen Sie die Befestigungsschrauben (Qualität min. Tighten the screws (quality nom. 10.9 DIN / ISO) using
10.9 DIN / ISO) mit einem Drehmomentschlüssel an. a torque wrench.
Entnehmen Sie die Anzugsmomente der Rahmenzeich- The relevant tightening torques shall be taken from the
nung. frame drawing.

Entfernen Sie die Transportmittel. Remove the lifting straps or ropes.

Entfernen Sie den Schutzstopfen (motorseitig) am Ge- Remove the plug (motor side) at the gearbox before
triebe vor dem Anschrauben des Hydromotors. connecting the hydraulic motor.

Achten Sie darauf, daß kein Schmutz oder Make sure that no dirt or foreign bodies
Fremdkörper in das Getriebe gelangt. are allowed to enter the gearbox.

Bauen Sie den Hydromotor an. Beachten Sie unbedingt Mount the hydraulic motor. Carefully observe the respec-
die Angaben des Herstellers. tive instructions given by the manufacturer.

• Achten Sie beim Anbau des Motors auf

sorgfältige Abdichtung (O-Ring Pos. 66). • When mounting the hydraulic motor make
sure that it is properly sealed off (O-ring
item 66).

Beachten Sie unbedingt die Sicher- The preceding safety notes of manufac-
heitshinweise des Herstellers. turer must be carefully observed.

Entfernen Sie die Schutzstopfen vor dem Anschrauben Remove the plugs before connecting the hydraulic oil
der Hydraulikölleitungen. lines.

Achten Sie darauf, daß kein Schmutz oder Make sure that no dirt or foreign bodies
Fremdkörper in die Hydraulikanlage ge- are allowed to enter the hydraulic system.
langen.

• Schließen Sie den Hydromotor an. • Connect the hydraulic motor.

Beachten Sie unbedingt die Sicher- The preceding safety notes of manufac-
heitshinweise des Herstellers. turer must be carefully observed.

• Schließen Sie die Lamellenhaltebremse an.

• Connect the multi-plate parking brake.

008 911 57 BOMAG 775

19.5
BDA 16633700 00 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 14/32

4. Einbau • 4. Mounting

Die Lamellenhaltebremse ist eine Sicher- The multi-plate parking brake is a safety
heitseinrichtung des Getriebes. device of the gearbox.

• Schließen Sie die Bremslüftleitung an.

Entfernen Sie dafür den Schutzstopfen • Connect the brake release line after remov-
ing the plug (item 71).
(Pos. 71).

Achten Sie darauf, daß kein Schmutz oder Make sure that no dirt or foreign bodies
Fremdkörper in den Bremslüftanschluß are allowed to enter the brake release port.
gelangt.

Sorgfältige Abdichtung des Brems- Make sure that the brake release port is
lüftanschlusses beachten. properly sealed.

• Es darf kein Staudruck in der Brems-

leitung vorhanden sein. • Back pressure is not allowed in the brake
release line.

Überprüfen Sie noch einmal den ordnungsgemäßen Sitz Check once again tight fit of all joining elements.
und die Festigkeit aller Verbindungselemente.

776 BOMAG 008 911 57

Wheel drive gear
BDA 16633700 from
00 GFT 220S/N
R3 9184
7. Pflege / Wartung • 7. Maintenance / Care
5.1 Einführung
Dieses Kapitel beschreibt die Handlungsschritte zur
Inbetriebnahme des Getriebes. Beachten Sie die ent-
sprechenden Sicherheitshinweise.
5.2 Handlungsschritte zur
Inbetriebnahme
Betätigen Sie im Gefahrenfall NOT-AUS.
• Berühren Sie keine umlaufenden Teile.
Bei der Befüllung dürfen keine Schmier-
stoffe in die Umwelt gelangen.
Führen Sie die Ölwechsel nur im betriebs-
warmen Zustand unmittelbar nach dem
Stillstand des Getriebes durch.
Hierdurch ist sichergestellt, daß kein Ab-
setzen der Feststoffpartikel stattgefunden
hat.
Befüllen Sie gemäß der Schmierölangabe das Getriebe
mit sauberem Öl.
Bei der Erstölbefüllung können Ölmenge und Ölmen-
genangabe durch im Getriebe vorhandenes Konservie-
rungsöl voneinander abweichen.
Vermeiden Sie Verunreinigungen des Ge-
triebes.
Eine Liste der von BOSCH-REXROTH zu-
gelassenen Öle finden Sie im Anhang B.
Füllen Sie das Öl durch die in der Einbauzeichnung
gekennzeichnete Schraube ein.
Überprüfen Sie den Ölstand, bevor Sie das Getriebe
anfahren.
Den korrekten Ölstand erkennen Sie bei Stillstand des
Getriebes durch die Öffnung im Getriebegehäuse.
Die max. Betriebstemperatur beträgt 90°C.
Überprüfen Sie nach Erreichen der Betriebstemperatur
das Getriebe auf Dichtigkeit.
Diese Prüfung können Sie während des Betriebes durch-
führen.
008 911 57 BOMAG
Bosch Rexroth AG 19.515/32
5.1 Introduction
This chapter describes the course of action to be fol-
lowed when taking the gearbox into service. The respec-
tive notes on safety shall be duly observed.
5.2 Commissioning Activties
In cases of emergency actuate
EMERGENCY-OFF.
• Do not touch any rotating parts.
When filling the gearbox take care that
lubricants are not allowed to pollute the
environment.
Make sure to perform oil changes
immediately after standstill with the
gearbox still being warm, to avoid any
setting of solid particles.
Fill the gearbox with clean oil as specified under the
heading lubrication.
At first oil fill, actual oil volume and specified oil volume
may vary due to preservation oil remains in the gearbox.
Ensure that no dirt or other contaminants
are allowed to enter the gearbox.
A list of oils approved by BOSCH-
REXROTH is given in Appendix B.
Fill in oil through the screw indicated in the installation
drawing.
Check the oil level before starting up the gearbox.
The correct oil level can be ascertained through the
opening in the gearbox housing, when the gearbox is not
operating.
The maximum operating temperature is 90°C.
When the operating temperature has been
reached, check the entire gearbox for tightness.
This check can be performed while the gearbox is run-
ning.
777
19.5
BDA 16633700 00 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 16/32

7. Pflege / Wartung • 7. Maintenance / Care

Die folgenden Überprüfungen dürfen Sie The following checks must only be carried
nur bei Stillstand des Getriebes durchfüh- out when the gearbox is at a standstill.
ren.

Überprüfen Sie nach ca. 10 Stunden Vollastbetrieb After 10 hours of full load operation check all fastening
sämtliche Befestigungsschrauben auf festen Sitz. screws and boltings for tightness.

Überprüfen Sie den festen Sitz aller Schrauben des Check whether all bolts of the gearbox are tight as re-
Getriebes. quired.

Erster Ölwechsel nach ca. 50 Motorbetriebsstunden First oil change is to be made after approx. 50 motor
durch BOMAG - Personal. operating hours, by BOMAG - personnel.

Weitere Ölwechsel sind entsprechend den im Further oil changes are to be made at intervals as per
Wartungsplan (Kapitel 7.3) angegebenen Intervallen the Maintenance Schedule given in Chapter 7.3.
durchzuführen.

Bei jedem Ölwechsel sind die Magnetverschlußschrau- Make sure that the magnetic screw plugs must be
ben zu reinigen. cleaned at each oil change.

778 BOMAG 008 911 57

Wheel drive gear
BDA 16633700 from
00 GFT 220S/N
R3 9184
7. Pflege / Wartung • 7. Maintenance / Care
7.1 Einführung
Dieses Kapitel zeigt Wartungsschritte und die zugehöri-
gen Sicherheitsmaßnahmen auf.
Berühren Sie keine umlaufenden Teile.
• Setzen Sie zu Wartungsarbeiten das Ge-
triebe still.
7.2 Handlungsschritte zu
Pflege und Wartung
Durch entsprechende Pflege und Wartung können Sie
die Lebensdauer von Maschinen und Anlagen wesentlich
verlängern.
Führen Sie wöchentlich Sichtkontrollen durch. Überprü-
fen Sie dabei insbesondere die Dichtigkeit des Getrie-
bes.
Führen Sie regelmäßig Geräuschkontrollen durch.
Führen Sie regelmäßig Ölstandskontrollen durch
(Ölstandskontrolleinrichtung, Markierungen, Ölstands-
kontrollschrauben).
Führen Sie die Ölwechsel nur im betriebs-
warmen Zustand unmittelbar nach dem
Stillstand des Getriebes durch.
Hierdurch ist sichergestellt, daß kein Ab-
setzen der Feststoffpartikel stattgefunden
hat.
Führen Sie nach Angaben des Wartungsplanes Ölwech-
sel durch.
Fangen Sie Altöl in geeigneten Behältern
auf und entsorgen Sie es unter Beachtung
der entsprechenden Vorschriften.
Alle Stundenangaben zu den Ölwechseln
beziehen sich auf Motorbetriebsstunden.
Erster Ölwechsel nach ca. 50 Motorbetriebsstunden
durch BOMAG - Personal.
Zweiter Ölwechsel nach 500 Motorbetriebsstunden.
Führen Sie weitere Ölwechsel nach jeweils 1000 Motor-
betriebsstunden durch, spätestens jedoch nach
12 Monaten.
Bei jedem Ölwechsel sind die Magnetverschlußschrau-
ben zu reinigen.
008 911 57 BOMAG
Bosch Rexroth AG 19.517/32
7.1 Introduction
This chapter indicates maintenance routines and related
safety measures.
Do not touch rotating components.
• If you intend to perform maintenance work
shut down the unit.
7.2 Maintenance and Care
Activities
The service life of machinery and equipment can be
considerably increased by taking appropriate mainte-
nance and care steps.
Perform visual inspections on a daily basis. In particular,
check the tightness of the gear.
Check the equipment regularly for unusual noise.
Make oil level checks at regular intervals (oil level moni-
toring device, markers, oil level plug).
Make sure to perform oil changes
immediately after standstill with the
gearbox still being warm, to avoid any
setting of solid particles.
Make oil changes as prescribed in the Maintenance
Schedule.
Collect spent oil in suitable containers and
dispose of the oil in line with the respec-
tive regulations.
All user specifications concerning oil
change intervals refer to motor operating
hours.
First oil change is to be made after approx. 50 motor
operating hours, by BOMAG - personnel.
Second oil change is to be made after 500 motor operat-
ing hours.
Change the oil every 1000 motor operating hours or after
12 months wichever is earlier.
Make sure that the magnetic screw plugs must be
cleaned at each oil change.
779
19.5
BDA 16633700 00 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 18/32

7. Pflege / Wartung • 7. Maintenance / Care

Überprüfen Sie mindestens einmal monatlich den festen Check the tightness of all screws and bolts at least once
Sitz aller Schrauben. a month.

7.3 Wartungsplan Getriebe 7.3 Maintenance Schedule

Gearbox
Nach 50 - erster Ölwechsel durch After 50 - First oil change by

Motorbetriebsstunden BOMAG - Personal motor operating hours BOMAG - personnel

- Magnetverschlußschrauben - Clean the magnetic screw

reinigen plugs

Nach 500 - zweiter Ölwechsel After 500 - Second oil change

Motorbetriebsstunden - Magnetverschlußschrauben motor operating hours - Clean the magnetic screw

reinigen plugs

Wöchentlich: - Sichtkontrolle Weekly: - Inspect visually

- Geräuschkontrolle - Check for unusual noise

- Ölstandskontrolle - Check oil level

Monatlich: - Schraubenverbindungen Monthly: - Check the tightness of all

kontrollieren* screws and bolts*

Halbjährlich: - Ölqualitätskontrolle Semi-annually: - Check oil quality

Jährlich: - Ölwechsel Annually: - Change oil

(spätestens jedoch - Magnetverschlußschrauben (or after 1000 motor - Clean the magnetic screw

nach jeweils 1000 reinigen operating hours whi- plugs

Motorbetriebsstunden) chever is earlier)

* Beachten Sie unbedingt die in der Einbauzeich- * Observe the tightening torques indicated in the
nung angegebenen Anzugsdrehmomente. installation drawing.

7.4 Wartungsplan Bremse 7.4 Maintenance

Schedule Brake
Die Bremse ist wartungsfrei. The brake is maintenance-free.

Bei Funktionsstörungen, thermischer Ü- In case of malfunctions, excessive thermal

berlastung und bei sämtlichen Reparatur- stress and all repair works on the multi-
arbeiten an der Lamellenhaltebremse plate parking brake, make sure to always
müssen immer: replace:

- Lamellen - disks
- Federn - springs
- Dichtelemente - seals.

ausgetauscht werden.

780 BOMAG 008 911 57

Wheel drive gear
BDA 16633700 from
00 GFT 220S/N
R3 9184 Bosch Rexroth AG 19.519/32
8. Ausbau • 8. Dismantling

8.1 Einführung 8.1 Introduction

Dieses Kapitel beschreibt den Ausbau des Getriebes In this chapter the procedure of dismantling the propel
aus dem Fahrwerksrahmen. Beachten Sie unbedingt die gear is described. It is mandatory to observe the safety
Sicherheitshinweise. Der Einbau ist im Kapitel 4 be- notes. A gearbox mounting description is given in Chap-
schrieben. ter 4.

Die Anlage ist nicht in Betrieb. The plant has been taken out of service.

• Sichern Sie die Anlage zuverlässig gegen

unbeabsichtigtes Einschalten. • Make sure reliable measures are taken to
prevent the plant from being activated
inadvertently.

• Stellen Sie sicher, daß die Tragkraft des

Kranes zur Aufnahme des Getriebes aus- • Make sure the crane carrying capacity is
adequate for gearbox lifting.
reicht.

Sichern Sie das Getriebe gegen unkontrol- Safeguard the gearbox against uncon-
lierte Bewegungen, z.B. Verrutschen. trolled movements, e.g. sliding.

• Vermeiden
Schläge.
Sie beim Ausbau grobe
• Avoid heavy blows when dismantling the
equipment.

• Vermeiden Sie Axialkräfte. • Make sure that axial forces are not
exerted.

8.2 Handlungsschritte zum 8.2 Dismantling Work to be

Ausbau Performed
Lassen Sie das Öl ab. Drain the oil from the gearbox.
Verwenden Sie dabei geeignete Auffanggefäße. For this purpose use suitable containers.

Fangen Sie evtl. auslaufendes Öl in geeig- Any oil spillage must be collected in
neten Gefäßen auf. suitable containers.

Achten Sie beim Transport auf eine aus- For gearbox handling make sure that the
reichende Tragkraft des Kranes. carrying capacity of the crane is sufficient.

• Benutzen Sie nur zugelassene Transport-

elemente. • Use approved handling elements only.

• Befestigen Sie das Getriebe sorgfältig am

Kranhaken. • Attach the gearbox carefully to the lifting
hook.

Straffen Sie die Anschlagmittel, ohne jedoch das Getrie- Tighten the lifting straps or ropes without lifting up the
be anzuheben. gearbox.

Stellen Sie sicher, daß das Getriebe nicht Make sure that the gearbox is not canted.
verkantet.

008 911 57 BOMAG 781

19.5
BDA 16633700 00 GFT 220 R3 9184
8. Ausbau • 8. Dismantling
Lösen Sie die Versorgung des Hydromotors.
Verschließen Sie die Hydraulikleitungen mit Stopfen.
Achten Sie darauf, daß kein Schmutz oder
Fremdkörper in die Hydraulikanlage ge-
langen.
Achtung!
Beim Abbau des Hydromotors kann je
nach Ausführung des Getriebes der Mit-
nehmer aus dem Eingriff der Lamellenver-
zahnung gezogen werden!
Achten Sie beim Einbau des Mitnehmers
auf dessen richtige Einbaulage.
Siehe Ersatzteilzeichng.: 0/6137/1184/1
Lösen Sie die Bremslüftleitung.
Verschließen Sie den Bremslüftanschluß mit einem
Stopfen.
Achten Sie darauf, daß kein Schmutz oder
Fremdkörper in den Bremslüftanschluß
gelangt.
Lösen Sie die Befestigungsschrauben des Getriebeflan-
sches.
Das Getriebe hängt nun am Kran.
Führen Sie das Getriebe vorsichtig aus dem Fahrwerks-
rahmen und legen Sie es ab.
782 BOMAG
Wheel drive gear
Bosch from
Rexroth AGS/N 20/32
Disconnect the hydraulic motor from the supply system.
Close off the hydraulic lines by means of plugs.
Make sure that no dirt or foreign bodies
are allowed to enter the hydraulic system.
Caution!
Depending on the gearbox design, the
coupler can be disengaged from the inner
gearing of the disks when disassembling
the hydraulic motor!
Make sure to observe its correct installa-
tion position when mounting the coupler.
See spare part drawing: 0/6137/1184/1
Disconnect the brake release line.
Close off the brake release port by means of a plug.
Make sure that no dirt or foreign bodies
are allowed to enter the brake release port.
Remove the fastening screws of the gearbox flange.
The gearbox is now suspended from the crane.
Move the gearbox carefully out of the bogie frame and
lay it down.
008 911 57
Wheel drive gear
BDA 16633700 from
00 GFT 220S/N
R3 9184 Bosch Rexroth AG 19.521/32
10. Ersatzteilbestellung • 10. Spare Parts Ordering

Die im Anhang „E“ aufgeführten Positio- Some of the parts list items listed in ap-
nen der Teileliste können zum Teil nur als pendix „E“ can only be purchased as spa-
Ersatzteil-Kits wie z.B.: re parts kits, e.g.:
• Dichtsatz • sealing kit
• Bremsen Reparatur-Satz • brake repair kit
• Planetensteg komplett • planet carrier complete.
bezogen werden. Please address your enquiries for the re-
Fragen Sie die entsprechenden Kits über quired kits to our spare parts sales de-
unseren Verkauf-Ersatzteile an. partment.

Das Anschriftenverzeichnis finden Sie im For list of addresses, see appendix A.

Anhang A.

Ersatzteile müssen den von BOSCH-REXROTH festge- Spare parts must satisfy the technical requirements
legten technischen Anforderungen genügen. Dies ist bei stipulated by BOSCH-REXROTH. Original spares sup-
Original BOSCH-REXROTH Ersatzteilen immer gewähr- plied by BOSCH-REXROTH always meet these de-
leistet. mands.

Geben Sie Ersatzteilbestellungen schriftlich auf. In drin- Please submit your spare parts orders in writing. In ur-
genden Fällen können Sie auch telefonisch oder über gent cases, the order can also be placed via phone or
Telefax bestellen, wenn Sie dies umgehend schriftlich fax; however, such orders must be confirmed in writing
bestätigen. without delay.

Richten Sie Ersatzteilbestellungen an die in Ihrer Nähe Please send your spare parts order to an agency of
niedergelassene Außenstelle von BOSCH-REXROTH BOSCH-REXROTH located in your area or send it di-
oder direkt an das Stammhaus (siehe angefügtes Ver- rectly to our main offices (see attached list of ad-
zeichnis der Anschriften). dresses).

Geben Sie bei einer Bestellung folgende Daten an: Spares orders should specify the following details:

- die Serialnummer - the serial number

- die Auftragsnummer - the order number
Sie finden diese Nummern auf dem Typenschild, das These numbers are given on the nameplate attached
an jedem Produkt angebracht ist. to each product.

- die Zeichnungsnummer - the drawing number

- die Positionsnummer - the item number
- die genaue Benennung - the exact designation
- die Teil-Nr. - the part-no.
Sie finden diese Nummern in der Teileliste. These numbers are included in the parts list.

- die Stückzahl der gewünschten Ersatzteile - the required spare parts quantity
- die gewünschte Versandart (z.B. Expressgut, Fracht- - the type of shipment desired (e.g. by express, freight,
gut, Luftfracht, Kurierdienst, usw.). air freight, messenger etc.).

Bei Ersatzbestellung des kompletten Please advise control data specified on the
Hydraulikverstellmotors sind die auf der installation drawing when submitting a
Einbauzeichnung aufgeführten Einstellda- spare order for the complete hydraulic
ten mit anzugeben. variable displacement motor.

008 911 57 BOMAG 783

19.5
BDA 16633700 00 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 22/32

Anhang • Appendix

784 BOMAG 008 911 57

Wheel drive gear
BDA 16633700 from
00 GFT 220S/N
R3 9184 19.524/32
Bosch Rexroth AG

B. Schmieröle • B. Lube Oils

Inhaltsverzeichnis Table of Contents

1. Schmierölempfehlung 1. Recommendation on Lube Oils
Übersicht RNM 17420-000 Overview RNM 17420-000

2. Schmierölempfehlung 2. Recommendation of Lube Oils

CLP 220 RNM 17421-005 CLP 220 RNM 17421-005

008 911 57 BOMAG 785

 19.5 Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Wheel drive gear from S/N
Mobile
Hydraulics

BRM-GT / Werknorm
Schmierölempfehlung RNM 17420-000
Übersicht 2004-10-01

Sachgebiet 17: Schmierstoffempfehlungen Ersatz für

LSN 935 1400: 2003-05-02

Änderungen

x Redaktionelle Überarbeitung und Umwandlung der LSN-Nummern in RNM-Nummern

(Rexroth Norm Mobile Hydraulics)

1. Zweck

Diese Norm legt empfohlene Schmieröle für den Einsatz in Bosch Rexroth–Getriebe für mobile und industrielle
Anwendungen fest.
Für Schmieröle in Windkraftanlagen gelten Sonderempfehlungen!

2. Anwendungsbereich

Diese Norm ist für den Produktbereich BRM-GT gültig.

(Bosch Rexroth, Mobile Hydraulics, Produktbereich Getriebetechnik)

3. Zuständigkeit
© Bosch Rexroth AG 2004

Für die Pflege dieser Norm ist BRM-GT/NOR zuständig.

4. Allgemeines

Die in der RNM 17421 und RNM 17422 aufgeführten Öle sind eine Auswahl der von BRM-GT empfohlenen
Schmieröle für Stirnrad,- Kegelrad- und Planetengetriebe. Es sind CLP-Industriegetriebeöle und
Kfz-Getriebeöle, die die von BRM-GT zwingend vorgeschriebenen Anforderungen erfüllen. Die
Empfehlungen basieren auf einschlägigen Produktinformationen sowie einer zum Teil jahrelangen
Erfahrung.

Die Auswahl der Ölsorte, (Mineralöl, Synthetiköl oder Kfz-Getriebeöl) wird primär durch den Anwender
vorgenommen. Hierbei spielt unter anderem die Logistik eine wesentliche Rolle. Eine qualitative Bewertung
zwischen diesen Ölen kann hieraus nicht abgeleitet werden.

Alle aufgeführten Öle sind mit dem bei BRM-GT eingesetzten Einkomponentenlack (kein Nitrolack) als
Innenanstrich sowie den standardmäßigen Elastomeren aus NBR und FPM (einsatztemperaturabhängig)
verträglich. Bei den mineralölbasischen Getriebeölen sollte eine Ölbaddauertemperatur von +85°C nicht
überschritten werden. Kurzfristig sind Spitzentemperaturen von +100°C zulässig, wobei diese die
Gebrauchsdauer des Schmiermittels erheblich herabsetzen können. Höhere Dauertemperaturen führen zu
einer erheblichen Herabsetzung der Betriebsviskosität und zum frühzeitigen Altern des Schmierstoffes. Das
Überschreiten einer zulässigen Grenztemperatur bewirkt eine chemischen Zersetzung der Ölmoleküle, die
RNM-17420_000_NOR_N_DE_2004-10-01.doc

sich durch Geruch, Ablagerungen und Rückstände im System bemerkbar machen. Sind höhere
Temperaturen zu erwarten oder zeigt die Praxis höhere Dauertemperaturen, so sind synthetische Öle auf
Basis von Polyalphaolefinen (POA) vorzusehen, da diese einen erheblich flacheren Temperatur-
Viskositätsverlauf aufweisen.

Bosch Rexroth AG erstellt: BRM-GT/NOR, Moormann

Mannesmannstraße 29 • D-58455 Witten geprüft:
Tel. +49 2302 877-167 • Fax +49 2302 877 478 freigegeben:
Seite 1 / 5
786 BOMAG 008 911 57
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Schmierölempfehlung, Übersicht RNM 17420-000 : 2004-10-01

Eine, für den Anwender bindende Vorgabe ist die auf dem Typenschild und /
Achtung! oder in der Bedienungsanleitung angegebene Viskosität sowie Sonderhinweise.

Bei Verwendung einer anderen Viskosität oder eines anderen als hier
empfohlenen Getriebeöles übernimmt der Betreiber die Verantwortung für die
technische Eignung des Schmierstoffes. Die Benutzung von Schmierstoffen, die
nicht den nachfolgend spezifizierten Qualitätsanforderungen entsprechen, kann
unter Umständen die BRM-GT-Gewährleistungsbedingungen außer Kraft setzen.
Es wird ausdrücklich darauf hingewiesen, daß jeder Ölhersteller
beziehungsweise Öllieferant für die Qualität seines Produktes verantwortlich ist,
zum Beispiel Verunreinigungen oder Chargenunterschiede.

Hinweis: Bei der BRM-GT Verzahnungsberechnung nach DIN 3990 mit zusätzlicher
Graufleckenberechnung nach FVA-Nr. 54 wird die erforderliche Schadenkraftstufe
(SKS) für das Öl ausgewiesen. Sollte hier eine SKS > 9 errechnet werden, muss in
der Bedienungsanleitung ein Hinweis auf eine eingeschränkte Ölauswahl mit der
Grauflecken-Tragfähigkeitsklasse „hoch“ erscheinen!

Hinweis: Die oberen und unteren Gebrauchstemperaturen einzelner Getriebeöle können zu den
technischen Kennwerten „Flammpunkt und Pourpoint“ stark abweichen. Diese sowie
weitere Daten und Eigenschaften der Getriebeöle sind stets den technischen
Datenblättern der Ölhersteller zu entnehmen.

Nach Angaben der Schmierstoffhersteller sind die aufgeführten Produkte weltweit unter dem selben
Handelsnamen verfügbar und weisen vergleichbare technologische Eigenschaften auf.

4.1 Synthetische Öle auf Basis von Polyalphaolefinen PAO

Synthetische Öle haben einen höheren Viskositätsindex (VI) als Mineralöle und vermindern somit die
Viskositätsabhängigkeit von der Temperatur. Die aufgelisteten synthetischen Öle auf Basis von
Polyalphaolefinen (Spalte LS 3) sind zwar in jedem Verhältnis mit Mineralölen mischbar, um jedoch
Eintrübungen und Additivausfällungen zu vermeiden, sollten nicht mehr als 5 bis 10% Restöl im Gehäuse
verbleiben.

4.2 Synthetische Öle auf Basis von Polyglykolen PG (zur Zeit nicht zulässig für BR-Getriebe)

Hinweis: Synthetische Öle auf Basis von Polyglykolen sind aufgrund eventueller Unverträglichkeiten
mit dem Anstrich, den Standarddichtungen und den eingesetzten Ölschauglasmaterialien
ohne vorherige Rücksprache mit dem Getriebehersteller nicht zugelassen!

Eine Vermischung von Mineralölen mit Polyglykolen muss unter allen

Achtung! Umständen vermieden werden!

4.3 Biologisch schnell abbaubare Öle auf Basis synthetischer Ester HEES

Unter bestimmten Umständen können auch, hier nicht aufgeführte, biologisch schnell abbaubare Schmieröle
(synthetische Ester HEES) eingesetzt werden. Die Ergebnisse diverser Forschungsvorhaben, zum Beispiel
FKM-Nr. 051950, das VDMA-Arbeitsblatt 24 569 sowie auch einschlägige Erfahrungen von
Dichtungsherstellern und Ölfirmen zeigen bei Einsatz von biologisch schnell abbaubaren Ölen mögliche
Unverträglichkeiten mit bestimmten Dichtungsmaterialien und Anstrichstoffen sowie Reibwertminderungen
bei Lamellen. Für den Einsatz dieser Öle werden unter Umständen Sondermaterialien (nicht standardmäßige
BRM-GT-Materialien) notwendig, die Verträglichkeitsuntersuchungen erfordern.

Hinweis: Vor Einsatz eines biologisch schnell abbaubaren Öles, (Erstbefüllung oder Umstellung) ist
Rücksprache mit dem Getriebehersteller zu nehmen!

008 911 57 BOMAG 787

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Schmierölempfehlung, Übersicht RNM 17420-000 : 2004-10-01

5. RNM 17421 „Schmierölempfehlung CLP ISO VG 46 – 680“

In dieser Werknorm sind Mineralöle aufgeführt, die nach DIN 51517 T.3 die Mindestanforderungen für
CLP-Öle erfüllen. Sie enthalten Wirkstoffe zur Erhöhung des Korrosionsschutzes und der
Alterungsbeständigkeit sowie zur Herabsetzung des Verschleißes im Mischreibungsgebiet
(Hochdruckzusätze, sogenannte Extrem-Pressure Additives). Die Schadenkraftstufe im FZG-Normaltest
A/8,3/90 nach DIN 51354 T.2 beträgt mindestens 12. Im FZG-Graufleckentest gemäß FVA-Nr. 54/I-IV
erreichen diese Öle eine Graufleckentragfähigkeit „hoch“ (SKS 10) oder aber mindestens „mittel“ (SKS 9).

Andere Öle, wie zum Beispiel Hydrauliköle HLP oder synthetische Öle HC, die die CLP-Bedingungen
erfüllen oder übertreffen, sind hier integriert.

Die RNM 17421 ist nach ISO Viskositätsklassen abgestuft. Die niedrig viskosen Öle werden fast
ausschließlich für den Einsatz in Lamellenbremsen benötigt.

Nicht alle in dieser Werknorm aufgeführten Öle eignen sich für jeden Anwendungsfall. Aus diesem Grund
wurden die Gruppenbezeichnungen LS 1 und LS 3 festgelegt.

Hinweis: Die erforderliche LS-Gruppe ist von der Konstruktion vorzugeben! Sie ist in der
Betriebsanleitung und / oder auf dem Typschild genannt. Bei der Auswahl eines Öles ist
darauf zu achten, daß alle von der Konstruktion angegebenen LS Gruppen erfüllt werden.
ƎSchutzvermerk DIN 34 beachtenƎ - ƎCopyright reservedƎ

LS 1: Verschärfter FZG-Test

Diese Öle haben auch beim verschärften FZG-Test A / 16,6 / 90 (doppelte Umfangsgeschwindigkeit) die
Schadenkraftstufe 12 erreicht.

Bezeichnung für ein Schmieröl mit verschärftem FZG-Test der Viskosität ISO VG 100 CLP 100 LS 1

LS 3: Vollsynthetische Öle (Polyalphaolefine PAO)

Bei der Umstellung von Mineralöl auf Polyalphaolefinöl können 5 bis zu 10% des Mineralöles nach dem
Ablassen im Gehäuse verbleiben. Eine Vermischung beider Ölsorten in dieser Größenordnung kann
bedenkenlos vorgenommen werden.

Hinweis: Bei einer Vermischung mit Resten des von BRM-GT eingesetzten Konservierungsöles
neigen PAO jedoch zur Schaumbildung. Daher ist bei der Erstbefüllung eines konservierten
Getriebes ein Spüllauf durchzuführen oder ein Mineralöl als Einlauföl zu verwenden.

Bezeichnung für ein synthetisches Schmieröl der Viskosität ISO VG 100 CLP 100 LS 3

6. RNM 17422 „Schmierölempfehlung Kfz-Getriebeöl HYP SAE

In dieser Werknorm sind Ein- und Mehrbereichsöle für Kfz-Getriebe nach DIN 51512 aufgeführt und der API-
Klassifikation GL 4 und / oder GL 5 zugeteilt. Sie sind unter anderem unter dem Gesichtspunkt einer
definierten Ist-Viskosität (ISO-Viskosität) ausgewählt, da die bei Kfz-Getriebeölen übliche SAE-Viskosität in
mehrere ISO-Viskositätsklassen fallen kann (siehe nachfolgendes Schaubild). Für diese Öle liegen noch
keine Grauflecken-Testergebnisse vor, weshalb sie ausschließlich für Mobilgetriebe zur Anwendung
kommen dürfen.

Hinweis: Für die Auswahl einer HYP-Ölsorte ist die Viskositätsangabe auf dem Typenschild und/oder
in der Bedienungsanleitung mit der Ölspezifikation der Bedienungsanleitung abzugleichen.

Bezeichnung für ein Kfz-Getriebeöl der Viskosität SAE 80W-90 HYP SAE 80W-90

788 BOMAG 008 911 57

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Schmierölempfehlung, Übersicht RNM 17420-000 : 2004-10-01

7. Vergleich der Viskositäts-Einteilung verschiedener Öle

8. Ölwechsel / Ölauffüllung

Die Lebensdauer und Betriebssicherheit eines Getriebes wird wesentlich beeinflusst von dem Reinheitsgrad
des verwendeten Öles. Für den ersten Ölwechsel nach der Inbetriebnahme des Getriebes sowie die
weiteren Ölwechsel sind die Vorschriften in den Betriebsanleitungen zu beachten. Die beim Ölwechsel im
Getriebe verbleibenden Restmengen sollten so gering wie möglich gehalten werden.

Hinweis: Beim Nachfüllen oder Mischen von Ölen sollten unbedingt die Qualitäts- und
Viskositätsanforderungen beachtet werden. Ein Vermischen von Ölen unterschiedlicher
Hersteller bei gleicher Viskosität kann zu Qualitätsminderungen führen. Hier sollte vorher
der Schmierstofflieferant auf mögliche Verträglichkeitsprobleme angesprochen werden.

Die aufgeführten Schmierstoffe dürfen auf keinen Fall mit anderen Stoffen
Achtung! vermischt werden. Nach dem Spülen sowie Reinigen mit Petroleum oder
anderen Reinigungsmitteln muss das Getriebe vollkommen rückstandsfrei von
den zuvor genannten Mitteln sein. Vor Inbetriebnahme ist ein zusätzlicher
Spüllauf durchzuführen.

008 911 57 BOMAG 789

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Schmierölempfehlung, Übersicht RNM 17420-000 : 2004-10-01

9. Verwendete Abkürzungen und Kurzzeichen

AGMA American Gear Manufacturers Association

API American Petroleum Institute

DIN Deutsches Institut für Normung

EP Extrem Pressure

FKM Forschungskuratorium Maschinenbau e.V.

FVA Forschungsvereinigung Antriebstechnik

FZG Forschungsstelle für Zahnräder und Getriebebau, TU München

GfT Gesellschaft für Tribologie

GL Gear Lubricant

HD Heavy Duty

HYP Hypoidöl

SAE Society of Automotive Engineers

VDMA Verband Deutscher Maschinen- und Anlagenbau e.V.

VG Viskositätsgrad (Viskosität bei 40°C in mm²/s)

VI Viskositätsindex

10. Literaturangaben, mitgeltende DIN-Normen

DIN 51502 Kurzbezeichnung der Schmierstoffe

DIN 51512 SAE-Viskositätsklassen für Kraftfahrzeuggetriebe

DIN 51517 T3 Schmieröle CLP „Mindestanforderungen“

DIN 51354 T2 FZG-Zahnrad-Verspannungs-Prüfmaschine „Prüfverfahren“

FVA-Nr.54/I-IV Graufleckentragfähigkeit

790 BOMAG 008 911 57

 Wheel
Industrial drive
Hydraulics
gear
Electric Drives from
and Controls
S/N
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics
19.5

BRM-GT / Company standard

Recommendation on Lube Oils RNM 17420-000
Overview 2004-10-01

Subject group 17: Lubricant Recommendations Replacement for

LSN 935 1400-EN: 2003-05-02

Modifications

Ɣ Editorial revision and transformation of the LSN numbers in RNM numbers

(Rexroth standard mobile Hydraulics)

1. Purpose

This standard specifies recommended lubricating oils to be applied in Bosch Rexroth-Gears for mobile and
industrially applications.
For wind turbine application please refer to specific lube oil recommendations.

2. Application

The standard is valid for the product unit BRM-GT.

(Bosch Rexroth, Mobile Hydraulics, Product Unit of Gear Technology)

3. Responsibility
© Bosch Rexroth AG 2004

Responsible for this standards is BRM-GT/NOR

4. General

The oils listed in RNM 17421 and RNM 17422 are a selection of lube oils recommended by BRM-GT for use
in cylindrical, bevel and planetary gearboxes. CLP industrial gear oils and motorcar transmission oils meet
the requirements specified by BRM-GT as mandatory. These recommendations are based on applicable
product information and many years of experience in this field.

The lube oil brands (mineral oil, synthetic oil or motorcar transmission oil) are primarily selected by the
Operator. In this context, logistics play an important role. The recommendations are not meant to provide
quality standards for the individual lube oils.

All oils listed are compatible with one-pot paint material (not nitrocellulose lacquer) BRM-GT uses for inside
paint coatings as well as the standard elastomers of NBR and FPM (depending on application temperature).
As regards mineral-oil based gearbox lube oils an oil bath temperature of +85°C should not be exceeded.
For short operating periods peak temperatures of +100°C are admissible, but it should be noted that these
may considerably reduce the useful life of the lubricant. Continuously prevailing higher temperatures will
reduce the operating viscosity significantly and lead to premature ageing of the lubricant. If an admissible
temperature limit is exceeded the oil molecules chemically decompose and cause smell, deposits and
residues in the system. If higher temperatures are to be expected or higher continuous temperatures are
RNM-17420_000_NOR_N_EN_2004-10-01.doc

experienced in operating practice, synthetic oils based on polyalphaolefins (PAO) are to be used that feature
a considerably flatter temperature-viscosity characteristic curve.

Bosch Rexroth AG prepared: BRM-GT/NOR, Moormann

Mannesmannstraße 29 • D-58455 Witten checked:
Tel. +49 2302 877-167 • Fax +49 2302 877 478 released:
Page 1 / 5
008 911 57 BOMAG 791
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Recommendation on Lube Oils ,Overview RNM 17420-000 : 2004-10-01

A mandatory requirement specified on the nameplate and/or in the operating

Attention! manual are the viscosity indication and the special notes.

If the viscosity requirements are not met or a gearbox lube oil other than listed
is used the responsibility for technical suitability of the lubricant lies solely
with the Operator. The use of lubricants not meeting the quality standards
described below may result in BRM-GT‘ warranty obligations becoming
forfeited. It is expressly pointed out that any lubricant manufacturer or
supplier is responsible for the quality of its product, eg with respect to
impurities or differences between individual batches.

Note: BRM-GT‘ gearteeth calculation according to DIN 3990 (including micro-pitting

determination to FVA No. 54) shows the required breakdown-load stage (SKS) for the
oil. If a breakdown-load stage SKS of > 9 is determined here, a note must be included
in the operating manual saying that the lubricant selection is restricted to brands
featuring a „high“ micro-pitting (frosting) load carrying property.

Note: The maximum and minimum application temperatures of individual gear oils may
deviate significantly with regard to the technical parameters of „flashpoint and pour
point“. Relevant data and properties of the gear oils must always be taken from the
technical data sheets issued by the oil producers.

As pointed out by the lubricant producers, the products listed are available under the same tradename on a
worldwide basis and have comparable technological characteristics.

4.1 Synthetic oils on polyalphaolefin basis - PAO

Synthetic oils have a higher viscosity index (VI) than mineral oils and are thus able to reduce the influence of
temperature on viscosity. Although the polyalphaolefin-based synthetic oils listed (Column LS 3) can be
mixed with mineral oil at any desired ratio, care should nevertheless be taken to limit the amount of residual
mineral oil in the gearbox casing to 5 to 10% to avoid clouding and additive precipitation.

4.2 Synthetic oils on polyglycols basis - PG (presently not permissible for BR gearboxes)

Note: In view of the fact that synthetic oils on polyglycol basis may be incompatible with the
paint coat, standard seals and oil sightglass materials employed, these lubricants
must not be used without prior consent obtained from the gearbox maker!

Attention! Mixing polyglycols with mineral oils is strictly prohibited!

4.3 Quickly biodegradable oils on synthetic-ester basis - HEES

Under certain conditions, quickly biodegradable lubricant oils (synthetic ester – HEES) not listed here may
also be employed. Results of various research projects, for example FKM No. 051950, VDMA Data Sheet
24 569 as well as applicable experience gained by seal manufacturers and oil companies indicate that
quickly biodegradable oils may be incompatible with certain seal and gasketing materials and paint materials
or may reduce the friction characteristics of multiple plates. If such oils are to be used, special materials
(not BRM-GT standard materials) may be needed that have to be tested to ensure they are compatible with
the oil.

Note: Before using quickly biodegradable oil (first filling or brand change) consult with the
gearbox manufacturer!

792 BOMAG 008 911 57

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Recommendation on Lube Oils ,Overview RNM 17420-000 : 2004-10-01

5. RNM 17421 „Lube Oil Recommendation CLP ISO VG 46 – 680“

The mineral oils listed in this company standard specification meet the minimum requirements given in
DIN 51517 T.3 for CLP oils. They contain constituents that improve corrosion protection and ageing
resistance as well as reduce wear in the mixed friction range (extreme pressure additives). When subjected
to normal FZG testing A/8,3/90 to DIN 51354 T.2 a breakdown-load stage of min. 12 is achieved. When
subjected to a FZG micro-pitting test as per FVA No. 54/I-IV these oils reach the micro-pitting (frosting)
load-carrying property category „high“ (SKS 10) or at least „medium“ (SKS 9).

Other oil brands meeting or exceeding CLP requirements are included such as hydraulic oils HLP or
synthetic oils HC.

The specification RNM 17421 describes ISO viscosity categories. Low-viscosity oils are almost exclusively
needed for use with multiplate brakes. They have been tested by the multiple-plate manufacturer for
compatibility and friction behavior.

Not all of the lubricants listed in this standard are suited for any conceivable application. For that reason,
LS Groups LS 1, LS 3 were established.

Note: The Design Department hast to specify the required LS Group! This group will be indicated
in the operating manual and/or on the nameplate. When selecting an oil brand care must be
taken to ensure that all the requirements of a given LS Group are met. In the event an oil
meets requirements of additional LS Groups this lubricant can be used as well.

LS 1: Aggrevated FZG test:

Even when FZG tested under aggravated conditions (test A / 16,6 / 90 – double peripheral speed) these oils
have reached the properties of breakdown-load stage 12.

Identification for a lube oil passed aggravated FZG testing of viscosity ISO VG 100 CLP 100 LS1

LS 3: Fully synthetic oils (polyalphaolefins PAO)

When replacing mineral oil by polyalphaolefin-based oil 5 to 10% of the mineral oil are allowed to remain in
the casing after draining. Mixing both lube oil types is perfectly allowable if this mixing ratio is observed.

Note: However, PAO oils tend to foaming when mixed with residues of preservation oil as
used by L+S. Therefore, prior to initial filling of a preserved gearbox the unit must
either be flushed out or a mineral oil is to be used as running-in oil.

Identification for a synthetic lube oil of viscosity ISO VG 100 CLP 100 LS 3

6. RNM 17422 „Recommendation for Motorcar Transmission Oil HYP SAE”

This company standard specification lists unigrade and multigrade lube oils for motorcar transmission units
to DIN 51512 and assigns them to API classification GL 4 and/or GL 5. The selection of these lube oils is
based, inter alia, on a defined ‚actual‘ viscosity (ISO viscosity) because the SAE viscosity parameter
commonly applied to motorcar transmission units may appear in several ISO viscosity categories (see
following diagram). It is to be noted that micro-pitting (frosting) test results are not yet available for these oils
so that they must exclusively be used for mobile gears.

Note: When selecting a HYP lubricant brand the viscosity specification on the nameplate
and/or in the operating manual is to be compared and adapted to the lubricant
specification included in the operating manual.

Identification for a motorcar transmission oil of viscosity SAE 80W-90 HYP SAE 80W-90

008 911 57 BOMAG 793

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Recommendation on Lube Oils ,Overview RNM 17420-000 : 2004-10-01

7. Viscosity Classification Comparison of Various Lubricants

ƎSchutzvermerk DIN 34 beachtenƎ - ƎCopyright reservedƎ

8. Oil Change / Topping up Oil

The life and operational safety of a gear unit is greatly dependent on the purity of the oil employed for
lubrication. For the first oil change after commissioning of the gearbox as well as further oil changes the
instructions given in the relevant operating manuals are to be followed. The oil volume remaining in the
gearbox should be kept to a minimum.

Note: When topping up oil or if oils are to be mixed the quality and viscosity requirements
have to be carefully observed. Mixing lubricants of different makers may bring down
the quality standard even if the viscosity properties coincide. In such a case the
lubricant supplier should be consulted in advance to check if there are compatibility
problems.

The lubricants listed must never be mixed with other substances.

Attention! Flushing/purging media or petroleum or other agents used for cleaning the
gearbox have to be thoroughly removed without residues left. The unit must
again be flushed out before it is commissioned.

794 BOMAG 008 911 57

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Recommendation on Lube Oils ,Overview RNM 17420-000 : 2004-10-01

9. Abbreviations and Symbols Used

AGMA American Gear Manufacturers Association

API American Petroleum Institute

DIN Deutsches Institut für Normung

EP Extreme pressure

FKM Forschungskuratorium Maschinenbau e.V.

FVA Forschungsvereinigung Antriebstechnik

FZG Forschungsstelle für Zahnräder und Getriebebau, TU München

GfT Gesellschaft für Tribologie

GL Gear lubricant

HD Heavy duty

HYP Hypoid oil

SAE Society of Automotive Engineers

VDMA Verband Deutscher Maschinen- und Anlagenbau e.V.

VG Degree of viscosity (viscosity at 40°C in mm²/s)

VI Viscosity index

10. References, Co-applicable DIN Standards

DIN 51502 Abbreviation used for the lubricants

DIN 51512 SAE- viscosity categories for motorcar transmission lube oils

DIN 51517 T3 Lube oils „minimum requirements“

DIN 51354 T2 FZG- gear test rig „method“

FVA-Nr.54/I-IV Micro-pitting (frosting) load-carrying property category

008 911 57 BOMAG 795

 19.5 Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Wheel drive gear from S/N
Mobile
Hydraulics

BRM-GT / Werknorm
Schmierölempfehlung RNM 17421-005
Viskositätsklasse ISO VG 220 bei 40°C mm² / s (cST) DIN 51519 2004-10-01

Sachgebiet 17: Schmierstoffempfehlungen Ersatz für

LSN 935 1410-7: 2003-05-02

Änderungen

x Redaktionelle Überarbeitung und Umwandlung der LSN-Nummern in RNM-Nummern

(Rexroth Norm Mobile Hydraulics)

1. Zweck

Diese Norm legt empfohlene Schmieröle für den Einsatz in Bosch Rexroth–Getrieben für mobile und industrielle
Anwendungen fest.
Für Schmieröle in Windkraftanlagen gelten Sonderempfehlungen!

2. Anwendungsbereich

Diese Norm ist für den Produktbereich BRM-GT gültig.

3. Zuständigkeit
© Bosch Rexroth AG 2004

Für die Pflege dieser Norm ist BRM-GT/NOR zuständig.

4. Schmieröle

Ölfirma Ölsorte Kennz. n. Pourp. 1) GFT 2) Gruppenbezeichn. 3)

DIN 51502 in °C LS1 LS3
ADDINOL ECO GEAR 220 M CLP -15 hoch x
ECO GEAR 220 S CLP HC -45 hoch x x
Agip BLASIA 220 CLP -20 x
ARAL Degol BG 220 Plus CLP -15 hoch x
Degol PAS 220 CLP HC -42 hoch x x
Degol ESG 220 CLP HC -45 hoch x
BECHEM ECOGEAR 220 M CLP -15 hoch x
ECOGEAR 220 S CLP HC -45 hoch x x
BP Energol GR-XF 220 CLP -21 hoch x
Enersyn HTX 220 CLP HC -40 x x
Castrol Alpha SP 220 CLP -21 hoch x
Alphasyn T 220 CLP HC -45 x
Tribol 1100/220 CLP -24 hoch
Tribol 1510/220 CLP HC -42 hoch x
OPTIGEAR BM 220 CLP -15 hoch
OPTIGEAR SYNTHETIC A 220 CLP HC -36 hoch x x
RNM-17421_005_NOR_N_DE_2004-10-01.doc

ESSO SPARTAN EP 220 CLP -24

FUCHS RENOLIN CLP 220 PLUS CLP -24 hoch x
RENOLIN UNISYN CLP 220 CLP HC -54 hoch x x
KLÜBER Klüberoil GEM 1 – 220 N CLP -10 hoch
Kuwait Q8 Goya NT 220 CLP -12 hoch
Q8 El Greco 220 CLP HC -24 hoch x

Bosch Rexroth AG erstellt: BRM-GT/NOR, Moormann

Mannesmannstraße 29 • D-58455 Witten geprüft:
Tel. +49 2302 877-167 • Fax +49 2302 877 478 freigegeben:
Seite 1 / 2
796 BOMAG 008 911 57
 Wheel drive gear from S/N 19.5
Seite 2 / 2
Schmierölempfehlung, ISO VG 220 RNM 17421-005 : 2004-10-01

Mobil Mobilgear XMP 220 CLP -24 hoch x

Mobilgear SHC XMP 220 CLP HC -45 hoch x x
MOTOREX GEAR COMPOUND 220 PLUS CLP -21 hoch
GEAR SINTEC CLP 220 CLP HC -51 hoch x
Shell Omala Oil F 220 CLP -18 hoch x
Omala Oil HD 220 CLP HC -48 hoch x x
TOTAL CARTER EP 220 CLP -12
CARTER SH 220 CLP HC -39 hoch x

1) Der Pourpoint ist nicht gleichzusetzen mit der niedrigsten Temperatur des Einsatzbereiches!
2) Graufleckentragfähigkeit GFT gem. FVA Nr. 54 / I – IV
3) Fehlt auf dem Typenschild und / oder in der Betriebsanleitung die Angabe einer bestimmten Gruppenbezeichnung, so
kann jedes der hier aufgeführten Öle eingesetzt werden.

LS1: Verschärfter FZG-Test:

Diese Öle haben auch im verschärften FZG-Test A/16,6/90 die Schadenskraftstufe • 12

LS3: Vollsynthetische Öle ( Polyalphaolefine POA )

Diese Öle sind mit Mineralölen mischbar.
PAO-Öle neigen bei einer Vermischung mit Resten von Konservierungsöl zur Schaumbildung!
Es sollte ein Spüllauf mit geeignetem Spülöl durchgeführt oder ein Mineralöl als Einlauföl verwendet werden.
ƎSchutzvermerk DIN 34 beachtenƎ - ƎCopyright reservedƎ

5. Hinweise

Die aufgelisteten Informationen sind Auszüge aus den aktuellen Produktdatenblätter zum
Zeitpunkt der Erstellung dieser Werknorm.

Bestandteil dieser Schmierölempfehlung ist die allg. Übersicht RNM 17420-000

Ölwechsel nach Betriebsanleitung !

Bosch Rexroth übernimmt für die empfohlenen Öle keine Gewähleistung!

Die Produktverantwortung für die aufgelisteten Öle liegt ausschließlich beim Ölhersteller.

Vor Einsatz einer bestimmten Ölsorte sind die technischen Produktdatenblätter und
die entsprechenden Sicherheitsdatenblätter zu beachten.

008 911 57 BOMAG 797

 19.5 Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Wheel drive gear from S/N
Mobile
Hydraulics

BRM-GT / Company standard

Recommendation of Lube Oils RNM 17421-005
Viscosity Class ISO VG 220 at 40°C mm² / s (cSt) DIN 51519 2004-10-01

Subject group 17: Lubricant Recommendations Replacement for

LSN 935 1410-7-EN: 2003-05-02

Modifications

Ɣ Editorial revision and transformation of the LSN numbers in RNM numbers

(Rexroth standard mobile Hydraulics)

1. Purpose

This standard specifies recommended lubricating oils to be applied in Bosch Rexroth-Gears for mobile and
industrially applications.
For wind turbine application please refer to specific lube oil recommendations.

2. Application

The standard is valid for the product unit BRM-GT.

(Bosch Rexroth, Mobile Hydraulics, Product Unit of Gear Technology)

3. Responsibility
© Bosch Rexroth AG 2004

Responsible for this standards is BRM-GT/NOR

4. Lube Oils

Supplier Oil Brand Identific. Pourp. 1) GFT 2) Group designation

DIN 51502 in °C LS1 LS3
ADDINOL ECO GEAR 220 M CLP -15 high x
ECO GEAR 220 S CLP HC -45 high x x
Agip BLASIA 220 CLP -20 x
ARAL Degol BG 220 Plus CLP -15 high x
Degol PAS 220 CLP HC -42 high x x
Degol ESG 220 CLP HC -45 high x
BECHEM ECOGEAR 220 M CLP -15 high x
ECOGEAR 220 S CLP HC -45 high x x
BP Energol GR-XF 220 CLP -21 high x
Enersyn HTX 220 CLP HC -40 x x
Castrol Alpha SP 220 CLP -21 high x
Alphasyn T 220 CLP HC -45 x
Tribol 1100/220 CLP -24 high
Tribol 1510/220 CLP HC -42 high x
OPTIGEAR BM 220 CLP -15 high
RNM-17421_005_NOR_N_EN_2004-10-01.doc

OPTIGEAR SYNTHETIC A 220 CLP HC -36 high x x

ESSO SPARTAN EP 220 CLP -24
FUCHS RENOLIN CLP 220 PLUS CLP -24 high x
RENOLIN UNISYN CLP 220 CLP HC -54 high x x
KLÜBER Klüberoil GEM 1 – 220 N CLP -10 high
Kuwait Q8 Goya NT 220 CLP -12 high
Q8 El Greco 220 CLP HC -24 high x

Bosch Rexroth AG prepared: BRM-GT/NOR, Moormann

Mannesmannstraße 29 • D-58455 Witten checked:
Tel. +49 2302 877-167 • Fax +49 2302 877 478 released:
Page 1 / 2
798 BOMAG 008 911 57
 Wheel drive gear from S/N 19.5
Page 2 / 2
Recommendation of Lube Oils, ISO VG 220 RNM 17421-005 : 2004-10-01

Mobil Mobilgear XMP 220 CLP -24 hoch x

Mobilgear SHC XMP 220 CLP HC -45 hoch x x
MOTOREX GEAR COMPOUND 220 PLUS CLP -21 hoch
GEAR SINTEC CLP 220 CLP HC -51 hoch x
Shell Omala Oil F 220 CLP -18 hoch x
Omala Oil HD 220 CLP HC -48 hoch x x
TOTAL CARTER EP 220 CLP -12
CARTER SH 220 CLP HC -39 hoch x

1) The pour point is not to be confused with the lowest application range temperature!
2) Micro-pitting (frosting) load-carrying property GFT as per FVA-Nr. 54 / I – IV.
3) If a gearbox lube oil specified for use lacks an indication of a certain L+S group, any of the lube oils listed here can be
used.

LS1: Aggravated FZG test:

Even when FZG tested (A/16,6/90) under aggravated conditions these oils reach the properties of
breakdown-load stage • 12.

LS3: Fully synthetic oils (polyalphaolefins PAO)

These oils can be mixed with mineral oils.
PAO oils tend to foaming when mixed with residues of preservation oil!
The unit must either be flushed out using a suitable purge oil or a mineral oil must be used as running-in oil.
?Schutzvermerk DIN 34 beachten? - ?Copyright

5. Note

The listed information are excerpts from current product data sheets at the time this company standard
was drawn up.

The generall overview RNM 17420-000 is part of this recommendation on lube oils.

Change of oil as prescribed in the service manual!

Bosch Rexroth does not accept any warranty for the recommended oils!
The product responsibility for the listed oils is exclusively with the oil manufacturer.

Before using a certain type of oil the technical product data sheets and the respective safety data sheets
are to be considered.

008 911 57 BOMAG 799

19.5
BDA 16633700 00 GFT 220 R3 9184 Wheel drive gear
Bosch from
Rexroth AGS/N 25/32

C. Anbauteile • C. Attachment Parts

Inhaltsverzeichnis Table of Contents

C. (in diesem Handbuch nicht enthalten) C. (does not form part of this manual)

800 BOMAG 008 911 57

Wheel drive gear
BDA 16633700 from
00 GFT 220S/N
R3 9184 Bosch Rexroth AG 19.526/32
D. Zeichnungen • D. Drawings

Inhaltsverzeichnis Table of Contents

Liste der technischen Daten Technical data sheet

Einbauzeichnung 0/6137/5184/0 Installation drawing 0/6137/5184/0

Ersatzteilzeichnung 0/6137/1184/1 Spare parts drawing 0/6137/1184/1

Unsachgemäße Handhabung beim Öffnen, Opening, disassembling and reassembling

Zerlegen und Zusammenbauen kann zur the equipment inexpertly may entail dan-
Gefährdung von Personen, der Anlage und ger to persons, the plant and the product.
des Produktes führen.

Derartige Arbeiten darf deshalb nur Fach- Such work must therefore be carried out
personal durchführen, das von BOSCH- only by expert personnel authorized and
REXROTH ermächtigt und besonders aus- especially trained by BOSCH-REXROTH or,
gebildet wurde. Selbstverständlich steht otherwise, by BOSCH-REXROTH's service
Ihnen auch der BOSCH-REXROTH- department available for this purpose.
Kundendienst zur Verfügung.

Für Schäden, gleich welcher Art, die durch BOSCH-REXROTH will not assume liability
Nichtbeachtung dieser Vorschrift entste- for any kind of damage resulting from the
hen, übernimmt BOSCH-REXROTH keine noncompliance with the instructions given
Haftung. in this operating manual.

008 911 57 BOMAG 801

19.5 Wheel drive gear from S/N
Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service

Liste der technischen Daten • List of technical data

Auftrag-Nr.: 3/376402
Kunde: 100325
Bomag GmbH
Bestellnummer: 5500000021/00150

Position: 010 74 ST
Materialnummer: 16633700
Kundenmaterial:
Materialbezeichnung: GFT 220 R3 9184 i=145,4 KDN-K
HYDROTRAC Fahrgetriebe
ohne Motor
ohne Ölfüllung
ersetzt durch Material-Nr: ..:
Ersatz für Material-Nr. .....: 16218480
Kundenversion ...............: 0
Arbeitsmaschine .............: Müllverdichter
Maschinenbez. des Kunden ....: BC 50 RB
Gerätegewicht, beladen ......: 50,0 t
Gerätegewicht, leer .........:
Getriebetyp .................: GFT
Getriebegröße ...............: 220
Stufenkennung ...............: R3
Ausführungsnummer d. Getrieb.: 9184
Übersetzung des Getriebes ...: 145,40
Motorart ....................: Hydraulikmotor
Motorlieferung L+S ..........: nein
Motorhersteller .............: Brueninghaus Hydromatik
Motortyp ....................: A6VM
Motornenngröße ..............: 200
Restliche Bezeichnung .......:
Motornenndrehzahl ...........: 3.901 1/min
Motor-max.Drehz. ............:
Effektiver Arbeitsdruck .....: 400 bar
Hochdruckabsicherung auf ....: 420 bar
Motor-Nennleistung ..........:
Motorkippmoment .............:
Antriebsräder-Anzahl ........: 4
Räderanzahl, gesamt .........: 4
Raddurchmesser ..............: 1.940,0 mm
Radbreite ...................: 1.575,0 mm
Turas-Durchmesser ...........:
Steigfähigkeit ..............:
Zugkraft ....................:
Abtriebsnenndrehmoment ......:
Abtriebsdrehmoment, max. ....: 184.950 Nm
Arbeitsgeschwindigkeit(m/min):
Fahrgeschwindigkeit ...(km/h): 9,8 km/h
Antriebsdrehzahl, max. ......: 3.901,00 1/min
Abtriebsdrehzahl, max. ......: 26,80 1/min
Radlast, radial .............:
Radlast, axial ..............:
Bremsenbauart ...... Bremse 1: Lamellenhaltebremse
Bremsmoment ........ Bremse 1: 1.325 Nm
Bremslüftdruck (max.) Bremse1: 50 bar
Bremsenbauart ...... Bremse 2:
Bremsmoment ........ Bremse 2:
Bremslüftdruck (max.) Bremse2:
Schmierung ..................: Tauchschmierung

Seite / Page 1/2

802 BOMAG 008 911 57
Wheel drive gear from S/N 19.5
Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service

Liste der technischen Daten • List of technical data

Schmierölgruppe : CLP 220

Ölinhalt, ca. ...............: 13,0 l*
Getriebegewicht ohne Öl, ca.: 850,0 kg
Anstrichvorschrift ..........: L+S Standard
Grundanstrich ...............: L+S Standard (grau ä.RAL 7032)
Außendeckanstrich ...........: Hempel 5521 B RAL 9005 schwarz
Zwischenanstrich ............:
Konservierung ...............: L+S Standard
Abnahme .....................: entfällt
Abnahmegesellschaft(en) .....: entfällt
Zeugnis EN 10204 ............: entfällt
Zeugnisse für ...............: entfällt
Protokolle ..................: entfällt
Zusätzliche Protokolle ......: entfällt
Einbauzeichnungsnummer ......: 0/6137/5184/0

* Genauer Ölinhalt muß am Getriebe ermittelt werden!

Seite / Page 2/2

008 911 57 BOMAG 803
19.5 Wheel drive gear from S/N
Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service

Liste der technischen Daten • List of technical data

Order-No.: 3/376402
Customer: 100325
Bomag GmbH
Your Order-No.: 5500000021/00150

Item: 010 74 PC
Material-No: 16633700
Kundenmaterial:
Designation: GFT 220 R3 9184 i=145,4 KDN-K
HYDROTRAC propel drive
without motor
without oil filling
substituted by material .....:
Substitute for material .....: 16218480
Customer version ............: 0
Type of machine .............: Garbage compressor
Machine designation of client: BC 50 RB
Machine weight, loaded ......: 50,0 t
Machine weight, empty .......:
Gear type ...................: GFT
Gear size ...................: 220
Stage key ...................: R3
Version no. of geardrive ....: 9184
Ratio of gear ...............: 145,40
Motor version ...............: Hydraulic motor
Motor supply L+S ............: no
Motor manufacturer ..........: Brueninghaus Hydromatik
Motor type ..................: A6VM
Motor nominal size...........: 200
Remainder designation .......:
Motor nominal speed .........: 3.901 1/min
Motor max. speed ............:
Rated working pressure ......: 400 bar
High pressure protection ....: 420 bar
Motor nominal power .........:
Motor stall torque ..........:
No. of driven wheels ........: 4
No. of wheels ...............: 4
Wheel diameter ..............: 1.940,0 mm
Wheel width .................: 1.575,0 mm
Sprocket pitch diameter .....:
Gradability .................:
Tractive effort .............:
Nominal output torque .......:
Output torque, max. .........: 184.950 Nm
Working speed ........(m/min):
Driving speed .........(km/h): 9,8 km/h
Maximal input speed .........: 3.901,00 1/min
Maximal output speed ........: 26,80 1/min
Wheel load, radial ..........:
Wheel load, axial ...........:
Brake 1 type ................: Multiple disk parking brake
Brake 1 torque ..............: 1.325 Nm
Release pressure(max.) Brake1: 50 bar
Brake 2 type ................:
Brake 2 torque ..............:
Release pressure(max.) Brake2:
Lubrication .................: Splash lubrication

Seite / Page 1/2

804 BOMAG 008 911 57
Wheel drive gear from S/N 19.5
Electric Drives Linear Motion and
and Controls Hydraulics Assembly Technologies Pneumatics Service

Liste der technischen Daten • List of technical data

Lubrication grp. : CLP 220

Oil quantity, appr. .........: 13,0 l*
Drive weight without oil,appr: 850,0 kg
Painting specification ......: L+S standard
Primer ......................: L+S standard, grey sim.RAL7032
Final cover paint ...........: Hempel 5521 B RAL 9005 schwarz
Intermediate coating ........:
Conservation ................: L+S standard
Classification ..............: n/a
Classification society(-ies) : n/a
Certificate EN 10204 ........: n/a
Certificates for ............: n/a
Reports .....................: n/a
Additional reports ..........: n/a
Installation drawing no. ....: 0/6137/5184/0

* Exact oil volume to be determined on the gearbox!

Seite / Page 2/2

008 911 57 BOMAG 805
19.5 Wheel drive gear from S/N

806 BOMAG 008 911 57

 20 Circuit diagrams

008 911 57 BOMAG 807

808 BOMAG 008 911 57
 20.1 Hydraulic diagram 571 908 16

008 911 57 BOMAG 809

20.1 Hydraulic diagram 571 908 16

810 BOMAG 008 911 57

Hydraulic diagram 571 908 16 20.1

008 911 57 BOMAG 811

20.1 Hydraulic diagram 571 908 16

812 BOMAG 008 911 57

 20.2 Wiring diagram 570 700 35

008 911 57 BOMAG 813

20.2 Wiring diagram 570 700 35

S/N Wiring diagram 570 700 35

S/N 101 570 571 001 ⇔ 101 570 571 006 BC772 RS-2
S/N 101 570 581 001 ⇔ 101 570 581 020 BC772 RB-2
S/N 101 570 591 001 ⇔ 101 570 591 006 BC672 RB-2
S/N 101 570 821 001 ⇔ 101 570 821 004 BC972 RB-2
S/N 101 570 831 001 ⇔ 101 570 831 014 BC1172 RB-2

814 BOMAG 008 911 57

Inhaltsverzeichnis: BC 772...1172 RB / TIER III

008 911 57
table of contents:
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing ï no.
001 vorläufig Stromlaufplan Circuit Diagram
002 vorläufig Versorgung, Zigarettenanzünder supply, cigarette lighter
003 vorläufig Zündschloß, Starter ignition switch, starter
004 vorläufig DEUTZ Steuergerät EDC 7 f. 6ï und 8ïZylindermot. DEUTZ controller EDC 7 for 6ï and 8ïzylinder engine
005 vorläufig Instrumente indicators
Wiring diagram 570 700 35

006 vorläufig Anzeigen, Störmeldungen monitoring, failure indication

007 vorläufig Fahrpumpen, Radmotoren, Startfreigabe driving pumps, weehl motors, starting release
008 vorläufig Fahrstufen, Bremse, Verzögerungspedal speed ranges, brakes, decelerator device
009 vorläufig Versorgung Steuerung, Warnsummer, Override supply controllers, warning buzzers, override
010 vorläufig Lenkung und Arbeitshydraulik steering and working hydraulic system
011 vorläufig Hupe, Schmieranlage, Tachograph, Sitzfunktionen horn, lubrication systhem, tachograph, seat funktions
012 vorläufig Heizung und Belüftung heating and ventilation
013 vorläufig Schutzbelüftung, Zyklon Abscheider, Klimatronik protected vent. system, cyclone separator, air cond.
014 vorläufig Kabine und Anbauteile cabin and attachmentïparts
101 vorläufig Bauteilliste component listing
201 vorläufig Schaltkasten eïbox

BOMAG
301 vorläufig Lokalisierungsgrafik Steckverbinder Draufsicht localization graphic connectors top view

03.04.2006
001 001
Werner Stromlaufplan 570 700 35
03.04.2006
20.2

815
circuit diagram 001
Seis
816
Zuleitung Steuerung Pin 54 30/54S 9:2
Zuleitung Steuerung Pin 56ï60 30/56ï60S
9:2

2,5qmm
Kabine K30
14:2
20.2

4qmm
geschaltetes "15/54"

2x6qmm
Batteriespannung 30 3:1

6qmm
15/54 X1:6
Zündschloß "15/54" 3:1

6qmm
6qmm
X1:23E X1:391/1 X1:21E X1:25E
Einspeisepunkt für Versorgung
Sicherungespotential 30! 30 30
1 K61 6E 5E
F89 F05 K11
V01 2:8 30A 30A
2 6A 5A 3:14
87
87 87a
X1:391/2 X1:21A
X1:25A
1,5qmm
2x4qmm

Einspeisepunkte für Versorgung

2,5qmm
4qmm
2x6qmm
6qmm
6qmm
Sicherungespotential K11:87!
X1:241 X1:242
X1:31E
X1:33E

0,11A
0,075A
X1:241
11:7
1 86 K61:87a 5:9 F24 K11:87 5:1
5:1
R10
1 220_O
K61 X1:298
F00 250A

057 665 63
2 2,5qmm X1:32E
2 85 X1:243
1x25qmm F122
10A
Anlassehauptleitung: 2x70qmm B+ 3:1 D+ 6:2
Ladeleitung 2x 10qmm oder 1x25qmm X1:32A
X1:81 1
X1:259

BOMAG
+ E21
X1:202
9:13
8:10

G01 2
11 21 31 41 51 61
ï S01
Batterie X14:6

0,075A
5A
Bei Steckdosenbetrieb je nach Stecker bis 16A möglich!
battery
max. 10A

12 22 32 42 52 62
B+ D+
+ 86 E20 1 2 X1:260 NotïAus Schalter
28V/80A + emergancy shut off
G03 G02 K62 XS
ï 24V 30
ï
85 K22 9:6
Bï W
87a 87
X2:N X2:J EMR
S30 3 X14:7 4:15
W XSï
Trennschalter 5:11 4:18
switch battery disconnect
4
X1:70 X1:256
31 31 3:1

2:10 13:10
Zigarettenanzünder Steckdose
cigarette lighter socket

03.04.2006
1 1

008 911 57
Wiring diagram 570 700 35

Werner Versorgung, Zigarettenanzünder 570 700 35

03.04.2006
Seis supply, cigarette lighter 002
 2:15 30 30 4:1
2:11 15/54
6qmm
2:6 B+ B+ 4:1 X1:23E
Anlasserhauptleitung 2x70qmm F13
30A

008 911 57
X1:23A

6qmm

Zündstartschalter
012 30 ignition switch
S00
01

50a 15/54

4qmm
1,5qmm

X1:293
Wiring diagram 570 700 35

X1:302

X1:8 X1:9

30
K05
7:2
87 87a

X1:7

BOMAG
2,5qmm
X14:9 X1:371
0,2A

0,2A

86 86
30 50 2 K11 K32
M01
M V47
85 85
ï 1

X1:256 X1:70

2:20 31 31 4:1

2:17 14:6

Starter
starter
Anzugswicklung KHD = 73A
Haltewicklung KHD = 12A

03.04.2006
1 1 570 700 35
Werner Zündschloß, Starter
03.04.2006
20.2

817
Seis ignition switch, starter 003
818
30 30
3:20 13:1
B+ Pedal
3:5 X1:24E 6:7
XSï
B124 2:19
20.2

1 + 1 elektronisches Fußpdal Diagnosestecker

F48 F93 elektronic foot pedal diagnosis
86 86 86 X22
80A 25A K15 K146 K60
2 F78
ï 2 S119 H04 1 H70 1
13
X1:24A S118

X4:A
X4:H
X4:G
X4:M
X4:F
X4:K
X4:B
2 2 Fehlertaster Motor
85 85 85
4qmm B46

4qmm
4qmm
14 failure push button engine

Williams Codierung
sw rt ws or gn bl

X1:92
X1:93
X1:94
X1:62
X1:64
X1:65
X1:71
X1:255

X10:B
X10:C
X10:A
X12:A
X12:C
X12:B
X6:1 X1:250
X6:2 X1:244
X6:3 X1:270
X6:4 X1:269
2 3 1 EMR
RPM 2:19
9:2
Option
option

X6:5
X6:6
X6:7
X6:8
X6:9
X6:10

X1:231
X1:232
X1:233
5V EDC 8:2
Handgas
8:2
4x2,5qmm AGND EDC "31" 4x2,5qmm
8:2

Sensor Wasserabscheider
sender water separator
"30"
Fehler EMR
Vers. Meldeleuchte
Glühen
Temperatur
Motoröldruck
"15"
CAN 1H
CAN 1L
CAN 2H
CAN 2L
ISO KïLinie

S2 S1

Fehler Motor
failure engine
Wasserabsch.
water separator

X1:235
X1:236
X1:237

XD2.1:3
XD2.1:9
XD2.1:6
XD2.1:5

XD2.1:2
XD2.1:8
XD2.1:11

XD2.1:61
XD2.1:13
XD2.1:10

XD2.1:79
XD2.1:77
XD2.1:33
XD2.1:60
XD2.1:59
XD2.1:30
XD2.1:39
XD2.1:53
XD2.1:35

XD2.1:78
XD2.1:38
XD2.1:20
XD2.1:52
XD2.1:89

XD2.1:22
XD2.1:54
XD2.1:40
XD2.1:34

X27.2:11
X27.2:10
A48 EDC7 Steuerung
4qmm

X17.1:1
X17.1:2
X1:5

XD2.2:28
XD2.2:8
XD2.2:3
XD2.2:7
XD2.2:24
XD2.2:27
XD2.2:32
XD2.2:18
XD2.2:35
XD2.2:26
XD2.2:15
XD2.2:9
XD2.2:10
XD2.2:19
XD2.2:23
XD2.2:34
XD2.2:33
XD2.2:36
XD2.2:25
XD2.3:4
XD2.3:13
XD2.3:6
XD2.3:12
XD2.3:7
XD2.3:3
XD2.3:15
XD2.3:14
XD2.3:16
XD2.3:8
XD2.2:4
XD2.2:5
X1:299

BOMAG
50i
K14 K2
4:4

X27.1:25
X27.1:20
X27.1:19
X27.1:27
X27.1:26
X27.1:33
X27.1:12
X27.1:18
X27.1:24
X27.1:30
X27.1:14
X27.1:13
X27.1:15
X27.1:21
X27.1:23
X27.1:22
X27.1:29
X27.1:28
X27.1:34
X27.1:35
X27.1:37
X27.1:36
X27.1:11
X27.1:42
X27.1:40
X27.1:41
X27.1:39
X27.1:4
X27.1:6
X27.1:7

30

ï ï ï ï Y02 2
4qmm 4qmm Y149 Y166 Y151 Y167
3 2 1 2 1 2 1 1 2 3 1 2 3 4 3 2 1 + + + + Y2 1
1 1 85 Y147 ï ï Y152 ï ï
R02 R02 K2 K14 Y148 Y150
R3.1 R3.2
2 2 50 + + + +
B88 B126 B113 B114 B130 B133
B6 B37 B43 B40.1 B40.2 B48 Y15.1 Y15.3 Y15.5 Y15.7 Y15.2 Y15.4 Y15.6 Y15.8

3:20 31 31 5:1

4:2 6:2 6:2 6:3 Injektor B3

jet pump B3
Glühkerze 1 Kraftstofftemperatur Motordrehzahlsensor1 Mag.vent. Flammglühanlage
glow plug 1 fuel temperature sender engine rpm 1 Injektor B2 solenoid valve glow plug system
jet pump B2
Glühkerze 2 EMR Motoröldruck Motordrehzahlsensor 2 Injektor A1 Injektor A3 Injektor A4 Injektor B1
glow plug 2 EMR engine oil pressure sender engine rpm 2
jet pump A1 jet pump A3 jet pump A4 jet pump B1
Kühlmitteltempratur Sensor Ladeluftdruck / Temperatur Injektor A2 Injektor B4
coolant temperature sensor charging air pressure / temperature jet pump A2 jet pump B4

03.04.2006
1 1

008 911 57
Wiring diagram 570 700 35

Werner DEUTZ Steuergerät EDC 7 f. 6ï und 8ïZylindermot. 570 700 35

03.04.2006
Seis 066_5 DEUTZ controller EDC 7 for 6ï and 8ïzylinder engine 004
 2:20 K11:87 K11:87 9:1

X1:29E

F24
15A

008 911 57
X1:29A
2:13 F24 F24 6:1
2:11 K61:87a K61:87a 6:7
X1:294 X1:295 X1:298

5 1 4 3 5 1
Wiring diagram 570 700 35

P00 +
E02 P14 + E22 P02 + E03 P03 + E01 P01 + E46 P12 +
1 1 1 1 1

_t _t n Q
2 2 2 2 2
ï G ï G ï G ï ï G ï

Modul 1
module 1
Modul 2
module 2
Modul 3
module 3
3 2 4 1 5 3 4

BOMAG
X1:300 X1:303 X1:301 X1:296
X1:291 X1:148 X1:292 X1:228

X14:8

X5:1

1 2
B53 1 1
R04 R03

2 2
X1:299 W X1:229
2:8
31 31
4:20 6:1

Kühlmitteltemperatur Motordrehzahl Tankanzeige

collant temperature trancducer, motor speed level gauge

Hydrauliköltemperatur Betriebsstundenzähler Voltmeter

hydraulic oil temperature engine hour meter volt meter

03.04.2006
1 1 570 700 35
Werner Instrumente
03.04.2006
20.2

819
Seis indicators 005
 820
F24 F24
5:20 9:1
D+ ESX 9:15 Abschmieren
2:9 11:2
Lüfter 1.GANG
12:14 30 30 9:7
20.2

K133 K48 2.GANG 9:7

9:9 7:3
87 87a 87 87a
X1:101 X1:104
X1:89 X1:84 X1:90 X1:91 X1:123

X1:125
X1:126

X1:124

rt
rt
ws/vi
br/rt
br
br/sw
sw
vi

vi
ws/bl
br/or
br
ws/vi
or X1:102 X1:105 or
1 2 0/3a 4 8 A15 A15 16 11 17 18 9

6 3 7 5 20 19 14 15 12 13 10

bl
bl
gr

sw
br/or

ws/rt

ws/gr
ws/br
ws/br
ws/gr

ws/gn
ws/gn

X1:106

X1:115
X1:119

X1:118
X1:121

X1:120
X1:122

X1:87 X1:88 X1:85 X1:86

X1:392/2 V02 2 1 X1:392/1 X1:397/1 1 2 V07 X1:397/2
X0:18 X0:45
Fehler
X1:394/2 V04 2 1 X1:394/1 X1:398/1 1 2 V08 X1:398/2
X1:109 X1:117

X0:52 X0:50 X1:108 X1:116

Fehler
X1:393/2 V03 2 1 X1:393/1 X1:399/1 1 2 V09 X1:399/2

20s
Fehler
X0:19 X0:13
X1:111

X1:395/2 V05 2 1 X1:395/1 X1:400/1 1 2 V10 X1:400/2

Steuerung
Gaspedal
X0:11 X0:10
Pedal X1:401/1 1 2 V11 X1:401/2
X1:112

X1:82 X1:83 4:19 X0:6 Fehler

D+
X1:403/1 1 2 V13 X1:403/2
X1:113

X1:114

X0:36 X0:51

ESX
X14:10 X1:210

BOMAG
5:20 K61:87a K61:87a 14:11
15

20s
20s
2min
K113

31

Kühlmitteltemperatur
collant temperature
Motoröldruck
engine oil pressure
Kühlmittelfüllstand
coolant tank
Luftfilter rechts
air cleaner rh.
Luftfilter links
air cleaner lh.
120s anzugsverzögert
120s switch on delay
K15 30 K60 30
4:12 4:14
X1:110
87a 87 87a 87 Verteilergetriebe
power takeïoff gear
Hydrauliköl min.
hydraulic oil min.
Hydrauliköltemp.
hydraulic oil temp.
Diff.ïdrucksch.
pressure. diff.
Diff.ïdrucksch.
pressure. diff.
Diff.ïdrucksch.
pressure. diff.
Diff.ïdrucksch.
pressure diff.
Diff.ïdrucksch.
pressure diff.
Bremsdruck
brake pressure
Verschmutzungssensor
contamination sensor

X1:103
30 30
3 3 3 3 1 1 3 K113 2 2 2 2 2 1 +
K146 B55 B03 B116 B129 B24 B20 B121 B122 B22 B21 B42 B05
4:13 6:11 B19
Q P P B25 P P Q P
87a 87 4 4 4 4 2 2 4 87 87a 1 1 1 1 1 2 ï

X14:11

X1:181
X1:182
X1:182
X1:191
X1:191

X1:181

X1:183
X1:187
X1:185
X1:186
X1:183

31
X1:184
X1:184

X1:205

5:20 31 7:1
Speisepumpe Speisepumpe Zwischengetr.
6:14
Speisepumpe Speisepumpe

Rücklauffilter nur BC 972 RB

return flow filter only acc. to BC 972 RB

Modul 1: Motorfunktionen Modul 2: Maschinenfunktionen

module 1: engine functions module 2: maschine functions

19.04.2006
1 1

008 911 57
Wiring diagram 570 700 35

Werner Anzeigen, Störmeldungen 570 700 35

19.04.2006
Seis monitoring, failure indication 006
 DEC 1 8:4
X1:338 X1:262 S04:12 8:10
X1:335 2 1
X1:46/2 X1:46/1
X9:4 X9:1 FM6

008 911 57
1
R32 X1:42/1
1k
2

1 1
R33 1 R34 R35 1 FM2
2k 1k 3k3 2
2 2 2

Fahrtrichtungsschalter nicht belegt X1:42/2

switch, travel direction V0R 33 13 24 44 not used
S31 X1:336
34 14 23 43
Wiring diagram 570 700 35

X9:5 X9:6 X9:3 X9:2

X1:339
X1:340 X1:337

Richtung
AGND
8,5V
Ain

X1:412/1 X1:413/1

X0:1
13 9

X0:32
X0:23
X0:29

1 1
V23 V25 K77 K77 ESX Steuerung
9:17 9:17
2 2 14 10

X0:22
X0:21
X0:46
X0:47
X0:48
X0:43

X1:412/2 X1:413/2

BOMAG
Vorwärts

Rückwärts
vorne Links
hinten Links

vorne rechts
hinten rechts

br nicht bei
X1:221 X1:223 X1:135 X1:157
V38 BC 672ï772
not used for
rt BC 672ï772

X1:149 X1:153 X1:131 X1:133 X1:155

200 ... 600mA
200 ... 600mA
200 ... 600mA
200 ... 600mA

86 86 H14
K05 K48 + 1 1 1 1 1 1 1 1
V34 Y17 V35 Y17 V32 Y16 V33 Y16 Y132 Y133 Y134 Y135
ï
85 85 2 2 2 2 2 2 2 2

1,08A
1,08A
1,08A
1,08A

X1:70 X1:70 X1:188

X1:222 X1:224 X1:136 X1:158
31 X1:154 X1:132 X1:134 X1:156
6:20 31 8:1
TandemïPumpe TandemïPumpe TandemïPumpe TandemïPumpe
3:9 6:14 rechts 2 rechts 4 links 1 links 3 Prop. Ventil Rad vorne li. Prop. Ventil Rad hinten re.
prop. valve weehl front lh. prop. valve weehl rear rh.
stromlos = qmax stromlos = qmax
Prop. Ventil Rad vorne re.
Ventile Fahrpumpe rückwärts Ventile Fahrpumpe vorwärts prop. valve weehl front rh.
solenoid valves, travel direction backw. solenoid valves, travel direction forw.
stromlos = qmax
Warnsummer Rückwärtsfahrt stromlos = Rückwärtsfahrt nicht aktiv stromlos = Vorwärtsfahrt nicht aktiv
buzzer, back up alarm strom = Rückwärtsfahrt aktiv strom = Vorwärtsfahrt aktiv
Prop. Ventil Rad hinten li.
prop. valve weehl rear lh.
stromlos = qmax

03.04.2006
1 1 570 700 35
Werner Fahrpumpen, Radmotoren, Startfreigabe
03.04.2006
20.2

821
Seis driving pumps, weehl motors, starting release 1 007
822
F25 9:1

X1:343 X1:261
20.2

31 X1:358
S01
2:17
Aktivierung Verzögerungspedal X1:357
32
enable decelerator pedal 7:19 S04:12 X1:41/2
X1:262 23
S02
12 123
S160 0 1 43 23 Bremsschalter 1 S02 Schalter Fahrstufen
S04 brake switch FM1 switch speed ranges
01
2 24
11 Komplett 872 701 02
44 24
X1:41/1
Verzögerungspedal

X40:6
X40:2
X13:3
5V EDC DEC 1
X13:1
X13:2

4:8 7:19 decelerator pedal R20 R21 R22 R23

1 k_O 1 k_O 1 k_O 1 k_O
Nur für BC 671ï771 RB/RS
only acc. to BC 671ï771 RB/RS

bl gr
KD1 KD2
S161

ws
sw
rt
ge
gn
vi
or
bei Option
Schalter Fahrstufen
switch speed ranges

X3:B
acc.to option
X40:3

decelerator pedal

Verbindung entfällt
connection not applied

X40:1
Fahrtverzögerungspedal
X1:359
X1:263

X42:5
X42:6
X41:11
X41:6
X41:4 X39:B
X41:3 X39:C
X41:5 X39:A
X41:1 X40:4
X41:2 X40:5
S04:11
8:11
Zusatzelektronik
A78

Bremse
high=Bremse auf
8,5V
AGND
Fahrstufen
additional electronic

X41:9

X42:1
X41:8

X42:2
X42:4
X41:10

X41:12
X0:1
X0:7

BOMAG
X0:23

X0:40
ESX Steuerung
X36:1
X0:62

X0:61
1

X3:C
R43

X3:A
499 _O
2
Handgas 5 k_O K77
4:8 8 7 S04:11

Bremse
AGND EDC X36:2 S120
4:8 9:17 8:10 X1:170
1./2. Fahrstufe

1 X1:151
R44

1,25A
1,25A

499 _O
1 2 Y04 1 Y03 1
H81 X36:3 V31 V37
2 2 2

X1:234
Nur für BC 671ï771 RB/RS
only acc. to BC 671ï771 RB/RS

31 X1:152 X1:192
7:20 31 9:1

Meldeleuchte Verzögerungsfunktion Magnetventil Bremse Stufenumschaltung

indicator light decelerator device solenoid valve brake Speed range selection
stromlos = Brmse zu
Handgas
strom = Bremse auf
hand throttle
Nur für Option Verzögerungspedal
only acc. to option decelerator device

03.04.2006
1 1

008 911 57
Wiring diagram 570 700 35

Werner Fahrstufen, Bremse, Verzögerungspedal 570 700 35

03.04.2006
Seis speed ranges, brakes, decelerator device 1 008
 K11:87 K11:87 11:1
5:20

X1:35E

F25
10A

008 911 57
X1:35A
F25 F25 10:1
8:20
2:19 30/54S 2,5qmm 6:6 ESX

2:19 30/56ï60S 4qmm

X1:26E
F24
6:20 X1:27E
RPM F84
4:8
10A

F67
30A X1:26A
30
K90
X1:27A
X1:257 9:4

2,5qmm
Elektronik
87 87a
Wiring diagram 570 700 35

21

X1:66
X2:H
X1:67
X2:G
S01

X2:U

5x0,75qmm
Leistung
2:17
22
X1:349
X1:349
X1:349

X1:258 X1:404/2 X1:405/2

X1:207
+UE/Dios
+UB/Dios
+UB/Dios

Drehzahl
CAN2ï
CAN2+
RxD
TxD
+ + + + + +

1x0,75qmm
2 2
V14 V15
1 1

X0:5
X0/1:3
X0/1:9

X0:4

X0:16
X0/1:10

X0:56
X0:57
X0:59
X0:60
X0:33
X0:53

X0:58

X0:28
X0:54
ESX Steuerung X1:404/1 X1:405/1 ESX Dios Modul

X0:2
X0:24
X0:25
X0:3
X0:44
1. Gang 2. Gang Summer
X0/1:11
X0/1:4

BOMAG
6:19 1.GANG
2.GANG
6:19
GND/Dios

X1:402/1 X1:410/1 X1:411/1 1

Relais Override
Motorabstellung
V42
Gehäuse Dios Modul

1 1 1 2
V12 V21 V22
2 2 2 KLIMA
GND für Knotenaddresse Dios

X1:402/2 X1:410/2 X1:411/2

X35:1
K90 86 K22 86 86 + K77/1 86 K77 86
H07
0,7A

K133
X1:185
X1:186

X1:184

ï
85 85 85 X35:2 85 85

0,075
0,075
0,075
0,021A
0,021A

31 X1:70 X1:70 X1:70 X1:70 X1:70 X1:70

8:20 31 10:1

9:17 2:17 6:10

10:4 8:11
10:4 7:6
Lampentest Warnsummer
warning buzzer 10:4 7:5

10:4

03.04.2006
1 1 570 700 35
Werner Versorgung Steuerung, Warnsummer, Override
03.04.2006
20.2

823
Seis supply controllers, warning buzzers, override 1 009
824
F25 X15:A
9:20
X1:349
1=Links /2=Rechts Schild/Schaufel 1=senken / 2=heben 3=schließen / 4=öffnen
1=left /2=right blade/shovel 1=let down / 2=lift 3=close / 4=open
1
20.2

BR/BN
1 1 3 Achse 3/4 mit Kontakten
S71 1 S70 4 1 3 10ï15 nur bei Schaufel
axle 3/4 with contacts B08
1 2 2 Vorrüstung Lenkrad 3 2 4
2 preassembling steering 2 4 10ï15 only acc. to shovel X15:B
JoyïStick
weehl 2
sieht Metall wenn Lehne unten

joyïstick X1:363
Initiator Armlehne

3 2 5 4 7 6 1 3 2 5 4 6 7 1 14 13 12 15 11 10 16 8 9
SW/BK
BL/BU

X2:A X2:B

X2:V

X1:346
X1:345
X1:344
X1:347
X1:348
X1:343
X1:321
X1:325
X1:326
X1:324
X1:323
X1:322
X1:330
X1:329
X1:328
X1:331
X1:332
X1:327
X1:352
X1:351
X1:350
X1:353
X1:354
X1:334
X1:333
CAN Bus LED display
CAN bus LED display X1:63

X1:44/2 X1:45/2 X1:47/2 + P18 ï X1:61

2 X1:43/2 2 2
FM4 2 FM5 FM7 X1:68
1 FM3 1 1
1 057 664 08

X1:44/1 X1:43/1 X1:45/1 X1:47/1 X1:69

X15:C
AGND F1 F2
8,5V

lenken
CAN+
CANï

links
rechts
lenken
AGND
8,5V
heben/
senken
senken
heben
auf/zu
schließen
öffnen
Schwim.
Lehne

links
rechts
X0:1
X0/1:1

X0:9

X0:8
X0/1:2

X0:15
X0:31
X0:17
X0:12

X0:14
X0:41

X0:39
X0:30
X0:35
X0:37

X0:38
X0:23
X0:27
X0:26

ESX Steuerung X0:34 ESX Dios Modul

BOMAG
X0:64
X0:49
X0:20
X0:42
X0:63
X0:65
X0:66
X0:67
X0:68
X0:55
X0/1:5
X0/1:6

9:15
ï
ï
ï
ï
ï

20 19 2 R36 1 Gehäuse
housing

heben
K77/1 47_O 390 mA

senken

lenken li

lenken re.

X1:406/2
Schwimmst.
9:15
öffnen/Dios

0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA

14 13 2 R38 1
schließen/Dios

K77/1 47_O 390 mA

X1:407/2
9:15 R40
10 9 2 1
K77/1 47_O 390 mA
X1:141 X1:143 X1:364

X1:408/2
9:15 R42 X1:137 X1:139
8 7 2 1 X1:159 X1:161 X1:163 X1:165

X1:409/2
K77/1 47_O 390 mA Y92 1 Y93 1 Y108 1 Y109 1 Y102 1 Y102 1 Y111 1 Y110 1
2 2 2 2 1,08A
1,08A

2 2
2 2 2 2 2 2

V19
V16
V17

V18
X1:189
X1:181
X1:182
X1:183
X1:187
X1:188

1 1 1 1
X1:160 X1:162 X1:164 X1:166 X1:138 X1:140 X1:142 X1:144
31
9:20 31 11:1

Lenken rechts Schild senken

steering right let down blade

X1:409/1
X1:406/1
X1:407/1

X1:408/1
Lenken links Schwimmstellung Schaufel schließen
floating position close shovel
steering left
Schwimmstellung Schaufel öffnen
Schild heben
lift blade floating position open shovel

03.04.2006
1 1

008 911 57
Wiring diagram 570 700 35

Werner Lenkung und Arbeitshydraulik 570 700 35

03.04.2006
Seis steering and working hydraulic system 010
 9:20 K11:87 K11:87 13:1
Abschmieren
6:19
X1:30E X1:34E X1:31E

F16 F23 F29

008 911 57
10A 15A 15A

X1:172
X1:30A X1:34A X1:31A

X1:171 Zusatzanzeige Geschwindigkeit

additional speedometer X1:341 X1:245

3A
X31:A
X34:4 1 2 86 30 S25 23
4 (+) K13
LA 15 K13
E04 1 E04 1 11:14
M08
P09 85 87 87a 24
M 8 (S) 2 2
Wiring diagram 570 700 35

Zentralschmieranlage
central lubrication system 3 (ï) X1:246
Z 31 X31:B X31:C X1:355

X34:3 5

X33:1
X33:2
X11:1 X21:1
7,5A

+ sw
M10 R06
X30:A M
B7 A2 ge

X1:173
X1:174
K13:87 ï
2,5A

14:19
X1:248 X28:1 Versorgung über F89
X1:356 Signalhörner Kabine
X1:241 A1 A3
br sw
2:13
23 1

BOMAG
S27 B15 3
8 S29 23
X28:3 B3 A5 S03 2 ge
Taster Schmieranlage X30:C R06
4 P09 V46
switch, lubrication system 24 X28:4
B52 bl 2 ws
4 6 1 9 1 24 br
B4 A6
X1:272 X28:2
A16

Initiator Schmierkolben
proximity switch lubrication piston
Lieferumfang GRAMMER
delivery equipment GRAMMER

X30:B 7 8 9 2 X11:2 X21:2

Im Lenkjoystick
in steering joystick

X1:190 X1:191 X1:364 X1:256

X1:342
10:20 31 31 13:1

11:16

Sensor Radmotor HL Tachograph Sitz mit Kompressor und Schalter

sensor wheelmotor rear lh. tachograph Im Lenkjoystick drivers seat with compressor and switch
in steering joystick
Tachomodul Sitzheizung
tacho controller Taster Signalhorn heating, drivers seat
Option Tachograph push buttonwarning horn
option tachograph

03.04.2006
1 1 570 700 35
Werner Hupe, Schmieranlage, Tachograph, Sitzfunktionen
03.04.2006
20.2

825
Seis horn, lubrication systhem, tachograph, seat funktions 011
826
K32:30 K32:87
14:2 14:3
F41:4
14:8
20.2

F40 G F90 F F02 F

Box 2 Box 2 Box 1
10A
7 5A
6 10A
6

X1:374
X1:265
2,5 qmm

123 13 31 42 24
1 2 3 12 11 13 14 16
Stufenschalter Frischluft
switch, fresh air
S44
5 7 11 3 1 10 14 32 41 23

Regel aus = 0,2A S28 X1:266 X1:267 X1:268

E30 Kleine Stufe = 0,3A
mittleter Stufe = 0,5A
große Stufe = 1A 1 1
Power Stufe = 1,7A R26 R27
Heizung Anlaufstrom beim Start = 4,2A
22 Ohm
10 Ohm

Heating
Schaltuhr Heizung 2 6 8 9 4 12 2 2
heater timer Lüfter
6:6
X1:373
10 9 5 6 8 7 4 15
X1:377

BOMAG
X8:1

2,5 qmm
15/54
30
87a
in

X1:375
X1:226
A53 n
1
Y14
max. 0,75A

20s; n kleiner 1300 1/min

2 20s; rpm lower 1300 1/min
X1:227 8s; n=0 1/min
8s; rpm=0 1/min S +
X1:376
M17 M
ï

X8:2
ï
15/54

K31
14:1
Kraftstoffpumpe Überwachung Lüfter Frischluft Lüfter
fuel pump heating unit monitoring blower blower fresh air

03.04.2006
1 1

008 911 57
Wiring diagram 570 700 35

Werner Heizung und Belüftung 570 700 35

03.04.2006
Seis heating and ventilation 012
 30
4:19
F24
9:6 Raumtemperatursensor
K11:87 sensor ambient temperature
11:20
X1:36E
Ausblastemperatursensor
F33 sensor outlet temperature X1:20E

008 911 57
X1:28E X1:22E X1:33E
10A
F50
F123 F94 F31 15A
X1:36A
10A
B29 B118 X1:20A
X1:28A X1:22A X1:33A
30 + ï + ï
K62

wird durch D+ aktiviert

2:10 nicht belegt
87 87a not used X1:253 X1:383 X1:381
Versorgung für Schutzbelüftungsanlage

Bel.
X1:251 X1:249

X23:1
X24:1

X23:2
X24:2

15/54
D+
Absicherung und Verkabelung nach Angabe X25:B X25:A
Hersteller der Schutzbelüftungsanlage
supply for protected ventilation system ge rt
Lüftermodul
Wiring diagram 570 700 35

X26:6
X26:7
fuse and wiring acc. to supplier PWM +

X26:13
X26:12
X26:14
blower module

X26:1
X27:1

X26:3
X27:3
X26:5

X27:2
of protected ventilation system

X26:4
A65 Klimatronik X27:4 A53

ï M+ Mï

X26:2
X26:10
X26:11
X26:9
X26:8
br gn sw
X25:C
1

31
V43 X1:247

Ventil
2 X1:129
Kupplung

1
B117 _t Thermostat Vereisungsschutz
X22:1 X22:2 thermostat antiïicing device
X1:252 2
optional
X1:130 E37 +

BOMAG
optional X1:127 2
X1:146
X7:6 X18:1 VD V36
1
4 Druckschalter ï

3A
pressure switch
B75 P
LP 3 HP
X29:1 X19:1 X1:414/2
or X7:5 X18:2
+ Y138 1 2 X1:147
X1:201
M26 M V26 X14:4 X17:1
0,42A

2 1
sw ï 2 1
X1:414/1
X19:2
X1: X29:2 V48 Y15
1 2
X1:382
1,75A

X1:70 X1:272 X1:128

X1:205 X14:5 X17:2
11:20 31 31 14:1

Zyklon Abscheider Magnetventil Heizen Magnetkupplung Verdampferlüfter

cyclone separator solenid valve heating magnetic clutch blower evaporator

Zusatzausrüstung Klimatronik KONVEKTA

Option klimatronic KONVEKTA

03.04.2006
1 1 570 700 35
Werner Schutzbelüftung, Zyklon Abscheider, Klimatronik
03.04.2006
20.2

827
Seis protected vent. system, cyclone separator, air cond. 013
 828
K30 K13:87
2:19 2x6qmm
11:16
20.2

X1:2 X1:1

2x6qmm
12:9 K32:30

30
K32
3:16
87
K32:87
12:19
H A B X1:372 X1:372
F49 F27 F28
10A
Box 2 8 F66 H F85 D F42 E F41 D F99 G F86 E F125 B F98 C Box 1 1 Box 1 2
10A 10A
Box 1 8 Box 1 4 Box 2 5 Box 2 4 Box 1 7 Box 1 5 Box 2 2 Box 2 3
15A 20A 10A 10A 15A 15A 10A 10A

F41:4
12:9 + 123 3 2 1 012 7 2
F126 S22
01
S16 2A
S53 1 1 2 S45 1 S38 1 S137 1 S26 1 ï S128 1
01
S20 5 1 8 5 S21 5 4
ws
5 3 4 5 5 5 5 Kamera 5
camera
X1:145 15 J S 86

X1:72
P32
K61:87a

1,5A
Impulsgeber

Spannungswandler
voltage transformer
X7:1 X7:2 6:9 gn A57 Interval switch
2,5A

+24 +12 E56 4 31 31b

24V E16 1 E23 1 E25 1 E29 1 1 1

BOMAG
X1:378
B11

2,9A
2,9A
2,9A
0,6A
2,9A
12V
2 2 2 2 2 sw 2

Rundumkennleuchte
rotary beacon
U01 ï E32
A12 15 53a 31b 53
2,5A

31b
53
53a

+ + B51 E17 1 P15 3 R77 R77 R77 R77 + +

ï ï E24 1 E26 1 E29 1 + E57 1 1
V 1 1 1 1

2,9A
M04 M M06 M M05 M M07 M B28

2,9A
2,9A
0,6A
2,9A
B51 31
2 2,9A 2 2 2 2
Radio 2 2 2 ï 2 Bildschirm 31 ï 31 ï 2

X1:150
1,7A
1,7A
1,7A
1,7A
7,9A
2,5A
3,3A
2,5A

radio monitor
K31
12:19 Scheinwerfer vorn X7:3 X7:4 Spiegelheizung Wischer vorn Wischer hinten Signalhorn
2x6qmm
head lights front mirror heating wiper, front wiper, rear warning horn

X1:3 X1:4 Scheinwerfer links/rechts Innenleuchten 1 1 Wascherpumpe Wascherpumpe

head lights lh./rh. inside light, cabin E28 E27 washer pump washer pump
2,9A 2,9A

X1:189
X1:189
2 2

31 X1:190 X1:190 31
13:20

Scheinwerfer Motorraum
head lights, engine area

Arbeitsscheinwerfer hinten
working head lights, rear

03.04.2006
1 1

008 911 57
Wiring diagram 570 700 35

Werner Kabine und Anbauteile 570 700 35

03.04.2006
Seis cabin and attachmentïparts 014
 Name Bl. Pf. Benennung title TYP
A12

A15
014
Wiring diagram 570 700 35
A15 006
006
2
7
13
Radio
Ueberwachungsmodul
Ueberwachungsmodul
Radio
monitoring module
monitoring module
20.2
A16 011 9 Elektronik Tachograph Electronic system, tachograph
A48 004 9 Elektronische Motorsteuerung Electronic engine management
A53 012 14 Modul Luefterueberwachung Modul blower monitoring
A53 013 18 Modul Luefterueberwachung Modul blower monitoring
A57 014 14 Intervallschalter Scheibenwischer Interval switch, wiper
A65 013 14 Steuerung Klimatronik Controller klimatronic
A78 008 3 Zusatzelektronik Additional control unit

B03 006 4 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B05 006 18 Druckschalter Bremse Pressure switch, brake
B08 010 19 Naeherungsinitiator Fahrhebel ’0’ïStell. Proximity switch, travel lever ’0’ pos. max. 1,08A
Seis
19.04.2006
Werner
19.04.2006

B11 014 19 Signalhorn Warning horn 2,5A

B15 011 6 Aufnehmer Geschwindigkeit Transducer, speed
B19 006 19 Magnetsensor Verschmutzung Magnetic sensor, contamination
B20 006 13 Temperaturschalter Hydraulikoel Temperature switch, hydraulic oil
B21 006 17 Differenzdruckschalter Hydr.ïOelfilter Pressure diff. switch, hydr. oil filter
B22 006 16 Differenzdruckschalter Hydr.ïOelfilter Pressure diff. switch, hydr. oil filter
B24 006 12 Schwimmerschalter Hydraulikoel Float switch, hydraulic oil
B25 006 11 Druckschalter Ruecklauffilter Pressure switch, return flow filter
B28 014 20 Signalhorn Warning horn 2,5A
B29 013 14 Raumthermostat Room thermostat
B42 006 17 Differenzdruckschalter Hydraulikoel Hydraulic oil pressure differential switch
B51 014 2 Lautsprecher Radio Speaker radio
B51 014 3 Lautsprecher Radio Speaker radio
B52 011 4 Naeherungsinitiator Schmierkolben Proximity switch, lubrication piston
B53 005 6 Temperaturgeber Kuehlmittel Temperature switch, collant
B55 006 3 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B75 013 16 Kuehlmitteldruck coolant pressure
B88 004 5 Druckgeber Motoroel Sender, engine oil pressure
B113 004 7 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B114 004 8 EMR Aufnehmer, Motordrehzahl 1 EMR Trancducer, engine speed 1
B116 006 4 Unterdruckschalter Luftfilter Vacuum switch, air cleaner
B117 013 15 Thermostat Klimaanlage Thermostar, air conditioning
B118 013 15 Temperaturfühler Auslaß Temperature sender outlet
B121 006 15 Differenzdruckschalter Hydr.ïOelfilter Pressure diff. switch, hydr. oil filter
B122 006 15 Differenzdruckschalter Hydr.ïOelfilter Pressure diff. switch, hydr. oil filter
B124 004 3 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B126 004 6 EMR Temperaturgeber Kraftstoff EMR fuel temperature sender
B129 006 12 Druckschalter Verteilergetriebe pressure switch power takeïoff gear
B130 004 9 EMR Aufnehmer, Motordrehzahl 2 EMR Trancducer, engine speed 2
component listing

B133 004 11 Sensor Ladeluftdruck / ïtemperatur sesnor charging air prssure / temperature
Bauteilliste

E01 005 14 Beleuchtung Tankanzeige Illumination, level gauge

E02 005 5 Beleuchtung Temperaturanzeige Illumination, temperature gauge
E03 005 10 Beleuchtung Drehzahlmesser Illumination, rpm meter
E04 011 10 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer
E04 011 11 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer
E16 014 4 Scheinwerfer links Head light, lh. 55W
E17 014 4 Scheinwerfer rechts Head light, rh. 55W
E20 002 12 Zigarettenanzuender Cigarette lighter
E21 002 12 Beleuchtung Zigarettenanzuender Illumination, cigarette lighter
E22 005 7 Beleuchtung Temperaturanzeige Hydr.ïoel Illumination, temp. gauge, hydraulic oil
E23 014 5 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
E24 014 5 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
E25 014 6 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E26 014 6 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E27 014 11 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55W
E28 014 10 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55W
E29 014 7 Innenleuchte Kabine Inside light, cabin 15W
E29 014 8 Innenleuchte Kabine Inside light, cabin 15W
E30 012 3 Heizgeraet Heating unit
E32 014 8 Kennleuchte Warning light 70W
E37 013 18 Klimaverdampfer Air conditioning, evaporator
E46 005 15 Beleuchtung Voltmeter Illumination volt meter
E56 014 9 Scheinwerfer Motorraum rechts Head light, engine area rh. 55W
E57 014 9 Scheinwerfer Motorraum links Head light, engine area lh. 55W
ESX 006 9 Elektronisches Steuergeraet Electronic system, control unit
ESX 007 12 Elektronisches Steuergeraet Electronic system, control unit
ESX 008 10 Elektronisches Steuergeraet Electronic system, control unit
ESX 009 5 Elektronisches Steuergeraet Electronic system, control unit
ESX 009 18 Elektronisches Steuergeraet Electronic system, control unit
ESX 010 8 Elektronisches Steuergeraet Electronic system, control unit max. 1,08A
ESX 010 18 Elektronisches Steuergeraet Electronic system, control unit 0,2A

F00 002 2 Hauptsicherung Batterie Fuse, main, battery 250A

F02 012 12 Ersatzsicherung Fuse, spare 10A
F05 002 15 Sicherung Steckdose Fuse, socket 30A
F13 003 9 Sicherung Startschalter Fuse, starter switch 30A
F16 011 4 Sicherung Zentralschmieranlage Fuse, central lubrication system 10A
1

F23 011 14 Sicherung Signalhorn Fuse, warning horn 15A

F24 005 5 Sicherung Ueberwachungsmodul Fuse, monitoring module 15A
F25 009 2 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 10A
F27 014 16 Sicherung Wischer u. Wascher vorne Fuse, windscr. wiper and washer, fr. 10A
F28 014 18 Sicherung Wischer u. Wascher hinten Fuse, windscr. wiper and washer, re. 10A
11

F29 011 18 Sicherung Kompressor Sitzverstell. Fuse, compr., seat height adjustm. 15A
F31 013 6 Sicherung Kabinenluefter Fuse, cabin ventilator 10A
F33 013 9 Sicherung Klimageraet Fuse, air conditioning 10A
F40 012 3 Sicherung Kabinenheizung Fuse, heating unit cab 10A
570 700 35

F41 014 8 Sicherung Rundumkennleuchte Fuse, rotary beacon 10A

F42 014 7 Sicherung Kabineninnenleuchte Fuse, inside light cab 10A
F48 004 2 Sicherung Gluehanlage Fuse, glow plug system 80A
F49 014 1 Sicherung Spannungswandler Fuse, voltage transformer 10A
F50 013 19 Sicherung Klimageraet Fuse, air conditioning 15A
101

F66 014 4 Sicherung Scheinwerfer vorne Fuse, head light front 15A
F67 009 7 Sicherung Steuerung (Potential 30) Fuse, controller (pot.30) 30A
008 911
F84 57 009 13 Sicherung Steuerung (Klemme 54) BOMAG
Fuse, controller (Pin 54) 10A 829
 Name Bl. Pf. Benennung title TYP

20.2 F85
F86
F89
014
014
002
6
10
12
Sicherung, Scheinwerfer vorne
Sicherung, Scheinwerfer hinten
Sicherung, Zigarettenanzuender
Fuse, head light front
Fuse, head lights rear
Fuse, cigarette lighter
20A
Wiring diagram 570 700 35
15A
30A
F90 012 8 Sicherung, Ansteuerung Fuse, actuation 5A
F93 004 4 Sicherung Steuerung (Potential 30) Fuse, controller (pot. 30) 25A
F94 013 3 Sicherung Schutzbelueftung Fuse, protected ventilation syst.
F98 014 13 Sicherung Spiegelheizung fuse,mirror heating 10A
F99 014 9 Sicherung Motorraumbeleuchtung fuse, illumination engine area 15A
FM1 008 13 Platinensicherung Multifuse 0,2A
FM2 007 19 Platinensicherung Multifuse 0,2A
FM3 010 8 Platinensicherung Multifuse 0,2A
FM4 010 4 Platinensicherung Multifuse 0,2A
FM5 010 11 Platinensicherung Multifuse 0,2A
FM6 007 7 Platinensicherung Multifuse 0,2A
Seis
19.04.2006
Werner
19.04.2006

FM7 010 13 Platinensicherung Multifuse 0,2A

F122 002 17 Sicherung EMR Fuse, EMR 10A
F123 013 2 Sicherung Schutzbelüftungsanlage Fuse, protected ventilation system
F125 014 11 Vorsicherung preïfusing 10A
F126 014 11 Sicherung Rückfahrkamera Fuse, back up camera system 2A

G01 002 2 Batterie Battery

G02 002 5 Generator Generator 28V/80A
G03 002 2 Batterie Battery

H04 004 10 Meldeleuchte Betriebsstoerung Indicator light, breakdown

H07 009 13 Warnsummer Betriebsstoerung Warning buzzer, breakdown 0,2A
H14 007 4 Warnsummer Rueckwaertsfahrt Backïup alarm buzzer max. 2,5A
H70 004 11 Anzeige Wasser im Diesel Indicator water in fuel
H81 008 5 Meldeleuchte Verzögerungsfunktion Indicator light, decelerator device

K05 007 2 Relais Startstrom Relay, starting current BOSCHW

K11 003 14 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHL
K13 011 14 Relais Signalhorn Relay, warning horn BOSCHW
K14 004 4 Relais Vorgluehen Relay, glow plug system K2DEUTZ
K15 004 12 Relais Gluehen beim Start Relay, glowing during starting BOSCHW
K22 009 6 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K32 003 16 Relais Kabine Relay, cabin BOSCHL
K48 007 3 Relais Fahrhebel 0ïStellung Relay, travel lever 0ïposition BOSCHW
K60 004 14 Relais Motoroeldruck Relay, engine oil pressure BOSCHW
K61 002 8 Relais Ladekontrolle Relay, charge control BOSCHW
K62 002 10 Relais D+ Relay, D+ BOSCHW
K77 009 17 Relais Override Relay, override SDS/SF4
K90 009 4 Relais, Meldeleuchte Stoerung SPS Relay, indicat.light brake down SPS BOSCHW
component listing

K113 006 11 Zeitrelais Timing relay BOSCHW

K133 009 9 Relais Test Relay, test BOSCHW
Bauteilliste

K146 004 13 Relais Kühlmitteltemperatur relay, coolant temperature BOSCHW

K77/1 009 15 Relais Override Relay, override SDS/SF4

M01 003 9 Starter Starter

M04 014 15 Scheibenwischermotor vorne Windscreen wiper motor, front 190W
M05 014 17 Scheibenwischermotor hinten Windscreen wiper motor, rear max 3,3A
M06 014 16 Scheibenwaschermotor vorne Windscreen washer motor, front 60W
M07 014 18 Scheibenwaschermotor hinten Windscreen washer motor, rear 60W
M08 011 3 Zentralschmieranlage Central lubrication system max. 3A
M10 011 18 Kompressor Fahrersitzhoehenverstellung Compr., operator’s seat height adjustm. 7,5A
M17 012 18 Zusatzluefter Additional blower max. 0,75A
M24 013 10 Stellmotor Luftklappe adjusting motor air inlet flap
M26 013 6 Zyklon Abscheider cyclone separator 3A

P00 005 12 Betriebsstundenzaehler Operating hour meter

P01 005 15 Tankanzeige Level gauge
P02 005 7 Temperaturanzeige Hydraulikoel Temperature gauge, hydraulic oil
P03 005 11 Drehzahlmesser Rpm meter
P09 011 10 Frequenzï und Geschwindigkeitsanzeige Frequencyï and Speedometer
P09 011 10 Frequenzï und Geschwindigkeitsanzeige Frequencyï and Speedometer
P12 005 16 Voltmeter Volt meter
P14 005 6 Anzeige Kuehlmitteltemperatur Temperature gauge, coolant
P15 014 11 BCM 03 Bildschirm BCM 03 terminal
P18 010 16 Diagnose Diagnostics max. 1,08A
P32 014 12 Kamera Rückraumüberwachung Camera, back up monitoring

R02 004 2 Gluehkerze Glow plug

R02 004 2 Gluehkerze Glow plug
R03 005 15 Geber Tankanzeige Sender, level gauge
R04 005 8 Geber Hydraulikoeltemperatur Sender, hydraulic oil temp.
R06 011 19 Heizung Fahrersitz Heating, operator’s seat
R06 011 19 Heizung Fahrersitz Heating, operator’s seat
R10 002 7 Parallelwiderstand Parallel resistor 220 OHM
R20 008 15 Widerstand Resistor 1 KOHM
R21 008 15 Widerstand Resistor 1 KOHM
R22 008 16 Widerstand Resistor 1 KOHM
R23 008 17 Widerstand Resistor 1 KOHM
2

R26 012 17 Widerstand Resistor 22 OHM

R27 012 18 Widerstand Resistor 10 OHM
R32 007 5 Widerstand Resistor 1 kOhm
R33 007 5 Widerstand Resistor 2 kOhm
R34 007 6 Widerstand Resistor 1 kOhm
11

R35 007 8 Widerstand Resistor 3,3 kOhm

R36 010 5 Widerstand Resistor 47 OHM
R38 010 5 Widerstand Resistor 47 OHM
R40 010 5 Widerstand Resistor 47 OHM
570 700 35

R42 010 5 Widerstand Resistor 47 OHM

R43 008 7 Widerstand Resistor 499Ohm
R44 008 7 Widerstand Resistor 499Ohm
R77 014 12 Widerstandsheizung Aussenspiegel Resistor heating outside mirror 40W
R77 014 13 Widerstandsheizung Aussenspiegel Resistor heating outside mirror 40W
102

R77 014 13 Widerstandsheizung Aussenspiegel Resistor heating outside mirror 40W

R77 014 14 Widerstandsheizung Aussenspiegel Resistor heating outside mirror 40W
830 BOMAG 008 911 57
 Name Bl. Pf. Benennung title TYP
S00

S01
003
Wiring diagram 570 700 35
S01 002
002
9
17
17
Startschalter
Schalter NOT AUS
Schalter NOT AUS
Starter switch
Switch, emergency off
Switch, emergency off
MERIT
NOTAUSH 20.2
S02 008 16 Fahrstufenschalter Switch, speed range selector
S02 008 19 Fahrstufenschalter Switch, speed range selector
S03 011 14 Taster Signalhorn Push button, warning horn
S04 008 10 Bremsschalter Switch, brake
S16 014 5 Schalter Arbeitsbeleuchtung vorne Switch, working head lights, front
S20 014 14 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 014 18 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S22 014 16 Schalter Scheibenwascher vorne Switch, windscreen washer, front
S25 011 19 Schalter Fahrersitzheizung Switch, heating, operator’s seat
S26 014 10 Schalter Arbeitsbeleuchtung hinten Switch, working head lights, rear
S27 011 3 Taster Zentralschmieranlage Push botton, central lubrication system
Seis
19.04.2006
Werner
19.04.2006

S28 012 8 Schalter Kabinenheizung Switch, cabin heating

S29 011 18 Schalter Fahrersitz Hoehenverstellung Switch, operator’s seat height adjustm.
S30 002 2 Batterietrennschalter Switch, battery disconnect
S31 007 5 Schalter Fahrtrichtung Switch, travel direction
S38 014 8 Schalter Kennleuchte Switch, warning light
S44 012 17 Schalter Kabinenluefter Switch, cabin ventilator
S45 014 7 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 014 4 Schalter Arbeitsbeleuchtung Switch, working lights
S70 010 10 Schalter Schubsschild Switch, dozer blade WAGO
S71 010 3 Schalter Lenkung Switch, steering max. 1,08A
S118 004 18 Schalter Fehlerdiagnose Switch, fault diagnosis
S119 004 6 Elektronisches Fusspedal Electronic foot pedal
S120 008 7 Schalter Motordrehzahl Switch, engine speed 5 kOhm
S128 014 13 Schalter Spiegelheizung Switch, mirror heating
S137 014 9 Schalter Motorraumbeleuchtung Switch, illumination engine area
S160 008 4 Schalter Aktivierung Verzögerungspedal Switch, enable decelerator pedal
S161 008 6 Verzögerungspedal decelerator pedal

U01 014 1 Spannungswandler Voltage transformer

V01 002 7 Diode Diode WAGO

V02 006 7 Diode Diode WAGO
V03 006 7 Diode Diode WAGO
V04 006 7 Diode Diode WAGO
V05 006 7 Diode Diode WAGO
V07 006 12 Diode Diode WAGO
V08 006 12 Diode Diode WAGO
V09 006 12 Diode Diode WAGO
V10 006 12 Diode Diode WAGO
component listing

V11 006 12 Diode Diode WAGO

V12 009 7 Diode Diode WAGO
Bauteilliste

V13 006 12 Diode Diode WAGO

V14 009 14 Diode Diode Wago
V15 009 15 Diode Diode Wago
V16 010 2 Diode Diode WAGO
V17 010 3 Diode Diode WAGO
V18 010 2 Diode Diode WAGO
V19 010 2 Diode Diode WAGO
V21 009 9 Diode Diode WAGO
V22 009 10 Diode Diode WAGO
V23 007 2 Diode Diode WAGO
V25 007 3 Diode Diode WAGO
V26 013 14 Diode Diode WAGO
V31 008 10 Diode Diode Lütze
V32 007 9 Diode Diode Lütze
V33 007 11 Diode Diode Lütze
V34 007 5 Diode Diode Lütze
V35 007 7 Diode Diode Lütze
V36 013 19 Diode Diode FE5B
V37 008 13 Diode Diode Lütze
V38 007 2 Diode Diode FE5B KabeldiodeDiode
V42 009 13 Diode (A2) Diode (A2) Diodenmodul
V43 013 6 Diode (A3) Diode (A3) Diodenmodul
V46 011 15 Diode (A6) Diode (A6) Diodenmodul
V47 003 12 Diode (A7) Diode (A7) Diodenmodul
V48 013 15 Diode (A8) Diode (A8) Diodenmodul

X0/1:1 010 18 DIOS STECKER Dios connector

X0/1:2 010 18 DIOS STECKER Dios connector
X0/1:3 009 18 DIOS STECKER Dios connector
X0/1:4 009 19 DIOS STECKER Dios connector
X0/1:5 010 18 DIOS STECKER Dios connector
X0/1:6 010 19 DIOS STECKER Dios connector
X0/1:9 009 19 DIOS STECKER Dios connector
X0/1:10 009 19 DIOS STECKER Dios connector
X0/1:11 009 18 DIOS STECKER Dios connector
X0:1 007 10 ESX STECKER esx connector
X0:1 008 13 ESX STECKER esx connector
3

X0:1 010 7 ESX STECKER esx connector

X0:2 009 4 ESX STECKER esx connector
X0:3 009 9 ESX STECKER esx connector
X0:4 009 10 ESX STECKER esx connector
X0:5 009 11 ESX STECKER esx connector
11

X0:6 006 9 ESX STECKER esx connector

X0:7 008 14 ESX STECKER esx connector
X0:8 010 3 ESX STECKER esx connector
X0:9 010 7 ESX STECKER esx connector
570 700 35

X0:10 006 10 ESX STECKER esx connector

X0:11 006 9 ESX STECKER esx connector
X0:12 010 14 ESX STECKER esx connector
X0:13 006 10 ESX STECKER esx connector
X0:14 010 6 ESX STECKER esx connector
103

X0:15 010 7 ESX STECKER esx connector

X0:16 009 4 ESX STECKER esx connector
008 911
X0:17 57 010 13 ESX STECKER BOMAG
esx connector 831
 Name Bl. Pf. Benennung title TYP

20.2 X0:18
X0:19
X0:20
006
006
010
9
9
8
ESX STECKER
ESX STECKER
ESX STECKER
esx connector
esx connector
esx connector
Wiring diagram 570 700 35
X0:21 007 10 ESX STECKER esx connector
X0:22 007 8 ESX STECKER esx connector
X0:23 007 11 ESX STECKER esx connector
X0:23 008 13 ESX STECKER esx connector
X0:23 010 8 ESX STECKER esx connector
X0:24 009 6 ESX STECKER esx connector
X0:25 009 7 ESX STECKER esx connector
X0:26 010 17 ESX STECKER esx connector
X0:27 010 16 ESX STECKER esx connector
X0:28 009 6 ESX STECKER esx connector
X0:29 007 19 ESX STECKER esx connector
Seis
19.04.2006
Werner
19.04.2006

X0:30 010 10 ESX STECKER esx connector

X0:31 010 12 ESX STECKER esx connector
X0:32 007 7 ESX STECKER esx connector
X0:33 009 9 ESX STECKER esx connector
X0:34 010 13 ESX STECKER esx connector
X0:35 010 11 ESX STECKER esx connector
X0:36 006 9 ESX STECKER esx connector
X0:37 010 15 ESX STECKER esx connector
X0:38 010 5 ESX STECKER esx connector
X0:39 010 5 ESX STECKER esx connector
X0:40 008 10 ESX STECKER esx connector
X0:41 010 11 ESX STECKER esx connector
X0:42 010 9 ESX STECKER esx connector
X0:43 007 19 ESX STECKER esx connector
X0:44 009 13 ESX STECKER esx connector
X0:45 006 10 ESX STECKER esx connector
X0:46 007 14 ESX STECKER esx connector
X0:47 007 16 ESX STECKER esx connector
X0:48 007 17 ESX STECKER esx connector
X0:49 010 7 ESX STECKER esx connector
X0:50 006 10 ESX STECKER esx connector
X0:51 006 10 ESX STECKER esx connector
X0:52 006 9 ESX STECKER esx connector
X0:53 009 9 ESX STECKER esx connector
X0:54 009 13 ESX STECKER esx connector
X0:55 010 16 ESX STECKER esx connector
X0:56 009 7 ESX STECKER esx connector
X0:57 009 8 ESX STECKER esx connector
X0:58 009 8 ESX STECKER esx connector
component listing

X0:59 009 8 ESX STECKER esx connector

X0:60 009 9 ESX STECKER esx connector
Bauteilliste

X0:61 008 10 ESX STECKER esx connector

X0:62 008 14 ESX STECKER esx connector
X0:63 010 11 ESX STECKER esx connector
X0:64 010 6 ESX STECKER esx connector
X0:65 010 14 ESX STECKER esx connector
X0:66 010 15 ESX STECKER esx connector
X0:67 010 15 ESX STECKER esx connector
X0:68 010 16 ESX STECKER esx connector
X1: 013 2 Wago Zentralelektrik Wago eïbox
X1:1 014 7 Wago Zentralelektrik Wago eïbox
X1:2 014 7 Wago Zentralelektrik Wago eïbox
X1:3 014 2 Wago Zentralelektrik Wago eïbox
X1:4 014 2 Wago Zentralelektrik Wago eïbox
X1:5 004 20 Wago Zentralelektrik Wago eïbox
X1:6 002 17 Wago Zentralelektrik Wago eïbox
X1:7 003 9 Wago Zentralelektrik Wago eïbox
X1:8 003 9 Wago Zentralelektrik Wago eïbox
X1:9 003 9 Wago Zentralelektrik Wago eïbox
X1:61 010 18 Wago Zentralelektrik Wago eïbox
X1:62 004 15 Wago Zentralelektrik Wago eïbox
X1:63 010 18 Wago Zentralelektrik Wago eïbox
X1:64 004 16 Wago Zentralelektrik Wago eïbox
X1:65 004 16 Wago Zentralelektrik Wago eïbox
X1:66 009 10 Wago Zentralelektrik Wago eïbox
X1:67 009 11 Wago Zentralelektrik Wago eïbox
X1:68 010 18 Wago Zentralelektrik Wago eïbox
X1:69 010 18 Wago Zentralelektrik Wago eïbox
X1:70 002 10 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:70 003 16 Wago Zentralelektrik Wago eïbox
X1:70 007 2 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:70 007 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:70 009 4 Wago Zentralelektrik Wago eïbox
X1:70 009 6 Wago Zentralelektrik Wago eïbox
X1:70 009 9 Wago Zentralelektrik Wago eïbox
X1:70 009 13 Wago Zentralelektrik Wago eïbox
X1:70 009 15 Wago Zentralelektrik Wago eïbox
X1:70 009 17 Wago Zentralelektrik Wago eïbox
4

X1:70 013 6 Wago Zentralelektrik Wago eïbox

X1:71 004 17 Wago Zentralelektrik Wago eïbox
X1:72 014 11 Wago Zentralelektrik Wago eïbox
X1:81 002 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:82 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
11

X1:83 006 4 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:84 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:85 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:86 006 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
570 700 35

X1:87 006 2 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:88 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:89 006 2 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:90 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:91 006 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
104

X1:92 004 12 Wago Zentralelektrik Wago eïbox

X1:93 004 13 Wago Zentralelektrik Wago eïbox
832 X1:94 004 14 Wago Zentralelektrik BOMAG
Wago eïbox 008 911 57
 Name Bl. Pf. Benennung title TYP
X1:101

X1:103
006
Wiring diagram 570 700 35
X1:102 006
006
7
9
5
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
WAGO EïBOX
WAGO EïBOX
WAGO EïBOX
20.2
X1:104 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:105 006 11 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:106 006 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:108 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:109 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:110 006 11 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:111 006 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:112 006 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:113 006 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:114 006 18 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:115 006 14 WAGO ZENTRALELEKTRIK WAGO EïBOX
Seis
19.04.2006
Werner
19.04.2006

X1:116 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:117 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:118 006 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:119 006 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:120 006 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:121 006 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:122 006 18 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:123 006 14 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:124 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:125 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:126 006 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:127 013 13 Wago Zentralelektrik Wago eïbox
X1:128 013 13 Wago Zentralelektrik Wago eïbox
X1:129 013 15 Wago Zentralelektrik Wago eïbox
X1:130 013 15 Wago Zentralelektrik Wago eïbox
X1:131 007 8 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:132 007 8 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:133 007 10 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:134 007 10 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:135 007 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:136 007 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:137 010 11 Wago Zentralelektrik Wago eïbox
X1:138 010 11 Wago Zentralelektrik Wago eïbox
X1:139 010 12 Wago Zentralelektrik Wago eïbox
X1:140 010 12 Wago Zentralelektrik Wago eïbox
X1:141 010 18 Wago Zentralelektrik Wago eïbox
X1:142 010 18 Wago Zentralelektrik Wago eïbox
X1:143 010 19 Wago Zentralelektrik Wago eïbox
X1:144 010 19 Wago Zentralelektrik Wago eïbox
component listing

X1:145 014 9 Wago Zentralelektrik Wago eïbox

X1:146 013 15 Wago Zentralelektrik Wago eïbox
Bauteilliste

X1:147 013 15 Wago Zentralelektrik Wago eïbox

X1:148 005 8 Wago Zentralelektrik Wago eïbox
X1:149 007 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:150 014 10 Wago Zentralelektrik Wago eïbox
X1:151 008 10 Wago Zentralelektrik Wago eïbox
X1:152 008 10 Wago Zentralelektrik Wago eïbox
X1:153 007 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:154 007 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:155 007 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:156 007 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:157 007 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:158 007 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:159 010 6 Wago Zentralelektrik Wago eïbox
X1:160 010 6 Wago Zentralelektrik Wago eïbox
X1:161 010 7 Wago Zentralelektrik Wago eïbox
X1:162 010 7 Wago Zentralelektrik Wago eïbox
X1:163 010 8 Wago Zentralelektrik Wago eïbox
X1:164 010 8 Wago Zentralelektrik Wago eïbox
X1:165 010 9 Wago Zentralelektrik Wago eïbox
X1:166 010 9 Wago Zentralelektrik Wago eïbox
X1:170 008 14 Wago Zentralelektrik Wago eïbox
X1:171 011 4 Wago Zentralelektrik Wago eïbox
X1:172 011 3 Wago Zentralelektrik Wago eïbox
X1:173 011 3 Wago Zentralelektrik Wago eïbox
X1:174 011 4 Wago Zentralelektrik Wago eïbox
X1:181 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:181 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:181 010 14 Wago Zentralelektrik Wago eïbox
X1:182 006 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:182 006 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:182 010 15 Wago Zentralelektrik Wago eïbox
X1:183 006 11 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:183 006 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:183 010 15 Wago Zentralelektrik Wago eïbox
X1:184 006 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:184 006 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:184 009 18 Wago Zentralelektrik Wago eïbox
5

X1:185 006 17 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:185 009 19 Wago Zentralelektrik Wago eïbox
X1:186 006 18 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:186 009 19 Wago Zentralelektrik Wago eïbox
X1:187 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
11

X1:187 010 16 Wago Zentralelektrik Wago eïbox

X1:188 007 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:188 010 16 Wago Zentralelektrik Wago eïbox
X1:189 010 14 Wago Zentralelektrik Wago eïbox
570 700 35

X1:189 014 9 Wago Zentralelektrik Wago eïbox

X1:189 014 9 Wago Zentralelektrik Wago eïbox
X1:190 011 6 Wago Zentralelektrik Wago eïbox
X1:190 014 10 Wago Zentralelektrik Wago eïbox
X1:190 014 11 Wago Zentralelektrik Wago eïbox
105

X1:191 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:191 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
008 911
X1:19157 011 7 Wago Zentralelektrik BOMAG
Wago eïbox 833
 Name Bl. Pf. Benennung title TYP

20.2 X1:192
X1:201
X1:202
008
013
002
14
15
7
Wago Zentralelektrik
Wago Zentralelektrik
WAGO ZENTRALELEKTRIK
Wago eïbox
Wago eïbox
WAGO EïBOX
Wiring diagram 570 700 35
X1:205 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:205 013 15 Wago Zentralelektrik Wago eïbox
X1:207 009 4 Wago Zentralelektrik Wago eïbox
X1:20A 013 19 Sika ï Klemme fuse terminal
X1:20E 013 19 Sika ï Klemme fuse terminal
X1:210 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:21A 002 12 Sika ï Klemme fuse terminal
X1:21E 002 12 Sika ï Klemme fuse terminal
X1:221 007 14 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:222 007 14 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:223 007 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
Seis
19.04.2006
Werner
19.04.2006

X1:224 007 16 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:226 012 3 Wago Zentralelektrik Wago eïbox
X1:227 012 3 Wago Zentralelektrik Wago eïbox
X1:228 005 15 Wago Zentralelektrik Wago eïbox
X1:229 005 15 Wago Zentralelektrik Wago eïbox
X1:22A 013 3 Sika ï Klemme fuse terminal
X1:22E 013 3 Sika ï Klemme fuse terminal
X1:231 004 6 Wago Zentralelektrik Wago eïbox
X1:232 004 6 Wago Zentralelektrik Wago eïbox
X1:233 004 7 Wago Zentralelektrik Wago eïbox
X1:234 008 5 Wago Zentralelektrik Wago eïbox
X1:235 004 6 Wago Zentralelektrik Wago eïbox
X1:236 004 6 Wago Zentralelektrik Wago eïbox
X1:237 004 7 Wago Zentralelektrik Wago eïbox
X1:23A 003 9 Sika ï Klemme fuse terminal
X1:23E 002 3 Sika ï Klemme fuse terminal
X1:23E 003 9 Sika ï Klemme fuse terminal
X1:241 002 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:242 002 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:243 002 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:244 004 10 Wago Zentralelektrik Wago eïbox
X1:245 011 19 Wago Zentralelektrik Wago eïbox
X1:246 011 19 Wago Zentralelektrik Wago eïbox
X1:247 013 15 Wago Zentralelektrik Wago eïbox
X1:248 011 3 Wago Zentralelektrik Wago eïbox
X1:249 013 10 Wago Zentralelektrik Wago eïbox
X1:24A 004 4 Sika ï Klemme fuse terminal
X1:24E 004 4 Sika ï Klemme fuse terminal
X1:250 004 10 Wago Zentralelektrik Wago eïbox
component listing

X1:251 013 9 Wago Zentralelektrik Wago eïbox

X1:252 013 13 Wago Zentralelektrik Wago eïbox
Bauteilliste

X1:253 013 17 Wago Zentralelektrik Wago eïbox

X1:255 004 18 Wago Zentralelektrik Wago eïbox
X1:256 002 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:256 003 12 Wago Zentralelektrik Wago eïbox
X1:256 011 15 Wago Zentralelektrik Wago eïbox
X1:257 009 13 Wago Zentralelektrik Wago eïbox
X1:258 009 13 Wago Zentralelektrik Wago eïbox
X1:259 002 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:25A 002 15 Sika ï Klemme fuse terminal
X1:25E 002 15 Sika ï Klemme fuse terminal
X1:260 002 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:261 008 10 Wago Zentralelektrik Wago eïbox
X1:262 007 18 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:262 008 10 Wago Zentralelektrik Wago eïbox
X1:263 008 10 Wago Zentralelektrik Wago eïbox
X1:265 012 18 Wago Zentralelektrik Wago eïbox
X1:266 012 17 Wago Zentralelektrik Wago eïbox
X1:267 012 18 Wago Zentralelektrik Wago eïbox
X1:268 012 19 Wago Zentralelektrik Wago eïbox
X1:269 004 11 Wago Zentralelektrik Wago eïbox
X1:26A 009 13 Sika ï Klemme fuse terminal
X1:26E 009 13 Sika ï Klemme fuse terminal
X1:270 004 11 Wago Zentralelektrik Wago eïbox
X1:272 011 3 Wago Zentralelektrik Wago eïbox
X1:272 013 9 Wago Zentralelektrik Wago eïbox
X1:27A 009 7 Sika ï Klemme fuse terminal
X1:27E 009 7 Sika ï Klemme fuse terminal
X1:28A 013 2 Sika ï Klemme fuse terminal
X1:28E 013 2 Sika ï Klemme fuse terminal
X1:291 005 7 Wago Zentralelektrik Wago eïbox
X1:292 005 11 Wago Zentralelektrik Wago eïbox
X1:293 003 10 Wago Zentralelektrik Wago eïbox
X1:294 005 5 Wago Zentralelektrik Wago eïbox
X1:295 005 7 Wago Zentralelektrik Wago eïbox
X1:296 005 15 Wago Zentralelektrik Wago eïbox
X1:298 002 11 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:298 005 11 Wago Zentralelektrik Wago eïbox
6

X1:299 004 20 Wago Zentralelektrik Wago eïbox

X1:299 005 5 Wago Zentralelektrik Wago eïbox
X1:29A 005 5 Sika ï Klemme fuse terminal
X1:29E 005 5 Sika ï Klemme fuse terminal
X1:300 005 7 Wago Zentralelektrik Wago eïbox
11

X1:301 005 11 Wago Zentralelektrik Wago eïbox

X1:302 003 13 Wago Zentralelektrik Wago eïbox
X1:303 005 8 Wago Zentralelektrik Wago eïbox
X1:30A 011 4 Sika ï Klemme fuse terminal
570 700 35

X1:30E 011 4 Sika ï Klemme fuse terminal

X1:31A 011 18 Sika ï Klemme fuse terminal
X1:31E 002 17 SIKA KLEMME fuse terminal
X1:31E 011 18 Sika ï Klemme fuse terminal
X1:321 010 6 Wago Zentralelektrik Wago eïbox
106

X1:322 010 8 Wago Zentralelektrik Wago eïbox

X1:323 010 7 Wago Zentralelektrik Wago eïbox
834 X1:324 010 7 Wago Zentralelektrik BOMAG
Wago eïbox 008 911 57
 Name Bl. Pf. Benennung title TYP
X1:325

X1:327
010
Wiring diagram 570 700 35
X1:326 010
010
6
7
11
Wago Zentralelektrik
Wago Zentralelektrik
Wago Zentralelektrik
Wago eïbox
Wago eïbox
Wago eïbox
20.2
X1:328 010 11 Wago Zentralelektrik Wago eïbox
X1:329 010 10 Wago Zentralelektrik Wago eïbox
X1:32A 002 17 Sika ï Klemme fuse terminal
X1:32E 002 17 Sika ï Klemme fuse terminal
X1:330 010 10 Wago Zentralelektrik Wago eïbox
X1:331 010 11 Wago Zentralelektrik Wago eïbox
X1:332 010 11 Wago Zentralelektrik Wago eïbox
X1:333 010 14 Wago Zentralelektrik Wago eïbox
X1:334 010 14 Wago Zentralelektrik Wago eïbox
X1:335 007 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:336 007 9 WAGO ZENTRALELEKTRIK WAGO EïBOX
Seis
19.04.2006
Werner
19.04.2006

X1:337 007 7 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:338 007 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:339 007 5 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:33A 013 6 Sika ï Klemme fuse terminal
X1:33E 002 17 SIKA KLEMME fuse terminal
X1:33E 013 6 Sika ï Klemme fuse terminal
X1:340 007 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:341 011 18 Wago Zentralelektrik Wago eïbox
X1:342 011 18 Wago Zentralelektrik Wago eïbox
X1:343 008 4 Wago Zentralelektrik Wago eïbox
X1:343 010 5 Wago Zentralelektrik Wago eïbox
X1:344 010 4 Wago Zentralelektrik Wago eïbox
X1:345 010 4 Wago Zentralelektrik Wago eïbox
X1:346 010 3 Wago Zentralelektrik Wago eïbox
X1:347 010 5 Wago Zentralelektrik Wago eïbox
X1:348 010 5 Wago Zentralelektrik Wago eïbox
X1:349 009 18 Wago Zentralelektrik Wago eïbox
X1:349 009 19 Wago Zentralelektrik Wago eïbox
X1:349 009 19 Wago Zentralelektrik Wago eïbox
X1:349 010 17 Wago Zentralelektrik Wago eïbox
X1:34A 011 14 Sika ï Klemme fuse terminal
X1:34E 011 14 Sika ï Klemme fuse terminal
X1:350 010 13 Wago Zentralelektrik Wago eïbox
X1:351 010 12 Wago Zentralelektrik Wago eïbox
X1:352 010 12 Wago Zentralelektrik Wago eïbox
X1:353 010 13 Wago Zentralelektrik Wago eïbox
X1:354 010 13 Wago Zentralelektrik Wago eïbox
X1:355 011 19 Wago Zentralelektrik Wago eïbox
X1:356 011 14 Wago Zentralelektrik Wago eïbox
component listing

X1:357 008 17 Wago Zentralelektrik Wago eïbox

X1:358 008 13 Wago Zentralelektrik Wago eïbox
Bauteilliste

X1:359 008 14 Wago Zentralelektrik Wago eïbox

X1:35A 009 2 Sika ï Klemme fuse terminal
X1:35E 009 2 Sika ï Klemme fuse terminal
X1:363 010 15 Wago Zentralelektrik Wago eïbox
X1:364 010 19 Wago Zentralelektrik Wago eïbox
X1:364 011 14 Wago Zentralelektrik Wago eïbox
X1:36A 013 9 Sika ï Klemme fuse terminal
X1:36E 013 9 Sika ï Klemme fuse terminal
X1:371 003 16 Wago Zentralelektrik Wago eïbox
X1:372 014 19 Wago Zentralelektrik Wago eïbox
X1:372 014 20 Wago Zentralelektrik Wago eïbox
X1:373 012 15 Wago Zentralelektrik Wago eïbox
X1:374 012 15 Wago Zentralelektrik Wago eïbox
X1:375 012 3 Wago Zentralelektrik Wago eïbox
X1:376 012 3 Wago Zentralelektrik Wago eïbox
X1:377 012 19 Wago Zentralelektrik Wago eïbox
X1:378 014 10 Wago Zentralelektrik Wago eïbox
X1:381 013 19 Wago Zentralelektrik Wago eïbox
X1:382 013 18 Wago Zentralelektrik Wago eïbox
X1:383 013 17 Wago Zentralelektrik Wago eïbox
X1:391/1 002 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:391/2 002 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:392/1 006 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:392/2 006 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:393/1 006 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:393/2 006 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:394/1 006 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:394/2 006 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:395/1 006 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:395/2 006 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:397/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:397/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:398/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:398/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:399/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:399/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:400/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
7

X1:400/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:401/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:401/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:402/1 009 7 Wago Zentralelektrik Wago eïbox
X1:402/2 009 7 Wago Zentralelektrik Wago eïbox
11

X1:403/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:403/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:404/1 009 14 Wago Zentralelektrik Wago eïbox
X1:404/2 009 14 Wago Zentralelektrik Wago eïbox
570 700 35

X1:405/1 009 15 Wago Zentralelektrik Wago eïbox

X1:405/2 009 15 Wago Zentralelektrik Wago eïbox
X1:406/1 010 2 Wago Zentralelektrik Wago eïbox
X1:406/2 010 2 Wago Zentralelektrik Wago eïbox
X1:407/1 010 3 Wago Zentralelektrik Wago eïbox
107

X1:407/2 010 3 Wago Zentralelektrik Wago eïbox

X1:408/1 010 2 Wago Zentralelektrik Wago eïbox
008 911 57
X1:408/2 010 2 Wago Zentralelektrik BOMAG
Wago eïbox 835
 Name Bl. Pf. Benennung title TYP

20.2 X1:409/1
X1:409/2
X1:41/1
010
010
008
2
2
13
Wago Zentralelektrik
Wago Zentralelektrik
WAGO ZENTRALELEKTRIK
Wago eïbox
Wago eïbox
WAGO EïBOX
Wiring diagram 570 700 35
X1:41/2 008 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:410/1 009 9 Wago Zentralelektrik Wago eïbox
X1:410/2 009 9 Wago Zentralelektrik Wago eïbox
X1:411/1 009 10 Wago Zentralelektrik Wago eïbox
X1:411/2 009 10 Wago Zentralelektrik Wago eïbox
X1:412/1 007 2 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:412/2 007 2 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:413/1 007 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:413/2 007 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:414/1 013 14 Wago Zentralelektrik Wago eïbox
X1:414/2 013 14 Wago Zentralelektrik Wago eïbox
Seis
19.04.2006
Werner
19.04.2006

X1:42/1 007 19 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:42/2 007 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:43/1 010 8 Wago Zentralelektrik Wago eïbox
X1:43/2 010 8 Wago Zentralelektrik Wago eïbox
X1:44/1 010 4 Wago Zentralelektrik Wago eïbox
X1:44/2 010 4 Wago Zentralelektrik Wago eïbox
X1:45/1 010 11 Wago Zentralelektrik Wago eïbox
X1:45/2 010 11 Wago Zentralelektrik Wago eïbox
X1:46/1 007 8 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:46/2 007 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:47/1 010 13 Wago Zentralelektrik Wago eïbox
X1:47/2 010 13 Wago Zentralelektrik Wago eïbox
X2:A 010 18 Datenschnittstelle data interface
X2:B 010 18 Datenschnittstelle data interface
X2:G 009 11 Datenschnittstelle data interface
X2:H 009 10 Datenschnittstelle data interface
X2:J 002 11 Datenschnittstelle data interface
X2:N 002 11 Datenschnittstelle data interface
X2:U 009 11 Datenschnittstelle data interface
X2:V 010 15 Datenschnittstelle data interface
X3:A 008 3 Stecker Handgas connector hand throttle
X3:B 008 2 Stecker Handgas connector hand throttle
X3:C 008 2 Stecker Handgas connector hand throttle
X4:A 004 15 EMR ï Diagnose EMRïdiagnosis
X4:B 004 17 EMR ï Diagnose EMRïdiagnosis
X4:F 004 16 EMR ï Diagnose EMRïdiagnosis
X4:G 004 16 EMR ï Diagnose EMRïdiagnosis
X4:H 004 15 EMR ï Diagnose EMRïdiagnosis
X4:K 004 17 EMR ï Diagnose EMRïdiagnosis
component listing

X4:M 004 16 EMR ï Diagnose EMRïdiagnosis

X5:1 005 7 Deutsch Stecker Senso Deutsch Connector sensor
Bauteilliste

X6:1 004 10 Wago Zentralelektrik Wago eïbox

X6:2 004 10 Wago Zentralelektrik Wago eïbox
X6:3 004 11 Wago Zentralelektrik Wago eïbox
X6:4 004 11 Wago Zentralelektrik Wago eïbox
X6:5 004 15 Wago Zentralelektrik Wago eïbox
X6:6 004 15 Wago Zentralelektrik Wago eïbox
X6:7 004 16 Wago Zentralelektrik Wago eïbox
X6:8 004 16 Wago Zentralelektrik Wago eïbox
X6:9 004 16 Wago Zentralelektrik Wago eïbox
X6:10 004 17 Wago Zentralelektrik Wago eïbox
X7:1 014 9 Stecker Rops connector on rops
X7:2 014 9 Stecker Rops connector on rops
X7:3 014 9 Stecker Rops connector on rops
X7:4 014 9 Stecker Rops connector on rops
X7:5 013 16 Stecker Rops connector on rops
X7:6 013 16 Stecker Rops connector on rops
X8:1 012 3 Pumpenstecker Kabine connector pump cabin;
X8:2 012 3 Pumpenstecker Kabine connector pump cabin;
X9:1 007 5 Stecker Schalter Rich connector direction switch
X9:2 007 9 Stecker Schalter Rich connector direction switch
X9:3 007 7 Stecker Schalter Rich connector direction switch
X9:4 007 5 Stecker Schalter Rich connector direction switch
X9:5 007 5 Stecker Schalter Rich connector direction switch
X9:6 007 6 Stecker Schalter Rich connector direction switch
XS 002 15 Steckdose Socket
X10:A 004 7 AMP Stecker Gaspedal AMP connector throttle
X10:B 004 6 AMP Stecker Gaspedal AMP connector throttle
X10:C 004 6 AMP Stecker Gaspedal AMP connector throttle
X11:1 011 18 Schnittstelle Sitz connector drivers seat
X11:2 011 18 Schnittstelle Sitz connector drivers seat
X12:A 004 7 AMP Stecker Gaspedal AMP connector throttle
X12:B 004 8 AMP Stecker Gaspedal AMP connector throttle
X12:C 004 7 AMP Stecker Gaspedal AMP connector throttle
X13:1 008 17 Stecker Stufenschalte connector speed range switch
X13:2 008 18 Stecker Stufenschalte connector speed range switch
X13:3 008 14 Stecker Stufenschalte connector speed range switch
X14:4 013 15 Stecker Motor connector engine
8

X14:5 013 16 Stecker Motor connector engine

X14:6 002 6 Motorschnittstelle engine interface
X14:7 002 6 Motorschnittstelle engine interface
X14:8 005 7 Motorschnittstelle engine interface
X14:9 003 9 Motorschnittstelle engine interface
11

X14:10 006 12 Stecker Motor connector engine

X14:11 006 12 Stecker Motor connector engine
X15:A 010 18 Stecker Lehne links connector arm rest lh.
X15:B 010 18 Stecker Lehne links connector arm rest lh.
570 700 35

X15:C 010 19 Stecker Lehne links connector arm rest lh.

X17:1 013 16 Stecker Klimakupplung connector clima clutch
X17:2 013 16 Stecker Klimakupplung connector clima clutch
X18:1 013 16 Stecker Druckschalter connector pressure switch
X18:2 013 16 Stecker Druckschalter connector pressure switch
108

X19:1 013 13 Stecker Heizventil connector heating valve

X19:2 013 13 Stecker Heizventil connector heating valve
836 X21:1 011 19 Schnittstelle Sitz BOMAG
connector drivers seat 008 911 57
 Name Bl. Pf. Benennung title TYP
X21:2

X22:2
011
Wiring diagram 570 700 35
X22:1 013
013
19
10
11
Schnittstelle Sitz
Stecker Luftklappe
Stecker Luftklappe
connector drivers seat
connector air flap
connector air flap
20.2
X23:1 013 14 Stecker Sensor connector sensor
X23:2 013 14 Stecker Sensor connector sensor
X24:1 013 15 Stecker Sensor connector sensor
X24:2 013 15 Stecker Sensor connector sensor
X25:A 013 19 Stecker Lüfter connector blower
X25:B 013 18 Stecker Lüfter connector blower
X25:C 013 18 Stecker Lüfter connector blower
X26:1 013 9 Stecker Klimasteuerun connector climacontrol
X26:2 013 9 Stecker Klimasteuerun connector climacontrol
X26:3 013 11 Stecker Klimasteuerun connector climacontrol
X26:4 013 10 Stecker Klimasteuerun connector climacontrol
Seis
19.04.2006
Werner
19.04.2006

X26:5 013 16 Stecker Klimasteuerun connector climacontrol

X26:6 013 12 Stecker Klimasteuerun connector climacontrol
X26:7 013 12 Stecker Klimasteuerun connector climacontrol
X26:8 013 15 Stecker Klimasteuerun connector climacontrol
X26:9 013 13 Stecker Klimasteuerun connector climacontrol
X26:10 013 10 Stecker Klimasteuerun connector climacontrol
X26:11 013 11 Stecker Klimasteuerun connector climacontrol
X26:12 013 13 Stecker Klimasteuerun connector climacontrol
X26:13 013 13 Stecker Klimasteuerun connector climacontrol
X26:14 013 13 Stecker Klimasteuerun connector climacontrol
X27:1 013 14 Stecker Klimasteuerun connector climacontrol
X27:2 013 14 Stecker Klimasteuerun connector climacontrol
X27:3 013 15 Stecker Klimasteuerun connector climacontrol
X27:4 013 15 Stecker Klimasteuerun connector climacontrol
X28:1 011 6 Stecker Radsensor connector wheel sensor
X28:2 011 6 Stecker Radsensor connector wheel sensor
X28:3 011 7 Stecker Radsensor connector wheel sensor
X28:4 011 7 Stecker Radsensor connector wheel sensor
X29:1 013 6 Stecker Zyklon Connector cyclone
X29:2 013 6 Stecker Zyklon Connector cyclone
X30:A 011 6 Verbindungsstecker Se connector sensor
X30:B 011 6 Verbindungsstecker Se connector sensor
X30:C 011 7 Verbindungsstecker Se connector sensor
X31:A 011 11 Verbindungsstecker An connector gauge
X31:B 011 9 Verbindungsstecker An connector gauge
X31:C 011 10 Verbindungsstecker An connector gauge
X33:1 011 4 Schmieranlage lubrication system
X33:2 011 4 Schmieranlage lubrication system
X34:1 011 4 Schmieranlage lubrication system
component listing

X34:2 011 4 Schmieranlage lubrication system

X34:3 011 3 Schmieranlage lubrication system
Bauteilliste

X34:4 011 3 Schmieranlage lubrication system

X34:5 011 4 Schmieranlage lubrication system
X35:1 009 13 Stecker Warnsummer connector warning buzzer
X35:2 009 13 Stecker Warnsummer connector warning buzzer
X36:1 008 7 Stecker Poti connector potentiometer
X36:2 008 6 Stecker Poti connector potentiometer
X36:3 008 7 Stecker Poti connector potentiometer
X39:A 008 7 Stecker Deceleratorpe connector decelerator pedal
X39:B 008 6 Stecker Deceleratorpe connector decelerator pedal
X39:C 008 6 Stecker Deceleratorpe connector decelerator pedal
X40:1 008 8 Stecker Deceleratorpe connector decelerator pedal
X40:2 008 8 Stecker Deceleratorpe connector decelerator pedal
X40:3 008 9 Stecker Deceleratorpe connector decelerator pedal
X40:4 008 7 Stecker Deceleratorpe connector decelerator pedal
X40:5 008 8 Stecker Decelelratorp connector decelerator pedal
X40:6 008 7 Stecker Deceleratorpe connector decelerator pedal
X41:1 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:2 008 8 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:3 008 6 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:4 008 6 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:5 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:6 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:8 008 8 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:9 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:10 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:11 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:12 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X42:1 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:2 008 2 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:4 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:5 008 2 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:6 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X17.1:1 004 2 2ïpol SPT 2ïpole SPT
X17.1:2 004 2 2ïpol SPT 2ïpole SPT
X27.1:4 004 18 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:6 004 19 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:7 004 19 Motor / 42ïpol EPC engine / 42ïpole EPC
9

X27.1:11 004 14 Motor / 42ïpol EPC engine / 42ïpole EPC

X27.1:12 004 6 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:13 004 8 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:14 004 8 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:15 004 9 Motor / 42ïpol EPC engine / 42ïpole EPC
11

X27.1:18 004 7 Motor / 42ïpol EPC engine / 42ïpole EPC

X27.1:19 004 5 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:20 004 4 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:21 004 10 Motor / 42ïpol EPC engine / 42ïpole EPC
570 700 35

X27.1:22 004 11 Motor / 42ïpol EPC engine / 42ïpole EPC

X27.1:23 004 10 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:24 004 7 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:25 004 4 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:26 004 5 Motor / 42ïpol EPC engine / 42ïpole EPC
109

X27.1:27 004 5 Motor / 42ïpol EPC engine / 42ïpole EPC

X27.1:28 004 11 Motor / 42ïpol EPC engine / 42ïpole EPC
008 911 57
X27.1:29 004 11 Motor / 42ïpol EPC BOMAG
engine / 42ïpole EPC 837
 Name Bl. Pf. Benennung title TYP

20.2 X27.1:30
X27.1:33
X27.1:34
004
004
004
7
6
12
Motor / 42ïpol EPC
Motor / 42ïpol EPC
Motor / 42ïpol EPC
engine / 42ïpole EPC
engine / 42ïpole EPC
engine / 42ïpole EPC
Wiring diagram 570 700 35
X27.1:35 004 12 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:36 004 14 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:37 004 13 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:39 004 17 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:40 004 16 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:41 004 16 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:42 004 15 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.2:10 004 3 12ïpol EPC 12ïpole EPC
X27.2:11 004 3 12ïpol EPC 12ïpole EPC
XD2.1:2 004 4 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:3 004 4 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
Seis
19.04.2006
Werner
19.04.2006

XD2.1:5 004 18 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH

XD2.1:6 004 18 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:8 004 4 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:9 004 5 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:10 004 17 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:11 004 17 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:13 004 11 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:20 004 14 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:22 004 10 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:30 004 10 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:33 004 7 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:34 004 16 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:35 004 16 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:38 004 11 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:39 004 13 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:40 004 15 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:52 004 16 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:53 004 15 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:54 004 12 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:59 004 8 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:60 004 7 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:61 004 8 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:77 004 6 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:78 004 7 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:79 004 6 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:89 004 17 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.2:3 004 4 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:4 004 19 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:5 004 19 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
component listing

XD2.2:7 004 5 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH

XD2.2:8 004 4 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
Bauteilliste

XD2.2:9 004 8 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH

XD2.2:10 004 8 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:15 004 7 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:18 004 6 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:19 004 9 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:23 004 10 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:24 004 5 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:25 004 11 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:26 004 7 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:27 004 5 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:28 004 4 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:32 004 6 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:33 004 11 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:34 004 10 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:35 004 7 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:36 004 11 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.3:3 004 15 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:4 004 12 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:6 004 13 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:7 004 14 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:8 004 18 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:12 004 14 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:13 004 12 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:14 004 16 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:15 004 16 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:16 004 17 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH

Y02 004 19 Magnetventil Flammgluehanlage Solenoid valve, glow plug system 18W
Y03 008 14 Magnetventil Fahrstufenumschaltung Solenoid valve, speed range selector
Y04 008 10 Magnetventil Bremse Solenoid valve, brake 1,25A
Y14 012 3 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 013 16 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 1,75A
Y16 007 10 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 1,08A
Y16 007 12 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 1,08A
Y17 007 6 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 1,08A
Y17 007 8 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 1,08A
Y92 010 6 Magnetventil Lenkung vorne rechts Solenoid valve, steering, front rh. max. 1,1A
10

Y93 010 7 Magnetventil Lenkung vorne links Solenoid valve, steering, front lh. max. 1,1A
Y102 010 11 Magnetventil Schwimmstellung So.valve, floating position max. 1,08A
Y102 010 12 Magnetventil Schwimmstellung So.valve, floating position max. 1,08A
Y108 010 8 Magnetventil Schaufel Heben solenoid valve, lifting shovel max. 1,1A
Y109 010 9 Magnetventil Schaufel Senken solenoid valve, let down shovel max. 1,1A
11

Y110 010 19 Magnetventil Schaufel oeffnen solenoid valve, open shovel max. 1,1A
Y111 010 18 Magnetventil Schaufel Schließen solenoid valve, close shovel max. 1,1A
Y132 007 14 Magnetventil Radmotor vorn links Solenoid valve, wheel motor front lh. max. 0,6A
Y133 007 16 Magnetventil Radmotor vorn rechts Solenoid valve, wheel motor front rh. max. 0,6A
570 700 35

Y134 007 17 Magnetventil Radmotor hinten links Solenoid valve, wheel motor rear lh. max. 0,6A
Y135 007 19 Magnetventil Radmotor hinten rechts Solenoid valve, wheel motor rear rh. max. 0,6A
Y138 013 13 Magnetveentil Heizung Solenoid valve, heating unit 0,42A
Y147 004 12 Injektor A1 jet pump A1
Y148 004 14 Injektor A2 jet pump A2
110

Y149 004 13 Injektor A3 jet pump A3

Y150 004 17 Injektor B1 jet pump B1
838 Y151 004 16 Injektor B2 BOMAG
jet pump B2 008 911 57
 Name Bl. Pf. Benennung title TYP

Seis
19.04.2006
Y152

Y167
004 16 Injektor B3
Wiring diagram 570 700 35
Y166 004 14 Injektor A4
004 18 Injektor B4
jet pump B3
jet pump A4
jet pump B4
20.2
Werner
19.04.2006
component listing
Bauteilliste
11
11
570 700 35
111

008 911 57 BOMAG 839

 008 911 57 BOMAG 840
404

402
408

394
400
403
405
406
407
409
414

392
398

393
395
396
397
399
412

401
410
413
415

391
411

K77 K77
H07

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
057 513 10

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
057 664 11 057 664 11
057 564 17

057 564 37
057 564 22 057 564 30
057 564 23
1x6qmm
1x6qmm

Seis

153 131 1x6qmm

Versorgung Kabine 1
Werner

154 132
155 133 1x6qmm Versorgung Kabine 1x6qmm
2
03.04.2006
03.04.2006

156 134
K11

157 135 1x6qmm Masse Kabine 3

158 136
057 543 08

1x6qmm Masse Kabine 4

159 137
160 138 Masse Schutzbelüftung 5
161 139
057 564 29

162 140 6
163 141
164 142 7
165 143
1x2,5qmm
1x4qmm

1x6qmm
1x6qmm

166 144 8
057 564 35

167 145 9
K05

168 146
15A
169 147 Klimatronik Konvekta 1x1,5qmm F50 20
170 148 Zigarettenanzünder + 30A
171 149 1x1,5qmm F89 21
Tachograph / BC 672 EB
057 564 19
K22

172 150 Schutzbelüftung 22

173 151
30A
174 152 Zündschloß 1x6qmm 1x6qmm
F13 23
187 181 25A
188 182 EDC7 Steuerung (30) 2x2,5qmm F93 24
189 183 30A
Steckdose 1x2,5qmm F05 25
190 184
10A
191 185 Prozessor Steuerung 1x2,5qmm 1x2,5qmm
F84 26
192 186
K113 K13

30A
206 201 Leistung Steuerung 5x0,75qmm F67 27 1x4qmm
207 202
Schutzbelüftung
208 203 28
209 204 15A
Instrumente 1x1,5qmm
K90

F24 29
210 205
Schmieranlage + 10A
226 221 1x1,5qmm F16 30
Tachograph / BC 672 EB
227 222 15A
Fahrersitz 1x1,5qmm F29 31 1x2,5qmm
228 223
K48

10A
229 224 EDC7 Steuerung (15) 1x1,5qmm F122 32
230 225
K11

10A
235 231 Zykon Abscheider 1x1,5qmm F31 33 1x2,5qmm
236 232 15A
K61

Signalhörner 1x1,5qmm F23 34

237 233
238 234 10A
Fahren und Bremse 1x1,5qmm F25 35
257 241 10A
258 242 Klimatronik Konvekta 1x1,5qmm F33
057 268 42

36
K62

259 243
260 244 37
261 245 45 41
262 246 45 41
K133

263 247 46 42
264 248 46 42

eïbox
265 249 47 43
057 564 25

266 250 47 43
057 564 36

Schaltkasten
057 564 21

267 251 48 44
057 543 12

1 2 1 2 1 2 1 2
1 2 1 2 1 2 1 2

268 252 48 44
057 564 38

269 253 61
270 254
K15

62
271 255
057 500 57

63
057 664 96

272 256 64
K146

300 291 65
301 292 66
302 292
293 67
K60

303 294 68
304 295 69
305 296 70
306 297 71
307 298 72

057 565 39
308 299 84 81
343 321 85 82

057 565 36
057 668 71

344 322 86 83
057 564 24

345 323 92 87
346 324 93 88
347 325 94 89
348 326 95 90
349 327 96 91
057 564 26

350 328 104 101

057 565 40
351 329 105 102

057 565 38
352 330 106 103
353 331 115 107
354 332 116 108
355 333 117 109
356 334 118 110
X2:AïV

357 335 119 111

358 336 119 111
057 555 96

359 337 120 112

360 338 121 113
361 339 122 114

057 565 37
362 340 125 123
363 341 126 124

057 565 35
364 342
129 127
data interface

375 371 130 128

Datenschnittstelle

376 372
377 373 6 1
378 374 7 2
057 556 04 (Kappe/cap)

057 665 63
383 381 8 3

057 665 61
384 382 9 4

X6:1..10
057 555 98

10 5

1
X6
2 R42 1 2 R10 1
47_O 220_O
2 R40 1 2 R27 1
47_O 10_O

1
057 564 43

057 199 46
diagnosis EMR
Diagnose EMR
X4:
2 R38 1 2 R26 1
47_O 22_O
2 R36 1 2 2 2 2 2 2 2 2
LU Motor
47_O
P18
8 7 6 5 4 3 2 1

057 664 03
1 1
1 1 1 1 1 1

LU Motor

570 700 35
057 664 08

V48
V47
V46
V45
V44
V43
V42
V41

201
057 665 62
Wiring diagram 570 700 35 20.2
008 911 57
Wiring diagram 570 700 35

X28
X4
X2
X17

X1
X30
X15
X3
X11
X35
X7 X21
X18
X13 X39
X23 X9
X26 X12 X40
X0
X19 X27 X10
X16 X31 X42 X36

BOMAG
X22 X41
X29 X24 X8
X14 X18
X17 X27.1 X25

X27.2
D2.1

X33
D2.2 D2.3
X34

03.04.2006
1 1 570 700 35
Werner Lokalisierungsgrafik Steckverbinder Draufsicht
03.04.2006
20.2

841
Seis localization graphic connectors top view 301
842
20.2

X18

X7

X29

X8

X23
X31 X11 X15 X13
X16 X41
X21
X4 X42
X36
X2 X19 X15 X26 X9
X0
X27

X24
X18 X22
X1

X30 X25 X12 X39

X35
X3 X10 X40

D2.2 X34
X17 X27.1
D2.1 X27.2

BOMAG
D2.3 X33

X14

X28

03.04.2006
1 1

008 911 57
Wiring diagram 570 700 35

Werner Lokalisierungsgrafik Steckverbinder Seitenansicht 570 700 35

03.04.2006
Seis localization graphic connectors side view 302
 20.3 Wiring diagram 570 700 37

008 911 57 BOMAG 843

20.3 Wiring diagram 570 700 37

S/N Wiring diagram 570 700 37

S/N 101 570 571 007 ⇔ 101 570 571 011 BC772 RS-2
S/N 101 570 581 021 ⇔ 101 570 581 034 BC772 RB-2
S/N 101 570 591 007 ⇔ 101 570 591 008 BC672 RB-2
S/N 101 570 821 005 ⇔ 101 570 821 007 BC972 RB-2
S/N 101 570 831 015 ⇔ 101 570 831 021 BC1172 RB-2

844 BOMAG 008 911 57

Inhaltsverzeichnis: BC 772...1172 RB / TIER III

008 911 57
table of contents:
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing ï no.
001 vorläufig Stromlaufplan Circuit Diagram
002 vorläufig Versorgung, Zigarettenanzünder supply, cigarette lighter
003 vorläufig Zündschloß, Starter ignition switch, starter
004 vorläufig DEUTZ Steuergerät EDC 7 f. 6ï und 8ïZylindermot. DEUTZ controller EDC 7 for 6ï and 8ïzylinder engine
005 vorläufig Instrumente indicators
Wiring diagram 570 700 37

006 vorläufig Anzeigen, Störmeldungen monitoring, failure indication

007 vorläufig Fahrpumpen, Radmotoren, Startfreigabe driving pumps, weehl motors, starting release
008 vorläufig Fahrstufen, Bremse, Verzögerungspedal speed ranges, brakes, decelerator device
009 vorläufig Versorgung Steuerung, Warnsummer, Override supply controllers, warning buzzers, override
010 vorläufig Lenkung und Arbeitshydraulik steering and working hydraulic system
011 vorläufig Hupe, Schmieranlage, Tachograph, Sitzfunktionen horn, lubrication systhem, tachograph, seat funktions
012 vorläufig Heizung und Belüftung heating and ventilation
013 vorläufig Schutzbelüftung, Zyklon Abscheider, Klimatronik protected vent. system, cyclone separator, air cond.
014 vorläufig Kabine und Anbauteile cabin and attachmentïparts
101 vorläufig Bauteilliste component listing
201 vorläufig Schaltkasten eïbox

BOMAG
301 vorläufig Lokalisierungsgrafik Steckverbinder Draufsicht localization graphic connectors top view

28.08.2006
001 001
Werner Stromlaufplan 570 700 37
28.08.2006
20.3

845
circuit diagram 001
Seis
846
Zuleitung Steuerung Pin 54 30/54S 9:2
Zuleitung Steuerung Pin 56ï60 30/56ï60S
9:2

2,5qmm
Kabine K30
14:2
20.3

4qmm
geschaltetes "15/54"

2x6qmm
Batteriespannung 30 3:1

6qmm
15/54 X1:6
Zündschloß "15/54" 3:1

6qmm
6qmm
X1:23E X1:391/1 X1:21E X1:25E
Einspeisepunkt für Versorgung
Sicherungespotential 30! 30 30
1 K61 6E 5E
F89 F05 K11
V01 2:8 30A 30A
2 6A 5A 3:14
87
87 87a
X1:391/2 X1:21A
X1:25A
1,5qmm
2x4qmm

Einspeisepunkte für Versorgung

2,5qmm
4qmm
2x6qmm
6qmm
6qmm
Sicherungespotential K11:87!
X1:241 X1:242
X1:31E
X1:33E

0,11A
0,075A
X1:241
11:7
1 86 K61:87a 5:9 F24 K11:87 5:1
5:1
R10
1 220_O
K61 X1:298
F00 250A

057 665 63
2 2,5qmm X1:32E
2 85 X1:243
1x25qmm F122
10A
Anlassehauptleitung: 2x70qmm B+ 3:1 D+ 6:2
Ladeleitung 2x 10qmm oder 1x25qmm X1:32A
X1:81 1
X1:259

BOMAG
+ E21
X1:202
9:13
8:10

G01 2
11 21 31 41 51 61
ï S01
Batterie X14:6

0,075A
5A
Bei Steckdosenbetrieb je nach Stecker bis 16A möglich!
battery
max. 10A

12 22 32 42 52 62
B+ D+
+ 86 E20 1 2 X1:260 NotïAus Schalter
28V/80A + emergancy shut off
G03 G02 K62 XS
ï 24V 30
ï
85 K22 9:6
Bï W
87a 87
X2:N X2:J EMR
S30 3 X14:7 4:15
W XSï
Trennschalter 5:11 4:18
switch battery disconnect
4
X1:70 X1:256
31 31 3:1

2:10 13:10
Zigarettenanzünder Steckdose
cigarette lighter socket

28.08.2006
1 1

008 911 57
Wiring diagram 570 700 37

Werner Versorgung, Zigarettenanzünder 570 700 37

28.08.2006
Seis supply, cigarette lighter 002
 2:15 30 30 4:1
2:11 15/54
6qmm
2:6 B+ B+ 4:1 X1:23E
Anlasserhauptleitung 2x70qmm F13
30A

008 911 57
X1:23A

6qmm

Zündstartschalter
012 30 ignition switch
S00
01

50a 15/54

4qmm
1,5qmm

X1:293
Wiring diagram 570 700 37

X1:302

X1:8 X1:9

30
K05
7:2
87 87a

X1:7

BOMAG
2,5qmm
X14:9 X1:371
0,2A

0,2A

86 86
30 50 2 K11 K32
M01
M V47
85 85
ï 1

X1:256 X1:70

2:20 31 31 4:1

2:17 14:6

Starter
starter
Anzugswicklung KHD = 73A
Haltewicklung KHD = 12A

28.08.2006
1 1 570 700 37
Werner Zündschloß, Starter
28.08.2006
20.3

847
Seis ignition switch, starter 003
848
30 30
3:20 13:1
B+ Pedal
3:5 X1:24E 6:7
XSï
B124 2:19
20.3

1 + 1 elektronisches Fußpdal Diagnosestecker

F48 F93 elektronic foot pedal diagnosis
86 86 86 X22
80A 25A K15 K146 K60
2 F78
ï 2 S119 H04 1 H70 1
13
X1:24A S118

X4:A
X4:H
X4:G
X4:M
X4:F
X4:K
X4:B
2 2 Fehlertaster Motor
85 85 85
4qmm B46

4qmm
4qmm
14 failure push button engine

Williams Codierung
sw rt ws or gn bl

X1:92
X1:93
X1:94
1
R24

X1:62
X1:64
X1:65
X1:71
2 X1:255

X10:B
X10:C
X10:A
X12:A
X12:C
X12:B
X6:1 X1:250
X6:2 X1:244
X6:3 X1:270
X6:4 X1:269
10 kOhm
2 3 1 EMR
RPM 2:19
9:2
Option
option

X6:5
X6:6
X6:7
X6:8
X6:9
X6:10

X1:231
X1:232
X1:233
5V EDC 8:2
Handgas
8:2
4x2,5qmm Dachkurve AGND EDC "31" 4x2,5qmm
8:2

Sensor Wasserabscheider
sender water separator
"30"
Fehler EMR
Vers. Meldeleuchte
Glühen
Temperatur
Motoröldruck
"15"
CAN 1H
CAN 1L
CAN 2H
CAN 2L
ISO KïLinie

S2 S1

Fehler Motor
failure engine
Wasserabsch.
water separator

X1:235
X1:236
X1:237

XD2.1:3
XD2.1:9
XD2.1:6
XD2.1:5

XD2.1:2
XD2.1:8
XD2.1:11

XD2.1:61
XD2.1:13
XD2.1:10

XD2.1:79
XD2.1:77
XD2.1:33
XD2.1:60
XD2.1:59
XD2.1:30
XD2.1:39
XD2.1:53
XD2.1:35

XD2.1:62
XD2.1:29
XD2.1:78
XD2.1:38
XD2.1:20
XD2.1:52
XD2.1:89

XD2.1:22
XD2.1:54
XD2.1:40
XD2.1:34

X27.2:11
X27.2:10
A48 EDC7 Steuerung
4qmm

X17.1:1
X17.1:2
X1:5

XD2.2:28
XD2.2:8
XD2.2:3
XD2.2:7
XD2.2:24
XD2.2:27
XD2.2:32
XD2.2:18
XD2.2:35
XD2.2:26
XD2.2:15
XD2.2:9
XD2.2:10
XD2.2:19
XD2.2:23
XD2.2:34
XD2.2:33
XD2.2:36
XD2.2:25
XD2.3:4
XD2.3:13
XD2.3:6
XD2.3:12
XD2.3:7
XD2.3:3
XD2.3:15
XD2.3:14
XD2.3:16
XD2.3:8
XD2.2:4
XD2.2:5
X1:299

BOMAG
50i
K14 K2
4:4

X27.1:25
X27.1:20
X27.1:19
X27.1:27
X27.1:26
X27.1:33
X27.1:12
X27.1:18
X27.1:24
X27.1:30
X27.1:14
X27.1:13
X27.1:15
X27.1:21
X27.1:23
X27.1:22
X27.1:29
X27.1:28
X27.1:34
X27.1:35
X27.1:37
X27.1:36
X27.1:11
X27.1:42
X27.1:40
X27.1:41
X27.1:39
X27.1:4
X27.1:6
X27.1:7

30

ï ï ï ï Y02 2
4qmm 4qmm Y149 Y166 Y151 Y167
3 2 1 2 1 2 1 1 2 3 1 2 3 4 3 2 1 + + + + Y2 1
1 1 85 Y147 ï ï Y152 ï ï
R02 R02 K2 K14 Y148 Y150
R3.1 R3.2
2 2 50 + + + +
B88 B126 B113 B114 B130 B133
B6 B37 B43 B40.1 B40.2 B48 Y15.1 Y15.3 Y15.5 Y15.7 Y15.2 Y15.4 Y15.6 Y15.8

3:20 31 31 5:1

4:2 6:2 6:2 6:3 Injektor B3

jet pump B3
Glühkerze 1 Kraftstofftemperatur Motordrehzahlsensor1 Mag.vent. Flammglühanlage
glow plug 1 fuel temperature sender engine rpm 1 Injektor B2 solenoid valve glow plug system
jet pump B2
Glühkerze 2 EMR Motoröldruck Motordrehzahlsensor 2 Injektor A1 Injektor A3 Injektor A4 Injektor B1
glow plug 2 EMR engine oil pressure sender engine rpm 2
jet pump A1 jet pump A3 jet pump A4 jet pump B1
Kühlmitteltempratur Sensor Ladeluftdruck / Temperatur Injektor A2 Injektor B4
coolant temperature sensor charging air pressure / temperature jet pump A2 jet pump B4

28.08.2006
1 1

008 911 57
Wiring diagram 570 700 37

Werner DEUTZ Steuergerät EDC 7 f. 6ï und 8ïZylindermot. 570 700 37

28.08.2006
Seis 066_7 DEUTZ controller EDC 7 for 6ï and 8ïzylinder engine 004
 2:20 K11:87 K11:87 9:1

X1:29E

F24
15A

008 911 57
X1:29A
2:13 F24 F24 6:1
2:11 K61:87a K61:87a 6:7
X1:294 X1:295 X1:298

5 1 4 3 5 1
Wiring diagram 570 700 37

P00 +
E02 P14 + E22 P02 + E03 P03 + E01 P01 + E46 P12 +
1 1 1 1 1

_t _t n Q
2 2 2 2 2
ï G ï G ï G ï ï G ï

Modul 1
module 1
Modul 2
module 2
Modul 3
module 3
3 2 4 1 5 3 4

BOMAG
X1:300 X1:303 X1:301 X1:296
X1:291 X1:148 X1:292 X1:228

X14:8

X5:1

1 2
B53 1 1
R04 R03

2 2
X1:299 W X1:229
2:8
31 31
4:20 6:1

Kühlmitteltemperatur Motordrehzahl Tankanzeige

collant temperature trancducer, motor speed level gauge

Hydrauliköltemperatur Betriebsstundenzähler Voltmeter

hydraulic oil temperature engine hour meter volt meter

28.08.2006
1 1 570 700 37
Werner Instrumente
28.08.2006
20.3

849
Seis indicators 005
 850
F24 F24
5:20 9:1
D+ ESX 9:15 Abschmieren
2:9 11:2
Lüfter 1.GANG
12:14 30 30 9:7
20.3

K133 K48 2.GANG 9:7

9:9 7:3
87 87a 87 87a
X1:101 X1:104
X1:89 X1:84 X1:90 X1:91 X1:123

X1:125
X1:126

X1:124

rt
rt
ws/vi
br/rt
br
br/sw
sw
vi

vi
ws/bl
br/or
br
ws/vi
or X1:102 X1:105 or
1 2 0/3a 4 8 A15 A15 16 11 17 18 9

6 3 7 5 20 19 14 15 12 13 10

bl
bl
gr

sw
br/or

ws/rt

ws/gr
ws/br
ws/br
ws/gr

ws/gn
ws/gn

X1:106

X1:115
X1:119

X1:118
X1:121

X1:120
X1:122

X1:87 X1:88 X1:85 X1:86

X1:392/2 V02 2 1 X1:392/1 X1:397/1 1 2 V07 X1:397/2
X0:18 X0:45
Fehler
X1:394/2 V04 2 1 X1:394/1 X1:398/1 1 2 V08 X1:398/2
X1:109 X1:117

X0:52 X0:50 X1:108 X1:116

Fehler
X1:393/2 V03 2 1 X1:393/1 X1:399/1 1 2 V09 X1:399/2

20s
Fehler
X0:19 X0:13
X1:111

X1:395/2 V05 2 1 X1:395/1 X1:400/1 1 2 V10 X1:400/2

Steuerung
Gaspedal
X0:11 X0:10
Pedal X1:401/1 1 2 V11 X1:401/2
X1:112

X1:82 X1:83 4:19 X0:6 Fehler

D+
X1:403/1 1 2 V13 X1:403/2
X1:113

X1:114

X0:36 X0:51

ESX
X14:10 X1:210

BOMAG
5:20 K61:87a K61:87a 14:11
15

20s
20s
2min
K113

31

Kühlmitteltemperatur
collant temperature
Motoröldruck
engine oil pressure
Kühlmittelfüllstand
coolant tank
Luftfilter rechts
air cleaner rh.
Luftfilter links
air cleaner lh.
120s anzugsverzögert
120s switch on delay
K15 30 K60 30
4:12 4:14
X1:110
87a 87 87a 87 Verteilergetriebe
power takeïoff gear
Hydrauliköl min.
hydraulic oil min.
Hydrauliköltemp.
hydraulic oil temp.
Diff.ïdrucksch.
pressure. diff.
Diff.ïdrucksch.
pressure. diff.
Diff.ïdrucksch.
pressure. diff.
Diff.ïdrucksch.
pressure diff.
Diff.ïdrucksch.
pressure diff.
Bremsdruck
brake pressure
Verschmutzungssensor
contamination sensor

X1:103
30 30
3 3 3 3 1 1 3 K113 2 2 2 2 2 1 +
K146 B55 B03 B116 B129 B24 B20 B121 B122 B22 B21 B42 B05
4:13 6:11 B19
Q P P B25 P P Q P
87a 87 4 4 4 4 2 2 4 87 87a 1 1 1 1 1 2 ï

X14:11

X1:181
X1:182
X1:182
X1:191
X1:191

X1:181

X1:183
X1:187
X1:185
X1:186
X1:183

31
X1:184
X1:184

X1:205

5:20 31 7:1
Speisepumpe Speisepumpe Zwischengetr.
6:14
Speisepumpe Speisepumpe

Rücklauffilter nur BC 972 RB

return flow filter only acc. to BC 972 RB

Modul 1: Motorfunktionen Modul 2: Maschinenfunktionen

module 1: engine functions module 2: maschine functions

28.08.2006
1 1

008 911 57
Wiring diagram 570 700 37

Werner Anzeigen, Störmeldungen 570 700 37

28.08.2006
Seis monitoring, failure indication 006
 DEC 1 8:4
X1:338 X1:262 S04:12 8:10
X1:335 2 1
X1:46/2 X1:46/1
X9:4 X9:1 FM6

008 911 57
1
R32 X1:42/1
1k
2

1 1
R33 1 R34 R35 1 FM2
2k 1k 3k3 2
2 2 2

Fahrtrichtungsschalter nicht belegt X1:42/2

switch, travel direction V0R 33 13 24 44 not used
S31 X1:336
34 14 23 43
Wiring diagram 570 700 37

X9:5 X9:6 X9:3 X9:2

X1:339
X1:340 X1:337

Richtung
AGND
8,5V
Ain

X1:412/1 X1:413/1

X0:1
13 9

X0:32
X0:23
X0:29

1 1
V23 V25 K77 K77 ESX Steuerung
9:17 9:17
2 2 14 10

X0:22
X0:21
X0:46
X0:47
X0:48
X0:43

X1:412/2 X1:413/2

BOMAG
Vorwärts

Rückwärts
vorne Links
hinten Links

vorne rechts
hinten rechts

br nicht bei
X1:221 X1:223 X1:135 X1:157
V38 BC 672ï772
not used for
rt BC 672ï772

X1:149 X1:153 X1:131 X1:133 X1:155

200 ... 600mA
200 ... 600mA
200 ... 600mA
200 ... 600mA

86 86 H14
K05 K48 + 1 1 1 1 1 1 1 1
V34 Y17 V35 Y17 V32 Y16 V33 Y16 Y132 Y133 Y134 Y135
ï
85 85 2 2 2 2 2 2 2 2

1,08A
1,08A
1,08A
1,08A

X1:70 X1:70 X1:188

X1:222 X1:224 X1:136 X1:158
31 X1:154 X1:132 X1:134 X1:156
6:20 31 8:1
TandemïPumpe TandemïPumpe TandemïPumpe TandemïPumpe
3:9 6:14 rechts 2 rechts 4 links 1 links 3 Prop. Ventil Rad vorne li. Prop. Ventil Rad hinten re.
prop. valve weehl front lh. prop. valve weehl rear rh.
stromlos = qmax stromlos = qmax
Prop. Ventil Rad vorne re.
Ventile Fahrpumpe rückwärts Ventile Fahrpumpe vorwärts prop. valve weehl front rh.
solenoid valves, travel direction backw. solenoid valves, travel direction forw.
stromlos = qmax
Warnsummer Rückwärtsfahrt stromlos = Rückwärtsfahrt nicht aktiv stromlos = Vorwärtsfahrt nicht aktiv
buzzer, back up alarm strom = Rückwärtsfahrt aktiv strom = Vorwärtsfahrt aktiv
Prop. Ventil Rad hinten li.
prop. valve weehl rear lh.
stromlos = qmax

28.08.2006
1 1 570 700 37
Werner Fahrpumpen, Radmotoren, Startfreigabe
28.08.2006
20.3

851
Seis driving pumps, weehl motors, starting release 1 007
852
F25 9:1

X1:343 X1:261
20.3

31 X1:358
S01
2:17
Aktivierung Verzögerungspedal X1:357
32
enable decelerator pedal 7:19 S04:12 X1:41/2
X1:262 23
S02
12 123
S160 0 1 43 23 Bremsschalter 1 S02 Schalter Fahrstufen
S04 brake switch FM1 switch speed ranges
01
2 24
11 Komplett 872 701 02
44 24
X1:41/1
Verzögerungspedal

X40:6
X40:2
X13:3
5V EDC DEC 1
X13:1
X13:2

4:8 7:19 decelerator pedal R20 R21 R22 R23

1 k_O 1 k_O 1 k_O 1 k_O
Nur für BC 671ï771 RB/RS
only acc. to BC 671ï771 RB/RS

bl gr
KD1 KD2
S161

ws
sw
rt
ge
gn
vi
or
bei Option
Schalter Fahrstufen
switch speed ranges

X3:B
acc.to option
X40:3

decelerator pedal

Verbindung entfällt
connection not applied

X40:1
Fahrtverzögerungspedal
X1:359
X1:263

X42:5
X42:6
X41:11
X41:6
X41:4 X39:B
X41:3 X39:C
X41:5 X39:A
X41:1 X40:4
X41:2 X40:5
S04:11
8:11
Zusatzelektronik
A78

Bremse
high=Bremse auf
8,5V
AGND
Fahrstufen
additional electronic

X41:9

X42:1
X41:8

X42:2
X42:4
X41:10

X41:12
X0:1
X0:7

BOMAG
X0:23

X0:40
ESX Steuerung
X36:1
X0:62

X0:61
1

X3:C
R43

X3:A
499 _O
2
Handgas 5 k_O K77
4:8 8 7 S04:11

Bremse
AGND EDC X36:2 S120
4:8 9:17 8:10 X1:170
1./2. Fahrstufe

1 X1:151
R44

1,25A
1,25A

499 _O
1 2 Y04 1 Y03 1
H81 X36:3 V31 V37
2 2 2

X1:234
Nur für BC 671ï771 RB/RS
only acc. to BC 671ï771 RB/RS

31 X1:152 X1:192
7:20 31 9:1

Meldeleuchte Verzögerungsfunktion Magnetventil Bremse Stufenumschaltung

indicator light decelerator device solenoid valve brake Speed range selection
stromlos = Brmse zu
Handgas
strom = Bremse auf
hand throttle
Nur für Option Verzögerungspedal
only acc. to option decelerator device

28.08.2006
1 1

008 911 57
Wiring diagram 570 700 37

Werner Fahrstufen, Bremse, Verzögerungspedal 570 700 37

28.08.2006
Seis speed ranges, brakes, decelerator device 1 008
 K11:87 K11:87 11:1
5:20

X1:35E

F25
10A

008 911 57
X1:35A
F25 F25 10:1
8:20
2:19 30/54S 2,5qmm 6:6 ESX

2:19 30/56ï60S 4qmm

X1:26E
F24
6:20 X1:27E
RPM F84
4:8
10A

F67
30A X1:26A
30
K90
X1:27A
X1:257 9:4

2,5qmm
Elektronik
87 87a
Wiring diagram 570 700 37

21

X1:66
X2:H
X1:67
X2:G
S01

X2:U

5x0,75qmm
Leistung
2:17
22
X1:349
X1:349
X1:349

X1:258 X1:404/2 X1:405/2

X1:207
+UE/Dios
+UB/Dios
+UB/Dios

Drehzahl
CAN2ï
CAN2+
RxD
TxD
+ + + + + +

1x0,75qmm
2 2
V14 V15
1 1

X0:5
X0/1:3
X0/1:9

X0:4

X0:16
X0/1:10

X0:56
X0:57
X0:59
X0:60
X0:33
X0:53

X0:58

X0:28
X0:54
ESX Steuerung X1:404/1 X1:405/1 ESX Dios Modul

X0:2
X0:24
X0:25
X0:3
X0:44
1. Gang 2. Gang Summer
X0/1:11
X0/1:4

BOMAG
6:19 1.GANG
2.GANG
6:19
GND/Dios

X1:402/1 X1:410/1 X1:411/1 1

Relais Override
Motorabstellung
V42
Gehäuse Dios Modul

1 1 1 2
V12 V21 V22
2 2 2 KLIMA
GND für Knotenaddresse Dios

X1:402/2 X1:410/2 X1:411/2

X35:1
K90 86 K22 86 86 + K77/1 86 K77 86
H07
0,7A

K133
X1:185
X1:186

X1:184

ï
85 85 85 X35:2 85 85

0,075
0,075
0,075
0,021A
0,021A

31 X1:70 X1:70 X1:70 X1:70 X1:70 X1:70

8:20 31 10:1

9:17 2:17 6:10

10:4 8:11
10:4 7:6
Lampentest Warnsummer
warning buzzer 10:4 7:5

10:4

28.08.2006
1 1 570 700 37
Werner Versorgung Steuerung, Warnsummer, Override
28.08.2006
20.3

853
Seis supply controllers, warning buzzers, override 1 009
854
F25 X15:A
9:20
X1:349
1=Links /2=Rechts Schild/Schaufel 1=senken / 2=heben 3=schließen / 4=öffnen
1=left /2=right blade/shovel 1=let down / 2=lift 3=close / 4=open
1
20.3

BR/BN
1 1 3 Achse 3/4 mit Kontakten
S71 1 S70 4 1 3 10ï15 nur bei Schaufel
axle 3/4 with contacts B08
1 2 2 Vorrüstung Lenkrad 3 2 4
2 preassembling steering 2 4 10ï15 only acc. to shovel X15:B
JoyïStick
weehl 2
sieht Metall wenn Lehne unten

joyïstick X1:363
Initiator Armlehne

3 2 5 4 7 6 1 3 2 5 4 6 7 1 14 13 12 15 11 10 16 8 9
SW/BK
BL/BU

X2:A X2:B

X2:V

X1:346
X1:345
X1:344
X1:347
X1:348
X1:343
X1:321
X1:325
X1:326
X1:324
X1:323
X1:322
X1:330
X1:329
X1:328
X1:331
X1:332
X1:327
X1:352
X1:351
X1:350
X1:353
X1:354
X1:334
X1:333
CAN Bus LED display
CAN bus LED display X1:63

X1:44/2 X1:45/2 X1:47/2 + P18 ï X1:61

2 X1:43/2 2 2
FM4 2 FM5 FM7 X1:68
1 FM3 1 1
1 057 664 08

X1:44/1 X1:43/1 X1:45/1 X1:47/1 X1:69

X15:C
AGND F1 F2
8,5V

lenken
CAN+
CANï

links
rechts
lenken
AGND
8,5V
heben/
senken
senken
heben
auf/zu
schließen
öffnen
Schwim.
Lehne

links
rechts
X0:1
X0/1:1

X0:9

X0:8
X0/1:2

X0:15
X0:31
X0:17
X0:12

X0:14
X0:41

X0:39
X0:30
X0:35
X0:37

X0:38
X0:23
X0:27
X0:26

ESX Steuerung X0:34 ESX Dios Modul

BOMAG
X0:64
X0:49
X0:20
X0:42
X0:63
X0:65
X0:66
X0:67
X0:68
X0:55
X0/1:5
X0/1:6

9:15
ï
ï
ï
ï
ï

20 19 2 R36 1 Gehäuse
housing

heben
K77/1 47_O 390 mA

senken

lenken li

lenken re.

X1:406/2
Schwimmst.
9:15
öffnen/Dios

0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA

14 13 2 R38 1
schließen/Dios

K77/1 47_O 390 mA

X1:407/2
9:15 R40
10 9 2 1
K77/1 47_O 390 mA
X1:141 X1:143 X1:364

X1:408/2
9:15 R42 X1:137 X1:139
8 7 2 1 X1:159 X1:161 X1:163 X1:165

X1:409/2
K77/1 47_O 390 mA Y92 1 Y93 1 Y108 1 Y109 1 Y102 1 Y102 1 Y111 1 Y110 1
2 2 2 2 1,08A
1,08A

2 2
2 2 2 2 2 2

V19
V16
V17

V18
X1:189
X1:181
X1:182
X1:183
X1:187
X1:188

1 1 1 1
X1:160 X1:162 X1:164 X1:166 X1:138 X1:140 X1:142 X1:144
31
9:20 31 11:1

Lenken rechts Schild senken

steering right let down blade

X1:409/1
X1:406/1
X1:407/1

X1:408/1
Lenken links Schwimmstellung Schaufel schließen
floating position close shovel
steering left
Schwimmstellung Schaufel öffnen
Schild heben
lift blade floating position open shovel

28.08.2006
1 1

008 911 57
Wiring diagram 570 700 37

Werner Lenkung und Arbeitshydraulik 570 700 37

28.08.2006
Seis steering and working hydraulic system 010
 9:20 K11:87 K11:87 13:1
Abschmieren
6:19
X1:30E X1:34E X1:31E

F16 F23 F29

008 911 57
10A 15A 15A

X1:172
X1:30A X1:34A X1:31A

X1:171 Zusatzanzeige Geschwindigkeit

additional speedometer X1:341 X1:245

3A
X31:A
X34:4 1 2 86 30 S25 23
4 (+) K13
LA 15 K13
E04 1 E04 1 11:14
M08
P09 85 87 87a 24
M 8 (S) 2 2
Wiring diagram 570 700 37

Zentralschmieranlage
central lubrication system 3 (ï) X1:246
Z 31 X31:B X31:C X1:355

X34:3 5

X33:1
X33:2
X11:1 X21:1
7,5A

+ sw
M10 R06
X30:A M
B7 A2 ge

X1:173
X1:174
K13:87 ï
2,5A

14:19
X1:248 X28:1 Versorgung über F89
X1:356 Signalhörner Kabine
X1:241 A1 A3
br sw
2:13
23 1

BOMAG
S27 B15 3
8 S29 23
X28:3 B3 A5 S03 2 ge
Taster Schmieranlage X30:C R06
4 P09 V46
switch, lubrication system 24 X28:4
B52 bl 2 ws
4 6 1 9 1 24 br
B4 A6
X1:272 X28:2
A16

Initiator Schmierkolben
proximity switch lubrication piston
Lieferumfang GRAMMER
delivery equipment GRAMMER

X30:B 7 8 9 2 X11:2 X21:2

Im Lenkjoystick
in steering joystick

X1:190 X1:191 X1:364 X1:256

X1:342
10:20 31 31 13:1

11:16

Sensor Radmotor HL Tachograph Sitz mit Kompressor und Schalter

sensor wheelmotor rear lh. tachograph Im Lenkjoystick drivers seat with compressor and switch
in steering joystick
Tachomodul Sitzheizung
tacho controller Taster Signalhorn heating, drivers seat
Option Tachograph push buttonwarning horn
option tachograph

28.08.2006
1 1 570 700 37
Werner Hupe, Schmieranlage, Tachograph, Sitzfunktionen
28.08.2006
20.3

855
Seis horn, lubrication systhem, tachograph, seat funktions 011
856
K32:30 K32:87
14:2 14:3
F41:4
14:8
20.3

F40 G F90 F F02 F

Box 2 Box 2 Box 1
10A
7 5A
6 10A
6

X1:374
X1:265
2,5 qmm

123 13 31 42 24
1 2 3 12 11 13 14 16
Stufenschalter Frischluft
switch, fresh air
S44
5 7 11 3 1 10 14 32 41 23

Regel aus = 0,2A S28 X1:266 X1:267 X1:268

E30 Kleine Stufe = 0,3A
mittleter Stufe = 0,5A
große Stufe = 1A 1 1
Power Stufe = 1,7A R26 R27
Heizung Anlaufstrom beim Start = 4,2A
22 Ohm
10 Ohm

Heating
Schaltuhr Heizung 2 6 8 9 4 12 2 2
heater timer Lüfter
6:6
X1:373
10 9 5 6 8 7 4 15
X1:377

BOMAG
X8:1

2,5 qmm
15/54
30
87a
in

X1:375
X1:226
A53 n
1
Y14
max. 0,75A

20s; n kleiner 1300 1/min

2 20s; rpm lower 1300 1/min
X1:227 8s; n=0 1/min
8s; rpm=0 1/min S +
X1:376
M17 M
ï

X8:2
ï
15/54

K31
14:1
Kraftstoffpumpe Überwachung Lüfter Frischluft Lüfter
fuel pump heating unit monitoring blower blower fresh air

28.08.2006
1 1

008 911 57
Wiring diagram 570 700 37

Werner Heizung und Belüftung 570 700 37

28.08.2006
Seis heating and ventilation 012
 30
4:19
F24
9:6 Raumtemperatursensor
K11:87 sensor ambient temperature
11:20
X1:36E
Ausblastemperatursensor
F33 sensor outlet temperature X1:20E

008 911 57
X1:28E X1:22E X1:33E
10A
F50
F123 F94 F31 15A
X1:36A
10A
B29 B118 X1:20A
X1:28A X1:22A X1:33A
30 + ï + ï
K62

wird durch D+ aktiviert

2:10 nicht belegt
87 87a not used X1:253 X1:383 X1:381
Versorgung für Schutzbelüftungsanlage

Bel.
X1:251 X1:249

X23:1
X24:1

X23:2
X24:2

15/54
D+
Absicherung und Verkabelung nach Angabe X25:B X25:A
Hersteller der Schutzbelüftungsanlage
supply for protected ventilation system ge rt
Lüftermodul
Wiring diagram 570 700 37

X26:6
X26:7
fuse and wiring acc. to supplier PWM +

X26:13
X26:12
X26:14
blower module

X26:1
X27:1

X26:3
X27:3
X26:5

X27:2
of protected ventilation system

X26:4
A65 Klimatronik X27:4 A53

ï M+ Mï

X26:2
X26:10
X26:11
X26:9
X26:8
br gn sw
X25:C
1

31
V43 X1:247

Ventil
2 X1:129
Kupplung

1
B117 _t Thermostat Vereisungsschutz
X22:1 X22:2 thermostat antiïicing device
X1:252 2
optional
X1:130 E37 +

BOMAG
optional X1:127 2
X1:146
X7:6 X18:1 VD V36
1
4 Druckschalter ï

3A
pressure switch
B75 P
LP 3 HP
X29:1 X19:1 X1:414/2
or X7:5 X18:2
+ Y138 1 2 X1:147
X1:201
M26 M V26 X14:4 X17:1
0,42A

2 1
sw ï 2 1
X1:414/1
X19:2
X1: X29:2 V48 Y15
1 2
X1:382
1,75A

X1:70 X1:272 X1:128

X1:205 X14:5 X17:2
11:20 31 31 14:1

Zyklon Abscheider Magnetventil Heizen Magnetkupplung Verdampferlüfter

cyclone separator solenid valve heating magnetic clutch blower evaporator

Zusatzausrüstung Klimatronik KONVEKTA

Option klimatronic KONVEKTA

28.08.2006
1 1 570 700 37
Werner Schutzbelüftung, Zyklon Abscheider, Klimatronik
28.08.2006
20.3

857
Seis protected vent. system, cyclone separator, air cond. 013
 858
K30 K13:87
2:19 2x6qmm
11:16
20.3

X1:2 X1:1

2x6qmm
12:9 K32:30

30
K32
3:16
87
K32:87
12:19
H A B X1:372 X1:372
F49 F27 F28
10A
Box 2 8 F66 H F85 D F42 E F41 D F99 G F86 E F125 B F98 C Box 1 1 Box 1 2
10A 10A
Box 1 8 Box 1 4 Box 2 5 Box 2 4 Box 1 7 Box 1 5 Box 2 2 Box 2 3
15A 20A 10A 10A 15A 15A 10A 10A

F41:4
12:9 + 123 3 2 1 012 7 2
F126 S22
01
S16 2A
S53 1 1 2 S45 1 S38 1 S137 1 S26 1 ï S128 1
01
S20 5 1 8 5 S21 5 4
ws
5 3 4 5 5 5 5 Kamera 5
camera
X1:145 15 J S 86

X1:72
P32
K61:87a

1,5A
Impulsgeber

Spannungswandler
voltage transformer
X7:1 X7:2 6:9 gn A57 Interval switch
2,5A

+24 +12 E56 4 31 31b

24V E16 1 E23 1 E25 1 E29 1 1 1

BOMAG
X1:378
B11

2,9A
2,9A
2,9A
0,6A
2,9A
12V
2 2 2 2 2 sw 2

Rundumkennleuchte
rotary beacon
U01 ï E32
A12 15 53a 31b 53
2,5A

31b
53
53a

+ + B51 E17 1 P15 3 R77 R77 R77 R77 + +

ï ï E24 1 E26 1 E29 1 + E57 1 1
V 1 1 1 1

2,9A
M04 M M06 M M05 M M07 M B28

2,9A
2,9A
0,6A
2,9A
B51 31
2 2,9A 2 2 2 2
Radio 2 2 2 ï 2 Bildschirm 31 ï 31 ï 2

X1:150
1,7A
1,7A
1,7A
1,7A
7,9A
2,5A
3,3A
2,5A

radio monitor
K31
12:19 Scheinwerfer vorn X7:3 X7:4 Spiegelheizung Wischer vorn Wischer hinten Signalhorn
2x6qmm
head lights front mirror heating wiper, front wiper, rear warning horn

X1:3 X1:4 Scheinwerfer links/rechts Innenleuchten 1 1 Wascherpumpe Wascherpumpe

head lights lh./rh. inside light, cabin E28 E27 washer pump washer pump
2,9A 2,9A

X1:189
X1:189
2 2

31 X1:190 X1:190 31
13:20

Scheinwerfer Motorraum
head lights, engine area

Arbeitsscheinwerfer hinten
working head lights, rear

28.08.2006
1 1

008 911 57
Wiring diagram 570 700 37

Werner Kabine und Anbauteile 570 700 37

28.08.2006
Seis cabin and attachmentïparts 014
 Name Bl. Pf. Benennung title TYP
A12

A15
014
Wiring diagram 570 700 37
A15 006
006
2
7
13
Radio
Ueberwachungsmodul
Ueberwachungsmodul
Radio
monitoring module
monitoring module
20.3
A16 011 9 Elektronik Tachograph Electronic system, tachograph
A48 004 9 Elektronische Motorsteuerung Electronic engine management
A53 012 14 Modul Luefterueberwachung Modul blower monitoring
A53 013 18 Modul Luefterueberwachung Modul blower monitoring
A57 014 14 Intervallschalter Scheibenwischer Interval switch, wiper
A65 013 14 Steuerung Klimatronik Controller klimatronic
A78 008 3 Zusatzelektronik Additional control unit

B03 006 4 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B05 006 18 Druckschalter Bremse Pressure switch, brake
B08 010 19 Naeherungsinitiator Fahrhebel ’0’ïStell. Proximity switch, travel lever ’0’ pos. max. 1,08A
Seis
28.08.2006
Werner
28.08.2006

B11 014 19 Signalhorn Warning horn 2,5A

B15 011 6 Aufnehmer Geschwindigkeit Transducer, speed
B19 006 19 Magnetsensor Verschmutzung Magnetic sensor, contamination
B20 006 13 Temperaturschalter Hydraulikoel Temperature switch, hydraulic oil
B21 006 17 Differenzdruckschalter Hydr.ïOelfilter Pressure diff. switch, hydr. oil filter
B22 006 16 Differenzdruckschalter Hydr.ïOelfilter Pressure diff. switch, hydr. oil filter
B24 006 12 Schwimmerschalter Hydraulikoel Float switch, hydraulic oil
B25 006 11 Druckschalter Ruecklauffilter Pressure switch, return flow filter
B28 014 20 Signalhorn Warning horn 2,5A
B29 013 14 Raumthermostat Room thermostat
B42 006 17 Differenzdruckschalter Hydraulikoel Hydraulic oil pressure differential switch
B51 014 2 Lautsprecher Radio Speaker radio
B51 014 3 Lautsprecher Radio Speaker radio
B52 011 4 Naeherungsinitiator Schmierkolben Proximity switch, lubrication piston
B53 005 6 Temperaturgeber Kuehlmittel Temperature switch, collant
B55 006 3 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B75 013 16 Kuehlmitteldruck coolant pressure
B88 004 5 Druckgeber Motoroel Sender, engine oil pressure
B113 004 7 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B114 004 8 EMR Aufnehmer, Motordrehzahl 1 EMR Trancducer, engine speed 1
B116 006 4 Unterdruckschalter Luftfilter Vacuum switch, air cleaner
B117 013 15 Thermostat Klimaanlage Thermostar, air conditioning
B118 013 15 Temperaturfühler Auslaß Temperature sender outlet
B121 006 15 Differenzdruckschalter Hydr.ïOelfilter Pressure diff. switch, hydr. oil filter
B122 006 15 Differenzdruckschalter Hydr.ïOelfilter Pressure diff. switch, hydr. oil filter
B124 004 3 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B126 004 6 EMR Temperaturgeber Kraftstoff EMR fuel temperature sender
B129 006 12 Druckschalter Verteilergetriebe pressure switch power takeïoff gear
B130 004 9 EMR Aufnehmer, Motordrehzahl 2 EMR Trancducer, engine speed 2
component listing

B133 004 11 Sensor Ladeluftdruck / ïtemperatur sesnor charging air prssure / temperature
Bauteilliste

E01 005 14 Beleuchtung Tankanzeige Illumination, level gauge

E02 005 5 Beleuchtung Temperaturanzeige Illumination, temperature gauge
E03 005 10 Beleuchtung Drehzahlmesser Illumination, rpm meter
E04 011 10 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer
E04 011 11 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer
E16 014 4 Scheinwerfer links Head light, lh. 55W
E17 014 4 Scheinwerfer rechts Head light, rh. 55W
E20 002 12 Zigarettenanzuender Cigarette lighter
E21 002 12 Beleuchtung Zigarettenanzuender Illumination, cigarette lighter
E22 005 7 Beleuchtung Temperaturanzeige Hydr.ïoel Illumination, temp. gauge, hydraulic oil
E23 014 5 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
E24 014 5 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
E25 014 6 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E26 014 6 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E27 014 11 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55W
E28 014 10 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55W
E29 014 7 Innenleuchte Kabine Inside light, cabin 15W
E29 014 8 Innenleuchte Kabine Inside light, cabin 15W
E30 012 3 Heizgeraet Heating unit
E32 014 8 Kennleuchte Warning light 70W
E37 013 18 Klimaverdampfer Air conditioning, evaporator
E46 005 15 Beleuchtung Voltmeter Illumination volt meter
E56 014 9 Scheinwerfer Motorraum rechts Head light, engine area rh. 55W
E57 014 9 Scheinwerfer Motorraum links Head light, engine area lh. 55W
ESX 006 9 Elektronisches Steuergeraet Electronic system, control unit
ESX 007 12 Elektronisches Steuergeraet Electronic system, control unit
ESX 008 10 Elektronisches Steuergeraet Electronic system, control unit
ESX 009 5 Elektronisches Steuergeraet Electronic system, control unit
ESX 009 18 Elektronisches Steuergeraet Electronic system, control unit
ESX 010 8 Elektronisches Steuergeraet Electronic system, control unit max. 1,08A
ESX 010 18 Elektronisches Steuergeraet Electronic system, control unit 0,2A

F00 002 2 Hauptsicherung Batterie Fuse, main, battery 250A

F02 012 12 Ersatzsicherung Fuse, spare 10A
F05 002 15 Sicherung Steckdose Fuse, socket 30A
F13 003 9 Sicherung Startschalter Fuse, starter switch 30A
F16 011 4 Sicherung Zentralschmieranlage Fuse, central lubrication system 10A
1

F23 011 14 Sicherung Signalhorn Fuse, warning horn 15A

F24 005 5 Sicherung Ueberwachungsmodul Fuse, monitoring module 15A
F25 009 2 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 10A
F27 014 16 Sicherung Wischer u. Wascher vorne Fuse, windscr. wiper and washer, fr. 10A
F28 014 18 Sicherung Wischer u. Wascher hinten Fuse, windscr. wiper and washer, re. 10A
11

F29 011 18 Sicherung Kompressor Sitzverstell. Fuse, compr., seat height adjustm. 15A
F31 013 6 Sicherung Kabinenluefter Fuse, cabin ventilator 10A
F33 013 9 Sicherung Klimageraet Fuse, air conditioning 10A
F40 012 3 Sicherung Kabinenheizung Fuse, heating unit cab 10A
570 700 37

F41 014 8 Sicherung Rundumkennleuchte Fuse, rotary beacon 10A

F42 014 7 Sicherung Kabineninnenleuchte Fuse, inside light cab 10A
F48 004 2 Sicherung Gluehanlage Fuse, glow plug system 80A
F49 014 1 Sicherung Spannungswandler Fuse, voltage transformer 10A
F50 013 19 Sicherung Klimageraet Fuse, air conditioning 15A
101

F66 014 4 Sicherung Scheinwerfer vorne Fuse, head light front 15A
F67 009 7 Sicherung Steuerung (Potential 30) Fuse, controller (pot.30) 30A
008 911
F84 57 009 13 Sicherung Steuerung (Klemme 54) BOMAG
Fuse, controller (Pin 54) 10A 859
 Name Bl. Pf. Benennung title TYP

20.3 F85
F86
F89
014
014
002
6
10
12
Sicherung, Scheinwerfer vorne
Sicherung, Scheinwerfer hinten
Sicherung, Zigarettenanzuender
Fuse, head light front
Fuse, head lights rear
Fuse, cigarette lighter
20A
Wiring diagram 570 700 37
15A
30A
F90 012 8 Sicherung, Ansteuerung Fuse, actuation 5A
F93 004 4 Sicherung Steuerung (Potential 30) Fuse, controller (pot. 30) 25A
F94 013 3 Sicherung Schutzbelueftung Fuse, protected ventilation syst.
F98 014 13 Sicherung Spiegelheizung fuse,mirror heating 10A
F99 014 9 Sicherung Motorraumbeleuchtung fuse, illumination engine area 15A
FM1 008 13 Platinensicherung Multifuse 0,2A
FM2 007 19 Platinensicherung Multifuse 0,2A
FM3 010 8 Platinensicherung Multifuse 0,2A
FM4 010 4 Platinensicherung Multifuse 0,2A
FM5 010 11 Platinensicherung Multifuse 0,2A
FM6 007 7 Platinensicherung Multifuse 0,2A
Seis
28.08.2006
Werner
28.08.2006

FM7 010 13 Platinensicherung Multifuse 0,2A

F122 002 17 Sicherung EMR Fuse, EMR 10A
F123 013 2 Sicherung Schutzbelüftungsanlage Fuse, protected ventilation system
F125 014 11 Vorsicherung preïfusing 10A
F126 014 11 Sicherung Rückfahrkamera Fuse, back up camera system 2A

G01 002 2 Batterie Battery

G02 002 5 Generator Generator 28V/80A
G03 002 2 Batterie Battery

H04 004 10 Meldeleuchte Betriebsstoerung Indicator light, breakdown

H07 009 13 Warnsummer Betriebsstoerung Warning buzzer, breakdown 0,2A
H14 007 4 Warnsummer Rueckwaertsfahrt Backïup alarm buzzer max. 2,5A
H70 004 11 Anzeige Wasser im Diesel Indicator water in fuel
H81 008 5 Meldeleuchte Verzögerungsfunktion Indicator light, decelerator device

K05 007 2 Relais Startstrom Relay, starting current BOSCHW

K11 003 14 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHL
K13 011 14 Relais Signalhorn Relay, warning horn BOSCHW
K14 004 4 Relais Vorgluehen Relay, glow plug system K2DEUTZ
K15 004 12 Relais Gluehen beim Start Relay, glowing during starting BOSCHW
K22 009 6 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K32 003 16 Relais Kabine Relay, cabin BOSCHL
K48 007 3 Relais Fahrhebel 0ïStellung Relay, travel lever 0ïposition BOSCHW
K60 004 14 Relais Motoroeldruck Relay, engine oil pressure BOSCHW
K61 002 8 Relais Ladekontrolle Relay, charge control BOSCHW
K62 002 10 Relais D+ Relay, D+ BOSCHW
K77 009 17 Relais Override Relay, override SDS/SF4
K90 009 4 Relais, Meldeleuchte Stoerung SPS Relay, indicat.light brake down SPS BOSCHW
component listing

K113 006 11 Zeitrelais Timing relay BOSCHW

K133 009 9 Relais Test Relay, test BOSCHW
Bauteilliste

K146 004 13 Relais Kühlmitteltemperatur relay, coolant temperature BOSCHW

K77/1 009 15 Relais Override Relay, override SDS/SF4

M01 003 9 Starter Starter

M04 014 15 Scheibenwischermotor vorne Windscreen wiper motor, front 190W
M05 014 17 Scheibenwischermotor hinten Windscreen wiper motor, rear max 3,3A
M06 014 16 Scheibenwaschermotor vorne Windscreen washer motor, front 60W
M07 014 18 Scheibenwaschermotor hinten Windscreen washer motor, rear 60W
M08 011 3 Zentralschmieranlage Central lubrication system max. 3A
M10 011 18 Kompressor Fahrersitzhoehenverstellung Compr., operator’s seat height adjustm. 7,5A
M17 012 18 Zusatzluefter Additional blower max. 0,75A
M24 013 10 Stellmotor Luftklappe adjusting motor air inlet flap
M26 013 6 Zyklon Abscheider cyclone separator 3A

P00 005 12 Betriebsstundenzaehler Operating hour meter

P01 005 15 Tankanzeige Level gauge
P02 005 7 Temperaturanzeige Hydraulikoel Temperature gauge, hydraulic oil
P03 005 11 Drehzahlmesser Rpm meter
P09 011 10 Frequenzï und Geschwindigkeitsanzeige Frequencyï and Speedometer
P09 011 10 Frequenzï und Geschwindigkeitsanzeige Frequencyï and Speedometer
P12 005 16 Voltmeter Volt meter
P14 005 6 Anzeige Kuehlmitteltemperatur Temperature gauge, coolant
P15 014 11 BCM 03 Bildschirm BCM 03 terminal
P18 010 16 Diagnose Diagnostics max. 1,08A
P32 014 12 Kamera Rückraumüberwachung Camera, back up monitoring

R02 004 2 Gluehkerze Glow plug

R02 004 2 Gluehkerze Glow plug
R03 005 15 Geber Tankanzeige Sender, level gauge
R04 005 8 Geber Hydraulikoeltemperatur Sender, hydraulic oil temp.
R06 011 19 Heizung Fahrersitz Heating, operator’s seat
R06 011 19 Heizung Fahrersitz Heating, operator’s seat
R10 002 7 Parallelwiderstand Parallel resistor 220 OHM
R20 008 15 Widerstand Resistor 1 KOHM
R21 008 15 Widerstand Resistor 1 KOHM
R22 008 16 Widerstand Resistor 1 KOHM
R23 008 17 Widerstand Resistor 1 KOHM
2

R24 004 5 Widerstand Resistor 10 kOHM

R26 012 17 Widerstand Resistor 22 OHM
R27 012 18 Widerstand Resistor 10 OHM
R32 007 5 Widerstand Resistor 1 kOhm
R33 007 5 Widerstand Resistor 2 kOhm
11

R34 007 6 Widerstand Resistor 1 kOhm

R35 007 8 Widerstand Resistor 3,3 kOhm
R36 010 5 Widerstand Resistor 47 OHM
R38 010 5 Widerstand Resistor 47 OHM
570 700 37

R40 010 5 Widerstand Resistor 47 OHM

R42 010 5 Widerstand Resistor 47 OHM
R43 008 7 Widerstand Resistor 499Ohm
R44 008 7 Widerstand Resistor 499Ohm
R77 014 12 Widerstandsheizung Aussenspiegel Resistor heating outside mirror 40W
102

R77 014 13 Widerstandsheizung Aussenspiegel Resistor heating outside mirror 40W

R77 014 13 Widerstandsheizung Aussenspiegel Resistor heating outside mirror 40W
860 R77 014 14 Widerstandsheizung Aussenspiegel BOMAG
Resistor heating outside mirror 40W 008 911 57
 Name Bl. Pf. Benennung title TYP

Wiring
S00 diagram
003 9
S01
570 700 37
Startschalter
002 17 Schalter NOT AUS
Starter switch
Switch, emergency off
MERIT
NOTAUSH
20.3
S01 002 17 Schalter NOT AUS Switch, emergency off
S02 008 16 Fahrstufenschalter Switch, speed range selector
S02 008 19 Fahrstufenschalter Switch, speed range selector
S03 011 14 Taster Signalhorn Push button, warning horn
S04 008 10 Bremsschalter Switch, brake
S16 014 5 Schalter Arbeitsbeleuchtung vorne Switch, working head lights, front
S20 014 14 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 014 18 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S22 014 16 Schalter Scheibenwascher vorne Switch, windscreen washer, front
S25 011 19 Schalter Fahrersitzheizung Switch, heating, operator’s seat
S26 014 10 Schalter Arbeitsbeleuchtung hinten Switch, working head lights, rear
Seis
28.08.2006
Werner
28.08.2006

S27 011 3 Taster Zentralschmieranlage Push botton, central lubrication system

S28 012 8 Schalter Kabinenheizung Switch, cabin heating
S29 011 18 Schalter Fahrersitz Hoehenverstellung Switch, operator’s seat height adjustm.
S30 002 2 Batterietrennschalter Switch, battery disconnect
S31 007 5 Schalter Fahrtrichtung Switch, travel direction
S38 014 8 Schalter Kennleuchte Switch, warning light
S44 012 17 Schalter Kabinenluefter Switch, cabin ventilator
S45 014 7 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 014 4 Schalter Arbeitsbeleuchtung Switch, working lights
S70 010 10 Schalter Schubsschild Switch, dozer blade WAGO
S71 010 3 Schalter Lenkung Switch, steering max. 1,08A
S118 004 18 Schalter Fehlerdiagnose Switch, fault diagnosis
S119 004 6 Elektronisches Fusspedal Electronic foot pedal
S120 008 7 Schalter Motordrehzahl Switch, engine speed 5 kOhm
S128 014 13 Schalter Spiegelheizung Switch, mirror heating
S137 014 9 Schalter Motorraumbeleuchtung Switch, illumination engine area
S160 008 4 Schalter Aktivierung Verzögerungspedal Switch, enable decelerator pedal
S161 008 6 Verzögerungspedal decelerator pedal

U01 014 1 Spannungswandler Voltage transformer

V01 002 7 Diode Diode WAGO

V02 006 7 Diode Diode WAGO
V03 006 7 Diode Diode WAGO
V04 006 7 Diode Diode WAGO
V05 006 7 Diode Diode WAGO
V07 006 12 Diode Diode WAGO
V08 006 12 Diode Diode WAGO
V09 006 12 Diode Diode WAGO
component listing

V10 006 12 Diode Diode WAGO

V11 006 12 Diode Diode WAGO
Bauteilliste

V12 009 7 Diode Diode WAGO

V13 006 12 Diode Diode WAGO
V14 009 14 Diode Diode Wago
V15 009 15 Diode Diode Wago
V16 010 2 Diode Diode WAGO
V17 010 3 Diode Diode WAGO
V18 010 2 Diode Diode WAGO
V19 010 2 Diode Diode WAGO
V21 009 9 Diode Diode WAGO
V22 009 10 Diode Diode WAGO
V23 007 2 Diode Diode WAGO
V25 007 3 Diode Diode WAGO
V26 013 14 Diode Diode WAGO
V31 008 10 Diode Diode Lütze
V32 007 9 Diode Diode Lütze
V33 007 11 Diode Diode Lütze
V34 007 5 Diode Diode Lütze
V35 007 7 Diode Diode Lütze
V36 013 19 Diode Diode FE5B
V37 008 13 Diode Diode Lütze
V38 007 2 Diode Diode FE5B KabeldiodeDiode
V42 009 13 Diode (A2) Diode (A2) Diodenmodul
V43 013 6 Diode (A3) Diode (A3) Diodenmodul
V46 011 15 Diode (A6) Diode (A6) Diodenmodul
V47 003 12 Diode (A7) Diode (A7) Diodenmodul
V48 013 15 Diode (A8) Diode (A8) Diodenmodul

X0/1:1 010 18 DIOS STECKER Dios connector

X0/1:2 010 18 DIOS STECKER Dios connector
X0/1:3 009 18 DIOS STECKER Dios connector
X0/1:4 009 19 DIOS STECKER Dios connector
X0/1:5 010 18 DIOS STECKER Dios connector
X0/1:6 010 19 DIOS STECKER Dios connector
X0/1:9 009 19 DIOS STECKER Dios connector
X0/1:10 009 19 DIOS STECKER Dios connector
X0/1:11 009 18 DIOS STECKER Dios connector
X0:1 007 10 ESX STECKER esx connector
3

X0:1 008 13 ESX STECKER esx connector

X0:1 010 7 ESX STECKER esx connector
X0:2 009 4 ESX STECKER esx connector
X0:3 009 9 ESX STECKER esx connector
X0:4 009 10 ESX STECKER esx connector
11

X0:5 009 11 ESX STECKER esx connector

X0:6 006 9 ESX STECKER esx connector
X0:7 008 14 ESX STECKER esx connector
X0:8 010 3 ESX STECKER esx connector
570 700 37

X0:9 010 7 ESX STECKER esx connector

X0:10 006 10 ESX STECKER esx connector
X0:11 006 9 ESX STECKER esx connector
X0:12 010 14 ESX STECKER esx connector
X0:13 006 10 ESX STECKER esx connector
103

X0:14 010 6 ESX STECKER esx connector

X0:15 010 7 ESX STECKER esx connector
008 911
X0:16 57 009 4 ESX STECKER BOMAG
esx connector 861
 Name Bl. Pf. Benennung title TYP

20.3 X0:17
X0:18
X0:19
010
006
006
13
9
9
ESX STECKER
ESX STECKER
ESX STECKER
esx connector
esx connector
esx connector
Wiring diagram 570 700 37
X0:20 010 8 ESX STECKER esx connector
X0:21 007 10 ESX STECKER esx connector
X0:22 007 8 ESX STECKER esx connector
X0:23 007 11 ESX STECKER esx connector
X0:23 008 13 ESX STECKER esx connector
X0:23 010 8 ESX STECKER esx connector
X0:24 009 6 ESX STECKER esx connector
X0:25 009 7 ESX STECKER esx connector
X0:26 010 17 ESX STECKER esx connector
X0:27 010 16 ESX STECKER esx connector
X0:28 009 6 ESX STECKER esx connector
Seis
28.08.2006
Werner
28.08.2006

X0:29 007 19 ESX STECKER esx connector

X0:30 010 10 ESX STECKER esx connector
X0:31 010 12 ESX STECKER esx connector
X0:32 007 7 ESX STECKER esx connector
X0:33 009 9 ESX STECKER esx connector
X0:34 010 13 ESX STECKER esx connector
X0:35 010 11 ESX STECKER esx connector
X0:36 006 9 ESX STECKER esx connector
X0:37 010 15 ESX STECKER esx connector
X0:38 010 5 ESX STECKER esx connector
X0:39 010 5 ESX STECKER esx connector
X0:40 008 10 ESX STECKER esx connector
X0:41 010 11 ESX STECKER esx connector
X0:42 010 9 ESX STECKER esx connector
X0:43 007 19 ESX STECKER esx connector
X0:44 009 13 ESX STECKER esx connector
X0:45 006 10 ESX STECKER esx connector
X0:46 007 14 ESX STECKER esx connector
X0:47 007 16 ESX STECKER esx connector
X0:48 007 17 ESX STECKER esx connector
X0:49 010 7 ESX STECKER esx connector
X0:50 006 10 ESX STECKER esx connector
X0:51 006 10 ESX STECKER esx connector
X0:52 006 9 ESX STECKER esx connector
X0:53 009 9 ESX STECKER esx connector
X0:54 009 13 ESX STECKER esx connector
X0:55 010 16 ESX STECKER esx connector
X0:56 009 7 ESX STECKER esx connector
X0:57 009 8 ESX STECKER esx connector
component listing

X0:58 009 8 ESX STECKER esx connector

X0:59 009 8 ESX STECKER esx connector
Bauteilliste

X0:60 009 9 ESX STECKER esx connector

X0:61 008 10 ESX STECKER esx connector
X0:62 008 14 ESX STECKER esx connector
X0:63 010 11 ESX STECKER esx connector
X0:64 010 6 ESX STECKER esx connector
X0:65 010 14 ESX STECKER esx connector
X0:66 010 15 ESX STECKER esx connector
X0:67 010 15 ESX STECKER esx connector
X0:68 010 16 ESX STECKER esx connector
X1: 013 2 Wago Zentralelektrik Wago eïbox
X1:1 014 7 Wago Zentralelektrik Wago eïbox
X1:2 014 7 Wago Zentralelektrik Wago eïbox
X1:3 014 2 Wago Zentralelektrik Wago eïbox
X1:4 014 2 Wago Zentralelektrik Wago eïbox
X1:5 004 20 Wago Zentralelektrik Wago eïbox
X1:6 002 17 Wago Zentralelektrik Wago eïbox
X1:7 003 9 Wago Zentralelektrik Wago eïbox
X1:8 003 9 Wago Zentralelektrik Wago eïbox
X1:9 003 9 Wago Zentralelektrik Wago eïbox
X1:61 010 18 Wago Zentralelektrik Wago eïbox
X1:62 004 15 Wago Zentralelektrik Wago eïbox
X1:63 010 18 Wago Zentralelektrik Wago eïbox
X1:64 004 16 Wago Zentralelektrik Wago eïbox
X1:65 004 16 Wago Zentralelektrik Wago eïbox
X1:66 009 10 Wago Zentralelektrik Wago eïbox
X1:67 009 11 Wago Zentralelektrik Wago eïbox
X1:68 010 18 Wago Zentralelektrik Wago eïbox
X1:69 010 18 Wago Zentralelektrik Wago eïbox
X1:70 002 10 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:70 003 16 Wago Zentralelektrik Wago eïbox
X1:70 007 2 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:70 007 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:70 009 4 Wago Zentralelektrik Wago eïbox
X1:70 009 6 Wago Zentralelektrik Wago eïbox
X1:70 009 9 Wago Zentralelektrik Wago eïbox
X1:70 009 13 Wago Zentralelektrik Wago eïbox
X1:70 009 15 Wago Zentralelektrik Wago eïbox
4

X1:70 009 17 Wago Zentralelektrik Wago eïbox

X1:70 013 6 Wago Zentralelektrik Wago eïbox
X1:71 004 17 Wago Zentralelektrik Wago eïbox
X1:72 014 11 Wago Zentralelektrik Wago eïbox
X1:81 002 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
11

X1:82 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:83 006 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:84 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:85 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
570 700 37

X1:86 006 4 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:87 006 2 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:88 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:89 006 2 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:90 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
104

X1:91 006 4 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:92 004 12 Wago Zentralelektrik Wago eïbox
862 X1:93 004 13 Wago Zentralelektrik BOMAG
Wago eïbox 008 911 57
 Name Bl. Pf. Benennung title TYP
X1:94

X1:102
004
Wiring diagram 570 700 37
X1:101 006
006
14
7
9
Wago Zentralelektrik
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
Wago eïbox
WAGO EïBOX
WAGO EïBOX
20.3
X1:103 006 5 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:104 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:105 006 11 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:106 006 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:108 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:109 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:110 006 11 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:111 006 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:112 006 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:113 006 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:114 006 18 WAGO ZENTRALELEKTRIK WAGO EïBOX
Seis
28.08.2006
Werner
28.08.2006

X1:115 006 14 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:116 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:117 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:118 006 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:119 006 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:120 006 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:121 006 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:122 006 18 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:123 006 14 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:124 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:125 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:126 006 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:127 013 13 Wago Zentralelektrik Wago eïbox
X1:128 013 13 Wago Zentralelektrik Wago eïbox
X1:129 013 15 Wago Zentralelektrik Wago eïbox
X1:130 013 15 Wago Zentralelektrik Wago eïbox
X1:131 007 8 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:132 007 8 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:133 007 10 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:134 007 10 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:135 007 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:136 007 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:137 010 11 Wago Zentralelektrik Wago eïbox
X1:138 010 11 Wago Zentralelektrik Wago eïbox
X1:139 010 12 Wago Zentralelektrik Wago eïbox
X1:140 010 12 Wago Zentralelektrik Wago eïbox
X1:141 010 18 Wago Zentralelektrik Wago eïbox
X1:142 010 18 Wago Zentralelektrik Wago eïbox
X1:143 010 19 Wago Zentralelektrik Wago eïbox
component listing

X1:144 010 19 Wago Zentralelektrik Wago eïbox

X1:145 014 9 Wago Zentralelektrik Wago eïbox
Bauteilliste

X1:146 013 15 Wago Zentralelektrik Wago eïbox

X1:147 013 15 Wago Zentralelektrik Wago eïbox
X1:148 005 8 Wago Zentralelektrik Wago eïbox
X1:149 007 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:150 014 10 Wago Zentralelektrik Wago eïbox
X1:151 008 10 Wago Zentralelektrik Wago eïbox
X1:152 008 10 Wago Zentralelektrik Wago eïbox
X1:153 007 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:154 007 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:155 007 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:156 007 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:157 007 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:158 007 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:159 010 6 Wago Zentralelektrik Wago eïbox
X1:160 010 6 Wago Zentralelektrik Wago eïbox
X1:161 010 7 Wago Zentralelektrik Wago eïbox
X1:162 010 7 Wago Zentralelektrik Wago eïbox
X1:163 010 8 Wago Zentralelektrik Wago eïbox
X1:164 010 8 Wago Zentralelektrik Wago eïbox
X1:165 010 9 Wago Zentralelektrik Wago eïbox
X1:166 010 9 Wago Zentralelektrik Wago eïbox
X1:170 008 14 Wago Zentralelektrik Wago eïbox
X1:171 011 4 Wago Zentralelektrik Wago eïbox
X1:172 011 3 Wago Zentralelektrik Wago eïbox
X1:173 011 3 Wago Zentralelektrik Wago eïbox
X1:174 011 4 Wago Zentralelektrik Wago eïbox
X1:181 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:181 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:181 010 14 Wago Zentralelektrik Wago eïbox
X1:182 006 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:182 006 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:182 010 15 Wago Zentralelektrik Wago eïbox
X1:183 006 11 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:183 006 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:183 010 15 Wago Zentralelektrik Wago eïbox
X1:184 006 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:184 006 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
5

X1:184 009 18 Wago Zentralelektrik Wago eïbox

X1:185 006 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:185 009 19 Wago Zentralelektrik Wago eïbox
X1:186 006 18 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:186 009 19 Wago Zentralelektrik Wago eïbox
11

X1:187 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:187 010 16 Wago Zentralelektrik Wago eïbox
X1:188 007 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:188 010 16 Wago Zentralelektrik Wago eïbox
570 700 37

X1:189 010 14 Wago Zentralelektrik Wago eïbox

X1:189 014 9 Wago Zentralelektrik Wago eïbox
X1:189 014 9 Wago Zentralelektrik Wago eïbox
X1:190 011 6 Wago Zentralelektrik Wago eïbox
X1:190 014 10 Wago Zentralelektrik Wago eïbox
105

X1:190 014 11 Wago Zentralelektrik Wago eïbox

X1:191 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
008 911
X1:19157 006 15 WAGO ZENTRALELEKTRIK BOMAG
WAGO EïBOX 863
 Name Bl. Pf. Benennung title TYP

20.3 X1:191
X1:192
X1:201
011
008
013
7
14
15
Wago Zentralelektrik
Wago Zentralelektrik
Wago Zentralelektrik
Wago eïbox
Wago eïbox
Wago eïbox
Wiring diagram 570 700 37
X1:202 002 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:205 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:205 013 15 Wago Zentralelektrik Wago eïbox
X1:207 009 4 Wago Zentralelektrik Wago eïbox
X1:20A 013 19 Sika ï Klemme fuse terminal
X1:20E 013 19 Sika ï Klemme fuse terminal
X1:210 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:21A 002 12 Sika ï Klemme fuse terminal
X1:21E 002 12 Sika ï Klemme fuse terminal
X1:221 007 14 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:222 007 14 WAGO ZENTRALELEKTRIK WAGO EïBOX
Seis
28.08.2006
Werner
28.08.2006

X1:223 007 16 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:224 007 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:226 012 3 Wago Zentralelektrik Wago eïbox
X1:227 012 3 Wago Zentralelektrik Wago eïbox
X1:228 005 15 Wago Zentralelektrik Wago eïbox
X1:229 005 15 Wago Zentralelektrik Wago eïbox
X1:22A 013 3 Sika ï Klemme fuse terminal
X1:22E 013 3 Sika ï Klemme fuse terminal
X1:231 004 6 Wago Zentralelektrik Wago eïbox
X1:232 004 6 Wago Zentralelektrik Wago eïbox
X1:233 004 7 Wago Zentralelektrik Wago eïbox
X1:234 008 5 Wago Zentralelektrik Wago eïbox
X1:235 004 6 Wago Zentralelektrik Wago eïbox
X1:236 004 6 Wago Zentralelektrik Wago eïbox
X1:237 004 7 Wago Zentralelektrik Wago eïbox
X1:23A 003 9 Sika ï Klemme fuse terminal
X1:23E 002 3 Sika ï Klemme fuse terminal
X1:23E 003 9 Sika ï Klemme fuse terminal
X1:241 002 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:242 002 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:243 002 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:244 004 10 Wago Zentralelektrik Wago eïbox
X1:245 011 19 Wago Zentralelektrik Wago eïbox
X1:246 011 19 Wago Zentralelektrik Wago eïbox
X1:247 013 15 Wago Zentralelektrik Wago eïbox
X1:248 011 3 Wago Zentralelektrik Wago eïbox
X1:249 013 10 Wago Zentralelektrik Wago eïbox
X1:24A 004 4 Sika ï Klemme fuse terminal
X1:24E 004 4 Sika ï Klemme fuse terminal
component listing

X1:250 004 10 Wago Zentralelektrik Wago eïbox

X1:251 013 9 Wago Zentralelektrik Wago eïbox
Bauteilliste

X1:252 013 13 Wago Zentralelektrik Wago eïbox

X1:253 013 17 Wago Zentralelektrik Wago eïbox
X1:255 004 18 Wago Zentralelektrik Wago eïbox
X1:256 002 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:256 003 12 Wago Zentralelektrik Wago eïbox
X1:256 011 15 Wago Zentralelektrik Wago eïbox
X1:257 009 13 Wago Zentralelektrik Wago eïbox
X1:258 009 13 Wago Zentralelektrik Wago eïbox
X1:259 002 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:25A 002 15 Sika ï Klemme fuse terminal
X1:25E 002 15 Sika ï Klemme fuse terminal
X1:260 002 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:261 008 10 Wago Zentralelektrik Wago eïbox
X1:262 007 18 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:262 008 10 Wago Zentralelektrik Wago eïbox
X1:263 008 10 Wago Zentralelektrik Wago eïbox
X1:265 012 18 Wago Zentralelektrik Wago eïbox
X1:266 012 17 Wago Zentralelektrik Wago eïbox
X1:267 012 18 Wago Zentralelektrik Wago eïbox
X1:268 012 19 Wago Zentralelektrik Wago eïbox
X1:269 004 11 Wago Zentralelektrik Wago eïbox
X1:26A 009 13 Sika ï Klemme fuse terminal
X1:26E 009 13 Sika ï Klemme fuse terminal
X1:270 004 11 Wago Zentralelektrik Wago eïbox
X1:272 011 3 Wago Zentralelektrik Wago eïbox
X1:272 013 9 Wago Zentralelektrik Wago eïbox
X1:27A 009 7 Sika ï Klemme fuse terminal
X1:27E 009 7 Sika ï Klemme fuse terminal
X1:28A 013 2 Sika ï Klemme fuse terminal
X1:28E 013 2 Sika ï Klemme fuse terminal
X1:291 005 7 Wago Zentralelektrik Wago eïbox
X1:292 005 11 Wago Zentralelektrik Wago eïbox
X1:293 003 10 Wago Zentralelektrik Wago eïbox
X1:294 005 5 Wago Zentralelektrik Wago eïbox
X1:295 005 7 Wago Zentralelektrik Wago eïbox
X1:296 005 15 Wago Zentralelektrik Wago eïbox
X1:298 002 11 WAGO ZENTRALELEKTRIK WAGO EïBOX
6

X1:298 005 11 Wago Zentralelektrik Wago eïbox

X1:299 004 20 Wago Zentralelektrik Wago eïbox
X1:299 005 5 Wago Zentralelektrik Wago eïbox
X1:29A 005 5 Sika ï Klemme fuse terminal
X1:29E 005 5 Sika ï Klemme fuse terminal
11

X1:300 005 7 Wago Zentralelektrik Wago eïbox

X1:301 005 11 Wago Zentralelektrik Wago eïbox
X1:302 003 13 Wago Zentralelektrik Wago eïbox
X1:303 005 8 Wago Zentralelektrik Wago eïbox
570 700 37

X1:30A 011 4 Sika ï Klemme fuse terminal

X1:30E 011 4 Sika ï Klemme fuse terminal
X1:31A 011 18 Sika ï Klemme fuse terminal
X1:31E 002 17 SIKA KLEMME fuse terminal
X1:31E 011 18 Sika ï Klemme fuse terminal
106

X1:321 010 6 Wago Zentralelektrik Wago eïbox

X1:322 010 8 Wago Zentralelektrik Wago eïbox
864 X1:323 010 7 Wago Zentralelektrik BOMAG
Wago eïbox 008 911 57
 Name Bl. Pf. Benennung title TYP
X1:324

X1:326
010
Wiring diagram 570 700 37
X1:325 010
010
7
6
7
Wago Zentralelektrik
Wago Zentralelektrik
Wago Zentralelektrik
Wago eïbox
Wago eïbox
Wago eïbox
20.3
X1:327 010 11 Wago Zentralelektrik Wago eïbox
X1:328 010 11 Wago Zentralelektrik Wago eïbox
X1:329 010 10 Wago Zentralelektrik Wago eïbox
X1:32A 002 17 Sika ï Klemme fuse terminal
X1:32E 002 17 Sika ï Klemme fuse terminal
X1:330 010 10 Wago Zentralelektrik Wago eïbox
X1:331 010 11 Wago Zentralelektrik Wago eïbox
X1:332 010 11 Wago Zentralelektrik Wago eïbox
X1:333 010 14 Wago Zentralelektrik Wago eïbox
X1:334 010 14 Wago Zentralelektrik Wago eïbox
X1:335 007 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
Seis
28.08.2006
Werner
28.08.2006

X1:336 007 9 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:337 007 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:338 007 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:339 007 5 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:33A 013 6 Sika ï Klemme fuse terminal
X1:33E 002 17 SIKA KLEMME fuse terminal
X1:33E 013 6 Sika ï Klemme fuse terminal
X1:340 007 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:341 011 18 Wago Zentralelektrik Wago eïbox
X1:342 011 18 Wago Zentralelektrik Wago eïbox
X1:343 008 4 Wago Zentralelektrik Wago eïbox
X1:343 010 5 Wago Zentralelektrik Wago eïbox
X1:344 010 4 Wago Zentralelektrik Wago eïbox
X1:345 010 4 Wago Zentralelektrik Wago eïbox
X1:346 010 3 Wago Zentralelektrik Wago eïbox
X1:347 010 5 Wago Zentralelektrik Wago eïbox
X1:348 010 5 Wago Zentralelektrik Wago eïbox
X1:349 009 18 Wago Zentralelektrik Wago eïbox
X1:349 009 19 Wago Zentralelektrik Wago eïbox
X1:349 009 19 Wago Zentralelektrik Wago eïbox
X1:349 010 17 Wago Zentralelektrik Wago eïbox
X1:34A 011 14 Sika ï Klemme fuse terminal
X1:34E 011 14 Sika ï Klemme fuse terminal
X1:350 010 13 Wago Zentralelektrik Wago eïbox
X1:351 010 12 Wago Zentralelektrik Wago eïbox
X1:352 010 12 Wago Zentralelektrik Wago eïbox
X1:353 010 13 Wago Zentralelektrik Wago eïbox
X1:354 010 13 Wago Zentralelektrik Wago eïbox
X1:355 011 19 Wago Zentralelektrik Wago eïbox
component listing

X1:356 011 14 Wago Zentralelektrik Wago eïbox

X1:357 008 17 Wago Zentralelektrik Wago eïbox
Bauteilliste

X1:358 008 13 Wago Zentralelektrik Wago eïbox

X1:359 008 14 Wago Zentralelektrik Wago eïbox
X1:35A 009 2 Sika ï Klemme fuse terminal
X1:35E 009 2 Sika ï Klemme fuse terminal
X1:363 010 15 Wago Zentralelektrik Wago eïbox
X1:364 010 19 Wago Zentralelektrik Wago eïbox
X1:364 011 14 Wago Zentralelektrik Wago eïbox
X1:36A 013 9 Sika ï Klemme fuse terminal
X1:36E 013 9 Sika ï Klemme fuse terminal
X1:371 003 16 Wago Zentralelektrik Wago eïbox
X1:372 014 19 Wago Zentralelektrik Wago eïbox
X1:372 014 20 Wago Zentralelektrik Wago eïbox
X1:373 012 15 Wago Zentralelektrik Wago eïbox
X1:374 012 15 Wago Zentralelektrik Wago eïbox
X1:375 012 3 Wago Zentralelektrik Wago eïbox
X1:376 012 3 Wago Zentralelektrik Wago eïbox
X1:377 012 19 Wago Zentralelektrik Wago eïbox
X1:378 014 10 Wago Zentralelektrik Wago eïbox
X1:381 013 19 Wago Zentralelektrik Wago eïbox
X1:382 013 18 Wago Zentralelektrik Wago eïbox
X1:383 013 17 Wago Zentralelektrik Wago eïbox
X1:391/1 002 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:391/2 002 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:392/1 006 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:392/2 006 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:393/1 006 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:393/2 006 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:394/1 006 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:394/2 006 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:395/1 006 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:395/2 006 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:397/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:397/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:398/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:398/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:399/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:399/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
7

X1:400/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:400/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:401/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:401/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:402/1 009 7 Wago Zentralelektrik Wago eïbox
11

X1:402/2 009 7 Wago Zentralelektrik Wago eïbox

X1:403/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:403/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:404/1 009 14 Wago Zentralelektrik Wago eïbox
570 700 37

X1:404/2 009 14 Wago Zentralelektrik Wago eïbox

X1:405/1 009 15 Wago Zentralelektrik Wago eïbox
X1:405/2 009 15 Wago Zentralelektrik Wago eïbox
X1:406/1 010 2 Wago Zentralelektrik Wago eïbox
X1:406/2 010 2 Wago Zentralelektrik Wago eïbox
107

X1:407/1 010 3 Wago Zentralelektrik Wago eïbox

X1:407/2 010 3 Wago Zentralelektrik Wago eïbox
008 911 57
X1:408/1 010 2 Wago Zentralelektrik BOMAG
Wago eïbox 865
 Name Bl. Pf. Benennung title TYP

20.3 X1:408/2
X1:409/1
X1:409/2
010
010
010
2
2
2
Wago Zentralelektrik
Wago Zentralelektrik
Wago Zentralelektrik
Wago eïbox
Wago eïbox
Wago eïbox
Wiring diagram 570 700 37
X1:41/1 008 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:41/2 008 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:410/1 009 9 Wago Zentralelektrik Wago eïbox
X1:410/2 009 9 Wago Zentralelektrik Wago eïbox
X1:411/1 009 10 Wago Zentralelektrik Wago eïbox
X1:411/2 009 10 Wago Zentralelektrik Wago eïbox
X1:412/1 007 2 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:412/2 007 2 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:413/1 007 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:413/2 007 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:414/1 013 14 Wago Zentralelektrik Wago eïbox
Seis
28.08.2006
Werner
28.08.2006

X1:414/2 013 14 Wago Zentralelektrik Wago eïbox

X1:42/1 007 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:42/2 007 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:43/1 010 8 Wago Zentralelektrik Wago eïbox
X1:43/2 010 8 Wago Zentralelektrik Wago eïbox
X1:44/1 010 4 Wago Zentralelektrik Wago eïbox
X1:44/2 010 4 Wago Zentralelektrik Wago eïbox
X1:45/1 010 11 Wago Zentralelektrik Wago eïbox
X1:45/2 010 11 Wago Zentralelektrik Wago eïbox
X1:46/1 007 8 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:46/2 007 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:47/1 010 13 Wago Zentralelektrik Wago eïbox
X1:47/2 010 13 Wago Zentralelektrik Wago eïbox
X2:A 010 18 Datenschnittstelle data interface
X2:B 010 18 Datenschnittstelle data interface
X2:G 009 11 Datenschnittstelle data interface
X2:H 009 10 Datenschnittstelle data interface
X2:J 002 11 Datenschnittstelle data interface
X2:N 002 11 Datenschnittstelle data interface
X2:U 009 11 Datenschnittstelle data interface
X2:V 010 15 Datenschnittstelle data interface
X3:A 008 3 Stecker Handgas connector hand throttle
X3:B 008 2 Stecker Handgas connector hand throttle
X3:C 008 2 Stecker Handgas connector hand throttle
X4:A 004 15 EMR ï Diagnose EMRïdiagnosis
X4:B 004 17 EMR ï Diagnose EMRïdiagnosis
X4:F 004 16 EMR ï Diagnose EMRïdiagnosis
X4:G 004 16 EMR ï Diagnose EMRïdiagnosis
X4:H 004 15 EMR ï Diagnose EMRïdiagnosis
component listing

X4:K 004 17 EMR ï Diagnose EMRïdiagnosis

X4:M 004 16 EMR ï Diagnose EMRïdiagnosis
Bauteilliste

X5:1 005 7 Deutsch Stecker Senso Deutsch Connector sensor

X6:1 004 10 Wago Zentralelektrik Wago eïbox
X6:2 004 10 Wago Zentralelektrik Wago eïbox
X6:3 004 11 Wago Zentralelektrik Wago eïbox
X6:4 004 11 Wago Zentralelektrik Wago eïbox
X6:5 004 15 Wago Zentralelektrik Wago eïbox
X6:6 004 15 Wago Zentralelektrik Wago eïbox
X6:7 004 16 Wago Zentralelektrik Wago eïbox
X6:8 004 16 Wago Zentralelektrik Wago eïbox
X6:9 004 16 Wago Zentralelektrik Wago eïbox
X6:10 004 17 Wago Zentralelektrik Wago eïbox
X7:1 014 9 Stecker Rops connector on rops
X7:2 014 9 Stecker Rops connector on rops
X7:3 014 9 Stecker Rops connector on rops
X7:4 014 9 Stecker Rops connector on rops
X7:5 013 16 Stecker Rops connector on rops
X7:6 013 16 Stecker Rops connector on rops
X8:1 012 3 Pumpenstecker Kabine connector pump cabin;
X8:2 012 3 Pumpenstecker Kabine connector pump cabin;
X9:1 007 5 Stecker Schalter Rich connector direction switch
X9:2 007 9 Stecker Schalter Rich connector direction switch
X9:3 007 7 Stecker Schalter Rich connector direction switch
X9:4 007 5 Stecker Schalter Rich connector direction switch
X9:5 007 5 Stecker Schalter Rich connector direction switch
X9:6 007 6 Stecker Schalter Rich connector direction switch
XS 002 15 Steckdose Socket
X10:A 004 7 AMP Stecker Gaspedal AMP connector throttle
X10:B 004 6 AMP Stecker Gaspedal AMP connector throttle
X10:C 004 6 AMP Stecker Gaspedal AMP connector throttle
X11:1 011 18 Schnittstelle Sitz connector drivers seat
X11:2 011 18 Schnittstelle Sitz connector drivers seat
X12:A 004 7 AMP Stecker Gaspedal AMP connector throttle
X12:B 004 8 AMP Stecker Gaspedal AMP connector throttle
X12:C 004 7 AMP Stecker Gaspedal AMP connector throttle
X13:1 008 17 Stecker Stufenschalte connector speed range switch
X13:2 008 18 Stecker Stufenschalte connector speed range switch
X13:3 008 14 Stecker Stufenschalte connector speed range switch
8

X14:4 013 15 Stecker Motor connector engine

X14:5 013 16 Stecker Motor connector engine
X14:6 002 6 Motorschnittstelle engine interface
X14:7 002 6 Motorschnittstelle engine interface
X14:8 005 7 Motorschnittstelle engine interface
11

X14:9 003 9 Motorschnittstelle engine interface

X14:10 006 12 Stecker Motor connector engine
X14:11 006 12 Stecker Motor connector engine
X15:A 010 18 Stecker Lehne links connector arm rest lh.
570 700 37

X15:B 010 18 Stecker Lehne links connector arm rest lh.

X15:C 010 19 Stecker Lehne links connector arm rest lh.
X17:1 013 16 Stecker Klimakupplung connector clima clutch
X17:2 013 16 Stecker Klimakupplung connector clima clutch
X18:1 013 16 Stecker Druckschalter connector pressure switch
108

X18:2 013 16 Stecker Druckschalter connector pressure switch

X19:1 013 13 Stecker Heizventil connector heating valve
866 X19:2 013 13 Stecker Heizventil BOMAG
connector heating valve 008 911 57
 Name Bl. Pf. Benennung title TYP
X21:1

X22:1
011
Wiring diagram 570 700 37
X21:2 011
013
19
19
10
Schnittstelle Sitz
Schnittstelle Sitz
Stecker Luftklappe
connector drivers seat
connector drivers seat
connector air flap
20.3
X22:2 013 11 Stecker Luftklappe connector air flap
X23:1 013 14 Stecker Sensor connector sensor
X23:2 013 14 Stecker Sensor connector sensor
X24:1 013 15 Stecker Sensor connector sensor
X24:2 013 15 Stecker Sensor connector sensor
X25:A 013 19 Stecker Lüfter connector blower
X25:B 013 18 Stecker Lüfter connector blower
X25:C 013 18 Stecker Lüfter connector blower
X26:1 013 9 Stecker Klimasteuerun connector climacontrol
X26:2 013 9 Stecker Klimasteuerun connector climacontrol
X26:3 013 11 Stecker Klimasteuerun connector climacontrol
Seis
28.08.2006
Werner
28.08.2006

X26:4 013 10 Stecker Klimasteuerun connector climacontrol

X26:5 013 16 Stecker Klimasteuerun connector climacontrol
X26:6 013 12 Stecker Klimasteuerun connector climacontrol
X26:7 013 12 Stecker Klimasteuerun connector climacontrol
X26:8 013 15 Stecker Klimasteuerun connector climacontrol
X26:9 013 13 Stecker Klimasteuerun connector climacontrol
X26:10 013 10 Stecker Klimasteuerun connector climacontrol
X26:11 013 11 Stecker Klimasteuerun connector climacontrol
X26:12 013 13 Stecker Klimasteuerun connector climacontrol
X26:13 013 13 Stecker Klimasteuerun connector climacontrol
X26:14 013 13 Stecker Klimasteuerun connector climacontrol
X27:1 013 14 Stecker Klimasteuerun connector climacontrol
X27:2 013 14 Stecker Klimasteuerun connector climacontrol
X27:3 013 15 Stecker Klimasteuerun connector climacontrol
X27:4 013 15 Stecker Klimasteuerun connector climacontrol
X28:1 011 6 Stecker Radsensor connector wheel sensor
X28:2 011 6 Stecker Radsensor connector wheel sensor
X28:3 011 7 Stecker Radsensor connector wheel sensor
X28:4 011 7 Stecker Radsensor connector wheel sensor
X29:1 013 6 Stecker Zyklon Connector cyclone
X29:2 013 6 Stecker Zyklon Connector cyclone
X30:A 011 6 Verbindungsstecker Se connector sensor
X30:B 011 6 Verbindungsstecker Se connector sensor
X30:C 011 7 Verbindungsstecker Se connector sensor
X31:A 011 11 Verbindungsstecker An connector gauge
X31:B 011 9 Verbindungsstecker An connector gauge
X31:C 011 10 Verbindungsstecker An connector gauge
X33:1 011 4 Schmieranlage lubrication system
X33:2 011 4 Schmieranlage lubrication system
component listing

X34:1 011 4 Schmieranlage lubrication system

X34:2 011 4 Schmieranlage lubrication system
Bauteilliste

X34:3 011 3 Schmieranlage lubrication system

X34:4 011 3 Schmieranlage lubrication system
X34:5 011 4 Schmieranlage lubrication system
X35:1 009 13 Stecker Warnsummer connector warning buzzer
X35:2 009 13 Stecker Warnsummer connector warning buzzer
X36:1 008 7 Stecker Poti connector potentiometer
X36:2 008 6 Stecker Poti connector potentiometer
X36:3 008 7 Stecker Poti connector potentiometer
X39:A 008 7 Stecker Deceleratorpe connector decelerator pedal
X39:B 008 6 Stecker Deceleratorpe connector decelerator pedal
X39:C 008 6 Stecker Deceleratorpe connector decelerator pedal
X40:1 008 8 Stecker Deceleratorpe connector decelerator pedal
X40:2 008 8 Stecker Deceleratorpe connector decelerator pedal
X40:3 008 9 Stecker Deceleratorpe connector decelerator pedal
X40:4 008 7 Stecker Deceleratorpe connector decelerator pedal
X40:5 008 8 Stecker Decelelratorp connector decelerator pedal
X40:6 008 7 Stecker Deceleratorpe connector decelerator pedal
X41:1 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:2 008 8 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:3 008 6 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:4 008 6 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:5 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:6 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:8 008 8 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:9 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:10 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:11 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:12 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X42:1 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:2 008 2 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:4 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:5 008 2 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:6 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X17.1:1 004 2 2ïpol SPT 2ïpole SPT
X17.1:2 004 2 2ïpol SPT 2ïpole SPT
X27.1:4 004 18 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:6 004 19 Motor / 42ïpol EPC engine / 42ïpole EPC
9

X27.1:7 004 19 Motor / 42ïpol EPC engine / 42ïpole EPC

X27.1:11 004 14 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:12 004 6 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:13 004 8 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:14 004 8 Motor / 42ïpol EPC engine / 42ïpole EPC
11

X27.1:15 004 9 Motor / 42ïpol EPC engine / 42ïpole EPC

X27.1:18 004 7 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:19 004 5 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:20 004 4 Motor / 42ïpol EPC engine / 42ïpole EPC
570 700 37

X27.1:21 004 10 Motor / 42ïpol EPC engine / 42ïpole EPC

X27.1:22 004 11 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:23 004 10 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:24 004 7 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:25 004 4 Motor / 42ïpol EPC engine / 42ïpole EPC
109

X27.1:26 004 5 Motor / 42ïpol EPC engine / 42ïpole EPC

X27.1:27 004 5 Motor / 42ïpol EPC engine / 42ïpole EPC
008 911 57
X27.1:28 004 11 Motor / 42ïpol EPC BOMAG
engine / 42ïpole EPC 867
 Name Bl. Pf. Benennung title TYP

20.3 X27.1:29
X27.1:30
X27.1:33
004
004
004
11
7
6
Motor / 42ïpol EPC
Motor / 42ïpol EPC
Motor / 42ïpol EPC
engine / 42ïpole EPC
engine / 42ïpole EPC
engine / 42ïpole EPC
Wiring diagram 570 700 37
X27.1:34 004 12 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:35 004 12 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:36 004 14 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:37 004 13 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:39 004 17 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:40 004 16 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:41 004 16 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:42 004 15 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.2:10 004 3 12ïpol EPC 12ïpole EPC
X27.2:11 004 3 12ïpol EPC 12ïpole EPC
XD2.1:2 004 4 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
Seis
28.08.2006
Werner
28.08.2006

XD2.1:3 004 4 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH

XD2.1:5 004 18 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:6 004 18 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:8 004 4 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:9 004 5 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:10 004 17 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:11 004 17 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:13 004 11 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:20 004 14 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:22 004 10 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:29 004 5 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:30 004 10 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:33 004 7 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:34 004 16 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:35 004 16 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:38 004 11 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:39 004 13 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:40 004 15 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:52 004 16 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:53 004 15 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:54 004 12 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:59 004 8 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:60 004 7 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:61 004 8 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:62 004 5 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:77 004 6 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:78 004 7 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:79 004 6 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:89 004 17 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
component listing

XD2.2:3 004 4 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH

XD2.2:4 004 19 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
Bauteilliste

XD2.2:5 004 19 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH

XD2.2:7 004 5 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:8 004 4 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:9 004 8 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:10 004 8 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:15 004 7 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:18 004 6 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:19 004 9 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:23 004 10 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:24 004 5 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:25 004 11 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:26 004 7 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:27 004 5 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:28 004 4 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:32 004 6 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:33 004 11 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:34 004 10 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:35 004 7 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:36 004 11 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.3:3 004 15 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:4 004 12 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:6 004 13 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:7 004 14 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:8 004 18 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:12 004 14 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:13 004 12 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:14 004 16 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:15 004 16 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:16 004 17 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH

Y02 004 19 Magnetventil Flammgluehanlage Solenoid valve, glow plug system 18W
Y03 008 14 Magnetventil Fahrstufenumschaltung Solenoid valve, speed range selector
Y04 008 10 Magnetventil Bremse Solenoid valve, brake 1,25A
Y14 012 3 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 013 16 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 1,75A
Y16 007 10 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 1,08A
Y16 007 12 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 1,08A
10

Y17 007 6 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 1,08A
Y17 007 8 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 1,08A
Y92 010 6 Magnetventil Lenkung vorne rechts Solenoid valve, steering, front rh. max. 1,1A
Y93 010 7 Magnetventil Lenkung vorne links Solenoid valve, steering, front lh. max. 1,1A
Y102 010 11 Magnetventil Schwimmstellung So.valve, floating position max. 1,08A
11

Y102 010 12 Magnetventil Schwimmstellung So.valve, floating position max. 1,08A

Y108 010 8 Magnetventil Schaufel Heben solenoid valve, lifting shovel max. 1,1A
Y109 010 9 Magnetventil Schaufel Senken solenoid valve, let down shovel max. 1,1A
Y110 010 19 Magnetventil Schaufel oeffnen solenoid valve, open shovel max. 1,1A
570 700 37

Y111 010 18 Magnetventil Schaufel Schließen solenoid valve, close shovel max. 1,1A
Y132 007 14 Magnetventil Radmotor vorn links Solenoid valve, wheel motor front lh. max. 0,6A
Y133 007 16 Magnetventil Radmotor vorn rechts Solenoid valve, wheel motor front rh. max. 0,6A
Y134 007 17 Magnetventil Radmotor hinten links Solenoid valve, wheel motor rear lh. max. 0,6A
Y135 007 19 Magnetventil Radmotor hinten rechts Solenoid valve, wheel motor rear rh. max. 0,6A
110

Y138 013 13 Magnetveentil Heizung Solenoid valve, heating unit 0,42A

Y147 004 12 Injektor A1 jet pump A1
868 Y148 004 14 Injektor A2 BOMAG
jet pump A2 008 911 57
 Name Bl. Pf. Benennung title TYP
Y149

Y151
004
Wiring diagram 570 700 37
Y150 004
004
13
17
16
Injektor A3
Injektor B1
Injektor B2
jet pump A3
jet pump B1
jet pump B2
20.3
Y152 004 16 Injektor B3 jet pump B3
Y166 004 14 Injektor A4 jet pump A4
Y167 004 18 Injektor B4 jet pump B4
Seis
28.08.2006
Werner
28.08.2006
component listing
Bauteilliste
11
11
570 700 37
111

008 911 57 BOMAG 869

 008 911 57 BOMAG 870
404

402
408

394
400
403
405
406
407
409
414

392
398

393
395
396
397
399
412

401
410
413
415

391
411

K77 K77
H07

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
057 513 10

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
057 664 11 057 664 11
057 564 17

057 564 37
057 564 22 057 564 30
057 564 23
1x6qmm
1x6qmm

Seis

153 131 1x6qmm

Versorgung Kabine 1
Werner

154 132
155 133 1x6qmm Versorgung Kabine 1x6qmm
2
10.07.2006
28.08.2006

156 134
K11

157 135 1x6qmm Masse Kabine 3

158 136
057 543 08

1x6qmm Masse Kabine 4

159 137
160 138 Masse Schutzbelüftung 5
161 139
057 564 29

162 140 6
163 141
164 142 7
165 143
1x2,5qmm
1x4qmm

1x6qmm
1x6qmm

166 144 8
057 564 35

167 145 9
K05

168 146
15A
169 147 Klimatronik Konvekta 1x1,5qmm F50 20
170 148 Zigarettenanzünder + 30A
171 149 1x1,5qmm F89 21
Tachograph / BC 672 EB
057 564 19
K22

172 150 Schutzbelüftung 22

173 151
30A
174 152 Zündschloß 1x6qmm 1x6qmm
F13 23
187 181 25A
188 182 EDC7 Steuerung (30) 2x2,5qmm F93 24
189 183 30A
Steckdose 1x2,5qmm F05 25
190 184
10A
191 185 Prozessor Steuerung 1x2,5qmm 1x2,5qmm
F84 26
192 186
K113 K13

30A
206 201 Leistung Steuerung 5x0,75qmm F67 27 1x4qmm
207 202
Schutzbelüftung
208 203 28
209 204 15A
Instrumente 1x1,5qmm
K90

F24 29
210 205
Schmieranlage + 10A
226 221 1x1,5qmm F16 30
Tachograph / BC 672 EB
227 222 15A
Fahrersitz 1x1,5qmm F29 31 1x2,5qmm
228 223
K48

10A
229 224 EDC7 Steuerung (15) 1x1,5qmm F122 32
230 225
K11

10A
235 231 Zykon Abscheider 1x1,5qmm F31 33 1x2,5qmm
236 232 15A
K61

Signalhörner 1x1,5qmm F23 34

237 233
238 234 10A
Fahren und Bremse 1x1,5qmm F25 35
257 241 10A
258 242 Klimatronik Konvekta 1x1,5qmm F33
057 268 42

36
K62

259 243
260 244 37
261 245 45 41
262 246 45 41
K133

263 247 46 42
264 248 46 42

eïbox
265 249 47 43
057 564 25

266 250 47 43
057 564 36

Schaltkasten
057 564 21

267 251 48 44
057 543 12

1 2 1 2 1 2 1 2
1 2 1 2 1 2 1 2

268 252 48 44
057 564 38

269 253 61
270 254
K15

62
271 255
057 500 57

63
057 664 96

272 256 64
K146

300 291 65
301 292 66
302 292
293 67
K60

303 294 68
304 295 69
305 296 70
306 297 71
307 298 72

057 565 39
308 299 84 81
343 321 85 82

057 565 36
057 668 71

344 322 86 83
057 564 24

345 323 92 87
346 324 93 88
347 325 94 89
348 326 95 90
349 327 96 91
057 564 26

350 328 104 101

057 565 40
351 329 105 102

057 565 38
352 330 106 103
353 331 115 107
354 332 116 108
355 333 117 109
356 334 118 110
X2:AïV

357 335 119 111

358 336 119 111
057 555 96

359 337 120 112

360 338 121 113
361 339 122 114

057 565 37
362 340 125 123
363 341 126 124

057 565 35
364 342
129 127
data interface

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S/N Wiring diagram 570 700 42

S/N 101 570 571 026 ⇔ 101 570 571 ... BC772 RS-2
S/N 101 570 581 075 ⇔ 101 570 581 ... BC772 RB-2
S/N 101 570 591 019 ⇔ 101 570 591 ... BC672 RB-2
S/N 101 570 821 026 ⇔ 101 570 821 ... BC972 RB-2
S/N 101 570 831 041 ⇔ 101 570 831 ... BC1172 RB-2

904 BOMAG 008 911 57

Inhaltsverzeichnis: BC 772...1172 RB / TIER III

008 911 57
table of contents:
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing ï no.
001 570 700 42 Stromlaufplan Circuit Diagram
002 570 700 42 Versorgung, Zigarettenanzünder supply, cigarette lighter
003 570 700 42 Zündschloß, Starter ignition switch, starter
004 570 700 42 DEUTZ Steuergerät EDC 7 f. 6ï und 8ïZylindermot. DEUTZ controller EDC 7 for 6ï and 8ïzylinder engine
005 570 700 42 Instrumente indicators
Wiring diagram 570 700 42

006 570 700 42 Anzeigen, Störmeldungen monitoring, failure indication

007 570 700 42 Fahrpumpen, Radmotoren, Startfreigabe driving pumps, weehl motors, starting release
008 570 700 42 Fahrstufen, Bremse, Verzögerungspedal speed ranges, brakes, decelerator device
009 570 700 42 Versorgung Steuerung, Warnsummer, Override supply controllers, warning buzzers, override
010 570 700 42 Lenkung und Arbeitshydraulik steering and working hydraulic system
011 570 700 42 Hupe, Schmieranlage, Tachograph, Sitzfunktionen horn, lubrication systhem, tachograph, seat funktions
012 570 700 42 Heizung und Belüftung heating and ventilation
013 570 700 42 Schutzbelüftung, Zyklon Abscheider, Klimatronik protected vent. system, cyclone separator, air cond.
014 570 700 42 Kabine und Anbauteile cabin and attachmentïparts
101 570 700 42 Bauteilliste component listing
201 570 700 42 Schaltkasten eïbox

BOMAG
301 570 700 42 Lokalisierungsgrafik Steckverbinder Draufsicht localization graphic connectors top view

06.08.2007
001 001
Werner Stromlaufplan 570 700 42
06.08.2007
20.5

905
circuit diagram 001
Seis
906
Zuleitung Steuerung Pin 54 30/54S 9:2
Zuleitung Steuerung Pin 56ï60 30/56ï60S
9:2

2,5qmm
Kabine K30
14:2
20.5

4qmm
geschaltetes "15/54"

2x6qmm
Batteriespannung 30 3:1

6qmm
15/54 X1:6
Zündschloß "15/54" 3:1

6qmm
6qmm
X1:23E X1:391/1 X1:21E X1:25E
Einspeisepunkt für Versorgung
Sicherungespotential 30! 30 30
1 K61 6E 5E
F89 F05 K11
V01 2:8 30A 30A
2 6A 5A 3:14
87
87 87a
X1:391/2 X1:21A
X1:25A
1,5qmm
2x4qmm

Einspeisepunkte für Versorgung

2,5qmm
4qmm
2x6qmm
6qmm
6qmm
Sicherungespotential K11:87!
X1:241 X1:242
X1:31E
X1:33E

0,11A
0,075A
X1:241
11:7
1 86 K61:87a 5:9 F24 K11:87 5:1
5:1
R10
1 220_O
K61 X1:298
F00 250A

057 665 63
2 2,5qmm X1:32E
2 85 X1:243
1x25qmm F122
10A
Anlassehauptleitung: 2x70qmm B+ 3:1 D+ 6:2
Ladeleitung 2x 10qmm oder 1x25qmm X1:32A
X1:81 1
X1:259

BOMAG
+ E21
X1:202
9:13
8:10

G01 2
11 21 31 41 51 61
ï S01
Batterie X14:6

0,075A
5A
Bei Steckdosenbetrieb je nach Stecker bis 16A möglich!
battery
max. 10A

12 22 32 42 52 62
B+ D+
+ 86 E20 1 2 X1:260 NotïAus Schalter
28V/80A + emergancy shut off
G03 G02 K62 XS
ï 24V 30
ï
85 K22 9:6
Bï W
87a 87
X2:N X2:J EMR
S30 3 X14:7 4:15
W XSï
Trennschalter 5:11 4:18
switch battery disconnect
4
X1:70 X1:256
31 31 3:1

2:10 13:10
Zigarettenanzünder Steckdose
cigarette lighter socket

06.08.2007
1 1

008 911 57
Wiring diagram 570 700 42

Werner Versorgung, Zigarettenanzünder 570 700 42

06.08.2007
Seis supply, cigarette lighter 002
 2:15 30 30 4:1
2:11 15/54
6qmm
2:6 B+ B+ 4:1 X1:23E
Anlasserhauptleitung 2x70qmm F13
30A

008 911 57
X1:23A

6qmm

Zündstartschalter
012 30 ignition switch
S00
01

50a 15/54

4qmm
1,5qmm

X1:293
Wiring diagram 570 700 42

X1:302

X1:8 X1:9

30
K05
7:2
87 87a

X1:7

BOMAG
2,5qmm
X14:9 X1:371
0,2A

0,2A

86 86
30 50 2 K11 K32
M01
M V47
85 85
ï 1

X1:256 X1:70

2:20 31 31 4:1

2:17 14:6

Starter
starter
Anzugswicklung KHD = 73A
Haltewicklung KHD = 12A

06.08.2007
1 1 570 700 42
Werner Zündschloß, Starter
06.08.2007
20.5

907
Seis ignition switch, starter 003
908
30 30
3:20 13:1
B+ Pedal
3:5 X1:24E 6:7
XSï
B124 2:19
20.5

1 + 1 elektronisches Fußpdal Diagnosestecker

F48 F93 elektronic foot pedal diagnosis
86 86 86 X22
80A 25A K15 K146 K60
2 F78
ï 2 S119 H04 1 H70 1
13
X1:24A S118

X4:A
X4:H
X4:G
X4:M
X4:F
X4:K
X4:B
2 2 Fehlertaster Motor
85 85 85
4qmm B46

4qmm
4qmm
14 failure push button engine

Williams Codierung
sw rt ws or gn bl

X1:92
X1:93
X1:94
1
R24

X1:62
X1:64
X1:65
X1:71
2 X1:255

X10:B
X10:C
X10:A
X12:A
X12:C
X12:B
X6:1 X1:250
X6:2 X1:244
X6:3 X1:270
X6:4 X1:269
10 kOhm
2 3 1 EMR
RPM 2:19
9:2
Option
option

X6:5
X6:6
X6:7
X6:8
X6:9
X6:10

X1:231
X1:232
X1:233
5V EDC 8:2
Handgas
8:2
4x2,5qmm Dachkurve AGND EDC "31" 4x2,5qmm
8:2

Sensor Wasserabscheider
sender water separator
"30"
Fehler EMR
Vers. Meldeleuchte
Glühen
Temperatur
Motoröldruck
"15"
CAN 1H
CAN 1L
CAN 2H
CAN 2L
ISO KïLinie

S2 S1

Fehler Motor
failure engine
Wasserabsch.
water separator

X1:235
X1:236
X1:237

XD2.1:3
XD2.1:9
XD2.1:6
XD2.1:5

XD2.1:2
XD2.1:8
XD2.1:11

XD2.1:61
XD2.1:13
XD2.1:10

XD2.1:79
XD2.1:77
XD2.1:33
XD2.1:60
XD2.1:59
XD2.1:30
XD2.1:39
XD2.1:53
XD2.1:35

XD2.1:62
XD2.1:29
XD2.1:78
XD2.1:38
XD2.1:20
XD2.1:52
XD2.1:89

XD2.1:22
XD2.1:54
XD2.1:40
XD2.1:34

X27.2:11
X27.2:10
A48 EDC7 Steuerung
4qmm

X17.1:1
X17.1:2
X1:5

XD2.2:28
XD2.2:8
XD2.2:3
XD2.2:7
XD2.2:24
XD2.2:27
XD2.2:32
XD2.2:18
XD2.2:35
XD2.2:26
XD2.2:15
XD2.2:9
XD2.2:10
XD2.2:19
XD2.2:23
XD2.2:34
XD2.2:33
XD2.2:36
XD2.2:25
XD2.3:4
XD2.3:13
XD2.3:6
XD2.3:12
XD2.3:7
XD2.3:3
XD2.3:15
XD2.3:14
XD2.3:16
XD2.3:8
XD2.2:4
XD2.2:5
X1:299

BOMAG
50i
K14 K2
4:4

X27.1:25
X27.1:20
X27.1:19
X27.1:27
X27.1:26
X27.1:33
X27.1:12
X27.1:18
X27.1:24
X27.1:30
X27.1:14
X27.1:13
X27.1:15
X27.1:21
X27.1:23
X27.1:22
X27.1:29
X27.1:28
X27.1:34
X27.1:35
X27.1:37
X27.1:36
X27.1:11
X27.1:42
X27.1:40
X27.1:41
X27.1:39
X27.1:4
X27.1:6
X27.1:7

30

ï ï ï ï Y02 2
4qmm 4qmm Y149 Y166 Y151 Y167
3 2 1 2 1 2 1 1 2 3 1 2 3 4 3 2 1 + + + + Y2 1
1 1 85 Y147 ï ï Y152 ï ï
R02 R02 K2 K14 Y148 Y150
R3.1 R3.2
2 2 50 + + + +
B88 B126 B113 B114 B130 B133
B6 B37 B43 B40.1 B40.2 B48 Y15.1 Y15.3 Y15.5 Y15.7 Y15.2 Y15.4 Y15.6 Y15.8

3:20 31 31 5:1

4:2 6:2 6:2 6:3 Injektor B3

jet pump B3
Glühkerze 1 Kraftstofftemperatur Motordrehzahlsensor1 Mag.vent. Flammglühanlage
glow plug 1 fuel temperature sender engine rpm 1 Injektor B2 solenoid valve glow plug system
jet pump B2
Glühkerze 2 EMR Motoröldruck Motordrehzahlsensor 2 Injektor A1 Injektor A3 Injektor A4 Injektor B1
glow plug 2 EMR engine oil pressure sender engine rpm 2
jet pump A1 jet pump A3 jet pump A4 jet pump B1
Kühlmitteltempratur Sensor Ladeluftdruck / Temperatur Injektor A2 Injektor B4
coolant temperature sensor charging air pressure / temperature jet pump A2 jet pump B4

06.08.2007
1 1

008 911 57
Wiring diagram 570 700 42

Werner DEUTZ Steuergerät EDC 7 f. 6ï und 8ïZylindermot. 570 700 42

06.08.2007
Seis 066_9 DEUTZ controller EDC 7 for 6ï and 8ïzylinder engine 004
 2:20 K11:87 K11:87 9:1

X1:29E

F24
15A

008 911 57
X1:29A
2:13 F24 F24 6:1
2:11 K61:87a K61:87a 6:7
X1:294 X1:295 X1:298

5 1 4 3 5 1
Wiring diagram 570 700 42

P00 +
E02 P14 + E22 P02 + E03 P03 + E01 P01 + E46 P12 +
1 1 1 1 1

_t _t n Q
2 2 2 2 2
ï G ï G ï G ï ï G ï

Modul 1
module 1
Modul 2
module 2
Modul 3
module 3
3 2 4 1 5 3 4

BOMAG
X1:300 X1:303 X1:301 X1:296
X1:291 X1:148 X1:292 X1:228

X14:8

X5:1

1 2
B53 1 1
R04 R03

2 2
X1:299 W X1:229
2:8
31 31
4:20 6:1

Kühlmitteltemperatur Motordrehzahl Tankanzeige

collant temperature trancducer, motor speed level gauge

Hydrauliköltemperatur Betriebsstundenzähler Voltmeter

hydraulic oil temperature engine hour meter volt meter

06.08.2007
1 1 570 700 42
Werner Instrumente
06.08.2007
20.5

909
Seis indicators 005
 910
F24 F24
5:20 9:1
D+ ESX 9:15 Abschmieren
2:9 11:2
Lüfter 1.GANG
12:14 30 30 9:7
20.5

K133 K48 2.GANG 9:7

9:9 7:3
87 87a 87 87a
X1:101 X1:104
X1:89 X1:84 X1:90 X1:91 X1:123

X1:125
X1:126

X1:124

rt
rt
ws/vi
br/rt
br
br/sw
sw
vi

vi
ws/bl
br/or
br
ws/vi
or X1:102 X1:105 or
1 2 0/3a 4 8 A15 A15 16 11 17 18 9

6 3 7 5 20 19 14 15 12 13 10

bl
bl
gr

sw
br/or

ws/rt

ws/gr
ws/br
ws/br
ws/gr

ws/gn
ws/gn

X1:106

X1:115
X1:119

X1:118
X1:121

X1:120
X1:122

X1:87 X1:88 X1:85 X1:86

X1:392/2 V02 2 1 X1:392/1 X1:397/1 1 2 V07 X1:397/2
X0:18 X0:45
Fehler
X1:394/2 V04 2 1 X1:394/1 X1:398/1 1 2 V08 X1:398/2
X1:109 X1:117

X0:52 X0:50 X1:108 X1:116

Fehler
X1:393/2 V03 2 1 X1:393/1 X1:399/1 1 2 V09 X1:399/2

20s
Fehler
X0:19 X0:13
X1:111

X1:395/2 V05 2 1 X1:395/1 X1:400/1 1 2 V10 X1:400/2

Steuerung
Gaspedal
X0:11 X0:10
Pedal X1:401/1 1 2 V11 X1:401/2
X1:112

X1:82 X1:83 4:19 X0:6 Fehler

D+
X1:403/1 1 2 V13 X1:403/2
X1:113

X1:114

X0:36 X0:51

ESX
X14:10 X1:210

BOMAG
5:20 K61:87a K61:87a 14:11
15

20s
20s
2min
K113

31

Kühlmitteltemperatur
collant temperature
Motoröldruck
engine oil pressure
Kühlmittelfüllstand
coolant tank
Luftfilter rechts
air cleaner rh.
Luftfilter links
air cleaner lh.
120s anzugsverzögert
120s switch on delay
K15 30 K60 30
4:12 4:14
X1:110
87a 87 87a 87 Verteilergetriebe
power takeïoff gear
Hydrauliköl min.
hydraulic oil min.
Hydrauliköltemp.
hydraulic oil temp.
Diff.ïdrucksch.
pressure. diff.
Diff.ïdrucksch.
pressure. diff.
Diff.ïdrucksch.
pressure. diff.
Diff.ïdrucksch.
pressure diff.
Diff.ïdrucksch.
pressure diff.
Bremsdruck
brake pressure
Verschmutzungssensor
contamination sensor

X1:103
30 30
3 3 3 3 1 1 3 K113 2 2 2 2 2 1 +
K146 B55 B03 B116 B129 B24 B20 B121 B122 B22 B21 B42 B05
4:13 6:11 B19
Q P P B25 P P Q P
87a 87 4 4 4 4 2 2 4 87 87a 1 1 1 1 1 2 ï

X14:11

X1:181
X1:182
X1:182
X1:191
X1:191

X1:181

X1:183
X1:187
X1:185
X1:186
X1:183

31
X1:184
X1:184

X1:205

5:20 31 7:1
Speisepumpe Speisepumpe Zwischengetr.
6:14
Speisepumpe Speisepumpe

Rücklauffilter nur BC 972 RB

return flow filter only acc. to BC 972 RB

Modul 1: Motorfunktionen Modul 2: Maschinenfunktionen

module 1: engine functions module 2: maschine functions

06.08.2007
1 1

008 911 57
Wiring diagram 570 700 42

Werner Anzeigen, Störmeldungen 570 700 42

06.08.2007
Seis monitoring, failure indication 006
 DEC 1 8:4
X1:338 X1:262 S04:12 8:10
X1:335 2 1
X1:46/2 X1:46/1
X9:4 X9:1 FM6

008 911 57
1
R32 X1:42/1
1k
2

1 1
R33 1 R34 R35 1 FM2
2k 1k 3k3 2
2 2 2

Fahrtrichtungsschalter nicht belegt X1:42/2

switch, travel direction V0R 33 13 24 44 not used
S31 X1:336
34 14 23 43
Wiring diagram 570 700 42

X9:5 X9:6 X9:3 X9:2

X1:339
X1:340 X1:337

Richtung
AGND
8,5V
Ain

X1:412/1 X1:413/1

X0:1
13 9

X0:32
X0:23
X0:29

1 1
V23 V25 K77 K77 ESX Steuerung
9:17 9:17
2 2 14 10

X0:22
X0:21
X0:46
X0:47
X0:48
X0:43

X1:412/2 X1:413/2

BOMAG
Vorwärts

Rückwärts
vorne Links
hinten Links

vorne rechts
hinten rechts

br nicht bei
X1:221 X1:223 X1:135 X1:157
V38 BC 672ï772
not used for
rt BC 672ï772

X1:149 X1:153 X1:131 X1:133 X1:155

200 ... 600mA
200 ... 600mA
200 ... 600mA
200 ... 600mA

86 86 H14
K05 K48 + 1 1 1 1 1 1 1 1
V34 Y17 V35 Y17 V32 Y16 V33 Y16 Y132 Y133 Y134 Y135
ï
85 85 2 2 2 2 2 2 2 2

1,08A
1,08A
1,08A
1,08A

X1:70 X1:70 X1:188

X1:222 X1:224 X1:136 X1:158
31 X1:154 X1:132 X1:134 X1:156
6:20 31 8:1
TandemïPumpe TandemïPumpe TandemïPumpe TandemïPumpe
3:9 6:14 rechts 2 rechts 4 links 1 links 3 Prop. Ventil Rad vorne li. Prop. Ventil Rad hinten re.
prop. valve weehl front lh. prop. valve weehl rear rh.
stromlos = qmax stromlos = qmax
Prop. Ventil Rad vorne re.
Ventile Fahrpumpe rückwärts Ventile Fahrpumpe vorwärts prop. valve weehl front rh.
solenoid valves, travel direction backw. solenoid valves, travel direction forw.
stromlos = qmax
Warnsummer Rückwärtsfahrt stromlos = Rückwärtsfahrt nicht aktiv stromlos = Vorwärtsfahrt nicht aktiv
buzzer, back up alarm strom = Rückwärtsfahrt aktiv strom = Vorwärtsfahrt aktiv
Prop. Ventil Rad hinten li.
prop. valve weehl rear lh.
stromlos = qmax

06.08.2007
1 1 570 700 42
Werner Fahrpumpen, Radmotoren, Startfreigabe
06.08.2007
20.5

911
Seis driving pumps, weehl motors, starting release 1 007
912
F25 9:1

X1:343 X1:261
20.5

31 X1:358
S01
2:17
Aktivierung Verzögerungspedal X1:357
32
enable decelerator pedal 7:19 S04:12 X1:41/2
X1:262 23
S02
12 123
S160 0 1 43 23 Bremsschalter 1 S02 Schalter Fahrstufen
S04 brake switch FM1 switch speed ranges
01
2 24
11 Komplett 872 701 02
44 24
X1:41/1
Verzögerungspedal

X40:6
X40:2
X13:3
5V EDC DEC 1
X13:1
X13:2

4:8 7:19 decelerator pedal R20 R21 R22 R23

1 k_O 1 k_O 1 k_O 1 k_O
Nur für BC 671ï771 RB/RS
only acc. to BC 671ï771 RB/RS

bl gr
KD1 KD2
S161

ws
sw
rt
ge
gn
vi
or
bei Option
Schalter Fahrstufen
switch speed ranges

X3:B
acc.to option
X40:3

decelerator pedal

Verbindung entfällt
connection not applied

X40:1
Fahrtverzögerungspedal
X1:359
X1:263

X42:5
X42:6
X41:11
X41:6
X41:4 X39:B
X41:3 X39:C
X41:5 X39:A
X41:1 X40:4
X41:2 X40:5
S04:11
8:11
Zusatzelektronik
A78

Bremse
high=Bremse auf
8,5V
AGND
Fahrstufen
additional electronic

X41:9

X42:1
X41:8

X42:2
X42:4
X41:10

X41:12
X0:1
X0:7

BOMAG
X0:23

X0:40
ESX Steuerung
X36:1
X0:62

X0:61
1

X3:C
R43

X3:A
499 _O
2
Handgas 5 k_O K77
4:8 8 7 S04:11

Bremse
AGND EDC X36:2 S120
4:8 9:17 8:10 X1:170
1./2. Fahrstufe

1 X1:151
R44

1,25A
1,25A

499 _O
1 2 Y04 1 Y03 1
H81 X36:3 V31 V37
2 2 2

X1:234
Nur für BC 671ï771 RB/RS
only acc. to BC 671ï771 RB/RS

31 X1:152 X1:192
7:20 31 9:1

Meldeleuchte Verzögerungsfunktion Magnetventil Bremse Stufenumschaltung

indicator light decelerator device solenoid valve brake Speed range selection
stromlos = Brmse zu
Handgas
strom = Bremse auf
hand throttle
Nur für Option Verzögerungspedal
only acc. to option decelerator device

06.08.2007
1 1

008 911 57
Wiring diagram 570 700 42

Werner Fahrstufen, Bremse, Verzögerungspedal 570 700 42

06.08.2007
Seis speed ranges, brakes, decelerator device 1 008
 K11:87 K11:87 11:1
5:20

X1:35E

F25
10A

008 911 57
X1:35A
F25 F25 10:1
8:20
2:19 30/54S 2,5qmm 6:6 ESX

2:19 30/56ï60S 4qmm

X1:26E
F24
6:20 X1:27E
RPM F84
4:8
10A

F67
30A X1:26A
30
K90
X1:27A
X1:257 9:4

2,5qmm
Elektronik
87 87a
Wiring diagram 570 700 42

21

X1:66
X2:H
X1:67
X2:G
S01

X2:U

5x0,75qmm
Leistung
2:17
22
X1:349
X1:349
X1:349

X1:258 X1:404/2 X1:405/2

X1:207
+UE/Dios
+UB/Dios
+UB/Dios

Drehzahl
CAN2ï
CAN2+
RxD
TxD
+ + + + + +

1x0,75qmm
2 2
V14 V15
1 1

X0:5
X0/1:3
X0/1:9

X0:4

X0:16
X0/1:10

X0:56
X0:57
X0:59
X0:60
X0:33
X0:53

X0:58

X0:28
X0:54
ESX Steuerung X1:404/1 X1:405/1 ESX Dios Modul

X0:2
X0:24
X0:25
X0:3
X0:44
1. Gang 2. Gang Summer
X0/1:11
X0/1:4

BOMAG
6:19 1.GANG
2.GANG
6:19
GND/Dios

X1:402/1 X1:410/1 X1:411/1 1

Relais Override
Motorabstellung
V42
Gehäuse Dios Modul

1 1 1 2
V12 V21 V22
2 2 2 KLIMA
GND für Knotenaddresse Dios

X1:402/2 X1:410/2 X1:411/2

X35:1
K90 86 K22 86 86 + K77/1 86 K77 86
H07
0,7A

K133
X1:185
X1:186

X1:184

ï
85 85 85 X35:2 85 85

0,075
0,075
0,075
0,021A
0,021A

31 X1:70 X1:70 X1:70 X1:70 X1:70 X1:70

8:20 31 10:1

9:17 2:17 6:10

10:5 8:11
10:5 7:6
Lampentest Warnsummer
warning buzzer 10:5 7:5

10:5

06.08.2007
1 1 570 700 42
Werner Versorgung Steuerung, Warnsummer, Override
06.08.2007
20.5

913
Seis supply controllers, warning buzzers, override 1 009
914
F25 X15:A
9:20
X1:349
Schild/Schaufel 1=senken / 2=heben 3=schließen / 4=öffnen
blade/shovel 1=let down / 2=lift 3=close / 4=open
1=Links /2=Rechts 1
20.5
BR/BN

1=left /2=right Achse 3/4 mit Kontakten

BR/BN
BR/BN
1 1 B169 B170 1 1 3 3
S70 4 10ï15 nur bei Schaufel
axle 3/4 with contacts B08
S71 1 2 2 LI RE 3 2 4
2 2 4 10ï15 only acc. to shovel X15:B

BL/BU

BL/BU
WS/WHT
WS/WHT
JoyïStick
2
sieht Metall wenn Lehne unten

joyïstick X1:363
Initiator Armlehne

3 2 5 4 7 6 1 3 2 5 4 6 7 1 14 13 12 15 11 10 16 8 9
SW/BK
BL/BU

X2:A X2:B

X2:V

X1:346
X1:345
X1:344
X1:347
X1:348
X1:343
X1:321
X1:325
X1:326
X1:324
X1:323
X1:322
X1:330
X1:329
X1:328
X1:331
X1:332
X1:327
X1:352
X1:351
X1:350
X1:353
X1:354
X1:334
X1:333
CAN Bus LED display

Sensoren Lenkanschlag
sens. steering stop limit
CAN bus LED display X1:63

X1:44/2 X1:45/2 X1:47/2 + P18 ï X1:61

2 X1:43/2 2 2
FM4 2 FM5 FM7 X1:68
1 FM3 1 1
1 057 664 08

X1:44/1 X1:43/1 X1:45/1 X1:47/1 X1:69

AGND F1 F2
8,5V

lenken
CAN+ X1:364

CANï

links
rechts
lenken
AGND
8,5V
heben/
senken
senken
heben
auf/zu
schließen
öffnen
Schwim.
Lehne

links
rechts
X0:1
X0/1:1

X0:9

X0:8
X0/1:2

X0:15
X0:31
X0:17
X0:12

X0:14
X0:41

X0:39
X0:30
X0:35
X0:37

X0:38
X0:23
X0:27
X0:26

X0:34

ESX Steuerung ESX Dios Modul

BOMAG
X0:64
X0:49
X0:20
X0:42
X0:63
X0:65
X0:66
X0:67
X0:68
X0:55
X0/1:5
X0/1:6

9:15
ï
ï
ï
ï
ï

20 19 2 R36 1 Gehäuse
housing

heben
K77/1 47_O 390 mA

senken

lenken li

lenken re.

X1:406/2
Schwimmst.
9:15
öffnen/Dios

0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA
0 ... 1000 mA

14 13 2 R38 1
schließen/Dios

K77/1 47_O 390 mA

X1:407/2
9:15 R40
10 9 2 1
K77/1 47_O 390 mA
X1:141 X1:143

X1:408/2
9:15 R42 X1:137 X1:139
8 7 2 1 X1:159 X1:161 X1:163 X1:165

X1:409/2
X1:308 K77/1 47_O 390 mA Y92 1 Y93 1 Y108 1 Y109 1 Y102 1 Y102 1 Y111 1 Y110 1
2 2 2 2
1,08A
1,08A

2 2
2 2 2 2 2 2

V19
V16
V17

V18
X1:189
X1:181
X1:182
X1:183
X1:187
X1:188

1 1 1 1
X1:160 X1:162 X1:164 X1:166 X1:138 X1:140 X1:142 X1:144
31
9:20 31 11:1

Lenken rechts Schild senken

steering right let down blade

X1:409/1
X1:406/1
X1:407/1

X1:408/1
Lenken links Schwimmstellung Schaufel schließen
floating position close shovel
steering left
Schwimmstellung Schaufel öffnen
Schild heben
lift blade floating position open shovel

06.08.2007
1 1

008 911 57
Wiring diagram 570 700 42

Werner Lenkung und Arbeitshydraulik 570 700 42

06.08.2007
Seis steering and working hydraulic system 010
 9:20 K11:87 K11:87 13:1
Abschmieren
6:19
X1:30E X1:34E X1:31E

F16 F23 F29

008 911 57
10A 15A 15A

X1:172
X1:30A X1:34A X1:31A

X1:171 Zusatzanzeige Geschwindigkeit

additional speedometer X1:341 X1:245

3A
X31:A
X34:4 1 2 86 30 S25 23
4 (+) K13
LA 15 K13
E04 1 E04 1 11:14
M08
P09 85 87 87a 24
M 8 (S) 2 2
Wiring diagram 570 700 42

Zentralschmieranlage
central lubrication system 3 (ï) X1:246
Z 31 X31:B X31:C X1:355

X34:3 5

X33:1
X33:2
X11:1 X21:1
7,5A

+ sw
M10 R06
X30:A M
B7 A2 ge

X1:173
X1:174
K13:87 ï
2,5A

14:19
X1:248 X28:1 Versorgung über F89
X1:356 Signalhörner Kabine
X1:241 A1 A3
br sw
2:13
23 1

BOMAG
S27 B15 3
8 S29 23
X28:3 B3 A5 S03 2 ge
Taster Schmieranlage X30:C R06
4 P09 V46
switch, lubrication system 24 X28:4
B52 bl 2 ws
4 6 1 9 1 24 br
B4 A6
X1:272 X28:2
A16

Initiator Schmierkolben
proximity switch lubrication piston
Lieferumfang GRAMMER
delivery equipment GRAMMER

X30:B 7 8 9 2 X11:2 X21:2

Im Lenkjoystick
in steering joystick

X1:190 X1:191 X1:364 X1:256

X1:342
10:20 31 31 13:1

11:16

Sensor Radmotor HL Tachograph Sitz mit Kompressor und Schalter

sensor wheelmotor rear lh. tachograph Im Lenkjoystick drivers seat with compressor and switch
in steering joystick
Tachomodul Sitzheizung
tacho controller Taster Signalhorn heating, drivers seat
Option Tachograph push buttonwarning horn
option tachograph

06.08.2007
1 1 570 700 42
Werner Hupe, Schmieranlage, Tachograph, Sitzfunktionen
06.08.2007
20.5

915
Seis horn, lubrication systhem, tachograph, seat funktions 011
916
K32:30 K32:87
14:2 14:3
F41:4
14:8
20.5

F40 G F90 F F02 F

Box 2 Box 2 Box 1
10A
7 5A
6 10A
6

X1:374
X1:265
2,5 qmm

123 13 31 42 24
1 2 3 12 11 13 14 16
Stufenschalter Frischluft
switch, fresh air
S44
5 7 11 3 1 10 14 32 41 23

Regel aus = 0,2A S28 X1:266 X1:267 X1:268

E30 Kleine Stufe = 0,3A
mittleter Stufe = 0,5A
große Stufe = 1A 1 1
Power Stufe = 1,7A R26 R27
Heizung Anlaufstrom beim Start = 4,2A
22 Ohm
10 Ohm

Heating
Schaltuhr Heizung 2 6 8 9 4 12 2 2
heater timer Lüfter
6:6
X1:373
10 9 5 6 8 7 4 15
X1:377

BOMAG
X8:1

2,5 qmm
15/54
30
87a
in

X1:375
X1:226
A53 n
1
Y14
max. 0,75A

20s; n kleiner 1300 1/min

2 20s; rpm lower 1300 1/min
X1:227 8s; n=0 1/min
8s; rpm=0 1/min S +
X1:376
M17 M
ï

X8:2
ï
15/54

K31
14:1
Kraftstoffpumpe Überwachung Lüfter Frischluft Lüfter
fuel pump heating unit monitoring blower blower fresh air

06.08.2007
1 1

008 911 57
Wiring diagram 570 700 42

Werner Heizung und Belüftung 570 700 42

06.08.2007
Seis heating and ventilation 012
 30
4:19
F24
9:6 Raumtemperatursensor
K11:87 sensor ambient temperature
11:20
X1:36E
Ausblastemperatursensor
F33 sensor outlet temperature X1:20E

008 911 57
X1:28E X1:22E X1:33E
10A
F50
F123 F94 F31 15A
X1:36A
10A
B29 B118 X1:20A
X1:28A X1:22A X1:33A
30 + ï + ï
K62

wird durch D+ aktiviert

2:10 nicht belegt
87 87a not used X1:253 X1:383 X1:381
Versorgung für Schutzbelüftungsanlage

Bel.
X1:251 X1:249

X23:1
X24:1

X23:2
X24:2

15/54
D+
Absicherung und Verkabelung nach Angabe X25:B X25:A
Hersteller der Schutzbelüftungsanlage
supply for protected ventilation system ge rt
Lüftermodul
Wiring diagram 570 700 42

X26:6
X26:7
fuse and wiring acc. to supplier PWM +

X26:13
X26:12
X26:14
blower module

X26:1
X27:1

X26:3
X27:3
X26:5

X27:2
of protected ventilation system

X26:4
A65 Klimatronik X27:4 A53

ï M+ Mï

X26:2
X26:10
X26:11
X26:9
X26:8
br gn sw
X25:C
1

31
V43 X1:247

Ventil
2 X1:129
Kupplung

1
B117 _t Thermostat Vereisungsschutz
X22:1 X22:2 thermostat antiïicing device
X1:252 2
optional
X1:130 E37 +

BOMAG
optional X1:127 2
X1:146
X7:6 X18:1 VD V36
1
4 Druckschalter ï

3A
pressure switch
B75 P
LP 3 HP
X29:1 X19:1 X1:414/2
or X7:5 X18:2
+ Y138 1 2 X1:147
X1:201
M26 M V26 X14:4 X17:1
0,42A

2 1
sw ï 2 1
X1:414/1
X19:2
X1: X29:2 V48 Y15
1 2
X1:382
1,75A

X1:70 X1:272 X1:128

X1:205 X14:5 X17:2
11:20 31 31 14:1

Zyklon Abscheider Magnetventil Heizen Magnetkupplung Verdampferlüfter

cyclone separator solenid valve heating magnetic clutch blower evaporator

Zusatzausrüstung Klimatronik KONVEKTA

Option klimatronic KONVEKTA

06.08.2007
1 1 570 700 42
Werner Schutzbelüftung, Zyklon Abscheider, Klimatronik
06.08.2007
20.5

917
Seis protected vent. system, cyclone separator, air cond. 013
 918
K30 K13:87
2:19 2x6qmm
11:16
20.5

X1:2 X1:1

2x6qmm
12:9 K32:30

30
K32
3:16
87
K32:87
12:19
H A B X1:372 X1:372
F49 F27 F28
10A
Box 2 8 F66 H F85 D F42 E F41 D F99 G F86 E F125 B F98 C Box 1 1 Box 1 2
10A 10A
Box 1 8 Box 1 4 Box 2 5 Box 2 4 Box 1 7 Box 1 5 Box 2 2 Box 2 3
15A 20A 10A 10A 15A 15A 10A 10A

F41:4 Kamera
camera
12:9 + 123 3 2 1 012 7 2
F126 S22
P32 01
S16 3,75A
S53 1 1 2 S45 1 S38 1 S137 1 S26 1 ï 1

S128
01
S20 5 1 8 5 S21 5 4
4
5 3 4 5 5 5 5 5

X1:72
K61:87a rt
X1:145 15 J S 86
6:9 ge

1,5A
Impulsgeber

Spannungswandler
voltage transformer
X7:1 X7:2 sw A57 Interval switch
2,5A

+24 +12 3 4
E56 31 31b
24V E16 1 E23 1 E25 1 E29 1 1 1

BOMAG
A107

X1:378
B11

2,9A
2,9A
2,9A
0,6A
2,9A
12V
2 2 2 2 2 2

Rundumkennleuchte
rotary beacon
U01 ï E32
A12 15 53a 31b 53
2,5A

31b
53
53a

+ + B51 E17 1 R77 R77 R77 R77 + +

ï ï E24 1 E26 1 E29 1 + E57 1 P15 4 1
1 1 1 1

2,9A
M04 M M06 M M05 M M07 M B28

2,9A
2,9A
0,6A
2,9A
B51 31
2 2,9A 2 2 2 2
Radio 2 2 2 ï 2 31 ï 31 ï 2

X1:150
1,7A
1,7A
1,7A
1,7A
7,9A
2,5A
3,3A
2,5A

radio
K31
12:19 Scheinwerfer vorn X7:3 X7:4 Bildschirm Spiegelheizung Wischer vorn Wischer hinten Signalhorn
2x6qmm
head lights front monitor mirror heating wiper, front wiper, rear warning horn

X1:3 X1:4 Scheinwerfer links/rechts Innenleuchten 1 1 Wascherpumpe Wascherpumpe

head lights lh./rh. inside light, cabin E28 E27 washer pump washer pump
2,9A 2,9A

X1:189
X1:189
2 2

31 X1:190 X1:190 31
13:20

Scheinwerfer Motorraum
head lights, engine area

Arbeitsscheinwerfer hinten
working head lights, rear

06.08.2007
1 1

008 911 57
Wiring diagram 570 700 42

Werner Kabine und Anbauteile 570 700 42

06.08.2007
Seis cabin and attachmentïparts 014
 Name Bl. Pf. Benennung title TYP
A12

A15
014
Wiring diagram 570 700 42
A15 006
006
2
7
13
Radio
Ueberwachungsmodul
Ueberwachungsmodul
Radio
monitoring module
monitoring module
20.5
A16 011 9 Elektronik Tachograph Electronic system, tachograph
A48 004 9 Elektronische Motorsteuerung Electronic engine management
A53 012 14 Modul Luefterueberwachung Modul blower monitoring
A53 013 18 Modul Luefterueberwachung Modul blower monitoring
A57 014 14 Intervallschalter Scheibenwischer Interval switch, wiper
A65 013 14 Steuerung Klimatronik Controller klimatronic
A78 008 3 Zusatzelektronik Additional control unit
A107 014 11 Umschaltbox switch box

B03 006 4 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B05 006 18 Druckschalter Bremse Pressure switch, brake
Seis
06.08.2007
Werner
06.08.2007

B08 010 19 Naeherungsinitiator Fahrhebel ’0’ïStell. Proximity switch, travel lever ’0’ pos. max. 1,08A
B11 014 19 Signalhorn Warning horn 2,5A
B15 011 6 Aufnehmer Geschwindigkeit Transducer, speed
B19 006 19 Magnetsensor Verschmutzung Magnetic sensor, contamination
B20 006 13 Temperaturschalter Hydraulikoel Temperature switch, hydraulic oil
B21 006 17 Differenzdruckschalter Hydr.ïOelfilter Pressure diff. switch, hydr. oil filter
B22 006 16 Differenzdruckschalter Hydr.ïOelfilter Pressure diff. switch, hydr. oil filter
B24 006 12 Schwimmerschalter Hydraulikoel Float switch, hydraulic oil
B25 006 11 Druckschalter Ruecklauffilter Pressure switch, return flow filter
B28 014 20 Signalhorn Warning horn 2,5A
B29 013 14 Raumthermostat Room thermostat
B42 006 17 Differenzdruckschalter Hydraulikoel Hydraulic oil pressure differential switch
B51 014 2 Lautsprecher Radio Speaker radio
B51 014 3 Lautsprecher Radio Speaker radio
B52 011 4 Naeherungsinitiator Schmierkolben Proximity switch, lubrication piston
B53 005 6 Temperaturgeber Kuehlmittel Temperature switch, collant
B55 006 3 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B75 013 16 Kuehlmitteldruck coolant pressure
B88 004 5 Druckgeber Motoroel Sender, engine oil pressure
B113 004 7 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B114 004 8 EMR Aufnehmer, Motordrehzahl 1 EMR Trancducer, engine speed 1
B116 006 4 Unterdruckschalter Luftfilter Vacuum switch, air cleaner
B117 013 15 Thermostat Klimaanlage Thermostar, air conditioning
B118 013 15 Temperaturfühler Auslaß Temperature sender outlet
B121 006 15 Differenzdruckschalter Hydr.ïOelfilter Pressure diff. switch, hydr. oil filter
B122 006 15 Differenzdruckschalter Hydr.ïOelfilter Pressure diff. switch, hydr. oil filter
B124 004 3 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B126 004 6 EMR Temperaturgeber Kraftstoff EMR fuel temperature sender
B129 006 12 Druckschalter Verteilergetriebe pressure switch power takeïoff gear
component listing

B130 004 9 EMR Aufnehmer, Motordrehzahl 2 EMR Trancducer, engine speed 2

B133 004 11 Sensor Ladeluftdruck / ïtemperatur sesnor charging air prssure / temperature
Bauteilliste

B169 010 7 Näherungsinitiator Lenkzylinder links proximity switch steering cylinder left
B170 010 8 Näherungsinitiator Lenkzylinder rechts proximity switch steering cylinder right

E01 005 14 Beleuchtung Tankanzeige Illumination, level gauge

E02 005 5 Beleuchtung Temperaturanzeige Illumination, temperature gauge
E03 005 10 Beleuchtung Drehzahlmesser Illumination, rpm meter
E04 011 10 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer
E04 011 11 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer
E16 014 4 Scheinwerfer links Head light, lh. 55W
E17 014 4 Scheinwerfer rechts Head light, rh. 55W
E20 002 12 Zigarettenanzuender Cigarette lighter
E21 002 12 Beleuchtung Zigarettenanzuender Illumination, cigarette lighter
E22 005 7 Beleuchtung Temperaturanzeige Hydr.ïoel Illumination, temp. gauge, hydraulic oil
E23 014 5 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
E24 014 5 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
E25 014 6 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E26 014 6 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E27 014 11 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55W
E28 014 10 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55W
E29 014 7 Innenleuchte Kabine Inside light, cabin 15W
E29 014 8 Innenleuchte Kabine Inside light, cabin 15W
E30 012 3 Heizgeraet Heating unit
E32 014 8 Kennleuchte Warning light 70W
E37 013 18 Klimaverdampfer Air conditioning, evaporator
E46 005 15 Beleuchtung Voltmeter Illumination volt meter
E56 014 9 Scheinwerfer Motorraum rechts Head light, engine area rh. 55W
E57 014 9 Scheinwerfer Motorraum links Head light, engine area lh. 55W
ESX 006 9 Elektronisches Steuergeraet Electronic system, control unit
ESX 007 12 Elektronisches Steuergeraet Electronic system, control unit
ESX 008 10 Elektronisches Steuergeraet Electronic system, control unit
ESX 009 5 Elektronisches Steuergeraet Electronic system, control unit
ESX 009 18 Elektronisches Steuergeraet Electronic system, control unit
ESX 010 9 Elektronisches Steuergeraet Electronic system, control unit max. 1,08A
ESX 010 19 Elektronisches Steuergeraet Electronic system, control unit 0,2A

F00 002 2 Hauptsicherung Batterie Fuse, main, battery 250A

F02 012 12 Ersatzsicherung Fuse, spare 10A
1

F05 002 15 Sicherung Steckdose Fuse, socket 30A

F13 003 9 Sicherung Startschalter Fuse, starter switch 30A
F16 011 4 Sicherung Zentralschmieranlage Fuse, central lubrication system 10A
F23 011 14 Sicherung Signalhorn Fuse, warning horn 15A
F24 005 5 Sicherung Ueberwachungsmodul Fuse, monitoring module 15A
11

F25 009 2 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 10A
F27 014 16 Sicherung Wischer u. Wascher vorne Fuse, windscr. wiper and washer, fr. 10A
F28 014 18 Sicherung Wischer u. Wascher hinten Fuse, windscr. wiper and washer, re. 10A
F29 011 18 Sicherung Kompressor Sitzverstell. Fuse, compr., seat height adjustm. 15A
570 700 42

F31 013 6 Sicherung Kabinenluefter Fuse, cabin ventilator 10A

F33 013 9 Sicherung Klimageraet Fuse, air conditioning 10A
F40 012 3 Sicherung Kabinenheizung Fuse, heating unit cab 10A
F41 014 8 Sicherung Rundumkennleuchte Fuse, rotary beacon 10A
F42 014 7 Sicherung Kabineninnenleuchte Fuse, inside light cab 10A
101

F48 004 2 Sicherung Gluehanlage Fuse, glow plug system 80A

F49 014 1 Sicherung Spannungswandler Fuse, voltage transformer 10A
008 911
F50 57 013 19 Sicherung Klimageraet BOMAG
Fuse, air conditioning 15A 919
 Name Bl. Pf. Benennung title TYP

20.5 F66
F67
F84
014
009
009
4
7
13
Sicherung Scheinwerfer vorne
Sicherung Steuerung (Potential 30)
Sicherung Steuerung (Klemme 54)
Fuse, head light front
Fuse, controller (pot.30)
Fuse, controller (Pin 54)
15A
Wiring diagram 570 700 42
30A
10A
F85 014 6 Sicherung, Scheinwerfer vorne Fuse, head light front 20A
F86 014 10 Sicherung, Scheinwerfer hinten Fuse, head lights rear 15A
F89 002 12 Sicherung, Zigarettenanzuender Fuse, cigarette lighter 30A
F90 012 8 Sicherung, Ansteuerung Fuse, actuation 5A
F93 004 4 Sicherung Steuerung (Potential 30) Fuse, controller (pot. 30) 25A
F94 013 3 Sicherung Schutzbelueftung Fuse, protected ventilation syst.
F98 014 13 Sicherung Spiegelheizung fuse,mirror heating 10A
F99 014 9 Sicherung Motorraumbeleuchtung fuse, illumination engine area 15A
FM1 008 13 Platinensicherung Multifuse 0,2A
FM2 007 19 Platinensicherung Multifuse 0,2A
FM3 010 9 Platinensicherung Multifuse 0,2A
Seis
06.08.2007
Werner
06.08.2007

FM4 010 5 Platinensicherung Multifuse 0,2A

FM5 010 11 Platinensicherung Multifuse 0,2A
FM6 007 7 Platinensicherung Multifuse 0,2A
FM7 010 14 Platinensicherung Multifuse 0,2A
F122 002 17 Sicherung EMR Fuse, EMR 10A
F123 013 2 Sicherung Schutzbelüftungsanlage Fuse, protected ventilation system
F125 014 11 Vorsicherung preïfusing 10A
F126 014 11 Sicherung Rückfahrkamera Fuse, back up camera system 2A

G01 002 2 Batterie Battery

G02 002 5 Generator Generator 28V/80A
G03 002 2 Batterie Battery

H04 004 10 Meldeleuchte Betriebsstoerung Indicator light, breakdown

H07 009 13 Warnsummer Betriebsstoerung Warning buzzer, breakdown 0,2A
H14 007 4 Warnsummer Rueckwaertsfahrt Backïup alarm buzzer max. 2,5A
H70 004 11 Anzeige Wasser im Diesel Indicator water in fuel
H81 008 5 Meldeleuchte Verzögerungsfunktion Indicator light, decelerator device

K05 007 2 Relais Startstrom Relay, starting current BOSCHW

K11 003 14 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHL
K13 011 14 Relais Signalhorn Relay, warning horn BOSCHW
K14 004 4 Relais Vorgluehen Relay, glow plug system K2DEUTZ
K15 004 12 Relais Gluehen beim Start Relay, glowing during starting BOSCHW
K22 009 6 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K32 003 16 Relais Kabine Relay, cabin BOSCHL
K48 007 3 Relais Fahrhebel 0ïStellung Relay, travel lever 0ïposition BOSCHW
K60 004 14 Relais Motoroeldruck Relay, engine oil pressure BOSCHW
K61 002 8 Relais Ladekontrolle Relay, charge control BOSCHW
component listing

K62 002 10 Relais D+ Relay, D+ BOSCHW

K77 009 17 Relais Override Relay, override SDS/SF4
Bauteilliste

K90 009 4 Relais, Meldeleuchte Stoerung SPS Relay, indicat.light brake down SPS BOSCHW
K113 006 11 Zeitrelais Timing relay BOSCHW
K133 009 9 Relais Test Relay, test BOSCHW
K146 004 13 Relais Kühlmitteltemperatur relay, coolant temperature BOSCHW
K77/1 009 15 Relais Override Relay, override SDS/SF4

M01 003 9 Starter Starter

M04 014 15 Scheibenwischermotor vorne Windscreen wiper motor, front 190W
M05 014 17 Scheibenwischermotor hinten Windscreen wiper motor, rear max 3,3A
M06 014 16 Scheibenwaschermotor vorne Windscreen washer motor, front 60W
M07 014 18 Scheibenwaschermotor hinten Windscreen washer motor, rear 60W
M08 011 3 Zentralschmieranlage Central lubrication system max. 3A
M10 011 18 Kompressor Fahrersitzhoehenverstellung Compr., operator’s seat height adjustm. 7,5A
M17 012 18 Zusatzluefter Additional blower max. 0,75A
M24 013 10 Stellmotor Luftklappe adjusting motor air inlet flap
M26 013 6 Zyklon Abscheider cyclone separator 3A

P00 005 12 Betriebsstundenzaehler Operating hour meter

P01 005 15 Tankanzeige Level gauge
P02 005 7 Temperaturanzeige Hydraulikoel Temperature gauge, hydraulic oil
P03 005 11 Drehzahlmesser Rpm meter
P09 011 10 Frequenzï und Geschwindigkeitsanzeige Frequencyï and Speedometer
P09 011 10 Frequenzï und Geschwindigkeitsanzeige Frequencyï and Speedometer
P12 005 16 Voltmeter Volt meter
P14 005 6 Anzeige Kuehlmitteltemperatur Temperature gauge, coolant
P15 014 11 BCM 03 Bildschirm BCM 03 terminal
P18 010 16 Diagnose Diagnostics max. 1,08A
P32 014 12 Kamera Rückraumüberwachung Camera, back up monitoring

R02 004 2 Gluehkerze Glow plug

R02 004 2 Gluehkerze Glow plug
R03 005 15 Geber Tankanzeige Sender, level gauge
R04 005 8 Geber Hydraulikoeltemperatur Sender, hydraulic oil temp.
R06 011 19 Heizung Fahrersitz Heating, operator’s seat
R06 011 19 Heizung Fahrersitz Heating, operator’s seat
R10 002 7 Parallelwiderstand Parallel resistor 220 OHM
R20 008 15 Widerstand Resistor 1 KOHM
2

R21 008 15 Widerstand Resistor 1 KOHM

R22 008 16 Widerstand Resistor 1 KOHM
R23 008 17 Widerstand Resistor 1 KOHM
R24 004 5 Widerstand Resistor 10 kOHM
R26 012 17 Widerstand Resistor 22 OHM
11

R27 012 18 Widerstand Resistor 10 OHM

R32 007 5 Widerstand Resistor 1 kOhm
R33 007 5 Widerstand Resistor 2 kOhm
R34 007 6 Widerstand Resistor 1 kOhm
570 700 42

R35 007 8 Widerstand Resistor 3,3 kOhm

R36 010 6 Widerstand Resistor 47 OHM
R38 010 6 Widerstand Resistor 47 OHM
R40 010 6 Widerstand Resistor 47 OHM
R42 010 6 Widerstand Resistor 47 OHM
102

R43 008 7 Widerstand Resistor 499Ohm

R44 008 7 Widerstand Resistor 499Ohm
920 R77 014 12 Widerstandsheizung Aussenspiegel BOMAG
Resistor heating outside mirror 40W 008 911 57
 Name Bl. Pf. Benennung title TYP
R77

R77
014 13 Widerstandsheizung Aussenspiegel
Wiring diagram 570 700 42
R77 014 13 Widerstandsheizung Aussenspiegel
014 14 Widerstandsheizung Aussenspiegel
Resistor heating outside mirror
Resistor heating outside mirror
Resistor heating outside mirror
40W
40W
40W
20.5
S00 003 9 Startschalter Starter switch MERIT
S01 002 17 Schalter NOT AUS Switch, emergency off NOTAUSH
S01 002 17 Schalter NOT AUS Switch, emergency off
S02 008 16 Fahrstufenschalter Switch, speed range selector
S02 008 19 Fahrstufenschalter Switch, speed range selector
S03 011 14 Taster Signalhorn Push button, warning horn
S04 008 10 Bremsschalter Switch, brake
S16 014 5 Schalter Arbeitsbeleuchtung vorne Switch, working head lights, front
S20 014 14 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 014 18 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
Seis
06.08.2007
Werner
06.08.2007

S22 014 16 Schalter Scheibenwascher vorne Switch, windscreen washer, front

S25 011 19 Schalter Fahrersitzheizung Switch, heating, operator’s seat
S26 014 10 Schalter Arbeitsbeleuchtung hinten Switch, working head lights, rear
S27 011 3 Taster Zentralschmieranlage Push botton, central lubrication system
S28 012 8 Schalter Kabinenheizung Switch, cabin heating
S29 011 18 Schalter Fahrersitz Hoehenverstellung Switch, operator’s seat height adjustm.
S30 002 2 Batterietrennschalter Switch, battery disconnect
S31 007 5 Schalter Fahrtrichtung Switch, travel direction
S38 014 8 Schalter Kennleuchte Switch, warning light
S44 012 17 Schalter Kabinenluefter Switch, cabin ventilator
S45 014 7 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 014 4 Schalter Arbeitsbeleuchtung Switch, working lights
S70 010 10 Schalter Schubsschild Switch, dozer blade WAGO
S71 010 4 Schalter Lenkung Switch, steering max. 1,08A
S118 004 18 Schalter Fehlerdiagnose Switch, fault diagnosis
S119 004 6 Elektronisches Fusspedal Electronic foot pedal
S120 008 7 Schalter Motordrehzahl Switch, engine speed 5 kOhm
S128 014 13 Schalter Spiegelheizung Switch, mirror heating
S137 014 9 Schalter Motorraumbeleuchtung Switch, illumination engine area
S160 008 4 Schalter Aktivierung Verzögerungspedal Switch, enable decelerator pedal
S161 008 6 Verzögerungspedal decelerator pedal

U01 014 1 Spannungswandler Voltage transformer

V01 002 7 Diode Diode WAGO

V02 006 7 Diode Diode WAGO
V03 006 7 Diode Diode WAGO
V04 006 7 Diode Diode WAGO
V05 006 7 Diode Diode WAGO
component listing

V07 006 12 Diode Diode WAGO

V08 006 12 Diode Diode WAGO
Bauteilliste

V09 006 12 Diode Diode WAGO

V10 006 12 Diode Diode WAGO
V11 006 12 Diode Diode WAGO
V12 009 7 Diode Diode WAGO
V13 006 12 Diode Diode WAGO
V14 009 14 Diode Diode Wago
V15 009 15 Diode Diode Wago
V16 010 3 Diode Diode WAGO
V17 010 4 Diode Diode WAGO
V18 010 3 Diode Diode WAGO
V19 010 2 Diode Diode WAGO
V21 009 9 Diode Diode WAGO
V22 009 10 Diode Diode WAGO
V23 007 2 Diode Diode WAGO
V25 007 3 Diode Diode WAGO
V26 013 14 Diode Diode WAGO
V31 008 10 Diode Diode Lütze
V32 007 9 Diode Diode Lütze
V33 007 11 Diode Diode Lütze
V34 007 5 Diode Diode Lütze
V35 007 7 Diode Diode Lütze
V36 013 19 Diode Diode FE5B
V37 008 13 Diode Diode Lütze
V38 007 2 Diode Diode FE5B KabeldiodeDiode
V42 009 13 Diode (A2) Diode (A2) Diodenmodul
V43 013 6 Diode (A3) Diode (A3) Diodenmodul
V46 011 15 Diode (A6) Diode (A6) Diodenmodul
V47 003 12 Diode (A7) Diode (A7) Diodenmodul
V48 013 15 Diode (A8) Diode (A8) Diodenmodul

X0/1:1 010 19 DIOS STECKER Dios connector

X0/1:2 010 19 DIOS STECKER Dios connector
X0/1:3 009 18 DIOS STECKER Dios connector
X0/1:4 009 19 DIOS STECKER Dios connector
X0/1:5 010 18 DIOS STECKER Dios connector
X0/1:6 010 19 DIOS STECKER Dios connector
X0/1:9 009 19 DIOS STECKER Dios connector
3

X0/1:10 009 19 DIOS STECKER Dios connector

X0/1:11 009 18 DIOS STECKER Dios connector
X0:1 007 10 ESX STECKER esx connector
X0:1 008 13 ESX STECKER esx connector
X0:1 010 8 ESX STECKER esx connector
11

X0:2 009 4 ESX STECKER esx connector

X0:3 009 9 ESX STECKER esx connector
X0:4 009 10 ESX STECKER esx connector
X0:5 009 11 ESX STECKER esx connector
570 700 42

X0:6 006 9 ESX STECKER esx connector

X0:7 008 14 ESX STECKER esx connector
X0:8 010 4 ESX STECKER esx connector
X0:9 010 8 ESX STECKER esx connector
X0:10 006 10 ESX STECKER esx connector
103

X0:11 006 9 ESX STECKER esx connector

X0:12 010 15 ESX STECKER esx connector
008 911
X0:13 57 006 10 ESX STECKER BOMAG
esx connector 921
 Name Bl. Pf. Benennung title TYP

20.5 X0:14
X0:15
X0:16
010
010
009
7
8
4
ESX STECKER
ESX STECKER
ESX STECKER
esx connector
esx connector
esx connector
Wiring diagram 570 700 42
X0:17 010 14 ESX STECKER esx connector
X0:18 006 9 ESX STECKER esx connector
X0:19 006 9 ESX STECKER esx connector
X0:20 010 9 ESX STECKER esx connector
X0:21 007 10 ESX STECKER esx connector
X0:22 007 8 ESX STECKER esx connector
X0:23 007 11 ESX STECKER esx connector
X0:23 008 13 ESX STECKER esx connector
X0:23 010 9 ESX STECKER esx connector
X0:24 009 6 ESX STECKER esx connector
X0:25 009 7 ESX STECKER esx connector
Seis
06.08.2007
Werner
06.08.2007

X0:26 010 17 ESX STECKER esx connector

X0:27 010 16 ESX STECKER esx connector
X0:28 009 6 ESX STECKER esx connector
X0:29 007 19 ESX STECKER esx connector
X0:30 010 10 ESX STECKER esx connector
X0:31 010 13 ESX STECKER esx connector
X0:32 007 7 ESX STECKER esx connector
X0:33 009 9 ESX STECKER esx connector
X0:34 010 14 ESX STECKER esx connector
X0:35 010 12 ESX STECKER esx connector
X0:36 006 9 ESX STECKER esx connector
X0:37 010 16 ESX STECKER esx connector
X0:38 010 5 ESX STECKER esx connector
X0:39 010 6 ESX STECKER esx connector
X0:40 008 10 ESX STECKER esx connector
X0:41 010 12 ESX STECKER esx connector
X0:42 010 10 ESX STECKER esx connector
X0:43 007 19 ESX STECKER esx connector
X0:44 009 13 ESX STECKER esx connector
X0:45 006 10 ESX STECKER esx connector
X0:46 007 14 ESX STECKER esx connector
X0:47 007 16 ESX STECKER esx connector
X0:48 007 17 ESX STECKER esx connector
X0:49 010 8 ESX STECKER esx connector
X0:50 006 10 ESX STECKER esx connector
X0:51 006 10 ESX STECKER esx connector
X0:52 006 9 ESX STECKER esx connector
X0:53 009 9 ESX STECKER esx connector
X0:54 009 13 ESX STECKER esx connector
component listing

X0:55 010 17 ESX STECKER esx connector

X0:56 009 7 ESX STECKER esx connector
Bauteilliste

X0:57 009 8 ESX STECKER esx connector

X0:58 009 8 ESX STECKER esx connector
X0:59 009 8 ESX STECKER esx connector
X0:60 009 9 ESX STECKER esx connector
X0:61 008 10 ESX STECKER esx connector
X0:62 008 14 ESX STECKER esx connector
X0:63 010 12 ESX STECKER esx connector
X0:64 010 7 ESX STECKER esx connector
X0:65 010 15 ESX STECKER esx connector
X0:66 010 16 ESX STECKER esx connector
X0:67 010 16 ESX STECKER esx connector
X0:68 010 16 ESX STECKER esx connector
X1: 013 2 Wago Zentralelektrik Wago eïbox
X1:1 014 7 Wago Zentralelektrik Wago eïbox
X1:2 014 7 Wago Zentralelektrik Wago eïbox
X1:3 014 2 Wago Zentralelektrik Wago eïbox
X1:4 014 2 Wago Zentralelektrik Wago eïbox
X1:5 004 20 Wago Zentralelektrik Wago eïbox
X1:6 002 17 Wago Zentralelektrik Wago eïbox
X1:7 003 9 Wago Zentralelektrik Wago eïbox
X1:8 003 9 Wago Zentralelektrik Wago eïbox
X1:9 003 9 Wago Zentralelektrik Wago eïbox
X1:61 010 19 Wago Zentralelektrik Wago eïbox
X1:62 004 15 Wago Zentralelektrik Wago eïbox
X1:63 010 19 Wago Zentralelektrik Wago eïbox
X1:64 004 16 Wago Zentralelektrik Wago eïbox
X1:65 004 16 Wago Zentralelektrik Wago eïbox
X1:66 009 10 Wago Zentralelektrik Wago eïbox
X1:67 009 11 Wago Zentralelektrik Wago eïbox
X1:68 010 19 Wago Zentralelektrik Wago eïbox
X1:69 010 19 Wago Zentralelektrik Wago eïbox
X1:70 002 10 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:70 003 16 Wago Zentralelektrik Wago eïbox
X1:70 007 2 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:70 007 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:70 009 4 Wago Zentralelektrik Wago eïbox
X1:70 009 6 Wago Zentralelektrik Wago eïbox
4

X1:70 009 9 Wago Zentralelektrik Wago eïbox

X1:70 009 13 Wago Zentralelektrik Wago eïbox
X1:70 009 15 Wago Zentralelektrik Wago eïbox
X1:70 009 17 Wago Zentralelektrik Wago eïbox
X1:70 013 6 Wago Zentralelektrik Wago eïbox
11

X1:71 004 17 Wago Zentralelektrik Wago eïbox

X1:72 014 11 Wago Zentralelektrik Wago eïbox
X1:81 002 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:82 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
570 700 42

X1:83 006 4 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:84 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:85 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:86 006 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:87 006 2 WAGO ZENTRALELEKTRIK WAGO EïBOX
104

X1:88 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:89 006 2 WAGO ZENTRALELEKTRIK WAGO EïBOX
922 X1:90 006 3 WAGO ZENTRALELEKTRIK BOMAG
WAGO EïBOX 008 911 57
 Name Bl. Pf. Benennung title TYP
X1:91

X1:93
006
Wiring diagram 570 700 42
X1:92 004
004
4
12
13
WAGO ZENTRALELEKTRIK
Wago Zentralelektrik
Wago Zentralelektrik
WAGO EïBOX
Wago eïbox
Wago eïbox
20.5
X1:94 004 14 Wago Zentralelektrik Wago eïbox
X1:101 006 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:102 006 9 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:103 006 5 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:104 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:105 006 11 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:106 006 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:108 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:109 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:110 006 11 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:111 006 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
Seis
06.08.2007
Werner
06.08.2007

X1:112 006 17 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:113 006 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:114 006 18 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:115 006 14 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:116 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:117 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:118 006 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:119 006 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:120 006 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:121 006 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:122 006 18 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:123 006 14 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:124 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:125 006 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:126 006 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:127 013 13 Wago Zentralelektrik Wago eïbox
X1:128 013 13 Wago Zentralelektrik Wago eïbox
X1:129 013 15 Wago Zentralelektrik Wago eïbox
X1:130 013 15 Wago Zentralelektrik Wago eïbox
X1:131 007 8 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:132 007 8 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:133 007 10 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:134 007 10 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:135 007 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:136 007 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:137 010 12 Wago Zentralelektrik Wago eïbox
X1:138 010 12 Wago Zentralelektrik Wago eïbox
X1:139 010 13 Wago Zentralelektrik Wago eïbox
X1:140 010 13 Wago Zentralelektrik Wago eïbox
component listing

X1:141 010 18 Wago Zentralelektrik Wago eïbox

X1:142 010 18 Wago Zentralelektrik Wago eïbox
Bauteilliste

X1:143 010 19 Wago Zentralelektrik Wago eïbox

X1:144 010 19 Wago Zentralelektrik Wago eïbox
X1:145 014 9 Wago Zentralelektrik Wago eïbox
X1:146 013 15 Wago Zentralelektrik Wago eïbox
X1:147 013 15 Wago Zentralelektrik Wago eïbox
X1:148 005 8 Wago Zentralelektrik Wago eïbox
X1:149 007 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:150 014 10 Wago Zentralelektrik Wago eïbox
X1:151 008 10 Wago Zentralelektrik Wago eïbox
X1:152 008 10 Wago Zentralelektrik Wago eïbox
X1:153 007 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:154 007 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:155 007 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:156 007 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:157 007 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:158 007 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:159 010 7 Wago Zentralelektrik Wago eïbox
X1:160 010 7 Wago Zentralelektrik Wago eïbox
X1:161 010 8 Wago Zentralelektrik Wago eïbox
X1:162 010 8 Wago Zentralelektrik Wago eïbox
X1:163 010 9 Wago Zentralelektrik Wago eïbox
X1:164 010 9 Wago Zentralelektrik Wago eïbox
X1:165 010 10 Wago Zentralelektrik Wago eïbox
X1:166 010 10 Wago Zentralelektrik Wago eïbox
X1:170 008 14 Wago Zentralelektrik Wago eïbox
X1:171 011 4 Wago Zentralelektrik Wago eïbox
X1:172 011 3 Wago Zentralelektrik Wago eïbox
X1:173 011 3 Wago Zentralelektrik Wago eïbox
X1:174 011 4 Wago Zentralelektrik Wago eïbox
X1:181 006 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:181 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:181 010 15 Wago Zentralelektrik Wago eïbox
X1:182 006 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:182 006 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:182 010 16 Wago Zentralelektrik Wago eïbox
X1:183 006 11 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:183 006 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
5

X1:183 010 16 Wago Zentralelektrik Wago eïbox

X1:184 006 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:184 006 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:184 009 18 Wago Zentralelektrik Wago eïbox
X1:185 006 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
11

X1:185 009 19 Wago Zentralelektrik Wago eïbox

X1:186 006 18 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:186 009 19 Wago Zentralelektrik Wago eïbox
X1:187 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
570 700 42

X1:187 010 16 Wago Zentralelektrik Wago eïbox

X1:188 007 4 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:188 010 17 Wago Zentralelektrik Wago eïbox
X1:189 010 15 Wago Zentralelektrik Wago eïbox
X1:189 014 9 Wago Zentralelektrik Wago eïbox
105

X1:189 014 9 Wago Zentralelektrik Wago eïbox

X1:190 011 6 Wago Zentralelektrik Wago eïbox
008 911
X1:19057 014 10 Wago Zentralelektrik BOMAG
Wago eïbox 923
 Name Bl. Pf. Benennung title TYP

20.5 X1:190
X1:191
X1:191
014
006
006
11
15
15
Wago Zentralelektrik
WAGO ZENTRALELEKTRIK
WAGO ZENTRALELEKTRIK
Wago eïbox
WAGO EïBOX
WAGO EïBOX
Wiring diagram 570 700 42
X1:191 011 7 Wago Zentralelektrik Wago eïbox
X1:192 008 14 Wago Zentralelektrik Wago eïbox
X1:201 013 15 Wago Zentralelektrik Wago eïbox
X1:202 002 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:205 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:205 013 15 Wago Zentralelektrik Wago eïbox
X1:207 009 4 Wago Zentralelektrik Wago eïbox
X1:20A 013 19 Sika ï Klemme fuse terminal
X1:20E 013 19 Sika ï Klemme fuse terminal
X1:210 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:21A 002 12 Sika ï Klemme fuse terminal
Seis
06.08.2007
Werner
06.08.2007

X1:21E 002 12 Sika ï Klemme fuse terminal

X1:221 007 14 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:222 007 14 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:223 007 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:224 007 16 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:226 012 3 Wago Zentralelektrik Wago eïbox
X1:227 012 3 Wago Zentralelektrik Wago eïbox
X1:228 005 15 Wago Zentralelektrik Wago eïbox
X1:229 005 15 Wago Zentralelektrik Wago eïbox
X1:22A 013 3 Sika ï Klemme fuse terminal
X1:22E 013 3 Sika ï Klemme fuse terminal
X1:231 004 6 Wago Zentralelektrik Wago eïbox
X1:232 004 6 Wago Zentralelektrik Wago eïbox
X1:233 004 7 Wago Zentralelektrik Wago eïbox
X1:234 008 5 Wago Zentralelektrik Wago eïbox
X1:235 004 6 Wago Zentralelektrik Wago eïbox
X1:236 004 6 Wago Zentralelektrik Wago eïbox
X1:237 004 7 Wago Zentralelektrik Wago eïbox
X1:23A 003 9 Sika ï Klemme fuse terminal
X1:23E 002 3 Sika ï Klemme fuse terminal
X1:23E 003 9 Sika ï Klemme fuse terminal
X1:241 002 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:242 002 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:243 002 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:244 004 10 Wago Zentralelektrik Wago eïbox
X1:245 011 19 Wago Zentralelektrik Wago eïbox
X1:246 011 19 Wago Zentralelektrik Wago eïbox
X1:247 013 15 Wago Zentralelektrik Wago eïbox
X1:248 011 3 Wago Zentralelektrik Wago eïbox
component listing

X1:249 013 10 Wago Zentralelektrik Wago eïbox

X1:24A 004 4 Sika ï Klemme fuse terminal
Bauteilliste

X1:24E 004 4 Sika ï Klemme fuse terminal

X1:250 004 10 Wago Zentralelektrik Wago eïbox
X1:251 013 9 Wago Zentralelektrik Wago eïbox
X1:252 013 13 Wago Zentralelektrik Wago eïbox
X1:253 013 17 Wago Zentralelektrik Wago eïbox
X1:255 004 18 Wago Zentralelektrik Wago eïbox
X1:256 002 15 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:256 003 12 Wago Zentralelektrik Wago eïbox
X1:256 011 15 Wago Zentralelektrik Wago eïbox
X1:257 009 13 Wago Zentralelektrik Wago eïbox
X1:258 009 13 Wago Zentralelektrik Wago eïbox
X1:259 002 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:25A 002 15 Sika ï Klemme fuse terminal
X1:25E 002 15 Sika ï Klemme fuse terminal
X1:260 002 17 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:261 008 10 Wago Zentralelektrik Wago eïbox
X1:262 007 18 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:262 008 10 Wago Zentralelektrik Wago eïbox
X1:263 008 10 Wago Zentralelektrik Wago eïbox
X1:265 012 18 Wago Zentralelektrik Wago eïbox
X1:266 012 17 Wago Zentralelektrik Wago eïbox
X1:267 012 18 Wago Zentralelektrik Wago eïbox
X1:268 012 19 Wago Zentralelektrik Wago eïbox
X1:269 004 11 Wago Zentralelektrik Wago eïbox
X1:26A 009 13 Sika ï Klemme fuse terminal
X1:26E 009 13 Sika ï Klemme fuse terminal
X1:270 004 11 Wago Zentralelektrik Wago eïbox
X1:272 011 3 Wago Zentralelektrik Wago eïbox
X1:272 013 9 Wago Zentralelektrik Wago eïbox
X1:27A 009 7 Sika ï Klemme fuse terminal
X1:27E 009 7 Sika ï Klemme fuse terminal
X1:28A 013 2 Sika ï Klemme fuse terminal
X1:28E 013 2 Sika ï Klemme fuse terminal
X1:291 005 7 Wago Zentralelektrik Wago eïbox
X1:292 005 11 Wago Zentralelektrik Wago eïbox
X1:293 003 10 Wago Zentralelektrik Wago eïbox
X1:294 005 5 Wago Zentralelektrik Wago eïbox
6

X1:295 005 7 Wago Zentralelektrik Wago eïbox

X1:296 005 15 Wago Zentralelektrik Wago eïbox
X1:298 002 11 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:298 005 11 Wago Zentralelektrik Wago eïbox
X1:299 004 20 Wago Zentralelektrik Wago eïbox
11

X1:299 005 5 Wago Zentralelektrik Wago eïbox

X1:29A 005 5 Sika ï Klemme fuse terminal
X1:29E 005 5 Sika ï Klemme fuse terminal
X1:300 005 7 Wago Zentralelektrik Wago eïbox
570 700 42

X1:301 005 11 Wago Zentralelektrik Wago eïbox

X1:302 003 13 Wago Zentralelektrik Wago eïbox
X1:303 005 8 Wago Zentralelektrik Wago eïbox
X1:308 010 2 Wago Zentralelektrik Wago eïbox
X1:30A 011 4 Sika ï Klemme fuse terminal
106

X1:30E 011 4 Sika ï Klemme fuse terminal

X1:31A 011 18 Sika ï Klemme fuse terminal
924 X1:31E 002 17 SIKA KLEMME BOMAG
fuse terminal 008 911 57
 Name Bl. Pf. Benennung title TYP
X1:31E

X1:322
011
Wiring diagram 570 700 42
X1:321 010
010
18
7
9
Sika ï Klemme
Wago Zentralelektrik
Wago Zentralelektrik
fuse terminal
Wago eïbox
Wago eïbox
20.5
X1:323 010 8 Wago Zentralelektrik Wago eïbox
X1:324 010 8 Wago Zentralelektrik Wago eïbox
X1:325 010 7 Wago Zentralelektrik Wago eïbox
X1:326 010 8 Wago Zentralelektrik Wago eïbox
X1:327 010 12 Wago Zentralelektrik Wago eïbox
X1:328 010 11 Wago Zentralelektrik Wago eïbox
X1:329 010 11 Wago Zentralelektrik Wago eïbox
X1:32A 002 17 Sika ï Klemme fuse terminal
X1:32E 002 17 Sika ï Klemme fuse terminal
X1:330 010 10 Wago Zentralelektrik Wago eïbox
X1:331 010 12 Wago Zentralelektrik Wago eïbox
Seis
06.08.2007
Werner
06.08.2007

X1:332 010 12 Wago Zentralelektrik Wago eïbox

X1:333 010 15 Wago Zentralelektrik Wago eïbox
X1:334 010 15 Wago Zentralelektrik Wago eïbox
X1:335 007 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:336 007 9 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:337 007 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:338 007 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:339 007 5 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:33A 013 6 Sika ï Klemme fuse terminal
X1:33E 002 17 SIKA KLEMME fuse terminal
X1:33E 013 6 Sika ï Klemme fuse terminal
X1:340 007 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:341 011 18 Wago Zentralelektrik Wago eïbox
X1:342 011 18 Wago Zentralelektrik Wago eïbox
X1:343 008 4 Wago Zentralelektrik Wago eïbox
X1:343 010 6 Wago Zentralelektrik Wago eïbox
X1:344 010 5 Wago Zentralelektrik Wago eïbox
X1:345 010 4 Wago Zentralelektrik Wago eïbox
X1:346 010 4 Wago Zentralelektrik Wago eïbox
X1:347 010 5 Wago Zentralelektrik Wago eïbox
X1:348 010 6 Wago Zentralelektrik Wago eïbox
X1:349 009 18 Wago Zentralelektrik Wago eïbox
X1:349 009 19 Wago Zentralelektrik Wago eïbox
X1:349 009 19 Wago Zentralelektrik Wago eïbox
X1:349 010 17 Wago Zentralelektrik Wago eïbox
X1:34A 011 14 Sika ï Klemme fuse terminal
X1:34E 011 14 Sika ï Klemme fuse terminal
X1:350 010 14 Wago Zentralelektrik Wago eïbox
X1:351 010 13 Wago Zentralelektrik Wago eïbox
component listing

X1:352 010 13 Wago Zentralelektrik Wago eïbox

X1:353 010 14 Wago Zentralelektrik Wago eïbox
Bauteilliste

X1:354 010 14 Wago Zentralelektrik Wago eïbox

X1:355 011 19 Wago Zentralelektrik Wago eïbox
X1:356 011 14 Wago Zentralelektrik Wago eïbox
X1:357 008 17 Wago Zentralelektrik Wago eïbox
X1:358 008 13 Wago Zentralelektrik Wago eïbox
X1:359 008 14 Wago Zentralelektrik Wago eïbox
X1:35A 009 2 Sika ï Klemme fuse terminal
X1:35E 009 2 Sika ï Klemme fuse terminal
X1:363 010 16 Wago Zentralelektrik Wago eïbox
X1:364 010 20 Wago Zentralelektrik Wago eïbox
X1:364 011 14 Wago Zentralelektrik Wago eïbox
X1:36A 013 9 Sika ï Klemme fuse terminal
X1:36E 013 9 Sika ï Klemme fuse terminal
X1:371 003 16 Wago Zentralelektrik Wago eïbox
X1:372 014 19 Wago Zentralelektrik Wago eïbox
X1:372 014 20 Wago Zentralelektrik Wago eïbox
X1:373 012 15 Wago Zentralelektrik Wago eïbox
X1:374 012 15 Wago Zentralelektrik Wago eïbox
X1:375 012 3 Wago Zentralelektrik Wago eïbox
X1:376 012 3 Wago Zentralelektrik Wago eïbox
X1:377 012 19 Wago Zentralelektrik Wago eïbox
X1:378 014 10 Wago Zentralelektrik Wago eïbox
X1:381 013 19 Wago Zentralelektrik Wago eïbox
X1:382 013 18 Wago Zentralelektrik Wago eïbox
X1:383 013 17 Wago Zentralelektrik Wago eïbox
X1:391/1 002 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:391/2 002 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:392/1 006 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:392/2 006 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:393/1 006 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:393/2 006 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:394/1 006 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:394/2 006 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:395/1 006 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:395/2 006 6 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:397/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:397/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
7

X1:398/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:398/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:399/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:399/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:400/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
11

X1:400/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:401/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:401/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:402/1 009 7 Wago Zentralelektrik Wago eïbox
570 700 42

X1:402/2 009 7 Wago Zentralelektrik Wago eïbox

X1:403/1 006 12 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:403/2 006 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:404/1 009 14 Wago Zentralelektrik Wago eïbox
X1:404/2 009 14 Wago Zentralelektrik Wago eïbox
107

X1:405/1 009 15 Wago Zentralelektrik Wago eïbox

X1:405/2 009 15 Wago Zentralelektrik Wago eïbox
008 911 57
X1:406/1 010 3 Wago Zentralelektrik BOMAG
Wago eïbox 925
 Name Bl. Pf. Benennung title TYP

20.5 X1:406/2
X1:407/1
X1:407/2
010
010
010
3
4
4
Wago Zentralelektrik
Wago Zentralelektrik
Wago Zentralelektrik
Wago eïbox
Wago eïbox
Wago eïbox
Wiring diagram 570 700 42
X1:408/1 010 3 Wago Zentralelektrik Wago eïbox
X1:408/2 010 3 Wago Zentralelektrik Wago eïbox
X1:409/1 010 2 Wago Zentralelektrik Wago eïbox
X1:409/2 010 2 Wago Zentralelektrik Wago eïbox
X1:41/1 008 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:41/2 008 13 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:410/1 009 9 Wago Zentralelektrik Wago eïbox
X1:410/2 009 9 Wago Zentralelektrik Wago eïbox
X1:411/1 009 10 Wago Zentralelektrik Wago eïbox
X1:411/2 009 10 Wago Zentralelektrik Wago eïbox
X1:412/1 007 2 WAGO ZENTRALELEKTRIK WAGO EïBOX
Seis
06.08.2007
Werner
06.08.2007

X1:412/2 007 2 WAGO ZENTRALELEKTRIK WAGO EïBOX

X1:413/1 007 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:413/2 007 3 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:414/1 013 14 Wago Zentralelektrik Wago eïbox
X1:414/2 013 14 Wago Zentralelektrik Wago eïbox
X1:42/1 007 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:42/2 007 19 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:43/1 010 9 Wago Zentralelektrik Wago eïbox
X1:43/2 010 9 Wago Zentralelektrik Wago eïbox
X1:44/1 010 5 Wago Zentralelektrik Wago eïbox
X1:44/2 010 5 Wago Zentralelektrik Wago eïbox
X1:45/1 010 11 Wago Zentralelektrik Wago eïbox
X1:45/2 010 11 Wago Zentralelektrik Wago eïbox
X1:46/1 007 8 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:46/2 007 7 WAGO ZENTRALELEKTRIK WAGO EïBOX
X1:47/1 010 14 Wago Zentralelektrik Wago eïbox
X1:47/2 010 14 Wago Zentralelektrik Wago eïbox
X2:A 010 19 Datenschnittstelle data interface
X2:B 010 19 Datenschnittstelle data interface
X2:G 009 11 Datenschnittstelle data interface
X2:H 009 10 Datenschnittstelle data interface
X2:J 002 11 Datenschnittstelle data interface
X2:N 002 11 Datenschnittstelle data interface
X2:U 009 11 Datenschnittstelle data interface
X2:V 010 15 Datenschnittstelle data interface
X3:A 008 3 Stecker Handgas connector hand throttle
X3:B 008 2 Stecker Handgas connector hand throttle
X3:C 008 2 Stecker Handgas connector hand throttle
X4:A 004 15 EMR ï Diagnose EMRïdiagnosis
component listing

X4:B 004 17 EMR ï Diagnose EMRïdiagnosis

X4:F 004 16 EMR ï Diagnose EMRïdiagnosis
Bauteilliste

X4:G 004 16 EMR ï Diagnose EMRïdiagnosis

X4:H 004 15 EMR ï Diagnose EMRïdiagnosis
X4:K 004 17 EMR ï Diagnose EMRïdiagnosis
X4:M 004 16 EMR ï Diagnose EMRïdiagnosis
X5:1 005 7 Deutsch Stecker Senso Deutsch Connector sensor
X6:1 004 10 Wago Zentralelektrik Wago eïbox
X6:2 004 10 Wago Zentralelektrik Wago eïbox
X6:3 004 11 Wago Zentralelektrik Wago eïbox
X6:4 004 11 Wago Zentralelektrik Wago eïbox
X6:5 004 15 Wago Zentralelektrik Wago eïbox
X6:6 004 15 Wago Zentralelektrik Wago eïbox
X6:7 004 16 Wago Zentralelektrik Wago eïbox
X6:8 004 16 Wago Zentralelektrik Wago eïbox
X6:9 004 16 Wago Zentralelektrik Wago eïbox
X6:10 004 17 Wago Zentralelektrik Wago eïbox
X7:1 014 9 Stecker Rops connector on rops
X7:2 014 9 Stecker Rops connector on rops
X7:3 014 9 Stecker Rops connector on rops
X7:4 014 9 Stecker Rops connector on rops
X7:5 013 16 Stecker Rops connector on rops
X7:6 013 16 Stecker Rops connector on rops
X8:1 012 3 Pumpenstecker Kabine connector pump cabin;
X8:2 012 3 Pumpenstecker Kabine connector pump cabin;
X9:1 007 5 Stecker Schalter Rich connector direction switch
X9:2 007 9 Stecker Schalter Rich connector direction switch
X9:3 007 7 Stecker Schalter Rich connector direction switch
X9:4 007 5 Stecker Schalter Rich connector direction switch
X9:5 007 5 Stecker Schalter Rich connector direction switch
X9:6 007 6 Stecker Schalter Rich connector direction switch
XS 002 15 Steckdose Socket
X10:A 004 7 AMP Stecker Gaspedal AMP connector throttle
X10:B 004 6 AMP Stecker Gaspedal AMP connector throttle
X10:C 004 6 AMP Stecker Gaspedal AMP connector throttle
X11:1 011 18 Schnittstelle Sitz connector drivers seat
X11:2 011 18 Schnittstelle Sitz connector drivers seat
X12:A 004 7 AMP Stecker Gaspedal AMP connector throttle
X12:B 004 8 AMP Stecker Gaspedal AMP connector throttle
8

X12:C 004 7 AMP Stecker Gaspedal AMP connector throttle

X13:1 008 17 Stecker Stufenschalte connector speed range switch
X13:2 008 18 Stecker Stufenschalte connector speed range switch
X13:3 008 14 Stecker Stufenschalte connector speed range switch
X14:4 013 15 Stecker Motor connector engine
11

X14:5 013 16 Stecker Motor connector engine

X14:6 002 6 Motorschnittstelle engine interface
X14:7 002 6 Motorschnittstelle engine interface
X14:8 005 7 Motorschnittstelle engine interface
570 700 42

X14:9 003 9 Motorschnittstelle engine interface

X14:10 006 12 Stecker Motor connector engine
X14:11 006 12 Stecker Motor connector engine
X15:A 010 18 Stecker Lehne links connector arm rest lh.
X15:B 010 18 Stecker Lehne links connector arm rest lh.
108

X15:C 010 20 Stecker Lehne links connector arm rest lh.

X17:1 013 16 Stecker Klimakupplung connector clima clutch
926 X17:2 013 16 Stecker Klimakupplung BOMAG
connector clima clutch 008 911 57
 Name Bl. Pf. Benennung title TYP
X18:1

X19:1
013
Wiring diagram 570 700 42
X18:2 013
013
16
16
13
Stecker Druckschalter
Stecker Druckschalter
Stecker Heizventil
connector pressure switch
connector pressure switch
connector heating valve
20.5
X19:2 013 13 Stecker Heizventil connector heating valve
X21:1 011 19 Schnittstelle Sitz connector drivers seat
X21:2 011 19 Schnittstelle Sitz connector drivers seat
X22:1 013 10 Stecker Luftklappe connector air flap
X22:2 013 11 Stecker Luftklappe connector air flap
X23:1 013 14 Stecker Sensor connector sensor
X23:2 013 14 Stecker Sensor connector sensor
X24:1 013 15 Stecker Sensor connector sensor
X24:2 013 15 Stecker Sensor connector sensor
X25:A 013 19 Stecker Lüfter connector blower
X25:B 013 18 Stecker Lüfter connector blower
Seis
06.08.2007
Werner
06.08.2007

X25:C 013 18 Stecker Lüfter connector blower

X26:1 013 9 Stecker Klimasteuerun connector climacontrol
X26:2 013 9 Stecker Klimasteuerun connector climacontrol
X26:3 013 11 Stecker Klimasteuerun connector climacontrol
X26:4 013 10 Stecker Klimasteuerun connector climacontrol
X26:5 013 16 Stecker Klimasteuerun connector climacontrol
X26:6 013 12 Stecker Klimasteuerun connector climacontrol
X26:7 013 12 Stecker Klimasteuerun connector climacontrol
X26:8 013 15 Stecker Klimasteuerun connector climacontrol
X26:9 013 13 Stecker Klimasteuerun connector climacontrol
X26:10 013 10 Stecker Klimasteuerun connector climacontrol
X26:11 013 11 Stecker Klimasteuerun connector climacontrol
X26:12 013 13 Stecker Klimasteuerun connector climacontrol
X26:13 013 13 Stecker Klimasteuerun connector climacontrol
X26:14 013 13 Stecker Klimasteuerun connector climacontrol
X27:1 013 14 Stecker Klimasteuerun connector climacontrol
X27:2 013 14 Stecker Klimasteuerun connector climacontrol
X27:3 013 15 Stecker Klimasteuerun connector climacontrol
X27:4 013 15 Stecker Klimasteuerun connector climacontrol
X28:1 011 6 Stecker Radsensor connector wheel sensor
X28:2 011 6 Stecker Radsensor connector wheel sensor
X28:3 011 7 Stecker Radsensor connector wheel sensor
X28:4 011 7 Stecker Radsensor connector wheel sensor
X29:1 013 6 Stecker Zyklon Connector cyclone
X29:2 013 6 Stecker Zyklon Connector cyclone
X30:A 011 6 Verbindungsstecker Se connector sensor
X30:B 011 6 Verbindungsstecker Se connector sensor
X30:C 011 7 Verbindungsstecker Se connector sensor
X31:A 011 11 Verbindungsstecker An connector gauge
component listing

X31:B 011 9 Verbindungsstecker An connector gauge

X31:C 011 10 Verbindungsstecker An connector gauge
Bauteilliste

X33:1 011 4 Schmieranlage lubrication system

X33:2 011 4 Schmieranlage lubrication system
X34:1 011 4 Schmieranlage lubrication system
X34:2 011 4 Schmieranlage lubrication system
X34:3 011 3 Schmieranlage lubrication system
X34:4 011 3 Schmieranlage lubrication system
X34:5 011 4 Schmieranlage lubrication system
X35:1 009 13 Stecker Warnsummer connector warning buzzer
X35:2 009 13 Stecker Warnsummer connector warning buzzer
X36:1 008 7 Stecker Poti connector potentiometer
X36:2 008 6 Stecker Poti connector potentiometer
X36:3 008 7 Stecker Poti connector potentiometer
X39:A 008 7 Stecker Deceleratorpe connector decelerator pedal
X39:B 008 6 Stecker Deceleratorpe connector decelerator pedal
X39:C 008 6 Stecker Deceleratorpe connector decelerator pedal
X40:1 008 8 Stecker Deceleratorpe connector decelerator pedal
X40:2 008 8 Stecker Deceleratorpe connector decelerator pedal
X40:3 008 9 Stecker Deceleratorpe connector decelerator pedal
X40:4 008 7 Stecker Deceleratorpe connector decelerator pedal
X40:5 008 8 Stecker Decelelratorp connector decelerator pedal
X40:6 008 7 Stecker Deceleratorpe connector decelerator pedal
X41:1 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:2 008 8 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:3 008 6 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:4 008 6 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:5 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:6 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:8 008 8 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:9 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:10 008 7 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:11 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X41:12 008 5 Stecker 1 Anpaßplatin connector 1 decelerator circuit board
X42:1 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:2 008 2 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:4 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:5 008 2 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
X42:6 008 3 Stecker 2 Anpaßplatin connector 2 decelerator circuit board
9

X17.1:1 004 2 2ïpol SPT 2ïpole SPT

X17.1:2 004 2 2ïpol SPT 2ïpole SPT
X27.1:4 004 18 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:6 004 19 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:7 004 19 Motor / 42ïpol EPC engine / 42ïpole EPC
11

X27.1:11 004 14 Motor / 42ïpol EPC engine / 42ïpole EPC

X27.1:12 004 6 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:13 004 8 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:14 004 8 Motor / 42ïpol EPC engine / 42ïpole EPC
570 700 42

X27.1:15 004 9 Motor / 42ïpol EPC engine / 42ïpole EPC

X27.1:18 004 7 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:19 004 5 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:20 004 4 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:21 004 10 Motor / 42ïpol EPC engine / 42ïpole EPC
109

X27.1:22 004 11 Motor / 42ïpol EPC engine / 42ïpole EPC

X27.1:23 004 10 Motor / 42ïpol EPC engine / 42ïpole EPC
008 911 57
X27.1:24 004 7 Motor / 42ïpol EPC BOMAG
engine / 42ïpole EPC 927
 Name Bl. Pf. Benennung title TYP

20.5 X27.1:25
X27.1:26
X27.1:27
004
004
004
4
5
5
Motor / 42ïpol EPC
Motor / 42ïpol EPC
Motor / 42ïpol EPC
engine / 42ïpole EPC
engine / 42ïpole EPC
engine / 42ïpole EPC
Wiring diagram 570 700 42
X27.1:28 004 11 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:29 004 11 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:30 004 7 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:33 004 6 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:34 004 12 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:35 004 12 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:36 004 14 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:37 004 13 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:39 004 17 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:40 004 16 Motor / 42ïpol EPC engine / 42ïpole EPC
X27.1:41 004 16 Motor / 42ïpol EPC engine / 42ïpole EPC
Seis
06.08.2007
Werner
06.08.2007

X27.1:42 004 15 Motor / 42ïpol EPC engine / 42ïpole EPC

X27.2:10 004 3 12ïpol EPC 12ïpole EPC
X27.2:11 004 3 12ïpol EPC 12ïpole EPC
XD2.1:2 004 4 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:3 004 4 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:5 004 18 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:6 004 18 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:8 004 4 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:9 004 5 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:10 004 17 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:11 004 17 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:13 004 11 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:20 004 14 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:22 004 10 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:29 004 5 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:30 004 10 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:33 004 7 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:34 004 16 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:35 004 16 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:38 004 11 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:39 004 13 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:40 004 15 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:52 004 16 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:53 004 15 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:54 004 12 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:59 004 8 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:60 004 7 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:61 004 8 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.1:62 004 5 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
component listing

XD2.1:77 004 6 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH

XD2.1:78 004 7 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
Bauteilliste

XD2.1:79 004 6 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH

XD2.1:89 004 17 EDC7 / 89ïpol BOSCH EDC7 / 89ïpol BOSCH
XD2.2:3 004 4 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:4 004 19 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:5 004 19 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:7 004 5 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:8 004 4 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:9 004 8 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:10 004 8 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:15 004 7 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:18 004 6 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:19 004 9 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:23 004 10 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:24 004 5 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:25 004 11 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:26 004 7 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:27 004 5 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:28 004 4 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:32 004 6 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:33 004 11 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:34 004 10 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:35 004 7 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.2:36 004 11 EDC7 / 36ïpol BOSCH EDC7 / 36ïpol BOSCH
XD2.3:3 004 15 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:4 004 12 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:6 004 13 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:7 004 14 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:8 004 18 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:12 004 14 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:13 004 12 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:14 004 16 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:15 004 16 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH
XD2.3:16 004 17 EDC7 / 16ïpol BOSCH EDC7 / 16ïpol BOSCH

Y02 004 19 Magnetventil Flammgluehanlage Solenoid valve, glow plug system 18W
Y03 008 14 Magnetventil Fahrstufenumschaltung Solenoid valve, speed range selector
Y04 008 10 Magnetventil Bremse Solenoid valve, brake 1,25A
10

Y14 012 3 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit

Y15 013 16 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 1,75A
Y16 007 10 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 1,08A
Y16 007 12 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 1,08A
Y17 007 6 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 1,08A
11

Y17 007 8 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 1,08A
Y92 010 7 Magnetventil Lenkung vorne rechts Solenoid valve, steering, front rh. max. 1,1A
Y93 010 8 Magnetventil Lenkung vorne links Solenoid valve, steering, front lh. max. 1,1A
Y102 010 12 Magnetventil Schwimmstellung So.valve, floating position max. 1,08A
570 700 42

Y102 010 13 Magnetventil Schwimmstellung So.valve, floating position max. 1,08A

Y108 010 9 Magnetventil Schaufel Heben solenoid valve, lifting shovel max. 1,1A
Y109 010 10 Magnetventil Schaufel Senken solenoid valve, let down shovel max. 1,1A
Y110 010 19 Magnetventil Schaufel oeffnen solenoid valve, open shovel max. 1,1A
Y111 010 18 Magnetventil Schaufel Schließen solenoid valve, close shovel max. 1,1A
110

Y132 007 14 Magnetventil Radmotor vorn links Solenoid valve, wheel motor front lh. max. 0,6A
Y133 007 16 Magnetventil Radmotor vorn rechts Solenoid valve, wheel motor front rh. max. 0,6A
928 Y134 007 17 Magnetventil Radmotor hinten links BOMAG
Solenoid valve, wheel motor rear lh. 008
max. 0,6A 911 57
 Name Bl. Pf. Benennung title TYP
Y135

Y147
007
Wiring diagram 570 700 42
Y138 013
004
19
13
12
Magnetventil Radmotor hinten rechts
Magnetveentil Heizung
Injektor A1
Solenoid valve, wheel motor rear rh.
Solenoid valve, heating unit
jet pump A1
max. 0,6A
0,42A 20.5
Y148 004 14 Injektor A2 jet pump A2
Y149 004 13 Injektor A3 jet pump A3
Y150 004 17 Injektor B1 jet pump B1
Y151 004 16 Injektor B2 jet pump B2
Y152 004 16 Injektor B3 jet pump B3
Y166 004 14 Injektor A4 jet pump A4
Y167 004 18 Injektor B4 jet pump B4
Seis
06.08.2007
Werner
06.08.2007
component listing
Bauteilliste
11
11
570 700 42
111

008 911 57 BOMAG 929

 008 911 57 BOMAG 930
404

402
408

394
400
403
405
406
407
409
414

392
398

393
395
396
397
399
412

401
410
413
415

391
411

K77 K77
H07

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
057 513 10

2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
057 664 11 057 664 11
057 564 17

057 564 37
057 564 22 057 564 30
057 564 23
1x6qmm
1x6qmm

Seis

153 131 Versorgung Kabine 1x6qmm

1
Werner

154 132
155 133 1x6qmm Versorgung Kabine 1x6qmm
2
06.08.2007
06.08.2007

156 134
K11

157 135 1x6qmm Masse Kabine 3

158 136
057 543 08

1x6qmm Masse Kabine 4

159 137
160 138 Masse Schutzbelüftung 5
161 139
057 564 29

162 140 6
163 141
164 142 7
165 143
1x2,5qmm
1x4qmm

1x6qmm
1x6qmm

166 144 8
057 564 35

167 145 9
K05

168 146 15A

169 147 Klimatronik Konvekta 1x1,5qmm F50 20
170 148 Zigarettenanzünder + 30A
171 149 1x1,5qmm F89 21
Tachograph / BC 672 EB
057 564 19
K22

172 150 Schutzbelüftung 22

173 151
30A
174 152 Zündschloß 1x6qmm 1x6qmm
F13 23
187 181 25A
188 182 EDC7 Steuerung (30) 2x2,5qmm F93 24
189 183 30A
Steckdose 1x2,5qmm F05 25
190 184
10A
191 185 Prozessor Steuerung 1x2,5qmm 1x2,5qmm
F84 26
192 186
K113 K13

30A
206 201 Leistung Steuerung 5x0,75qmm F67 27 1x4qmm
207 202
Schutzbelüftung
208 203 28
209 204 15A
Instrumente 1x1,5qmm
K90

F24 29
210 205
Schmieranlage + 10A
226 221 1x1,5qmm F16 30
Tachograph / BC 672 EB
227 222 15A
Fahrersitz 1x1,5qmm F29 31 1x2,5qmm
228 223
K48

10A
229 224 EDC7 Steuerung (15) 1x1,5qmm F122 32
230 225
K11

10A
235 231 Zykon Abscheider 1x1,5qmm F31 33 1x2,5qmm
236 232 15A
K61

Signalhörner 1x1,5qmm F23 34

237 233
238 234 10A
Fahren und Bremse 1x1,5qmm F25 35
257 241 10A
258 242 Klimatronik Konvekta 1x1,5qmm F33
057 268 42

36
K62

259 243
260 244 37
261 245 45 41
262 246 45 41
K133

263 247 46 42
264 248 46 42

eïbox
265 249 47 43
057 564 25

266 250 47 43
057 564 36

Schaltkasten
057 564 21

267 251 48 44
057 543 12

1 2 1 2 1 2 1 2
1 2 1 2 1 2 1 2

268 252 48 44
057 564 38

269 253 61
270 254
K15

62
271 255
057 500 57

63
057 664 96

272 256 64
K146

300 291 65
301 292 66
302 292
293 67
K60

303 294 68
304 295 69
305 296 70
306 297 71
307 298 72

057 565 39
308 299 84 81
343 321 85 82

057 565 36
057 668 71

344 322 86 83
057 564 24

345 323 92 87
346 324 93 88
347 325 94 89
348 326 95 90
349 327 96 91
057 564 26

350 328 104 101

057 565 40
351 329 105 102

057 565 38
352 330 106 103
353 331 115 107
354 332 116 108
355 333 117 109
356 334 118 110
X2:AïV

357 335 119 111

358 336 119 111
057 555 96

359 337 120 112

360 338 121 113
361 339 122 114

057 565 37
362 340 125 123
363 341 126 124

057 565 35
364 342
129 127
data interface

375 371 130 128

Datenschnittstelle

376 372
377 373 6 1
378 374 7 2
057 556 04 (Kappe/cap)

057 665 63
383 381 8 3

057 665 61
384 382 9 4

X6:1..10
057 555 98

10 5

1
X6
2 R42 1 2 R10 1
47_O 220_O
2 R40 1 2 R27 1
47_O 10_O

1
057 564 43

057 199 46
diagnosis EMR
Diagnose EMR
X4:
2 R38 1 2 R26 1
47_O 22_O
2 R36 1 2 2 2 2 2 2 2 2
LU Motor
47_O
P18
8 7 6 5 4 3 2 1

057 664 03
1 1
1 1 1 1 1 1

LU Motor

570 700 42
057 664 08

V48
V47
V46
V45
V44
V43
V42
V41

201
057 665 62
Wiring diagram 570 700 42 20.5
008 911 57
Wiring diagram 570 700 42

X28
X4
X2
X17

X1
X30
X15
X3
X11
X35
X7 X21
X18
X13 X39
X23 X9
X26 X12 X40
X0
X19 X27 X10
X16 X31 X42 X36

BOMAG
X22 X41
X29 X24 X8
X14 X18
X17 X27.1 X25

X27.2
D2.1

X33
D2.2 D2.3
X34

06.08.2007
1 1 570 700 42
Werner Lokalisierungsgrafik Steckverbinder Draufsicht
06.08.2007
20.5

931
Seis localization graphic connectors top view 301
932
20.5

X18

X7

X29

X8

X23
X31 X11 X15 X13
X16 X41
X21
X4 X42
X36
X2 X19 X15 X26 X9
X0
X27

X24
X18 X22
X1

X30 X25 X12 X39

X35
X3 X10 X40

D2.2 X34
X17 X27.1
D2.1 X27.2

BOMAG
D2.3 X33

X14

X28

06.08.2007
1 1

008 911 57
Wiring diagram 570 700 42

Werner Lokalisierungsgrafik Steckverbinder Seitenansicht 570 700 42

06.08.2007
Seis localization graphic connectors side view 302