Dokumen - Tips - bw211 212 213d 40 Service Manual e 00891163c08pdf PDF

Service - Manual
BW 211 / 212 / 213 D-40

BW 211 / 212 / 213 PD-40
S/N 101 582 42 . . . . S/N 101 582 43 . . . . S/N 101 582 44 . . . .
S/N 861 583 00 . . . . S/N 101 583 02 . . . . S/N 101 583 03 . . . . S/N 101 582 55 . . . .
S/N 101 582 47 . . . . S/N 101 582 48 . . . . S/N 101 582 49 . . . .
Single drum roller
Catalogue number.
008 911 63 03/2008

Table of Contents
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 24
Maintenance 29
2.1 General notes on maintenance 30
2.2 Table of fuels and lubricants 32
2.3 Running-in instructions 33
2.4 Maintenance chart 34
Technical data 37
3.1 Technical data 38
Connection overview 47
4.1 Connection overview 48
Tests and adjustments 51
5.1 Special tools, tests and adjustments 52
5.2 Checking the rotation speeds 56
5.3 Checking / adjusting the neutral positions of the travel pump 58
5.4 Pressure tests in the travel circuit 60
5.5 Checking / adjusting the vibrator shaft speeds 62
5.6 Pressure measurements in the vibration circuit 63
5.7 Check the leakage rate of the vibration motor 64
5.8 Pressure test in steering circuit 65
Flushing and bleeding 67
6.1 Special tools for flushing 68
6.2 Flushing - general 73
6.3 Flushing schematic travel circuit (distribution travel pump) 75
6.4 Flushing the travel circuit (travel pump distribution) 77
6.5 Flushing schematic travel circuit (distribution axle motor) 83
6.6 Flushing the travel circuit (axle motor distribution) 88
6.7 Flushing schematic for vibration drive 93
6.8 Flushing the vibration circuit 94
6.9 Bleeding the travel circuit 98
6.10 Bleeding the vibration circuit 100
Fundamental electrics 103
7.1 Understanding circuit diagrams 104
7.2 Terminal designations 109
7.3 Current and voltage 113
7.4 CAN-Bus 116
7.5 Resistance 118
7.6 Series / parallel connection 120
7.7 Ohm's law 122
7.8 Electrical energy 122
7.9 Formula diagram 123
7.10 Metrology 124
7.11 Diodes, relays, fuses 127
008 911 63 BOMAG 3

Table of Contents
7.12 Batteries 130

7.13 Three-phase generator 133
7.14 Electric starter 141
7.15 Telemecanique switch 144
7.16 Inductive proximity switches 147
7.17 Angle sensors 148
7.18 Plug connectors 150
7.19 Deutsch plug, series DT and DTM 150
7.20 Plugs and terminals in spring clamping technology 157
7.21 Electric modules 160
Special tools, electrics 161
8.1 Special tools, electrics 162
Electronic modules 171
9.1 BEM, BOMAG Evib-meter 173
9.2 Electric module K04 234
9.3 Heating/air conditioning control 238
Speedometer Module 245
10.1 Speedometer module 246
Service Training 249
11.1 Service Training 251
Engine 315
12.1 Diesel engine, general 316
12.2 Service side 317
12.3 Starter side 318
12.4 Lubrication oil circuit 319
12.5 Oil pressure switch and low oil pressure circuitry 321
12.6 Check the engine oil level 322
12.7 Changing engine oil and oil filter cartridges 323
12.8 Coolant circuit 325
12.9 Coolant temperature switch 327
12.10 Disassembling and assembling the coolant temperature switch 328
12.11 Replacing the thermostat 329
12.12 Checking the thermostat in disassembled state 330
12.13 Check the coolant level 331
12.14 Change the coolant 331
12.15 Checking the anti-freeze concentration 332
12.16 Clean the cooling fins on engine and hydraulic oil cooler 333
12.17 Three-phase generator 334
12.18 Fuel supply 336
12.19 Injection system 339
12.20 Injection pump replacement during service 340
12.21 Injection valve replacement during service 349
12.22 Checking / repairing injection valves 352
12.23 Fuel filter 357
12.24 Check, clean the water separator 359
12.25 Change the fuel pre-filter cartridge 359
12.26 Change the fuel filter cartridge 361
4 BOMAG 008 911 63

Table of Contents
12.27 Checking the compression 361

12.28 Check, adjust the valve clearance 362
12.29 Boost fuel solenoid valve 364
12.30 Engine shut-down solenoid 365
12.31 Air filter 366
12.32 Cleaning, changing the dry air filter cartridge 367
12.33 Heating flange on engine 369
12.34 Checking the heating flange control 372
12.35 Electric throttle control 373
12.36 Engine monitoring 375
12.37 Engine 378
12.38 Special tools, Deutz engine (BFM 2012) 380
Air conditioning system 393
13.1 Physical basics 394
13.2 Refrigerant R134a 397
13.3 Compressor oil / refrigeration oil 398
13.4 Working principle of the air conditioning system 399
13.5 Monitoring devices 399
13.6 Description of components 400
13.7 Checking the compressor oil level 406
13.8 Checking the magnetic clutch 407
13.9 Inspection and maintenance work 408
13.10 Checking, replacing the refrigerant compressor V-belt 408
13.11 Service the air conditioning 409
13.12 Drying and evacuation 412
13.13 Emptying in case of repair 412
13.14 Leak test 413
13.15 Filling instructions 414
13.16 Trouble shooting in refrigerant circuit, basic principles 417
13.17 Trouble shooting, refrigerant circuit diagram 421
13.18 Trouble shooting procedure 422
13.19 Steam table for R134a 432
Replacing the cab window panes 437
14.1 Assembly of window panes 438
14.2 Special tools 439
14.3 Auxiliary materials 440
14.4 Removing and installing the window pane 442
Drum 447
15.1 Special tools, drum, single drum rollers 448
15.2 Repair overview for drum 450
15.3 Removing and installing the drum 457
15.4 Repairing the drum 462
15.5 Disassembling and assembling the change-over weight 495
15.6 Changing the rubber buffers and adjusting the pretension 498
Oscillating articulated joint 501
16.1 Special tools, oscillating articulated joint (BW177 to BW 216) 502
16.2 Repair overview oscillating articulated joint 504
008 911 63 BOMAG 5

Table of Contents
16.3 Removing and installing the oscillating articulated joint 508

16.4 Dismantling the oscillating articulated joint 510
16.5 Assembling the oscillating articulated joint 515
Suppliers documentation 525
17.1 Travel pump 527
17.2 Vibration pump 617
17.3 Drum drive 655
17.4 Vibration motor 705
17.5 Axle drive motor 729
17.6 Axle 811
Circuit diagrams 933
18.1 Hydraulic diagram 581 202 10 935
18.2 Hydraulic diagram 581 202 11 939
18.3 Wiring diagram 582 702 09 943
18.4 Wiring diagram 582 702 29 979
18.5 Wiring diagram 582 702 41 1013
6 BOMAG 008 911 63

1 General
008 911 63 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 63

Safety regulations 1.2

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

These safety regulations must be read and ap- steering wheel.
plied by every person involved in the repair of this
machine. The applicable accident prevention in-
●
On machines with articulated joint keep the articu-
structions and the safety regulations in the oper-
lated joint locked during work.
ating and maintenance instructions must be ●
Use protective clothes like hard hat, safety boots
additionally observed. and gloves.
Repair work shall only performed by appropriately
●
Keep unauthorized persons away from the machine
trained personnel or by the after sales service of during repair work.
BOMAG. ●
Tools, lifting gear, lifting tackle, supports and other
auxiliary equipment must be fully functional and in
Any suggestions, safety precautions and warn-
safe condition.
ings in this section are intended as a mnemonic
aid for well trained and experienced expert me- ●
Use only safe and approved lifting gear of sifficient
chanics. This manual should not be considered a load bearing capacity to remove and install parts or
bible on workshop safety. components from and to the machine.
Workshop equipment and facilities as well as the

●
Be careful with cleansing agents. Do not use easily
use and waste disposal of solvent, fluids, gases inflammable or harmful substances, such as gaso-
and chemicals are subject to legal regulations, line or paint thinners for cleaning.
which are intended to provide a minimum on safe- ●
Cleaning or repair work on the fuel tank is very dan-
ty. It is obviously your own responsibility to know gerous. Do not smoke or allow any ignitable sparks
and adhere to these regulations. or open fire in the vicinity when cleaning or repairing
This manual contain headers like "Note", "Attention", a tank. .
"Danger" and "Environment", which must be strictly ●
When performing welding work strictly comply with
complied with in order to avoid dangers for health and the respective welding instructions.
for the environment.
Precautions and codes of conduct for
! Danger welding work
Paragraphs marked like this highlight possible Welding work should only be performed by specially
dangers for persons. instructed expert personnel.
! Caution ! Danger
Paragraphs marked like this highlight possible Electric shock!
dangers for machines or parts of the machine.
Sparks, fire hazard, burning of skin!
Infrared or ultraviolet radiation (arc), flashing of
i Note
eyes!
Paragraphs marked like this contain technical infor-
mation for the optimal economical use of the machine. Health hazard caused by welding work on highly
alloyed work pieces, metal coatings, paint coat-
ings, plastic coatings, oil containing dirt deposits,
Environment grease or solvent residues, etc.!
Paragraphs marked like this point out practices ●
Check welding equipment and cables for damage
for safe and environmental disposal of fuels and before use (also the validity of inspection stickers).
lubricants as well as replacement parts.
●
Ensure good conductivity between earth cable and
Observe the regulations for the protection of the work piece.
environment.
●
Start the extraction fan before starting work and
guide with the progressing work as required.
General
●
Always isolate the burner when laying it down (re-
●
Before starting repair work stand the machine on move possible electrode residues).
level and solid ground.
●
Protect cables from being damaged, use cables
●
Always secure the machine against unintended roll- with insulated couplings.
ing.
●
Ensure sufficient fire protection, keep a fire extin-
●
Secure the engine reliably against unintentional guisher at hand.
starting.
008 911 63 BOMAG 9

●
In case of welding work in fire or explosion endan- full face visor; a facility suitable for rinsing the eyes
gered environments, you should always ask for a should also be available.
welding permission. ●
Avoid prolonged and repetitive contact with oil, es-
●
Remove combustible parts from the vicinity or cover pecially with old oil. In case of open incisions and in-
such parts. juries seek medical advice immediately.
●
Name a fire watch during and after welding work. ●
Apply protective cream before starting work, so that
●
Do not clamp the welding rod holder and the inert oil can be easier removed from the skin.
gas welding gun under your arm and lay these parts ●
Wash with soap and water to ensure that all oil has
only on an insulated top. been removed (a skin cleaning agent and a nail
●
Place the inert gas bottles in a safe place and se- brush will help). Lanolin containing agents will re-
cure them against falling over. place natural skin oils that were lost.
●
Use a protective screen or an arcing shield with
●
Do not use gasoline, kerosene, diesel, thinner or
welding glass, wear welding gloves and clothes, solvents to wash the skin.
this applies also for assisting persons. ●
Do not put oil soaked cloths into your pockets.
●
Switch the welding unit off before connecting weld- ●
Avoid clothes, especially underpants, getting soiled
ing cables. by oil.
Behaviour in case of faults
●
Overalls must be washed at regular intervals.
Clothes that cannot be washed, must be disposed
●
Check electrode holders and electric cables at reg- of.
ular intervals.
●
If possible degrease components before handling.
●
In case of deficiencies switch off the welding unit
and inform supervising persons.
Environment
●
In case of an extractor fan failure or any other fault
inform the supervising persons. It is strictly prohibited to drain off oil into the soil,
the sewer system or into natural waters. Entrust
Maintenance; waste disposal special companies with the waste disposal of old
oil. If in doubt you should consult your local au-
●
Replace damaged insulating jaws and welding rod
thorities.
holders immediately.
●
Replace the welding wire reels only in deenergized
Hydraulics
state.
●
Hydraulic oil escaping under pressure can pene-
What to do in case of accidents; First Aid trate the skin and cause severe injury. You should
●
Keep calm. therefore relieve the pressure in the system before
disconnecting any lines.
●
Call first air helpers.
●
Before applying pressure to the system make sure
●
Report the accident.
that all line connections and ports have been prop-
●
In case of an electric accident: Interrupt the power erly tightened and are in perfect condition.
supply and remove the injured person from the ●
Hydraulic oil leaking out of a small opening can
electric circuit. If breathing and heart have stopped
hardly be noticed, therefore please use a piece of
apply reactivation measures and call for an emer-
cardboard or wood when checking for leaks. When
gency doctor.
being injured by hydraulic oil consult a physician im-
mediately, as otherwise this may cause severe in-
Old oils fections.
Prolonged and repetitive contact with mineral oils will ●
Do not step in front of or behind the drums/wheels/
remove the natural greases from the skin and causes crawler tracks when performing adjustment work in
dryness, irritation and dermatitis. Moreover, used en- the hydraulic system while the engine is running.
gine oils contain potentially hazardous contaminants, Block drums and/or wheels / crawler tracks with
which could cause skin cancer. Appropriate skin pro- wedges.
tection agents and washing facilities must therefore
be provided.
●
Wear protective clothes and safety gloves, if possi-
ble.
●
If there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
10 BOMAG 008 911 63


Reattach all guards and safety installations after plastic material, a so-called fluoroelastomer. Under
all work has been completed. normal operating conditions this material is safe and
does not impose any danger to health.
Environment However, if this material becomes damaged by fire or
extreme heat, it may decompose and form highly
It is strictly prohibited to drain off hydraulic oil
caustic hydrofluoric acid, which can cause severe
into the soil, the sewer system or into natural wa-
burns in contact with skin.
ters. Entrust special companies with the waste
disposal of old oil. If in doubt you should consult ●
If the material is in such a state it must only be
your local authorities. touched with special protective gloves. These
gloves must be disposed of directly after use.
Fuels ●
If the material has contacted the skin despite these
measures, take off the soiled clothes and seek
medical advice immediately. In the meantime wash
! Danger
the affected parts of the skin for 15 to 60 minutes
Repair work on fuel systems must only be per- with cold water or lime water.
formed by appropriately trained personnel.
The following notes refer to general safety precau- Poisonous substances
tions for danger free handling of fuel. These notes are
Some of the fluids and substances used are toxic and
only general instructions; in case of uncertainties you
must under no circumstances be consumed.
should consult the person responsible for fire protec-
tion. Skin contact, especially with open wounds, should be
strictly avoided.
Fuel vapours not only are easily inflammable, but also
highly explosive inside closed rooms and toxic; dilu- These fluids and substances are, amongst others,
tion with air creates an easily inflammable mixture. anti-freeze agents, hydraulic oils, washing additives,
The vapours are heavier than air and therefore sink lubricants and various bonding agents.
down to the ground. Inside a workshop they may eas-
ily become distributed by draft. Even the smallest por- Engine
tion of spilled fuel is therefore potentially dangerous.
●
Fire extinguishers charged with FOAM, SCHAUM, ! Danger
CO2 GAS or POWDER must be available wherever
Do not work on the fuel system while the engine is
fuel is stored, filled in, drained off, or where work on
running - danger to life!
fuel systems is performed.
After the engine has stopped wait until the pres-
●
The vehicle battery must always be disconnected,
sure has dropped (on Commonm Rail engines ap-
BEFORE work in the fuel system is started. While
prox. 5 minutes, other engines 1 minute), because
working on the fuel system you should not discon-
the system is under high pressure - danger to life!
nect the battery, because this could generate
sparks, which would ignite explosive fuel vapours. Keep out of the danger zone during the initial test
rung. Danger caused by high pressure in case of
●
Wherever fuel is stored, filled, drained off or where
leaks - danger to life!
work on fuel systems is carried out, all potential ig-
nition sources must be extinguished or removed. When performing work on the fuel system make
Search lights must be fire proof and well protected sure that the motor cannot be started unitention-
against possible contact with running out fuel. ally - danger to life!
●
Maintenance and cleaning work on the engine must
Hot fuels onyl be performed with the engine stopped and
cooled down. Make sure that the electric system
Before draining fuel off the tank for repair work, you
has been switched off (ignition key pulled out).
must strictly apply the following measures:
●
Observe the accident prevention regulations for
●
Allow the fuel to cool down, to prevent any contact
electric systems (e.g. -VDE-0100/-0101/-0104/-
with a hot fluid.
0105 Electric precautions against dangerous con-
●
Vent the system, by removing the filler cap in a well tact voltages).
ventilated area. Screw the filler cap back on, until ●
Cover all electric components properly before wet
the tank is finally emptied.
cleaning.
Synthetic rubber
Many O-rings, hoses and similar parts, which are ap-
parently made of natural rubber, are actually made of
008 911 63 BOMAG 11

Air conditioning system from April 1989). Paragraph 10 of the pressure ves-
sel directive demands that these pressure contain-
ers must be periodically inspected and tested by a
! Caution specialist, according to paragraph 32. In this case
Lines in the air conditioning system must only be periodically recurring inspections consist of external
loosened by trained and explicitly instructed ex- examinations, normally on containers in operation.
perts. The refrigerant container must be visually inspected
two times per year, within the frame work of major
●
Wear safety goggles! Put on your safety goggles.
inspections. Special attention must thereby be paid
This will protect your eyes against coming into con-
to signs of corrosion and mechanical damage. If the
tact with refrigerant, which could cause severe
container is in no good condition, it should be re-
damage by freezing.
placed for safety reasons, in order to protect the op-
●
Wear safety gloves and an apron! Refrigerant are erator or third parties against the dangers when
excellent solvents for greases and oils. In contact handling or operating pressure vessels.
with skin they will remove the protective grease film. ●
Secure pressure vessels against tipping over or roll-
However, degreased skin is very sensitive against
ing away.
cold temperatures and germs.
●
Do not throw pressure vessels. Pressure vessels
●
Do not allow liquid refrigerants to come into contact
may thereby be deformed to such an extent, that
with skin! Refrigerant takes the heat required for
they will crack. The sudden evaporation and escape
evaporation from the environment. Very low tem-
of refrigerant releases excessive forces. This ap-
peratures may be reached. The results may be local
plies also when snapping off valves on bottles. Bot-
frost injuries (boiling point of R134a -26.5°C at am-
tles must therefore only be transported with the
bient pressure).
safety caps properly installed.
●
Do not inhale higher concentrations of refrigerant ●
Refrigerant bottles must never be placed near heat-
vapours! Escaping refrigerant vapours will mix with
ing radiators. Higher temperatures will cause higher
the ambient air and displace the oxygen required for
pressures, whereby the permissible pressure of the
breathing.
vessel may be exceeded. The pressure vessel di-
●
Smoking is strictly prohibited! Refrigerants may be rective therefore specifies that a pressure vessel
decomposed by a glowing cigarette. The resulting should not be warmed up to temperatures above 50
substances are highly toxic and must not be in- °C.
haled. ●
Do not heat up refrigerant bottles with an open
●
Welding and soldering on refrigeration equipment! flame. Excessive temperatures can damage the
Before starting welding or soldering work on vehi- material and cause the decomposition of refriger-
cles, (in the vicinity ant.
of air conditioning components) all refrigerant must ●
Do not overfill refrigerant bottles, since any temper-
be drawn out and the rests removed by blowing out
ature increase will cause enormous pressures.
the system with nitrogen. The decomposition prod-
ucts created from the refrigerant under the influence
of heat not only are highly toxic, but also have a Environment
strong corrosive effect, so that pipes and system In operation, during maintenance and repair work
components may be attacked. The substance is and when taking refrigeration systems our of
mainly fluorohydrogen. service it is not permitted to let refrigerant escape
●
Pungent smell! In case of a pungent smell the afore into the atmosphere, which would contradict the
mentioned decomposition products have already current status of technology.
been created. Extreme care must be exercised not
to inhale these substances, as otherwise the respi- Battery
ratory system, the lungs and other organs may be
harmed.
●
Wear goggles and face protection (acid).
●
Wear suitable clothes to protect face, hands and
●
When blowing out components with compressed air body (acid).
and nitrogen the gas mixture escaping from the
components must be extracted via suitable exhaust
●
Work and store accumulators only well ventilated
facilities (workshop exhaust systems). rooms. (Development of oxyhydrogen gas).
●
Do not lean over the battery while it is under load,
Handling pressure vessels being charged or tested. (Danger of explosion).
●
Since the fluid container is pressurized, the manu- ●
Burning cigarettes, flames or sparks can cause ex-
facture and testing of these pressure vessels is gov- plosion of the accumulator
erned by the pressure vessel directive. (New edition ●
Keep ignition sources away from the battery.
12 BOMAG 008 911 63


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

●
Use only genuine BOMAG spare parts for repair
purposes. Original parts and accessories have
been specially designed for this machine.
●
We wish to make explicitly clear that we have not
tested or approved any parts or accessories not
supplied by us. The installation and/or use of such
products may therefore have an adverse effect on
the specific characteristics of the machine and
thereby impair the active and/or passive driving
safety. The manufacturer explicitly excludes any li-
ability for damage caused by the use of non-original
parts or accessories.
●
Unauthorized changes to the machine are prohibit-
ed for safety reasons.
●
If tests on the articulated joint need to be performed
with the engine running, do not stand in the articu-
lation area of the machine, danger of injury!
●
Do not perform cleaning work while the engine is
running.
●
If tests must be performed with the engine running
do not touch rotating parts of the engine, danger of
injury.
●
Exhaust gases are highly dangerous. Always en-
sure an adequate supply of fresh air when starting
the engine in closed rooms.
●
Refuel only with the engine shut down. Ensure strict
cleanliness and do not spill any fuel.
●
Keep used filters in a separate waste container and
dispose of environmentally.
●
Dispose of oils and fuel environmentally when per-
forming repair or maintenance work.
●
Do not refuel in closed rooms.
●
Do not heat up oil higher than 160 °C because it
may ignite.
●
Wipe off spilled oil and fuel.
●
Do not smoke when refuelling or when checking the
acid level in the battery.
●
Do not check the acid level of the battery with a na-
ked flame, danger of explosion!
●
Old batteries contain lead and must be properly dis-
posed of.
008 911 63 BOMAG 13

1.3 General repair instructions
General Electrics
1.3 General repair i nstructions
●
Before removing or disassembling and parts, hoses General
or components mark these parts for easier assem-
bly. The electric and electronic systems in construction
equipment are becoming more and more extensive.
●
Before assembly oil or grease all parts, as far as this Electronic elements are increasingly gaining impor-
is necessary. tance in hydraulic and mechanical vehicle systems.
Diagnostics according to plan
A structured approach in trouble shooting saves time
and helps to avoid mistakes and expenses, especially
in the fields of electrics and electronics. Understand-
ing electronic controls requires the knowledge of
some basic terms concerning their general perform-
ance. In many cases error logs are just simply read
out and control units are replaced without any further
trouble shooting. This is in most cases unnecessary
and, even more important, very expensive.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
●
In approx. 10 % of the examined cases the prob-
lems were caused by control units.
●
In approx. 15 % sensors and actuators were the
cause of the problems.
By far the highest proportion of all faults could be
traced back to wiring and connections (plugs, etc.).
General:
●
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Electric signals must be checked at
the locations to which they are applied, i.e. on con-
trol unit or sensor technology. So, if the system had
been diagnosed without unplugging the control unit
and checking the wiring, one should be alerted.
●
Check for good cable and ground contacts, there-
fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
●
Perform trouble shooting in a systematic way. Do
not become confused by the high number and vari-
ety of electric cables, current can only flow in a
closed circuit. You should first become acquainted
with the function of the corresponding electric circuit
by following the correct wiring diagram. Detected
faults should be rectified immediately. If the system
still does not work correctly after this measure, trou-
ble shooting must be continued. Several faults very
rarely occur at the same time, but it is not impossi-
ble.
●
Do not disconnect or connect battery or generator
while the engine is running.
●
Do not operate the main battery switch under load.
14 BOMAG 008 911 63

General repair instructions 1.3

●
Do not use jump leads after the battery has been re- Battery
moved.
Rules for the handling of batteries
●
Sensors and electric actuators on control units must
never be connected individually or between exter- Even though it may be conveniently installed in the
nal power sources for the purpose of testing, but engine compartment, it should never be used as a rest
only in connection with the control unit in question, for tools. When connecting the poles, e.g. by means
as otherwise there may be a risk of destruction of a spanner, the battery will become an "electric
(damage)! welder".
●
Disconnecting the control unit plug connectors with As a measure to avoid short circuits you should first
the control unit switched on, i.e. with the power sup- disconnect the negative pole during disassembly and
ply (terminal 15 "On"), is not permitted. Switch the reconnect the negative pole last during assembly.
voltage supply "off" first - then pull out the plug. Terminal clamps should be assembled with as little
●
Even with an existing polarity reversal protection in- force as possible.
correct polarity must be strictly avoided. Incorrect Poles and terminal clamps should always be kept
polarity can cause damage to control units! clean to avoid transition resistances during starting
and the related development of heat.
●
Plug-in connectors on control units are only dust
and water tight if the mating connector is plugged You should obviously also pay attention to secure fas-
on! Control units must be protected against spray tening of the battery in the vehicle.
water, until the mating connector is finally plugged
on!
●
Unauthorized opening of the control electronics (mi-
cro controller MC) as well as changes or repairs on
the wiring can lead to dangerous malfunctions.
●
Do not use any radio equipment or mobile phones
inside the driver's cab without an appropriate out-
side antenna or in the vicinity of the control electron-
ics!
Electrical system and welding work
●
Surge voltages in the electric system must be strict-
ly avoided:
●
When performing welding work always fasten the
earth clamp of the welding unit in the immediate vi-
cinity of the welding location.
! Caution
Switch off the main battery switch, doisconnect
the generator and pull the plug out on the control
unit before starting welding work.
008 911 63 BOMAG 15

Hydraulic system ●
After changing a component perform a high and
charge pressure test, if necessary check the speed
of the exciter shaft.
! Caution
●
The operating pressure of the exciter shaft to a
Do not open any hydraulic components if you
great extent depends on the base under the vibrat-
have not been properly trained and without exact
ing drum. If the soil is too hard place the drums on
knowledge.
old rubber tires. Do not activate the vibration on a
Please note hard, concreted base, danger of bearing damage.
Cleanliness is of utmost importance. Make sure that ●
After the completion of all tests perform a test run
no dirt or other contaminating substances can enter and then check all connections and fittings for leaks
into the system. with the engine still stopped and the hydraulic sys-
tem depressurized.
●
Clean fittings, filler covers and the area around such
parts before disassembly to avoid entering of dirt. Before commissioning
●
Before disconnecting hoses, pipes or similar relieve ●
After changing a component clean the hydraulic oil
the system pressure with the engine shut down. tank thoroughly.
●
During repair work keep all openings closed with ●
Fill the housings of hydraulic pumps and motors
clean plastic plugs and caps. with hydraulic oil.
●
Do not run pumps and motors without oil. ●
Use only hydraulic oils according to the specifica-
●
When cleaning hydraulic components take care not tion in the maintenance instructions.
to damage any fine machine surfaces. ●
After changing a component clean the hydraulic
●
Chemical and rubber soluble cleansing agents may system as described in the flushing instructions in
only be used to clean metal parts. Do not let such order to prevent all other components from being
substances come in contact with sealing material. damaged by abrasion and metal chips remaining in
the system.
●
Rinse of cleaned parts thoroughly, dry them with
compressed air and apply anti-corrosion oil immedi-
●
Change the hydraulic oil filter.
ately. Do not install parts that show traces of corro- Commissioning
sion.
●
Bleed the hydraulic circuits.
●
Avoid the formation of rust on fine machined caused
by hand sweat. ●
Start up the system without load.
●
Grease must not used as a sliding agent for assem- ●
Check the hydraulic oil level in the tank, fill up oil if
bly work. Use hydraulic oil. necessary.
●
Do not start the engine after the hydraulic oil has After commissioning
been drained off. ●
Check system pressures and speeds.
●
Use only the specified pressure gauges. Risk of ●
Check fittings and flanges for leaks.
damaging the pressure gauges under too high pres-
sure. ●
After each repair check all adjustment data, rota-
tional speeds and nominal values in the hydraulic
●
Clean ports and fittings before removal so that no
system, adjust if necessary.
dirt can enter into the hydraulic system.
●
Do not adjust pressure relief valves and control
●
Check the hydraulic oil level before and after the
valves to values above their specified values.
work.
●
Use only clean oil according to specification.
●
Check the hydraulic system for leaks, find and rec-
tify the cause.
●
Fill new hydraulic units with hydraulic oil before
starting operation.
●
After changing a component thoroughly flush and
bleed the entire hydraulic system.
●
Perform measurements at operating temperature of
the hydraulic oil (approx. 40 ¯C).
16 BOMAG 008 911 63


Air conditioning system damp air is drawn into the component by the differ-
ence in temperatures.
CFC - halon prohibition ●
Damaged or leaking parts of the air conditioning
The CFC - halon prohibition from May 06, 1991 regu- must not be repaired by welding or soldering, but
lates the withdrawal from the use of CFC and the han- must generally be replaced.
dling of these refrigerants.
●
Do not fill up refrigerant, but extract existing refrig-
Contents: erant and refill the system.
Since 1995 CFC (R12) is no longer permitted for use ●
Different types of refrigerant must not be mixed.
in new systems. Only the refrigerant specified for the corresponding
In operation, during maintenance and repair work and air conditioning system must be used.
when taking refrigeration systems our of service it is ●
Refrigerant circuits with refrigerant type R134a
not permitted to let refrigerant escape into the atmos-
must only be operated with the compressor oil / re-
phere, which would contradict the current status of
frigeration oil approved for the compressor.
technology.
Work on refrigeration systems must only be carried
●
Used compressor oil / refrigeration oil must be dis-
out by persons with well founded knowledge about posed of as hazardous waste.
such systems and who have the necessary technical ●
Due to its chemical properties compressor oil / re-
equipment available. frigeration oil must never be disposed of together
The use of refrigerant must be documented. with engine or transmission oil.
Old systems should be converted to refrigerants
●
Compressor oil / refrigeration oil is highly hydro-
harmless to ozone (refrigerant substitutes). scopic. Oil cans must strictly be kept closed until
use. Oil rests should not be used, if the can had
For this reason the Federal Environmental Agency at been opened over a longer period of time.
the end of 1995 published suitable replacement refrig-
erants for R 12. As a consequence old systems must ●
All O-rings as well as pipe and hose fittings must be
no longer be filled with R12. As soon as such a system oiled with compressor/refrigeration oil be-
is opened for service, the system must be converted foreiassembly.
to a suitable replacement or service refrigerant. Old ●
When replacing a heat exchanger, e.g. evaporator
systems may still be used, as long as they are leak or condenser, any compressor oil / refrigeration oil
tight. R 134a was nominated as replacement for R 12. lost by exchanging the components, must be re-
Inside the European Union the "EU-Directive 2037/ placed with fresh oil.
2000 on substances causing decomposition of the ●
A too high compressor oil / refrigeration oil level ad-
ozone layer" regulates the production, use and avail- versely affects the cooling performance and a too
ability of CFC and H-CFC. low oil level has a negative effect on the lifetime of
●
In case of a repair on the refrigeration system you the compressor.
should first evacuate the air conditioning system for ●
If a air conditioning unit needs to be opened, the
at least 45 minutes to remove any moisture from the dryer must be replaced in any case.
system, before you start to refill. Moisture bonded in
the compressor oil / refrigeration oil (PAG oil) can
●
Always use new O-rings when reassembling the
only be removed from the system by changing the unit.
oil. ●
Always use two spanners when connecting pipes or
●
During repair work on refrigerant lines and compo- hoses, to prevent the pipe end from being damaged
nents, these must be kept closed as far as possible, .
in order to prevent the invasion of air, moisture and ●
Tighten screw fittings with the specified torque.
dirt, because the operational reliability of the system
can only be assured if all components in the refrig-
●
Check the connections of pipes, fittings or compo-
erant circuit are clean and dry from inside. nents thoroughly; do not use if damaged.
●
Make sure that no dirt or foreign parts can enter into
●
Do not leave the refrigerant circuit unnecessarily
the compressor or the air conditioning system. The open to the atmosphere. Do not attempt to repair
area around the refrigerant hoses should be bent or burst pipes.
cleaned with a gasoline free solvent. ●
Compressor valves must only be opened after the
●
All parts to be reused should be cleaned with a system has been properly sealed.
gasoline free solvent and blow-dried with clean ●
The use of leak detection colouring matter is not
compressed air or dried with a lint-free cloth. permitted, because its chemical composition is un-
●
Before opening all components should have known and its effect on compressor oil and rubber
warmed up to ambient temperature, to avoid that elements is not predictable. The use of leak detec-
008 911 63 BOMAG 17

tion colouring matter makes any warranty claims Fuel hoses

null and void.
●
Tools used on refrigeration circuits must be of ex-
cellent condition, thus to avoid the damage of any
connections.
●
The dryer is to be installed last, after all connections
in the refrigerant circuit have been tightened.
●
After completion of repair work screw locking caps
(with seals) on all connections with valves and on
the service connections. Start up of the air condi-
tioning system. Observe the filling capacity.
●
Before start up of the air conditioning system after a Fig. 1
new filling: - Turn the compressor approx. 10 revo-
lutions by hand using the clutch or V-belt pulley of
the magnetic clutch. - Start the engine with the com- ! Caution
pressor/control valve switched off. - Once the idle All fuel hoses have two layers of material, a rein-
speed of the engine has stabilized switch on the forced rubber coating outside and an internal Vi-
compressor and run it for at least 10 minutes at idle ton hose. If a fuel hose has come loose one must
speed and maximum cooling power. make absolutely sure that the internal Viton layer
has not been separated from the reinforced outer
●
Never operate the compressor over longer periods
layer. In case of a separation the hose needs to be
of time with high engine speeds without a sufficient
replaced.
amount of refrigerant in the system. This could
probably cause overheating and internal damage.
18 BOMAG 008 911 63


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
pr event the sealing lip from being damaged.
be tracked down to careless assembly, causing dam-
age not only to the seal or gasket, but also to the mat-
ing surfaces. Careful assembly work is mandatory if
good results are to be achieved.
●
Before assembling replacement seals make sure
that the running surface is free of pitting, flutes, cor-
rosion or other damage.
●
Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
●
Sealing compound should only be used if specially
requested in the instructions. In all other cases
these joints should be assembled in dry condition.
●
Sealing compound must be applied thin and evenly
on the corresponding surfaces; take care that the Fig. 3
compound does not enter into oil galleries or blind ●
Lubricate the outer rim 1 (Fig. 3) of the seal and
threaded bores.
press it flat on the housing seat.
●
Before assembly remove any residues of old seal-
ing compound. Do not use any tools that could dam-
age the sealing surfaces. i Note
If possible, use a "bell" 1 (Fig. 3), to make sure that
●
Examine the contact faces for scratches and burrs, the seal will not skew. In some cases it may be ad-
remove these with a fine file or an oilstone; take visable to assemble the seal into the housing first, be-
care that no grinding dust and dirt enters into fore sliding it over the shaft. Under no circumstances
tapped bores or enclosed components. should the full weight of the shaft rest on the seal.
●
Blow lines, ducts and gaps out with compressed air,
If you have no proper service tools at hand, use a suit-
replace any O-rings and seals that have been dis-
able drift punch with a diameter which is about 0.4mm
lodged by the compressed air.
smaller than the outer diameter of the seal. Use VERY
Assembly of radial seals LIGHT blows with the hammer if no press is available.
●
Press or knock the seal into the housing, until it is
flush with the housing surface.
Fig. 2
●
Lubricate sealing lips 1 (Fig. 2) with clean grease; in
case of double seals fill the space between the seal-
ing lips with a generous amount of grease.
●
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.
i Note
If possible, use an assembly sleeve 1 (Fig. 2), to pro-
tect the lip fr om being damag ed by s harp edg es,
008 911 63 BOMAG 19

Feather keys and keyways Ball and roller bearings
! Caution ! Caution
Feather keys must only be reused if they show no Ball and roller bearings must only be reinstalled
differences to new feather keys, any notches must after it has been assured that they are in perfect
be considered as initial signs of wear. condition.
Fig. 4
●
Clean and thoroughly examine the feather key.
●
Debur and thoroughly clean the edges of the key-
way with a fine file before reassembling.
Fig. 5
●
Remove any lubricant residues from the bearing to
be examined by washing it with gasoline or any oth-
er appropriate degreasing agent. Cleanliness is of
utmost importance for all related work.
●
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. If necessary replace the bearing with
a new one, since these symptoms are first signs of
wear.
●
Hold the bearing with you thumb and the index fin-
ger by the inner race, rotate the outer race and
make sure that it runs without friction. Hold the
bearing by the outer race and repeat this test with
the inner race.
●
Move the outer race gently to and fro while holding
it by the inner race; check for resistance while rotat-
ing and replace the bearing if it does not work cor-
rectly.
●
Lubricate the bearing with an appropriate lubricant
before reinstalling.
20 BOMAG 008 911 63


●
Check shaft and bearing housing for discolouration Screws and nuts
or other signs of movement between bearing and
seats. Tightening torque
●
Make sure that shaft and housing are free of burrs
before assembling the bearing. ! Caution
●
If a bearing of a pair of bearings shows any defects, Always tighten nuts or screws to the specified
we highly recommend the replacement of both tightening torque. Tightening torques deviating
bearings. from the ones in the table are specially mentioned
in the repair instructions.
●
On greased bearings (e.g. wheel bearings) fill the
space between bearing and outer seal with the rec- Damaged screws must under no circumstances
ommended type of grease before assembling the be used any longer. Recutting threads with thread
seal. cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
●
Always mark the individual parts of separable bear-
roded thread pitches can cause incorrect torque
ings (e.g. taper roller bearings) to enable correct re-
value readings.
assembling. Never assemble the rollers to an outer
race that has already been used, replace the com- Self-locking nuts must be generally renewed.
plete bearing instead. The use of screws with too high strength can
cause damage!
●
Nut of a higher strength can generally be used in-
stead of nuts of a lower strength classification.
●
When checking or retightening screw joints to the
specified tightening torque you should first relieve
by a quarter turn and then tighten to the correct
torque.
●
Before tightening you should lightly oil the thread, in
order to ensure low friction movement. The same
applies for self-locking nuts.
Fig. 6 ●
Make sure that no oil or grease will enter into tapped
bores. The hydraulic power generated when turning
in the screw could cause breakage of the effected
! Caution
part.
When assembling the bearing to the shaft load
must only be applied to the inner race 1 (Fig. 6).
When fitting the bearing into the housing load
must only be applied to the outer race (2).
008 911 63 BOMAG 21

Strength classes of metric screws Strength classes of metric nuts

The strength classes (from 3.6 to 12.9) are specified Nuts are differentiated by three load groups. Each
for all strength classes from a nominal diameter of load group has a special designation system for the
5mm. The corresponding identification can be found strength class assigned, so that the load group can be
where allowed for by the shape of the screw. clearly identified.
Nuts for screw joints with full load capability (4, 5,
6, 8, 10, 12)
Fig. 8 Identification of nuts

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

nut screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
Fig. 7 Identification of screws 6 6.8
8 8.8
Example: A screw is identified with 12.9.
9 9.8
The first number corresponds with 1/100 of the nomi- 10 10.8
nal tensile strength (minimum tensile strength) in N/ 12 12.8
mm2.
Nuts for screw joints with limited load factor (04,
●
The nominal tensile strength is 12 X 100N/mm2 = 05)
1200 N/mm2. The preceding "0" indicates that, due to their low
The second number specifies 10-times the ration be- height, nuts 2 (Fig. 8) in this group are only able to
tween lower yield point and nominal tensile strength withstand the force of a screw to a limited extent.
(yield point ratio). Nut height below 0.8 d (d = nominal dimension).
Nuts for screw joints without specified load factor
i Note (11H, 14H, 17H, 22H)
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas- This standard contains strength classes (hardness
tic deformation). classes) for nuts 3 (Fig. 8), for which no load values
can be specified, e.g. because of their shape and di-
When exceeding the upper yield point the material will mensions, but which can only be classified by their
not restore its original shape after being relieved. hardness.
●
The lower tensile strength is 9/10 X 1200 N/mm2 = Nut height below 0,5 d (d = nominal dimension).
1080 N/mm2.
i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.
22 BOMAG 008 911 63


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

For small nuts (Fig. 9) the clock system can be used
for identification.
●
The 12 o'clock position is identified by a dot or the
manufacturer's symbol.
●
The strength class is identified by a dash (b).
008 911 63 BOMAG 23

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

●
black oiled
●
with surface protection A4C
●
with surface protection DACROMET
i Note
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with metric unified thread1
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M4 3 5 5
M5 6 9 10
M6 10 15 18
M8 25 35 45
M10 50 75 83
M12 88 123 147
M14 137 196 235
M16 211 300 358
M18 290 412 490
M20 412 578 696
M22 560 785 942
M24 711 1000 1200
M27 1050 1480 1774
M30 1420 2010 2400
1 Coefficient of friction µ tot. = 0,14
Tightening torques for screws with metric unified fine thread1
Screw dimension
8.8 10.9 12.9
M8 x 1 26 37 48
M10 x 1.25 52 76 88
M12 x 1,25 98 137 126
M12 x 1.5 93 127 152
M14 x 1.5 152 216 255
M16 x 1.5 225 318 383
M18 x 1.5 324 466 554
M20 x 1.5 461 628 775
M22 x 1.5 618 863 1058
M24 x 2 780 1098 1294
M27 x2 1147 1578 1920
M30 x 2 1568 2254 2695
24 BOMAG 008 911 63

Tightening torques 1.4

Tightening torques for screws treated with anti-seizure paste OKS 2401 (copper paste)
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 X 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
3/4“ - 10 UNC 276 388 464
3/4“ - 16 UNC 308 432 520
1 Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive
effects. Prevents seizure and corrosion.
Tightening torques for wheel nuts (fine thread) 1 2
Thread diameter
10.9
M12x1.5 100
M14x1.5 150
M18x1.5 300 - 350
M20x1.5 400 - 500
M22x1.5 500 - 600
2 These values result in a 90% utilization of the yield point

008 911 63 BOMAG 25

The values specified in the table apply for screws:

●
black oiled
●
with surface protection A4C
●
with surface protection DACROMET
i Note
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks,
as the metric ISO-thread, whereas Withworth has a flank of only 55°.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with UNC thread, 1 UNC Unified Coarse Thread Series, American Unified
Coarse Thread
Screw dimension
8.8 10.9 12.9
1/4“ - 20 11 15 19
5/16“ - 18 23 32 39
3/8“ - 16 39 55 66
7/16“ - 14 62 87 105
1/2“ - 13 96 135 160
9/16“ - 12 140 200 235
5/8“ - 11 195 275 330
3/4“ - 10 345 485 580
7/8“ - 9 560 770 940
1“ - 8 850 1200 1450
1 1/8“ - 7 1200 1700 2000
1 1/4“ - 7 1700 2400 2900
1 3/8“ - 6 2200 3100 3700
1 1/2“ - 6 3000 4200 5100
Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread
Screw dimension
8.8 10.9 12.9
1/4“ - 28 13 18 22
5/16“ - 24 25 35 42
3/8“ - 24 45 63 76
7/16“ - 20 70 100 120
1/2“ - 20 110 155 185
9/16“ - 18 155 220 260
5/8“ - 18 220 310 370
3/4“ - 16 385 540 650
7/8“ -14 620 870 1050
26 BOMAG 008 911 63

Tightening torques 1.4

Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread
Screw dimension
8.8 10.9 12.9
1“ - 12 930 1300 1600
1 1/8“ - 12 1350 1900 2300
1 1/4“ - 12 1900 2700 3200
1 3/8“ - 12 2600 3700 4400
1 1/2“ - 12 3300 4600 5600

008 911 63 BOMAG 27

28 BOMAG 008 911 63

2 Maintenance
008 911 63 BOMAG 29

2.1 General notes on maintenance
2.1 General notes on maintenance the engine's performance and temperature level as
well as the quality of the exhaust gas.
When servicing the machine pay careful attention to If your machine has to operate permanently in "thin
all applicable safety instructions. air" (at high altitudes) and with full power, you should
Thorough maintenance of the machine ensures max- consult the after sales service of BOMAG or the serv-
imum reliability and prolongs the lifetime of important ice department of the engine manufacturer.
components. The necessary effort can by no means
be compared with the problems and malfunctions that Notes on the hydraulic system
could occur if this is not observed.
During maintenance work in the hydraulic system
The terms left/right are always related to travel direc- cleanliness is of utmost importance. Make sure that
tion forward. no dirt or other impurities can enter into the system.
●
Clean machine and engine thoroughly before start- Small particles can flute valves, cause pumps to seize
ing maintenance work. and block restrictors and pilot bores, thereby causing
●
For maintenance work park the machine on level costly repairs.
ground. ●
If during the daily oil level check the oil level is found
●
Maintenance work must generally be carried out to have dropped, check all lines, hoses and compo-
with the engine shut down. nents for leakages.
●
Depressurize hydraulic lines before working on
●
Seal external leaks immediately. If necessary in-
them. form the responsible service department.
●
Disconnect the battery and cover it with insulation
●
Do not store drums with hydraulic oil outside, or at
material before starting to work on electrical compo- least keep them under a cover. During weather
nents. changes water may penetrate through the bung-
hole.
●
Always attach the articulation lock (transport lock)
before starting to work in the articulation area of the
●
Always fill the hydraulic system using the filling and
machine. filtering unit (BOMAG part-no.
007 610 01). This unit is equipped with a fine filter,
which filters the hydraulic oil and prolongs the life-
Environment time of the system filter.
Catch running out oils, coolant and fuel and do ●
Clean fittings, filler caps and their immediate sur-
not let them seep into the ground or into the sew- rounding area before removing them, so that no dirt
age system. Dispose of oils, coolant and fuels en- can fall in.
vironmentally.
●
Do not leave the tank opening unnecessarily open,
cover it so that no dirt can fall in.
Notes on the fuel system
The lifetime of the diesel engine is decisively depend- Notes on the cooling system
ing on the cleanliness of the fuel.
On water cooled engines the preparation and monitor-
●
Keep the engine free of dirt and water as this could ing of the coolant is of utmost importance, as other-
damage the injection elements of the engine. wise engine failures caused by corrosion, caviation
●
Zinc lined drums are not suitable for storing fuel. and freezing may occur.
●
The fuel drum should rest for a longer period of time The coolant is a mixture of water and a cooling system
before drawing off fuel. protection agent.
●
Do not let the suction hose disturb the sludge on the The cooling system must be permanently monitored.
bottom of the drum. Apart from the coolant level inspection this includes
also the inspection of the concentration of cooling sys-
●
Do not draw off fuel from near the bottom of the fuel tem protection agent.
drum.
The concentration of the cooling system protection
●
Fuel left in the fuel drum is not suitable for the en- agent can be checked with commercially available
gine and should only be used for cleaning purpos- test instruments (glycomat).
es.
! Danger
Notes on the engine performance
Health hazard!
Combustion air and fuel injection rates of the diesel
engine have been carefully adjusted and determine
30 BOMAG 008 911 63

General notes on maintenance 2.1

The mixing of nitride based cooling system pro-
tection agents with amine based agents will cause
the generation of highly toxic nitrosamines.
Environment
Cooling system protection agents must be dis-
posed of environmentally.
008 911 63 BOMAG 31

2.2 Table of fuels and lubricants
2.2 Table of fuels and lubricants
Assembly Fuel or lubricant Quantity approx.
Summer Winter Attention

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

oil filter
API: CG-4/CH-4
SAE 10W/40
(-20 °C to +40 °C)
SAE 15W/40
(-15 °C to +40 °C)
Fuel
Diesel Winter diesel fuel approx. 150 litres
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres
46 mm2/s at 40 °C
Vibration bearings Engine oil SAE 15W/40 approx. 0,8 litres
Drive axle Gear oil SAE 90, API GL5 approx. 9,5 litres
Wheel hubs Gear oil SAE 90, API GL5 approx. 1,9 per side
Air conditioning system Refrigerant R134A approx. 1400 g
Tires (only BW 213) Water approx. 295 litres
Calcium chloride (CaCl2) or magnesium chloride approx. 100 kg
(MgCl2)
Engine cooling system Cooling system protection agent approx. 16 litres

32 BOMAG 008 911 63

Running-in instructions 2.3

2.3 Running-in instructions
The following maintenance work must be per-
formed when running in new machines or over-
hauled engines:
! Caution
Up to approx. 250 operating hours check the en-
gine oil level twice every day.
Depending on the load the engine is subjected to,
the oil consumption will drop to the normal level
after approx. 100 to 250 operating hours.
After a running-in time of 30 minutes

●
Retighten the V-belt
After 250 operating hours
●
Retighten bolted connections on intake and exhaust
tubes, oil sump and engine mounts.
●
Retighten the bolted connections on the machine.
●
Retighten all wheel fastening screws with the spec-
ified tightening torque.
●
Changing engine oil and oil filter
●
1. Oil change vibration bearings
●
Oil change in drive axle
●
Oil change in wheel hubs
After 500 operating hours
●
2. Oil change vibration bearings
008 911 63 BOMAG 33

2.4 Maintenance chart

y
l
i
a
d s s s
, s s r r r
s s r r u u u
r
s u r u u o o o
n o u o o h h h
o h o h h
i h g g g
t g g n n n
c g g n n i
t i
t i
t
u n n i
t i
t a a a
No. Maintenance work Remark r i
t t i
t a a r r r
s a a r r e e e
n r
i e
r
e
e e p p p
p p o o o
n p p o o d
i 0 0 0
- o o 0 0 0 0 0 e
r
g 0 0 5 0 0 0 0 i
n 5 1 2 5 1 2 3 u
i 2 q
n r y y y y y y e
n e r r r r r r r
e e e e e e
u t
f v v v v v v s
R a e e e e e e a
5.6 Check the engine oil level Dipstick mark X
5.7 Check the water separator X
5.8 Check the fuel level X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Check the coolant level Inspection glass X
5.11 Check the dust separator X
5.12 Check the tire pressure X
5.13 Clean the cooling fins on engine and hy- X
draulic oil cooler
5.14 Check the oil level in the drive axle X
5.15 Check the oil level in the wheel hubs X
5.16 Check the oil level in the vibration bear- X
ings
5.17 Change engine oil and oil filter car- min. 1x per year X X
tridge1
5.18 Drain the sludge from the fuel tank X
5.19 Service the battery Pole grease X
5.20 Check, replace the refrigerant compres- X
sor V-belt
5.21 Service the air conditioning X
5.22 Check, adjust the valve clearance Intake = 0,3 mm X
Exhaust = 0,5 mm
5.23 Check, replace the ribbed V-belt X
5.24 Change the fuel filter cartridge X
5.25 Change the fuel pre-filter cartridge X
5.26 Check the engine mounts X X
5.27 Oil change in drive axle min. 1x per year X X
5.28 Oil change in wheel hubs min. 1x per year X X
5.29 Oil change vibration bearings2 see foot note, min. X X
1 x per year
5.30 Retighten the fastening of the axle on X
the frame
34 BOMAG 008 911 63

Maintenance chart 2.4

y
l
i
a
d s s s
, s s r r r
s s r r u u u
s r r u u o o o
n u
o
u o o h h h
o h o h h
i h g g g
t g g n n n
c g g n n i
t i
t i
t
u i
n n i
t i
t a a a
No. Maintenance work Remark r
t t i
t a a r r r
a
s r a r r e e e
n e r e e p p p
i e p p o o o
n p
i
p o o 0 0 0 d
- o o 0 0 0 0 0 e
r
g 0 0 5 0 0 0 0 i
n 5
i 1 2 5 1 2 3 u
2 q
n r y y y y y y e
n e r r r r r r r
e e e e e e
u t
f v v v v v v s
R a e e e e e e a
5.31 Tighten the wheel nuts X X
5.32 Check the ROPS X
5.33 Clean the oil bath air filter min. 1x per year X
5.34 Change hydraulic oil and breather filter 3 at least every 2 X
years
5.35 Change the hydraulic oil filter*** at least every 2 X
years
5.36 Change the coolant at least every 2 X
years
5.37 Check the injection valves X
5.38 Service the combustion air filter min. 1x per year, X
safety cartridge at
least every 2 years
5.39 Adjusting the scrapers X
5.40 Adjust the parking brake X
5.41 Change the tires X
5.42 Change the fresh air filter in the cabin X
5.43 Tightening torques X
5.44 Engine conservation X
1 Oil change intervals depend on quality of oil and fuel (sulphur content)
2 Oil change intervals after 250 h, after 500 h, after 1000 h, and then every 1000 h.
3 Also in case of repair in the hydraulic system.
008 911 63 BOMAG 35

36 BOMAG 008 911 63

3 Technical data
008 911 63 BOMAG 37

3.1 Technical data
3.1 Technical data
Fig. 10
Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 211 D-40 2960 2250 1500 2268 2972 490 5840 60 60 25 2130
BW 211 PD-40 2960 2250 1480 2268 2972 490 5840 60 60 25 2130
1 BW 211 D-40 BW 211 PD-40
Weights
Operating weight (CECE) kg 9500 10500
with ROPS and cabin
Axle load, drum (CECE) kg 5750 6750
Rear axle load (CECE) kg 3750 3750
Static linear load kg/cm 27 -
Travel characteristics
Travel speed (1) km/h 0 ... 6 0 ... 6
Travel speed (2) km/h 0 ... 10 0 ... 10
Max. gradability (depend- % 45 49
ing on soil)
Engine
Engine manufacturer Deutz Deutz
Type BF4M 2012C BF4M 2012C
Cooling Water Water
Number of cylinders 4 4
Rated power DIN ISO kW 98 98
3046
Rated speed 1 rpm 2300 2300
Fuel Diesel Diesel
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydr.-mech. hydr.-mech.
38 BOMAG 008 911 63

Technical data 3.1

1 BW 211 D-40 BW 211 PD-40
Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic
Vibration
Vibrating drum 1 1
Frequency Hz 30/36 30/36
Amplitude mm 1,8/0,9 1,64/0,82
Tires
Tire size 23.1-26/12 PR TL C7 23.1-26/12TL R1
Air pressure bar 1,4 1,4
Filling capacities
Engine Litres 10 10
Fuel Litres 250 250
Hydraulic oil Litres 60 60
Coolant Litres 16 16
1 The right for technical modifications remains reserved
008 911 63 BOMAG 39

3.1 Technical data
Fig. 11
mm
BW 212 D-40 2960 2250 1500 2268 2972 490 5840 60 60 25 2130
BW 212 PD-40 2960 2250 1480 2268 2972 490 5840 60 60 25 2130
1 BW 212 D-40 BW 212 PD-40
Weights
with ROPS and cabin
Static linear load kg/cm 33,6 -
Travel speed (1) km/h 0 ... 6 0 ... 6
Travel speed (2) km/h 0 ... 10 0 ... 10
ing on soil)
Engine
Cooling Water Water
3046
Fuel Diesel Diesel
Driven axles 2 2
Brakes
40 BOMAG 008 911 63

Technical data 3.1

1 BW 212 D-40 BW 212 PD-40
Steering
Vibration
Vibrating drum 1 1
Amplitude mm 1,8/0,9 1,64/0,82
Tires
Filling capacities
Engine Litres 10 10
Fuel Litres 250 250
008 911 63 BOMAG 41

3.1 Technical data
Fig. 12
mm
BW 213 D-40 2960 2250 1500 2268 2972 490 5840 60 60 35 2130
BW 213 PD-40 2960 2250 1480 2268 2972 490 5840 60 60 25 2130
1 BW 213 D-40 BW 213 PD-40
Weights
with ROPS and cabin
Static linear load kg/cm 36,7 -
Travel speed (1) km/h 0 ... 6 0 ... 6
Travel speed (2) km/h 0 ... 10 0 ... 10
ing on soil)
Engine
Cooling Water Water
3046
Fuel Diesel Diesel
Driven axles 2 2
Brakes
42 BOMAG 008 911 63

Technical data 3.1

1 BW 213 D-40 BW 213 PD-40
Steering
Vibration
Vibrating drum 1 1
Amplitude mm 1,8/0,9 1,64/0,82
Tires
Filling capacities
Engine Litres 10 10
Fuel Litres 250 250
008 911 63 BOMAG 43

3.1 Technical data
Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 900 ± 200
High idle speed rpm 2430 ± 50
Specific fuel consumption g/kWh 243
Valve clearance intake mm 0,3
Valve clearance exhaust mm 0,5
Injection valves opening pressure bar 220
Travel pump
Manufacturer Sauer
Type 90R 075
System Axial piston/swash plate
Max. displacement cm3/rev. 75
Max. flow capacity l/min 172,9
High pressure limitation bar 400 +26
Charge pressure, high idle bar 26
Drum drive motor

Manufacturer Poclain
Type MSE 18 1 CX
System Radial piston
Displacement (stage 1) cm3/rev. 2800
Perm. leak oil rate l/min 2
Axle drive motor

Manufacturer Sauer
Type 51D 110
System Axial piston – bent axle
Max. displacement (stage 1) cm3/rev. 110
Min. displacement (stage 2) cm3/rev. 69
Perm. leak oil rate l/min 2
Flushing rate l/min 16
Flushing pressure limitation bar 16
Vibration pump
Manufacturer Sauer
Type 42R 041
Max. displacement cm3/rev. 41
Start up pressure bar 345 +26
Operating pressure (soil dependent) bar approx. 100
Vibration motor
Type A10FM 45
Displacement cm3/rev. 45
Flushing rate l/min 6
Flushing pressure limitation bar 13
Check steering/
Type HY/ZFS11/16
System Gear
Displacement cm3/rev. 16
Max. steering pressure bar 175 +26
44 BOMAG 008 911 63

Technical data 3.1
Steering valve
Manufacturer Danfoss
Type OSPC 500 ON
System Rotary spool valve
Rear axle
Manufacturer Dana
Type CHC 192/51HD
Differential No-Spin
Degree of locking % 100
Reduction ratio 43,72

008 911 63 BOMAG 45

3.1 Technical data
46 BOMAG 008 911 63

4 Connection overview
008 911 63 BOMAG 47

4.1 Connection overview
Fig. 1 Travel pump
48 BOMAG 008 911 63

Connection overview 4.1

1 Control solenoid, high frequency 21 Connection D, charge pressure to filter
2 Control solenoid, low frequency 22 Multi function valve 345 bar (boost check and
3 Multi-function valve 400 bar (boost check and pressure relief valve), vibration drive high frequen-
pressure relief valve), travel system cy
4 Connection, charge pressure to brake solenoid 23 Connection S, suction line charge pump from hy-
valve, travel speed range selection and charge oil draulic oil tank
supply for vibration pump 24 Multi function valve 345 bar (boost check and
5 Multi-function valve 400 bar (boost check and pr essure relief valve), vibration drive low frequen-
pressure relief valve), travel system cy
6 Setscrew, mechanical neutral position 25 Charge pressure relief valve, vibration pump
(blocked)
7 Connection L, leak oil connection to vibration
pump 26 Connection E, charge oil from travel pump
8 Lever, travel control 27 Connection L1, leak oil connection to travel pump
9 Pilot pressure test port 28 Pressure test port MB, high pressure reverse
10 High pressure port B, high pressure reverse 29 Charge oil from filter
11 Charge pressure relief valve, 26 bar 30 Pressure test port MA, high pressure forward
12 Adjustment screw, low frequency 31 High pressure port A, high pressure forward
13 Connection L2, leak oil to tank 32 Setscrew, mechanical neutral position, vibration
14 Pressure test port MB, high frequency 33 Leak oil connection D, leak oil from axle drive mo-
tor
15 High pressure test port MA, low frequency
34 Leak oil connection A, leak oil from travel pump
16 High pressure port A, low frequency
35 Leak oil connection G, leak oil from drum drive
17 High pressure port B, high frequency
motor
18 Charge pump, internal
36 Leak oil connection F, leak oil from vibration motor
19 Connection L2, to drum drive motor (flushing)
37 Radiator inlet
20 Adjustment screw, high frequency
008 911 63 BOMAG 49

4.1 Connection overview
50 BOMAG 008 911 63

5 Tests and adjustments
008 911 63 BOMAG 51

5.1 Special tools, tests and adjustments

1. Vibration reed frequency meter
1000 - 4000 rpm
17 - 67 Hz
BOMAG part-no.: 300 120 80
Fig. 1
2. Sirometer (frequency meter)
800 - 50.000 rpm
14 - 750 Hz
Fig. 2
3. Anti-freeze tester, quick and accurate measuring,
sturdy plastic housing, automatic temperature
correction, no after-dripping, instructions for use
on unit, reading down to -40 °C. Material: Plastic,
Temperature range: down to -40 °C
Fig. 3
4. Digital rpm-meter for petrol engines
Fig. 4
52 BOMAG 008 911 63

Special tools, tests and adjustments 5.1

5. Digital rpm-meter for petrol engines
Fig. 5
6. Digital rpm-meter, optical/mechanical, universal
use
Fig. 6
7. Infrared manual thermometer, -18 to 275°C
Fig. 7
8. Hydraulic test case, large
i Note
4 X 600 bar pressure gauges
4 X 60 bar pressure gauges
8 pressure test hoses
Fig. 8
008 911 63 BOMAG 53

9. Hydraulic test case, small

i Note
1X 25 bar pressure gauge
1X 150 bar pressure gauge
2X 400 bar pressure gauges
4 pressure test hoses
Fig. 9
10. Pressure test hoses
1000 mm BOMAG part-no.: 079 930 02
2500 mm BOMAG part-no.: 079 930 03
Fig. 10
11. Pressure gauge
60 bar BOMAG part-no.: 059 721 07
600 bar BOMAG part-no.: 059 721 04
Fig. 11
12. Adapter for pressure test hose
Fig. 12
54 BOMAG 008 911 63

Special tools, tests and adjustments 5.1

13. Gear pump testing device
Fig. 13
14. Vacuum pump for hydraulic oil tank
BOMAG part-no.: 007 610 04 (12 Volt)
BOMAG part-no.: 007 610 24 (24 Volt)
Fig. 14
008 911 63 BOMAG 55

5.2 Checking the rotation speeds
5.2 Checking the rotation speeds

Special tools
Vibration reed frequency meter, RPM-meter for
diesel engines.
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
2. Block the wheels with suitable chocks.
Fig. 1
Check the engine speed
i Note
If necessary, the engine speed may also be
checked with the vibration Reed frequency meter.
1. Connect the RPM-meter to the injection line (Fig.
2).
2. Run the engine with maximum speed.
3. Apply the brake.
4. Measure the rotation speeds.
Nominal value idle speed:
Low idle speed, see technical data.
High idle speed, see technical data.
5. Switch the vibration on .
Nominal value nominal speed:
Fig. 2
See technical data.
Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting for the engine.
56 BOMAG 008 911 63

Checking the rotation speeds 5.2

Checking the exciter shaft speed
1. Switch the vibration on at max. engine speed.
2. Apply the brake.
3. Measure the speed of the vibrator shaft, rest the
tester on your thumb (Fig. 3).
Nominal value:
See technical data.
Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting in the vibration circuit.
Fig. 3
008 911 63 BOMAG 57

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

tions of the travel pump
Special tools
Hydraulic test case
! Caution
1. Block drums and wheels with suitable chocks
(Fig. 1).
Fig. 1
2. Unhook the travel cable (Fig. 2) from the pump.
Fig. 2
3. Pull the plug (Fig. 3) off the brake solenoid valve
to close the brake.
Fig. 3
58 BOMAG 008 911 63

Checking / adjusting the neutral positions of the travel pump 5.3

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

chanical neutral position (Fig. 7), until the pres-
sures on both pressure gauges are identical.
Fig. 7
008 911 63 BOMAG 59

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

Special tools
Hydraulic test case
! Caution
1. Block drums and wheels with suitable chocks
(Fig. 1).
Fig. 1
2. Pull the plug (Fig. 3) off the brake solenoid valve
to close the brake.
Fig. 2
3. Connect 600 bar pressure gauges to the high
pressure test ports for "forward travel" and "re-
verse travel" and a 60 bar pressure gauge to the
charge pressure test port (Fig. 2).
5. Read charge and high pressure gauges.
Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = charge pressure at high
Fig. 3 idle
Evaluation of test
If the nominal value is not reached, check the
steering/charge pump.
60 BOMAG 008 911 63

Pressure tests in the travel circuit 5.4

Measurement with quickly operated travel le-
ver
6. Move the travel lever (Fig. 4) quickly forward,
read the pressure gauge.
Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = pressure override
Evaluation of test
Fig. 4
If the specified high pressure is not reached,
check the travel pump.
If the charge pressure drops considerably during
the high pressure test, check the components in-
dividually.
008 911 63 BOMAG 61

5.5 Checking / adjusting the vibrator shaft speeds
5.5 Checking / adjusting the vibrator shaft

speeds
Special tools
Vibration reed frequency meter
! Caution
1. Drive the machine on an elastic base (rubber
buffers) (Fig. 1).
2. Apply the parking brake and block the wheels ad-
ditionally with suitable chocks.
4. Switch on vibration high frequency / low ampli-
tude or low frequency / high amplitude.
Fig. 1
5. Measure the speed (Fig. 2), rest the tester on
your thumb.
Nominal value
high amplitude/
low frequency = see technical data
low amplitude/
high frequency = see technical data
Evaluation of test
In case of deviations exceeding 10% determine
the cause, perform trouble shooting for engine /
vibration circuit and check vibration motor.
Fig. 2
6. Adjust the speed on the corresponding adjust-
ment screw (Fig. 2).
i Note
Turning the adjustment screw in reduces the
speed, turning the screw out increases the
speed.
Fig. 3
62 BOMAG 008 911 63

Pressure measurements in the vibration circuit 5.6

5.6 Pressure measurements in the vibra-
tion circuit
Special tools
Hydraulic test case
! Caution
1. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
2. Block the wheels with suitable chocks.
3. Apply the brake.
Fig. 1
4. Connect a 60 bar pressure gauge (Fig. 2) to the
charge pressure test port.
5. Connect a 600 bar pressure gauge each to the
high pressure test ports for "high amplitude" and
"low amplitude".
7. Switch on vibration with high or low frequency.
Nominal value
Charge pressure = charge pressure at high idle
(see technical data of travel pump).
Start-up pressure = vibration pump start-up pres-
Fig. 2 sure (see technical data of vibration pump).
Operating pressure = vibration pump operating
pressure (see technical data of vibration pump).
Evaluation of test
If the charge pressure drops, check the compo-
nents individually.
If the starting pressure is not reached, check the
vibration pump.
If the starting pressure is only reached for one fre-
quency, check the high pressure relief valves.
008 911 63 BOMAG 63

5.7 Check the leakage rate of the vibration motor
5.7 Check the leakage rate of the vibration

motor
! Caution
1. Drive the drum of the machine on an elastic base
(rubber buffers) (Fig. 1) and block the wheels ad-
ditionally with suitable chocks.
2. Apply the brake.
Fig. 1
3. Block the flushing valve (Fig. 2) with washers.
Fig. 2
4. Disconnect the leak oil hose (Fig. 3), connect a
measuring hose and hold it into a measuring
beaker.
6. Switch the vibration on and measure the running
out leak oil during one timed minute.
Nominal value
max. 1.5 litre/min
Evaluation of test
If the permissible leak oil rate is exceeded, re-
place the vibration motor.
Fig. 3
64 BOMAG 008 911 63

Pressure test in steering circuit 5.8

5.8 Pressure test in steering circuit
Special tools
Hydraulic test case, gear pump testing equipment
! Caution
ture of the hydraulic oil (approx. 50 °C).
Measurement 1
1. Connect a 600 bar pressure gauge to the steering
pressure test port (Fig. 1).
2. Start the engine and run it at idle speed.
! Danger
Danger of crushing, do not access the articu-
lation area of the machine!
3. Turn the steering against an end stop.
4. Read the pressure gauge.
Nominal value
Fig. 1
see technical data, max. steering pressure of
Evaluation of test 1
If the nominal value is reached, check the steer-
ing cylinder.
Measurement 2
5. Disconnect the hydraulic hoses from ports L and
R (Fig. 2) (machines with one steering cylinder)
on the steering cylinder and close them with
plugs.
Fig. 2
6. Disconnect the hydraulic hoses from ports L and
R (Fig. 3) (machines with two steering cylinder)
on the steering cylinders and close them with
plugs.
7. Start the engine and run it at idle speed.
8. Turn the steering wheel.
9. Read the pressure gauge.
Nominal value
see technical data for steering/charge pump.
Fig. 3
008 911 63 BOMAG 65

5.8 Pressure test in steering circuit
If the nominal value is reached, replace the steer-
ing cylinder.
If the nominal value is not reached, check the
10. Reconnect the hydraulic hoses to the steering
cylinders.
Measurement 3
11. Actuate the emergency stop switch.
Fig. 4
12. Close the pump outlet port (Fig. 5) with the gear
pump test equipment.
13. Crank the engine with the starter
Nominal value
see technical data for steering/charge pump.
If the nominal value is reached, replace the steer-
ing valve.
If the nominal value is not reached, replace the
Fig. 5
66 BOMAG 008 911 63

6 Flushing and bleeding
008 911 63 BOMAG 67

6.1 Special tools for flushing

1. Filling and filtering unit with oil bag
2. Filter element
Fig. 1
3. Flushing filter (S connection)
4. Filter element 1µ
5. Flushing hose 20S - 25S (2 pieces)
6. Screw socket R1“ - 25S (2 pieces)
Fig. 2
7. Flushing filter (L connection)
8. Filter element
9. Flushing hose 15L (2 pieces)
10. Screw socket R3/4“ -- 15L (2 pieces)
Fig. 3
11. SAE-flange 1“ - 20S
12. O-ring
BOMAG part-no. 062 203 30
Fig. 4
68 BOMAG 008 911 63

Special tools for flushing 6.1

13. Flanged plate 1“ - 25S
14. O-ring
BOMAG part-no. 062 202 22
Fig. 5
15. Reducing fitting 18L - 15L
Fig. 6
16. Reducing fitting 25S - 20S
Fig. 7
17. Reducing fitting 20S - 16S
Fig. 8
008 911 63 BOMAG 69

18. Connecting socket 15L

Fig. 9
19. Connecting socket 18L
Fig. 10
20. Connecting socket 16S
Fig. 11
21. Connecting fitting 20S
Fig. 12
70 BOMAG 008 911 63

Special tools for flushing 6.1

22. Connecting fitting 25S
Fig. 13
23. Angular fitting 18L
Fig. 14
24. Elbow fitting 16L
Fig. 15
25. Elbow 20S
Fig. 16
008 911 63 BOMAG 71

26. Elbow 25S

Fig. 17
27. Pipe connection 16S - 16S
Fig. 18
28. Connecting hose 15L
Fig. 19
72 BOMAG 008 911 63

Flushing - general 6.2

6.2 Flushing - general Clean the hydraulic tank
! Caution
Solid particles in the circuit will very quickly
cause damage to machine components.
Environment
Environmental damage
Catch running out hydraulic oil and dispose
of environmentally.
Changing a component
Fig. 2
! Caution
Always flush the complete oil circuit after ! Caution
you have replaced a component. Change the oil in case of excessive contam-
ination, oil discoloration or if the oil change
Chips (abrasion) in the oil interval is almost due.
● Open and clean all components in the oil ● Filter the tank content with the filling and fil-
circuit, replace if necessary. tering unit and pump it into the oil bag.
● Clean all high pressure hoses in the oil cir- ● Mark all hoses and disconnect them from
cuit, replace if necessary. the hydraulic oil tank.
● If abrasion is found in the travel circuit you ● Clean the oil tank thoroughly from inside, if
should also flush the vibration circuit. necessary remove the complete tank cover.
● If abrasion is found in the vibration circuit ● Reconnect all hoses.
you should also flush the travel circuit.
● Fill the hydraulic oil tank again with the fill-
ing and filtering unit.
Before flushing
Change the filter element Bleeding
Fig. 3
Fig. 1
● Change the hydraulic oil filter element (1). ● Always bleed closed hydraulic circuits if
lines had been removed or connected.
008 911 63 BOMAG 73

6.2 Flushing - general
Servicing the flushing filter kit
Fig. 4
● Replace the filter element of the flushing fil-

ter when the red control pin of the contami-
nation indicator is pressed out during the
filtering process.
● Clean hoses and connections and store the
flushing kit in a clean and protected envi-
ronment.
74 BOMAG 008 911 63

Flushing schematic travel circuit (distribution travel pump) 6.3
008 911 63 BOMAG 75

6.3 Flushing schematic travel circuit (distribution travel pump)
1 Elbow union (tool) 13 High pressure hose (A, drum drive motor for-
2 Connecting union (tool) ward)
3 Drum drive motor 14 High pressure hose (B, axle motor reverse)
4 Axle motor 15 High pressure hose (A, axle motor forward)
5 Screw socket R1 - 25S (tool) 16 High pressure hose (B, axle motor reverse)
6 Flushing hose 25S - 20S (tool) 17 High pressure port (B, drum drive motor reverse)
7 Flushing hose 25S - 20S (tool) 18 Flushing hose 25S - 20S (tool)
8 Flushing filter with filter element 1µ (tool) 19 Flushing hose 25S - 20S (tool)
9 Elbow union (tool)

10 Reducing fitting (tool)
11 Travel pump
12 High pressure hose (B, drum drive motor reverse)

76 BOMAG 008 911 63

Flushing the travel circuit (travel pump distribution) 6.4

6.4 Flushing the travel circuit (travel
pump distribution)
Flushing the drum drive

Replacing the hydraulic oil filter element
Cleaning the hydraulic oil tank
i Note
Observe the chapter "Flushing - General"
Installing the flushing filter
! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
The flushing filter must be installed in the low
pressure side in the return flow to the pump,
so that only cleaned oil will enter the travel
pump in forward travel.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
Fig. 1
1. Disconnect the high pressure hose 12 (see chap-
ter "Flushing schematic - travel circuit") from the
travel pump (high pressure port 17) and connect
it with the flushing hose (7) (flushing filter inlet
"IN").
2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port 17) on the travel
pump.
Disconnect the drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
cuit by joining the high pressure hoses (12 and
13) on the drum drive motor together.
Fig. 2
008 911 63 BOMAG 77

6.4 Flushing the travel circuit (travel pump distribution)
Bleeding the travel circuit
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 3
Flushing the hoses
4. Block drums and wheels with suitable chocks.
Fig. 4
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 5
! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
5. Start the engine and shift the travel lever to travel
direction forward.
6. Perform the flushing process at various engine
speeds for approx. 10 minutes.
7. Shut down the engine.
8. Reconnect the hydraulic hoses (12 and 13) to the
drum drive motor.
Fig. 6
78 BOMAG 008 911 63


Flushing the drum drive motor
! Danger
Danger of accident!
The drum must rotate freely.
9. Jack up the front of the machine, so that the drum
can rotate freely.
10. Secure the rear wheels with chocks.
11. Pre-select the slow speed range.
Fig. 7
i Note
flushing process.
Fig. 8
! Caution
12. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
13. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve forward travel.
Fig. 9 15. Remove the flushing filter and reconnect the high
pr essure lines.
008 911 63 BOMAG 79

Flushing the axle drive

"IN").
17. Connect the flushing hose (19) (flushing filter out-
let "OUT") to the (high pressure port 16) on the
travel pump.
Fig. 10
Disconnecting the axle motor
18. Take the axle drive motor out of the hydraulic cir-
15) on the axle drive motor together.
Fig. 11
i Note
Fig. 12
80 BOMAG 008 911 63


Flushing the hoses
Fig. 13
i Note
flushing process.
Fig. 14
! Caution
direction forward.
axle drive motor.
Fig. 15
Flushing the axle motor
! Danger
Danger of accident!
Both wheels must be off the ground. The
wheels must be able to rotate freely.
24. Jack up the rear of the machine, so that the
wheels can rotate freely.
25. Secure the drum with wheel chocks.
Fig. 16
008 911 63 BOMAG 81

i Note
flushing process.
Fig. 17
! Caution
pressure lines.
31. Bleed the travel circuit (see corresponding chap-
ter).
Keep circulating the tank content.
32. After completing the bleeding process circulate
the tank content with the filtering unit for another
15 minutes.
Function test
33. Check the hydraulic oil level in the tank, fill up if
necessary.
34. Check all connections for leaks with the engine
running (visual inspection).
35. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or starting
on a gradient.
36. Check all ports and connections for leak tightness
(visual inspection).
Fig. 19
82 BOMAG 008 911 63

Flushing schematic travel circuit (distribution axle motor) 6.5
008 911 63 BOMAG 83

6.5 Flushing schematic travel circuit (distribution axle motor)
84 BOMAG 008 911 63

008 911 63 BOMAG 85

6.5 Flushing schematic travel circuit (distribution axle motor)
86 BOMAG 008 911 63


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

008 911 63 BOMAG 87

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

distribution)
Flushing the drum drive

i Note
! Caution
so that only cleaned oil will enter the travel
pump in forward travel.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
Fig. 1
"IN").
2. Connect the flushing hose (18) (flushing filter out-
let "OUT") to the (high pressure port 16) on the
travel pump.
Disconnect the drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
13) on the drum drive motor together.
Fig. 2
88 BOMAG 008 911 63

Flushing the travel circuit (axle motor distribution) 6.6

i Note
Fig. 3
Flushing the hoses
i Note
flushing process.
Fig. 4
Fig. 5
! Caution
direction forward.
drum drive motor.
Fig. 6
008 911 63 BOMAG 89

Flushing the drum drive motor
! Danger
Danger of accident!
The drum must rotate freely.
9. Jack up the front of the machine, so that the drum
can rotate freely.
10. Secure the rear wheels with chocks.
Fig. 7
i Note
flushing process.
Fig. 8
! Caution
Fig. 9
90 BOMAG 008 911 63

Flushing the travel circuit (axle motor distribution) 6.6

Flushing the axle motor
! Danger
Danger of accident!
Both wheels must be off the ground. The
wheels must be able to rotate freely.
15. Jack up the rear of the machine, so that the
wheels can rotate freely.
16. Secure the drum with wheel chocks.
Fig. 10
i Note
flushing process.
Fig. 11
! Caution
pressure lines.
22. Bleed the travel circuit (see corresponding chap-
ter).
15 minutes.
008 911 63 BOMAG 91

Function test
necessary.
25. Check all connections for leaks with the engine
running (visual inspection).
26. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or starting
on a gradient.
Fig. 13
92 BOMAG 008 911 63

Flushing schematic for vibration drive 6.7
1 Elbow union (tool) 7 Flushing hose 25S - 20S (tool)

2 Connecting union (tool) 8 Flushing filter with filter element 1µ (tool)
3 Vibration motor 9 SAE flange (tool)
4 Vibration pump 10 High pressure hose (B, high frequency)
5 Screw socket R1 - 25S (tool) 11 High pressure hose (A, low frequency)
6 Flushing hose 25S - 20S (tool)

008 911 63 BOMAG 93

6.8 Flushing the vibration circuit

i Note
! Caution
so that only cleaned oil will enter the vibration
pump in high frequency.
For the connection schematic shown here the
vibration must always be filtered with "high
frequency / low amplitude".
Fig. 1
ter "Flushing schematic - vibration circuit") from
the vibration pump (4) and connect it with the
flushing hose (7) (flushing filter inlet "IN").
2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port A) on the vibra-
tion pump.
Disconnect the vibration motor
3. Take the vibration motor out of the hydraulic cir-
11) on the vibration motor together.
Fig. 2
94 BOMAG 008 911 63

Flushing the vibration circuit 6.8

Bleeding the vibration circuit
i Note
Bleeding the vibration circuit, see chapter "Bleed-
ing the vibration circuit".
Fig. 3
Flushing the hoses
Fig. 4
i Note
flushing process.
Fig. 5
! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
5. Switch on vibration with high frequency.
7. Flush the circuit for approx. 10 minutes, thereby
switch the vibration on and off at intervals of ap-
prox. 30 seconds.
Fig. 6 vibration motor.
008 911 63 BOMAG 95

Flushing the vibration motor

10. Unscrew the fastening screws for the vibration
motor and pull the motor out of the coupling.
Fig. 7
i Note
flushing process.
Fig. 8
! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
utes. Switch the vibration on and off at intervals of
approx. 30 seconds.
14. Remove the flushing filter and reinstall the vibra-
tion motor.
Fig. 9
Bleeding the vibration circuit
15. Bleed the vibration circuit (see corresponding
chapter).
15 minutes.
96 BOMAG 008 911 63

Flushing the vibration circuit 6.8

Function test
necessary.
18. Test drive.
Fig. 10
008 911 63 BOMAG 97

6.9 Bleeding the travel circuit
6.9 Bleeding the travel circuit
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
! Danger
The engine should not start.
Fig. 1
4. Hold the open ends of the pressure test hoses
(Fig. 2) into a container.
5. Operate the starter motor for approx. 30 seconds.
Wait one minute and repeat this procedure, until
oil starts to run out from the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 2
7. Unlock the emergency stop switch
Fig. 3
98 BOMAG 008 911 63

Bleeding the travel circuit 6.9

8. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Pause for approx. 30 seconds and keep repeat-
ing this procedure, until the gauge shows a con-
stant charge pressure reading.
Fig. 4
! Caution
With the flushing filter installed shift the travel
lever only to travel direction forward, as oth-
erwise the flushing filter will be subjected to
oil flow from the wrong direction.
! Danger
Run the engine with idle speed.
10. Start the engine.
11. Shift the travel lever (Fig. 5) approx. 1/3 to for-
ward direction.
Fig. 5 12. After approx. 1 to 2 minutes shut down the engine
for a minute.
i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
008 911 63 BOMAG 99

6.10 Bleeding the vibration circuit
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
Fig. 1
4. Hold the open ends of the pressure test hoses
(Fig. 2) into a container.
5. Crank the engine approx. 10 seconds with the
starter motor. Wait one minute and keep repeat-
ing this procedure, until oil starts to run out from
the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 2
7. Unlock the emergency stop switch
Fig. 3
100 BOMAG 008 911 63

Bleeding the vibration circuit 6.10

8. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Wait for approx. 30 seconds and repeat the pro-
cedure, until the pressure gauge shows a con-
stant charge pressure.
Fig. 4
! Caution
With the flushing filter installed use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-
tion.
10. For bleeding switch on vibration with high fre-
quency (Fig. 5).
11. Start the engine.
12. After running the engine 1 to 2 minutes pause for
approx. one minute.
Fig. 5 i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
008 911 63 BOMAG 101

102 BOMAG 008 911 63

7 Fundamental electrics
008 911 63 BOMAG 103

7.1 Understanding circuit diagrams

Wiring diagrams are graphical representations of circuitry conditions, related to the electrical system. They do
not contain any information about the actual type of wiring, they only serve the purpose of visualizing the circuitry
logics.
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system.
This plan provides the following information:
●
Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses,
switches, consumers, relays, ...
●
The sequence in which current flows through the individual elements in the electric circuit.
●
Connections between the examined, faulty electric circuit and other circuits in the vehicle wiring system.
●
Pin assignment of plug-and-socket connections.
Structure
●
Table of contents
●
Function groups
●
List of components
Table of contents
The table of contents lists all function groups.
Fig. 6 Table of contents
Example:
Function group "Warning systems“, drawing number XXX XX can be found on page no. 8.
104 BOMAG 008 911 63

Understanding circuit diagrams 7.1

Function groups
On the individual pages the electric circuits are combined to function groups.
Arrangement of current paths
The individual current paths must be read as follows:
●
From top (plus potential) to bottom (minus potential).
●
From left to right.
●
From function group to function group.
●
Via cross references for potentials and relays.
Fig. 7 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 63 BOMAG 105

Current paths
The pages of a circuit diagram are sub-divided into current paths (Fig. 1) (0 ..... 20).
Fig. 1 Current paths
106 BOMAG 008 911 63

Understanding circuit diagrams 7.1

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

Example:
The warning horn "B 11" is located on page no. 8 in current path 3.
008 911 63 BOMAG 107

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
108 BOMAG 008 911 63

Terminal designations 7.2

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

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

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

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

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

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

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

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

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

50a Battery changeover relay, output for starter control
50b Starter control, parallel operation of 2 starters with sequence control
008 911 63 BOMAG 109


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)
110 BOMAG 008 911 63

Terminal designations 7.2

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

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

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

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

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

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

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

88a Relay contact on maker and two-way contact, (maker side) output 1
88b Relay contact on maker and two-way contact, (maker side) output 2
88c Relay contact on maker and two-way contact, (maker side) output 3
88z Relay contact on maker, input 1
88y Relay contact on maker, input 2
88x Relay contact on maker, input 3
B+ Battery Plus
B- Battery Minus
D+ Dynamo Plus
D- Dynamo Minus
DF Dynamo field (generator excitation current)
DF1 Dynamo field 1 (generator excitation
current)
008 911 63 BOMAG 111


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

112 BOMAG 008 911 63

Current and voltage 7.3

7.3 Current and voltage The following statements concerning electric volt-
age can be made
●
electric voltage is the pressure or force applied to
General
free electrons.
If one wants to describe electric current, this can most ●
the electric voltage is the cause of electric current
simply be accomplished by means of a comparison:
●
electric voltage is a result of the equalization at-
One simply compares electric current with water. tempt of electric charges.
Voltage is measured with a Voltmeter.
Voltage
Unit, Volt
The electric voltage (U) is measured in Volt (V).
Fig. 1
1 (Fig. 1) Charge
2 Voltage
3 Current
The equalization attempt between different electric
charges is referred to as electric voltage.
Voltage sources have two poles of different charge.
On the one side we have the plus pole with a lack of
electrons, on the opposite side the minus pole with a
surplus of electrons. This electric "pressure" is known
as electric voltage.
Fig. 2
If there is a connection between these two poles a dis-
charge will take place, resulting in the flow of an elec-
tric current.
Plus pole= lack of electrons
Minus pole = excess of electrons
008 911 63 BOMAG 113

7.3 Current and voltage
Current Types of current

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

Converting alternating current into a direct current sig-
nal by means of a rectifier results in an pulsating direct
current.
114 BOMAG 008 911 63

Current and voltage 7.3

Pulse width modulation (PWM)
Fig. 4 PWM
The PWM signal is in most cases generated by a con-
trol and can be used to trigger proportional valves.
The signal (square wave signal) is changed in its
pulse control factor, the period, however, remains un-
changed.
The following applies:
●
The signal voltage cannot be measured.
●
The current can be measured.
! Caution
Solenoid valves must not be interference sup-
pressed with suppressor diodes.
008 911 63 BOMAG 115

7.4 CAN-Bus
7.4 CAN-Bus
Controller Area Network

created by Bosch at the end of the eighties for automobile applications.
Development objectives:
Real-time critical, robust and low price communication of control units, such as transmission and engine control,
but also less time critical applications in the field of convenience electronics, such as air conditioning.
Fig. 1 CAN
Why CAN?
●
Networking of control units for the realization of complex functions.
●
Reduction of the extend of wiring and plug connections.
●
Better diagnostic possibilities (central diagnostics socket).
Characteristics of CAN
It is a kind of serial data transmission. The individual bits are transmitted one after the other, only 2 lines are
required.
CAN lines are twisted together 30 to 40 times per metre. Electromagnetic interferences therefore always occur
simultaneously in both lines, the software is thus able to filter out interfering signals more easily.
Wire (+) = cable colour blue
Wire (-) = cable colour yellow
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
116 BOMAG 008 911 63

CAN-Bus 7.4
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 63 BOMAG 117

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

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

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

Rule of thumb:
●
The thicker the cable cross-section, the lower the
voltage loss.
●
The shorter the cable, the better the current.
118 BOMAG 008 911 63

Resistance 7.5
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 63 BOMAG 119

7.6 Series / parallel connection
7.6 Series / parallel connection ●

In series connection the plus pole of the first battery
must be connected with the minus pole of the sec-
Series connection ond battery.
In a series circuit the resistors (consumers) are lined ●
The sum of all individual voltages is applied to the
up one after the other and the same current (I) passes free poles.
through each of the consumers However, series con- ●
The total capacity (Ah) is identical with the capacity
nection of consumers is not suitable in practice, as of the individual battery.
each resistance causes a voltage drop. In the vehicle
wiring system all consumers are designed for the
same vehicle voltage (e.g. 12 Volt).
Fig. 1 Series connection
Current
In series connection the current is identical at every
point.
Itotal = I1 = I2 = I3
Voltage
The sum of all partial voltages is identical with the total
voltage.
Utotal = U1 + U2 + U3
Resistance
The sum of all partial resistances is identical with the
total resistance.
Rtotal = R1 + R2 + R3
Series connection of batteries
Fig. 2
In order to achieve a vehicle voltage of 24 V two bat-
teries of the same type and capacity must be connect-
ed in series mode.
120 BOMAG 008 911 63

Series / parallel connection 7.6

Parallel connection ●
In parallel connection the plus pole of the first bat-
In parallel connection all resistances (consumers) are tery is connected with the plus pole of the second
connected between feed and return line. battery and the minus pole of the first battery with
the minus pole of the second battery.
●
All resistances (consumers) are supplied with the
same voltage.
●
Plus and minus poles have the voltage of the single
battery applied.
●
Each of the resistances (consumers) draws as
much current as required.
●
The total capacity (Ah) is identical with the sum of
all battery capacities.
The disadvantage of a parallel connection becomes
apparent, by equalizing currents flowing between par-
allel batteries, if the batteries have different states of
charging.
Fig. 3 Parallel connection
Current
The total current is the sum of all currents.
Itotal = I1 + I2 + I3
Voltage
The voltage values are identical at every resistance
(consumer).
Utotal = U1 = U2 = U3
Resistance
The total resistance is less than the lowest individual
resistance.
Parallel connection of batteries
Fig. 4
By connecting 2 batteries of same type and capacity
in parallel mode the capacity can be doubled, be-
cause the individual capacities add up to the total ca-
pacity.
008 911 63 BOMAG 121

7.7 Ohm's law
7.7 Ohm's law 7.8 Electrical energy

In a closed electric circuit voltage, current and resist-
ance must always be considered in close relation.
This relation is represented by Ohm's Law.
Fig. 1
In a closed electric circuit current and voltage gener-
ate energy.
Fig. 1 If a current of 1 Ampere flows at a voltage of 1 Volt,
According to this law a voltage of 1V is required to let energy of 1 Watt is produced.
1A (ampere) flow through a conductor with a resist-
Advice
ance of 1 (Ohm Ω).
By means of this triangle the formula can be easily re-
Advice arranged, the value you are looking form must just be
By means of this triangle the formula can be easily re- blanked off with a finger.
arranged, the value you are looking form must just be
Energy P = I multiplied with U
blanked off with a finger.
Amperage I = P divided by U
Voltage U = I multiplied with R
Voltage U = P divided by I
Resistance R = U divided by I
U = Voltage in Volt
Amperage I = U divided by R
I = Current in Ampere
U = Voltage in Volt
P = Power in Watt
I = Current in Ampere
R = Resistance in OHM Ω
122 BOMAG 008 911 63

Formula diagram 7.9

7.9 Formula diagram
Description:
●
Select the desired value from the inner circle.
●
Determine the formula variables in the quarter circle
●
Calculate
Example:
P = 150 Watt
U = 24 Volt
Sought for = Current in Ampere
I = P : U = 150 W : 24 Volt = 6.25 Ampere
Fig. 1 Formula diagram
Resistance, R Ohm Ω
Voltage, U Volt
Current, I Ampere
Power, P Watt
008 911 63 BOMAG 123

7.10 Metrology
7.10 Metrology Multimeter

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

If voltage is present, the corresponding light emitting
diode will light up.
124 BOMAG 008 911 63

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

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

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

●
During the measurement the current must be able
to flow through the meter, i.e. the electric circuit
must be opened. The meter is connected in series
with the consumer.
Advice
If the electric circuit is difficult to access and the inter-
nal resistance of the consumer is known, the voltage
may also be measured at the consumer.
The current value can then be calculated with the help
of Ohm's law.
008 911 63 BOMAG 125

7.10 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.
●
The component to be tested does not need to be re-
moved.
●
The magnetic coil can also be tested under a pro-
tective cap.
Fig. 2
126 BOMAG 008 911 63

Diodes, relays, fuses 7.11

7.11 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:
●
At 0.6 – 0.7 Volt (silicium diode) the diode becomes
conductive.
Negative voltage on diode:
●
The diode does not allow current to pass through.
Fig. 2 Marking of the cathode

Diodes are used:
●
For rectifying A.C. voltage.
●
For absorbing voltage peaks (free-wheeling diode).
●
For construction of logical circuits.
Fig. 3 Diode circuitry

●
The solenoid valve Y48 (Fig. 3) is supplied with
electric current when switch S34 is switched to po-
sition "1" or "2".
●
Solenoid valve Y20 is supplied, if the switch is in po-
sition "1".
●
Solenoid valve Y21 is supplied, if the switch is in po-
sition "2".
The three diodes V02 serve as free-wheeling diodes
with the function of of eliminating voltage peaks.
008 911 63 BOMAG 127

7.11 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
128 BOMAG 008 911 63

Diodes, relays, fuses 7.11

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:
●
approx. 1 hour with 1.5 times the rated current
●
approx. 1 minute with 2.5 times the rated current.
A 5 Amp fuse loaded with 1.5 times the rated current
(7.5 Amp) will finally melt after approx. 1.5 hours.
Yellow = 5 A
Brown = 7.5 A
White = 8 A
Red = 16 A
Blue = 25 A
008 911 63 BOMAG 129

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

●
Is the battery leaking? Can traces of impact, shock
or compression be found in the leaking area?
●
Check for e.g. incorrect fastening, foreign bodies on
the battery mounting surface and similar.
Testing batteries with screw plugs
Checking the acid density:
●
The cells are filled with diluted sulphuric acid as
electrolyte (approx. 25 Vol% sulphuric acid in dis-
tilled water), also referred to as accumulator acid,
Fig. 2 which has a density of 1.285 kg/dm3 at a tempera-
All cells are filled with a conductive fluid, the electro- ture of +27° Celsius. This means that one litre of
lyte. For a 12 Volt battery 6 cells are connected in se- electrolyte has a weight of 1.285 kg. As the cell is
ries. being discharged lead sulphate (PbSO4) will form
on both electrodes and the electrolyte will increas-
Capacity ingly change to water. Since water has a lower spe-
is a synonym for the amount of current taken up and cific weight than diluted sulphuric acid the density of
discharged by a battery over a specified period of the electrolyte will also drop during the discharge
time. and with a fully discharged cell and a temperature
of 27°C it will only be 1.18 kg/dm3.
●
With a lead cell the acid density is therefore a meas-
ure for the charge condition. This characteristic is
used to determine the charge condition of a lead
130 BOMAG 008 911 63

Batteries 7.12
battery. The so-called acid tester (hydrometer) is
used for this purpose. In a battery of good condition
the acid density should be the same in all cells.
Acid density at 27 °C in kg/dm 3
●
1.25 -1.28, open-circuit voltage approx. 12.7 Volt.
Battery is charged.
●
1.20 -1.24, open circuit voltage approx.12.4 to 12.5
Volt, is 50% discharged. Charging is necessary.
●
1.19 and less, open circuit voltage less than 12.3
Volt. Battery is insufficiently charged. Battery needs
to be recharged immediately.
Fig. 4 Battery and generator tester
i Note The battery and generator tester comes with an 8-line
If the current consumption during charging is not 1/20 LC display with background illumination and is able to
of the nominal capacity (example 100 Ah battery: print out test results via an (optional) integrated ther-
100Ah x 1/20 = 5 A) or full charging of the battery re- mal printer.
sults in a final acid density of only 1.24 kg/dm3 or less,
the battery shows normal wear by aging. The battery
was insufficient charging or exhaustive discharge. i Note
Before testing clean the poles and ensure good con-
nection between clamps and poles.
The test program calculates the text messages "good"
or "replace" on the basis of the charge condition (de-
rived from the battery voltage) and the currently avail-
able starting power of the battery. A battery with 45%
starting power may thus be rated good and another
one with 75% starting power as poor ("replace").
The starting power represents the ratio of detected
cold testing current to the entered cold testing current
of the battery.
The starting power can exceed 100%.
Fig. 3 Reading the acid level

●
Maximum permissible tolerance between highest
and lowest measuring value of the 6 cells: 0.03 kg/
dm3.
Testing batteries without screw plugs
On closed batteries the acid density cannot be meas-
ured, we therefore recommend testing with the follow-
ing mobile tester:
008 911 63 BOMAG 131

7.12 Batteries
Charge condition with hydrometer
Fig. 5 Charge condition

Green = Charge condition >65%
Dark = Charge condition <65%
Light = Electrolyte level too low
! Danger
Danger of explosion!!! If the electrolyte level is too
low, the battery must no longer be charged.
132 BOMAG 008 911 63

Three-phase generator 7.13

7.13 Three-phase generator Design and function
In the generator the armature windings are located in-
General side the stationary stator, whereas the exciter winding
is arranged on the internally revolving rotor (Fig. 6).
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve-
hicle with electric current at a steady voltage already
at idling speed.
! Caution
Before removing the generator you must discon-
nect the ground cable from the minus pole of the
battery while the ignition is switched off. Do not
disconnect the generator while the engine is run-
ning, because this may cause extremely high volt-
age peaks in the vehicle wiring system ("Load
Dump"), which could possibly damage control
units, radios or other electronic equipment.
When disassembling the battery cable, the B+-nut
underneath on the generator side may also be
Fig. 6 Rotor with claw poles
loosened. This nut must in this case be retight-
ened.
When connecting e.g. the battery cable to the ter-
minal of the generator you must make sure that
the polarity is correct (generator B+ to the + pole
of the battery). Mixing up the polarities by mistake
causes short circuit and damage to the rectifier el-
ements - the generator will be out of function.
The generator can only be operated with the bat-
tery connected. Under special conditions emer-
gency operation without battery is permitted, the
lif etime 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 63 BOMAG 133

7.13 Three-phase generator
This includes :
●
Electric motors
●
Relays
Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc-
es work with alternating or three-phase current.
This includes :
●
Accumulators
●
Control units
●
All electronics
●
Communication equipment.
Charge control light
It has by no means the function to show whether the
ignition is switched on or off. It has the function of in-
dicating that the generator works correctly. Under nor-
mal operating conditions the generator should work
and the charge control light should be off. The charge
control lamp receives (+) from the battery at one pole.
The other pole is connected to (D+), i.e. the (+) carbon
Fig. 8 3-phase current of the generator. If the generator is working correctly,
The generator first of all produces three-phase volt- (+) is attached to both connections on the charge con-
age / three-phase current. trol lamp. Since there is no difference in voltage, no
current can flow, the lamp does not light up. If the gen-
The wiring diagram (Fig. 8) shows the 3 windings in Y- erator does not work, current flows via the (+) carbon
connection and the 6 associated rectifier diodes. through the armature winding, via the (-) carbon to
The diodes D1, D2, D3 are also referred to as minus ground and from there back to the battery. The electric
diodes, because they have B- as common connection circuit is closed, battery voltage is applied to the
(minus plate). charge control lamp and the lamp lights up. Since the
The other diodes are the plus diodes. generator does not work when the engine is not run-
ning, the charge control lamp is not connected directly
The rectifier diodes have the effect that the negative to the battery, but via the ignition switch. When the ig-
half-wave is suppressed and only the positive section nition is off, the charge control lamp is dead.
of the wave is allowed to pass, resulting in a pulsating
D.C. voltage. Voltage regulator
Reverse current protection A generator without regulator would just work light a
bicycle dynamo. The power output would increase
The rectifier diodes also prevent discharging of the with rising speed. The voltage output would fluctuate
battery via the stator windings. The current can only with the load. (In case of a bicycle dynamo the tail light
flow from the generator to the battery. bulb is overloaded when the head light does not con-
Why does three-phase current need to be rectified sume any power). The function of the regulator is the
and how does this work? provision of a uniform vehicle voltage, almost com-
pletely independent from speed and load of the gen-
There are a few components for which can either be erator.
operated with alternating current or direct current, be-
cause they work independently from the current flow
direction.
This includes :
●
Incandescent lamps
●
Fluorescent lamps
●
Glow lamps
●
Electric heating elements.
There are also a few components that could be oper-
ated either with alternating current, direct current or
three-phase current, if the components were designed
accordingly.
134 BOMAG 008 911 63


Checking the generator
First one must check whether the generator is actually
defective.
●
This can be easily found out by checking whether
the charge control light in the dashboard lights up. If
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula-
tor, the wiring or the V-belt.
●
When the engine is at rest, the charge control light
must light up. If not, the lamp may probably be de-
fective. Defects on generator or wiring are obviously
also possible.
The following points allow to contain faults in the volt-
age supply within certain limits.
●
Cable connections on the generator OK?
●
V-belt OK?
●
Generator ground (engine ground) OK?
●
Pre-excitation from vehicle electronics OK?
Only if all criteria mentioned above are OK, the fault
must be in the generator itself. In this case it must be
Fig. 9 Regulator with diode plate and rectifier diodes
replaced or the following trouble shooting procedure
In most cases voltage regulators (Fig. 9) with carbon must be performed.
brushes form a compact component. The voltage reg-
ulator is maintenance free and the wear of carbon
brushes is only so little, that they hardly ever need to
be replaced during the lifetime of a machine.
The regulator has the following function:
●
To maintain the vehicle voltage under any operating
conditions below 14.4 V.
●
To match the regulator voltage to the temperature.
●
Smooth rising of generator current when switching
loads (convenience function to avoid jerking of the
engine).
008 911 63 BOMAG 135

Checking the pre-excitation circuit Measuring the charge current

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

sign)
If the charge control light or LED stays on when the
engine is running, you should proceed as follows:
●
Temporarily bridge connections D+ and B+ on the
three-phase alternator (Fig. 10). The bridging must
be made using an insulated cable with a cross-sec-
tion of approx. 1.0 mm, which is stripped for approx.
5 mm on either end. This cable must be fitted with a
consumer (X), e.g. a light bulb of 21 W, 12 V, in
case of a 12 V system.
If this measure does not clear the fault, the alternator
must be defective.
136 BOMAG 008 911 63


Checking the rotor Checking the stator
i Note
The rotor coils can only be measured in disassembled
state.
Fig. 11 Rotor
●
Remove the regulator with carbon brush.
Fig. 12 Stator
●
Contact the rotor slip ring with the tester points.
●
The resistance should be between 3 and 6 OHM Ω.
i Note
●
The rotor coils should not have continuity to ground. The stator coils can only be measured in disassem-
bled state.
●
Measure the resistance of all three coils.
●
The coils should not have contact among each oth-
er.
008 911 63 BOMAG 137

Checking the regulator voltage with the generator Checking the regulator voltage with the multime-
tester ter
The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) thermal printer.
Fig. 14
●
All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
Fig. 13 ●
The generator ground connection must be OK.
The generator test assesses the regulator voltage and ●
The battery should be in good condition – the idle
the ripple factor of the generator voltage. speed voltage of the battery should be at least 12.6
●
All plug-and-socket connectors must be free of cor- Volt.
rosion and intermittent contact. ●
If possible switch off all consumers.
●
The generator ground connection must be OK. ●
Perform the measurement at raised engine speed.
●
The battery should be in good condition – the idle ●
The voltage (B+) should adjust itself at 13 to 14 Volt.
speed voltage of the battery should be at least 12.6
Volt.
●
If possible switch off all consumers.
●
Perform the measurement at raised engine speed.
138 BOMAG 008 911 63


Checking the regulator in disassembled state
On a Bosch generator unscrew two fastening screws
for the regulator and lift the regulator off. For this work
the generator does not need to be removed.
The Delco-Remy generator needs to be removed
and partly dismantled, if the regulator needs to be dis-
assembled. Unscrew the housing screws to do so.
Pull rotor with drive bearing and V-belt pulley out of
the stator. Unscrew the ends of the stator winding
from the diode carrier and separate the stator from the
collector ring bearing. Disassemble exciter diodes and
brush holders and remove also the regulator. Fig. 16
E.g minus controlled regulator
i Note One connects the regulator (Fig. 16) with D+ and D- to
When testing the regulator one should be aware that
the power source, as shown in the illustration, and the
there are 2 different types of regulators:
lamp to both carbon brushes, instead of the exciter
winding. When slowly increasing the voltage the lamp
●
If the carbon brush is not connected to ground the will first become brighter, because the regulator al-
regulator is a so-called minus controlled regulator. lows all lamp current (= exciter current) to flow at volt-
The exciter winding is positioned between D+ and age values up to 14.4V. Once the regulator voltage is
DF, the regulator therefore regulates the exciter reached, the regulator switches the lamp current off.
winding on the ground side. The other carbon brush When returning the voltage back below the control
is connected with the cathodes of the exciter di- voltage, the regulator will switch the lamp back on.
odes, terminal D+. This leaves one further terminal, With this test the major difficulty is the problem to re-
this is DF. move the regulator an identify terminals D+, DF and
D+ (vehicle wiring system) D-.
D- (ground contact, mostly located on one of the fas-
tening screws)
DF (Dynamo Field)
Fig. 17
Fig. 18
Fig. 15
The illustrations (Fig. 17) and (Fig. 18) show two dif-
●
If the carbon brush is connected to ground the reg-
ferent regulator types.
ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
The basic function of a disassembled regulator can be
easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).
008 911 63 BOMAG 139

Replacing carbon brushes

●
On a Bosch generator unscrew two fastening
screws for the regulator and lift the regulator off.
Pull out the carbon brushes from underneath. Their
minimum length is 5 mm, shorter carbon brushes
need to be replaced, unsolder both connection litz
wires. Solder the litz wires of the new carbon brush-
es, insert these and fasten the regulator again. For
this work the generator does not need to be re-
moved.
●
For replacing the carbon brushes in the Delco-
Remy generator the generator needs to be disas-
sembled and partly dismantled. The carbon brush
holder is located inside the collector ring bearing.
140 BOMAG 008 911 63

Electric starter 7.14

7.14 Electric starter ●
establish the gear connection between starter and
combustion engine.
The starter converts the electric energy stored in the ●
to maintain this connection.
battery into mechanical energy. The starter can only
generate its power when a battery with appropriate
●
to switch on the starter current.
capacity is available. After starting the engine:
Duties of the starter: ●
to return the starter pinion to initial position.
●
to accelerate the combustion engine to start speed ●
to switch off the starter current.
with lowest possible current consumption.
Fig. 1 Electric starter For purposes like e.g. purging the fuel systems,
1 Pinion starters may be operated for maximum 1 minute
2 Roller free-wheeling without interruption. Then you should wait for at
least 30 minutes (cooling down) until trying again.
3 Steep thread During the 1 minute starting period this process
4 Guide ring should not be interrupted.
5 Spring winding Starter motors must not be cleaned with high
6 Armature pr essure 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 63 BOMAG 141

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

This type of starter uses a solenoid to engage the pin-
ion with the ring gear. The engaging solenoid contains
switching contacts for the starting current. When clos-
ing the starter switch, the relay holding winding is ac-
tive and current flows also through the series
connection of pick-up winding and electric motor. The
engaging solenoid picks up and moves the free-
wheeling with the pinion forward via the engaging le-
ver and the engaging spring. In case of a favourable
position of the pinion to the ring gear a tooth of the pin-
ion will directly engage in a tooth gap. In this case the
pinion will engage over the entire length of the screw
path, until the contact bridge in the engaging relay
touches the relay contacts. The starter motor is no
switched on. However, if the pinion does not directly Fig. 2 Switching position during engagement
find a tooth gap, the ring gear will block any further en-
gaging movement. The engaging lever in this case
compresses the engaging spring and the main contact
closes, even though the pinion and the ring gear are
not engaged. The electric motor keeps rotating the
pinion in front of the ring gear face, until a pinion tooth
gap matches a tooth on the ring gear and the preload-
ed engaging spring moves pinion and free-wheeling
forward. When switching the relay winding off, the re-
turn spring forces the relay armature and the pinion
with free-wheeling back to rest position. This disen-
gagement is supported by the steep thread.
Magnetic switch
The magnetic switch is normally arranged directly
above the starter. Fig. 3 Switching position during starting
With the starter switch switched on, both the pickup 1 Ground
winding and the holding winding are energized and 2 Battery
shift the iron core in axial direction. With a lever this
iron core pulls the starter pinion towards the engine 3 Starter switch
flywheel. 4 Pull-in winding
Once the gears are engaged the starter current is ap- 5 Holding winding
plied to the back through a large cross-section. At the 6 Exciter winding
same time the pickup winding is shorted via the starter 7 Restoring spring
current and thus switched off as a measure to reduce
8 Driver
the load on the energy household.
9 Pinion
10 Flywheel
142 BOMAG 008 911 63

Electric starter 7.14

Trouble shooting "Starter" Testing and measuring the electric starter
The most frequent fault is definitely a fully discharged
battery. i Note
If the starter rotates too slowly, either the brushes The highest current flows when the starter is blocked!
are partly worn off, or parts of the exciter or armature (Short circuit current in starter). This is the case when
winding is shorted. In some cases oxidized electric the pinion is engaged and the starter has the duty to
contacts or a soiled ground connection causing ex- accelerate the flywheel to starting speed.
tremely high voltage losses in the overall starter sys-
tem are the cause of problems. Function test with starter installed
If the starter only emits a clicking sound,- either

●
Initiate the starting process and measure the volt-
the magnetic switch is defect / soiled (dismantle and age on the pickup solenoid switch (50a). At least
clean))- the main contacts on the magnetic switch are 10.8 Volt should be applied.
worn off / soiled (scrape off carefully with a file and ●
When operating the starter switch the magnetic
clean)- the starter motor is defective / soiled (remove switch must engage in the flywheel ring gear (no-
armature and clean), cover cleaned, moveable parts ticeable clicking sound) and release the starting
with grease. current to the starter. On most magnetic switches
the voltage can be measured with the multimeter. If
Frequently a jammed return mechanism is the reason
this does not happen even though voltage is ap-
for a starter failure.
plied, replace the magnetic switch.
Occasionally worn contacts are found on the magnetic
return switch Function tests with disassembled starter
Defects on the actual starter motor including pinion
and carbon brushes are very rare. ! Caution
With a trouble shooting chart the faults in the starter Before removing the starter you must disconnect
system can be narrowed down. The starter system the ground cable from the minus pole of the bat-
can only work when many conditions are fulfilled at tery while the ignition is switched off.
the same time. ●
Check the wear on the carbon brushes and their
●
Immobilizer deactivated? contact pressure.
●
Ignition switch OK? ●
Check the collector, it must not have electrical con-
●
Travel lever in correct position? tact with the rotor shaft.
●
Emergency stop not actuated? ●
Check the drive pinion for excessive wear.
●
Battery sufficiently charged? ●
The return mechanism should not be tight, if neces-
●
Battery poles OK? sary grease amply with silicon grease (Bosch PZ 2
V3) or a comparable grease.
●
Main battery fuse OK?
●
Measure the resistance of the magnetic switch main
●
Main battery switch closed?
contact in disengaged condition. Maximum value
●
Main starter cable (terminal 30) OK? 0.2 OHM Ω.
●
Starter control cable (terminal 50) OK, voltage
drop?
●
Ground cable OK?
●
Switching of magnetic switches OK?
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
●
the experience of the specialist
●
the failure probability of the component to be tested
and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault
must be in the starter itself. In this case it can be re-
paired or replaced.
008 911 63 BOMAG 143

7.15 Telemecanique switch

Example of terminal designations
Fig. 1 Terminal designations

●
Normally open contact 23 located on block 2
●
●
Normally closed contact 12 located on block 1
●
Normally closed contact 11 located on block 1
●
●
●
●
●
●
i Note
If e.g. block 5 is not needed to design a switch, the
numbering for blocks 1,2,3,4 and 6 remains un-
changed.
144 BOMAG 008 911 63

Telemecanique switch 7.15

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

●
Lift up the interlock (2) and pull out the front element
(3).
Fig. 3 Folding down the switch block
●
Fold down the switch block (4).
●
Loosen screw (1).
008 911 63 BOMAG 145

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

●
Clip on the switch block (4).
i Note
Fig. 6 Observe the marks.
Hook in the switch block at the bottom first (Fig. 7).
●
Clip the fastening adapter (6) onto the front element
(3).
i Note
Watch the marls on front element (Fig. 6) and fasten-
ing flange.
●
Tighten the screw (1) with a tightening torque of 0.6
Nm.
146 BOMAG 008 911 63

Inductive proximity switches 7.16

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

On sensors with PNP-circuitry the output stage con-
tains a PNP-transistor, which switches the load
against the positive operating voltage. The load is
connected between the output and the negative oper-
ating voltage. The switch is designed with a normally
open contact, i.e. the contact closes when the initiator
comes in "contact" with metal.
008 911 63 BOMAG 147

7.17 Angle sensors
7.17 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.
148 BOMAG 008 911 63

Angle sensors 7.17

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.
●
at -35° = 4 mA output current
●
at 0° = 12 mA output current
●
at +35° = 20 mA output current.
008 911 63 BOMAG 149

7.18 Plug connectors
7.18 Plug connectors 7.19 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:
●
Vibration acceleration
●
Temperature fluctuations, high and low tempera-
tures
●
Dampness
●
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:
●
Low transition resistances of the conductive parts.
●
High insulation strength between conductive parts
with different voltage potentials. Fig. 3 Crimp connections
●
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.
●
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.
150 BOMAG 008 911 63

Deutsch plug, series DT and DTM 7.19

DT Series
Fig. 1 DT plug connection
Fig. 2 DT Series
Fig. 3 Sectional drawing
008 911 63 BOMAG 151

7.19 Deutsch plug, series DT and DTM
Installing DT contacts
Fig. 4
●
Insert the contacts through the rubber grommet until
they click into place.
●
Insert the orange wedge in direction of arrow.
! Caution
nals and connections must withstand a pulling
force of 45 N without any difficulties.
i Note
Use the same method when assembling the socket.
152 BOMAG 008 911 63


Disassembling DT contacts
Fig. 5
●
Pull the orange wedge out with long nose pliers.
●
Slightly pull the lead and unlock the interlocking
hook with a screw driver.
●
Pull the contact out of the socket.
i Note
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
008 911 63 BOMAG 153

DTM Series
Fig. 1 DTM plug connection
Fig. 2 DTM Series
Fig. 3 Sectional drawing
154 BOMAG 008 911 63


Installing DTM contacts
Fig. 4
●
Insert the contacts through the rubber grommet until
they click into place.
●
Insert the orange wedge, until it clicks into place.
! Caution
nals and connections must withstand a pulling
force of 45 N without any difficulties.
i Note
008 911 63 BOMAG 155

Disassembling DTM contacts
Fig. 5
●
Pull the orange wedge (interlock) out with long nose
pliers.
●
Slightly pull the lead and unlock the interlocking
hook with a screw driver.
●
Pull the contact out of the socket.
i Note
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
156 BOMAG 008 911 63

Plugs and terminals in spring clamping technology 7.20

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

The connecting clamp clamps up to 3 or 5 stripped
fine conductors of 0.08 mm² to 4 mm², single or multi-
ple strand up to 2.5 mm². And this even without tools
(Fig. 3).
That's how it works
●
Strip 9-10 mm of the lead. Fig. 3 Connecting clamp
●
Open the actuating lever and insert the strand.
●
Return the actuating lever to initial position.
! Caution
nals must withstand a pulling force of 45 N with-
out any difficulties.
008 911 63 BOMAG 157

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

●
Insert a screw driver into the actuating opening until
it bottoms.
●
Strip 9-10 mm of the lead and insert it into the
clamp.
●
Pull out the screw driver.
! Caution
Measuring signals
On these terminal blocks the bridge slot is most suita-
ble for tapping off and measuring signals. Here you
may directly insert a 4 mm test adapter (see special
tools for electrics) for connecting a measuring lead.
This test adapter is standard in the central electrics of
heavy equipment machines.
Fig. 5 Test adapter
158 BOMAG 008 911 63

Plugs and terminals in spring clamping technology 7.20

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

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

●
The most reliable measurements on the plug can be
made when using the measuring and connecting
cable with 2mm plug (see special tools for
electrics).
008 911 63 BOMAG 159

7.21 Electric modules
7.21 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.
160 BOMAG 008 911 63

8 Special tools, electrics
008 911 63 BOMAG 161

8.1 Special tools, electrics

Measuring equipment
14. Electric test case
Fig. 2
15. Multimeter
Fig. 3
16. Test prod black, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.
17. Test prod red, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.
Fig. 4
18. Test prod black, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.
19. Test prod red, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.
Fig. 5
162 BOMAG 008 911 63

Special tools, electrics 8.1

20. Measuring and connecting lines with 4mm plug,
high flexible design, black, length 0.5 m.
high flexible design, black, length 1 m.
high flexible design, black, length 2 m.
Fig. 6 high flexible design, red, length 0.5 m.
high flexible design, red, length 1 m.
high flexible design, red, length 2 m.
26. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, black, length 300 mm.
sign, black, length 600 mm.
sign, red, length 300 mm.
Fig. 7
sign, red, length 600 mm.
30. Transition plug connector, with 4 mm plug on one
side and 2 mm socket on the other, insulated de-
sign
Fig. 8
008 911 63 BOMAG 163

31. Magnetic coil tester

Fig. 9
32. Clip-on measuring instrument
Fig. 10
33. Battery - generator tester
Fig. 11
Spring clamps (Wago or Weidmüller)
34. Cranked screwdriver (Fig. 12) to open spring
clamps (Fig. 13).
Fig. 12
164 BOMAG 008 911 63


35. Testing adapter to measure the signals from the
series spring clamps (Wago).
Fig. 13
Deutsch contacts
36. Tool to disassemble the interlocking on Deutsch
plugs (series DT and DTM).
Fig. 14
37. Crimping pliers for Deutsch contacts of series DT
and DTM, size AWG 20,16 and 12.
AWG 20 = 0.5 mm2 cable cross-section
AWG 16 = 1,5 mm2 cable cross-section
Fig. 15
38. Crimping pliers for Deutsch contacts of series
HDT, size AWG 6 and 8.
Fig. 16
008 911 63 BOMAG 165

39. Disassembly tool for Deutsch contacts of series

HDP.
AWG 20, BOMAG part-no.: 079 900 78
Fig. 17
ITT contacts
40. Installation tool for ITT crimp contacts of series
CA-COM, contact size 15S/16S/15/16.
Fig. 18
41. Disassembly tool for ITT male contacts of series
CA-COM, contact size 15S/16S/15/16.
Fig. 19
42. Disassembly tool for ITT female contacts of se-
ries CA-COM, contact size 15S/16S/15/16.
Fig. 20
166 BOMAG 008 911 63


Schaltbau contacts
43. Disassembly tool for Schaltbau contacts of series
M1, M2.
Fig. 21
44. Crimping pliers for Schaltbau contacts of series
M1, M2 with connecting cross-section 0.14 - 6.0
mm2.
Fig. 22
FCI Burndy contacts
45. Disassembly tool for FCI Burndy contacts of se-
ries TRIM TRIO
Fig. 23
AMP contacts
46. Crimping pliers for AMP-contacts of series FAS-
TIN-FASTON with a connecting cross-section of
1.0 - 2.5 mm2 (18 -14 AWG).
Fig. 24
008 911 63 BOMAG 167

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

PER-SEAL with connecting cross-section 0.75 -
1.25 mm2.
Fig. 25
48. Crimping pliers for AMP-contacts of series .070-
SERIES with a connecting cross-section of AWG
20 - 18 (0.5 - 0.9 mm2) and AWG 16 (1.25 - 1.5
mm2).
Fig. 26
TON with connecting cross-section AWG 14 - 10.
Fig. 27
TON with connecting cross-section AWG 16 - 14
and AWG 18.
Fig. 28
168 BOMAG 008 911 63


51. Crimping tool for Powertimer contacts with indi-
vidual strand sealing (example: ESX control)
Fig. 29
52. Crimping jaws for Crimping tool 079 900 25
Fig. 30
53. 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 mm 2, BOMAG part-no.: 079
900 76
Spare sleeve 2,5 mm2, BOMAG part-no.: 079
900 77
Fig. 31
Universal tools
54. Universal pressing pliers with toggle lever trans-
mission and adjustable end pressure for Crimp-
ing roller connector 0.14 - 1.0 mm2.
Fig. 32
008 911 63 BOMAG 169

55. Precision pressing pliers for non-insulated flat

male and female connectors0.5 - 6,0 mm2.
Fig. 33
Measuring adapter
56. Current measurement adapter for Hirschmann
plugs.
Fig. 34
57. Voltage measurement adapter for Deutsch plugs,
8-piece (2 to 12 pole).
Fig. 35
58. Current measurement adapter for Deutsch and
AMP plugs, 2 pole.
Fig. 36
170 BOMAG 008 911 63

9 Electronic modules
008 911 63 BOMAG 171

172 BOMAG 008 911 63

9.1 BEM, BOMAG Evib-meter
008 911 63 BOMAG 173

Bild 37
i Hinweis
The documentation "Service Training Electrics MESX" contains also the documentation BEM (BOMAG Evib-me-
ter).
The BOP (BOMAG Operation Panel) is only installed in connection with BVC machines, BEM-machines are
equipped wit display module. The display module is used for the output of fault codes and display values, as
well as for the input of code numbers.
174 BOMAG 008 911 63

BEM, BOMAG Evib-meter 9.1
Service Training
Electrics
MESX
008 097 05 Version 4.00
Status: 05.06.2007 Page 1 of 59

Author: T.Löw / TE
Dateiname: p:\schulung\elektrik\wz\mesx_bvc\englis ch\schulung elektrik mesx_v4.00_gb.doc
008 911 63 BOMAG 175

Service Training MESX
Table of contents
1 Document alteration list.....................................................................................................................3
2 Proof of software change MESX.......................................................................................................4
3 Proof of software change BOP..........................................................................................................6
4 Known faults......................................................................................................................................7
5 How to proceed when replacing components?.................................................................................8
5.1 How to proceed when replacing an ESX control? .....................................................................8
5.2 How to proceed when replacing a rear axle sensor? ................................................................8
5.3 Which components can be replaced without a subsequent adjustment procedure? ................8
5.4 List of machine types .................................................................................................................9
6 Possible adjustments on machines without BOP ...........................................................................12
6.1 Description of the Display Module ...........................................................................................12
6.2 Input of code numbers .............................................................................................................12
6.3 Changing the machine type (only via display module) ............................................................13
6.4 Inverting the direction signal (only via display module) ...........................................................14
6.5 Changing the bit rate (only with display module).....................................................................15
7 Adjustment/display possibilities on machines with BOP.................................................................16
7.1 Adjusting the machine type (BOP)...........................................................................................16
7.2 Inverting the direction signal via the BOP control terminal......................................................18
7.3 Accessing the diagnostics menu .............................................................................................20
7.3.1 Extended diagnostics on machines with circular exciter (BTMplus, BTMprof) ................. 22
7.3.2 Extended diagnose BVC machines ......................................................................................... 23
7.4 Changing the printout language...............................................................................................24
7.5 Setting the machine serial number ..........................................................................................26
7.6 Teaching distance pulses ........................................................................................................28
7.7 Activating the amplitude limitation (only BVC machines) ........................................................30
7.8 Changing the display mode (metric/imperial) ..........................................................................32
7.9 Switching the GPS Receiver Voltage Supply Mode ................................................................34
8 Possible settings on the BCM05mobile ..........................................................................................36
8.1 Reading the software version ..................................................................................................36
8.2 Changing the language............................................................................................................36
8.3 Changing the unit system (metric/imperial) .............................................................................36
9 Block diagram BEM.........................................................................................................................37
10 Block diagram BTMplus / VARIOCONTROL...............................................................................38
11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile................................................39
12 Description of the signals on the ESX-control.............................................................................40
13 Fault codes of the ESX control....................................................................................................45
13.1 Overview...............................................................................................................................45
13.2 Description of fault reactions................................................................................................46
13.3 Detailed description of fault codes and their possible causes ............................................47
14 Input codes for ESX control (only via BEM display module) .......................................................51
14.1 Travel system .......................................................................................................................51
14.2 Vibration ...............................................................................................................................52
14.3 Light......................................................................................................................................52
14.4 Acceleration transducer........................................................................................................53
14.5 Diesel engine........................................................................................................................53
14.6 Setting the machine type......................................................................................................54
14.7 Parameter change................................................................................................................55
15 Terminology in connection with ESX...........................................................................................56
Status:05.06.2007 Page 2 of 59
Author: T.Löw / TE
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1 Document alteration list
Version Date Description of changes resp.

0.00 27.04.2004 Creation of version 1 Löw
1.00 05.05.2004  Block diagrams added Löw
 Description of display module extended
 "Proof of software change" added
1.01 23.07.2004  Description of BOP display pages added. Löw
2.00 31.08.04  Input code 4602 replaced by code 4606 Löw
 Machine type BW219D added
3.00 15.10.2004  Item "How to proceed when replacing components?" added Löw
 Description for ESX Pin 0:35 added
 Description fault code 4601 and 4606 corrected
 Description Software Version 3.00 added
3.01 14.02.2005  Description Code 7534 from version 3.00 added Löw,
 Description Software change V3.01 added Horch
 Description Code 7573 from version 3.01 added
 Description of menus "Amplitude limitation" and "Imperial
display" added
 Description Software Version up to 3.03 added
 Terminal designation MESX changed from X0 to X44
 Description of codes 7502, 7511, 7512, 7532, 7541, 7542,
7550, 7551, 7552, 7562, 7571, 7572, 7576 from version 3.03
added
 Proof of "Software change" changed to "Software MESX"
 Item "Proof of software change BOP" added
 Item "Adjustment possibilities on BCM05mobile" added
 Block diagram BTMplus / VARIOCONTROL and
BCM05mobile added
 Serial numbers added to list of machine types
4.00 01.05.2007  Description of "GPS Mode" menu added Löw
 Item "Change language" changed for BCM 05
 Description fault code 4531 and 4532 extended
 List of machine types extended
Author: T.Löw / TE
008 911 63 BOMAG 177

2 Proof of software change MESX

1.00 25.03.2004 Creation of version 1.00 Löw
1.01 05.04.2004  Printout modified Löw
 Amplitude limitation for Automatic changed to 0.3 mm
 Default setting in Automatic changed to "MAX"
1.02 13.04.2004  BW213 BVC implemented Löw
 Printer control modified (Xon, Xoff protocol)
 Software version and revision documented in printout
 Finished criterion extended (weak spots of 2 m are tested)
 Bmfsa code input for DH machines modified
1.03 05.05.2004  Learning mode for travel distance modified (value range Löw
check)
 Finished criterion for polygonal drum deactivated
 2-stage jump information implemented
 Self-latching of control during shut-down implemented
 Saving of current adjustment values during shut-down
implemented.
 Bmfsa code input for DH machines modified
 BW211 D, BW213 D and BW213 DH implemented
 Query for software version of BOP implemented
1.04 16.04.2004  BW226 BVC Polygon implemented Löw
 Max. adjustment angle limited to 80°
 Max. valve current for BW177 limited to 1000mA
1.05 26.07.2004  BW219DH and BW213 BVC Polygon implemented Löw
 Termination criteria for while loops incorporated into Evib
calculation
2.00 31.08.2004  Number of machine variants extended to 25 (BW219D) Löw
 Problem with sporadic SW crash eliminated
3.00 15.10.2004  Distance pulse changed to 10m for BW226 Löw
 Amplitude limitation realized in automatic mode
 Simulation mode realized
 Changeover metric/imperial realized
 minimum required BOP version changed to 3.00 (always
the same version as MESX)
3.01 16.11.2004  The ESC-key does not abort the printout, it only resets the Löw
measurement
 Machine variant BW226BVC added
3.02 01.12.2004  Machine type BW216D activated Löw
 Completion report for BW226BVC with smooth drum
activated
3.03 14.02.2005  Designation on printout modified (RC; DI) Löw
 Default setting for amplitude limitation set to "inactive".
 Machine types 177PDH, 179DH, 179PDH, 213PDH,
214DH, 214PDH 216D, 216DH,216PDH, 219PDH, 226DH,
226PDH, 226BVC RC" enabled.
 Controller settings for BW213BVC and BW226BVC
optimized with respect to pressure peaks
 Minimum speed for swivelling of of exciter changed to 0.18
km/h => Build-up of the machine with vibration at standstill
is thereby avoided
3.04 10.05.2005  Vibration detection for BW177DH/PDH and BW179DH/PDH Löw

corrected
3.05 19.05.2005  Phase response correction acceleration transducer Löw
activated
 "Flash Request" activated
Author: T.Löw / TE
178 BOMAG 008 911 63


4.00 01.05.2005  Languages Slovakian, Slovenian, Czech, Romanian added Löw
 Function "vCheckMMISoftwareVersion" corrected
 Teach mode for distance via BCM implemented
 Triggering of a relay for GPS receiver voltage supply
implemented
 GPS mode changed: Off and ON now independent from
engine run, Automatic depending on engine run!
 Setting of work number in serial number has been realized
 ATTENTION: Signal distribution for CAN message
MMI_CONFIG_DATA_2 0x156 was changed!!!
 new machine types:211PD, 213PD, 216PD, 219PD + "low
cost" designs:
177D40,1777DHC,177D_40,177DHC,177PDHC,177PDH_
40,179DHC,179PDHC,211D_40,211PD_40,213D_40,213D
HC,213PDHC,213PD_40,214DHC,214PDHC,216DHC,216
PDHC,212D_40,212PD_40
 Pulse numbers changed to 10m for BW219D
 VM classes taken from V3.90, VM class is sent to BCM
Author: T.Löw / TE
008 911 63 BOMAG 179

3 Proof of software change BOP

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

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

 Designation "ESX" replaced by "MESX" and "BOP" by
"BOP"
3.02 10.02.2005  Amplitude bar graph in imperial display mode corrected Löw
4.00 01.05.2007  Flags for all EU-languages and additionally Japan and Löw
China stored in OPUS
 Page for changing over GPS Receiver Mode implemented
 Triggering for fault LED in BVC diagnostics page 2
activated
Author: T.Löw / TE
180 BOMAG 008 911 63

4 Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
Behaviour of machine Possible cause
During initial commissioning the display shows the Bit rate on bmfsa not set to 125 kbit
reading "ct0" => see "Setting the bit rate"
Author: T.Löw / TE
008 911 63 BOMAG 181

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

because in such a case the correct function of the control cannot
be assured!
You should therefore set the machine type first! see "5.4 List of
machine types, or "7.1 Adjusting the machine type (BOP)").
After setting the machine type check the following items:
Check the direction signal, invert the signal if necessary, see 6.4, or 7.2.
Set the machine serial number (only on machines with BOP), see: 7.5
Set the printer language (only machines with printer), see: 7.4
5.2 How to proceed when replacing a rear axle sensor?
Check the direction signal, invert the signal if necessary, see 6.4, or 7.2.
5.3 Which components can be replaced without a subsequent

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

recommended.
Author: T.Löw / TE
182 BOMAG 008 911 63

5.4 List of machine types
Since the same control is used for all single drum rollers with the new measuring technology, it is
necessary to adjust the machine type after installing a new control.
This is necessary during first time commissioning as well as in case of a spare parts installation. This
type adjustment is necessary, because the machines have e.g. different axle loads or different drum
widths, which requires the calculation of measuring values to be adapted. The adjustment procedure
is described under items "6.3 Changing the machine type (only via display module)" or "7.1 Adjusting
the machine type (BOP)".
The following machine types can be adjusted:
Machine type First serial number Last serial number Code Available from
version
177 D 101 582 20 1001 XXX XXX XX XXXX 7500 1.00
177 DH 101 582 21 1001 XXX XXX XX XXXX 7501 1.00
177 PDH 101 582 22 1001 XXX XXX XX XXXX 7502 3.03
177 BVC 101 582 23 1001 XXX XXX XX XXXX 7503 1.00
179 DH 101 582 24 1001 XXX XXX XX XXXX 7511 3.03
211 D 101 582 40 1001 XXX XXX XX XXXX 7520 1.03
101 582 41 1001
101 583 09 1001
211 PD 101 582 45 1001 XXX XXX XX XXXX 7529 4.00
101 583 10 1001
213 D 101 582 50 1001 XXX XXX XX XXXX 7530 1.03
101 583 08 1001
213 DH 101 582 51 1001 XXX XXX XX XXXX 7531 1.03
101 583 14 1001
213 PD 101 582 46 1001 XXX XXX XX XXXX 7539 4.00
101 583 13 1001
101 583 16 1001
213 BVC plates 101 582 54 1001 XXX XXX XX XXXX 7534 3.00
101 583 06 1001
213 BVC DI 101 582 53 1001 XXX XXX XX XXXX 7535 1.05
101 583 16 1001
214 DH 101 582 58 1001 XXX XXX XX XXXX 7541 3.03
101 583 19 1001
101 583 20 1001
216 D 101 582 62 1001 XXX XXX XX XXXX 7550 3.03
101 583 23 1001
216 DH 101 582 60 1001 XXX XXX XX XXXX 7551 3.03
101 582 64 1001
216 PD 101 582 63 1001 XXX XXX XX XXXX 7559 4.00
101 583 24 1001
101 582 65 1001
219 D 101 582 72 1001 XXX XXX XX XXXX 7560 2.00
101 582 10 1001
219 DH 101 582 70 1001 XXX XXX XX XXXX 7561 1.05
101 582 77 1001
219 PD 101 582 73 1001 XXX XXX XX XXXX 7569 4.00
101 582 11 1001
101 582 78 1001
Author: T.Löw / TE
008 911 63 BOMAG 183

version
226 DH 101 582 80 1001 XXX XXX XX XXXX 7571 3.03
101 582 83 1001
101 582 88 1001
101 582 84 1001
101 582 89 1001
101 582 85 1001
101 582 86 1001
226 BVC DI 101 582 82 1001 XXX XXX XX XXXX 7575 1.04
101 582 85 1001
101 582 86 1001
226 BVC RC 101 582 82 1001 XXX XXX XX XXXX 7576 3.03
101 582 85 1001
101 582 86 1001
version
VARIOCONTROL 101 582 12 1001 XXX XXX XX XXXX 7537 4.00
VARIOCONTROL+ 101 582 13 1001 XXX XXX XX XXXX 7538 4.00
version
177 D-40 101 582 26 1001 XXX XXX XX XXXX 7600 4.00
177 DH-40 101 582 27 1001
177 DHC-4 101 582 00 1001 XXX XXX XX XXXX 7601 4.00
177 PDHC-4 101 582 01 1001 XXX XXX XX XXXX 7602 4.00
177 PDH-40 101 582 28 1001 XXX XXX XX XXXX 7609 4.00
211 D-40 101 583 02 1001 XXX XXX XX XXXX 7620 4.00
101 583 25 1001
211 PD-40 101 583 03 1001 XXX XXX XX XXXX 7629 4.00
101 583 26 1001
212 D-40 101 582 43 1001 XXX XXX XX XXXX 7680 4.00
212 PD-40 101 583 48 1001 XXX XXX XX XXXX 7689 4.00
213 D-40 101 582 44 1001 XXX XXX XX XXXX 7630 4.00
101 582 55 1001
101 583 07 1001
213 DH-40 101 582 56 1001
101 583 11 1001
101 583 12 1001
213 PD-40 101 582 49 1001 XXX XXX XX XXXX 7639 4.00
213 PDH-40 101 582 57 1001
101 583 17 1001
101 583 18 1001
101 583 21 1001
Status:05.06.2007 Page 10 of 59
Author: T.Löw / TE
184 BOMAG 008 911 63

101 583 22 1001
Status:05.06.2007 Page 11 of 59
Author: T.Löw / TE
008 911 63 BOMAG 185

6 Possible adjustments on machines without BOP
6.1 Description of the Display Module
Note: The display module described next is only used in machines without the Bomag
Operation Panel (BOP). On machines with BOP the settings are made via the BOP!
(See item 7 "Adjustment/display possibilities on machines with BOP")
The display module consists of a 4-digit display and two keys, F1 and F2.
It is used for the output of fault codes and display values as well as for the input of code numbers.
Faults and warnings are displayed by flashing. If several faults are detected, the displayed fault codes
will change in a 3 second cycle.
Display values are permanently displayed, whereby values from 0 0 0 0 …9 9 9 9 are possible. Higher
values lead to the display " - - - - ", negative values are indicated by the "minus dot" lighting up (see
illustration).
n
g
i
s
2
4 7
5
/
7
6
6
5 7
5
1 0
The following description describes the input of code numbers.
6.2 Input of code numbers

For the diagnostics of control inputs and outputs various code numbers can be entered via the display
module of the control. The input of a code number is performed as follows:
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.
1. 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 .
2. When pressing the right hand key (F2) the flashing digit will move one digit to the right. When the
4th digit is flashing, the right hand key (F2) is pressed once again to confirm the input. The desired
function is then executed or the desired value is displayed respectively.
In order to terminate a display function you must either enter code number 0000 or switch the
ignition off.
Status: 05.06.2007 Functions of the ESX control Page 12 of 59

Author: T.Löw / TE
186 BOMAG 008 911 63

6.3 Changing the machine type (only via display module)
For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the
display module of the central electrics when switching the ignition on. It can also be checked at any
time by entering code 7000.
Setting the machine type requires the following sequence:
Note: Parameter adjustments can only be performed when the engine is not running!
Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type".
The display module now permanently shows the code 7010.
Select and enter the machine from the table above.
The display module now permanently shows the entered code. (e.g. 7533 )
Enter code number 7 0 1 1 . This code number confirms the entered machine type.
After confirming the machine type the control initiates a restart, the display module shows the new
machine type for approx. 3 seconds.
Switch the ignition off and on again.
After this the newly adjusted machine type will be displayed for approx. 3 seconds.
Attention: A machine must not be operated with a wrong type setting, because in such a
case the correct function of the control cannot be assured!
New controls are delivered with the default machine type setting 7500.

Author: T.Löw / TE
008 911 63 BOMAG 187

6.4 Inverting the direction signal (only via display module)
Depending on the installation position, the axle sensor used delivers a 12 V output signal in forward and
reverse.
This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the the travel direction correspond with the actual travel direction.
Enter code number 7 6 0 0 . This code number activates the function "Invert direction signal“.
The display module now permanently shows the code 7600.
Enter code number 7 6 0 1 . This code number inverts the direction signal.
The display module now permanently shows the code 0001 (signal inverted), or the code 0000
(signal not inverted).
In succession the code number 1 0 0 1 can be used to check whether the direction signal is correctly
interpreted (see item 14 "Input codes for ESX control").

Author: T.Löw / TE
188 BOMAG 008 911 63

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

Author: T.Löw / TE
008 911 63 BOMAG 189

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

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

Author: T.Löw / TE
190 BOMAG 008 911 63

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

Author: T.Löw / TE
008 911 63 BOMAG 191

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

Author: T.Löw / TE
192 BOMAG 008 911 63

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

Author: T.Löw / TE
008 911 63 BOMAG 193

7.3 Accessing the diagnostics menu
Press key "F5" to open the screen page "Diagnose1". The following screen is displayed:

Author: T.Löw / TE
194 BOMAG 008 911 63

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

Author: T.Löw / TE
008 911 63 BOMAG 195

7.3.1 Extended diagnostics on machines with circular exciter (BTMplus,

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

Author: T.Löw / TE
196 BOMAG 008 911 63

7.3.2 Extended diagnose BVC machines
4.25 V Uexciter: actual voltage of exciter position potentiometer
4.23 V Ubv: actual voltage front acceleration transducer
4.24 V Ubh: actual voltage rear acceleration transducer
98 % Ampl: Triggering of solenoid valve for vibration valve in percent
Direction: Status MESX input travel direction (LED on = 12 V)
Lights: Status MESX input light detection (LED on = 12 V)
MD+ Status MESX input MD+ (detection engine running) (LED on = 12 V)
Vibration: Status of vibration detection in the MESX (LED on = Vibration ON)
+01234 Distance pulses detected by the MESX (10 cm steps). The actually detected
travel direction can be recognized by the roller symbol above.

Author: T.Löw / TE
008 911 63 BOMAG 197

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

Author: T.Löw / TE
198 BOMAG 008 911 63

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

Author: T.Löw / TE
008 911 63 BOMAG 199

7.5 Setting the machine serial number
Press key "F7" to open the screen page "Serial number". The following screen is displayed:

Author: T.Löw / TE
200 BOMAG 008 911 63

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

Author: T.Löw / TE
008 911 63 BOMAG 201

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

Author: T.Löw / TE
202 BOMAG 008 911 63

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

Author: T.Löw / TE
008 911 63 BOMAG 203

7.7 Activating the amplitude limitation (only BVC machines)
Press key "F3" to open the screen page "Amplitude limitation". The following screen is displayed:

Author: T.Löw / TE
204 BOMAG 008 911 63

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

Author: T.Löw / TE
008 911 63 BOMAG 205

7.8 Changing the display mode (metric/imperial)
Press key "F4" to open the screen page "Display mode". The following screen is displayed:

Author: T.Löw / TE
206 BOMAG 008 911 63

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

Author: T.Löw / TE
008 911 63 BOMAG 207

7.9 Switching the GPS Receiver Voltage Supply Mode
Press key "F14" to open the screen page "GPS Mode". The following screen is displayed:

Author: T.Löw / TE
208 BOMAG 008 911 63

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

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

Author: T.Löw / TE
008 911 63 BOMAG 209

8 Possible settings on the BCM05mobile

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

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

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

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

Author: T.Löw / TE
210 BOMAG 008 911 63

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008 911 63 BOMAG 215

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008 911 63 BOMAG 217

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218 BOMAG 008 911 63

Service Training Fault codes of the ESX control
13 Fault codes of the ESX control
13.1 Overview
Fault code Fault description

4501 - Position controller (exciter potentiometer, valves)
4540
4601 - Acceleration transducer
4620
8000 - Internal software errors
8250
Status: 05.06.2007 Fault codes of the ESX control Page 45 of 59

Author: T.Löw / TE
008 911 63 BOMAG 219

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008 911 63 BOMAG 221

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224 BOMAG 008 911 63

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008 911 63 BOMAG 225

9
5
f
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2
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g
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n n n n n n F N
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n
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n T 0 /
g n D V T V T V T D I 2
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226 BOMAG 008 911 63

9
5
f
o
3
5
e
g
a
P
V V F

n n F N
i i O O
e e e e
g g n i
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t a
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p D D D D 0 0 p
n
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p
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1 2
n r r n
o e
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t c c t .
c u u c e
n 1 d 2 d
s r s n i n
u r
f e n e n u g
f
r a
r c a
y c t r y n
e a u f u t a l e
l f l
c p d o d o p e s
u s n e s
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s
n e s
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a g r
a g i
d d r
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f f
s t
o n o n l o o o
n o v i
n i o v n s
a
r o
i t e t e i u
o + t
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p r r h
t a t e
t D
p M
a
t
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i e s l
r l e s r t s
i
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t D A S A S n n S
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n
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4 I t u
S 1 1 S A
008 911 63 BOMAG 227

9
5
f
o
4
5
e
g
a
P
s
s e s
u
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a e
d v d
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C a
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p
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c e a t y
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n i
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f n
e
c i
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a m „ c y
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p p n a t
s d
y i o m e
i
e t
t d t
n
c d i
s e h
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o j f e a
n n d
i a n t
n m
o e o e t
h i c
h s s e
t t
c i
p e m l
s h
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c w t
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c f s
S -
o i n e
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M e D S S C P 7 E
0 T
g h
t 0 /
2
n 9 . w
i g 9 6 ö
n 0
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5 .
a
r t e 7 0 T
T
t d .
e o .
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c t : :
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v
r 6
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t
n 7 7 7 7 a t
e 4 I t u
S 1 S A
228 BOMAG 008 911 63

9
5
f
o
5
5
e
g
a
P
s
n
o
i
t
c
u
r
0 t
0 s
n
6 i
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s e e n s
u u e
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d v a
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t p p a t
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n
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s o
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D o c
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t r
c i
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d v
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S 1 S A
008 911 63 BOMAG 229

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

loosened, slipped off
broken off,
corroded,
socket / plug faulty
Status: 05.06.2007 Terminology Page 56 of 59

Author: T.Löw / TE
230 BOMAG 008 911 63

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)
Anal og ue
In contrast to Digital many conditions are permitted within a certain range. For instance room
temperature 0° to 40°; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 Ω to 300 Ω;
valve 0% to 100% opened (proportional valve)
Status: 01.04.2005 General terminolog y Page 57 of 59

Author: T.Löw / TE
008 911 63 BOMAG 231

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.
disturbance
variable (z)
input (w) a Output (y)

Controll distance
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.
disturbance
variable (z)
input (w) + e u Output (y)

Controll distance
-
Marking Closed loop control Control

Operating path: closed open
(closed loop control circuit) (control chain)
Measurement and Value to be adjusted is Values to be controlled
comparison of value to measured and compared. are not measured and
be adjusted: compared.
Reaction to faults Counteracts to all faults Does not respond to
(generally): targeting the system to be unknown faults
controlled.
Technical expense: Low effort: High expense if many
Measurement of the value to faults have to be
be controlled, comparison of considered, low expense
nominal and actual value, if not faults occur.
power amplification
Performance in For unstable systems closed In unstable systems
unstable systems loop controls must be used. controls cannot be used.
Status: 05.06.2007 Terminology Page 58 of 59

Author: T.Löw / TE
232 BOMAG 008 911 63

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

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

Certain outputs on the ESX are designed as so-called PWM – digital outputs. This means
that these outputs are special current outputs. Here it is possible to measure a current, but
no voltage. These outputs are used to trigger proportional valves.
Status: 01.04.2005 General terminolog y Page 59 of 59

Author: T.Löw / TE
008 911 63 BOMAG 233

9.2 Electric module K04
234 BOMAG 008 911 63

008 911 63 BOMAG 235

236 BOMAG 008 911 63

Electric module K04 9.2
008 911 63 BOMAG 237

9.3 Heating/air conditioning control
238 BOMAG 008 911 63

008 911 63 BOMAG 239

240 BOMAG 008 911 63

Heating/air conditioning control 9.3
008 911 63 BOMAG 241

242 BOMAG 008 911 63

Heating/air conditioning control 9.3
008 911 63 BOMAG 243

244 BOMAG 008 911 63

10 Speedometer Module
008 911 63 BOMAG 245

10.1 Speedometer module
Fig. 1 Speedometer module
Description of function
With the programmable module BM UPM the software
realizes a speedometer function. To ensure that the
tachometer function is not only realized for one spe-
cial roller, there is a possibility to adapt the module to
any machine with the help of a self-teaching mode.
●
Whenever the module is switched on the system
runs a self-test by passing through the entire dis-
play range in both directions. The display self-test
takes approx. 15 seconds.
●
After this the module changes to measuring mode.
The frequency of the travel pulses of the roller is de-
tected and converted to a proportional output volt-
age that triggers the display.
●
The output signal for the display is a PWM-signal.
Manual testing of the speedometer
When the module is in learning mode a manual dis-
play test can be performed via the input "Test". For
this purpose the input "IN" must be energized with 12
Volt, whereupon the speedometer is constantly trig-
gered with 3 Volt.
246 BOMAG 008 911 63

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

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

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

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

In self-teach mode the number of arriving path pulses
is detected at the input (IN). The number of recorded
pulses is referred to as pulse number per 10 or 18 m
(machine dependent) travel distance of the roller.
●
Connect the ground cable (-).
●
Connect the sensor signal (speed sensor) to fre-
quency input (IN).
●
Install a cable bridge from terminal "15/54" to the
connection "Teach".
●
Connect potential "Ignition / 15" to connection "15/
54".
●
Switch on the ignition, start the engine and travel a
distance of exactly 10 m.
! Caution
BW24RH, BW27RH, C550H and C560H = travel 18
meters.
All other machines = travel 15 meters.
i Note
If the module is in teach mode the LED on output
"OUT +" will flash with the frequency of the path puls-
es arriving at input (IN).
●
Disconnect the cable bridge from "Teach" to "15/
54“.
●
Switch the ignition off and on again (Reset).
The module has now learned the pulses of the
speed sensor.
●
Connect the speedometer (0 to 6 Volt) to "OUT +"
and "OUT –“.
008 911 63 BOMAG 247

248 BOMAG 008 911 63

11 Service Training
008 911 63 BOMAG 249

250 BOMAG 008 911 63

11.1 Service Training
008 911 63 BOMAG 251

252 BOMAG 008 911 63

Service Training 11.1
Service Training
Single Drum Rollers

BW 211 / 212 / 213 D- 40
11/2005
008 911 63 BOMAG 253

Service Training
Table of cont ents
Travel syst em E1
Travel pump E3
Control E6
Charge pressure relief valve E 11
High pressure relief valve E 12
Pressure override E 14
Axle drive motor E 16
Drum drive motor E 20
Test and adjustment points, travel system E 25
Trouble shooting in travel system E 29
BW 211 / 212 / 213 D-40
254 BOMAG 008 911 63

Service Training
Vibration F1
Vibration pump F3
High pressure relief valves F6
Control F7
Charge pump F8
Vibration motor F9
Drum F 12
Test and adjustment points, vibration system F 14
Trouble shooting in vibration system F 16
Steering G1
Steering pump(s) G2
Steering valve G4
Articulated joint G6
Measuring and adjustment points G8
Trouble shooting steering system G9
BW 211 / 212 / 213 D-40
008 911 63 BOMAG 255

Service Training
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BW 211 / 212 / 213 D-40 -E1-
256 BOMAG 008 911 63

Service Training
The travel system of the single drum rollers is a closed hydraulic circuit and consists mainly of:
• travel pump with control and safety elements,
• Drum drive motor without brake,
• axle drive motor,
• rear axle with brake,
• charge pump (also for vibration circuit),
• hydraulic oil filter (in charge circuit),
• hydraulic oil cooler with thermostat
• hydraulic lines.
Travel pump and vibration pump are connected to a tandem pump unit. The charge pump is an integral
part of the vibration pump.
The travel pump is the first pump section, flanged directly to the flywheel side of the diesel engine.
The pump delivers the hydraulic oil to the travel motors for drum and axle drives. The multi-function
valves in the pump limit the pressure in the closed circuit to (∆p = 400 bar between low and high
pressure sides).
A flushing valve in the axle drive motor (and in the Sauer drum drive motor 51 C 110) flushes a certain
oil quantity out of the closed circuit when the machine is driving (∆p between the two sides of the closed
circuit).
Leakage in the individual components of the circuit are replaced by the charge circuit through the boost
check valves in the travel pump.
The charge pumps draw hydraulic oil out of the tank and deliver it through the hydraulic oil filter and the
charge pressure relief valve to the boost check valves in travel and vibration pumps. The machine is
fitted with two charge pumps. One pump is integrated in the vibration pump and the other pump is driven
by the auxiliary output of the engine and serves primarily as steering pump.
The charge circuit provides the oil for the charge system and the control functions in the closed circuits
for travel and vibration drive, as well as to release the parking brakes and to change the travel speed
ranges.
The travel motor in the axle is desired with variable displacement. The operator can choose from two
different travel speed ranges.
BW 211 / 212 / 213 D-40 -E2-
008 911 63 BOMAG 257

Service Training
Travel pump
The travel pump is a swash plate operated axial piston pump with variable displacement, most suitable
for applications in hydrostatic drives with closed circuit.
M4 M5
2
A from/to
Travel motor
25 bar
4
3
1
from/to
Travel motor
B
Charge pressure to vibration pump
Charge pressure from hydraulic oil filter
Fig. 2: Hydraulic diagram of travel pump
1 Pump drive 3 Charge pressure relief valve

2 Servo control 4 Multi-function valves
BW 211 / 212 / 213 D-40 -E3-
258 BOMAG 008 911 63

Service Training
The travel pump delivers the hydraulic oil to the motors on rear axle and drum. The pump flow is
proportional to the pump speed (output speed of diesel engine) and the actual displacement (swashing
angle of swash plate) of the pump.
7 1
6
5
Fig. 3: Travel pump
1 Control lever 5 Cylinder block

2 Drive shaft 6 Valve plate
3 Swash plate bearing 7 Control piston
4 Pistons with slipper pads
With the servo control the swashing angle can be infinitely adjusted from neutral position (0) to both
maximum displacement positions.
When altering the swash plate position through the neutral position, the oil flow will be reversed and the
machine will drive to the opposite direction.
All valves as well as the safety and control elements needed for operation in a closed circuit, are
integrated in the pump.
Note:
These machines are equipped with two charge pumps.
BW 211 / 212 / 213 D-40 -E4-
008 911 63 BOMAG 259

Service Training
Cross-sectional view of travel pump
2
4
5
1 3
9
10
8
11
Fig. 4: Cross-sectional view of travel pump
1 Retainer for swash plate 7 Swash plate bearing

2 Sliding block 8 Swash plate guide
3 Control piston 9 Swash plate
4 Servo arm 10 Swashing lever
5 Servo valve 11 Charge pump (only in vibration pump)
6 Feedback device
BW 211 / 212 / 213 D-40 -E5-
260 BOMAG 008 911 63

Service Training
View of the rotating grou p
4 3
5
Fig. 5: Travel pump, view of the rotating group
1 Working pistons
2 Slipper pad
3 Pre-tensioning spring
4 Cylinder block
5 Drive shaft
BW 211 / 212 / 213 D-40 -E6-
008 911 63 BOMAG 261

Service Training
Description of function
2 3 4 5 6
1
8 6 7
Fig. 6: Function of travel pump
1 Drive shaft 5 Cylinder block

2 Drive shaft bearing 6 Multi-function valves
3 Swash plate 7 Charge pump (only in vibration pump)
4 Pistons with slipper pads 8 Valve plate
The drive shaft (1) is directly driven by the diesel engine via an elastic coupling. the shaft turns the tightly
connected cylinder block (5).
With the rotation of the drive shaft (1) the cylinder block (5) moves the working pistons (4). The slipper
pads of the working pistons abut against the swash plate (3).
BW 211 / 212 / 213 D-40 -E7-
262 BOMAG 008 911 63

Service Training
When moving the swash plate out of neutral position, the working pistons will perform a stroke
movement with every rotation of the cylinder block.
The slipper pads are hydrostatically balanced and are retained on the sliding face of the swashing cradle
by a retaining device.
During a full rotation of the cylinder block each working piston will move through the bottom and top dead
centre back to the initial position. During this movement each piston performs a complete stroke.
During the piston stroke each piston draws in a certain quantity of oil from the low pressure side of the
hydraulic circuit and presses it out into the high pressure side.
BW 211 / 212 / 213 D-40 -E8-
008 911 63 BOMAG 263

Service Training
Tandem pu mp
BW 211 / 212 / 213 D-40 -E9-
264 BOMAG 008 911 63

Service Training
Tandem pump, connection s and adjust ment points
32
Thermostat
housing
Fig. 7: Connections and adjustment points
BW 211 / 212 / 213 D-40 - E 10 -
008 911 63 BOMAG 265

Service Training
1 Control solenoid, high frequency (vibration pump)
2 Control solenoid, low frequency (vibration pump)
3 Multi-function valve 400 bar (charging and pressure limitation), travel system
4 Charge pressure to solenoid valve for brakes and speed range selector, charging vibration
5 Multi-function valve 400 bar (charging and pressure limitation), travel system
6
7 Port L, leak oil to vibration pump
8 Travel lever
9 Pressure test port, pilot pressure
10 High pressure port B, high pressure reverse
11 Charge pressure relief valve, 26 bar
12 Adjustment screw, low frequency
13 Port L2, leak oil to tank
14 Pressure test port MB, high frequency
15 Pressure test port MA, low frequency
16 High pressure port A, low frequency
17 High pressure port B, high frequency
18 End plate with integrated charge pump (only in vibration pump)
19 Port L2
20 Adjustment screw, high frequency
21 Port D, charge pressure to filter
22 Multi-function valve 345 bar (charging and pressure limitation), vibration high frequency
23 Port S, suction line between hydraulic oil tank and charge pump
24 Multi-function valve 345 bar (charging and pressure limitation), vibration low frequency
25 Charge pressure relief valve, vibration pump (blocked)
26 Port E, charge oil from travel pump
27 Port L1, leak oil port to travel pump
28 Pressure test port MB, high pressure reverse
29 Charge oil from filter
30 Pressure test port MA, high pressure forward
31 High pressure port A, high pressure forward
32 Adjustment screw for mechanical neutral position, vibration
Thermostat housing: 33, 34, 35, 36 Leak oil port

37 cooler inlet
BW 211 / 212 / 213 D-40 - E 11 -
266 BOMAG 008 911 63

Service Training
servo control
The servo control (mechanical – hydraulic displacement control) converts the mechanical input signal
of the pump control lever into a position controlling output signal. This position controlling signal
determines the swashing angle of the swash plate (the displacement of the pump), as well as the
swashing direction (flow direction of the pressure fluid).
The flow quantity delivered by the variable displacement pump is proportional to the value of the
mechanical input signal. A mechanical feedback device ensures the fixed correlation between the
mechanical input signal and the swashing angle of the swash plate (displacement of pump).
Servo cylinder
Control piston
Sliding block
Servo arm
Fig. 8: Control piston
A mechanical safety device (spring) makes sure that a too fast lever movement will not cause any
damage to the servo control.
The pump displacement can be adjusted by actuating the pump control lever via travel lever and travel
control cable. This requires only very little manual forces and only a slight movement of the lever.
Since the control is spring centred, the swash plate will automatically return to neutral position under the
following conditions, thereby interrupting the oil flow and braking the machine:
BW 211 / 212 / 213 D-40 - E 12 -
008 911 63 BOMAG 267

Service Training
• when shutting the engine down,
• if the external control cable comes loose,
• if the pressure in the charge circuit drops below a certain value.
BW 211 / 212 / 213 D-40 - E 13 -
268 BOMAG 008 911 63

Service Training
Multi-function valves
High pressure limitation
Pumps of series 90 are equipped with so-called multi-function valves, which activate a pressure override
and a pressure relief valve, one after the other.
1 2
3
A
6 5
B
4
Fig. 9: Multi-function valves
1 to the control 6 Drive shaft

2 Multi-function valve 7 to the control piston
3 Charge pump 8 to the control piston
4 Charge pressure relief valve A Port A
5 Pilot pressure relief valve B Port B
If the adjusted pressure is reached, the pressure override will move the swash plate quickly back
towards neutral position, thereby limiting the system pressure. The average response time is less than
90 ms.
BW 211 / 212 / 213 D-40 - E 14 -
008 911 63 BOMAG 269

Service Training
In case of a very quick increase in pressure (pressure peaks) the system utilizes the function of the
pressure relief valves as a protection for the hydraulic systems. In such a case the pressure override
works as a pre-control unit for the control piston of the pressure relief valve. The pressure level of the
high pressure relief valve is higher than the pressure level of the pressure override. The high pressure
relief valves will only respond if the pressure override is not able to swash the pump back quick enough
in case of sudden pressure peaks.
2 3
4
5
1
6
9 7
8
10
11
Fig. 10: Multi-function valve, details
1 Reducing fitting 7 Check valve

2 Hydraulic by-pass piston 8 Pressure limitation
3 Spring plate 9 Spring
4 Spring 10 By-pass housing
5 High pressure relief valve 10 By-pass sleeve
6 Valve seat
Pressure override and high pressure relief valve are both parts of the multi-function valve, which is
screwed into the pump.
With its possibility to swash the swash plate inside the pump back within a period of 90 ms, the pressure
override makes sure that the high pressure relief valves will only respond in exceptional cases. This
protects the hydraulic circuit against overheating and reduces the load on the diesel engine.
Note:
The multi function valves must be tightened with a torque of 89 Nm!
BW 211 / 212 / 213 D-40 - E 15 -
270 BOMAG 008 911 63

Service Training
Charge pr essure relief valve
The machines are equipped with two charge pumps, one driven by the auxiliary output of the engine
(steering and charge pump) and the other pump is integrated in the vibration pump.
The pressures of both pumps are limited by a charge pressure relief valve.
The charge pressure relief valve is a direct acting valve with fixed adjustment and is part of the safety
elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted
value (26 bar).
The charge circuit compensates leaks and flushing quantities in the closed travel and vibration circuits
and provides the necessary pressure to control the travel and vibration pumps and to operate the multi-
disc brakes in the travel drives.
Since feeding of cool and filtered oil is only possible in the low pressure side of the closed circuit, the
pressure in the low pressure side is almost identical with the pressure in the charge circuit.
When parking the machine on level ground with the engine running, the pressures in both sides of the
closed circuit are identical (charge pressure).
BW 211 / 212 / 213 D-40 - E 16 -
008 911 63 BOMAG 271

Service Training
Flushing valve
Fig. 11Cross-section of flushing valve
1 Flushing spool
2 Flushing pressure relief valve
The flushing valve is integrated in the axle drive motor. In case of a pressure increase in one of the two
sides of the closed circuit the flushing valves have the function to flush a certain quantity of oil out of the
low pressure side.
The valve is operated by the pressure difference between the two sides of the closed circuit (A and B).
If the pressure in one side is higher than in the other, this pressure will move the valve out of neutral
position against the neutral setting spring. Oil can now flow out of the low pressure side. This oil flows
through a thermostat valve back to the tank. The oil quantity flushed out of the closed circuit is
immediately replaced by oil entering from the charge circuit through the corresponding boost check
valve (part of the multi-function valve).
In this way the closed travel circuit is permanently supplied with cool and filtered oil and the temperature
household of the hydraulic system is maintained at a permissible level.
BW 211 / 212 / 213 D-40 - E 17 -
272 BOMAG 008 911 63

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

2 Flushing valve 8 Universal joint
3 Control 9 Output shaft
4 Spindle with ball 10 Output shaft bearing
5 Qmin-screw 11 Working piston
6 Valve plate
BW 211 / 212 / 213 D-40 - E 18 -
008 911 63 BOMAG 273

Service Training
The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle
between cylinder block and output shaft.
With a large angle position the motor works with maximum displacement, slow speed and high torque.
When changing the swash plate position to minimal angle the motor works with minimum displacement,
high speed and low torque.
The displacement is changed by a control piston, which is tightly connected with the valve segment.
Changing of the displacement is accomplished by pressurizing the corresponding control piston side
with pressure oil from the charge circuit via a 4/2-way solenoid valve.
Function
The motor is connected with the travel pump via the high pressure ports A and B. The hydraulic oil flows
under high pressure through the corresponding port to the back of the working pistons. Since the
working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a
stroke movement, thereby causing a rotation of the output shaft.
Once the respective piston has passed its dead centre (max. extended position), it will change to the
low pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is
thereby displaced out of the cylinder chamber through the low pressure side back to the pump.
The synchronizing shaft with roller surfaces ensures uniform rotation of output shaft and cylinder block.
The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the
connection between output shaft and pistons no other parts are required. The output shaft runs in two
tapered roller bearings.
BW 211 / 212 / 213 D-40 - E 19 -
274 BOMAG 008 911 63

Service Training
Rear axle
Releasing the axle drive brake manually (on both axle drive designs)
For manual releasing of the brakes on the rear axle you should proceed as follows:
Fig. 13: Manual releasing of rear axle brakes
• Slacken the counter nut (Fig. 14, Pos. 1) and back it off by approx. 8 mm.
• Turn the brake releasing screw (2) in against the stop.
• To release the brake tighten the screw for max. 1 complete turn.
At ten ti on !
Turn the screws on bot h sides in unif orml y (alternately by 1/4 of a turn)
• Repeat this procedure on the opposite side of the axle.
BW 211 / 212 / 213 D-40 - E 20 -
008 911 63 BOMAG 275

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

2 Piston with roller
3 Oil distributor
4 Cylinder block
5 Cam ring
6 Bearing plate
The housing consists of:
BW 211 / 212 / 213 D-40 - E 21 -
276 BOMAG 008 911 63

Service Training
• bearing section (drive shaft bearings),
• torque section (cam race) and
• oil distributor.
Pressure oil flows through the flat distributor to the working pistons in the cylinder block. This pressure
oil presses the working pistons with the rollers against the cam race of the torque section and forces the
rollers to roll along the cam race.
This transforms the axial movement of the pistons to a radial movement of the cylinder block. The
cylinder block transfers this rotation via a splined connection to the output shaft.
The output shaft runs in two tapered roller bearings. It transfers the rotary movement via the drive disc
and the rubber elements to the drum.
The function of the radial piston motor is described hereunder. The piston positions described in this
explanation can be seen in the related illustration.
The movement of a piston along the cam race must be examined in several phases during a full rotation:
2
3
Fig. 15: Function of the radial piston motor
BW 211 / 212 / 213 D-40 - E 22 -
008 911 63 BOMAG 277

Service Training
Piston position 1:
The oil enters into the oil distributor under pressure, flows through the distributor and presses against
the piston. The rotation starts at this point. The pressure applied to the back of the piston moves the
roller along the cam and causes a rotation of the cylinder block.
Piston position 2:
At this point the opening cross-section for the oil flow to the piston has reached its maximum size. The
piston continues his travel along the cam race towards the valley between two cams. As the movement
continues the opening cross-section for the oil supply decreases.
Piston position 3:
Once the piston has reached the bottom of the valley, the oil flow to the piston is interrupted. The piston
is no longer driven. It has reached its dead centre. Now another piston must be driven to move the first
piston out of the dead centre.
Piston position 4:
Other driven pistons now move the first piston out of the dead centre. The oil behind the piston is now
connected with the low pressure side and the reverse movement of the piston presses the oil back to
the pump.
Piston position 5:
The pumping movement of the motor back to the pump comes to an end, the connecting bore between
cylinder chamber and low pressure side closes again. The piston will now reach its second dead centre
position. This point is the start of a new working cycle.
Reversing the oil flow reverses also the rotation of the motor.
The output shaft runs in two tapered roller bearings. It transmits the rotary movement via the drive disc
and the rubber elements to the drum.
BW 211 / 212 / 213 D-40 - E 23 -
278 BOMAG 008 911 63

Service Training
Travel circu it: Drum drive with radial pisto n motor
1
4
6 1
n
i o
c t
r e
1 Travel pump
i
d
e l
2 Vibration pump
a v 3 Travel lever
T r 4 Hydraulic oil filter
High pressure 5 Rear axle
Low pressure 6 Axle drive motor
7 Drum drive motor
Charge pressure
8 Hydraulic oil tank
Leak oil (case pressure)
Fig. 16: Single drum rollers D-40, travel circuit, hose installation
BW 211 / 212 / 213 D-40 - E 24 -
008 911 63 BOMAG 279

Service Training
Brake cont rol: Travel motor in axle
Brake valve
Charge pressure
Brake releasing pressure
Leak oil
Fig. 17: Brake circuit
BW 211 / 212 / 213 D-40 - E 25 -
280 BOMAG 008 911 63

Service Training
Travel drive, components and test poi nts
Travel pump :
2
2 1
1
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values
diagram
1 Test port, forward 10, MD max. 426 bar
2 High pressure port, forward 10, A
3 Charge pressure port 7, MA 26 bar
BW 211 / 212 / 213 D-40 - E 26 -
008 911 63 BOMAG 281

Service Training
Travel pump: rig ht hand side
2 3
1
diagram
1 Test port, reverse 10, MC max. 426 bar
2 High pressure port, reverse 10, B
3 Travel control (travel control cable)
BW 211 / 212 / 213 D-40 - E 27 -
282 BOMAG 008 911 63

Service Training
Front travel motor, withou t brake (radial piston mo tor)
2 1
2 1
45 3
4
6
3

diagram
1 High pressure port, forward 12, L
2 High pressure port, reverse 12, R
3 Cross-flushing of travel pump T1 12
4 Leak oil port 12, 1
BW 211 / 212 / 213 D-40 - E 28 -
008 911 63 BOMAG 283

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

diagram
1 Solenoid for speed range selector Y31 14 Motor Qmax---
valve depressurized,
Motor Qmin---
26 bar
2 Flushing valve 14
3 High pressure port, drum drive 14, A
motor forward
4 High pressure port, drum drive 14, B
motor reverse
5 High pressure from travel pump 14, A
forward
6 High pressure from travel pump 14, B
reverse
7 Qmin- setscrew 14
BW 211 / 212 / 213 D-40 - E 29 -
284 BOMAG 008 911 63

Service Training
Brake valve
11

diagram
1 Brake valve Y 04 08, open, 12V closed,
de-energized
BW 211 / 212 / 213 D-40 - E 30 -
008 911 63 BOMAG 285

Service Training
Travel lever co nsol e
BW 211 / 212 / 213 D-40 - E 31 -
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Service Training
Travel lever

diagram
1 Initiator for backup alarm B14 0 / 12V, normally
closed
2 Initiator for brake B13 Normally closed,
opened in braking
position
0/12V
BW 211 / 212 / 213 D-40 - E 32 -
008 911 63 BOMAG 287

Service Training
Trouble shoot ing

The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The numerical values specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
'
l
) a
e r
s t
r u
e e
v N
e l
y '
r
n n
d o i
n r
a n e
. i
o v d
TROUBLE SHOOTING TRAVEL w t e e
r c l
o r e h
e l
c
f
( i v a g
SYSTEM e d a
i
e i
n
r r t
v e t t
r n h o a
t n e
d o i
BW 211 / 212 / 213 D-40 t o w
o t
h
d r
e
s e
n s l e v
s e e p l o
S e v v s i
M o i a l o
r r
O d d t e c
v i
T e e e a l
n i
P i n i
n t
r u
h h h . r a
M c c c x d
Y a a a a y
S M M M M H
POSSIBLE CAUSES
Brake valve (electric/mechanical/hydraulic) 1
Brake in axle-drive motor (mechanical/hydraulic) 2 2 3
Travel speed range switch position /defective/wiring 1
Charge pump / charge pressure relief valve(s)
2 3
dirty/defective
Pump control (servo control) 2 1 2 3
Pressure override/ travel pump high pressure limitation
3 2 3 3
dirty/out of adjustment/defective
Adjustment of travel cable 1 2
Travel pump mechanical neutral 3 3
Travel pump(s) defective 3 3 2
Axle drive motor control valve (electric / mechanical / hydraulic) 1 2
Flushing valve axle drive motor seized 3
Travel motor(s) defective 3 3
Hydraulic oil cooler soiled (internally/externally) 1
Thermostat (hydraulics) soiled/jammed/defective 2
Clutch- Dieselmotor-Pumpe 2
Dieselmotor 1
BW 211 / 212 / 213 D-40
288 BOMAG 008 911 63

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

Travel pump
Charge oil
Vibration pump
D M3 E
L2 N
Block
M1
M2
S
B
2
1
M4
M5
Fig. 1: Vibration circuit
1 Vibration pump
2 Vibration motor
BW 211 / 212 / 213 D-40 -F1-
008 911 63 BOMAG 289

Service Training
Vibration pump and travel pump are joined together to a tandem pump unit. This tandem unit is directly
driven by the diesel engine.
When operating a 4/3-way solenoid valve on the pump control the pump is actuated out of neutral
position to one of the two possible displacement positions, pilot oil from the charge circuit is guided to
one of the two control piston sides. The swash plate inside the pump will swash to the corresponding
side and the pump will deliver oil to the vibration motor. The vibration motor starts and rotates the
vibrator shaft inside the drum.
When altering the position of the swash plate through the neutral position to the opposite side, the oil
flow will change its direction and the vibration motor will change its sense of rotation.
Since the end stops for the swash plate are set to different swashing angles to both directions, the angle
for the piston stroke is also different to both sides. This angle influences the length of the piston stroke
and thereby the actual displacement of the pump.
• Large angle = high displacement = high vibrator shaft speed (frequency)
• Small angle = low displacement = slow vibrator shaft speed (frequency)
The eccentric weights on the vibrator shaft are fitted with additional change-over weights. Depending
on the sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic
weights.
This results in the following constellations:
• Basic weight + change-over weight = high amplitude
• Basic weight - change-over weight = low amplitude
In order to achieve effective compaction results the vibration system is designed in such a way, that high
amplitude is coupled with low frequency and low amplitude with high frequency.
Fig. 2:
BW 211 / 212 / 213 D-40 -F2-
290 BOMAG 008 911 63

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

Travel pump
Charge oil
Vibration p ump
D M3 E
1 Vibration pump
L2 N 2 Charge pump
3 High pressure limitation
Block
4 4/3-way solenoid valve
M1
M2
S
B
M4
M5
Fig. 3: Hydraulic diagram vibration pump
BW 211 / 212 / 213 D-40 -F3-
008 911 63 BOMAG 291

Service Training
Function
1 2
5 4 3
Fig. 4Cross-section of vibration pump
1 Servo piston
2 Working pistons
3 Charge pump
4 Valve plate
5 Roller bearing
6 Swash plate
BW 211 / 212 / 213 D-40 -F4-
292 BOMAG 008 911 63

Service Training
1
2
4 3
Fig. 5 Cross-section of vibration pump
1 Control
2 Servo piston
3 Friction free swash plate bearing
4 Attachment plate
5 Spool valve
The engine drives the drive shaft with the cylinder block. The cylinder block carries the working pistons.
The slipper pads rest against the sliding surface of the swash plate and are at the same time held on
the sliding surface by a retaining device.
During each rotation the piston pass through their upper and lower dead centre back to their initial
position. Between both dead centres each piston performs a full working stroke. During this stroke
movement oil is drawn in from the low pressure side of the closed circuit and pressed out through the
slots in the valve plate into the high pressure side. The oil quantity depends on the piston area and the
length of the working stroke.
BW 211 / 212 / 213 D-40 -F5-
008 911 63 BOMAG 293

Service Training
During the suction stroke the oil is drawn into the piston chamber, i.e. the charge pressure forces it into
the piston chamber. On the opposite side the piston presses the oil out into the high pressure side of he
closed circuit.
Control
The electro-hydraulic displacement control (remote control) converts the electric input signal to a load
controlling output signal. Since the pump is not equipped with a proportional control, but a 12 Volt
solenoid valve, the pump is always actuated to one of the two end stop positions.
Charge pumps
These machines are equipped with two charge pumps.
One of the pumps is an external gear pump, which is directly driven by the auxiliary output of the engine
and serves also as steering pump.
The second pump is an internal gear pump and is located in the end cover of the vibration pump.
The oil flow generated by the charge pumps is joined together with the return flow from the steering
valve before the hydraulic oil filter and flows through the filter to the charge ports on travel pump and
vibration pump.
BW 211 / 212 / 213 D-40 -F6-
294 BOMAG 008 911 63

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

2 Closed circuit
3 High pressure relief valve with
integrated boost check valve
Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the
vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this
phase. The high pressure relief valve reduces these pressure peaks to a value of max. 371 bar
(pressure difference between high and low pressure side = 345 bar + charge pressure = 26 bar).
The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the
closed vibration circuit. The function of these valves has already been described in the chapter "travel
system".
BW 211 / 212 / 213 D-40 -F7-
008 911 63 BOMAG 295

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

2 Flushing valve
3 Working pistons with slipper pads
4 Roller bearing for output shaft
5 Radial seal
6 Output shaft
7 swash plate
8 Retaining plate
9 Pre-tensioning spring
BW 211 / 212 / 213 D-40 -F8-
296 BOMAG 008 911 63

Service Training
The output torque raises with increasing pressure difference between low and high pressure side in the
closed circuit.
Changing the flow direction of the oil will also change the sense of rotation of the vibration motor.
When switching the vibration on the motor must first start to move the resting vibration shaft. This
resistance causes a hydraulic starting pressure, which is limited to 345 bar by the corresponding high
pressure relief valve. Once the vibrator shaft has reached its final speed, the pressure will drop to a
value between 100 and 150 bar (operating pressure). The value of the operating pressure mainly
depends on the condition of the ground (degree of compaction, material etc.).
• Hard ground = High operating pressure
• Loose ground = Low operating pressure
A MA
3 1
B MB
Fig. 8Circuit diagram of vibration motor
1 Vibration motor
2 Flushing valve
BW 211 / 212 / 213 D-40 -F9-
008 911 63 BOMAG 297

Service Training
The vibration motor is equipped with an integrated flushing valve. When switching the vibration on a
pressure difference will appear between the two sides of the closed circuit. The higher pressure moves
the valve spool of the flushing valve against the neutral setting spring, so that oil can flow out of the low
pressure side.
Fig. 9 Flushing valve
1 Flushing spool
2 Flushing pressure limitation valve
The flushing valve is fitted with a downstream 13 bar pressure relief valve. This valve ensures that only
a certain quantity of hydraulic oil is flushed out of the low pressure side.
This oil flows via a thermostat valve back to the hydraulic tank. The flushed out oil is immediately
replaced with fresh and filtered oil through the corresponding boost check valve.
BW 211 / 212 / 213 D-40 - F 10 -
298 BOMAG 008 911 63

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

2 Vibration bearing 9 Coupling vibr.-motor – vibrator shaft
3 Basic weight 10 Travel bearing
4 Vibrator housing 11 Travel bearing housing
5 Cooling fan 12 Rubber buffer
6 Vibrator shaft 13 Vibration motor
7 Elastic coupling between shafts 14 Flanged bearing housing
BW 211 / 212 / 213 D-40 - F 11 -
008 911 63 BOMAG 299

Service Training
Vibration system: Components and test ports
Vibration pump
11
2
3
2
5 6 3
6
5 4
4
diagram
1 Pressure test port, charge pressure MA 26 bar
2 Hydraulic oil filter (charge circuit) 07
with visual pressure differential
indicator
3 High pressure port, low MF
amplitude
4 High pressure port, high ME
amplitude
5 Solenoid valve, low amplitude Y08 12V / 3,33A
6 Solenoid valve, high amplitude Y07 12V / 3,33A
BW 211 / 212 / 213 D-40 - F 12 -
300 BOMAG 008 911 63

Service Training
Vibration pump

diagram
1 Pressure test port, vibration MF max. 371 bar
pressure low amplitude
2 Pressure test port, vibration ME max. 371 bar
pressure high amplitude
low amplitude high amplitude
BW 211 / 212 / 213 D-40 - F 13 -
008 911 63 BOMAG 301

Service Training
Vibration motor

diagram
1 High pressure port, high amplitude 16
2 High pressure port, low amplitude 16
3 Leak oil and flushing oil port 16 approx. 7 l/min,
incl. flushing
quantity
4 Flushing spool 16
5 Flushing valve 16 13 bar
BW 211 / 212 / 213 D-40 - F 14 -
302 BOMAG 008 911 63

Service Training
Trouble shoot ing

Procedure:
) e
K d
O t
u
e i
r l
u p
s m w
s a l
o
TROUBLE SHOOTING e
r e o
p n o
e o t
VIBRATION g t
r h d
e
a i e
h w p
c y s
BW 211 / 212 / 213 D-40 S ( l
n n t
f
M o o a
O i
t n h
s
T a o r
r i
P i
b t t
e
a i
M v r c
Y b x
o i
S N V E
POSSIBLE CAUSES
Vibration switch (amplitude pre-selection) 1 1
Vibration push button (on/off) 1
Electrics defective / wiring 2 2
Pump control (electrical / hydraulic) 1 1
Pressure override / high pressure relief valves in vibration pump
2
soiled/out of adjustment/ defective
Charge pump / charge pressure relief valve
2
soiled/ defective
Vibration pump frequency adjustment 2
Vibration pump defective 2 2
Coupling between diesel engine and travel pump defective
Exciter shaft bearings defective 3
Vibration motor coupling defective 2
Vibration motor defective 2 1
Diesel engine 1
BW 211 / 212 / 213 D-40
008 911 63 BOMAG 303

Service Training
Steering
Single drum rollers of series BW 211 / 212 / 213 D-40 are equipped with a hydrostatically operated
articulated steering system.
The steering system mainly consists of steering pump, steering valve, steering cylinders and pressure
resistant connecting hoses.
to charge
system
1
7
6
5
3
2
4
from steering pump
Fig. 1Steering hydraulics
1 Rating pump
2 Distributor valve
3 Steering pressure relief valve (∆p =175 bar)
4 Check valve (pre-loaded to 0.5 bar)
5 Anti-cavitation valve
6 Shock valves (240 bar)
7 Steering cylinders
The steering pump draws the hydraulic oil out of the hydraulic oil tank and delivers it to the steering valve
and the connected steering unit under the operator's platform of the machine. If the steering is not
operated, the complete oil supply will flow through the fine filter to the charge system for the closed travel
circuits.
When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side
of the steering cylinder. A rating pump inside the steering unit measures the exact oil quantity
corresponding with the turning angle of the steering wheel and delivers the oil to the steering cylinders.
The steering cylinders retract or extend and steer the machine.
The steering unit is equipped with a pressure relief valve. This valve limits the steering pressure to 175
bar. The charge pressure must, however, be added to this value, because the oil leaving the steering
system enters the charge circuit. The actual steering pressure is therefore approx. 200 bar.
BW 211 / 212 / 213 D-40 -G1-
304 BOMAG 008 911 63

Service Training
Steering p ump
The steering pump is a gear pump with fixed displacement. It is driven by the auxiliary drive of the diesel
engine, draws the hydraulic oil out of the hydraulic oil tank and pumps it through the steering valve to
the steering cylinders or to the boost check valves for travel and vibration circuits.
9 9 6 1 7
8
2
4 5
Fig. 2Steering pump
1 Housing
2 Flange
3 Shaft
4 Bearing plate
5 Bearing plate
6 Cover
7 Gear (driving)
8 Gear (driven)
9 Seals
BW 211 / 212 / 213 D-40 -G2-
008 911 63 BOMAG 305

Service Training
Working principle of the gear pumps
The drive gear of the steering pump is connected with the auxiliary drive of the diesel engine via a
coupling. Drive gear and driven gear are positioned by a bearing plate in such a way, that the teeth of
both gears mesh with minimum clearance when rotating.
The displacement chambers are created between the tooth flanks, the inside wall of the housing and
the faces of the bearing plates.
When the pump is running the chambers transport hydraulic oil from the suction side to the pressure
side. This causes a vacuum in the suction line by which the hydraulic oil is drawn out of the tank. The
tooth chambers transport the fluid to the outlet of the pump from where it is pressed to the consumers.
To ensure a safe function of the pump the tooth chambers must be so tightly sealed that the hydraulic
fluid can be transported from the suction side to the pressure side without any losses.
For this purpose external gear pumps are fitted with gap seals. This causes pressure dependent fluid
losses from the pressure side to the suction side. As a measure to ensure that these losses are reduced
to a minimum, the bearing plate on the cover side is pressed against the faces of the gears by an axial
pressure field.
This pressure field is always under the actual system pressure.
BW 211 / 212 / 213 D-40 -G3-
306 BOMAG 008 911 63

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

2 Housing
3 Inner spool
4 Outer spool
5 Universal shaft
6 Ring gear
7 Gear
8 Check valve
9 Pressure relief valve
When turning the steering wheel the distributor valve guides the oil flow from the pump to the rating
pump. The rating pump guides the oil flow through the distributor valve to the corresponding
sides of the steering cylinders. The rating pump measures the exact oil quantity in accordance with the
rotation angle of the steering wheel.
This oil flow to the steering cylinders articulates the machine and causes a steering movement.
BW 211 / 212 / 213 D-40 -G4-
008 911 63 BOMAG 307

Service Training
240 bar
∆p = 175 bar
240 bar
0,5 bar
Fig. 4Steering valve, hydraulic diagram
The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar.
The charge pressure value must be added to this pressure, because the oil leaving the steering system
is fed into the charge circuit for the closed travel circuits.
The steering unit is fitted with so-called shock valves in each supply line to the steering cylinder. These
valves are adjusted to an opening pressure of 240 bar. The valves compensate extreme pressure peaks
which may occur, e.g. when driving over obstructions, and protect the system against overloads.
Each of these shock valves is fitted with an additional anti-cavitation valve. If the shock valves respond
these anti-cavitation valves protect the system against cavitation damage.
A check valve at the inlet of the steering unit makes sure that no oil will flow back to the pump in case
of pressure peaks caused by sudden steering movements. In such a case the steering cylinders would
act as pumps and press the oil back to the pump.
BW 211 / 212 / 213 D-40 -G5-
308 BOMAG 008 911 63

Service Training
Ar ti cu lat ed j oi nt
Front and rear frames of the single drum rollers are connected by an oscillating articulated joint. This
ensures that drum and wheels are at all times in contact with the ground, even when driving extreme
curves.
Fig. 5Articulated joint
BW 211 / 212 / 213 D-40 -G6-
008 911 63 BOMAG 309

Service Training
The rear console is tightly bolted to the rear frame.
The front console is fastened with screws to the rear cross-member of the front frame. The use of rocker
bearings between front and rear frame ensures that both frames can oscillate to each other for +/- 12°.
This gives drum and wheels excellent ground contact, even under extremely severe conditions.
The front console is connected with the rear console by two vertical bolts. The vertical bolts are mounted
in friction bearings.
The steering cylinder anchor point is welded to the front console.
When turning the steering wheel the steering cylinder will extend or retract. The piston rod swivels the
front console around the vertical bolts. This articulates the machine and results in a steering movement.
All bearings on the articulated joint are maintenance free and do not require any lubrication.
Notes on assembly:
When assembling or repairing the articulated joint the correct pretension of the centre pin is of highest
importance.
Please follow the instructions in the repair manual for the articulated joint.
BW 211 / 212 / 213 D-40 -G7-
310 BOMAG 008 911 63

Service Training
Steering: Compon ents and test ports

Steering p ump

diagram
1 Steering pump (and charge pump) 09
2 Steering pressure test port MB max. 175+26 bar
BW 211 / 212 / 213 D-40 -G8-
008 911 63 BOMAG 311

Service Training
Vibration and noi se damper
The damper is located in the steering/charge circuit directly after the steering and charge pump.
It is subjected to hydraulic oil flow and has the function of eliminating any vibrations and noises.
The damper is mounted to the front plate of the rear frame, between both steering cylinders.
BW 211 / 212 / 213 D-40 -G9-
312 BOMAG 008 911 63

Service Training
Steering valve
The steering valve is located under the operator's stand
BW 211 / 212 / 213 D-40 - G 10 -
008 911 63 BOMAG 313

Service Training
Trouble shoot ing

Procedure:
TROUBL E SHOOTING STEERING

SYSTEM
BW 211 / 212 / 213 D-40
d
e
h
c e
a v
n e o
o r
i
t t m
c o o
n n t
u e
S f r d
a r
M g a
n s h
O i
r p g
T e o
e t
P t n
s i
r
M s d e
e
Y o n t
S N E S
POSSIBLE CAUSES
Steering orbitrol valve 2 2 1
Steering/charge pump 1 1 2
Steering cylinder 3 3 3
Articulated joint 3 3 2
BW 211 / 212 / 213 D-40
314 BOMAG 008 911 63

12 Engine
008 911 63 BOMAG 315

12.1 Diesel engine, general
12.1 Diesel engine, general
Fig. 1 Engine compartment The pistons are made of aluminium alloy. The side
Single drum rollers of series BW211/213 D/PD-4 and walls of the slightly externally arranged combustion
BW213/214 DHC/PDHC-4 are powered by Deutz die- trough are inclined towards the inside by 10°. All pis-
sel engines type BF4M 2012 C with intercooling. The tons are fitted with three piston rings and a cast iron
intercooler reduces the thermal load on the engine, r ing carrier for the first ring. The pistons are oil mist lu-
the exhaust temperature and the fuel consumption bricated.
and thus enables a higher power output. The forged crankshaft is designed with integrated
The engines are characterized by the following posi- counter weights.
tive features: The block-type cylinder head is made of cast steel.
●
short and compact design Each of the cylinders has an inlet and an outlet valve.
●
low noise level The valve guides are shrunk into the cylinders. The
valve seat rings are made of high quality steel and
●
almost vibration free operation also shrunk fit.
●
low fuel consumption
●
low exhaust emissions (EPA II)
●
high power reserves and
●
excellent access to all service locations.
Crankcase and cylinders on this engine are made of
alloyed cast iron. This provides rigidness and high
wear resistance.
The forged steel conrods are designed with balancing
weights in the area of the conrod bearing seats. These
weights compensate manufacturing tolerances with
respect to weight and position of the centre of gravity.
316 BOMAG 008 911 63

Service side 12.2

12.2 Service side
Fig. 1 Service side

1 Oil filler neck
2 Lubrication oil cooler
3 Engine solenoid
4 Oil pressure switch (B06)
5 Radiator fan
6 Fuel pump
7 V-belt pulley
8 Main fuel filter
9 Lubrication oil filter
10 Oil sump
11 Oil dipstick
12 Compressor (only BW24/27 RH
13 Plug-in injection pumps
14 Generator
15 Heating flange (R19, option)
16 Hydraulic pump
17 Tensioning roller with torsion spring
18 Crankcase ventilation valve
008 911 63 BOMAG 317

12.3 Starter side
12.3 Starter side
Fig. 1 Starter side

1 Exhaust manifold
2 Exhaust turbo charger
3 Oil filling (optional)
4 Engine mounts
5 Oil return line from turbo charger
6 Relay (starter)
7 Ribbed V-belt
8 Coolant inlet
9 Coolant outlet
10 Coolant pump
11 Connection of compensation line
318 BOMAG 008 911 63

Lubrication oil circuit 12.4

12.4 Lubrication oil circuit
Fig. 1 Lubrication oil circuit 18 Leak oil return line

1 Oil sump 19 Oil filter
2 Return flow from turbo charger to crankcase 20 Suction line
3 Turbo charger 21 Crankshaft bearings
4 Oil line to turbo charger 22 Conrod bearings
5 Line to mass balancing gear (2 x)
6 Oil pressure sensor
7 Valve with pulse lubrication
8 Push rod, oil supply to rocker arms
9 Line to spray nozzles
10 Rocker arm
11 Return flow to oil sump
12 Nozzle for piston cooling
13 Camshaft bearings
14 Main oil channel
16 Oil pump
17 Pressure relief valve
008 911 63 BOMAG 319

12.4 Lubrication oil circuit
General
The oil inside the combustion engine has the function
of lubricating and cooling all drive components, re-
moving impurities and neutralizing chemically effec-
tive combustion products, transferring forces and
damping vibrations.. The oil is only able to fulfil this
function, if sufficient quantities are transported to the
critical points in the engine and if its properties are
adapted to the prevailing requirements by corre-
sponding manufacturing processes and refining (addi-
tives).
Figure (1) shows pressure circulation lubrication in
combination with splash and oil mist lubrication. Here
oil is transported under pressure to all bearing loca-
tions by the oil pump (16), while sliding surfaces are
splash or oil mist lubricated. After flowing through the
bearing locations and along sliding surfaces the oil is
collected in the oil sump (1) under the drive, where the
oil is cooled, defoamed by calming and stored.
The oil filter (19) removes solid foreign particles from
the engine oil (combustion residues, metal abrasion,
dust) and thus maintains the function of the lubrication
oil during the maintenance intervals.
320 BOMAG 008 911 63

Oil pressure switch and low oil pressure circuitry 12.5

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

circuit diagram
1 B06 Oil pressure switch Below 0.8 bar the contact switches to
engine ground, closed without pres-
sure. Tightening torque 20 ± 2 Nm
with copper ring.
008 911 63 BOMAG 321

12.6 Check the engine oil level
12.6 Check the engine oil level
! Danger
Danger of injury!
Support the engine hood for all maintenance and
repair work.
i Note
The machine must be parked horizontally with the en-
gine shut down.
Fig. 2 Oil pressure switch

The oil pressure switch (B06) is mounted to the en-
gine oil filter. After starting it reports when a safe op-
erating pressure has been reached and causes the
warning light in the monitoring board (A15) to light, if
the engine oil pressure drops below approx. 0.8 bar.
In case of too low engine oil pressure with the engine
running, the monitoring board (A15) will send a time
delayed (10 sec.) 12 V signal to relay (K22, terminal
86). The relay interrupts the electric power supply to
the solenoid valve (Y13) and the diesel engine is shut Fig. 3
down.
●
Pull the dipstick (Fig. 3) out, wipe it off with a lint-
free, clean cloth and reinsert it until it bottoms.
●
Pull the dipstick back out again.
●
If the oil level is below the "MAX" mark fill in oil.
●
If the oil level is above the “Max” mark determine the
cause and drain the oil off.
! Caution
Before longer work periods you should always top
the oil up to the "MAX"-mark.
For quality and quantity of oil refer to the table of

f uels and lubricants.
322 BOMAG 008 911 63

Changing engine oil and oil filter cartridges 12.7

12.7 Changing engine oil and oil fil-
ter cartridges
! Caution
The oil change at 500 operating hours refers to the
use of oils of oil quality class API CG-4/CH-4 or
ACAE E3-96/E5-02 respectively.
Refer also to the chapter 5.2, fuels and lubricants.
Drain the engine oil only when the engine is warm.
! Danger Fig. 5
Danger of scalding! ●
Thoroughly clean the outside of both filter cartridges
When draining off hot oil. (Fig. 5).
By hot oil when unscrewing the engine oil filter. ●
Unscrew both filter cartridges using an appropriate
filter wrench.
Environment
Catch running out oil and dispose of environmen- i Note
tally together with the engine oil filter cartridge. The filter cartridges are fitted with a valve that pre-
vents engine oil from running out during removal and
installation.
●
Clean the sealing face on the filter carrier from any
dirt.
●
Slightly oil the rubber seal on the new filter cartridg-
es.
Fig. 4
●
Unscrew the drain plug (Fig. 4) and catch running
out oil.
●
Turn the drain plug tightly back in.
Fig. 6
●
Turn the new filter cartridges (Fig. 6) on by hand,
until the seal contacts.
●
Tighten the filter cartridges for another half turn.
008 911 63 BOMAG 323

12.7 Changing engine oil and oil filter cartridges
Fig. 7
●
Fill in new engine oil (Fig. 7).
For quality and quantity of oil refer to the table of
fuels and lubricants.
●
Tighten the oil filler cap properly.
! Caution
Before starting crank the engine with the starter
motor until the oil pressure warning light goes
out.
●
After a short test run check the oil level on the dip-
stick, if necessary top up to the top dipstick mark.
●
Check filter cartridge and drain plug for leaks after a
short test run.
●
Shut the engine down and wait for about 15 min-
utes, so that all oil can flow back into the oil sump.
●
Check the oil level again, if necessary fill up to the
Max.-mark.
324 BOMAG 008 911 63

Coolant circuit 12.8

12.8 Coolant circuit
Fig. 1 Coolant circuit

1 Radiator
2 To radiator
3 From radiator
4 Coolant pump
6 Cylinder cooling
7 Cylinder head cooling
8 Ventilation connection from cylinder head to heat
exchanger
9 Fan
008 911 63 BOMAG 325

12.8 Coolant circuit
General
In order to avoid thermal overloads, burning of lubrica-
tion oil on piston sliding surfaces and uncontrolled
burns caused by high component temperatures, the
components surrounding the combustion chamber,
like cylinders, cylinder head, valves and possibly also
the pistons, must be cooled intensively.
Brief description
The coolant pump ("water pump") draws coolant
through the hose lines directly out of the radiator and
forces it first of all through the lubrication oil cooler,
which is integrated in the engine. The coolant then en- Fig. 2 Direct heating
ters into the engine, flows up along the cylinders into
the cylinder head and to the thermostat at the coolant 1 Thermostat
outlet. Form their the coolant is returned through the 2 Coolant pump
corresponding lines to the radiator inlet. When the en- 3 Lubrication oil cooler
gine is cold the coolant is pumped in a short circuit 4 Heat exchanger
through the engine, until the response temperature of
the thermostat (start of opening) is reached. The wa-
ter pump draws cold coolant out of the radiator, as re-
quired to replenish the hot out flowing coolant.
The coolant is a mixture of water and anti-freeze
agent. The anti-freeze agent increases the boiling
temperature of the mixture and thus enables temper-
atures of up to 120° C at an overpressure of up to 1.4
bar.
The coolant compensation tank enables reliable gas
separation, thus avoiding cavitation in the cooling sys-
tem, which mainly occurs in the suction side of the
pump. The air volume inside the compensation must
be so high, that quick build-up of pressure in case of
heating and expansion of coolant is assured and any
escape of coolant during after-boiling is avoided.
The radiator (1) dissipates the waste heat generated
in the engine into the into the environment.
Part of the combustion heat is transferred to the lubri-
cation oil. The lubrication oil cooler (5) serves the
function of cooling the lubrication oil.
Heating
Water-cooled DEUTZ diesel engines utilize the cool-
ant to heat the driver's cab. For this purpose the en-
gine coolant is guided directly to the heat exchanger
and the heat is directly dissipated into the environ-
ment (direct heating).
326 BOMAG 008 911 63

Coolant temperature switch 12.9

12.9 Coolant temperature switch
Fig. 1 Coolant temperature switch

circuit diagram
B152 Coolant temperature switch Contact switches at approx. 110° C
to engine ground
008 911 63 BOMAG 327

12.10 Disassembling and assembling the coolant temperature switch
12.10Disassembling and assem- Installation
bling the coolant temperature ●

Clean thread and seat for switch.
switch ●
Install the temperature switch with Loctite 577 and
a new seal, tightening torque 20 Nm.
Removal ●
Push the plug back on (plug interlock clicks into
●
Turn the battery disconnecting switch to position place).
"OFF". ●
Check the plug interlock by lightly pulling on the wir-
●
Open the lid on the coolant reservoir. ing loom.
●
Fill in coolant up to the “MAX” mark .
! Danger ●
Run the engine up to operating temperature.
Danger of scalding!
Do not remove the cap from the compensation i Note
tank when the engine is still hot. Check the area around the coolant temperature sen-
sor for leaks.
●
Let the engine cool down and check the coolant lev-
el again, top up if necessary.
Fig. 2 Temperature switch

●
Press in the locking wire and disconnect the plug
(Fig. 2).
●
Lay a cloth around the temperature switch and
catch running out coolant.
Environment
Dispose of escaping coolant environmentally
●
Unscrew the temperature switch.

●
Remove and dispose of the seal (Fig. 3).
328 BOMAG 008 911 63

Replacing the thermostat 12.11

12.11Replacing the thermostat
●
Open the lid on the coolant reservoir.
! Danger
Danger of scalding!
Do not remove the cap from the compensation
tank when the engine is still hot.
●
Drain the coolant from the engine and catch it.
Environment
Catch running out coolant and dispose of environ-
mentally. Fig. 6
●
Assemble the outlet socket (Fig. 6).
●
Tightening torque: 30 Nm.
●
Install the coolant hose again.
●
Fill in coolant up to the “MAX” mark .
●
Run the engine up to operating temperature.
i Note
Check for leaks around the thermostat.
●
Let the engine cool down and check the coolant lev-
Fig. 4
●
Disconnect the coolant hose.
●
Remove the outlet socket (Fig. 4).
●
Remove the thermostat.
Fig. 5
●
Fit a new seal to the thermostat.
●
Insert the new thermostat with the seal ring (Fig. 5).
i Note
Mind the installation position. The arrow (ventilation
groove) points up.
008 911 63 BOMAG 329

12.12 Checking the thermostat in disassembled state
12.12Checking the thermostat in The temperature increase should not exceed 1°C/
min, as otherwise the start of opening will be delayed
disassembled state accordingly.
The thermostat serves the optimal temperature con-
trol of the coolant, in order to promote efficient com-
bustion and to bring the engine quickly to operating
temperature after starting. At temperatures below ap-
prox. 83°C the thermostat is closed. Once the coolant
temperature has reached about 83°C, the thermostat
will start to open, at about 95° C it is fully open. In this
condition the full coolant flow is guided through the ra-
diator.
Fig. 3
●
Measure and write down the measurement "b" on
the thermostat . (Fig. 3).
●
Calculate the stroke.
Stroke = b - a
i Note
Fig. 1 The stroke at the given temperature (T2) should be
min. 8 mm.
●
Measure and write down the measurement "a" on
the thermostat (Fig. 4).
i Note
"a" = beginning of stroke at approx. 83 ± 2°C (T1)
"b" = end of stroke at approx. 95 °C (T2)
Fig. 2
●
Warm up the thermostat in a water bath (Fig. 2).
i Note
In order to determine the exact start of opening the
temperature should be measured as close to the ther-
mostat as possible, but without touching it.
The water must thereby be stirred continuously, to en-
sure even temperature distribution.
330 BOMAG 008 911 63

Check the coolant level 12.13

12.13Check the coolant level 12.14Change the coolant
! Danger ! Danger
Danger of scalding! Danger of scalding!
Fill up coolant only when the engine is cold. Change the coolant only when the engine is cold.
Environment
Catch running out coolant and dispose of environ-
mentally.
Fig. 4
●
Check the coolant level (Fig. 4).
! Caution
Fig. 5
If, during the daily inspection the coolant level is
found to have dropped, check all lines, hoses and ●
Set the cock valve for the cabin heater to position
engine for leaks. "warm".
●
To top up unscrew the filler cap and fill in coolant up
to the MAX-mark.
For quality of coolant refer to the chapter 5.2, fuels
and lubricants.
Fig. 6
●
Unscrew the plug, let the coolant run out and catch
it.
●
Screw the plug back in once all coolant has run out.
008 911 63 BOMAG 331

12.15 Checking the anti-freeze concentration
12.15Checking the anti-freeze con-

centration
! Caution
In order to avoid damage to the engine e.g. by cor-
rosion, cavitation and freezing, particular atten-
tion must be paid to the inspection of the coolant.
! Danger
Danger of scalding!
Check the anti-freeze concentration only when the
Fig. 7
engine is cold.
●
Unscrew the cap and fill in coolant up to the MAX-
mark.
●
Perform the inspection with conventional test equip-
ment.
For quality of coolant refer to the chapter 5.2, fuels ●
The anti-freeze concentration (additive) must be at
and lubricants.
least 35 Vol% and maximum 45 Vol%.
●
Start the diesel engine and run it warm to operating
temperature.
! Danger
●
Let the engine cool down and check the coolant lev- Health hazard!
The mixing of nitrite based anti-freeze agents with
amine based agents results in the formation of
health affecting nitrosamines.
Environment
Catch all anti-freeze agent and dispose of environ-
mentally.
332 BOMAG 008 911 63

Clean the cooling fins on engine and hydraulic oil cooler 12.16
12.16Clean the cooling fins on en-
gine and hydraulic oil cooler
! Danger
Danger of injury!
Perform cleaning work only after the engine has
cooled down and with the engine stopped.
! Caution
Do not damage any cooling fins on the cooler core
when cleaning.
i Note
Dirt on fan blades and oil cooler reduce the cooling ef-
fect. Dirt deposits in these areas are substantially sup-
ported by oil and fuel on these surfaces. For this
reason you should always seal any oil or fuel leaks in
the vicinity of the cooling fan or the oil cooler and clean
the cooling surfaces after.
Cleaning with compressed air
Fig. 8
i Note
Start to blow out from the exhaust side.
●
Blow the cooler (Fig. 8) out with compressed air.
Cleaning with cold cleansing agent
! Caution
Protect electrical equipment such as generator,
regulator and starter against the direct water jet.
●
Spray the engine with a suitable cleansing agent,
e.g. cold cleanser, let it soak in for a while and spray
it off with a strong water jet.
●
Run the engine warm for a while to avoid corrosion.
008 911 63 BOMAG 333

12.17Three-phase generator
Fig. 1
1 Generator (G02)

circuit diagram
B+ B+ Battery Plus 14.4 Volt, 90 Amp.
D+ D+ Dynamo Plus 14.4 Volt, maximum load 0.2 Amp.
W W Rotational speed signal pulsing D.C. voltage to determine the
engine speed
334 BOMAG 008 911 63


General
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.
i Note
The generator is maintenance free. Function tests and
repair work must only be performed in authorized
workshops.
! 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
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.
008 911 63 BOMAG 335

12.18 Fuel supply
12.18Fuel supply
Fig. 1 Fuel supply 11 Pressure retaining valve - 5 bar

1 Water separator sensor connection 12 Return flow to tank
2 Flow to fuel lift pump 13 Fuel tank
3 Fuel lift pump 14 Manual fuel pump
4 Connecting line between fuel lift pump and main 15 Fuel pre-filter
filter (fuel pre-pressure up to 10 bar) 16 Water separator
5 Main fuel filter (pressure proof) 17 Fuel pre-heating connection (option)
6 Connecting line between main filter and flow to in- 18 Fuel pre-heating (R79) 200 Watt (option)
jection pumps
19 Water separator sensor (B124)
7 Single-cylinder injection pump
8 High pressure line
9 Injection nozzle
10 Leak oil line
336 BOMAG 008 911 63

Fuel supply 12.18

Work in the low pressure system
Service and repair work in the low pressure system,
including main fuel filter changes, are only permitted
under absolutely clean environmental conditions, be-
cause even smallest dirt particles entering into the
high pressure fuel system will cause considerable
damage. Air pollution, like dirt, dust, moisture etc.
must be strictly avoided. Before starting work in the
fuel system (including filter changes) the engine must
be thoroughly cleaned and dried (steam cleaning
equipment). Engine compartments in which dirt de-
posits may come loose, must be covered with new
and clean foil. When working in the open you may
need to apply protective measures against dust enter-
ing because of wind.
! Danger
For diesel fuel the ignition temperature, i.e. the
temperature at which fuel will ignite when coming
into contact with air, is approx. 220°C, but may de-
viate strongly because of impurities.
Fuel conducting components and lines therefore
are a source of danger inside the engine compart-
ment, because leaks may lead to fire resulting in
considerably damage to material and persons.
008 911 63 BOMAG 337

12.18 Fuel supply
Check valve
Fig. 1
●
According to our experience, it is not always as-
sured that only clean fuel will be used. Fuel tanks
are frequently filled without suitable precautions
against contamination or fuel filters are inappropri-
ately serviced. Many damage analyses on injection
pumps and injection valves have revealed that most
of these components had failed due to premature
wear. Wear on injection pump plunger and injection
valve needle seat is caused by contaminated fuel. Fig. 2 Observe the direction of flow
Modern exhaust optimized diesel engines with high
pressure injection systems strictly require clean fuel i Note
to be able to work reliably over their entire lifetime. From August 2006 the check valve (Fig. 2) is used by
If the throttle resistances of pre-cleaner/main filter BOMAG in series machines.
caused by contaminated fuel are so high that the
fuel pump is no longer able to ensure a sufficient
fuel supply, the injection pumps will draw the re- ! Caution
quired fuel through the leak fuiel return line from the This valve must strictly be installed into the fuel
tank without filtration. The engine is no longer able return line by our customers.
to provide its full power, operation of construction
equipment or other machines, however, may still be
possible to a limited extent. After short time opera-
tion under such conditions the injection system
components may already be pre-damaged.
338 BOMAG 008 911 63

Injection system 12.19

12.19Injection system
The injection system serves the fuel supply for the die-
sel engine.
The low pressure side of an injection system includes
fuel tank, fuel filter and fuel lines.
In the high pressure side the injection pump generates
the pressure required for injection. The fuel is pumped
through the pressure line to the injection pump, from
where it is injected into the combustion chamber.
Load and speed of the diesel engine are adjusted via
the fuel quantity without throttling the intake air. With
a sufficient injection quantity the speed of an unloaded
diesel engine may therefore rise up to the point of self
destruction. A governor for engine speed limitation is
therefore required.
Single cylinder plug-in injection pumps

Deutz diesel engines series 2012/1013 are equipped
with Bosch cylinder plug-in injection pumps series PF
33.
Fig. 3 Single cylinder plug-in injection pump
The concept of plug-in injection pumps enables the re-
alization of high injection pressures, combined with The drive cams 2 (Fig. 3) for the single PF-injection
short injection lines, which is necessary to ensure a pumps are located on the camshaft (1) for engine
high hydraulic stiffness of the injection system. This, in valve control.
turn, creates the prerequisite for maintaining low ex- Permissible manufacturing tolerances for the compo-
haust emission values (soot) in combination with low nents:
fuel consumption values. ●
Cylinder crankcase
The start of injection is influenced by: ●
Camshaft
●
the fuel consumption
●
Roller-type plunger
●
the power
●
Plug-in injection pump
●
the exhaust emission
are determined and eliminated by the adjustment of
of the engine. the start of injection.
The term "start of injection" refers to the start of the in- However, in cases of interest for BOMAG field engi-
jection pump delivering fuel. neers engines are not completely overhauled, but in-
dividual injection pumps are replaced. Crankcase,
camshaft and roller-type plunger remain unchanged.
This results in a certain installation measurement for
the drive, which is specified on the engine type plate.
It is stamped as "CODE" in the column "EP" for each
cylinder.
008 911 63 BOMAG 339

12.20 Injection pump replacement during service
Injection valves 12.20Injection pump replacement

Injection valves have the following functions: during service
●
Preparation of fuel
●
Forming of the injection sequence Disassembly
●
Sealing against the combustion chamber
The peak injection pressure of the diesel fuel is up to ! Caution
1000 bar. Under these conditions the fuel no longer Ensure strict cleanliness when working on the in-
behaves like a rigid fluid, but it is compressible. During jection system.
the short injection period (1ms) the injection system is
"blown up" and, depending on the nozzle size, more
or less fuel will enter into the combustion chamber.
Fig. 4 Design of injection valve Fig. 1
1 Tensioning nut ●
Disassemble pressure control valve and cylinder
2 Nozzle head cover (Fig. 1).
3 Intermediate piece ●
Disconnect the cable plugs from shut-down sole-
noid, governor and temperature sensor.
4 Pressure bolt
5 Pressure spring
●
Swing the holding plate to the side.
6 Shim
i Note
A thicker shim 6 (Fig. 4) increases the opening pres-
sure.
! Caution
When replacing an injection pump and/or an injec-
tion valve, you must also replace the high pres-
sure line between pump and valve.
Fig. 2
●
Remove the engine shut-down assy (Fig. 2).
340 BOMAG 008 911 63

Injection pump replacement during service 12.20
Fig. 3 Fig. 5
●
Use the shut-down lever to push the governor rod to ●
Set the cylinder of the injection pump to be disas-
stop position (Fig. 3). sembled to top dead centre (TDC) for ignition
●
Insert and fasten the pressing device 100 830. (valves overlapping) (Fig. 5).
●
Turn the crankshaft for approx. 120° against the
sense of rotation.
i Note
Illustration shows view on flywheel.
Fig. 4
●
Use the knurled fastening screw to force the gover-
nor rod to stop position (Fig. 4).
i Note
Tighten the knurled fastening screw by hand. Fig. 6
●
Remove the injection line (Fig. 6).
i Note
Close the connections with protection caps.
008 911 63 BOMAG 341

Fig. 7
●
Carefully remove the shim with a rod-type magneto
(Fig. 7).
342 BOMAG 008 911 63


Determining the start of injection
Fig. 8 Injection pump code BFM 2012
i Note
Old injection pump and shim are not required for this
purpose.
Example:
The injection pump for cylinder 3 is to be replaced on
an engine BF6M 2012.
Procedure:
●
Read the EP-code for cylinder 3 in the column "EP"
on the type plate (table) (Fig. 8), e.g. 295.
i Note
Sequence of reading: Line 1 = cyl.1, line 2 = cyl.2, etc.
●
Take the corrected injection pump installation
measurement (EK) matching the EP-code from the
table (Fig. 11), e.g. 120.875 mm.
Fig. 10 Injection pump length "A" and L o
i Note
Measurement "A" (Fig. 3) determines by how many 1/
100 of a mm the distance between cylinder crankcase
contact surface and plunger foot is longer than the ba-
sic measurement Lo.
Basic measurement of injection pump (Lo ) = 117.5
mm.
●
Determine the theoretical thickness of the shim
(TS).
TS = EK - (Lo + A/100)
TS = 120.875 mm - (117.5 mm + 42/100 mm)
TS = 2.955 mm
Fig. 9 Length of injection pump (A) ●
Choose the shim thickness (SS) from the table.
●
Read the coefficient for the injection pump length
(A) (Fig. 9) on the new injection pump, e.g. 42.
008 911 63 BOMAG 343

TS 2.955 mm = SS 3.0 mm
Theor. thickness "TS" Shim thickness "SS" Theor. thickness "TS" Shim thickness "SS"
(mm) (mm) (mm) (mm)
0.95 - 1.049 1.0 2.45 - 2.549 2.5
1.05 - 1.149 1.1 2.55 - 2.649 2.6
1.15 - 1.249 1.2 2.65 - 2.749 2.7
1.25 - 1.349 1.3 2.75 - 2.849 2.8
1.35 - 1.449 1.4 2.85 - 2.949 2.9
1.45 - 1.549 1.5 2.95 - 3.049 3.0
1.55 - 1.649 1.6 3.05 - 3.149 3.1
1.65 - 1.749 1.7 3.15 - 3.249 3.2
1.75 - 1.849 1.8 3.25 - 3.349 3.3
1.85 - 1.949 1.9 3.35 - 3.449 3.4
1.95 - 2.049 2.0 3.45 - 3.549 3.5
2.05 - 2.149 2.1 3.55 - 3.649 3.6
2.15 - 2.249 2.2 3.65 - 3.749 3.7
2.25 - 2.349 2.3 3.75 - 3.849 3.8
2.35 - 2.449 2.4
344 BOMAG 008 911 63

Fig. 11 Table of injection pump codes BFM 2012
008 911 63 BOMAG 345

Assembly
Fig. 15
●
Slightly oil the receiving bore in the crankcase and
Fig. 12 the O-rings on the injection pump.
●
Carefully insert the injection pump control lever into
the governor rod. (Fig. 15).
! Caution
The roller plunger for the corresponding injection
pump must be positioned on the base circle of
camshaft.
Fig. 13
●
Lay the newly determined shim on roller plungers
(Fig. 12) and (Fig. 13).
Fig. 16
●
Attach the flange (Fig. 16).
! Caution
The chamfer must face towards the injection
pump body.
Fig. 14
●
Turn the injection pump control lever approx. to
middle position (Fig. 14).
346 BOMAG 008 911 63

Fig. 20
Fig. 17
●
Slightly oil the screws and tighten with a torque of 5
●
Turn the screws in again for 60°, then tighten in
Nm (Fig. 17). steps to a torque of 7 Nm, 10 Nm and 30 Nm. (Fig.
20).
i Note
Always start with the outer screw furthest away from
the flywheel.
Fig. 18
●
Loosen the screws again for 60° (Fig. 18).
Fig. 21
●
Turn the knurled fastening screw back (Fig. 21).
●
Remove the pressing device.
! Caution
Check whether the governor rod is light moving
between stop and start position.
Operate the shut-down lever to do so.
Fig. 19
●
Carefully turn the injection pump with an open end
spanner anti-clockwise against the noticeable end
stop (Fig. 19).
008 911 63 BOMAG 347

Fig. 22
●
Assemble a new O-ring (Fig. 22). Fig. 24
! Caution
i Note
Cover the O-ring slightly with oil. Take care that the sealing cones match exactly
when assembling the injection line. Subsequent
bending is not permitted. The injection line must
never be used twice.
●
Install the new injection line with the sealing rubber
(Fig. 24).
●
Pre-tension the injection line cap nuts on injection
pump and injection valve with a torque of approx. 5
Nm (use claw spanner 8018).
●
Tighten the cap nut with 25 ± 3.5 Nm.
Fig. 23
●
Use the shut-down lever to push the governor rod to
stop position and hold it (Fig. 23).
●
Assemble the engine shut-down assy.
●
Tighten the screws with 21 Nm.
●
Plug the cable plug onto the shut-down magneto.
Fig. 25
●
Install the gasket (Fig. 25).
348 BOMAG 008 911 63

Injection valve replacement during service 12.21

12.21Injection valve replacement
during service
i Note
Injection valves may wear mechanically over the
course of time. Spray pattern and injection pressure
should be tested on an injection valve test bench ("hy-
drostesting"). The nozzles must be disassembled for
this purpose. In case of excessive deposits on the
nozzles these may be cleaned in an ultrasonic bath
with gasoline. The injection pressure can be corrected
by means of shims.
Fig. 26
●
Assemble cylinder head cover and holding plate ! Caution
(Fig. 26). Ensure strict cleanliness when working on the in-
jection system. Use only clean testing oil acc. to
●
Tighten the screws with 11 Nm.
ISO 4113 or clean diesel fuel to test the injection
valves.
i Note
Ensure the sealing rubber is fitted correctly. Removal
●
If necessary assemble the pressure control valve
with a new seal.
●
Tighten the screws with 8.5 Nm.
Fig. 1
●
Disassemble pressure control valve and cylinder
head cover (Fig. 4).
●
Disconnect the cable plugs from shut-down sole-
noid, governor and temperature sensor.
●
Swing the holding plate to the side.
008 911 63 BOMAG 349

12.21 Injection valve replacement during service
Installation
Fig. 2
●
Disassemble the injection lines (Fig. 2). Fig. 1
●
Slide the new seal rings with some grease over the
i Note injection valves and insert the injection valves (Fig.
Close connections on injection valves and injection 1).
pumps with protective caps.
! Caution
The chamfer on the injection valves must point
away from the claws.
Fig. 3
●
Disassemble the claws and take out the injection
valves (Fig. 3).
Fig. 2
i Note ●
Attach the claws and turn the screws in loosely (Fig.
In case of tight fit use the extracting device 150 800 2).
with puller 110 030.
Pull out the seal ring with the extracting device 120
680.
350 BOMAG 008 911 63

Injection valve replacement during service 12.21
Fig. 3 Fig. 5
●
Pre-tension the injection line cap nuts on injection
! Caution pumps and injection valves with a torque of approx.
Take care that the sealing cones match exactly 5 Nm (Fig. 5).
when assembling the injection line. Subsequent ●
Tighten the cap nuts with 25 + 3.5 Nm.
bending is not permitted. The injection line must
never be used twice.
i Note
●
Install the new injection lines with the sealing rub-
Use a claw spanner 8018.
bers (Fig. 3).
●
Tighten the cap nuts finger tight.
Fig. 6
●
Install the gasket (Fig. 25).
Fig. 4
●
Tighten the screws for the claws with 16 + 5 Nm
(Fig. 4).
008 911 63 BOMAG 351

12.22 Checking / repairing injection valves
12.22Checking / repairing injection

valves
Special tools:
Nozzle tester 8008
Holder for Injection valve 110 110
Long socket 8012
! Caution
Ensure strict cleanliness when working on the in-
jection system. Use only clean testing oil acc. to
Fig. 7 ISO 4113 or clean diesel fuel to test the injection
●
Assemble cylinder head cover and holding plate valves.
(Fig. 26).
●
Tighten the screws with 11 Nm. Check the injection valves
i Note i Note
Ensure the sealing rubber is fitted correctly. The injection valves are leak fuel free. Fuel cannot
flow off and will accumulate above the nozzle needle
●
If necessary assemble the pressure control valve in the spring chamber of the nozzle holder. Operation
with a new seal. of the nozzle tester hand leever is in this case no long-
●
Tighten the screws with 8.5 Nm. er possible. In order to eliminate the pressure inside
the spring chamber the clamping nut must be slack-
ened and retightened again before each test.
Fig. 1
●
Loosen the clamping screw by approx. 180° and
tighten it again (Fig. 1).
Tightening instructions: 30 - 40 Nm
i Note
Use injection valve holder 110 110.
352 BOMAG 008 911 63

Checking / repairing injection valves 12.22

Adjusting tze opening pressure on the in-
jection valve
i Note
If the opening pressure needs toi be corrected: De-
tach the injection valve from the nozzle tester 8008.
Unscrew the clamping nut and remove all parts. Use
injection valve holder 110 110.
Fig. 2
●
Mount the injection valve to the nozzle tester (Fig.
2).
! Danger
Keep your hands away from the nozzle spray jet.
Fuel will penetrate deeply into the flesh and may
cause blood poisoning.
Fig. 4
●
Unscrew the clamping nut and remove all parts
(Fig. 4).
Fig. 3
●
Slowly press the lever of the nozzle tester 8008
down with the pressure gauge connected (Fig. 3). Fig. 5
Opening pressure: 220 bar Sequence of disassembly (Fig. 5):
1 Tensioning nut
i Note 2 Injection nozzle
The opening pressure is reached, when the pointer 3 Intermediate piece
stops or suddenly drops. 4 Pressure bolt
The pressure inside the spring chamber will have 5 Pressure spring
build up again after approx. 3 - 4 strokes. In order to 6 Shim
repeat the test the clamping nut needs to be slack-
ened and retightened again, as specified.
●
Clean all parts with clean diesel fuel and blow off
with compressed air.
Once identical values are measured during 3 tests,
the values can be considered valid.
008 911 63 BOMAG 353

Fig. 6 Fig. 8
●
Assemble the shim (Fig. 8).
! Caution
Nozzle needle and nozzle body have been fitted i Note
by lapping and must never be mixed up by mis- Adjust the opening pressure by choosing the required
take or replaced individually. Do not touch the shim. A thicker shim increases the opening pressure.
nozzle needle with your fingers. With the nozzle
body in vertical position, the nozzle needle must
smoothly slide on its seat just by its own weight
(Fig. 6).
i Note
If the needle slides down jerkily, wash out the nozzle
body with diesel fuel again, replace if necessary.
Clean the new injection nozzle also in clean diesel fu-
el.
Fig. 9
●
Assemble the pressure spring.
Fig. 7
●
Check the seat areas of the intermediate piece for
signs of wear. Make sure that the centring pins are
present (Fig. 7).
Fig. 10
●
Install the pressure bolt with the centring collar to-
wards the pressure spring (Fig. 10).
354 BOMAG 008 911 63

Checking / repairing injection valves 12.22
Fig. 11 Fig. 13
●
Insert the centring pins of the intermediate piece ●
Screw on the clamping nut.
into the bores of the nozzle holder (Fig. 11).
i Note
The chamfer points towards the pressure bolt.
Fig. 14
●
Tighten the clamping nut.
i Note
Fig. 12
Use the injection valve holder 110 110 and a long
●
Attach the centring bores of the injection nozzle to socket 8012.
the centring pins of the intermediate piece (Fig. 12).
Tightening torque: 30 to 40 Nm
i Note
The nozzle needle must not drop out of the nozzle
body.
008 911 63 BOMAG 355

Leak test Rattle and spray pattern test
Fig. 1 Fig. 1
●
Dry nozzle and nozzle holder - blow dry with com- ●
Switch off the pressure gauge on the tester.
pressed air.
●
Press the hand klever of the tester slowly down, to i Note
a point about 20 bar before the previously indicated The rattle test enables audible testing of the nozzle
opening pressure (Fig. 1). needle movement inside the nozzle body. In compar-
ison with used injection valves, new ones have a dif-
ferent rattling behaviour. It becomes worse as the
wear in the needle seat area progresses.
! Caution
A used injection valve must audibly rattle and
spray off well atomized fuel when operating the le-
ver quickly. The spray pattern may be noticeably
different from the one produced by a new injection
valve.
If an injection nozzle does not rattle despite of
cleaning, it nees to be replaced by a new one!
Fig. 2
i Note
The nozzle is leak tight, if no drop drips off within a pe-
riod of 10 seconds.
! Caution
If a drop drips off (Fig. 2), the injection valve must
be dismantled and the leak must be eliminated by
thorough cleaning. If this does not lead to a suc-
cess, replace the injection nozzle.
Rework is not permitted!
356 BOMAG 008 911 63

Fuel filter 12.23

12.23Fuel filter
Fig. 1 Fuel pre-filter

1 Hand pump
2 Bleeding valve
3 Filter element
4 Water and dirt collecting bowl
5 Drain valve
6 Water separator sensor connection (B124)
7 Fuel pre-heating connection (R79) 200 Watt (op-
tion)
008 911 63 BOMAG 357

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

In diesel engines the pre-heating of the fuel prevents
malfunctions caused by the formation of jelly (paraffin
separation) in the fuel under low temperatures.
Fig. 2 Main fuel filter
The integrated heating is a starting aid for cold weath-
er applications. The heating is delivered with an auto-
matic thermostat to start the heating when the fuel ! Caution
temperature drops below 7°C. The generated heat The main fuel filter is subjected to the approx. 10
works directly under the filter element and melts the bar fuel pre-pressure from the fuel lift pump. This
wax crystals that have formed, so that the fuel can pressure value is considerably higher than on oth-
flow through the filter element without restriction. The er engines. You should therefore only use original
heating automatically shuts down at a fuel tempera- filter elements (Fig. 2) at this point. Similar looking
ture of 24°C. The 200W heating is supplied with 12V filters with identical dimensions are not necessar-
D.C-current. The heater is activated when operating ily pressure proof!
the ignition switch; this should take place at least 5
A filter, with insufficient pressure resistance, will
minutes before starting the engine.
be destroyed and disintegrate by this high pres-
A normal On/Off switch may be installed to operate sure This will cause severe damage in the injec-
the relay. This can be used to e.g. interrupt the current tion system!
flow to the relay in the summer season.
Draining off water or fuel

Should the filter element be clogged prematurely (no-
ticeable e.g. by a drop in power), operation of the ma-
chine can be continued with the following procedure:
●
Open the bleeding screw (this applies atmospheric
pressure to the filter element and loosens larger dirt
particles from the underside of the filter, which will
then drop down).
358 BOMAG 008 911 63

Check, clean the water separator 12.24

12.24Check, clean the water sepa- 12.25Change the fuel pre-filter car-
rator tridge
! Danger ! Danger
Danger of injury! Fire hazard!
Support the engine hood for all maintenance and When working on the fuel system do not use open
repair work. fire, do not smoke and do not spill any fuel.
Catch running out fuel, do not let it seep into the
i Note ground.
The service intervals for the water separator depend Do not inhale any fuel fumes.
on the water content in the fuel and can therefore not
be determined precisely. After taking the engine into
operation you should therefore check the water sepa-
rator every day for signs of water.
If a to high quantity is drained off, the filter must be re-
filled with fuel. See chapter "maintenance as re-
quired", bleeding the fuel system.
Environment
Catch running out fuel and dispose of environ-
mentally.
Fig. 4
●
Close the shut-off cock (Fig. 4) again
Fig. 3
●
Slacken the drain plug (Fig. 3) for a few turns and
catch running out fuel / water.
●
Tighten the drain plug again and check for leaks, if Fig. 5
necessary replace the seal ring.
●
Unscrew the fuel filter cartridge (Fig. 5) using an ap-
propriate filter wrench.
●
dirt.
008 911 63 BOMAG 359

12.25 Change the fuel pre-filter cartridge
Fig. 6 Fig. 8
●
Unscrew the water separator from the filter car- ●
Slacken the bleeding screw (Fig. 8) on the fuel pre-
tridge (Fig. 6). filter for 2 to 3 turns.
●
Operate the hand pump manually, until fuel flows
out of the slackened bleeding screw (Fig. 8) without
air bubbles.
●
Then tighten the bleeding screw while pumping.
Fig. 7
●
Apply a thin coat of oil to the rubber seal of the water
separator 1 (Fig. 7).
●
Screw the water separator on by hand (2), until the
seal contacts.
●
Tighten the water separator for another half turn (3).
●
Fill the filter cartridge with clean diesel fuel (4).
●
Apply some oil to the rubber seal of the filter ele-
ment (5) and screw it on by hand, until the seal con-
tacts.
●
Tighten the filter element for another half turn (6).
●
Open the shut-off cock (Fig. 4) again.
●
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.
360 BOMAG 008 911 63

Change the fuel filter cartridge 12.26

12.26Change the fuel filter cartridge 12.27Checking the compression
●
Adjust the valves.
! Danger ●
Disassemble the injection valves.
Fire hazard!
When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground.
Do not inhale any fuel fumes.
Fig. 1
●
Insert the connecting piece 100 110 with seal ring
(Fig. 4).
Fig. 9
●
Loosen and unscrew the fuel filter cartridge (Fig. 9)
using an appropriate filter wrench.
●
dirt.
Fig. 2
●
Attach the claws (Fig. 2).
●
Tighten the screw.
Fig. 10
●
Slightly oil the rubber seal (Fig. 10) on the new filter
cartridge.
●
Fill the filter cartridge with clean diesel fuel.
●
Turn the new filter cartridge on by hand, until the
seal contacts.
●
Tighten the filter element for another half turn.
●
Check the filter cartridge for leaks after a short test
run.
Fig. 3
●
Screw on the adapter for connecting piece 100 110
(Fig. 3).
008 911 63 BOMAG 361

12.28 Check, adjust the valve clearance
12.28Check, adjust the valve clear-

ance
! Caution
Before checking the valve clearance let the engine
cool down for at least 30 minutes. The engine oil
temperature must be less than 80 °C.
After a short test run check the engine for leaks.
Valve adjustment schematic
Fig. 4
●
Connect the compression tester 8005 (Fig. 4).
●
Crank the engine with the starter.
i Note
Check the compression on each of the cylinders.
Compression: 30 - 38 bar
The measured compression depends on the starter
speed during the measuring process and the altitude
of the engine location. Limit values can therefore not
be specified exactly. It is recommended to use the Fig. 5
compression measurement to compare the cylinders
of an engine among each other. Should a deviation of Valve 1 (Fig. 5) white = not adjustable
more than 15% be measured, the affected cylinders Valve (2) black = adjustable
should be dismantled to examine the cause.
●
Remove the compression tester 8005 and the con-
necting piece 100 110.
●
Install the injection valves.
Fig. 6
Crankshaft position 1 (Fig. 6) (4 cylinder engine)

●
Crank the engine with the starter or a spanner by
the V-belt pulley until both valves on cylinder 1 are
“overlapping”.
Overlapping means: Exhaust valve not yet closed, in-
take valve starts to open.
●
Perform the adjustment of the valve by following the
adjustment diagram "crankshaft position 1", black
mark.
●
For control purposes mark the respective rocker
arm with while chalk once the corresponding valve
is adjusted.
362 BOMAG 008 911 63

Check, adjust the valve clearance 12.28
Fig. 7 Fig. 9
Crankshaft position 2 (Fig. 7) (4 cylinder engine)

●
Check valve clearance 2 (Fig. 9) between rocker
arm (1) and valve (3) with a feeler gauge.
●
Turn the crankshaft one revolution (360°) further.
Intake valve = 0,3 mm
●
Perform the adjustment of the valve by following the
adjustment diagram "crankshaft position 2", black Exhaust valve = 0,5 mm
mark. The feeler gauge must fit with little resistance.
●
If the gap is too narrow or too wide for the feeler
Checking the valve clearance gauge, the valve must be adjusted.
●
Loosen the crankcase ventilation valve and swing it
to the side. Adjusting the valve clearance
Fig. 8 Fig. 10
●
Remove the valve cover (Fig. 8). ●
Slightly slacken the counter nut. Adjust setscrew 7
●
Crankshaft position as per "valve adjustment sche- (Fig. 10) with a screwdriver, until the feeler gauge
matic". (6) can be inserted and pulled out with little resist-
ance after retightening the counter nut.
●
Perform tests and adjustments on all other adjusta-
ble valves.
●
Check the gasket of the valve cover, replace it if
necessary.
●
Reassemble the cylinder head cover.
●
Swivel the ventilation valve back to correct position
and fasten it.
●
Fasten the air filter again and ensure correct fit of
combustion air hoses and clamps.
008 911 63 BOMAG 363

12.29 Boost fuel solenoid valve
12.29Boost fuel solenoid valve for rising the engine torque during the acceleration
phase after starting. For this compensation and to as-
During the starting process the solenoid valve is sup- sure starting of the cold engine additional fuel needs
plied with 12 Volt. to be injected at the time of starting and accelerating.
This injection adaptation serves the purpose of com-
pensating for condensation and leakage losses and
Fig. 11
1 Boost fuel solenoid valve

circuit diagram
1 Y01 Boost fuel solenoid valve 12 Volt, approx. 3,5 Amp.

364 BOMAG 008 911 63

Engine shut-down solenoid 12.30

12.30Engine shut-down solenoid
Fig. 1
1 Engine shut-down solenoid

circuit diagram
1 Y13 Engine solenoid 12 Volt, approx. 4 Amp.
General
When switching the ignition on, the engine solenoid is
supplied with 12 Volt.
Interrupting this power supply shuts down the engine.
The engine shut-down can be triggered through the
ignition switch (S00), the emergency stop button
(S01) or the monitoring board in case of too low oil
pressure.
008 911 63 BOMAG 365

12.31 Air filter
12.31Air filter gine speed and inclination) and thus enable long
lasting and low wear engine operation.
The air filter retains the dust contained in the intake air The air filter has the additional function of damping the
and keeps it away from the engine in order to avoid air intake noise. This damping is achieved by the de-
engine wear. sign of the air filter in from of a reflection silencer
On paved roads the dust content in the air is 1 mg/m3 based on the principle of a Helmholz resonator, damp-
on average, on sealed roads or construction sites the ing the intake noise by its resonance frequency.
dust content can rise up to 40 mg/m3.
Dry air filters with integrated dust separator are char-
acterized by a good filtering effect (irrespective of en-
Fig. 2

circuit diagram
Visual differential pressure indica-
tor
! Caution and withstand mechanical loads caused by en-

gine vibrations and pressure pulsation.
Combustion air lines between filter and engine
("clean air lines") must be absolutely leak tight
366 BOMAG 008 911 63

Cleaning, changing the dry air filter cartridge 12.32

12.32Cleaning, changing the dry air
filter cartridge
! Caution
Perform cleaning, maintenance and repair work
only with the engine shut down. Do not start the
engine after removing the filter element.
Fig. 5
●
Pull the main filter element (Fig. 5) with light turning
movements.
Cleaning the main filter element
! Caution
If necessary, the main filter element may be
Fig. 3 cleaned up to five times. It must be renewed at the
Servicing of the dry air filter is necessary when the yel- latest after a maximum utilization period of two
low piston (Fig. 3) has reached the inscription "Serv- years.
ice" in front of a red background, but at the latest after The number of cleaning intervals of the main filter
2 years. element can be marked on the safety element with
After completion of the filter service reset the indicator a ball pen or a felt pen.
back to "Zero" by pressing the button. Cleaning does not make sense if the main filter el-
ement is covered with a sooty deposit. Use a new
Removing the main filter element filter cartridge.
●
Fully open the engine hood. Incorrectly handled inserts may be ineffective be-
cause of damage (e.g. cracks) and cause damage
to the engine.
Replace the safety cartridge if the main filter ele-
ment is defective!
Additional cleaning intervals between two filter
services signalized by the fault monitoring board
are not necessary.
Fig. 4
●
Unclip three clamps on the housing cover and take
off the cover (Fig. 4).
008 911 63 BOMAG 367

12.32 Cleaning, changing the dry air filter cartridge
! Caution
When assembling the inner part make sure that
the notch in the cover engages in the opening of
the inner part.
Installing the main filter element

●
Slide the main filter element carefully into the hous-
ing.
When closing the housing cover the main filter ele-
ment is automatically forced in the correct position.
●
Reinstall the service covers.
Fig. 6
Changing the safety filter element
i Note
For cleaning purposes fit a tube to the compressed air ! Caution
gun (Fig. 6), the end of which should be bent for ap- The safety filter element must not be cleaned and
prox. 90°. should not be used again after it has been re-
The length should reach down to the bottom of the moved.
cartridge. Break the seal only to replace the safety filter ele-
●
Blow the cartridge out with compressed air (max. 5 ment.
bar) from inside to outside by moving the tube up The safety filter element must be replaced:
and down inside the cartridge, until it if free of dust.
if the main filter element is defective,
●
Examine the filter cartridge with a torch for cracks
after five service intervals of the filter cartridge,
and holes in the paper bellows.
at the latest after 2 years,
! Caution if the warning light comes on again after servicing

the main filter cartridge.
Do not continue to run the machine with a dam-
aged main filter element. If in doubt use a new ●
Remove the housing cover and pull the main filter
main filter element. element off.
Cleaning the dust bowl
Fig. 8
●
Perforate the seal of the safety filter element from
Fig. 7 inside to outside using a suitable tool (Fig. 8) and
pull both latches up.
●
Pull the internal part (Fig. 7) out and remove the
dust from the cover. ●
Grip the safety element by both latches and pull it
out with slight turning movements.
●
Reinsert the inner part.
●
Push in a new safety filter element.
●
Reassemble main filter element and cover.
368 BOMAG 008 911 63

Heating flange on engine 12.33

! Caution 12.33Heating flange on engine
Make sure that the cover locks engage correctly.
Fig. 1 Heating flange

The heating flange is a component with an electrically
operated heating wire and high energy density used to
heat up the intake air in case of very low ambient tem-
peratures.
The heating power is approx. 2000 Watt.
The heating power improves the cold starting charac-
teristics and the exhaust emissions (white smoke) of
the diesel engine.
A differentiation is made between preheating, to as-
sure the cold start ability of the engine, and subse-
quent heating.
i Note
Pre-heating is triggered by switching on the ignition
(12 Volt on control unit A13, terminals 15(7) and S(2)).
With a coolant temperature of -30°C the preheating
time will be max. 52 seconds, with +5°C the minimum
time will be 38 seconds. During the preheating period
the control light in the monitoring board is permanently
on. In case of a fault the lamp will flash.
A fter-heating is triggered by the starting process (12
Volt on control unit A13, terminal 50(5)). With a cool-
ant temperature of -30°C the subsequent heating time
will be max. 180 seconds, with +25°C the minimum
time will be 35 seconds. This after-heating time is not
indicated by the control light.
! Caution
Multiple activation of the heater control in short
term operation (low generator running time) dis-
charges the starter battery.
If the engine does not start properly in case of au-
tomatic starting of the heating flange because the
starter does not get energized due to a fault and
does not crank the engine, the starting process
must be completely aborted (ignition key to OFF,
voltage supply to heating flange interrupted). In
order to avoid damage to heating flange or charge
air hoses caused by overheating, another start of
008 911 63 BOMAG 369

12.33 Heating flange on engine
the engine must be avoided and trouble shooting

should be performed instead.
Several successive starting attempts can cause
overheating of the heating flange .
Fig. 3
1 Heating control unit (A13)
2 Heating relay (K14)
Fig. 2 Heating flange (R19) with hose socket BF4M 2012 C
Fig. 4 Coolant temperature sensor

1 Temperature sensor (B113) for heating flange
control (A13)
2 Coolant temperature switch (B30)
370 BOMAG 008 911 63

Heating flange on engine 12.33

circuit diagram
R19 Heating flange With a coolant temperature of -30°C
(Fig. 2) the preheating time will be max. 52
seconds, with +5°C the minimum
time will be 38 seconds.
With a coolant temperature of -30°C
the after-heating time will be max.
180 seconds, with +25°C the mini-
mum time will be 35 seconds.
12 Volt
approx. 2000 Watt
approx. 167 A
approx. 0.07 Ohm
2 (Fig. 3)) A13 Heating control unit 12 Volt

3 (Fig. 3) K14 Heating relay 12 Volt
1 (Fig. 4) B113 Temperature sensor for heating approx. 2 Ohm at 20°C

flange control (A13)
2 (Fig. 4) B30 Coolant temperature switch Contact switches at approx. 110° C
to ground
Fig. 5 Heating flange function diagram

1 Heating start
2 Signal lamp
3 Start
4 Switching relay
5 Condition
6 Terminal 15/S
7 Terminal L
8 Terminal 50
9 Terminal R
10 Start process
11 Ready for starting: 0 sec.
008 911 63 BOMAG 371

12.34 Checking the heating flange control
12.34Checking the heating flange perature sensor is pulled off (simulated sensor fail-
ure), a coolant temperature of 0° C is assumed.
control
●
Start the heating process.
Depending on the coolant temperature the control
light (K)(Fig. 1) will light between 30s and 50s, the
heating flange relay is energized.
●
Place a tong-test ammeter over the heating flange
connecting line.
Rated current: 165 Amp +- 10 Amp.
i Note
The relay must remain energized for another approx.
15 seconds, after the control light has gone out.
After the engine has started the after heating time
must continue for 35 to 180 seconds. This after-heat-
Fig. 1 Monitoring module, old design (A15)
ing time is not indicated by the control light.
Fig. 2 Monitoring module, new design (A15)
i Note
During the preheating period the control light K (Fig.
1), c (Fig. 2) is permanently on. In case of a fault the
lamp will flash.
●
The lamp flashes with a frequency of 1 Hz during
the pre-heating phase.
Sensor failure: Either short circuit or cable break-
age at the input to the control unit (A13), terminal
T(4)
●
The lamp flashes with a frequency of 2.5 Hz over
the entire heating phase.
Heating flange failure: Either short circuit or cable
breakage at the output of the control unit (A13),
terminal R(6)
i Note
The heating flange only becomes active at a coolant
temperature below 25°C. When the plug of the tem-
372 BOMAG 008 911 63

Electric throttle control 12.35

12.35Electric throttle control
Fig. 1 Engine solenoid
Throttle control switch
Fig. 2 Throttle control switch

The throttle control switch (S120) is used to change
from "MIN" to "MAX" idle speed and vice versa.
008 911 63 BOMAG 373

12.35 Electric throttle control
Throttle control solenoid Y120

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

The throttle control solenoid 5 (Fig. 3)) is equipped
with a pick-up winding (4) and a holding winding (3), Fig. 5
both switched in series. The holding winding has a ●
Measure the gap between stop screw 1 (Fig. 5) and
much higher resistance than the pick-up winding. The
throttle lever (2).
"aux"-connection is connected between the two wind-
ings. The engine solenoid is equipped with a limit
switch (2), which is mechanically connected with the ! Caution
governor rod (1) on the diesel engine. This switch The gap should be min. 0.1 mm and max. 0.5 mm.
bridges the holding winding until the end position of
the governor rod is reached (high engine speed) If the gap is too small, the limit switch in the sole-
noid may not be able to operate.
This bridging has the effect, that the "aux"-terminal
has the same potential as the "+"-terminal. If the In case of a too wide gap the engine will not reach
bridge is open, the "aux"-terminal has almost the its maximum speed.
same potential as the "-" terminal, because of the low
resistance of the pick-up winding and the high resist-
ance of the holding winding.
Adjusting the solenoid
Fig. 4
●
Switch on the ignition.
●
Turn the rotary switch (Fig. 4) to position "MAX".
374 BOMAG 008 911 63

Engine monitoring 12.36

12.36Engine monitoring
Fig. 1 Monitoring module, old design Tank gauge, Pin 2: (0Ω ⇒tank fuel, 65Ω ⇒tank empty,
Output warning buzzer, Pin 1: +UB switching. 26Ω ⇒tank ½. If no level switch is connected or the ca-
ble is broken, the gauge will go out.
Output engine shut down, Pin 9: +UB switching.
Water separator, Pin 3 and 4: Resistance <500kΩ .
Pos. Designation Control light Warning Engine Engine Remedy

buzzer shut-down shut-down
time time
10 sec. 2 min.
a Control light, over- red, flashing X X Switch off vibration, run
heating of engine Low-active engine with idle speed or
shut down engine if nec-
essary, clean engine oil
cooler and radiator, if
necessary repair engine.
b Engine oil pressure red, flashing X X Check the engine oil lev-
control light Low-active el, if necessary repair the
engine.
c Control light for en- not used
gine air filter Low-active
d Charge control light yellow, lights Check V-belt, if neces-
High-active sary repair the generator
i Control light, water yellow, lights X X Check, clean the water
in diesel filter separator
k Control light, pre- yellow, lights
heating monitoring Low-active
j Coolant provision not used
Low-active
e Hydraulic oil filter yellow, lights X X Change the hydraulic oil
Low-active filter
008 911 63 BOMAG 375

12.36 Engine monitoring
Fig. 2 Monitoring module, new design Tank gauge, Pin 1: (0Ω ⇒tank fuel, 65Ω ⇒tank empty,
Output warning buzzer, Pin 23: +UB switching. 26Ω ⇒tank ½. If no level switch is connected or the ca-
ble is broken, the gauge will go out.
Output engine shut down, Pin 24: +UB switching.
Water separator, Pin 21 and 22: Resistance <500kΩ .
Pos. Designation Control light Warning Engine Engine Remedy

buzzer shut-down shut-down
time time
10 sec. 2 min.
g Control light, over- red, flashing X X Switch off vibration, run
heating of engine Low-active engine with idle speed or
shut down engine if nec-
essary, clean engine oil
cooler and radiator, if
necessary repair engine.
d Engine oil pressure red, flashing X X Check the engine oil lev-
control light Low-active el, if necessary repair the
engine.
h Control light for en- not used
gine air filter Low-active
f Charge control light yellow, lights Check V-belt, if neces-
High-active sary repair the generator
a Control light, water in yellow, lights X X Check, clean the water
diesel filter Low-active separator
b Control light, preheat- yellow, lights
ing monitoring Low-active
e Coolant provision not used
Low-active
i Hydraulic oil filter yellow, lights X X Change the hydraulic oil
Low-active filter
376 BOMAG 008 911 63

Engine monitoring 12.36

Water separator ●
Push the plug back on, the plug interlock clicks into
place.
●
ing loom.
Engine overheating
Fig. 3 Sensor water separator

●
Press the plug interlock and disconnect the plug
(Deutsch plug).
●
Bridge both contacts on the plug of the wiring loom.
i Note ●
Press on the locking wire (Fig. 5) and pull off the
Control light i (Fig. 1) a (Fig. 2) lights up. An audible plug.
warning will sound and the engine is shut down after ●
Bridge both contacts on the plug of the wiring loom.
2 minutes.
●
Push the plug back together, the plug interlock
i Note
clicks into place.
Control light a (Fig. 1) g (Fig. 2) flashes. An audible
●
Check the plug interlock by lightly pulling on the wir- warning will sound and the engine is shut down after
ing loom. 2 minutes.
Engine oil pressure ●
Push the plug back on, the plug interlock clicks into
place.
●
ing loom.
Emergency stop switch
Fig. 4 Oil pressure switch

●
Press on the locking wire and pull off the plug 1 (Fig.
4).
●
Apply the contact to engine ground. Fig. 6 Emergency stop switch
●
Press the emergency stop switch (Fig. 6). The en-
i Note gine should stop immediately.
The control light b (Fig. 1) d (Fig. 2) flashes. An audi-
ble warning will sound and the engine is shut down af-
ter 10 seconds.
008 911 63 BOMAG 377

12.37 Engine
12.37Engine
Faults Possible cause Remedy
The engine Starter defective or pinion not engaging Have examined by a specialist
does not start
Fuel tank empty Fill and bleed the tank
Temperature below starting limit Use winter fuel and engine oil acc. to the
ambient temperature.
Fuel filter clogged, in winter due to paraf- Change the filter. use winter fuel
fin separation.
Fuel lines leaking Check all line connections for leakages
and tighten the fittings.
Battery discharged or not connected Tighten the pole clamps, check the cable
connections
Injection valves or injection pump defec- Have examined by a specialist
tive
The engine Battery power too low, battery clamps Have the battery checked, clean the ter-
starts poorly and loose or oxidized, causing the starter to minal clamps, tighten them and cover
works irregularly turn too slowly them with acid free grease
with poor power
Especially during winter: the use of too Use engine oil suitable for the ambient
viscous engine oil temperature
Fuel supply restricted, in winter fuel sys- Change the fuel filter. Check the line con-
tem clogged due to paraffin separation nections for leaks and tighten the fittings.
Use winter fuel in the cold season.
Incorrect valve clearance Adjust the valve clearance
Injection valve defective Have examined by a specialist
Injection lines leaking Check the lines for leakages
Turbo charger defective Have examined by a specialist
Dry air filter dirty clean, replace if necessary
Excessive play in the throttle cable Adjust the throttle cable, change it if nec-
essary
Excessive ex- Engine oil level too high Drain the oil to the upper dipstick mark
haust smoke
Dry air filter dirty clean, replace if necessary
Exhaust gas turbo-charger defective Have examined by a specialist
Poor compression due to burned or bro- Have compression rings and pistons ex-
ken compression rings or incorrect valve amined by a specialist, adjust the valve
clearance clearance
378 BOMAG 008 911 63

Engine 12.37
Engine over- Cooling fins on radiator extremely soiled Clean the cooling fins
heats, shut (the warning light "engine oil temperature"
down immedi- lights)
ately!
Engine oil level too low Top up engine oil to the upper dipstick
mark
Filling capacity of the injection pump not Have adjusted by a specialist
correctly adjusted
Cooling air flow restricted Clean the cooling air duct
V-belt loos or broken Tension or replace the V-belt
Poor engine Engine oil level too high Drain the engine oil down to the upper dip-
power stick mark
Dry air filter dirty clean, change if necessary
Exhaust gas turbo-charger defective Have examined by a specialist
Charge air hose leaking Check fastening and connections
Engine oil pres- Engine oil level too low (control light "en- Top up oil
sure too low gine oil pressure" lights, the warning
buzzer sounds)
Leakages in the lubrication system Shut the engine down immediately, check
fittings on oil lines, lubrication oil filter and
oil cooler for leaks, if necessary tighten
the fittings.
The charge con- Generator speed too low Check the V-belt tension, replace the V-
trol light lights belt if necessary
during opera-
tion, the warning The generator does not charge the bat- Have examined by a specialis
buzzer sounds tery, because generator or regulator is de-
fective

008 911 63 BOMAG 379

12.38 Special tools, Deutz engine (BFM 2012)
12.38Special tools, Deutz engine

(BFM 2012)
Deutsch English Français Español No.
Druckpumpe für Kühlmitteldichtheitsprüfung 8002

057 250 66
Pressure pump for coolant leakage test.
Pompe refoulante pour contrôle de l’étanchéité du

liquide refroidisseur
Bomba de presión para pruebas de estanqueidad

sistema de líquido refrigerante
35409 ©
Kompressionsdruckprüfer 8005
057 250 67
Compression tester
Compressiomètre
Compresímetro
35410 ©
Düsenprüfgerät 8008
Nozzle tester
Pompe d’essai d’injecteurs
Comprobador para inyectores
35411 ©
Stecknuss SW 15, lange Ausführung für Einspritz- 8012

ventil. (Überwurfmutter)
Socket a/flats 15, long version for injector

(cap nut)
Douille de 15, version longue pour injecteur

(écrou-raccord).
Llave de vaso de 15, versión larga, para inyector

(tuerca de unión)
35412 ©
380 BOMAG 008 911 63

Special tools, Deutz engine (BFM 2012) 12.38
008 911 63 BOMAG 381

057 250 78
382 BOMAG 008 911 63

Anschlußstück für Kompressionsdruckprüfer 100 110
Connector for compression tester
Raccord pour compressiomètre
Pieza de empalme para el compresímetro
35421 ©
Durchdrehvorrichtung 100 320

057 250 80
Turning gear
Dispositif vireur
Dispositivo de viraje
35422 ©
Durchdrehvorrichtung 100 330

079 947 19
Turning gear
Dispositif vireur
Dispositivo de viraje
35423 ©
Messuhr M2T mit Feststellring. 100 400

057 250 81
Dial gauge M2T with locking ring
Comparateur M2T avec bague

d’immobilisation
Comparador M2T con anillo exterior

de bloqueo
35424 ©
008 911 63 BOMAG 383

No. Deutsch English Français Español
100 750 Messbalken mit Abstandsblättchen zum Messen

057 250 83 des OT und des Kolbenüberstandes.
Measuring bar with spacers for gauging

TDC and piston projection
Barre de mesure avec plaquettes d’écartement

pour mesurer le PMH et la cote de dépassement du
piston
Barra de medición con plaquitas distanciadoras

35425 © para la medición del PMS y saliente de pistón
100 800 Messgerät zum Messen und Blockieren der

Regelstange.
Measuring device for measuring and

locking control rod
Appareil de mesure et de blocage de la

crémaillère.
Equipo de medición y de bloqueo de la cremallera
35426 ©
100 810 Einstellbolzen für MAG-Wellen.
Adjusting pin for mass balancing shafts
Pige de calage pour arbres à masses d’équilibrage

(MAG)
Pernos de ajuste para ejes equilibradores

de masa „MAG".
35427 ©
100 830 Andrückvorrichtung für Regelstange
Press-on device for control rod
Dispositif de montage de cremaillère
Dispositivo de presión para la cremallera
35428 ©
384 BOMAG 008 911 63

Messvorrichtung für Grundkreismessung 100 890

„Einspritzpumpe und Förderbeginn“.
Measuring device for base circle measurement
Dispositif de mesure du cercle de base
Dispositivo de medición del círculo base

“bomba de inyección y comienzo de alimentación“
35429 ©
Gradscheibe 360 mit Befestigung an der

° 101 020
Schwungscheibe für OT und FB Einstellung.
Graduated disc 360 with device for fastening

°
to flywheel for TDC and COD setting
Disque gradué 360 avec fixation sur volant moteur

°
pour réglage du PMH et point de calage du début

d’injection
Disco graduado 360 con fijación en el volante,

°
para ajuste del PMS y comienzo de alimentación 35430 ©
Adapter für Gradscheibe. 101 030
Adapter for graduated disc
Adaptateur pour disque gradué
Adaptador para el disco graduado
35431 ©
Zeiger für Gradscheibe. 101 300
Pointer for graduated disc
Index pour disque gradué
Indicador para el disco graduado
35432 ©
008 911 63 BOMAG 385

386 BOMAG 008 911 63

Spezialschlüssel für Einspritzleitung 110 500

057 250 86
Special wrench for injection line
Clé spéciale pour conduite d’injection
Llave especial para tubería de inyección
35436 ©
Ausziehvorrichtung für den Dichtring unter 120 680

dem Einspritzventil.
Extractor for sealing ring beneath injector
Outil d’extraction pour le joint de l’injecteur
Dispositivo de extracción para el anillo de

junta del inyector
35437 ©
Aufspannbock für Zylinderkopf. 120 900 057 250 90

Clamping stand for cylinder head
Chevalet d’ablocage pour culasse
Caballete de sujeción para culata
35438 ©
Aufspannplatte für 120 900. 120 910
Clamping plate for 120 900 057 250 91
Plaque d’ablocage pour 120 900
Placa de sujeción para 120 900
35439 ©
008 911 63 BOMAG 387

No. Deutsch English Français Español
121 410 Montagewerkzeug für Ventilschaftabdichtung
Sleeve for fitting valve stem seal
Outil de montage pour joint de tige de soupape
Util de montaje para juntas de vástago de válvula
35440 ©
130 300 Kolbenring-Auflegezange
Piston ring pliers
Pince à monter les segments de piston
Alicates para colocar aros de pistón
35441 ©
130 440 Trapeznut-Verschleißlehre
Trapezoidal groove wear gauge
Jauge d’usure pour gorge trapézoïdale
Calibre de desgaste para ranura trapezoidal
35442 ©
130 660 Kolbenringspannband Ø 98 mm

057 250 97
Piston ring compressor
Collier à segments de piston de Ø 98 mm
Compresor de aros de pistón, Ø 98 mm
35443 ©
388 BOMAG 008 911 63

Kolbenringspannband Ø 101 mm 130 670

057 250 98
Piston ring compressor
Collier à segments de piston de Ø 101 mm
Compresor de aros de pistón, Ø 101 mm
35443 ©
Montagewerkzeug für Kurbelwellendichtring vorn. 142 670
Assembly tool for front crankshaft seal

079 947 26
Outil de montage de bague d’étanchéité de
vilebrequin AV
Herramienta de montaje para el retén delantero del

cigüeñal
35445 ©
Montagewerkzeug für Kurbelwellendichtring hinten. 142 830

079 947 27
Assembly tool for rear crankshaft seal
Outil de montage de bague d’étanchéité de

vilebrequin AR
Herramienta de montaje para el retén trasero del

cigüeñal
35446 ©
Montagewerkzeug für MAG-Buchsen. 143 780
Assembly tool for engine balancer bushes
Outil de montage de douilles d’arbres à masses

d’équilibrage
Herramienta de montaje para casquillos de ejes

equilibradores
35447 ©
008 911 63 BOMAG 389

057 250 99
079 947 18
390 BOMAG 008 911 63

Maul-Steckaufsatz für Drehmomentschlüssel 160 340

(mit großem Vierkant 14 x 18 mm) für Lüfter (Ein- /
Ausbau) - Zentralmutter
Open jawed wrench socket for torque wrench
(large square wrench 14 x 18 mm) for fan
(assembly and removal) – center nut
Embout à mâchoire pour clé dynamométrique
(à grand quatre-pans 14 x 18 mm) pour ventilateur
(démontage/remontage) – écrou central
Boca enchufable para llave dinamométrica
(con macho cuadrado grande 14 x 18 mm) para
(montaje/desmontaje) tuerca central del ventilador 35455 ©
Gegenhalter für Zahnrad Luftpresser 170 630
Dolly for air compressor gear
Dispositif de maintien pour pignon de compresseur

d’air
Dispositivo de retención para rueda dentada

compresor de aire
35450 ©
Motormontagebock für doppelseitige Auf- 6066

spannung
Engine assembly stand for double-sided

chucking
Chevalet de montage moteur avec double

ablocage
Caballete de montaje para sujeción bilateral 079 947 30

del motor
35451 ©
1 Satz Aufspannwinkel für doppelseitige Auf 6066/158

spannung.
1 Set of angled clamping plates for

double-sided chucking
1 jeu d’équerre de fixation pour double ablocage
1 juego de angulares para sujeción bilateral 079 947 31
35452 ©
008 911 63 BOMAG 391

392 BOMAG 008 911 63

13 Air conditioning system
008 911 63 BOMAG 393

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

conditioning system one must first become familiar
with the physical basics of such a system.
The four well known physical conditions of water apply
also for the refrigerant in the air conditioning system.
1. gaseous (invisible)
2. vaporous
3. liquid
4. solid
Fig. 2
Heat always flows from the warmer to the colder mat-
ter. Any matter consists of a mass of moving mole-
cules. The rapidly moving molecules or a warmer
matter dissipate part of their energy to the slower
moving molecules with less heat. The movement of
the molecules in the warmer matter becomes slower
and the molecules in the cooler matter are accelerat-
ed. This process continued, until all molecules in the
two matters move with identical speed. The matters
have then reached an identical temperature and the
transfer of heat stops.
Fig. 1
If the water in a container is heated up (absorption of
heat), the rising steam is visible. If the steam is heated
up further, due to the absorption of heat, the visible
steam will turn into invisible gas. This process is re-
versible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into
water and finally into ice.
394 BOMAG 008 911 63

Physical basics 13.1

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

In the pressure - temperature diagram for the refriger-
ant the drawn in closed curve shows the cycle of the
refrigerant. This cycle permanently continues in direc-
tion of the arrow.
The characters A, B, C, D stand for:
Fig. 3 Steam pressure curve A - compression
Steam pressure curve for refrigerant R134a B- condensation
The steam pressure curve is a means for explaining C- relaxation
the operation principle of an air conditioning system. D- evaporation.
A- liquid
B- gaseous
The diagram shows the evaporation curve of R134a.
The diagram for example shows, that R134a is liquid
at 0°C and a pressure of 5 bar, but becomes gaseous
at 40°C and 5 bar.
For better understanding one must also be aware of
the following:
1. A gas heats up when being compressed (e.g. air
pump, turbo charger, ...).
2. When relieving gas it will cool down (e.g. white frost
forms on the valve when relieving air pressure from a
car tire).
3. Condensing gas dissipates a lot of heat energy.
008 911 63 BOMAG 395

13.1 Physical basics
Excerpt from the wet steam table 1 R134a
1 This table is used for the determination of evaporation and con-

densation temperature.
Saturation temperature Overpressure (pressure gauge Absolute pressure (pamb = 1 bar
reading Pe in bar) P in bar)
-20 0,33 1,33
-10 1,01 2,01
0 1,93 2,93
10 3,15 4,15
20 4,72 5,72

396 BOMAG 008 911 63

Refrigerant R134a 13.2

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

Physical properties of R134a:
- 26.5 °C
The steam pressure curves of R134a and other refrig-
erants are partly very similar, making a clear differen-
Solidification point: tiation solely by pressure impossible. With R 134a the
-101.6 °C compressor is lubricated by special synthetic refriger-
ation oils, e.g. PAG-oils (polyalkylene glycol oils).
Critical temperature:
Behaviour with metals:
100,6 °C
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
Critical pressure:
contamination of the refrigerant, e.g. with chlorine
compounds, leads to aggressiveness against certain
40.56 bar (absolute) metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.
Critical point:
Critical point (critical temperature and critical pres- Critical temperature / critical pressure:
sure) means that above this point there is no separat- Up to a gas pressure of 39.5 bar overpressure (this
ing interface between liquid and gas. Above its critical corresponds with a temperature of 101 °C) the refrig-
point any substance is gaseous. At temperatures be- erant R134a remains chemically stable, above this
low the critical point all refrigerant types in pressure temperature the refrigerant decomposes (see com-
containers have a liquid and a gaseous phase, i.e. a bustibility).
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature. Water content:
In liquid refrigerant water can only be dissolved in very
low quantities. In contrast to this refrigerant steam
mixes with water steam at any ratio. If the dryer in the
008 911 63 BOMAG 397

13.3 Compressor oil / refrigeration oil
liquid container has absorbed approx. 8 gr. of water, 13.3 Compressor oil / refrigeration
the refrigerant circuit transports possibly existing wa-
ter in form of droplets. This water flows to the nozzle oil
of the expansion valve and turns to ice. The air condi- The compressor oil lubricates the movable parts in the
tioning system stops cooling. Water destroys the air compressor, seals e.g. the gap between piston and
conditioning system, because under high pressures cylinder inside the compressor to prevent refrigerant
and temperatures and in connection with other con- loss and prevents other seals in the system from dry-
taminants it forms acids. ing up.
Part of the compressor oil dissolves in the refrigerant
Inflammability: until saturation is reached, so that a gas mixture of re-
frigerant, water steam, compressor oil and contrast
Refrigerant is not inflammable. On the contrary, it has agent circulates through the system.
fire inhibiting or fire extinguishing properties. Refriger-
ant is decomposed by flames or glowing surfaces. Ul- Compressor oil (the oil quantity should be 10 % of the
traviolet light also cracks refrigerant (caused by refrigerant weight) mixes with the refrigerant and cir-
electric welding). This results in toxic fission products, culates permanently through the system.
these must not be inhaled. However, irritation of the In connection with R134a- air conditioning systems
mucous membranes is an early and in-time warning. special synthetic compressor oils, e.g. polyalkylene
glycol (PAG) oils, are used. This is necessary, be-
cause e.g. mineral oil does not mix with R134a. Apart
Filling factor: from this, the materials in the R134a air conditioning
In a container there must be a steam space above the system may be attacked when the mixture is flowing
liquid space. The liquid expands with increasing tem- through the refrigerant circuit under high pressure and
perature. The steam filled space becomes smaller. at high temperatures or if the lubrication film in the
From a certain time on the container will be filled with compressor tears off. The use of non-permitted oils
just liquid. After this only a minor temperature in- can cause damage to the air conditioning system, you
crease is enough to generate very high pressures in should therefore only used the approved oils.
the container, because the liquid would like to expand,
but there is no more room. The related forces are high
enough to cause the container to burst. In order to Properties of compressor oil / refrigeration oil:
avoid overfilling of a container the pressure gas direc- The most important properties are high solvency in
tive clearly specifies how many kilograms of refriger- connection with refrigerants, good lubrication charac-
ant may be filled into the container per litre volume. teristics, that they are free of acids and their low water
Multiplied with the internal volume this "filling factor" content. For this purpose only certain oils can be
determines the permissible filling capacity For refrig- used. PAG-oils suitable for use with refrigerant R134a
erants used in motor vehicles it is 1.15 kg/l. are highly hygroscopic and will not mix with other oil.
As a protection against the invasion of moisture drums
must immediately be closed again after they had been
opened. Compressor oil ages under the effect of
Environmental aspects moisture and acids, becomes dark, viscous and ag-
The contribution of R134a to the greenhouse effect is gressive against metals.
by factor 10 smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for
newly produced construction equipment were succes-
sively converted to refrigerant R134a. This refrigerant
does not contain any chlorine and is thus harmless for
the ozone layer. Until approx. 1992 air conditioning
systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decompo-
sition potential and also a potential to amplify the
greenhouse effect. Conversion programs for existing
old systems with the ozone damaging R12 are in ef-
fect. For reasons of protecting the environment refrig-
erant must not be discharged into the atmosphere.
398 BOMAG 008 911 63

Working principle of the air conditioning system 13.4

13.4 Working principle of the air 13.5 Monitoring devices
conditioning system
All air conditioning systems are based on the same
principle. They extract heat from the surrounding en- Pressure switch
vironment. Everybody knows the effect: if a sweating The pressure switch (8) is used as monitoring feature
body is exposed to wind it will cool down, because for too high and too low pressures. The switching con-
heat is extracted. For this purpose a refrigerant circu- tacts (4 and 5) effect the magnetic clutch of the com-
lates in a closed circuit inside the vehicle. This refrig- pressor via a relay (6).
erant thereby continuously changes its physical state
between liquid and gaseous. If the system pressure increases excessively, e.g. be-
cause of a excessively soiled condenser, a failed fan
or a defective expansion valve, the high pressure con-
tact (5) will cut off the electric power supply to the
magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off
pressure by the set differential pressure, the magnetic
clutch of the compressor is switched on again.
The low pressure contact (4) interrupts the electric
power supply to the magnetic clutch when the set
pressure is fallen short of (possible causes: lack of re-
frigerant, defective expansion valve, too low heat
load, defective evaporator fan, ...). Since the refriger-
ant R134a has an evaporation temperature of 0 °C at
an overpressure of 2 bar, the low pressure contact (4)
Fig. 1 Principle sketch of an air conditioning system
is set to approx. 1.5 bar to avoid icing. The switch on
An engine driven compressor (1) draws in gaseous re- pressure is 0.5 to 2 bar higher than the shut-off pres-
frigerant from the evaporator (5) and compresses it. sure (depending on system, see description of com-
During this process the temperature of the refrigerant ponents.)
increases tremendously.
Thermostat
The refrigerant vapour is then pumped to the con-
denser (2). This condenser is arranged directly in front A frost protection thermostat (3) protects the evapora-
of the vehicle radiator, so that a sufficient air flow is as- tor against icing. Similar to the pressure switch, the
sured. In the condenser (2) the gas is cooled down thermostat activates or deactivates the magnetic
and consequently liquefied. clutch for the compressor. Depending on the design,
the feeler of the temperature control is mounted be-
In the dryer / liquid container (3) the refrigerant is then
tween the fins of the evaporator or attached to the
collected and freed of moisture and contaminants.
evaporator outlet (suction side). With fixed tempera-
The expansion valve (4) regulates the flow rate from ture controls the control switches the compressor off
the dryer / liquid container (3) back to the evaporator at about 1 °C and back on again at about 2.5°C to 5.5
(5) and the circuit starts again. °C (depending on system, see description of compo-
nents.)
With adjustable temperature regulators the switching
point can be changed so that the compressor is al-
ready shut down at higher temperatures. This enables
regulation of the air temperature.
008 911 63 BOMAG 399

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

●
1 Switch
●
2 Fuse
●
3 Thermostat
●
4 Low pressure switch contact Fig. 1
●
5 High pressure switch contact The compressor is mounted to the engine and has the
duty to build up the refrigerant pressure required for
●
6 Relay
the function of the system. Coupling and decoupling is
●
7 Connection for magnetic clutch accomplished by an electromagnetically controlled
●
8 Pressure switch mechanical clutch, which is integrated in the V-belt
pulley of the compressor.
Compressor data
Displacement: 155 cm²
Weight: 6,9 kg
max. rpm: 6000
Sense of rotation: cw
Refrigerant: R134a
Oil quantity (scope of delivery): 207 gr
Oil: PAG SP-20 (H14-003-404)
! Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only refrigeration oil
PAG SP-20 (H14-003-404).
or condenser, any compressor oil / refrigeration
oil lost by exchanging the components, must be
replaced with fresh oil.
The actual quantity depends on the amount of oil
that may have been lost in connection with the
possible replacement of other components.
Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
The following table shows how much compressor oil /
refrigeration oil will be lost in connection with various
types of work on the air conditioning system.
400 BOMAG 008 911 63

Description of components 13.6

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
To avoid excessive oil in the A/C-system and thus The condenser is located in front of the the radiator for
a poor cooling effect, the oil level in the A/C-sys- the machine. It emits heat energy from the system into
tem must be adjusted accordingly. the surrounding air and liquefies the gaseous refriger-
The quantity depends on the amount of oil that ant.
may have been lost in connection with the possi-
ble replacement of other components.
i Note
The compressor oil quantity must be 10% of the The fins must be free of dirt and damage.
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system re-
! Caution
quires a compressor oil / refrigerant oil filling of
100 gr. When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
Procedure: changing the components, must be replaced with
Drain and measure the compressor oil from the fresh oil.
old compressor.
Drain the compressor oil from the new compres-
sor and only fill in the exact quantity that had been
drained out of the old compressor. The compres-
sor oil from the new compressor can be used for
this purpose.
i Note
Topping up compressor oil / refrigeration oil is possi-
ble on a pressureless compressor directly into the oil
pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
into the pressure side of the refrigeration system dur-
ing the evacuation process.
008 911 63 BOMAG 401

Dryer / filter / fluid container / inspection Safety valve

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

Response pressure 32 +/- 4 bar
Dryer / filter
Tightening torque 10 - 15 Nm
The fluid container collects the fluid drops and passes
these then as a constant flow to the expansion valve. Inspection glass
Moisture that has entered during assembly of the re-
frigerant circuit is absorbed by a dryer in the fluid con-
tainer.
At evaporation temperatures below zero the refriger-
ant will deposit previously absorbed moisture on the
expansion valve, where this water turns into ice and
thus adversely affects the controllability of the expan-
sion valve. Moreover, moisture in the refrigerant cir-
cuit causes corrosion, forms acids and enters into
chemical compositions.
Inside the refrigerant container the heavy liquid refrig-
erant collects in the lower part of the container, flows
through a rising pipe to the outlet marked "A" and thus
ensures bubble free operation of the expansion valve.
Fig. 3
i Note During operation the refrigerant must flow through the
Since the absorbing capacity of this filter/dryer is lim- inspection glass without air bubbles. In most cases
ited, it must be changed within certain service inter- the presence of air bubbles is a sign for a too low re-
vals. We recommend to replace it 1 x per years, frigerant level in the system. Apart from this, the refrig-
before the start of the season. erant may not sufficiently condense as a result of a
soiled evaporator or a defective condenser fan and
the fluid level in the refrigerant container may drop
! Caution down to a level, at which gaseous refrigerant could
The filter/dryer must generally be replaced when- flow through the rising tube to the inspection glass.
ever opening the refrigerant circuit, because This results in abnormally high temperatures in and on
moisture will enter in such a case. the fluid lines (between refrigerant container and ex-
This requires emptying the air conditioning sys- pansion valve), as well as very high pressures in the
tem! pressure side.
Installation position: However, incorrect evacuation or filling may also be
the reason for air entering into the system and since
The arrow marks on the filter/dryer must point in air cannot be condensed, one will not be able to get
flow direction, i.e. towards the expansion valve. rid of these bubbles by topping up refrigerant. In this
Filter/dryer cannot be treated for further use! case the air conditioning system needs to be evacuat-
ed and refilled.
402 BOMAG 008 911 63


i Note Expansion valve
Air in the system is characterized by high pressures
and temperatures.
On R134a refrigeration systems from KONVEKTA the
inspection glasses are equipped with moisture indica-
tors. In addition to the float, the dryer/collector/inspec-
tion glass combination has an indicator pearl
integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection
glass and should only be checked after approx. 5 min-
utes continuous operation, because the refrigerant
must first evenly distribute all over the system.
! Danger
In case of mechanical damage or corrosion on
this pressure container this collector unit must be
replaced, to avoid bursting and further damage. Fig. 1
The expansion valve is mounted inside the HKL-mod-
ule in the cabin. The expansion valve always allows a
small amount of the high pressure liquefied refrigerant
to flow into the evaporator, which has a much lower
pressure. This lower pressure causes these liquid re-
frigerant to expand and to evaporate to gaseous state.
The heat required for this evaporation process is tak-
en from the ambient air through the lamellas and sup-
plied to the refrigerant. This is the so-called cooling
effect.
The thermostatic expansion valve operates with an
external pressure compensation. This type of expan-
sion valve works with high accuracy, because it uses
pressure and temperature at the evaporator outlet and
adjusts and overheating of approx. 7 K. The already
installed expansion valves and the ones delivered as
spare parts have this overheating value pre-set. In or-
der to prevent a loss in performance or compressor
damage you should only use original expansion
valves, because adjusting expansion valves takes a
lot of time and care.
i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+
008 911 63 BOMAG 403

Evaporator Defroster thermostat
Fig. 1 Fig. 1
The evaporator is mounted inside the HKL-module in The feeler of a defroster thermostat to switch off the
the cabin. It consists of a heat exchanger (inside air - magnetic clutch in case of icing up or to switch the
refrigerant), with refrigerant flowing to a pipe system clutch back on after defrosting, is mounted on the
with cooling flanges. evaporator. The correct adjustment of the defroster
thermostat as well as the correct feeler assembly
As with the condenser, correct operation of all fans should be checked during maintenance.
and cleanliness of the fins must be assured.
Switching point on: + 1°C (± 1°C)
Air conditioning systems have a circulation air filter
mounted in the air flow in front of the evaporator, Switching point off: + 5,5°C (± 1°C)
which should be cleaned or changed by the operator
after each third trip, depending on the amount of dirt. i Note
A condensation water filter is mounted in the air flow It is very important that the feeler is mounted down-
after the evaporator. This filter has the function to col- stream of the evaporator, but before the pressure sen-
lect the water that has condensed from the air in the sor, in countercurrent direction, with full length and
evaporator block and to discharge this water into the insulated against the outside temperature.
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.
! Caution
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.
404 BOMAG 008 911 63


Pressure switch Pipes and hoses
Pipes and hoses in air conditioning systems must
meet very high requirements with respect to resist-
ance against heat and pressure. The requirements
concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through
the hose material, are very high. Pipes and hoses to
be used must therefore be specially made for air con-
ditioning purposes. For this reason the hoses have an
inside lining of butyl rubber and an outside coating of
EDPM rubber. Hose sections exposed to heat are pro-
vided with a special heat insulation.
O-rings are made of a special type of chloroprene rub-
ber (neoprene). Before assembly of the air condition-
ing system these O-rings must be lubricated with
Fig. 1 compressor oil / refrigeration oil. The O-rings must al-
ways be replaced when assembling A/C-components.
After a minimum pressure is reached in the low pres-
sure side or a maximum pressure in the high pressure Recommended tightening torques for O-ring
side, the pressure switch will switch of the magnetic sealed fittings
clutch of the compressor, thus to avoid destruction of
system components by excessive pressure or draw- Thread Spanner width Torque
ing in external gases and foreign matter as a result of 5/8“ 17 or 19 13,6 - 20,3 Nm
too low pressure. 3/4“ 32,5 - 39,3 Nm
7/8“ 27 35,3 - 42,0 Nm
Working pressure:
1 1/16“ 32 40,7 - 47,5 Nm
Low pressure off: 1,5 ±0,5 bar M30X2 36 105,0 - 115,0
Low pressure on: 3.5 bar Nm
M36X2 41 165,0 - 175,0
Overpressure off: 25,0 ±1,5 bar
Nm
Overpressure on: 18,0 ±1,5 bar
Bending radii for air conditioning hoses
Hose type Nominal width Bending radius

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

008 911 63 BOMAG 405

13.7 Checking the compressor oil level
13.7 Checking the compressor oil

level
Checking the compressor oil level / refrig-

eration oil level
! Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only compressor oil / re-
frigeration oil PAG SP-20 (H14-003-404).
●
Run the compressor for 10 minutes at engine idle
speed.
●
In order to avoid any compressor oil losses you
should slowly drain all refrigerant from the air condi- Fig. 2
tioning system. ●
Turn the nut that hold the armature clockwise with a
socket wrench, until the counterweight is correctly
positioned.
i Note
2 o'clock position with inclination to the right (Fig. 2).
10 o'clock position with inclination to the left
●
Insert the oil dipstick.
●
Pull out the dipstick and count the notches covered
by oil.
●
Drain off oil or fill up as specified in the table.
Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
Fig. 1
Fastening angle (de- Oil dipstick in incre-
●
Measure the fastening angle (Fig. 1) of the com- gree) ments
pressor (oil plug at top) 0 5-7
●
Remove the oil filler plug. 10 6-8
20 7-9
30 8-10
40 9-11
50 10-12
60 11-13
90 16-18
●
Screw the oil filler plug back in.
! Caution
The contact area must be clean and should be free
of damage.
Use a new O-ring.
Tightening torque 15 to 25 Nm
●
Refill the air conditioning system.
406 BOMAG 008 911 63

Checking the magnetic clutch 13.8

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

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

●
Measure the air gap on the magnetic clutch be-
tween V-belt pulley (2) and thrust plate (1).
008 911 63 BOMAG 407

13.9 Inspection and maintenance work
13.9 Inspection and maintenance 13.10Checking, replacing the refrig-

work erant compressor V-belt1
●
Visual inspection of the complete system for dam-
age. ! Danger
●
Check the compressor mounting bracket on the ve- Danger of injury!
hicle engine for tight fit and damage.
Work on the V-belt must only be performed with
●
Check the condition, alignment and tightness of the the engine shut down.
V-belt.
Wear safety goggles.
●
Check the routing of refrigerant hoses and cables in
the area of the vehicle engine and transmission, as
Check the V-belt
well as on the chassis for chafing and rectify any de-
tected faults. Ensure sufficient clearance to hot
parts, such as the exhaust; install a protective
shield, if necessary.
●
Check the routing of hoses and hoses on the at-
tachment box or in the cabin.
●
Check all hose and screw fittings for leaks.
●
Check the fastening of the condenser unit.
●
Clean the condenser fins, replace the condenser
block if damaged fins are found.
●
Check the fastening of the evaporator unit.
●
Check the function of evaporator and condenser
fans. Fig. 4
●
Check the electric control panel. If discolorations on ●
Inspect the entire circumference of the V-belt (Fig.
conductors are found, these should be replaced 4) visually for damage and cracks. Replace dam-
and possibly also the corresponding relays. aged or cracked V-belts.
●
Switch on the cooling system and check the refrig- ●
Check with thumb pressure whether the V-belt can
erant level. be depressed more than 10 to 15 mm (0.4 – 0.6
inches) between the V-belt pulleys, retighten if nec-
●
Filter/dryer and filter/dryer/fluid container combina- essary.
tions must always be replaced after opening the re-
frigerant circuit. If these are in service for more than
1 year, there is a risk that they may be clogged by Tighten the V-belt.
excessive absorption of moisture! The filter/dryer
should be replaced in regular intervals.
●
Measure the temperature on the evaporator: Meas-
ure the intake air temperature - Measure the blow
out air temperature - The temperature difference
should be at least 8-10 K.
●
Measuring the pressure in the refrigerant circuit
Fig. 5
●
Slightly slacken fastening screws 1, 2 and 3 (Fig.
5).
1 Optional equipment
408 BOMAG 008 911 63

Service the air conditioning 13.11

Press the compressor in direction of arrow, until the
13.11Service the air conditioning1
●
correct V-belt tension is reached.

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

●
Start the engine.
1 Optional equipment
008 911 63 BOMAG 409

13.11 Service the air conditioning
Fig. 7 Fig. 9
●
Switch the air conditioning (Fig. 7) on. ●
Check whether the white float (Fig. 9) inside the in-
spection glass of the drier/collector unit floats right
at the top.
i Note
The refrigerant level is correct.
Fig. 8
●
Choose a cooling temperature with the rotary switch
for cabin heater (Fig. 8) in the blue section.
●
Open the air outlet nozzles.
●
Check, whether the outflowing air is noticeably cool-
er. Fig. 10
●
If the white float (Fig. 10) inside the inspection glass
of the drier/collector unit floats at the bottom, inform
i Note
the service department.
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on. i Note
The refrigerant level is not correct.
●
Open the hood.
●
Refrigerant must be filled up, if necessary check the
air conditioning system for leaks.
410 BOMAG 008 911 63

Service the air conditioning 13.11

Checking the moisture level of the drying
agent
Fig. 12
●
Check the drier/collector unit (Fig. 12) for mechani-
cal damage or rust.
Fig. 11
●
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.
●
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 63 BOMAG 411

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

Evacuation of air conditioning systems using R-type For repair work the air conditioning systems must very
refrigerants not only has the purpose of emptying the often be emptied of all refrigerant.
system of all air before filling in refrigerant, but also to Especially with expensive refrigerants and larger
verify the leak tightness over a longer lifetime in the amounts of oil it may be necessary to keep the refrig-
achieved vacuum. However, the most important factor erant for later use.
in this work step is the drying of the system.
For later use these refrigerants must be drawn out
Any water residues in the refrigerant circuit will com- with suitable equipment and intermediately stored in
bine with the refrigerant, which will lead to the previ- collecting containers.
ously described consequential damage.
Vacuum pumps with a capacity of more than 100 l/min
Environment
and a final pressure of less than 30 micron, i.e. 0.039
mbar should be used to evacuate the refrigeration Contaminated refrigerant must be disposed of en-
system. vironmentally
The refrigerant compressor is not suitable for the pur- Releasing refrigerant into the atmosphere is pro-
pose of evacuation, because it is not able to achieve hibited (see restrictive injunction concerning
a sufficient final vacuum and, apart from this, may be CFC, day of enforcement 01. 08. 1991, § 8)
mechanically damaged because of a lack of lubrica-
tion when running empty during evacuation.
! Danger
It is common practice to evacuate the refrigeration For draining refrigeration systems you should not
system to a final vacuum of 1 Torr, i.e. 1.33 mbar. simply use any delivery containers, but only ap-
An exact time for evacuation and drying cannot be propriate pressure bottles, which must be special-
predicted. It can only be determined by means of a ly marked and should comply with the pressure
vacuum meter. However, if there is no vacuum meter gas directive.
at hand it is generally better to evacuate 1 hour longer
When transferring refrigerant you must make sure
than 1 hour too less.
that the bottle does not contain more than the per-
Function drying: mitted amount of refrigerant in litres and has suf-
ficient gas space for expansion (filling factor: 0,7).
Under normal ambient pressure (1.013 mbar) evapo-
rates absolute at 100° C. If the pressure is reduced, In order to reduce the evacuation period in case of
water will already evaporate, e.g. under a pressure of short repairs, you may fill the refrigerant circuit with
10 mbar, at an ambient temperature of almost 7°C, approx. 0.5 bar nitrogen when opening. This ensures
but the water will not evaporate all at once. Since it is that nitrogen will flow out of the refrigerant circuit while
very difficult to separate the steam from the vacuum in it is open and no air or moisture can enter. However,
the system, the evacuation process is supported by the necessity for vacuum generation and a dryer
the co-called vacuum breaking (filling the circuit with change remains.
dried nitrogen). With vacuum breaking the filled in
dried nitrogen absorbs the moisture in the refrigerant
circuit, which can then be easily discharged together
with the nitrogen.
412 BOMAG 008 911 63

Leak test 13.14

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

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

Points susceptible for leakage are sprayed with a
soapy solution. Bubbles indicate the leak. The detec-
tion limit for R 134a is 250 g/year.
008 911 63 BOMAG 413

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

machines takes place under various conditions.
In most large series production facilities highly compli-
cated equipment is available for this purpose, where-
as individual machines at the place of installation must
be filled directly from the refrigerant container.
Liquid refrigerant is only used to pre-fill the pressure
side of the evacuated refrigeration system (protective
filling).
After switching the refrigeration system on and watch-
ing the inspection glass, gaseous refrigerant can be
filled into the system while the engine is running, if the
refrigerant level is found to be too low (gas bubbles in
the inspection glass).
! Caution
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from
the refrigerant bottle care must be taken not to overfill
the system. As an additional control and for statistical
purposes, e.g. for refilling, it is important to write down
the weight of the filled in refrigerant.
With correct operation of the air conditioning the re-
frigerant container should be about 1/3 filled with liq-
uid refrigerant, the evaporator should be maximally
filled at the calculated evaporation temperature, i.e.
the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the
pressure gauge.
i Note
White frost on the suction line is no measure for as-
sessing the filling.
414 BOMAG 008 911 63

Filling instructions 13.15
Fig. 1 10 Filter dryer

1 High pressure - gaseous 11 Fluid container
2 High pressure - liquid 12 Condenser
3 Low pressure - gaseous 13 Manual shut-off valve (not used)
4 Compressor 14 Pressure switch with high and low pressure con-
5 Compressor pressure switch (not used) tacts
6 not used 15 Defroster thermostat
7 Evaporator 16 Vacuum meter
8 Expansion valve 17 Low pressure gauge
9 Inspection glass 18 High pressure gauge
008 911 63 BOMAG 415

13.15 Filling instructions
19 Pressure reducing valve 16 Switch off the vacuum pump, watch the pressure
20 Vacuum pump gauges to see whether the vacuum is maintained.
21 Nitrogen bottle 17 Open the valve on the refrigerant bottle and open
the black and red hand wheels on the pressure
22 Refrigerant bottle
gauge bar. Fill refrigerant into the system, until a
23 Pressure gauge bar pressure equilibrium between suction and pres-
sure side is reached (reading of pressure gaug-
Filling instructions es).
1 Connect the service adapter with the blue hand 18 Close the red hand wheel.
wheel in the suction side. 19 Perform a leak test with the electronic leak detec-
2 Connect the service adapter with the red hand tor.
wheel in the pressure side (the hand wheels on 20 Start the engine and switch on the system.
the service adapters must be fully backed out - left 21 Open the blue hand wheel and continue filling in
hand stop) refrigerant until the inspection glass is free or air
3 Connect the blue suction hose below the blue bubbles (in fluid container/dryer combinations the
hand wheel on the pressure gauge bar to the blue white pearl should float in the upper third of the in-
service adapter. spection glass). Then close the refrigerant bottle.
4 Connect the red pressure hose below the red 22 Close the blue hand wheel on the pressure gauge
hand wheel on the pressure gauge bar to the red bar.
service adapter. 23 Preparing the test run: -Close windows and doors
5 Connect the yellow hose below the yellow hand -Fan on full speed stage -Mount measuring feel-
wheel on the manometer bar to the 2-stage vacu- ers to air discharge and air intake.
um pump. 24 Run the system for approx. 20 minutes with medi-
6 Connect the last hose below the black hand wheel um engine speed.
on the nitrogen bottle via the pressure reducing 25 The temperature difference between air discharge
valve. and air intake should be (depending on type of air
7 Check on the pressure gauge bar that all hand condition) 8-10°C. The ambient temperature
wheels are closed. thereby is approx. 20°C. (These data are only ref-
8 Turn the hand wheels on both service adapter erence values, which may be influenced by possi-
clockwise. This opens the valves (right hand ble insolation)
stop). 26 Switch off system and engine and check for leaks
9 Open the valve on the nitrogen bottle (only via again.
pressure reducer); pressure approx. 20 bar. 27 Turn out (left hand stop) and remove the hand
10 Open the black and red hand wheels on the pres- wheels on both service adapters.
sure gauge bar and fill nitrogen into the system, 28 Fit all valves with dust caps.
until a pressure of approx. 3.5 to 5.0 bar is indicat- 29 Perform a leak test.
ed on the suction side.
30 Mark the system with the corresponding type
11 Then open the blue hand wheel and raise the plates and information decals, such as type of oil
pressure in the suction side (max. 10 bar). Check and refrigerant.
for leaks with a leak detection fluid or soapsuds.
12 If the system is leak tight, release the nitrogen
from the system. For this purpose disconnect the
hose from the nitrogen bottle and open the red,
blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand
wheels on the pressure gauge bar. In case of a
leak no or only an insufficient vacuum will be
reached. In this case proceed as described under
point 9-12. Once the leak is sealed continue with
point 14.
15 Once a sufficient vacuum is reached, both pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.
416 BOMAG 008 911 63

Trouble shooting in refrigerant circuit, basic principles 13.16

13.16Trouble shooting in refriger-
ant circuit, basic principles
Basic principles
Requirements
For trouble shooting two requirements must be ful-
filled:
●
Expert knowledge
●
technical equipment
Technical equipment
The most important aids for trouble shooting are pres-
sure gauges and thermometer. The refrigerant condi-
tions, like overheating and excessive cooling provide
important Information when searching for faults. Even
your own senses are important aids for trouble shoot-
ing. Bubbles in the sight glass, dirt and white frost can
be visibly perceived. If the compressor draws in wet
steam, this can be noticed by the suction line and it
may also be audibly detectable. An overloaded com- Fig. 2 Pressure gauge
pressor can even be smelled.
Example:
The following tools and auxiliary materials should be
A totally empty air conditioning system holds an at-
available for trouble shooting:
mospheric pressure of approx. Pamp = 1 bar.
●
Service station
Filling the system with refrigerant causes an excess
●
Pressure gauge pressure of Pe = 3 bar.
●
Thermometer
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
●
dry nitrogen
●
Refrigerant bottle for new refrigerant Evacuating the system down to Pe = -0.6 bar, creates
a "vacuum" (negative excess pressure).
●
Container for old oil
●
Vacuum pump Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
●
Hoses
●
Scales
●
Suction station
●
Leak detector
The measuring equipment must be checked at regular
intervals. Calibration can only be made by an ap-
proved testing authority.
Pressure gauge
Most pressure gauges used in practice are (for cost
reasons) excess pressure gauges. These pressure
gauges measure the excess pressure in relation to the
ambient pressure (air pressure). In order to achieve
the absolute (actual) pressure the ambient pressure
must be added to the pressure gauge reading. The
absolute pressure is needed for the calculation and
determination of material data.
Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = excess pressure (pressure gauge reading)
008 911 63 BOMAG 417

13.16 Trouble shooting in refrigerant circuit, basic principles
Pressure gauge with saturation temperature scale If the suction condition of the compressor is directly on
the dew line, an e.g. incorrect evaporator load can
cause "wet suction". This can lead to two processes,
which are destructive for the compressor. The liquid
refrigerant washes off the lubricating film between pis-
ton and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in
the cylinder causes a direct energy transfer from pis-
ton to cylinder cover during compression. The valve
plate may then be damaged by so-called fluid strokes.
Apart from protecting the compressor against fluid,
overheating has further advantages. Since the fluid
proportions in the drawn in steam reduces the flow
rate of the compressor, it may be increased by a over-
heating. Overheating also improves the oil recircula-
tion.
Common overheating values
The optimal overheating value is approx. 5 - 8 Kelvin.
With this overheating the maximum system power is
reached. However, the thermostatic expansion valve
Fig. 3 Absolute pressure gauge is unable to regulate this value exactly. Depending on
design and operating conditions overheating fluctu-
Temperature scales on the pressure gauges always
ates within a range between 4 and 12 Kelvin. The in-
refer to the absolute pressures Pabs. Please note that
fluence of the ambient air on the suction line causes
it is not possible to measure a temperature directly
an additional overheating effect.
with a pressure gauge. The indicated temperatures
are just reference values. Only the saturation temper- Overheating is calculated as follows:
ature is assigned to the measured pressure.
∆ to2h = to2h - to
If the refrigerant is fluid, the temperature is below the
saturation temperature. ∆ to2h, overheating at evaporator outlet in K
If the refrigerant is gaseous, the temperature is above to2h, temperature at evaporator outlet in °C
the saturation temperature. to, evaporation temperature in °C
Pressure gauges must indicate 0 bar when not con- „h“ represents "overheated"
nected to the system.
Low pressure gauges have a blue, high pressure Supercooling
gauges a red border.
Thermometer
It is the function of the expansion valve to reduce the
Normally digital thermometers with surface or contact refrigerant to a lower pressure level (evaporation
feelers are used. Especially for high temperature dif- pressure) after it has been liquefied. For an optimal
ferences excellent heat insulation of the measuring lo- function of the valve pure fluid must be applied to its
cation is of utmost importance. The sparing use of a inlet port.
heat conducting paste is highly recommended. If the
The refrigerant must "squeeze" (literally speaking)
measuring location is soiled, it needs to be cleaned
through a throttle gap inside the expansion valve.
and probably treated with a fine emery cloth. Only the
When comparing a certain mass of refrigerant in fluid
temperature of the feeler is measured. Due to missing
and in vaporous state (with constant pressure), the
heat insulation and insulating oxide layers on the line,
vaporous refrigerant requires a much higher volume.
temperature differences of a few degrees Kelvin be-
That's why the vaporous refrigerant needs a much
tween the measured and the actual values may arise.
longer time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve
Overheating
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are If the refrigeration system is operated with the "expan-
not compressible and must therefore not enter into the sion valve inlet" condition directly on the boiling curve,
compression chamber of the compressor. slightest fluctuations in operating condition may cause
418 BOMAG 008 911 63

Trouble shooting in refrigerant circuit, basic principles 13.16

a formation of bubbles in front of the expansion ele-
ment.
For this reason one shifts the condition "Expansion
Valve Inlet" away from the boiling curve into the fluid
area and refers to this condition as Supercooling. This
supercooling ensures a fluid supply in front of the ex-
pansion valve.
Common supercooling values
In systems with fluid container the supercooling at the
fluid container outlet is approx. Zero "0" Kelvin (as-
sumed that the system is filled with the correct refrig-
erant quantity). In this case the fluid container
provides the required fluid supply.
Supercooling is calculated as follows:
∆ tc2u = tc - tc2u

∆ tc2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
„u“ represents "supercooled"
008 911 63 BOMAG 419

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

1 Hot gas line (overheated steam)
2 Deheating (overheated steam)
3 Condenser / liquefier
4 Condensation (wet steam)
5 Fluid line (supercooled fluid)
6 Expansion valve
7 Injection line (wet steam)
8 Evaporation (wet steam)
9 Evaporator
10 Overheating (overheated steam)
11 Suction steam line (overheated steam)
12 Compressor
13 Supercooling (fluid)
14 Compression
15 Expansion
420 BOMAG 008 911 63

Trouble shooting, refrigerant circuit diagram 13.17

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

1 Cold air 14 Condenser
2 Evaporator 15 Cooling air
3 Thermostat 16 Pressure gauge, low pressure
4 Warm air
5 Fan
6 Inspection glass
7 Expansion valve
8 Pressure gauge, high pressure
9 Pressure switch with high and low pressure con-
tacts
10 Dryer
11 Fluid container
12 Hot air
008 911 63 BOMAG 421

13.18 Trouble shooting procedure
13.18Trouble shooting procedure ●

Evaporator and heating (with highest fresh air fan
speed) do not draw leak air.
●
The fresh air fan runs when the engine is running
Procedure
and the air conditioning system is set to max. cool-
Knowledge ing power.
Trouble shooting is not possible with exact knowledge
●
Ambient temperature above 15 °C.
about the system design, the installed components ●
The thermostat is correctly installed and the switch-
and their function in the system trouble shooting is not ing temperatures are correct.
possible:
Visual inspection
With the appropriate experience some faults can be
visually detected or felt. Frequently occurring con-
denser soiling or formation of steam bubbles in the in-
spection glass can be quickly detected.
In case of unusual formation of hoarfrost on the evap-
orator the hoarfrost pattern provides useful informa-
tion. Hoarfrost only occurring at the inlet side is a clear
indication of insufficient refrigerant feed, which in turn
indicates an incorrectly working expansion valve or a
lack of refrigerant.. Complete hoarfrost covering indi-
cates load problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the
naked eye. At the end of the evaporator there should
be an area which is dry or at least drier at evaporator
temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a
local cooling can be felt or if condensation develops,
this is a clear indicator for an extreme pressure drop
in the line. Similar phenomena can be noticed in case
of blocked filters.
Unusually cold pressure lines indicate "wet" intake of
the compressor.
The oil level in the compressor sight glass provides in-
formation about the oil quantity and the oil recircula-
tion in the system. However, the oil level may also be
considerably influenced by condensing refrigerant.
Discoloration informs about the state of the oil.
Water in the system can simply be detected through
the inspection glass with moisture indicator.
i Note
The dangerous part of common rules is that they ap-
ply in most, but not in all cases. The refrigerant states
in the individual piping sections or components must
therefore be exactly determined by means of pressure
and temperature measurements.
Test prerequisites
●
Cooler and condenser are clean, clean if neces-
sary.
●
The ribbed belt for compressor and generator is
correctly tightened.
●
All air ducts, covers and seals are OK and correctly
fitted. Flaps reach their end positions.
●
The engine has operating temperature.
422 BOMAG 008 911 63

Trouble shooting procedure 13.18

Measuring points and measurements
Fig. 2 Flow diagram with measuring points to assess the filling quantity. In systems with fluid con-
●
C, condenser measuring points tainer the inspection glass is most suitable to check
●
E, expansion valve measuring points the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
●
O, evaporator measuring points
The hot gas temperature can be used to check wheth-
●
V, compressor measuring points
er the compressor runs in the permissible operating
The flow diagram contains "Minimum Requirements" range.
which must be fulfilled to be able to check the system
or perform trouble shooting. Example: Measurement of overheating
Temperature and pressure at the evaporator outlet
●
a) Which measuring equipment is required ?
can be used to derive the overheating of the evapora- ●
b) Where to measure with which size ?
tor. Overheating is a clear indicator for the evaporator ●
c) A pressure gauge connected to the evaporator
filling level. In case of excessive overheating the re- indicates "Peo2 = 1.7 bar". How high is the evapora-
frigerant quantity fed into the evaporator is too low, in tor pressure "Po" ?
case of insufficient overheating it is too high. In indi-
vidual cases one must then check if this situation is ●
d) How high is the evaporator temperature "to" ?
caused by the expansion element or by insufficient fill- ●
e) A thermal sensor attached to the evaporator out-
ing. A differentiation is only possible if there is a clear let measures the temperature "to2h = +3 °C". How
indicator for the refrigerant filling quantity. high is the overheating „∆to2h“ ?
Pressure and temperature at the condenser outlet can ●
f) Evaluation of the measured overheating.
be used to derive the supercooling. This can be used
008 911 63 BOMAG 423

Solution: be a defect in the expansion valve or problems in the

●
a) Pressure gauge, thermometer, steam table oil recirculation.
●
b) Evaporation pressure "Peo2" and temperature The following list contains pressure values in a sys-
"to2h" are measured at the same point on the evap- tem, that can be expected at various ambient temper-
atures (measured at medium speeds).
orator outlet.
●
c) Po = Peo2 + Pamb, "Evaporation pressure = Suction pressure (low pressure gauge)
pressure on evaporator + atmospheric pressure" =
Ambient temperature in °C Excess pressure in bar
1.7 bar + 1 bar = 2.7 bar.
25 approx. 2,0
●
d) "Pc" = 2,7 bar can then be used to derive an con- 30 approx. 2,5
densing temperature "to" of -2,2 °C from the steam 35 approx. 3
table for R134a. High pressure (high pressure gauge)
●
e) ∆to2h = to2h - to, „Overheating at evaporator out-
let = evaporator outlet temperature - evaporation Ambient temperature in °C Excess pressure in bar
temperature" = 3 °C - (-2.2 °C) = 5.2 Kelvin. 25 approx. 8,0
35 approx. 13
●
f) The determined overheating is within the usual 40 approx. 16
range of 4 - 12 Kelvin. 45 approx. 18
Example: Measuring supercooling
●
a) Which measuring equipment is required ?
●
b) Where to measure with which size ?
●
c) A pressure gauge connected to the condenser in-
dicates "Pec2 = 15 bar". How high is the condensing
pressure "Pc" ?
●
d) How high is the condensing temperature "tc" ?
●
e) A thermal sensor attached to the condenser out-
let measures the temperature "tc2u = 58 °C". How
high is the supercooling "∆tc2u" ?
●
f) Evaluation of the measured supercooling.
Solution:
●
a) Pressure gauge, thermometer, steam table
●
b) Condensing pressure "Pec2" and temperature
"tc2u" are measured at the same point on the con-
denser.
●
c) Pc = Pec2 + Pamb, "Evaporation pressure =
pressure on evaporator + atmospheric pressure" =
15 bar + 1 bar = 16 bar.
●
d) "Pcc = 16 bar can then be used to derive an con-
densing temperature "tc" of 57.9 °C from the steam
table for R134a.
●
e) ∆tc2u = tc - tc2u, "Supercooling at condenser out-
let = condensing temperature - condenser outlet
temperature" = 57.9°C - 58 °C) = -0.1 Kelvin.
●
f) The determined overheating is within the usual
range of approx. "0" Zero Kelvin.
Typical faults and possible causes
Most faults in the refrigerant side of the system can be
clearly assigned with the help a checklist. r Occur-
ring faults frequently have a similar appearance, but
different causes. An evaporator showing hoarfrost
may be quite normal. However, there may also
424 BOMAG 008 911 63


Values effecting the operating pressures tions, it is mandatory to know these dependencies.
Since the pressures occurring in a refrigeration sys- The following table contains some of these dependen-
tem are highly dependent on environmental condi- cies.
Measuring value Suction pressure High pressure
increases drops increases drops
Compressor speed increases X X
drops X X
Vehicle interior tempera- increases X X
ture drops X X
Ambient temperature increases X X
drops X X
Humidity increases X X
drops X X
008 911 63 BOMAG 425

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
426 BOMAG 008 911 63


Suction pressure normal (1), high pressure too
high (2)
Fig. 4

Condenser dirty high hot gas temperature, low cool- clean
ing power
Condenser fan failed high hot gas temperature, high pres- repair
sure shut down
overfilled high hot gas temperature, low su- Correct the filling capacity
percooling, low cooling power
Leak gas (air) high hot gas temperature, low renew filling
measured supercooling, low cooling
power
Restriction between compressor and high hot gas temperature, low cool- Check lines and valves
condenser ing power
008 911 63 BOMAG 427

Suction pressure too high (1), high pressure too

low to normal (2)
Fig. 5

Compressor defective Cooling power too low Replace the compressor
428 BOMAG 008 911 63


Suction pressure too high (1), high pressure too
high (2)
Fig. 6

Expansion valve defective overheating too low, wet operation Replace the valve
of compressor
008 911 63 BOMAG 429

Other faults
Symptom Cause Possible effect Remedy

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

V-belt loose or excessively worn V-belt slips and generates noise Retention or renew the V-belt
Magnetic clutch loud Magnetic clutch runs until high pres- Repair or replace the magnetic
sure builds up, then the clutch starts clutch
to slip
Refrigerant compressor is loud Mounting bracket is loose, internal Repair the mounting bracket, re-
parts worn, low oil level in compres- place the compressor, renew the re-
sor frigeration oil
Fan is loud, fan motor excessively Replace the fan motor
worn
Whistling and rattling noise in opera- V-belt pulley and bearing worn Replace the bearing, check V-belt
tion, noticeable unevenness when pulley for wear
turning by hand
Rattling noise or vibration of high System overfilled Draw out refrigerant
pressure line, knocking noise in
compressor, ball in inspection glass
floating at the top
Expansion valve loud excessive moisture in system Replace the dryer
Hissing noise in evaporator housing, refrigerant level in system too low Perform a leak test, fill up the system
on expansion valve, turbidity in in-
spection glass or ball does not float
430 BOMAG 008 911 63


Inspection glass

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

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

008 911 63 BOMAG 431

13.19 Steam table for R134a
Tempera- Pres- Density spec. volume spec. enthalpy Evapora-

ture sure tion heat
of the fluid of the of the fluid of the of the fluid of the
steam steam steam
432 BOMAG 008 911 63

Steam table for R134a 13.19
008 911 63 BOMAG 433

434 BOMAG 008 911 63

Steam table for R134a 13.19
008 911 63 BOMAG 435

436 BOMAG 008 911 63

14 Replacing the cab window panes
008 911 63 BOMAG 437

14.1 Assembly of window panes
Fig. 1
1 Glass panes
2 Fastening element
3 Fixing washer and spacer
4 Washer
5 Hexagon nut, self locking
6 Protective cap
438 BOMAG 008 911 63

Special tools 14.2

14.2 Special tools
1. Locking handle for fastening element
Fig. 1
2. Suction lifter
commercial
Fig. 2
008 911 63 BOMAG 439

14.3 Auxiliary materials
14.3 Auxiliary materials

Safety gloves
3. Cutter
Commercial
Fig. 1
4. Window glass bonding agent
Fig. 2
5. Activator
Fig. 3
440 BOMAG 008 911 63

Auxiliary materials 14.3

6. Silicone sealant
Fig. 4
008 911 63 BOMAG 441

14.4 Removing and installing the window pane
14.4 Removing and installing the window

pane
Environment
Dispose of glass splinters fro0m machine and
cabin or inside cabin in an environmentally
friendly way.
! Danger
Danger of cutting
Wear safety gloves.
1. Pull large glass rests off the bonding strip (Fig. 1).
Fig. 1
2. Clean the sealing surfaces from any adhesive
material (Fig. 2).
3. Use a cutter to remove adhesive residues with
glass rests.
4. Cover places without adhesive residues with an
activator.
Fig. 2
5. Insert the fastening element with washer into the
bore in the glass pane (Fig. 3).
Fig. 3
442 BOMAG 008 911 63

Removing and installing the window pane 14.4

6. Turn the fixing and spacer washer hand-tight onto
the thread of the fastening element (Fig. 4).
i Note
Do not overtighten the thread.
Fig. 4
7. Lay an approx. 1 cm high triangular bead of glass
pane bonding agent on the inside of the pane, ap-
prox. 1.5 cm away from the edge (Fig. 5).
i Note
Apply window pane bonding agent only to the
sides (sealing areas) which have contact with the
cabin.
Fig. 5
8. Attach the suction lifter to the outside of the pane
(Fig. 6).
9. Install the window pane so that the fastening ele-
ments fit into the bores of the fastening bars.
10. Press the glass pane against the sealing surface.
Fig. 6
11. Assemble the washer and the self-locking hexa-
gon nut.
12. Fasten the window pane to the fastening bar us-
ing a locking handle and a ring spanner (Fig. 7).
i Note
Only use the locking handle to counter.
13. Press the protective cap onto the hexagon nut.
Fig. 7
008 911 63 BOMAG 443

14. Remove the suction lifter (Fig. 8).
Fig. 8
15. Clean the joining edges on the window pane (Fig.
9).
i Note
The joint flanks must be solid, dry and free of dirt,
dust, grease, oil and other foreign substances.
16. Mask the upper and lower contact areas to the
cabin.
Fig. 9
17. Apply silicone sealant evenly and under pressure
first to the inside joint edge (Fig. 10).
Fig. 10
18. Then apply silicone sealant evenly and under
pressure to the outside joint edge (Fig. 11).
Fig. 11
444 BOMAG 008 911 63

Removing and installing the window pane 14.4

19. Then spray the joints from inside and outside with
water containing washing up liquid (Fig. 12).
Fig. 12
20. Treat the inside joint (Fig. 13)
Fig. 13
21. and the outside joint (Fig. 14) with a scraper or a
spattle.
i Note
Once the silicone sealing agent has cured it can
only be removed mechanically.
Fig. 14
008 911 63 BOMAG 445

446 BOMAG 008 911 63

15 Drum
008 911 63 BOMAG 447

15.1 Special tools, drum, single drum rollers
15.1 Special tools, drum, single drum roll-

ers
1. Disassembly device for side plate
Fig. 1
2. Assembly device for side plate
Fig. 2
3. Assembly device for coupling hub and flanged
hub
Fig. 3
448 BOMAG 008 911 63

Special tools, drum, single drum rollers 15.1

4. Pressing plate for cylinder roller bearing
Fig. 4
5. Pressing plate for travel bearing
Fig. 5
6. Pressing bushing for radial seal
Fig. 6
7. Lifting device for exciter unit
Fig. 7
008 911 63 BOMAG 449

15.2 Repair overview for drum
450 BOMAG 008 911 63

Repair overview for drum 15.2

1 Drum 13 Flanged hub
2 Cylinder roller bearing 14 Vibrator shaft
3 Coupling 15 Coupling
4 Vibration motor 16 Vibrator shaft
5 Cover 17 Change-over weight
6 Grooved ball bearing 18 Cylinder roller bearing
7 Spacer block 19 Basic weight
8 Rectangular rubber buffer 20 Flanged housing
9 Side plate 21 Flange
10 Spacer ring 22 Cylinder roller bearing
11 Grooved ball bearing 23 Cover
12 Mechanical seal
008 911 63 BOMAG 451

452 BOMAG 008 911 63

008 911 63 BOMAG 453

454 BOMAG 008 911 63

008 911 63 BOMAG 455

456 BOMAG 008 911 63

Removing and installing the drum 15.3

15.3 Removing and installing the drum
i Note
After disassembling the side plate (vibration mo-
tor side) the drum can be lifted sideways out of
the frame (Fig. 1).
Fig. 1
i Note
However, the drum can also be removed without
having to disassemble the side plate, if it is lifted
up and out of the frame (Fig. 2).
Fig. 2
Removing the drum
i Note
The following section describes the procedure for
lifting the frame sideways out of the drum.
Environment
Catch running out hydraulic oil and dispose
of environmentally.
1. Mark the hydraulic hoses (Fig. 3)on the travel mo-
tor and disconnect them from the ports.
2. Close all hydraulic hoses and motor ports with
suitable plugs.
Fig. 3
008 911 63 BOMAG 457

3. Mark the hydraulic hoses on the vibration motor

(Fig. 4) and disconnect them from the ports.
4. Close all hydraulic hoses and motor ports with
suitable plugs.
Fig. 4
5. Unscrew screws 1 (Fig. 5) from holding plate (2)
for hydraulic hoses from both sides.
Fig. 5
6. Unscrew screws (Fig. 6) from the spacer piece on
vibration and travel motors.
Fig. 6
7. Fasten the lifting gear to the side plate on the vi-
bration side.
8. Support the front cross-member safely with suita-
ble trestles or wooden blocks (Fig. 7).
9. Unscrew plugs (1) and screws (2).
Fig. 7
458 BOMAG 008 911 63


10. Support the rear cross-member safely with suita-
ble trestles or wooden blocks (Fig. 8).
11. Unscrew plugs (1) and screws (2).
! Danger
Danger of squashing! Do not stand or step
under loads being loaded.
12. Take off the side plate.
Fig. 8
13. Fasten the lifting tackle to the drum and lift the
drum carefully sideways out of the front frame
(Fig. 9).
! Danger
under loads being loaded.
Fig. 9
14. Check all rubber buffers (Fig. 10), replace if nec-
essary (see corresponding chapter).
Fig. 10
15. Check rectangular rubber buffers (Fig. 11), re-
place if necessary.
Fig. 11
008 911 63 BOMAG 459

Installing the drum

! Danger
Danger of squashing!
Do not stand or step under loads being load-
ed.
1. Place the drum into the frame and align it parallel
to the frame (Fig. 12).
Fig. 12
2. Attach the side plate, insert screws 2 (Fig. 13) into
the rear cross-member, slide on washers, turn on
and tighten the nuts.
i Note
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
3. Close the screw holes with plugs (1).
Fig. 13
4. Attach the side plate, insert screws 2 (Fig. 14) into
the rear cross-member, slide on washers, turn on
and tighten the nuts.
i Note
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
5. Close the screw holes with plugs (1).
Fig. 14
6. Fasten the spacer pieces with screws (Fig. 15)
and nuts to the side plate.
Fig. 15
460 BOMAG 008 911 63


Adjust the pretension of the rubber buffers.
7. Measure distance „X“ between spacer piece 1
(Fig. 16) and side plate.
8. Calculate the thickness of the compensation
plates.
Nominal value:
Distance "X" + 2 mm
9. Turn one screw (3) into the welded nut (2) at top
and bottom and open a sufficient gap to insert the
compensation plates.
Fig. 16
10. Insert the compensation plates (Fig. 17). Insert
screws (1), slide on washers (3), turn on and
tighten nuts (2).
11. Unscrew the screws from the welded nuts.
Fig. 17
12. Connect hydraulic hoses to the connections on
travel motor and vibration motor according to the
marking.
Fig. 18
13. Fasten holding plate 2 (Fig. 19) for hydraulic hos-
es with screws (1).
! Caution
After connecting the hydraulic components
and before starting operation bleed the hy-
draulic system, check the function and in-
spect the system for leaks.
Fig. 19
008 911 63 BOMAG 461

15.4 Repairing the drum
Removing the travel motor

! Danger
Do not stand or step under suspended loads.
1. Attach the lifting tackle to the travel motor.
2. Unscrew all nuts (Fig. 3) from the rubber buffers.
3. Take the drive disc with the travel motor off the
rubber buffers.
Fig. 1
4. Unscrew the nuts, pull out the screws and re-
move the support legs (Fig. 4).
Fig. 2
5. Attach the lifting tackle to the travel motor (Fig. 3).
! Danger
Fig. 3
462 BOMAG 008 911 63

Repairing the drum 15.4

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

motor side)
1. Unscrew both socket head cap screws from the
flange (Fig. 5).
Fig. 5
2. Mount bracket 1 (Fig. 8) for the lifting device to
the flange.
3. Unscrew screws (2) from the flange.
i Note
Do not unscrew the thin drawn screws.
Fig. 6
008 911 63 BOMAG 463

4. Slide the lifting device over the bracket.

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

motor side)
1. Unscrew fastening screws 1 (Fig. 9) for the fan.
2. Loosen clamping screw (2).
3. Pull the coupling hub off the shaft.
Fig. 9
464 BOMAG 008 911 63


4. Unscrew all other fastening screws 1 (Fig. 10)
from the flange.
5. Press the flange off the flanged housing with forc-
ing screws (2).
Fig. 10
Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.
6. Lift the flange off the flanged housing (Fig. 11).
7. Take the O-ring out of the groove in the flanged
housing.
Fig. 11
8. Unclip the circlip from the groove in the flange
(Fig. 12).
Fig. 12
9. Press the cylinder roller bearing with forcing
screws out of the flange (Fig. 13).
Fig. 13
008 911 63 BOMAG 465

10. Take the exciter unit (Fig. 14) out of the flanged
housing.
Fig. 14
11. Knock the radial seal (Fig. 15) out of the flanged
housing.
Fig. 15
12. Unclip the circlip from the groove in the flanged
housing (Fig. 16).
Fig. 16
screws out of the flanged housing (Fig. 17).
Fig. 17
466 BOMAG 008 911 63


14. Extract inner ring 1 (Fig. 18) for the radial seal
and inner bearing races (2).
! Danger
Danger of burning!
Wear safety gloves.
i Note
If the rings are very tight, heat them up with a
torch.
Fig. 18
15. Unclip the circlip from the basic weight (Fig. 19).
Fig. 19
16. To change shaft 1 (Fig. 20) knock out dowel pins
(2 and 3) and press the shaft out of the basic
weight.
i Note
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).
Fig. 20
008 911 63 BOMAG 467

Disassembling the exciter unit (vibra-

tion motor side)
1. Unscrew fastening screw 1 (Fig. 21).
2. Take rectangular rubber buffer (2) with spacer
block (3) off the side plate.
i Note
Remove both rectangular rubber buffers.
Fig. 21
3. Unscrew fastening screws 1 (Fig. 22).
4. Force cover (2) together with the attached vibra-
tion motor off the side plate with forcing screws.
Fig. 22
5. To change the vibration motor loosen clamping
screw 1 (Fig. 23) and pull off coupling half (2).
Fig. 23
468 BOMAG 008 911 63


6. Unscrew nut 1 (Fig. 24), take off conical socket
(2) and conical disc (3).
7. Take the vibration motor off the cover.
Fig. 24
8. Remove the coupling element (Fig. 25).
Fig. 25
9. Fasten the lifting device.
! Caution
The four short fastening screws (2) must re-
main screwed in (the two others are not visi-
ble).
Fig. 26
11. Press the exciter unit out of the drum with forcing
screws (Fig. 27).
i Note
The second forcing screw is covered by the side
plate.
Fig. 27
008 911 63 BOMAG 469

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

1. Take off V-ring 1 (Fig. 29).
2. Unclip circlip (2).
Fig. 29
3. Attach the disassembly device to the side plate
(Fig. 30) and force off the side plate.
Fig. 30
4. Lift the side plate of the flanged hub (Fig. 31).
Fig. 31
470 BOMAG 008 911 63


5. Knock the grooved roller bearing out of the side
plate (Fig. 32) and take out the spacer ring.
Fig. 32
6. Unclip the circlip from the side plate (Fig. 33).
Fig. 33
7. Take the mechanical seal off the flanged hub
(Fig. 34).
Fig. 34
008 911 63 BOMAG 471

Dismantling the exciter unit (vibration

motor side)
1. Unscrew the fastening from the coupling hub.
2. Pull coupling hub (2) off the shaft using a pulling
device (Fig. 35).
Fig. 35
3. Loosen hose clamp 1 (Fig. 36).
4. Pull coupling hub (2) off the shaft.
Fig. 36
5. Unscrew all other fastening screws 1 (Fig. 37)
and press the flanged hub off the flanged housing
with forcing screws (2).
6. Take off the flanged hub.
7. Take the O-ring out of the groove in the flanged
housing.
Fig. 37
472 BOMAG 008 911 63


hub (Fig. 38).
Fig. 38
9. Knock the cylinder roller bearing out of the flang-
ed hub (Fig. 39).
Fig. 39
Environment
Environmental damage!
mentally.
10. Lift the exciter unit out of the flanged housing (Fig.
40).
Fig. 40
11. Knock the radial seal (Fig. 41) out of the flanged
housing.
Fig. 41
008 911 63 BOMAG 473


housing (Fig. 42).
Fig. 42
screws out of the flanged housing (Fig. 43).
Fig. 43
14. Extract inner rings 1 (Fig. 44) for the radial seals
and inner bearing races (2) from the shaft.
! Danger
Danger of burning!
Wear protective gloves.
i Note
If the rings are very tight, heat them up with a
torch.
Fig. 44
15. Unclip the circlip from the basic weight and re-
move the cover (Fig. 45).
i Note
The shafts cannot be pressed out. If damaged
they must be replaced with basic weight and cov-
er.
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).
Fig. 45
474 BOMAG 008 911 63


Assembling the exciter unit (vibration
motor side)
! Caution
Ensure strict cleanliness.
i Note
If the shafts are damaged they must be inserted
into the basic weight or the cover as follows.
! Danger
When working with liquid nitrogen protect
your face and wear gloves.
Do not place any unintended parts into liquid
Fig. 46 nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.
! Caution
Close the bores on the short shaft with a
screw.
1. Cool the shaft down in liquid nitrogen.
2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
46).
3. Secure shaft 1 (Fig. 47) with dowel pins (2 and 3).
! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.
i Note
Unscrew the screw from the shaft.
Fig. 47
! Caution
Close the bores on the short shaft with a
screw.
48).
Fig. 48
008 911 63 BOMAG 475

! Caution
i Note
Unscrew the screw from the shaft.
Fig. 49
7. Insert the fitting key into the keyway in the respec-
tive shaft (Fig. 50).
Fig. 50
8. Insert the circlip into the groove in the basic
weight and on the cover (Fig. 51).
Fig. 51
! Danger
Danger of burning!
Wear safety gloves.
9. Heat the inner bearing race up to approx. 100° C
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 52).
Fig. 52
476 BOMAG 008 911 63


! Danger
Danger of burning!
Wear safety gloves.
10. Heat the inner ring up to approx. 50° C and slide
it onto the short shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 53).
Fig. 53
! Danger
Danger of burning!
Wear safety gloves.
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 54).
Fig. 54
! Danger
Danger of burning!
Wear safety gloves.
it onto the longer shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 55).
Fig. 55
13. Press cylinder roller bearing 1 (Fig. 56) with
pressing plate (2) into the flanged housing until it
bottoms.
Fig. 56
008 911 63 BOMAG 477

14. Insert the circlip into the groove in the flanged

housing (Fig. 57).
Fig. 57
15. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 58).
16. Fill approx. 1.2 l oil SAE-15W/40 into the flanged
housing.
Fig. 58
! Caution
17. Insert the exciter unit with the longer shaft for-
ward into the flanged housing (Fig. 59).
Fig. 59
pressing plate (2) into the flanged hub until it bot-
toms.
Fig. 60
478 BOMAG 008 911 63


19. Insert the circlip into the groove in the flanged hub
(Fig. 61).
Fig. 61
20. Attach the flanged hub to the flanged housing
(Fig. 62).
! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
21. Unscrew eye bolts (1) and replace them with
short screws.
22. Turn short screws (2) into the tapped bores in the
flanged housing (four screws) and tighten them.
Fig. 62
23. Apply some grease to the sealing lip of radial seal
1 (Fig. 63).
24. Insert the radial seal into the flanged hub with the
sealing lip facing down and press it down against
the stop with pressing bushing (2).
Fig. 63 ! Danger
Danger of burning!
Wear protective gloves.
25. Heat the coupling hub up to approx. 80 °C and
slide it onto the shaft against the stop (Fig. 64).
Fig. 64
008 911 63 BOMAG 479


1 (Fig. 65).
27. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).
Fig. 65
28. Cover the thread of screw 1 (Fig. 66) with a screw
retention agent (e.g. Loctite CVX strong, blue,
582).
29. Slide on the new U-seal ring (2), turn in and tight-
en the screws.
Fig. 66 ! Danger
Danger of burning!
Wear safety gloves.
30. Heat coupling hub 1 (Fig. 67) with marking letter
“L“ up t approx. 80° C and slide it over the shaft
against the shoulder.
31. Turn in and tighten clamping screw (2).
Fig. 67
480 BOMAG 008 911 63


Assembling and installing the side
plate
1. Fill grooved ball bearing 1 (Fig. 68) on both sides
with grease.
2. Press the grooved ball bearing completely in us-
ing pressing plate (2).
Fig. 68
3. Insert the circlip into the groove in the side plate
(Fig. 69).
Fig. 69
4. Apply a thick coat of grease to the spacer ring on
both sides and insert it into the side plate (Fig.
70).
Fig. 70
008 911 63 BOMAG 481

5. Fill grooved ball bearing 1 (Fig. 71) on one sides

with grease.
6. Insert the grooved ball bearing with the grease
side forward and press it completely in with
pressing plate (2).
i Note
Grease the other side after installing the exciter
unit.
Fig. 71
7. Insert the oiled loop-ring into the mechanical seal
(Fig. 72).
8. Clean the sliding surfaces of the mechanical seal
and cover them with oil.
Fig. 72
9. Lay one half of the radial seal on the flanged hub
with the sliding surface pointing up (Fig. 73).
Fig. 73
10. Lay the second half of the mechanical seal down
with the sliding face pointing down (Fig. 74).
Fig. 74
482 BOMAG 008 911 63


11. Bolt the threaded section of the assembly device
to the flanged hub (Fig. 75).
Fig. 75 ! Caution
under suspended loads.
12. Lay the side plate on the flanged hub (Fig. 76).
Fig. 76
13. Attach bushing 2 (Fig. 77) of the assembly device
and turn on nut (1).
Fig. 77
14. Pull the side plate with the assembly device onto
the flanged hub.
! Caution
During assembly make sure that the mechan-
ical seal slides correctly into the side plate
and the loop rings are not damaged (Fig. 78).
Fig. 78
008 911 63 BOMAG 483

15. Remove the assembly device.

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

motor side)
! Danger
When working with liquid nitrogen protect
your face and wear gloves.
Do not place any unintended parts into liquid
nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.
! Caution
Ensure strict cleanliness.
Fig. 80
80).
! Caution
Fig. 81
484 BOMAG 008 911 63


4. Insert the circlip into the groove in the basic
weight and on the cover (Fig. 82).
Fig. 82
! Danger
Danger of burning!
Wear safety gloves.
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 83).
Fig. 83
! Danger
Danger of burning!
Wear safety gloves.
it onto the shaft against the shoulder with the wid-
er chamfer facing towards the outside (Fig. 84).
Fig. 84 ! Danger
Danger of burning!
Wear safety gloves.
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 85).
Fig. 85
008 911 63 BOMAG 485


pressing plate (2) into the flanged housing until it
bottoms.
Fig. 86
9. Insert the circlip into the groove in the flanged
housing (Fig. 87).
Fig. 87
10. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 88).
11. Fill approx. 1.2 l oil SAE-15W/40 into the flanged
housing.
Fig. 88 ! Caution
12. Insert the exciter unit into the flanged housing
(Fig. 89).
Fig. 89
486 BOMAG 008 911 63


pressing plate (2) into the flange until it bottoms.
Fig. 90
14. Insert the circlip into the groove in the flange (Fig.
91).
Fig. 91
15. Lift the flange onto the flanged housing and align
it the bores (Fig. 92).
! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
Fig. 92
16. Turn the screws into the tapped bores of the
flanged housing and tighten them (Fig. 93).
Fig. 93
008 911 63 BOMAG 487


1 (Fig. 94).
18. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).
Fig. 94
19. Cover the thread of screw 1 (Fig. 95) with a screw
retention agent (e.g. Loctite CVX strong, blue,
582).
20. Slide on the new U-seal ring (2), turn in and tight-
en the screws.
Fig. 95
21. Insert the fitting key into the keyway of the shaft
(Fig. 96).
Fig. 96 ! Danger
Danger of burning!
Wear safety gloves.
22. Slide the fan with assembly disc over the shaft.
23. Heat coupling hub 1 (Fig. 97) with marking letter
“R“ up to approx. 80° C and slide it over the shaft
against the shoulder.
24. Turn in and tighten clamping screw (2).
25. Assemble the fan to the coupling hub.
Fig. 97
488 BOMAG 008 911 63


Assembling the exciter unit (travel
motor side)
1. Check coupling elements, replace if necessary.
2. Insert the coupling element into the coupling hub
(Fig. 98).
! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.
3. Fasten the lifting device to the exciter unit.
Fig. 98 ! Caution
4. Insert the vibrator unit into the drum (Fig. 99).
Fig. 99
i Note
Insert the exciter unit so that oil filler plug 1 (Fig.
100) is in line with bore (2) in the drum.
Fig. 100
008 911 63 BOMAG 489

5. Turn in and tighten screws 2 (Fig. 101).

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

! Danger
1. Fasten the lifting tackle to the travel motor and at-
tach the motor to the drive disc (Fig. 103).
Fig. 103
2. Turn in and tighten the fastening screws (Fig.
104).
Fig. 104
490 BOMAG 008 911 63


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

motor side)
! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.
! Danger
1. Fasten the lifting gear to the exciter unit and insert
it into the drum (Fig. 107).
Fig. 107
008 911 63 BOMAG 491

! Caution
Ensure correct engagement of coupling and
alignment of shaft (Fig. 108).
If the shafts are not correctly in line determine
the cause, if necessary measure the drum.
Fig. 108
2. Turn in and tighten screws 1 (Fig. 109).
3. Remove the lifting gear.
4. Fit cover (2) to the drum.
Fig. 109
5. Check the end float of the exciter shafts (Fig.
110).
Nominal value: 0.6...1.8 mm
Fig. 110
6. Attach disc 1 (Fig. 111), turn in and tighten the
fastening screws (2).
Fig. 111
492 BOMAG 008 911 63


7. Lay a new V-ring over the journal of the flanged
hub (Fig. 112).
8. Fill the grooved ball bearing with grease.
Fig. 112
9. Check coupling element, replace if necessary.
10. Insert the coupling element into the coupling hub
(Fig. 113).
Fig. 113
11. Fasten the vibration motor to the cover so that
sockets 1 (Fig. 114) and ventilation bore (2) are
opposite each other.
Fig. 114
12. Slide on coupling half 2 (Fig. 115) and secure with
clamping screw (1).
Fig. 115
008 911 63 BOMAG 493

13. Attach the cover with the installed vibration mo-

tor, turn in and tighten the screws (Fig. 116).
Fig. 116
14. Install rectangular rubber buffers 2 (Fig. 117) with
attached spacer block (3) and screws (1) to the
side plate.
i Note
Assemble both rectangular rubber buffers.
Fig. 117
494 BOMAG 008 911 63

Disassembling and assembling the change-over weight 15.5

15.5 Disassembling and assembling the
change-over weight
Dismantling the change-over weight

1. Unscrew all screws (Fig. 3).
Fig. 1
2. Force the cover with forcing screws (Fig. 4) off the
basic weight.
Environment
Environmental hazard!
mentally.
Fig. 2
3. Take the change-over weight out of the basic
weight (Fig. 5).
Fig. 3
008 911 63 BOMAG 495

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

grooves.
Fig. 4
Assembling the change-over weight

1. Insert the new O-rings 1 and 2 (Fig. 5) with
grease.
Fig. 5
2. Place the change-over weight into the basic
weight (Fig. 6).
Fig. 6
3. Fill aprox 2,5 litres of silicone oil 47 V 1000 cst (up
to the upper edge of the change-over weight) into
the basic weight (Fig. 10).
Fig. 7
496 BOMAG 008 911 63

Disassembling and assembling the change-over weight 15.5

4. Lay the cover on (Fig. 11), so that the raised are-
as are in line.
5. Screw the screws in with screw locking agent
(e.g. Loctite green 270) and tighten them with
120 Nm.
6. Check the axial clearance of the shaft.
i Note
The shaft must have clearance.
Fig. 8
008 911 63 BOMAG 497

15.6 Changing the rubber buffers and adjusting the pretension
15.6 Changing the rubber buffers and ad-

justing the pretension
Relieve the rubber buffers
1. Lift the frame up by both sides, until rubber buff-
ers and rectangular buffers are relieved of any
load (Fig. 1).
2. Loosen all fastening screws.
Fig. 1
3. Turn one screw each into the welded nuts (Fig. 2)
on the spacer blocks.
Fig. 2
4. Remove the compensation shims 1 (Fig. 3).
Fig. 3
498 BOMAG 008 911 63

Changing the rubber buffers and adjusting the pretension 15.6

5. Unscrew the screws (Fig. 4) from the welded
nuts.
Fig. 4
Changing the rubber buffers
6. Unscrew nut 1 (Fig. 3) and remove the washer.
7. Unscrew screws (2).
8. Take off rubber buffer (3).
9. Attach the new rubber buffer to the drive disc and
align the bores to the tapped bores in the drum.
10. Turn in and tighten the fastening screws.
11. Assemble the washer, turn on and tighten the nut.
Fig. 5
Adjusting the pre-load
12. Measure distance „X“ between spacer piece and
side plate (Fig. 6).
13. Calculate the thickness of the compensation
plates.
Nominal value:
Distance „X“ + 2 mm
Fig. 6
14. Turn in screws into each welded nut and provide
sufficient space to insert the compensation plates
(Fig. 7).
Fig. 7
008 911 63 BOMAG 499

15.6 Changing the rubber buffers and adjusting the pretension
15. Insert the compensation shims 1 (Fig. 8).
Fig. 8
16. Unscrew the screws (Fig. 9) from the welded
nuts.
Fig. 9
17. Tighten the fastening screws (Fig. 10).
18. Lower the frame again.
Fig. 10
500 BOMAG 008 911 63

16 Oscillating articulated joint
008 911 63 BOMAG 501

16.1 Special tools, oscillating articulated joint (BW177 to BW 216)
16.1 Special tools, oscillating articulated

joint (BW177 to BW 216)
1. Pressing device for rocker bearings
Fig. 1
2. Pressing bushing for outer rocker bearing race
Fig. 2
3. Pressing bushing for inner rocker bearing race
Fig. 3
502 BOMAG 008 911 63

Special tools, oscillating articulated joint (BW177 to BW 216) 16.1

4. Guide pin
Fig. 4
5. Clamping device
Fig. 5
6. Disassembly device
Fig. 6
008 911 63 BOMAG 503

16.2 Repair overview oscillating articulated joint
504 BOMAG 008 911 63

Repair overview oscillating articulated joint 16.2
1 Housing 12 Cover
2 Seal ring 13 Cover
3 Cover 14 Intermediate ring
4 Self-aligning bearing 15 Self-aligning bearing
5 Bolt 16 Intermediate ring
6 Shim/supporting disc 17 Self-aligning bearing
7 Belleville springs 18 Carrier
8 Self-aligning bearing 19 Friction bearing
9 Console 20 V-ring
10 Belleville springs 21 Seal ring
11 Shim/supporting disc
008 911 63 BOMAG 505

16.2 Repair overview oscillating articulated joint
506 BOMAG 008 911 63

Repair overview oscillating articulated joint 16.2
008 911 63 BOMAG 507

16.3 Removing and installing the oscillating articulated joint
16.3 Removing and installing the oscillat-

ing articulated joint
1. Jack up the frame (Fig. 1) at the back and secure
it with trestles or wooden blocks.
Fig. 1
2. Support the rear frame near the oscillating articu-
lated joint (Fig. 2) on both sides safely with tres-
tles or wooden blocks.
Fig. 2
3. Fasten the lifting tackle to the front frame near the
oscillating articulated joint (Fig. 3).
Fig. 3
508 BOMAG 008 911 63

Removing and installing the oscillating articulated joint 16.3

4. Unscrew fastening screws 1 (Fig. 4) and take off
axle holder (2).
5. Knock out bearing bolt (3).
6. Retract steering cylinder (4).
Fig. 4
! Danger
Danger of accident!
7. Support the oscillating articulated joint in the mid-
dle with a suitable jack or a similar device.
8. Unscrew fastening screws 1 (Fig. 5) and take off
with disc (2).
Fig. 5
9. Unscrew nuts 3 (Fig. 6) and take off the clamping
washers (2).
10. Pull out the fastening screws (1).
11. Slightly raise the front frame and lower the oscil-
lating articulated joint to the ground.
12. Pull out the oscillating articulated joint.
Fig. 6
Note on assembly
13. Insert the bolt for the steering cylinder so that
groove (2) is in line with tapped bores (1).
Fig. 7
008 911 63 BOMAG 509

16.4 Dismantling the oscillating articulated joint
16.4 Dismantling the oscillating articulated

joint
1. Unscrew the nuts from hexagon screw 1 (Fig. 1)
and pull out the hexagon screw.
2. Unscrew the screws (2) for the cover.
Fig. 1
3. Take off the cover with Belleville springs, shim
and backing disc (Fig. 2).
4. Disassemble also the cover from the opposite
side.
i Note
No Belleville springs, shim and backing disc are
under this cover.
Fig. 2
5. Drive the console with a plastic hammer to one
side against the end stop (Fig. 3).
i Note
The outer race of the rocker bearing is thereby
stripped off.
Fig. 3
510 BOMAG 008 911 63

Dismantling the oscillating articulated joint 16.4

6. Force inner race 1 (Fig. 4) of the rocker bearing
off the bolt.
7. Take of supporting disc (2).
8. Drive the console to the opposite side and re-
move the rocker bearing in the same way.
Fig. 4
10. Press bolt (3) out of the console with forcing
screws (2).
i Note
Remove the bolt on the opposite side in the same
way.
Fig. 5
11. Lift console 1 (Fig. 6) off housing (2).
Fig. 6
12. Take the seal rings out of the console (Fig. 7).
Fig. 7
008 911 63 BOMAG 511

13. Remove the cover from the housing.

14. Take off shims 1 (Fig. 8), backing disc (2) and
Belleville springs (3).
Fig. 8
15. Unscrew bolts 1 (Fig. 9) and take off cover (2).
Fig. 9
16. Take the intermediate ring out of the housing
(Fig. 10).
Fig. 10
17. Place the plate 1 (Fig. 11) on the beam.
18. Attach the puller (2) to the housing (3) and sepa-
rate the carrier from the rocker bearings.
Fig. 11
512 BOMAG 008 911 63

Dismantling the oscillating articulated joint 16.4

19. Pull the housing off the beam (Fig. 12).
Fig. 12
20. Drive the outer race of the friction bearing out of
the housing (Fig. 13).
Fig. 13
21. Drive the friction bearing out of the housing (Fig.
14).
Fig. 14
22. Take seal ring 1 (Fig. 15) and V-ring (2) off the
beam.
Fig. 15
008 911 63 BOMAG 513

23. Check rocker bearings, if necessary press out of

the housing (Fig. 16).
Fig. 16
514 BOMAG 008 911 63

Assembling the oscillating articulated joint 16.5

16.5 Assembling the oscillating articulated
joint
1. If previously disassembled, press the rocker
bearing fully into the housing with a pressing
mandrel (Fig. 1).
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
! Caution
Do not use any grease.
Fig. 1
2. Slide the new V-ring on the beam against the stop
with the lip facing up (Fig. 2).
Fig. 2
3. Lay the seal ring into the beam (Fig. 3).
4. Fill the space between V-ring and seal ring with
multi-purpose grease.
Fig. 3
008 911 63 BOMAG 515

16.5 Assembling the oscillating articulated joint
5. Press the friction bearing fully into the housing

with the chamfered side pointing towards the out-
side (Fig. 4).
Fig. 4
6. Slide the housing over the beam (Fig. 5).
i Note
The journal on the housing must be centrally in
the recess of the beam.
Fig. 5
7. Press the seal ring carefully towards the inside,
until it sits in the recess of the housing (Fig. 6).
Fig. 6
8. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.
! Caution
9. Press the outer rocker bearing race 1 (Fig. 7) in
until it bottoms with the wider outer rim forward
using pressing sleeve (2).
Fig. 7
516 BOMAG 008 911 63


10. Press inner rocker bearing race 1 (Fig. 8) in until
it bottoms, using pressing sleeve (2).
Fig. 8
11. Insert the intermediate ring (Fig. 9).
Fig. 9
12. Press inner rocker bearing race 1 (Fig. 10) in until
it bottoms, using pressing sleeve (2).
Fig. 10
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
! Caution
13. Press the outer rocker bearing race 1 (Fig. 11) in
until it bottoms with the wider outer rim pointing
up, using pressing sleeve (2).
Fig. 11
008 911 63 BOMAG 517

14. Press in intermediate ring 1 (Fig. 12) until it bot-

toms.
15. Attach cover (2) with the machined edge forward.
16. Turn in screws (3) and tighten crosswise.
Fig. 12
Determining the shim thickness
17. Determine the shim thickness, for this purpose
stand the cross-member on a wooden board with
an ∅ 18 mm bore.
! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
18. Slide the rod of the tensioning device in from un-
derneath, attach the plate, screw on the nut and
Fig. 13 tighten.
19. Measure the distance from housing edge to inter-
mediate ring (Fig. 13) and write it down, e.g. 4,7
mm.
i Note
From this measured value of 4.7 mm subtract the
fixed value of 4.0 mm to determine the shim thick-
ness.
Calculation example:
4,7 mm - 4,0 mm = 0,7 mm
measured value: 4,7 mm
fixed value: 4,0 mm
Shim thickness: 0,7 mm
20. Remove the tensioning device.
518 BOMAG 008 911 63


21. Insert shim 2 (Fig. 14) of appropriate thickness
and backing disc (1) into the cover.
Fig. 14
22. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 15).
Fig. 15
23. Assemble cover 2 (Fig. 16) with Belleville springs,
shim and backing disc.
Fig. 16
25. Press the new sealing rings into the respective
groove in the console (Fig. 17).
Fig. 17
008 911 63 BOMAG 519

26. Lift console 1 (Fig. 18) over the housing (2).
Fig. 18
27. Turn four guide pins into the housing bores (Fig.
19).
Fig. 19
i Note
Perform the following eight work steps on both
sides.
28. Slide the bolt over the guide pins (Fig. 20) and
drive in until it bottoms.
Fig. 20
! Caution
When driving in the bolt make sure that the
seal ring is not pressed out through the back
of the console (Fig. 21).
Fig. 21
520 BOMAG 008 911 63


29. Unscrew the guide pins .
30. Turn in the screws and tighten with 75 Nm (Fig.
22).
Fig. 22
31. Slide the backing discs over the bolt (Fig. 23).
Fig. 23
32. Drive the inner rocker bearing race on against the
end stop with the wider outer rim forward (Fig.
24).
Fig. 24
33. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.
! Caution
34. Attach the outer rocker bearing race with the wid-
er outer rim facing towards the outside (Fig. 25)
and drive it in until it bottoms.
Fig. 25
008 911 63 BOMAG 521

35. Attach cover 1 (Fig. 26) to the bottom side of the

console.
36. Turn in and tighten screws (2).
Fig. 26
Determining the shim thickness
37. Determine the shim thickness, for this purpose in-
sert rod 1 (Fig. 27) of the tensioning device from
underneath. Attach plate (2), screw on nut (3) and
tighten.
! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
Fig. 27
38. Measure the distance from outer rocker bearing
race to console surface (Fig. 28) and write it
down, e.g. 3.4 mm.
i Note
From this measured value of 3.4 mm subtract the
fixed value of 2.2 mm to determine the shim thick-
ness.
Calculation example:
3.4 mm - 2.2 mm = 1.2 mm
measured value: 3,4 mm
Fig. 28 fixed value: 2,2 mm
Shim thickness: 1.2 mm
39. Remove the tensioning device.
522 BOMAG 008 911 63


40. Insert shims 2 (Fig. 29) of appropriate thickness
and backing disc (1) into the cover.
Fig. 29
41. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 30).
Fig. 30
42. Assemble cover 1 (Fig. 31) with Belleville springs,
shims and supporting discs.
Fig. 31
44. Insert hexagon screw 1 (Fig. 32) so that the screw
head rests on the upper side of the console.
Fig. 32
008 911 63 BOMAG 523

45. Assemble the washer, turn on and tighten the nut

with 120 Nm (Fig. 33).
Fig. 33
524 BOMAG 008 911 63

17 Suppliers documentation
008 911 63 BOMAG 525

526 BOMAG 008 911 63

17.1 Travel pump
008 911 63 BOMAG 527

17.1 Travel pump
Bild 34
528 BOMAG 008 911 63

Travel pump 17.1
Series 90
Axial Piston
Pumps and Motors
Service Manual
008 911 63 BOMAG 529

17.1 Travel pump
Series 90 Introduction
Introduction
Use of this Manual
This manual includes information for the norm al opera- Since dirt and contamination are the greatest enemies of
tion, m aintenance, and servicing of the Series 90 f amily any type of hydr aulic equipment, cleanliness require-
of hydrostatic pumps and motors. ments must be strictly adhered to. This is especially
important when changing the system filter and during
The manual also includes the description of the units and adjustment and repair activities.
their individual components, tro ubleshooting informa-
tion, adjustment instructions, and minor repair proce- For further information refer to Series 90 Technic al
dures. Unit w arranty obligations should not be affected if Information. For inform ation about fluid requirements
maintenance, adjustment, and minor repairs are per- refer to SAUER-SUNDSTRAND BLN 9887 or SDF (Id No.
formed according to the procedures described in this 697581).
manual.
A worldwide network of SAUER-SUNDSTRAND A utho-
Many service and adjustment activities can be performed rized Service Centers is available should repairs be
without removing the unit from the vehicle or m achine. needed. Contact any SAUER-SUNDSTRAND A utho-
However, adequate access to the unit must be available, rized Service Center for details. A list of all Service
and the unit must be thoroughly cleaned before beginning Centers can be found in bulletin BLN-2-400527, or in
maintenance, adjustment, or rep air activities. brochure SAW (Ident. No. 698266).
Safety Precautions
Observe the following safety precautions when using and servicing hydrostatic products.
Loss of Hydrostatic Braking Ability Fluid under Hi gh Pressure
WARNING WARNING
The loss of hydrostatic drive line power in any Use caution when dealing with hydraulic fluid
mode of operation (e.g., forward, reverse, or "neu- under pressure. Escaping hydraulic fluid under
tral" mode) may cause the loss of hydrostatic pressure can have sufficient force to penetrate
brakin g capacity. A braking system, redundant to your skin causing serious injury. This fluid may
the hydrostatic transmission must, therefore, be also be hot enough to burn. Serious infection or
provided which is adequate to stop and hold the reactions can develop if proper medical treat-
system should the condition develop. ment is not administered immediately.
S000 001E S000 003E
Disable Work Function Flammable Cleaning Solvents
WARNING WARNING
Certain service procedures may require the ve- Some cleaning solvents are flammable. To avoid
hicle/machine to be disabled (wheels raised off possible fire, do not use cleaning solvents in an
the ground, work function disconnected, etc.) area where a source of ignition may be present.
while performing them in order to prevent injury S000 004E
to the technician and bystanders.
S000 005E
Copyright 1987-1998, SAUER-SUNDSTRAND Gm bH & Co. S90MVCTCD

S90PVMFCD
All rights reserved. Contents sub ject to ch ange.
2
530 BOMAG 008 911 63

Travel pump 17.1
Series 90 Contents
Contents
Introduction ......................................................................................................................................................................... 2
Use of this M anual ........................................................................................................................................................................................ 2
Safety Precautions ........................................................................................................................................................................................ 2
Functional Description ....................................................................................................................................................... 5
General Description and Cross Sectional Views ......................................................................................................................................... 5
Variable Displacement Pumps ................................................................................................................................................................ 5
Fixed Displacement Motor ..................................................................................................................................................................... 5
Variable Displacement Motor .................................................................................................................................................................. 6
The System Circuit ....................................................................................................................................................................................... 7
The Basic Closed Circuit ........................................................................................................................................................................ 7
Case Drain and Heat Exchanger ........................................................................................................................................................... 7
Common Features of Pumps and Motors .................................................................................................................................................... 8
End Caps and Shafts ............................................................................................................................................................................. 8
Speed Sensors ....................................................................................................................................................................................... 8
Pump Features ............................................................................................................................................................................................. 9
Charge Pump .......................................................................................................................................................................................... 9
Charge Relief Valve ................................................................................................................................................................................. 9
Multi-Function Valves .............................................................................................................................................................................. 9
Pressure Limiter and High Pressure Relief Valves ....................................................................................................................... 10
System Check Valves .................................................................................................................................................................... 10
Bypass V alves ................................................................................................................................................................................ 10
Displacement Limiters .......................................................................................................................................................................... 11
Auxiliary Mounting Pads ....................................................................................................................................................................... 11
Filtration Options ................................................................................................................................................................................... 11
Pressure Override (POR) - 180 Frame Size Only ............................................................................................................................. 12
Pump Control Options .......................................................................................................................................................................... 13
Manual Displacement Control (MDC) ........................................................................................................................................... 13
Hydraulic Displacement Control (HDC) ........................................................................................................................................ 13
Electric Displacement Control (EDC) ............................................................................................................................................ 14
Automotive Control (FBA II B) ....................................................................................................................................................... 14
3-Position (FNR) Electric Control .................................................................................................................................................. 14
Motor Features ........................................................................................................................................................................................... 15
Motor Loop Fl ushing Valve and Charge Relief Valve ........................................................................................................................... 15
Variable Motor Displacement Limiters .................................................................................................................................................. 15
Variable Motor Controls ........................................................................................................................................................................ 16
Hydraulic 2-Position Control .......................................................................................................................................................... 16
Electric 2-Position Control .............................................................................................................................................................. 16
Technical Specifications .................................................................................................................................................. 17
General Specifications ................................................................................................................................................................................ 17
Circuit Diagrams ......................................................................................................................................................................................... 17
Hydraulic Parameters ................................................................................................................................................................................. 18
Size Specific Data ....................................................................................................................................................................................... 19
Pressure Measurement ................................................................................................................................................... 20
Required Tools ............................................................................................................................................................................................ 20
Port Locations and Pressure G auge Installation ....................................................................................................................................... 20
Variable Pump ....................................................................................................................................................................................... 20
Fixed Motor ........................................................................................................................................................................................... 23
Variable Motor ....................................................................................................................................................................................... 24
Initial Start-Up Procedure ................................................................................................................................................ 25
Fluid and Filter Maintenance ...........................................................................................................................................2 6
Troubleshooting ................................................................................................................................................................ 27
"NEUTRAL" Difficult or Impossible to Find ................................................................................................................................................. 27
System Operating Hot ................................................................................................................................................................................ 27
Transmission Operates Normally in One Direction Only .......................................................................................................................... 28
System Will Not Operate in Either Direction .............................................................................................................................................. 28
Low Motor Output Torque ........................................................................................................................................................................... 29
Improper Motor O utput Speed .................................................................................................................................................................... 29
Excessive Noise and/or Vibration .............................................................................................................................................................. 30
System Response is Sl uggish .................................................................................................................................................................... 30
008 911 63 BOMAG 531

17.1 Travel pump
Series 90 Contents
Inspections and Adjustments ......................................................................................................................................... 31
Pump Adjustments ...................................................................................................................................................................................... 31
Charge Pressure Relief Valve Adjustment ........................................................................................................................................... 31
Multi-Function Valve Pressure Adjustment .......................................................................................................................................... 33
Engaging the Bypass F unction ............................................................................................................................................................ 35
Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size) ....................................................................... 36
Displacement Limiter Adjustment ......................................................................................................................................................... 37
Pump Control Adjustments ......................................................................................................................................................................... 38
Standard M anual Displacement Control (MDC) Adjustment .............................................................................................................. 38
Non-Linear Manual Displacement Control (MDC) .............................................................................................................................. 39
MDC Neutral St art Switch (NSS) Adj ustments .................................................................................................................................... 40
Hydraulic Displacement Control (HDC) and Electric Displ acement Control (EDC) Adj ustment ....................................................... 46
Motor Adjustments ...................................................................................................................................................................................... 48
Charge Relief Valve Adjustment ........................................................................................................................................................... 48
Displacement Limiter Adjustment (MV) ................................................................................................................................................ 49
Displacement Control Adjustments ...................................................................................................................................................... 49
Speed Sensor Adjustment .......................................................................................................................................................................... 50
Minor Repair Instructions ................................................................................................................................................ 51
Pump and Motor Minor Repair .................................................................................................................................................................... 53
Pump / Fitting Torq ues .......................................................................................................................................................................... 53
Shaft Seal and Shaft Replacement ...................................................................................................................................................... 54
Pump Minor Repairs ................................................................................................................................................................................... 56
Multi-Function Valve Cartridges ........................................................................................................................................................... 56
Pressure Override Valve (Option for 180 Frame Size) ....................................................................................................................... 57
Charge Relief Valve ............................................................................................................................................................................... 57
Charge Pump - Remove ...................................................................................................................................................................... 58
Installing the Charge Pump .................................................................................................................................................................. 60
Auxiliary Pad Installation ....................................................................................................................................................................... 62
Auxiliary Pad Conversion ..................................................................................................................................................................... 63
Filtration Options ................................................................................................................................................................................... 64
Pump controls ....................................................................................................................................................................................... 65
Cover Plate ..................................................................................................................................................................................... 65
Manual Displacement Control (MDC) ........................................................................................................................................... 66
Solenoid Override Valve for MDC .................................................................................................................................................. 67
Solenoid Override Valve for MDC with Press ure Released Brake .............................................................................................. 67
Hydraulic and Electric Displacement Controls ............................................................................................................................. 68
Pressure Control Pilot (PCP) for Electric Displ acement Control .................................................................................................. 68
3-Position (FNR) Electric Control .................................................................................................................................................. 69
Displacement Control Components............................................................................................................................................... 69
Minor Repair - Motor ................................................................................................................................................................................... 71
Loop Flushing and Charge Relief Valves ............................................................................................................................................. 71
Variable Motor Displacement Limiters .................................................................................................................................................. 73
Variable Motor Controls ............................................................................................................................................................................... 74
Electrohydraulic 2-Position Control (Types NA, NB, NC, and ND) ..................................................................................................... 74
Hydraulic 2-Position Control (Type PT) ............................................................................................................................................... 74
Control Plugs ........................................................................................................................................................................................ 74
Variable Motor Control Orifices ............................................................................................................................................................ 75
Speed Sensor .............................................................................................................................................................................................. 77
Exploded View Parts Drawings / Parts Lists .................................................................................................................. 78
Variable P umps ........................................................................................................................................................................................... 78
Minor Repair P arts ................................................................................................................................................................................ 78
Parts List ............................................................................................................................................................................................... 79
Variable P ump Controls ........................................................................................................................................................................ 80
Control Parts List .................................................................................................................................................................................. 81
Filter and Options ................................................................................................................................................................................. 82
Parts List Filter and Options ................................................................................................................................................................. 83
Name Plates ......................................................................................................................................................................................... 83
Fixed Motor ................................................................................................................................................................................................. 84
Parts List ............................................................................................................................................................................................... 85
Name Plates ......................................................................................................................................................................................... 85
Variable Motor .............................................................................................................................................................................................. 86
Parts List ............................................................................................................................................................................................... 87
Name Plate ............................................................................................................................................................................................ 87
532 BOMAG 008 911 63

Travel pump 17.1
Series 90 Functional Description

Functional Description
This section describes the operation of p umps, motors, and their v arious serviceable features. It is a useful reference for
readers unfamiliar with the functioning of a specific system.
General Description and Cross Sectional Views
Variable Displacement Pumps
The Variable Displacement Pump (PV) is designed to

convert an input torque into hydr aulic power. The inp ut
shaft turns the pump cylinder which contains a ring of
pistons. The pistons r un against a tilted pl ate, called the
swashplate. This causes the pistons to compress the
hydraulic fluid which imparts the inp ut energy into the
hydraulic fluid. The high press ure fluid is then ported o ut
to provide power to a remote function.
The swashplate angle can be varied by the control piston.

Altering the swashplate angle varies the displacement of
fluid in a given revolution of the inp ut sh aft.
F000 539
Series 90 Variable Displaceme nt Pump (PV)
Slider Block
Servo Arm
Servo V alve
Cradle Hold Down
Servo Piston
Feed Back
Cradle Bearing
Cradle
Cradle Leveler
Cradle Guide
Charge Pump
P001 413E
Series 90 PV Cross Section
Fixed Displacement Motor
The Fixed Displacement Motor (MF) is designed to

convert an input of hydraulic power into an output torque.
It operates in the reverse m anner of the p ump. The high
pressure hydraulic fluid enters through the input port. The
fluid pressure builds behind the pistons c ausing them to
move down the swashplate (the path of least resistance).
As the piston returns up the swashplate again, the fl uid is
allowed to exit thro ugh the exit port. The spinning pistons
are housed in a cylinder which is connected to the o utput
shaft. The o utput torque can be applied to a mechanical
function.
90000347
Series 90 Fixed Displacement Motor (MF)
008 911 63 BOMAG 533

17.1 Travel pump
In the Fixed Displ acement Motor the "swashplate" is

Loop Flushing Valve fixed, so any variation in motor speed and torque must be
Valve Plate Piston made by the input mechanism, i.e. the p ump.
Roller Bearing
Output Shaft
Fixed Swashplate
End Cap Cylinder Block
90000190E
Series 90 MF Cross Section
Variable Displacement Motor
The Variable Displacement Motor (MV) operates in the

same manner as the fixed motor. However, its sw ashplate
is not fixed; it c an be switched between minimum and
maxim um angle to amplify torque or speed like the
Variable Displacement Pump.
90000348
Series 90 Variable Displacement Motor (MV)
Minimum Angle
Valve Plate Piston Control Piston
End Cap
Roller Bearing
Cradle Swashplate
Output Shaft
"A" "A" Partial Section "A-A"

Cradle Swashplate in Full
Displacement Position
Cradle Swashplate
Cylinder Block
Electric 2-Position Control (option al) Maximum Angle
Control Piston
90000234E
Series 90 MV Cross Section
534 BOMAG 008 911 63

Travel pump 17.1

The System Circuit
System loop (low pressure)

Control Handle Displ acement Control Valve
Case drain fluid
Heat Exchanger
System loop (high pressure)
Bypass Valve
Orificed Reservoir
Control fluid
Check Valve
Vacuum Gauge
Suction line
Heat Exchanger
Charge Pressure Purge Relief Valve

Multi-Function Relief Valve
Servo Control Valve
Variable Cylinder Fixed Displacement
Displacement Motor
Pump
to Pump
Case
Servo Pres.
Relief Valve
Charge Pump
Input
Output Shaft
Shaft
Multi-Function Valve Motor Swashplate
Pump Swashplate Servo Control
Cylinder Loop Flushing Valve
Pump Fixed Motor

90000800E
Circuit Diagram for Series 90 PV a nd 90 MF
The Basic Closed Circuit
The main ports of the p ump are connected by hydraulic

lines to the main ports of the motor. Fl uid flows, in either
direction, from the p ump to the motor then back to the
pump in this closed circ uit. Either of the hydr aulic lines
can be under high pressure. In pumping mode the
position of the p ump swashplate determines which line is
high pressure as well as the direction of fl uid flow.
Case Drain and Heat Exchanger
The pump and motor req uire case drain lines to remove Reservoir
hot fluid from the system. The motor sho uld be dr ained
from its topmost dr ain port to ens ure the case remains full Input MF Output
of fl uid. The motor case drain c an then be connected to PV
the lower drain port on the p ump housing and out the top
most port. A he at exchanger, with a bypass valve, is
required to cool the case drain fluid before it ret urns to the
reservoir.
Flow (Bi-directional)
Case Drain Line

90000803E
Basic Closed Circuit
008 911 63 BOMAG 535

17.1 Travel pump

Common Features of Pumps and Motors
End Caps and Shafts
Series 90 pumps and motors can be supplied with a

variety of end caps and shafts to allow for almost any
configuration. For p umps, end caps are available with
system ports on either side ("side ports") or both ports on
one side ("twin ports"). Motors h ave end caps with ports
on the face of the end c ap ("axial ports") or both ports on
one side ("twin ports"). See the Series 90 Technic al
Inform ation manuals (BLN-10029 and BLN-10030) or the
Series 90 Price Book (BLN-2-40588) for information on
available options.
Removing the end cap will void the warranty on a

Series 90 pump or motor.
Speed Sensors
An optional speed sensor can be installed on Series 90

pumps and motors to provide unit speed information. The
sensor reads a magnetic ring wrapped about the unit's
cylinder. See the corresponding Section to loc ate, install
and adjust the sensor.
90000810
Speed Sensor
536 BOMAG 008 911 63

Travel pump 17.1

Pump Features
Charge Pump
The charge pump is necessary to supply cool fluid to the

system, to m aintain positive pressure in the main system
loop, to provide pressure to operate the control system,
and to m ake up for intern al le akage. Charge pressure
must be at its specified press ure under all conditions of
driving and braking to prevent d amage to the tr ansmis-
sion.
The charge pump is a fixed-displacement, gerotor type

pump installed in the v ariable displacement pump and
driven off the m ain pump shaft. Charge pressure is limited
by a relief v alve.
90000243
The standard charge pump will be s atisfactory for most
PV with Char ge Pump
applications. However, if the ch arge pump sizes available
for the given m ain pump size are not adequate, a gear
pump may be mounted to the auxiliary mounting pad and Case
supply the required addition al ch arge flow. Drain
Charge Relief V alve
Line
System
Charge Relief Valve Check
Valves
The charge relief valve on the pump serves to maintain Input PV PF
charge pressure at a designated level. A direct- acting
poppet valve relieves charge pressure whenever it sur- Charge
Pump
passes a certain level. This level is nomin ally set refer-
encing case pressure at 1500 rpm. This nomin al setting
assumes the pump is in ne utral (zero flow); in forw ard or
reverse charge pressure will be lower. The ch arge relief
valve setting is specified on the model code of the p ump.
Inlet Filter
Tank
90000804E
Pump Char ge System
Multi-Function Valves
The multi-function valve incorporates

the system check valve,
the pressure limiter valve,
the high pressure relief valve and
the bypass v alve
in a replaceable c artridge.
These functions are described separately. There are two

multi-function valve cartridges in each Series 90 pump to
handle functions in either direction. See corresponding
Sections for adjustments and repairs.
NOTE: Some m ulti-function valves do not incl ude a 90000243

pressure limiter valve. Multi-Function Valve
008 911 63 BOMAG 537

17.1 Travel pump

Pressure Limiter and High Pressure Relief Valves
Series 90 pumps are designed with a sequenced pres-

Pressure Limiter Ho using High Pressure sure limiting system and high pressure relief v alves.
Relief / check Check Valve When the preset pressure is reached, the pressure limiter
Pressure Limiter Valve Poppet Poppet
Lock Nut system acts to r apidly destroke the pump so as to limit the
system pressure. For unusually rapid load application,
the high pressure relief v alve acts to immedi ately limit
Pressure Limiter system pressure by cross-porting system flow to the low
Adjustment Screw pressure side of the loop. The press ure limiter valve acts
as the pilot for the high press ure relief v alve spool. The
high pressure relief v alve is sequenced to operate at
Bypass approximately 35 bar (500 psi) above the level th at ini-
Actuator Pressure Limiter Bypass tiates the pressure limiter valve.
Valve Poppet
Both the pressure limiter sensing valves and relief v alves
are built into the m ulti-function valves (see above).
90000806E
NOTE: For some applications, such as dual path ve-
Cross Section of Multi-Function Valve
hicles, the pressure limiter function may be de-
feated so that only the high press ure relief v alve
function remains.
System Check Valves
The system check valves allow pressurized flow from the

charge pump to enter the low press ure side of the loop
whenever system pressure dips below a certain level.
To Control This is needed as the pump will gener ally lose system
pressure due to leakage and other factors. Since the
Multi-Function Valve pump c an operate in either direction, two system check
valves are used to direct the charge supply into the low
pressure lines. The system check v alves are poppet
Servo Piston Bypass
Adjustment
valves located in the multi-function valve assembly.
Port "A"
Bypass Valves
Servo Pres.
Relief Valve
Port "B"
The bypass valves ("tow") can be operated when it is
desired to move the vehicle or mech anical function when
Servo Piston the pump is not r unning. The v alve is opened by manually
Charge Pressure
Relief Valve
resetting the valve position.
Multi-Function Valve The bypass valves are built into the m ulti-function valves.
90000801E
Circuit Diagram showing Pressure
Control Mechanism
10
538 BOMAG 008 911 63

Travel pump 17.1

Displacement Limiters
All Series 90 p umps are designed for optional mechanical

displacement (stroke) limiters. The m aximum displace-
ment of the p ump c an be limited in either direction.
The setting can be set as low as 0° in either direction.
For instructions on adjustment see corresponding Sec-

tion.
90000244
Auxiliary Mounting Pads PV with Displacement Limiters
Auxiliary mounting pads are available on all Series 90

pumps. SAE A thro ugh E mo unts are available (availabil-
ity varies by pump size). This p ad is used for mounting
auxiliary hydraulic pumps and for mo unting additional
Series 90 pumps to make tandem pumps. The pads allow
for full through-torque capability.
90000242
Filtration Options PV with Auxillary Mountin g Pad
All Series 90 p umps are available with provisions for

either suction or charge pressure filtration (integral or
remote mounted) to filter the fl uid entering the charge
circuit.
Suction Filtration
The suction filter is pl aced in the circuit between the

reservoir and the inlet to the ch arge pump. When s uction
filtr ation is used, a red ucer fitting is pl aced in the charge
pressure g auge port (M3). Filtr ation devices of this type
are provided by the user.
90000243
PV with Suction Filtration
(No filtration device attached)
Char ge Pressure Filtration
The pressure filter may be integrally mounted directly on

the pump or a filter m ay be remotely mounted for ease of
servicing.
A 125 m screen, located in the reservoir or the ch arge

inlet line, is recommended when using this filtr ation
option.
90000246 90000247
PV with Inte gral Charge PV with Remote Char ge
Pump Pump
11
008 911 63 BOMAG 539

17.1 Travel pump

Pressure Override (POR) - 180 Frame Size Only
To Control
The pressure override valve (POR) modulates the control

pressure to the displ acement control to m aintain a pump
Multi-Function Valve
displacement which will prod uce a system pressure level
less than or equal to the POR setting. For unusually rapid
load application, the high press ure relief v alve function of
Pressure
Override Control Valve Bypass the multif unction valves is available to also limit the
Adjustment pressure level.
Port "A"
Shuttle
The pressure override consists of a three-way normally
Valve open valve which operates in series with the p ump
Port "B" displacement control. Control supply pressure is nor-
mally ported thro ugh the pressure override valve to the
displacement control valve for controlling the p ump's
displacement. If the system dem ands a pressure above
Charge Pressure
the override setting, the POR v alve will override the
Multi-Function Valve
Relief Valve control by reducing the control pressure s upplied to the
displacement control. As the control press ure reduces,
the internal forces tending to rot ate the sw ashplate
90000802E overcome the force of the servo pistons and allow the
POR-Valve (180 Frame Size only) pump's displacement to decrease.
12
540 BOMAG 008 911 63

Travel pump 17.1

Pump Control Options
Manual Displacement Control (MDC)
The manual displacement control converts a mechanical input signal to a hydraulic signal using a spring- centered four-
way servo valve. This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rot ates
the cradle swashplate through an angular rotation of ±17°, th us varying the pump’s displacement from full displacement
in one direction to f ull displacement in the opposite direction.
The MDC is designed so the angular position of the p ump swashplate is proportion al to the rot ation of the control inp ut
sh aft.
Non-Linear MDC
The non-linear m anual displacement control operates in

the same manner as the regular MDC except th at it is
designed so the change in the angular position of the
pump swashplate progressively increases as the control
input shaft is rot ated toward its maximum displacement
position.
Solenoid Override Valve for MDC
A solenoid override valve option (not shown here) is

available for MDC. This s afety fe ature will return the 90000237
swashplate to zero displ acement position when acti- PV with Manual Displacement Control
vated. The v alve may be set in either a normally open or
normally closed mode.
Neutral Start Switch (NSS)
The neutral start switch is an optional feature available

with MDC. When connected properly with the vehicle’s
electrical system, the ne utral start switch ensures that the
prime mover can be started only when the control is in a
neutral position.
90000239
PV with Manual Displacement Control and
Hydraulic Displacement Control (HDC) Neutral Start Switch
The hydraulic displacement control uses a hydraulic input

signal to operate a spring-centered four-way servo valve.
This valve ports hydraulic pressure to either side of a
dual-acting servo piston. The servo piston rotates the
cradle swashplate through an angular rotation of ±17°,
thus varying the pump’s displacement from f ull displace-
ment in one direction to f ull displacement in the opposite
direction. The HDC is designed so the angular position of
the pump swashplate is proportional to inp ut pressure.
90000240
PV with Hydraulic Displacement Control
13
008 911 63 BOMAG 541

17.1 Travel pump
Electric Displacement Control (EDC)
The electric displacement control is simil ar to the hydr au-

lic displacement control with the inp ut signal pressure
controlled by a pressure control pilot (PCP) v alve. The
PCP valve converts a DC electrical input signal to a
hydraulic signal which operates a spring- centered fo ur-
way servo valve. This v alve ports hydraulic pressure to
either side of a dual-acting servo piston. The servo piston
rotates the cr adle swashplate through an angular rotation
of ±17°, th us v arying the pump’s displacement from full
displacement in one direction to f ull displacement in the
90000241 opposite direction. The control is designed so the angular
PV with Electric Displacement Control position of the sw ashplate is proportional to the EDC
inp ut.
Automotive Control (FBA II B)
Automotive Control allows a vehicle to be driven in a

manner similar to an automobile with an automatic trans-
mission.
The Automotive Control includes a three-position electric

control to provide direction control.
3-Position (FNR) Electric Control
This control utilizes a 12 or 24 VDC electrically operated

spool valve to port pressure to either side of the p ump
displacement control piston. Energizing one of the sole-
noids will cause the pump to go to its m aximum displace-
ment in the corresponding direction.
All functions of the three-position (FNR) electric control

are preset at the f actory.
90000354
PV with 3-Position (FNR) Electric Control
14
542 BOMAG 008 911 63

Travel pump 17.1

Motor Features
Motor Loop Flushin g Valve and Charge Relief

Valve
All Series 90 motors are designed to accommodate a loop

flushing valve. The loop fl ushing valve is used in instal-
lations which require additional fl uid to be removed from
the main hydraulic circuit because of transmission cool-
ing requirements, or unusual circuits requiring additional
loop flushing to remove excessive contamination in the
high pressure circuit. 90000248
Loop Flushin g Valve (MF)
A shuttle valve and charge relief v alve are installed in the
motor end cap to provide the loop fl ushing function. The
shuttle valve provides a circuit between the low press ure
side of the closed loop and the ch arge relief valve in the
motor end cap.
The motor charge relief valve regulates the charge pres- Top of Motor Charge Relief V alve
sure level only when there is a pressure differential in the
main loop. The sh uttle valve is spring centered to the
closed position so that no high press ure fluid is lost from
the circuit when reversing pressures.
For charge relief v alve adjustment see corresponding

Section.
Loop Flushing Shuttle Valve End Cap
90000238E
Motor Charge Relief Valve and Loop Flushin g

Shuttle Valve
Variable Motor Displacement Limiters
All Series 90 v ariable motors include mechanical dis-

placement (stroke) limiters. Both the m aximum and mini-
mum displacement of the motor c an be limited.
The range of the settings is as follows:
055 MV 075 MV
Minimum 19 - 40 cm3 26 - 54 cm3

Displacement 1.2 - 2.4 in
3
1.6 - 3.3 in3 90000352
Maximum MV Maximum Displacement Limiter
65 - 100 % 65 - 100 % (Minimum Displacement Limiters on opposite side)
Displacement
T002 251E
15
008 911 63 BOMAG 543

17.1 Travel pump

Variable Motor Controls
Hydraulic 2-Position Control
This control utilizes a hydraulically operated three-way

hydraulic valve to port system press ure to either of the
motor displacement control pistons. The motor is nor-
mally held at its m aximum displacement. Supplying pilot
hydraulic pressure to the valve will c ause the motor to go
to its minim um displacement.
90000350
MV with Hydraulic 2-Position Control
Electric 2-Position Control
This control utilizes an electric solenoid operated three-

way hydraulic valve to port system press ure to either of
the motor displacement control pistons. The motor is
normally held at its m aximum displacement. Energizing
the solenoid will c ause the motor to go to its minim um
displacement.
90000351
MV with Electric 2-Position Control
16
544 BOMAG 008 911 63

Travel pump 17.1
Series 90 Technical Specifications

Technical Specifications
General Specifications
Design Port Connections

(for details see chapter "Pressure Measurement")
Variable Pumps and Motors: Axial piston pump of vari-
able displacement, cradle swashplate design. Main pressure ports: SAE fl ange, Code 62,
Remaining ports: SAE str aight thread O-ring boss.
Fixed Motors: Axial piston motor with fixed displ acement,
fixed swashplate design. Direction of Rotation
Type of Mounting (per SAE J744) Clockwise or counterclockwise (motors are bi-directional)
SAE fl ange, Size "B", 2 bolts, Recommended Installation Position

SAE fl ange, Size "C and E", 4 bolts.
Pump installation recommended with control position on
Cartridge flange, 2 bolts (for motor only). the top or side. Cons ult SAUER-SUNDSTRAND for non-
conformance guidelines. The ho using must always be
filled with hydraulic fluid.
Circuit Diagrams
L2 M3
A M1
M3
Vg max
X5
A
M1
M5
M4
B M2
L1
M2
B
MV with Electrohydraulic 2-Position
Control
L1 S L2
PV with Char ge Pump and Manual

Displacement Control L2 M3
A M1
B M2
L1
90000811
MF 90000812
90000813
17
008 911 63 BOMAG 545

17.1 Travel pump
Hydraulic Parameters

Temperatur e Range1)
System Pressure Range bar psi
°C [°F]
Minimum -40 [-40] intermittent, cold start
Rated Pressure 420 6000
Rated 104 [220]
Maximum 115 [240] intermittent
Maximum Pressure 480 6960
T002 006E
T002 252E 1)
At the hottest point, normally the case
drain port.
Charge Pump Inlet Vacuum Viscosity

bar abs in Hg
(on pumps only) 2
mm /s [SUS]
Minimum 7 [49] intermittent
Minimum Vacuum
0.7 10 Recommended
(continuous) 12-60 [70-278]
operating range
Minimum Vacuum during in termittent,
Cold Star t 0.2 25 Maximum 1600 [7500]
cold start
(Intermittent) T002 010E
T002 253E
Cleanliness Level and β x-Ra

tio
Case Pressure bar psi Required f luid cleanliness
ISO 4406 Class 18 / 13
level
Maximum (Continuous) 3 44 Recomm ended βx-ra

f or suction f iltration
tio
β35-45= 75 (β10 ≥2
)
Recomm ended βx-ra tio

Maximum during Cold Start
5 73 f or charge pressure β15-20= 75 (β10 ≥1 0)
(Intermittent) f iltration
Recommended inlet
T002 254E screen size f or charge 100 m-125 m
pressure f iltration
T002 007E
Hydraulic Fluid Cleanliness

Refer to SAUER-SUNDSTRAND BLN 9887 or SDF (Id Refer to SAUER-SUNDSTRAND Publications BLN 9887
No. 697581). Also refer to p ublication ATI-E 9101 for or SDF (NO. 697581) and ATI-E 9201.
inform ation relating to biogradable fluids.
Refer to Series 90 technic al information for definitions.
18
546 BOMAG 008 911 63

Travel pump 17.1

Size Specific Data
Variable Displacement Pumps
Dimension 030 PV 042 PV 055 PV 075 PV 100 PV 130 PV 180 PV 250 PV
Displacement cm3 30 42 55 75 100 130 180 250

(maximum) in3 1.83 2.56 3.35 4.57 6.10 7.93 10.98 15.25
Minimum Speed min-1 (rpm) 500 500 500 500 500 500 500 500
Rated Speed min-1 (rpm) 4200 4200 3900 3600 3300 3100 2600 2300
Maximum Speed min-1 (rpm) 4600 4600 4250 3950 3650 3400 2850 2500
Maximum attainable Speed
min-1 (rpm) 5000 5000 4700 4300 4000 3700 3150 2750
at max. Displacement
Theoretical Torque at Nm / bar 0.48 0.67 0.88 1.19 1.59 2.07 2.87 3.97
max. Displacement lbf in / 1000 psi 290 380 530 730 870 1260 1750 2433
Weight kg 28 34 40 49 68 88 136 154
(only base unit) lb 62 75 88 108 150 195 300 340
T002 257E
Fixed and Variable Displacement Motors
Einheit 030 MF 042 MF 055 MF 075 MF 100 MF 130 MF 055 MV 075 MV
cm3 30 42 55 75 100 130 55 75

Displacement (maximum)
in3 1.83 2.56 3.35 4.57 6.10 7.93 3.35 4.57
cm3
Displacement (minimum) -- -- -- -- -- -- 19 26
in3
at maximum
min-1 (rpm) 4200 4200 3900 3600 3300 3100 3900 3600
Rated displacement
speed at minimum
min-1 (rpm) -- -- -- -- -- -- 4600 4250
displacement
at maximum
min (rpm)
-1
4600 4600 4250 3950 3650 3400 4250 3950
Maximum displacement
speed at minimum
min-1 (rpm) -- -- -- -- -- -- 5100 4700
displacement
Max. attainable speed at
min-1 (rpm) 5000 5000 4700 4300 4000 3700 4700 4300
max. displacement
Theoretical torque at max. Nm / bar 0.48 0.67 0.88 1.19 1.59 2.07 0.88 1.19
displacement lbf in / 1000 psi 290 380 530 730 970 1260 530 730
Maximum flow ar max. /
l min 138 193 234 296 365 442 234 296
displacement ga / l min 36.5 51 62 78 96 117 62 78
kW 111 155 187 237 292 354 224 282
Max. corner power
hp 149 208 251 318 392 475 300 378
Weight kg 11 15 22 26 34 45 39 44
SAE-Flange lb 24 34 49 57 74 99 86 98
Weight kg 21 26 33 40 46
-- -- --
Cartridge Motor lb 46 57 72 88 101
T002 258E
Refer to Series 90 technic al information for definitions.
19
008 911 63 BOMAG 547

17.1 Travel pump
Series 90 Pressure Measurement

Pressure Measurement
Required Tools
The service procedures described in this m anual for Pressure gauges should be c alibrated frequently to en-
Series 90 pumps and motors can be performed using sure accuracy. Snubbers are recommended to protect
common mechanic's tools. Special tools, if req uired are pressure gauges.
shown.
Port Locations and Pressure Gau ge Installation
The following sections list the ports for e ach type of Outline drawings showing port loc ations follow the t ables
hydraulic unit. The recommended press ure gauge and below.
fitting are also specified.
Variable Pump
Gauge Size Gauge Size

Port Function and Port Function and
Fitting
Fitting
System Pressure 1000 bar or 10 000 psi Case Pressure
M1 L1
Port "A" 9 / 16-18 O-ring 10 bar or 100 psi
L2
System Pressure 1000 bar or 10 000 psi
M2 030
Port "B" 9 / 16-18 O-ring fitting 7 / 8-14 O-ring
M3 50 bar or 1000 psi 042
Charge Pressure
(M6) 9 / 16-18 O-ring 055
M4 50 bar or 1000 psi 075 1-1 / 16-12 O-ring
Servo Pressure 100
M5 9 / 16-18 O-ring
T002 259E 130 1-5 / 16-12 O-ring
180
1-5 / 8-12 O-ring
250
50 bar or 1000 psi
X1 HDC / EDC 7 / 16-20 O-ring
X2 Control Pressure or
9 / 16-18 O-ring
External Control 50 bar or 1000 psi
X3
Pressure 9 / 16-18 O-ring
S Charge Pump Inlet Vacuum Gauge, Tee into
Inlet Line
030
1-1 / 16-12 O-ring
042
055
1-5 / 16-12 O-ring
075
100
130 1-5 / 8-12 O-ring
180
1-1 / 2 SAE-Split
250 Flange
T002 260E
20
548 BOMAG 008 911 63

Travel pump 17.1
Servo / Displ acement

Cylinder Pressure
Gauge Port M4
Case Drain
Port L1
System Press ure

Port B

Cylinder Pressure
Gauge Port M5
Top View
90000814E
System Pressure
Port B External Control Pressure
System Pressure Supply Port X3
Gauge Port M2 Speed Sensor
Charge Inlet Press ure
System Pressure
Gauge Port M1
Carge Pump
Inlet Port S System Pressure Case Drain Port L2 Charge Pressure
Port A Gauge Port M3
Left Side View Right Side View
90000815E
90000816E
PV with Side Port End Cap and Manual Displacement Control
21
008 911 63 BOMAG 549

17.1 Travel pump

Cylinder Pressure
System Pressure Gauge Port M4
Case Drain
Gauge Port M2 Port L1
System Pressure
Port B
Charge Pump Inlet

Port S
System Pressure
Port A
System Pressure Servo / Displ acement
Gauge Port M1 Cylinder Pressure
Case Drain Port L2 Gauge Port M5
Top View
Left Side View
90000819E
90000820E
PV with Twin Port End Cap and Manual Displacement Control
Charge Pressure
Gauge Port M6
(before the filter)
Port E
(from filter)
Port D
(to filter)
Charge Pressure
Gauge Port M3
Charge Pressure
(after the filter)
Gauge Port M3
(after the filter)
Rear View Rear View
90000817E
90000818E
PV with Side Port End Cap and Remote Pressure Filtration PV with Side Port End Cap and Inte gral Pressure Filtration
22
550 BOMAG 008 911 63

Travel pump 17.1

Fixed Motor

Fitting Fitting
System Pressure 1000 bar or 10 000 psi L1 Case Pressure)
M1
Por t "A" 9 / 16-18 O-ring L2 10 bar or 500 psi
System Pressure 1000 bar or 10 000 psi 030
M2
Por t "B" 9 / 16-18 O-ring 042 7 / 8-14 O-ring
M3 50 bar or 1000 psi 055
Charge Pressure
9 / 16-18 O-ring 075
T002 261E 100 1-1 / 16-12 O-ring
130
T002 262E
System Pressure
Gauge Port M1
Charge Pressure System Pressure
Gauge Port M3 Gauge Port M2 Case Drain Port L1
System Pressure Port B

Speed Sensor
System Pressure Port A Case Drain Port L2
Rear View Left Side View
MF with SAE Flan ge
System Pressure
Gauge Port M1
Charge Pressure System Pressure Case Drain Port L1
Gauge Port M3 Gauge Port M2
Speed Sensor
System Pressure Port B
System Pressure Port A Case Drain Port L2
Rear View Left Side View
90000821E
MF with Cartridge Flange
23
008 911 63 BOMAG 551

17.1 Travel pump

Variable Motor

Fitting Fitting
Systempressure 1000 bar or 10 000 psi Control Cylinbder
M1 1000 bar or 10 000 psi
Port "A" 9 / 16-18 O-ring M4 Pressure "Minimum
7 / 16-20 O-ring
Systempressure 1000 bar or 10 000 psi Displacement"
M2
Port "B" 9 / 16-18 O-ring Control Cylinbder
1000 bar or 10 000 psi
M3 50 bar or 1000 psi M5 Pressure"Maximum
Charge Pressure 7 / 16-20 O-ring
9 / 16-18 O-ring Displacement"
T002 263E L1 10 bar or 500 psi
Case Pressure
L2 1-1 / 16-12 O-ring
T002 264E
Displacement Control
Cylinder Pressure
Gauge Port M4
System Pressure Min. Displacement
Gauge Port M2
Control Pressure Displacement Control
Port X1 Cylinder Pressure
(Hydraulic 2-Position Control) Gauge Port M5
Max. Displacement
(Earlier Production -
Not available as gauge
port with servo orifices)
System Pressure Port B Displacement Control

Cylinder Pressure
Gauge Port M5
Max. Displacement
(Newer Production)
Left Side View
MV with Cartrid ge Flange and Hydraulic 2-Position Control (SAE Flan ge Version Similar)
Case Drain Port L1

System Pressure
Gauge Port M1
charge Pressure
Gauge Port M3
(Same position as in MF)
Speed Sensor
System Pressure Port A

Case Drain Port L2
Right Side View
90000823E
MV with SAE Flan ge (Cartridge Flange Version Similar)
24
552 BOMAG 008 911 63

Travel pump 17.1
Series 90 Initial Start-Up Procedure

Initial Start-Up Procedure
The following start-up procedure should always be fol- connections for EDC) be disconnected at the p ump
lowed when starting- up a new Series 90 installation or control until after initial start-up. This will ens ure that the
when restarting an installation in which either the p ump or pump remains in its ne utral position.
motor had been removed.
WARNING WARNING
The following procedure may require the vehicle/ Do not start prime mover unless pump is in neutral
machine to be disabled (wheels raised off the ground, position (0° swashplate angle). Take precautions to
work function disconnected, etc.) while performing prevent machine movement in case pump is actuated
the procedure in order to prevent injury to the during initial start up.
technician and bystanders. Take necessary safety S000008E
precautions before moving the vehicle/machine.
S000 007E
“Jog” or slowly rotate prime mover until charge pressure

starts to rise. St art the prime mover and run at the lowest
Prior to inst alling the pump and/or motor, inspect the units possible RPM until charge pressure has been estab-
for damage incurred during shipping and handling. Make lished. Excess air may be bled from the high press ure
certain all system components (reservoir, hoses, valves, lines through the high pressure system gauge port.
fittings, heat exchanger, etc.) are clean prior to filling with
fluid. Once charge pressure has been established, increase
speed to normal operating RPM. Ch arge pressure should
Fill the reservoir with recommended hydraulic fluid. This be as indicated in the p ump model code. If ch arge
fluid should be passed through a 10 micron (nominal, no pressure is inadequate, shut down and determine c ause
bypass) filter prior to entering the reservoir. The use of for improper pressure. Refer to Tro ubleshooting.
contaminated fluid will c ause damage to the components,
which may result in unexpected vehicle/machine move-
ment. See the p ublications BLN-9887 and SDF 697581 WARNING
for further related information. Take necessary precautions that the motor shaft
remains stationary durin g the adjustment
The inlet line le ading from the reservoir to the p ump must procedure.
be filled prior to st art-up. Check inlet line for properly S000010E
tightened fittings and make s ure it is free of restrictions Shut down the prime mover and connect the external
and air le aks. control input signal. Also reconnect the m achine function
if disconnected earlier. Start the prime mover, checking
Be certain to fill the pump and/or motor housing with to be certain the pump remains in neutral. With the prime
clean hydraulic fluid prior to start up. mover at normal operating speed, slowly check for for-
ward and reverse machine operation.
Fill the housing by pouring filtered oil into the upper case
drain port. Charge pressure may slightly decrease during forward or
reverse operation. Contin ue to cycle slowly between
Install a 50 bar (or 1000 psi) press ure gauge in the charge forward and reverse for at le ast five minutes.
pressure gauge port to monitor the ch arge pressure
during start-up. Shut down prime mover, remove g auges, and plug ports.
Check reservoir level and add filtered fl uid if needed.
It is recommended th at the external control inp ut signal
(linkage for MDC, hydraulic lines for HDC, or electric al The transmission is now re ady for operation.
25
008 911 63 BOMAG 553

17.1 Travel pump
Series 90 Fluid and Filter Maintenance

Fluid and Filter Maintenance
To ensure optimum service life of Series 90 prod ucts,

regular maintenance of the fl uid and filter m ust be per-
formed. Contaminated fluid is the m ain cause of unit
Mano- failure. Care should be taken to maintain fluid cleanliness
Vacuummeter while performing any service procedure.
Hydraulic fluid reservoir Check the reservoir daily for proper fl uid level, the pres-
ence of water (noted by a cloudy to milky appearance, or
Filter free water in bottom of reservoir), and rancid fluid odor
(indicating excessive heat). If either of these conditions
Charge pump
occur, change the fl uid and filter immedi ately.
It is recommended that the fluid and filter be changed

per the vehicle/machine manufacturer’s recommenda-
Adjustable
Charge pressure relief valve
tions or at the following intervals:
to low
pressure
side and First change
control To pump case
500 operating hours after start up
second and subsequent changes

P000 797E
Suction Filtration Schematic every 2000 operating hours or once a ye ar.
This recommendation applies for the most applications.

High temperatures and pressures will result in acceler-
ated fl uid aging and an earlier fluid change may be
required. At lower fl uid loads longer change intervalls are
Screen possible. Therefore we suggest to check the fl uid with the
manufacturer for suitability. This should be done at latest
half way between fluid changes.
Hydraulic fluid reservoir
Adjustable
Charge pressure It m ay be necessary to change the fl uid more frequently
relief valve than the above intervals if the fl uid becomes contami-
nated with foreign m atter (dirt, w ater, grease, etc.) or if
Charge pump
the fluid has been sub jected to temper ature levels greater
than the recommended m aximum. Never reuse fluid.
to low
pressure To pump case The filter sho uld be changed whenever the fluid is changed
side and
control or whenever the filter indic ator shows that it is necess ary
to change the filter.
Filter
Cleanliness Level and β x-Ra

tio
Required f luid cleanliness
ISO 4406 Class 18 / 13
level
P000 798E Recomm ended βx-ra tio
β35-45= 75 (β10 ≥2
)
f or suction f iltration
Charge Pressure Filtration Schematic Recomm ended βx-ra tio
(Partial flow) f or charge pressure β15-20= 75 (β10 ≥1 0)
f iltration
Recommended inlet
screen size f or charge 100 m-125 m
pressure f iltration
T002 007E
26
554 BOMAG 008 911 63

Travel pump 17.1
Series 90 Toubleshootin g
Troubleshootin g
This section provides general steps to follow if cert ain undesirable system conditions are o bserved. Follow the steps in
a section until the pro blem is solved. Some of the items will be system specific. For are as covered in this m anual, a section
is referenced. Always observe the safety precautions listed in the section "Introduction" and related to your
specific equipment.
"NEUTRAL" Difficult or Impossible to Find
Check Description Action
1. Input to pump control. Input to control module is operating Check control input and repair or re-
improperly. place as necessary.
2. Pump displacement control. Control linkages are not secure, control Adjust, repair, or replace control mod-
orifices are blocked, etc. ule as necessary.
If the above actions do not remedy the problem

contact a SAUER-SUNDSTRAND A uthorized Service Center.
System Operatin g Hot
1. Oil level in reservoir. Insufficient hydraulic fluid will not meet Fill reservoir to proper level.
cooling demands of system.
2. Heat exchanger. Heat exchanger not sufficiently cooling Check air flow and input air tempera-
the system. ture for heat exchanger. Clean, repair
or replace heat exchanger.
3. Charge pressure. Low charge pressure will overwork sys- Measure charge pressure. Inspect and
tem. adjust or replace charge relief valve. Or
repair leaky charge pump.
4. Charge pump inlet v acuum. High inlet vacuum will overwork sys- Check charge inlet vacuum. If high,
tem. A dirty filter will incre ase the inlet inspect inlet filter and replace as neces-
vacuum. Inadequate line size will re- sary. Check for adequate line size,
strict flow. length or other restrictions.
5. System relief pressure settings. If the system relief settings are too low, Verify settings of pressure limiters and
the relief valves will be overworked. high pressure relief valves and adjust
or replace multi-function valves as nec-
essary.
6. For internal le akage in motor.
Leakage will reduce low side system Monitor motor case flow without loop
pressure and overwork the system. flushing in the circ uit (use defeat spool).
If flow is excessive, repl ace motor.
7. System pressure. High system pressure will overheat Measure system pressure. If pressure
system. is high reduce loads.
27
008 911 63 BOMAG 555

17.1 Travel pump
Transmission Operates Normally in One Direction Only

1. Input to p ump control. Input to control mod ule is operating Check control input and repair or re-
2. Pump displacement control. Control linkages are not secure, control Repair or replace control module as
orifices are blocked, etc. necessary.
3. Interchange system pressure limit- Interchanging the multi-function valves Interchange multi-function valves. If the
ers, high pressure relief valves, and will show if the problem is related to the problem changes direction, repair or
system check valves. valve functions contained in the m ulti- replace the valve on the side th at does
function valves. not operate.
4. Charge pressure. If charge pressure decays in one direc- Measure charge pressure in forward
tion the loop fl ushing valve may be and reverse. If press ure decays in one
“sticking” in one direction. direction, inspect and repair the motor
loop flushing valve.
System Will Not Operate in Either Direction
1. Oil level in reservoir. Insufficient hydraulic fluid to s upply Fill reservoir to proper level.
system loop.
2. Input to p ump control. Input to control mod ule is operating Check control input and repair or re-
3. Pump displacement control. Control linkages are not secure, control Repair or replace control module as
4. Ensure bypass valve(s) are closed. If bypass v alve(s) is open, the system Close bypass valves. Replace multi-
loop will be depressurized. function valve if defective.
5. Charge pressure with pump in neu- Low charge pressure insufficient to re- Measure charge pressure with the p ump
tral. charge system loop. in neutral. If pressure is low, go to step
6; otherwise contin ue with step 5.
6. Ch arge pressure with p u mp in Low charge pressure with the pump in Measure charge pressure with pump in
stroke. stroke indicates a motor charge relief stroke. If pressure is low, adjust or
valve or system pressure relief valve replace motor charge relief valve, oth-
may be improperly set. erwise go to step 9.
7. Pump charge relief valve. A pump charge relief valve that is le aky Adjust or replace pump charge relief
or set too low will depressurize the valve as necessary.
system.
8. Charge pump inlet filter. A clogged filter will undersupply system Inspect filter and replace if necessary.
loop.
9. Charge pump. A malfunctioning charge pump will pro- Repair or replace the charge pump. If
vide insufficient charge flow. OK go to l ast step.
28
556 BOMAG 008 911 63

Travel pump 17.1
10.Pump displacement control. Control linkages are not secure, control Repair or replace control module as
11. System pressure. Low system pressure will not provide Measure system pressure. Continue
power necessary to move load. with next step.
12.System multi-function valves. Defective m ulti-function valves will Repair or replace multi-function valve(s).
cause system pressure to be low.

Low Motor Output Torque
1. System pressure at motor. Low system pressure at the motor will Measure system pressure at motor. If
reduce torque. pressure limiter setting is low, incre ase
setting.
2. Variable motor stuck at minimum Minimum motor displacement yields low Check control supply pressure or re-
displacement. output torque. pair displacement control. Check mo-
tor control orifices.
3. For internal le akage. Internal leakage will red uce system Check for leakage in O-rings, g askets,
pressure. and other fittings. Rep air unit as re-
quired, or replace leaky unit.

Improper Motor Output Speed
1. Oil level in reservoir. Insufficient hydraulic fluid will reduce Fill oil to proper level.
motor speed.
2. Pump o utput flow. Incorrect outflow will a ffect o utp ut Measure pump output and check for
speed. Incorrect output flow indic ates proper pump speed and see that the
the swashplate is out of position. pump is in full stroke.
3. Variable motor displacement con- If v ariable motor displacement control See if v ariable motor displacement con-
trol. is not functioning correctly, variable trol is responding. If not, rep air or re-
motor swashplate may be in wrong place control.
position.
4. For internal le akage. Intern al leakage will red uce system Check for leakage in O-rings, gaskets,
pressure. and other fittings. Rep air unit as re-
quired, or replace leaky unit.

29
008 911 63 BOMAG 557

17.1 Travel pump
Excessive Noise and/or Vibration

1. Oil in reservoir. Insufficient hydraulic fluid will le ad to Fill reservoir to proper level.
cavitation.
2. Air in system. Air bubbles will lead to cavitation. Look for foam in reservoir. Check for
leaks on inlet side of system loop. After-
wards, let reservoir settle until bubbles
are gone. Run system at low speed to
move system fluid to reservoir. Repeat.
3. Pump inlet vacuum. High inlet vacuum will create noise. A Inspect and replace filter as necessary.
dirty filter will incre ase the inlet v acuum. Check for proper suction line size.
4. Shaft couplings. A loose shaft coupling will cause exces- Replace loose shaft coupling in charge
sive noise. pump or replace p ump or motor.
5. Shaft alignment. Unaligned shafts will create excessive Align shafts.

frictional noise.

contact a SAUER-SUNDSTRAND Authorized Service Center.
System Response is Slu ggish
1. Oil level in reservoir. Insufficient hydraulic fluid will reduce Fill reservoir to proper level.
output pressure.
2. Multi-function valves’ pressure set- Incorrect pressure settings will affect Adjust or replace multi-function valves.
tings. system reaction time.
3. Pump inlet vacuum. High pump inlet v acuum will reduce Measure charge inlet vacuum. If high
system pressure. replace inlet filter.
4. Prime mover speed. Low engine speed will reduce system Adjust engine speed.
performance.
5. Charge and control pressures. Incorrect charge or control pressures Measure charge and control pressures
will affect system performance. and correct if necessary.
6. System internal le akage. Internal le akage will red uce system Check for leakage in O-rings, gaskets,
pressure. and other fittings.

contact a SAUER-SUNDSTRAND Authorized Service Center.
30
558 BOMAG 008 911 63

Travel pump 17.1
Series 90 Inspections and Adjustments
Inspections and Adjustments
This section offers instr uction on how to perform inspections and adjustments on pump and motor components. Re ad
through the entire related section before beginning a service activity. Refer to the corresponding section for loc ation of
gauge ports and s uggested gauge size.
Pump Adjustments
Charge Pressure Relief Valve Adjustment
The following procedure explains how to check and adjust

the charge pressure relief valve.
WARNING
The following procedure may require the vehicle/
machine to be disabled (wheels raised off the ground,
work function disconnected, etc.) while performing
the procedure in order to prevent injury to the
technician and bystanders. Take necessary safety
S000 007E
90000243
Charge Pressure Gauge Port (Reducer fittin g shown - if
filtration device attached)
1. To measure pump charge pressure, install a pres-
sure gauge in the p ump charge pressure gauge port
(M3). Also inst all a gauge to measure case pressure
(tee into L1 or L2 or use servo gauge port). Operate
the system with the p ump in “neutral” (zero displace-
ment) when measuring pump charge pressure. Nominal
90L055 EA 1 N Charge Pressure
2. The table shows the acceptable p ump charge pres- 6 S 3 C6 C 03
sure range for some nomin al charge relief valve HNN 35 35 24
settings (see sample model code at right). These
pressures assume 1500 pump rpm and a reservoir Model Code on Unit Name Plate (“24 bar”)
temper ature of 50°C (120°F ), and are referenced to
case pressure (see footnote on next page). Smaller
displacement charge pumps will produce charge
pressure readings in the lower portion of the r ange, Model Code Measured Charge Pressure *
while larger displacement charge pumps will prod uce 18.1 bis 21.7 bar
readings in the higher portion of the r ange. 20
(262 to 315 psi)
22.0 bis 26.9 bar
24
(319 to 390 psi)
25.8 bis 30.7 bar
28
(374 to 445 psi)
T002 266E
* This is the actual charge pressure por t gauge reading minus the
case pressure por t gauge reading.
Note: These pressures ass ume a pump speed of

1450 - 1500 rpm. At higher p ump input speeds
(with higher charge flows) the charge pressure
will rise over the r ated setting.
* This is the actual charge pressure port gauge reading minus

the case pressure port gauge reading.
31
008 911 63 BOMAG 559

17.1 Travel pump
3. Earlier production Series 90 p umps are equipped

with a shim adjustable charge pressure relief valve.
Shim kits are available from SAUER-SUNDSTRAND.
Adjustment of ch arge pressure is accomplished by
removing the plug [1 inch Hex] and changing the shim
thickness behind the spring. The pl ug for this type of
charge relief valve should be torqued to 68 Nm
(50 lbf ft).
Later production Series 90 pumps are equipped with

90000262 90000264 an external screw adjustable charge pressure relief
Shim Adjustable Char ge Screw Adjustable Char ge valve. Adjustment of the ch arge pressure is accom-
Pressure Relief Valve Pressure Relief Valve plished by loosening the lock n ut -
(Pump) (Pump)
Frame Size Wrench Size
030 - 100 1-1 / 16 inch
130 - 250 1-5 / 8 inch
T002 267E
and t urning the adjustment plug with a l arge screw-

driver or a 1/2 inch hex wrench.
Clockwise rotation of the pl ug increases the setting,

and counterclockwise rotation decreases the setting
(at a rate of approximately 3.9 bar (50 psi) per t urn).
The lock nut for this type of ch arge relief valve should
be torqued to 52 Nm (39 l bf ft).
4. Once the desired charge pressure setting is achieved,

remove the g auges.
32
560 BOMAG 008 911 63

Travel pump 17.1

Multi-Function Valve Pressure Adjustment
Adjustment of the pressure limiter setting and the high

pressure relief valve setting is accomplished simulta-
neously. The latter is automatically set approximately
35 bar (500 psi) above the former.
In order to adjust the pressure limiter setting, the motor

output sh aft m ust be locked so it does not rot ate. This
may be accomplished by locking the vehicle’s brakes or
rigidly fixing the work function so it c annot rotate.
WARNING
Take necessary precautions that the motor shaft
remains stationary during the adjustment procedure.
S000 010E
90000258
Multi-Function Valves on PV
1. Install two 1000 bar (or 10 000 psi) pressure gauges

in the high pressure gauge ports (M1 and M2). Install
a 50 bar (or 1000 psi) pressure g auge in the p ump
charge pressure gauge port (M3).
2. Start the prime mover and operate at normal speed.
3. Loosen locking nut.

early
10 mm
042 - 100
newer
19 mm
030 - 100
early 130 13 mm
130 - 250 24 mm
T002 268E
4. Insert a internal hex wrench into the pressure adjust-

ing screw.
Frame Size Internal Hex Wrench Size

early 90000259
3 mm
042 - 100 Loosen Pressure Adjustin g Screw Lock Nut
newer
5 mm
030 - 100
early 130 4 mm
130 - 250 8 mm
T002 269E
Note: A plastic dust plug is installed in the adjusting

screw on 030 and l ate 042 through 250 units.
33
008 911 63 BOMAG 561

17.1 Travel pump
90L055 EA 1 N 5. The factory preset pressure limiter setting is shown

on the model code as at right. It is referenced to
6 S 3 C6 C 03 charge pressure, so the pressure limiter setting is the
HNN 35 35 24 difference between the high and low pressure sides
of the system loop. Activ ate or move the control inp ut
so that pressure increases in the high press ure side
Pressure Limiter Setting of the closed circuit to the press ure limiter pressure
Ports A and B (differential setting. The press ure limiter setting is re ached when
pressure in 10s of bars, the pressure stops increasing and remains steady at
e.g. “35” = 350 bar) a given pressure level ( as shown on the gauges).
6. Return the p ump to its “ne utral” (zero flow) position

and adjust the press ure limiter setting by rotating the
pressure adjusting screw with the intern al hex wrench.
Clockwise rotation of the press ure adjustment screw

will increase the pressure setting, and counterclock-
wise rotation will decrease the pressure setting. Each
complete rotation of the pressure adjusting screw
changes the pressure as shown in the following t able.
Approx Change per Rev of the

Frame Size
Adjusting Screw
early
80 bar (1157 psi) per Rev
042 - 100
newer
90 bar (1300 psi) per Rev
030 - 100
130 - 250 80 bar (1157 psi) per Rev
90000260
T002 270E
Rotate Pressure Adjustin g Screw
7. To verify the actual pressure setting, actuate or move

the control input so that the pump again develops
pressure in the high press ure circuit to the newly
adjusted pressure limiter press ure setting, and read
the high pressure gauge. Then allow the pump to
return to its “neutral” position. The press ure in the
high pressure circuit should return to the ch arge
pressure setting.
8. While holding the pressure adjusting screw station-

ary, tighten the press ure adjusting screw lock.
Frame Size Torque

early
3 Nm (26 lbf in)
042 - 100
newer
20 Nm (15 lbf ft)
030 - 100
130 - 250 40 Nm (30 lbf ft)
T002 271E
Do not overtorque.
90000261 9. Shut down the prime mover, remove the g auges and
Tighten Lock Nut install the g auge port plugs. Replace the pl astic dust
plugs (if used).
The same procedure is used for setting the press ure limit
of the other multi-f unction valve, but the control input
signal must be activated or moved in the opposite direc-
tion so that high pressure develops in the opposite side
of the closed circuit.
34
562 BOMAG 008 911 63

Travel pump 17.1

Engaging the Bypass Function
The bypass function is performed by the multi-function

valve cartridges. The prime mover sho uld be sh ut down
when opening or closing the bypass v alves.
The bypass valves on both of the m ulti-function valves

must be opened to engaged the bypass function.
1. Using a
newer
1-1 / 16 inch
030 - 100
130 - 250 1-3 / 8 inch
T002 272E
wrench on the middle sized hex of the m ulti-function

90000266
valve cartridge, and a
Loosenin g and Rotatin g Bypass Hex on Multi-Function
Frame Size Wrench Size Valve
newer
1-1 / 4 inch Opening Bypass Valve
030 - 100
allows flow to circuit
130 - 250 1-5 / 8 inch Bypass through Multi-Function Valves
T002 273E Actuator
wrench on the large hex to prevent rot ation of the

cartridge assembly, rotate the middle hex three
revolutions counterclockwise to open the bypass
valve. Do not rotate more than 3-1/2 revolutions,
as additional rotation will permit external leak-
age.
2. For units with an MDC-type control, prior to moving 90000827E

the vehicle or otherwise causing the motor sh aft to Multi-Function Valve with Bypass Function En gaged
turn, move the control h andle of the manual displace-
ment control on the p ump to the m axim um f ull
forward position. Hold the h andle in this position
during bypass valve operation.
Caution
"Tow" at extremely low speeds and for short
distances only.
S000 011E
3. To close the bypass valve, rotate the middle hex

clockwise until it is se ated. Then torq ue the middle
hex.
Frame Size Torque
newer
41 Nm (30 lbf ft)
030 - 100
130 - 250 100 Nm (75 lbf ft)
T002 274E
35
008 911 63 BOMAG 563

17.1 Travel pump

Pressure Override (POR) Valve Pressure
Adjustment (Option for 180 Frame Size)
The Pressure Override Valve is explained in the corre-

sponding section.
1. Install two 1000 bar (or 10 000 psi) pressure gauges

Pressure Override V alve Adjusting Screw in the high pressure gauge ports (M1 and M2). Install
Lock N ut
a 50 bar (or 1000 psi) pressure g auge in the p ump
charge pressure gauge port (M3).
2. Start the prime mover and operate at normal speed.
3. With the p ump operating at approximately 20% dis-

placement, load the work function and note the
pressure as the POR v alve operates (pump displace-
ment reduces to “zero”).
4. Adjustment of the pressure override setting is m ade

by loosening the lock n ut with a 9/16 inch hex wrench
and turning the adjustment screw with a 3/16 inch
internal hex wrench. The POR setting should be at
Right Side View least 50 bar (750 psi) below the high pressure relief
90000828E valve setting of the m ulti-function valves for proper
Pressure Override Valve for 180 Frame Size operation.
5. Following the adjustment, torq ue the lock n ut to

43 Nm (32 lbf ft).
6. Shut down the prime mover and remove the gauges

and install the g auge port pl ugs.
36
564 BOMAG 008 911 63

Travel pump 17.1

Displacement Limiter Adjustment
The maximum displacement can be limited in either

direction.
1. Loosen the seal lock nut retaining the displacement

limiter adjusting screw.
030 - 100 13 mm
130 17 mm
180 - 250 19 mm
T002 275E
2. Rotate the adjusting screw.

Frame Size Internal Hex Wrench Size
030 - 100 4 mm
90000267
130 5 mm
Loosen Displacement Limiter Lock Nut
180 - 250 6 mm
T002 276E
Rotating the adjusting screw clockwise will decrease

the maximum displacement of the p ump while rotat-
ing the adjusting screw counterclockwise will in-
crease the maximum displacement.
Caution
Care should be taken in adjusting displacement
limiters to avoid undesirable flow or speed conditions.
The seal lock nut must be retorqued after every
adjustment to prevent an unexpected change in
operating conditions and to prevent external leakage
during unit operation.
S000 012E
90000268
Rotate Adjusting Screw
3 . After establishing the desired m aximum displace-
ment setting, tighten the lock n ut on the adjusting
screw as follows.
Frame Size Torque
030 - 100 24 Nm (18 lbf ft)
130 48 Nm (35 lbf ft)
180 - 250 125 Nm (92 lbf ft)
T002 278E
4. One turn of the adjusting screw will change the

maximum displacement approximately as follows.
Approx Change in Disp per Rev of

Frame Size
Adjusting Screw 90000269
030 2.8 cm3 / Rev (0.17 in3 / Rev) Tighten Lock Nut
042 3.5 cm3 / Rev (0.21 in3 / Rev)
055 4.2 cm3 / Rev (0.26 in3 / Rev)
075 5.1 cm3 / Rev (0.31 in3 / Rev)
100 6.2 cm3 / Rev (0.38 in3 / Rev)
130 8.8 cm3 / Rev (0.53 in3 / Rev)
180 12.5 cm3 / Rev (0.76 in3 / Rev)
250 17.3 cm3 / Rev (1.06 in3 / Rev)
T002 277E
37
008 911 63 BOMAG 565

17.1 Travel pump

Pump Control Adjustments
Standard Manual Displacement Control (MDC)

Adjustment
There are no adjustable elements in the m anual dis-

placement control. The control spool is held in its “ne utral”
position by centering springs and washers on each end of
the spool. Since there is no centering spring on the control
input shaft, the sh aft will automatic ally assume the appro-
priate position when the control is installed on the p ump.
90000237
Variable Displacement Pump with Standard Manual
38
566 BOMAG 008 911 63

Travel pump 17.1

Non-Linear Manual Displacement Control
(MDC)
A centering spring, loc ated on the control inp ut sh aft,

locates the control shaft in its “ne utral” position. A bias
spring on the control spool m aintains a force on the spool
and the control link age to elimin ate looseness (“free-
play”) in the link age.
The “neutral” adjustment is the only adjustment th at can

be m ade on the nonline ar m anual displacement control.
All other functions are preset at the f actory.
This adjustment must be made on a test stand or on the

vehicle/machine with the prime mover oper ating. 90000829
Variable Displacement Pump with Non-Linear Manual
WARNING
S000 007E
1. Install two 50 bar (or 1000 psi) gauges in each of the

displacement control cylinder gauge ports (M4 and
M5). Disconnect the external control link age from the
control handle and m ake certain the control sh aft is
in its “ne utral” position. St art the prime mover and
operate at normal speed.
2. Loosen the lock nut on the ne utral adjusting screw 90000357 90000358
with a 13 mm hex wrench. Rotate Neutral Adjustin g Tighten Neutral Adjustin g
Screw Screw Lock Nut
3. Using a 4 mm intern al hex wrench, rotate the ne utral
adjusting screw clockwise until the press ure increases
on one of the press ure gauges. Note the angular
position of the wrench.
4. Rotate the adjusting screw counterclockwise until the

pressure increases by an equal amount on the other
gauge. Note the angular position of the wrench.
5. Rotate the adjusting screw clockwise half the dis-

tance between the locations noted above. The g auges
should read the s ame pressure (case pressure),
indicating that the control is in its “ne utral” position.
6 . Hold the adjusting screw stationary and tighten the

lock nut to 13.5 Nm (10 l bf ft). Do not overtorque
the nut.
7 . Once the neutral position is set, stop the prime

mover, remove the g auges, and install the g auge
port plugs. Reconnect the external control linkage.
39
008 911 63 BOMAG 567

17.1 Travel pump

MDC Neutral Start Switch (NSS) Adjustments
The neutral start switch (NSS) provides a means to

A A prevent the system prime mover from st arting while the
pump control handle and control input sh aft are in a
Control Shaft Switch Cam position which would command the pump to go “in-
stroke” in either the “forw ard” or “reverse” direction.
Switch Lock N ut When the control inp ut shaft is in its “ne utral” position, the
inner end of the switch pin moves into a slot on the
Neutral Start Switch
eccentric cam attached to the control shaft. This allows
Eccentric Pl ug the spring lo aded NSS to close, completing the electric al
Switch Pin starting circuit for the prime mover.
Special Lock Nut
for Eccentric Plug
When the control input sh aft is NOT in its “ne utral”
MDC with Neutral Start switch position, the eccentric c am moves the switch pin o ut of
the slot. This forces the NSS to open, breaking the
electrical st arting circuit for the prime mover.
The neutral st art switch is thre aded into the speci al lock
nut for the eccentric pl ug.
Turning the NSS clockwise (CW) into the speci al nut will
move the NSS closer to the switch c am on the control
Orifice Check V alve Seat shaft, and will narrow the NSS deadband. Turning the
Control Spool Assem bly
Control Link Assem bly
NSS counterclockwise (CCW) out of the speci al n ut will
move the NSS f arther from the switch c am on the control
View at Section A-A shaft, and will widen the NSS de adband.
90000830E
The switch pin is located in an eccentric plug which is
Components of the Standard Manual Displacement Control turned to move the center of the NSS de adband.
with Neutral Start Switch
(continued)
40
568 BOMAG 008 911 63

Travel pump 17.1

The NSS m ust be adjusted to meet the following three
req uirements:
NSS Deadband Control Shaft
(Switch closed, "ON") ("Free-Play")
i. The distance the control h andle can be t urned with-
out opening the NSS is c alled the “NSS Deadband.” Control Deadband
The distance the control h andle can be moved with- ("Neutral")
out moving the control spool eno ugh to port hydr aulic
fluid to the p ump displacement control cylinders is
Total Control
called the “Control De adband.” These deadbands Shaft Rotation
must be centered in rel ation to e ach other.
Since the position of the control de adband cannot be Control Shaft

adjusted, the position of the NSS de adband must be
adjusted to match it.
ii. The NSS de adband must be wide enough so the NSS

will not open within the loose area of control h andle
movement caused by normal operating clearances in
the control linkage (control shaft “free-play”).
By setting the NSS to open o utside this area, the

control spool springs or control shaft centering spring
can always act to ret urn the h andle to “neutral” and
re-close the NSS.
iii. The NSS de adband m ust be n arrow enough so the

NSS will open before the unit builds 7 bar (100 psi)
differenti al system pressure in either direction.
90000831E
(continued) Neutral Start Switch Adjustment Requirements
41
008 911 63 BOMAG 569

17.1 Travel pump

NSS Deadband Adjustment (Conditions ii & iii)
The NSS de adband must be wide enough so the NSS will

not open within the control sh aft “free-play” area, and it
must be narrow enough so the NSS will open before the
unit builds 7 bar (100 psi) differenti al system pressure in
either direction.
1. Install two 1000 bar (10 000 psi) pressure gauges in

the system pressure g auge ports M1 and M2.
2. Using two 1-1/8 inch wrenches, hold the neutral start

switch from t urning and loosen the lockn ut.
3. Disconnect the external control link age and make

certain the control sh aft is in its “ne utral” position.
4. Attach a continuity checker to the termin als of the

switch. With the control sh aft in its “ne utral” position,
turn the switch clockwise (CW) until electrical conti-
90000253
Loosenin g the NSS Lock Nut
nuity is broken, then turn the switch counterclockwise
(CCW) until electrical continuity is obtained. Turn the
switch counterclockwise (CCW) an additional 1/4
turn (90°) after continuity has been obtained.
5. Hold the switch in place and tighten the lockn ut to

27 Nm (20 l bf ft) torq ue.
Control Shaft
6. With the continuity checker attached to the switch,
rotate the control h andle (or the control sh aft) in e ach
direction to assure continuity is broken when the
control is not in the “ne utral” position.
Switch Lock Nut
Switch Cam 7 . If contin uity is o btained in “ne utral” and satisfactorily

Neutral Start Switch interr upted in e ach direction, proceed to check the
switch with the prime mover r unning. The switch
must open before the unit builds 7 bar (100 psi)
Switch Pin 1-1/8 in. hex wrench differenti al system pressure in either direction.
Torque: 27 Nm (20 l bf ft)
If the switch opens after the unit builds system
90000832E pressure in either direction, loosen the switch lock
NSS nut and turn the switch clockwise (CW) 1/12 turn
(30°). Tighten the switch lock n ut and recheck the
switch operation. Repeat this proced ure if neces-
sary.
8. If continuity is not interrupted with an equal move-

ment of the control h andle in e ach direction, turn off
prime mover, remove the press ure gauges, and
contin ue with the next section.
9. If ne utral start switch operation is satisfactory, turn

off the prime mover, remove the press ure gauges,
and reconnect the external control link age.
90000870
Checkin g Continuity of NSS (System Pressure Gau ges
installed on far side)
42
570 BOMAG 008 911 63

Travel pump 17.1

Neutral Start Switch Eccentric Plug Adjustment (Con- 12.7 9.14
dition i) (0.5) (0.36)
The NSS deadband and the control de adband must be
centered in relation to e ach other.
Since the position of the control de adband cannot be 3.175 1.52

adjusted, the position of the NSS de adband must be
(0.125) (0.06)
adjusted to m atch it. The switch pin is loc ated in an 25.4+
eccentric plug which is t urned to move the center of the (1.0)
NSS deadband.
90000834E
The MDC should be installed on the p ump and be in its
Eccentric Plug Adjustment Tool
“neutral” position when adjusting the ne utral start switch
eccentric plug.
The accompanying drawing provides dimensions for an

Eccentric Plug Adjustment Tool.
1. Hold the switch and eccentric plug from t urning and

use two 1-1/8 inch wrenches to loosen the lockn ut.
Remove the neutral start switch.
WARNING Switch
Lock Nut
Do not start the prime mover while the neutral start Eccentric Plug
switch is removed from the control. Case pressure X
Switch Pin
will force the pin out of the eccentric plu g, causing Special Lock Nut
oil loss. for Eccentric Plug Neutral Start Switch
S000 032E
MDC with Neutral Start Switch
Special Lock Nut

for Eccentric Plug
Control Eccentric Plug

Mounting
Surface
Switch Pin
View in Direction X
(Switch and lock nut removed)
90000833E
NSS with Eccentric Plu g
2. Note the slots on the eccentric plug for the adjust-

ment tool. Hold the eccentric pl ug in pl ace with the
adjustment tool, and loosen the lock n ut with a
1-1/8 inch wrench.
(continued)
90000256 90000257
Loosen Eccentric Lock Nut NSS Removed
43
008 911 63 BOMAG 571

17.1 Travel pump
3. Position the eccentric pl ug so the switch pin is offset

Switch Pin
toward the control mounting surface. This will provide
Eccentric Plug
the best contact between the pin and the cam on the
control shaft.
4. Hold the control shaft in its “ne utral” position (in the
center of the control sh aft “free-play” area). Locate
the switch pin in the slot of the switch c am by turning
90˚ 90˚
the eccentric plug while checking the pin position
(depth) in the pl ug. When the pin eng ages the cam
slot, the pin will be at its m aximum depth in the pl ug.
Eccentric Plug
Adj ustment Range
Hand tighten the pl ug lock nut to hold the eccentric
Control Mounting plug in position.
Surface
90000835E 5. Turn the control shaft an equal amount in either
Eccentric Plug Adjustment direction from “ne utral.” The switch pin sho uld move
out of the eccentric pl ug an equal distance when the
control shaft is t urned. Turn the eccentric plug to
center the switch pin with the c am slot. Only a small
amount of adjustment in either direction sho uld be
needed to center the pin.
6. While holding the eccentric plug in place, tighten the

eccentric plug lock nut to 27 Nm (20 lbf ft). Reinstall
and adjust the switch as outlined in the previo us
section.
Note: The eccentric plug normally requires between

5-1/2 and 6-1/2 turns to install into the control
housing .
90000256
Adjust the Eccentric Plu g
Caution
Do not turn the eccentric plug into or out of the
housing beyond specifications.
S000 014E
7. Once the switch is correctly adjusted, hold the switch

in place and tighten the lockn ut to 27 Nm (20 l bf ft)
torque.
(continued)
44
572 BOMAG 008 911 63

Travel pump 17.1

Checkin g Switch Continuity
Recheck switch continuity to determine whether addi-

tion al adjustment of the eccentric pl ug is necessary.
WARNING
S000 007E
1. Install two 50 bar (or 1000 psi) g auges in each of the

displacement control cylinder gauge ports (M4 and
M5). Attach a continuity checker to the termin als of
the neutral start switch.
2. Energize the starter circuit, and start the prime

mover.
3 . While operating at normal speed and with the p ump

in its “neutral” (zero flow) position, note the pressure
reading on the g auges. This reading should be noted
as the base pressure.
4. Slowly move the control handle in one direction while

observing the pressure gauges and the contin uity
checker. Continuity must b e broken before the pres-
sure on either g auge increases more than 1 bar
(12 psi) from the base pressure obtained at “neutral.”
5. Slowly move the control h andle in the opposite

direction. Again, continuity must be broken before
the gauge pressure increases more than 1 bar (12 psi)
from base pressure.
6. Continuity must again be verified when the control is 90000255

returned to neutral. Checkin g Continuity of NSS
(Gauges installed in Servo Gau ge Ports)
7 . If continuity is not broken at base pressure plus 0 to
1 bar (0 to 12 psi) in either direction, stop the prime
mover and readjust the eccentric plug as described
in the previo us section. If the press ure difference is
equal in each direction but greater than 1 bar (12 psi),
loosen the switch locknut and t urn the switch clock-
wise 1/12 turn (30°) to increase the sensitivity. Re-
tighten the lockn ut and recheck pressure differences
and continuity.
8. After verifying proper control and switch operation,

stop the prime mover. Remove the continuity checker
and pressure gauges. Reinstall the servo pressure
port plugs and reconnect the electrical leads from the
machine starter circuit to the ne utral start switch.
Install and adjust, if necessary, the external control
linkage.
45
008 911 63 BOMAG 573

17.1 Travel pump

Hydraulic Displacement Control (HDC) and
Electric Displacement Control (EDC) Adjust-
ment
The “neutral” adjustment is the only adjustment that c an

be made on hydraulic and electric displacement controls.
All other f unctions are preset at the f actory.
This adjustment must be made on a test st and or on the

vehicle/machine with the prime mover oper ating.
The neutral adjustment is performed by adjusting a

neutral adjusting shaft (earlier production EDCs) or a
90000240 neutral adjusting screw (HDCs and current production
PV with Hydraulic Displacement Control EDCs).
WARNING
S000 007E
90000241
PV with Electric Displacement Control
1. Install two 50 bar (or 1000 psi) gauges in each of the

two displacement control cylinder gauge ports (M4
and M5). Disconnect the extern al control inp ut (hy-
draulic or electronic) from the control. St art the prime
mover and operate at normal speed.
2. Loosen the lock nut with a 17 mm hex wrench for the
neutral adjusting shaft or with a 10 mm or 13 mm hex
wrench for the neutral adjusting screw.
90000249
Install Gau ges in Displacement Control Cylinder Gau ge
Ports
46
574 BOMAG 008 911 63

Travel pump 17.1
3. Using a 5 mm intern al hex wrench for the neutral

adjusting shaft or a 3 mm or 4 mm intern al hex
wrench for the neutral adjusting screw, rotate clock-
wise until the press ure increases in one of the
pressure gauges. Note the angular position of the
wrench. Then rotate the neutral adjusting shaft or
screw counterclockwise until the pressure increases
by an eq ual amount on the other g auge. Again note
the angular position of the wrench.
4. Rotate the ne utral shaft or adjusting screw clockwise 90000250 90000252

half the dist ance between the locations noted above. Rotate Neutral Adjustin g Tighten Neutral Adjustin g
Shaft Shaft Lock Nut
The gauges should read the s ame pressure (case (Early production) (Early production)
pressure), indicating that the control is in its “ne utral”
position.
5. Hold the neutral adjusting shaft or screw stationary.

Tighten the ne utral shaft lock nut (e arly production
controls) to 22 Nm (195 lbf in.). Tighten the neutral
adjusting screw lock nut (later production controls) to
7 Nm (62 lbf in.) for the 6 mm screw or 13.5 Nm
(120 lbf in.) for the 8 mm screw. Do not overtorque
the nut.
6 . Once the neutral position is set, stop the prime

mover, remove the g auges, and install the g auge 90000251 90000318
port plugs. Reconnect the external control inp ut. Rotate Neutral Adjustin g Tighten Neutral Adjustin g
Screw Screw Lock Nut
(Later production) (Later production)
90000355 90000356
Rotate Neutral Adjustin g Tighten Neutral Adjustin g
Shaft Shaft Lock Nut
(Current production HDC) (Current production HDC)
47
008 911 63 BOMAG 575

17.1 Travel pump

Motor Adjustments
Charge Relief Valve Adjustment
1. To measure motor charge pressure, install a 50 bar

(or 1000 psi) pressure gauge in the motor charge
pressure gauge port (M3). Size 30 and 42 don’t have
the M3 gauge port. Inst all pressure gauge in the
motor system pressure gauge port. For this kind of
measurement add 1 bar (14.5 psi) to the nomin al
values shown in the table. Also inst all a gauge to
measure case pressure. Operate the system with the
pump in stroke (forward or reverse) when measuring
motor charge pressure.
90000248 2. The following table shows acceptable motor ch arge

Charge Pressure Gauge Port (MF) pressures for some nomin al ch arge relief valve set-
tings (see model code at right). These press ures
90M055 NC 0 N Nominal charge
assume a reservoir temperature of 50°C (120°F).
Pressure Setting
8 N 0 C6 W 00 They are referenced to c ase pressure and assume a
NNN 00 00 24 one pump/one motor system.
Motor Charge Pressure 3. Earlier production Series 90 motors are equipped

Model Code
(±1.4 bar [±20 psi]) with a shim adjustable charge relief valve. Shim kits
are available as service items. Adj ustment of the
10 8.1 bar (117 psi)
charge pressure is accomplished by removing the
plug (7/8 inch hex) and changing the shim thickness
18 16.1 bar (233 psi)
behind the spring. The pl ug for this type ch arge relief
port should be torqued to 68 Nm (50 l bf ft).
20 18.1 bar (262 psi)
Later production Series 90 motors are equipped with
24 22.1 bar (320 psi) an external screw adjustable charge relief valve.
Adjustment of ch arge pressure is accomplished by
28 26.1 bar (378 psi) loosening the lock nut,
30 30.0 bar (435 psi) Frame Size Wrench Size
030 - 130 1-1 / 16 inch
T002 279E
T002 293E
Model Code at the Name Plate (24 ba r)
and t urning the adjustment plug with a l arge screw-
driver or a 1/2 inch hex wrench. Clockwise rotation of
the plug increases the setting, and counterclockwise
rotation decreases the setting ( at a r ate of approxi-
mately 5.4 bar [78 psi] per t urn). The lock nut for this
type charge relief valve should be torqued to 52 Nm
(38 lbf ft).
4. Once the desired charge pressure setting is achieved,

remove the gauges.
90000263 90000343
Shim Adjustable Char ge Screw Adjustable Char ge
Pressure Relief Valve Pressure Relief Valve
(Motor) (Motor)
48
576 BOMAG 008 911 63

Travel pump 17.1

Displacement Limiter Adjustment (MV)
Tamper-Resistant Cap
Both the m aximum and minimum displacement may be
limited. Seal Lock N ut
Maximum Displacement
1. Remove the tamper resistant c ap from the displace- Limiter Screw
ment limiter screw. Loosen the se al lock nut retaining
the displacement limiter adjusting screw with a 19 mm
wrench.
Caution
The displacement limiters act as travel stops for the
swashplate. Do not turn the limiter screws
counterclockwise beyond the point of contact with
the swashplate for either the maximum or minimum
displacement position.
S000 015E
2. All adjustments can only be done when the motor is

Minimum Displacement
running and the pump is in neutral position. Steer the
Limiter Screw
respective displacement limiter by the control.
Seal Lock Nut
Rotate the adjusting screw with a 6 mm intern al hex Tamper-Resistant Cap
wrench. Rotating the m aximum displacement adjust-
SAE Fl ange Version shown
ing screw clockwise will decrease the m aximum
(Cartridge Version simil ar)
displacement of the motor. Rot ating the minim um
displacement adjusting screw clockwise will incre ase 90000837E
the minimum displacement of the motor. MV Displacement Limiters
Caution
Care should be taken in adjusting displacement
limiters to avoid undesirable flow or speed
conditions. See corresponding section for speed
and pressure limits.
The seal lock nut must be retorqued after every

adjustment to prevent an unexpected change in
S000 016E 90000359 90000360
Rotate Adjustin g Screw for Tighten Lock Nut for
Minimum Displacement Minimum Displacement
3 . After establishing the desired displacement setting, Limiter Limiter
tighten the lock n ut on the adjusting screw to 54 Nm
(40 lbf ft). Install a new tamper resistant c ap.
4. One turn of the adjusting screw will change the

maximum or minim um displacement according to the
following chart.
Frame Size
Adjusting Screw
055 5.6 cm3 / Rev (0.34 in3 / Rev)
075 7.1 cm3 / Rev (0.43 in3 / Rev)
T002 280E
Displacement Control Adjustments
All variable motor displacement control settings do not 90000352

require adjusting. Maximum Displacement Limiter
49
008 911 63 BOMAG 577

17.1 Travel pump

Speed Sensor Adjustment
When installing or adjusting the speed sensor on a pump

or motor, it m ust be set at a specific distance from the
speed ring on the unit’s cylinder. To loc ate the position of
Gap the speed sensor on the unit or description see the
corresponding section.
Speed Sensor 1. Loosen the sensor lock nut with an 1-1/16 inch hex
Magnetic Speed Ring wrench.
90000838E
Cross Section View of Speed Sensor in Variable Pump 2. Turn the sensor clockwise (CW) by hand until it
contacts the speed ring.
Gap
3. Turn the sensor counterclockwise (CCW) 1/2 turn
(180°) to establish the nomin al gap of 0.71 mm
(0.028 inch).
4. Then turn the sensor clockwise (CW) until the wrench

Magnetic Speed Ring
flats on sensor body are positioned at a 22° angle to
Speed Sensor the pump shaft center line.
90000839E Note: Many adjustable wrenches have a 22° handle

Cross Section View of Speed Sensor in fixed Motor offset.
5. The fin a l sensor position sho u ld b e b etween

1/2 (180°) and 1/4 t urn (90°) counterclockwise (CCW)
from the point where the sensor cont acts the speed
Gap ring.
6. Hold sensor in position with a 1/2 inch hex wrench

Speed Sensor while tightening the lock n ut to 13 Nm (10 l bf ft).
Magnetic Speed Ring
90000840E
Cross Section View of Speed Sensor in Variable Motor
Shaft Centerline
1/2 in. Wrench Flats
22˚ 22˚
Speed Sensor with Speed Sensor with

Packard Connector Turck Connector
Shaft Centerline
1/2 in. Wrench Flats
22˚ 22˚
Speed Sensor with Speed Sensor with

Packard Connector Turck Connector
90000841E
Positionin g Speed Sensor relative to Pump or Motor Shaft
50
578 BOMAG 008 911 63

Travel pump 17.1
Series 90 Minor Repair Instructions
Minor Repair Instructions
Minor repairs may be performed, following the proce- items must be kept free of foreign m ateri als and chemi-
dures in this section, witho ut voiding the unit warranty. cals.
Altho ugh specific models are shown, these procedures
apply to all series and types of units in the Series 90 Protect all exposed sealing surfaces and open cavities
Family. from damage and foreign material.
Cleanliness is a primary means of ensuring satisfactory It is recommended th at all gaskets and O-rings be
transmission life, on either new or rep aired units. Clean- replaced when servicing. All g asket sealing surfaces
ing parts by using a solvent wash and air drying is must be cleaned prior to installing new gaskets. Lightly
adequate, providing clean solvent is used. As with any lubricate all O-rings with cle an petroleum jelly prior to
precision equipment, the intern al mechanism and related assembly.
51
008 911 63 BOMAG 579

17.1 Travel pump
Hydrostatic Unit Outlines for Minor Repair Reference
Charge Pressure
Relief Valve
Control Filtration Options

Control Orifice
Charge Pump Shaft Seal
Main Shaft Speed Sensor

(Auxiliary Pad)
Left Side View Right Side View

90000843E
SAE-Flan ge PV
Ch a rge Press ure Ch a rge Press ure

Relief Va lve Relief V alve
Loop Flushing
V alve
Loop Flushing
V alve
Sh aft Sh aft
Se al Se al
(Speed Sensor) (Speed Sensor)
Left Side View Left Side View
90000844E
SAE Flange MF Cartridge Flange MF
Control Orifices
Maximum Angle Control Orifices
Charge Pressure Displacement Limiter
Relief Valve Charge Pressure Maximum Angle
Relief Valve Displacement Limiter
Loop Flushing Loop Flushing
Valve Valve
Shaft Shaft
Seal Seal
Control Control
Minim um Angle
Minim um Angle Displacement Limiter
Displacement Limiter
Left Side View Left Side View

90000845E
Cartrid ge Flange MV SAE Flange MV
52
580 BOMAG 008 911 63

Travel pump 17.1

Pump and Motor Minor Repair
Pump / Fittin g Torques

Description Torque
If any plugs or fittings are removed from the p ump or 7 / 16-20 O-ring 20 Nm
motor during servicing, they should be torqued as indi- 9 / 16 inch Hex Wrench (15 lbf ft)
cated in the accompanying table. 7 / 16-20 O-ring 12 Nm
3 / 16 inch Internal Hex Wrench (9 lbf ft)
Always install new O-rings before reinstalling the plugs or 9 / 16-18 O-ring 37 Nm
fittings. 11 / 16 inch Hex Wrench (27 lbf ft)
9 / 16-18 O-ring 23 Nm
3 / 4-16 O-ring 68 Nm
7 / 8 inch Hex Wrench (50 lbf ft)
3 / 4-16 O-ring 68 Nm
7 / 8-14 O-ring 95 Nm
Caution 1 inch Hex Wrench (70 lbf ft)
Plugs or fittings installed into aluminum housin gs 7 / 8-14 O-ring 68 Nm
should always be torqued to the lower values 3 / 8 inch Internal Hex Wrench (50 lbf ft)
specified for internal hex plugs of the same size. 1-1 / 16-12 O-ring 163 Nm
S000 017E 1 1 / 4 inch Hex Wrench (120 lbf ft)
1-1 / 16-12 O-ring 115 Nm
1-5 / 16-12 O-ring 190 Nm
1-1 / 2 inch Hex Wrench (140 lbf ft)
1-5 / 16-12 O-ring 129 Nm
1-5 / 8-12 O-ring 224 Nm
1-7 / 8 inch Hex Wrench (165 lbf ft)
T002 281E
53
008 911 63 BOMAG 581

17.1 Travel pump

Shaft Seal and Shaft Replacement
Lip type shaft seals are used on Series 90 pumps and

motors. These seals and/or the shafts can be replaced
without ma jor disassembly of the unit. However, repl ace-
ment usually requires removal of the pump or motor from
the machine.
1. Position the pump with the sh aft f acing up.
Note: If the unit is positioned horizont ally when the

shaft is removed, the cylinder block could move
out of pl ace, making shaft installation diffic ult.
2. Remove the three or four screws holding the ret ainer

plate and seal carrier to the ho using, using a 10 mm
hex wrench (030 and 042 units), a 5 mm intern al hex
90000270 90000271
wrench (055 through 100 units), or a 6 mm intern al
Remove Screws Holdin g Remove Seal Carrier hex wrench (130 through 250 units). Remove the
Retainer Plate and Seal retainer plate.
Carrier
Note: Certain e arlier production units use a one piece
retainer plate and seal c arrier.
3. After removing the screws, the spring force on the

shaft may move the se al carrier out of its bore by
approximately 5 mm (1/4 inch). If the se al carrier
does not move from its bore after removing the
screws, pry it from its bore as shown and/or lightly tap
the end of the sh aft with a soft mallet.
4. Remove the O-ring from the seal c arrier.
5. Place seal carrier and seal in an arbor press and

90000272 90000273 press out old seal.
Press Out Old Seal New Seal Installed in Carrier
6. Inspect the seal carrier, the new se al and the O-ring
Screw for any d amage or nicks.
Retaining Plate
Seal Carrier 7. Using the arbor press, press the new seal into seal
Seal carrier. Be c areful not to d amage the seal.
Screw
Seal Carrier
(One Piece) Note: The outside diameter of the seal m ay be lightly
coated with a sealant (such as Loctite High
Seal
Performance Sealant #59231) prior to inst alla-
O-ring tion. This aids in preventing le aks caused by
damage to the seal bore in the se al c arrier.
90000846E
Series 90 Shaft Seal Components
54
582 BOMAG 008 911 63

Travel pump 17.1
Roller Bearing
8. Inspect the sealing area on the shaft for rust, wear, Assembly Retaining Ring
or contamin ation. Tapered
Shaft
If the shaft is not being replaced proceed to step Splined OR Roller Bearing
Shaft
12.
OR
9. Remove shaft and roller bearing assembly from
OR
pump or motor. The bearing assembly can be trans- Straight Key
ferred to the new sh aft. Shaft
90000866E
10. Remove the retaining ring th at secures roller bearing Fixed Motor Shaft Confi guration
assembly with a sn ap ring pliers. Remove the roller
bearing assembly. Roller Bearing
Assembly Retaining Ring
11. Place roller bearing assembly on new sh aft and Rollen Bearing
Splined
secure with the ret aining ring. Shaft
OR
Tapered
12. Wrap spline or key end of sh aft with pl astic film to Shaft
prevent damage to the se aling lip on the se al during OR
install ation.
OR
13. Prior to assembly, lubricate the O-ring on the O.D. of
Straigt Key
the seal carrier and the I.D. of the se al with clean Shaft
petroleum jelly.
90000867E
14. Assemble the seal carrier and seal over the sh aft and Variable Pump Shaft Confi guration
into the housing bore. Install the retainer plate (if
used).
Roller Bearing
Assembly Retaining
15. Install the screws and torque like the tables. Ring
Splined
Pumps Shaft
Frame Size Torque Pumps
OR
030 - 042 12 Nm (9 lbf ft) Tapered
055 - 100 16 Nm (12 lbf ft) Shaft
130 - 250 32 Nm (24 lbf ft)
T002 282E 90000868E
Variable Motor Shaft Confi guration
Motors
Frame Size Torque Motors
030 - 100 9.5 Nm (7 lbf ft)
130 22.5 Nm (16.6 lbf ft)
T002 283E
Note: Torque the screws in a seq uenced pattern then

recheck.
90000274 90000275
Install Seal Carrier Torque Retainer Screw
55
008 911 63 BOMAG 583

17.1 Travel pump

Pump Minor Repairs
Multi-Function Valve Cartrid ges
1. The multi-function valve cartridge is removed with a

hex wrench on the largest hex on the cartridge.
030 - 100 1-1 / 4 inch
130 - 250 1-5 / 8 inch
T002 284E
2. Inspect cartridge for damage to p arts and O-rings.
90000276 90000277 The multi-function valve cartridge may be disas-

Remove Multi-Function Install and Torque Cartrid ge sembled for cleaning. However, if the pressure limiter
Valve Cartridge housing assembly is disassembled, the pressure
settings must be readjusted. Usually, if there is
contamination problem, it will be in the valve seat
assembly. If it is not necess ary to cle an the interior of
the cartridge, proceed to step 7.
Note: Multi-function valve components are not sold

sep arately as service parts (except O-rings).
90000278
Multi-Function Valve Cartrid ge Components 3. On early versions of the m ulti-function valves, the
(Earlier production)
valve seat assembly is held by a retaining ring.
Remove retaining ring with a sn ap ring pliers.
On late versions, the v alve seat section is pressed over

a lip. Pl ace the cartridge in a vise and pry the lower
section off with an appropriate tool. Maintain sufficient
control to prevent the contents from flying loose.
90000279
Multi-Function Valve Cartrid ge Components
(Later production) 4. Remove press ure limiter lock n ut and bypass actuator.
5. Unscrew the pressure limiter adjustment screw from

the bypass actuator. Clean and inspect all disas-
sembled parts.
Pressure Limiter High Pressure
Pressure Limiter Relief/Check
Lock Nut
Valve Spring 6. Reassemble with new, lightly l ubricated O-rings by
Valve Poppet
Pressure Limiter
reversing the above procedure. For early versions
Housing
Spring Seat assemble with the ret aining ring. For late versions,
Check Valve
Poppet
place the cartridge in a vise and press on lower
assembly.
Caution
The pressure settings must be readjusted after
disassemblin g the pressure limiter housing of the
multi-function valve cartridge.
Valve Seat S000 018E
Pressure Limiter Spring
Pressure Limiter Valve Poppet
Adjustment Screw Pressure Limiter 7. Install cartridge in multi-function valve cavity and torque.
Valve Poppet
Bypass
Frame Size Torque
Actuator
030 - 100 89 Nm (66 lbf ft)
90000869E
Multi-Function Valve Cartrid ge Sectional View 130 - 250 210 Nm (155 lbf ft)
T002 285E
Do not overtorque the multi-function valve cartridge.
56
584 BOMAG 008 911 63

Travel pump 17.1
Screws
Pressure Override Valve (Option for 180 Frame
Size) Pressure Override
Valve
1. Remove the four screws attaching the pressure
override valve to the p ump end cap with a 5 mm O-rings
intern al hex wrench. Remove the O-rings.
2 . Inspect valve for damage to parts.
3. Install new O-rings. Install the valve onto the p ump

end cap and torque the screws to 16 Nm (12 lbf ft).
Charge Relief Valve
The pump charge relief valve may be shim adjustable

(early models) or screw adjustable (late models).
1. Remove the shim adjustable charge relief v alve plug 90000870E

Pressure Override Valve Components
with a 1 inch hex wrench.
Before removing the screw adjustable relief v alve

plug, m ark the plug, lock nut, and housing so as to
approximately maint ain the original adjustment when
assembling. Remove the screw adjustable charge
relief valve plug by loosening the lock n ut with a
wrench.
030 - 100 1-1 / 16 inch
130 - 250 1-5 / 8 inch
T002 286E
Unscrew the plug with a large screwdriver or 1/2 inch

hex wrench. 90000280 90000262
Remove Charge Relief Valve Shim Adjustable Char ge
(Shim adjustable) Relief Valve
2. Remove the spring and relief v alve poppet.
3. Inspect the poppet and mating seat in the end c ap for

damage or foreign material.
When inspecting shim adjustable valves, do not alter

the shims or interch ange parts with another valve.
4. Install the poppet and spring. For shim adjustable

valves, install the pl ug and torque to 68 Nm (50 l bf ft).
For screw adjustable v alves, install the plug with its
lock nut, aligning the marks made at disassembly,
and torque the lock n ut to 52 Nm (38 l bf ft).
90000264 90000265
Remove Charge Relief Valve Screw Adjustable Char ge
Check the charge pressure and adjust, if necessary. (Screw adjustable) Relief Valve
57
008 911 63 BOMAG 585

17.1 Travel pump

Charge Pump - Remove
The following procedure shows how to remove and install

a charge pump.
1. For pumps with an auxiliary mounting pad, remove

the four screws holding the p ad to the end c ap and
remove the pad. Refer to the A uxiliary Mounting Pad
Installation instructions (next section) for det ails.
Note: At e arlier production frame size 75 pumps with

twin ports secure the end cap to the p ump
housing with a cl amp to avoid gasket damage.
90000281 90000303
Remove Auxiliary Pad Remove Auxiliary Pad
Adapter Screws Adapter
Caution
Do not allow the force of the cylinder block spring
and swashplate leveler springs to separate the end
cap from the pump housing. Gasket damage and
external leakage may result.
S000 019E
2. Remove the six screws holding the charge pump

cover retainer.
90000282 90000284 030 - 100 10 mm
Remove Retainer Screws Remove Charge Pump Cover
130 - 250 13 mm
T002 287E
3. Remove the retainer and the ch arge pump cover. For
pumps with an auxiliary mounting pad, remove the
auxiliary drive coupling. Note the orient ation of the
gerotor.
4. Remove the charge pump shaft and charge pump

drive key.
5. Remove the spacer plate(s), if present (intermediate

production pumps only).
90000297
Remove Drive Couplin g Remove the charge pump outer port plate, if present
(early and intermediate production pumps).
Discharge Gerotor Discharge Remove the charge pump gerotor assembly.

Assembly
Alignment Pin
6. Remove the outer eccentric ring and alignment pin.
Inlet Inlet
7. Remove the inner port plate.
Alignment Pin
Gerotor Assembly 8. Inspect all p arts for abnormal we ar or damage.
Left Hand Rotation Right Hand Rotation
(Outside looking into pump) (Outside looking into pump)
90000871E
Orientin g Alignment Pin
58
586 BOMAG 008 911 63

Travel pump 17.1

Note: If a different displ acement charge pump is be-
ing installed, the gerotor assembly, gerotor outer Standard End C ap Screws
eccentric ring, and inner port plate (early and Alignment Pin
late production pumps) or outer spacer plate(s) Charge Pump Assem bly
(intermediate production pumps) must be re- Thin Port Plate
placed together. If different thickness port pl ates
Key
are used in an early production charge pump Thick Port Pl ate
Shaft
assembly, the thicker pl ate is the inner port Eccentric Ring
O-ring
plate (installed next to the p ump end cap). Cover
Gerotor Assem bly
Each charge pump assembly includes a different quan- Journal Bearing

tity / types of port pl ates and spacer plates. Cover Ret ainer
Retainer Screw
The charge pump kit "No Ch arge Pump" includes a
spacer.
90000872E
Charge Pump Components (Early Production)
Standard End Cap Screw
Alignment Pin
Thin Port Pl ate
Charge Pump Assembly
Key Eccentric Ring
Shaft Gerotor Assem bly
O-ring Thin Port Plate
Cover Spacer Plate(s)
Journal Bearing
Cover Retainer
Retainer Screw
90000873E
Charge Pump Components (Intermediate Production)
Standard End C ap Screw
Alignment Pin
Charge Pump Assem bly
Key
Shaft Port Plate

O-ring Eccentric Ring
Cover Gerotor Assem bly
Journal Bearing
Cover Retainer
Retainer Screw
90000874E
Charge Pump Components (Late Production)
Standard End C ap Screw
Spacer
Shaft
O-ring
Cover
Plug
Journal Bearing
Cover Retainer
Retainer Screw
90000875E
"No Charge Pump" Components
59
008 911 63 BOMAG 587

17.1 Travel pump

Installing the Charge Pump
Discharge Gerotor Discharge
Assembly
Alignment Pin Be sure to install the charge pump in the proper orienta-
tion. If unsure of ch arge pump rotation, refer to the model
Inlet
code.
Inlet
Alignment Pin Note: The charge pump rotation is determined by the

Gerotor Assembly orientation of the gerotor assembly outer ec-
centric ring and the location of the alignment pin
Left Hand Rotation Right Hand Rotation in the end c ap.
(Outside looking into pump) (Outside looking into pump)
90000871E
Do not mix ch arge pump piece p arts from differ-
Orientin g Alignment Pin ent production periods. Alw ays install as a com-
plete assembly.
1. Install the inner port pl ate and the gerotor assembly

outer ring.
2. Install the alignment pin to properly orient the port

plates and outer eccentric ring for corresponding
pump rotation.
3. Prior to installation, apply a sm all q uantity of petro-

leum jelly to the I.D., O.D., and side faces of the
gerotor assembly to provide initi al l ubrication.
4. Install the gerotor assembly.
90000285 90000286 5. Install the o uter port plate (early production and
Install Inner Port Plate Install Gerotor Assembly intermediate production pumps only).
Outer Ring
6. Install the sp acer plate, if present (intermedi ate
production pumps).
7. Install the charge pump drive key into the charge

pump shaft and retain with petroleum jelly.
90000287 90000288
Install Ali gnment Pin Install Gerotor Assembly
90000289 90000290
Install Outer Port Plate Install Spacer Plate
(Early and intermediate (Intermediate production
production only) only)
60
588 BOMAG 008 911 63

Travel pump 17.1

Note: Intermediate production 75 cc and 100 cc pumps
use the same charge pump drive shaft. Two
keyways are provided in the drive shaft for the
charge pumps used in these units. The re ar
keyway (with identifier groove) is used in 75 cc 100 cc 75 cc
pumps. The front keyw ay (closest to the inter-
nally splined end of the sh aft) is used in 100 cc
pumps.
8. Install the charge pump shaft. The intern ally splined

end of the sh aft m ust engage the main p ump shaft.
Note: The outside diameter of the intern ally splined

end of some early production charge pump
shafts was chamfered. Early production end
caps may not be machined to accept a non- 90000291 90000292
ch a mfered sh a ft. Alw a ys u se a ch a mfered Keyways in Charge Pump Install Charge Pump Shaft
Shaft (Intermediate Produc-
charge pump shaft in p umps with the e arly end
tion 075 and 100)
cap.
9. For pumps with an auxiliary mounting pad, install the

auxiliary drive coupling.
10. Install a new O-ring onto the non- auxiliary pad charge
pump cover. (If an auxiliary pad is installed, an O-ring
is not used on the cover.)
11. Carefully remove the alignment pin from the ch arge

pump parts. Install the pin in its hole in the ch arge
pump cover (see previous p age for correct orienta-
tion) and retain with petroleum jelly. Install the cover
(with alignment pin) into the end c ap and aligned
charge pump parts. (Take care not to d amage the
cover O-ring, if used.)
Caution
In order to avoid loss of char ge pressure in pumps
with an auxiliary mounting pad, always install the
charge pump cover with the pad drain hole located
on the same side of the end cap as the charge inlet
port. Refer to the section Auxiliary Pad Installation“ 90000293 90000294
for details. Alignment Pin Installed in Install Char ge Pump Cover
S000 020E Cover
12. Install the charge pump cover retainer and the six hex
screws and torque the screws.
Frame Size Torque
030 - 100 13.5 Nm (10 lbf ft)
130 - 250 32 Nm (24 lbf ft)
T002 288E
13. For pumps with auxiliary mounting pads, install the

O-ring and auxiliary mounting pad adaptor onto the
end cap. Refer to the corresponding section for 90000283 90000295
Install Cover Retainer Torque Retainer Screws
instructions on auxiliary p ad installation.
61
008 911 63 BOMAG 589

17.1 Travel pump

Auxiliary Pad Installation
1. Remove the six screws holding the charge pump

cover retainer. Remove the ret ainer.
030 - 100 10 mm
130 - 250 13 mm
T002 287E
2. Remove the charge pump cover and its O-ring.
Note: The original charge pump cover will not be used

when installing the auxiliary p ad.
90000282 90000284
Remove Screws and Remove Charge Pump Cover 3. Remove the four l arge screws which fasten the end
Retainer
cap to the p ump housing.
Frame Size Wrench Sizes

Internal Hex External Hex
030 -
8 mm
early 042
late 042 10 mm
055 19 mm
075 - 100 24 mm
100 - 130 14 mm
180 - 250 17 mm
T002 289E
Note: At e arlier production frame size 75 pumps with

90000296
Remove Large End Cap Screws twin ports secure the end cap to the p ump
housing with a cl amp to avoid gasket damage.
Charge Pump Parts
Cover Caution
Assembly
Coupling Do not allow the force of the cylinder block spring
Special Washer (Typical) and swashplate leveler springs to separate the end
Journal Bearing
End Cap cap from the pump housing. Gasket damage and
Screw O-ring external leakage may result.
S000 019E
auxiliary Pad
(Typical)
O-ring Cover Retainer
Retainer Screw
Auxiliary Pad Kit
Pad Cover 4. Take care to assure the surfaces are clean and free
Screw
of any foreign material or p aint prior to inst alling the
auxiliary p ad.
90000876E
Auxiliary Pad Components (Typical)
5. Install the auxiliary drive coupling onto the p ump
drive shaft spline ( auxiliary drive spline must be
toward the rear of the pump).
62
590 BOMAG 008 911 63

Travel pump 17.1

6. Carefully remove the alignment pin from the ch arge
pump parts. Install the pin in its hole in the new
charge pump cover (with hole for the auxiliary cou-
pling) and retain with petroleum jelly. Install the new
charge pump cover with alignment pin into the end
cap and the aligned charge pump p arts.
Caution
In order to avoid loss of char ge pressure in pumps
with an auxiliary mounting pad, always install the
charge pump cover with the pad drain hole lo-
cated on the same side of the end cap as the
charge inlet port. Refer to the section "Auxiliary
Pad Installation" for details.
S000 020E 90000297 90000298
Install Drive Couplin g Install Ali gnment Pin in
Cover (CCW rotation shown)
7. Install the charge pump cover retainer and the six hex
screws and torque the screws.
Frame Size Torque
030 - 100 13.5 Nm (10 lbf ft)
130 - 250 32 Nm (24 lbf ft)
T002 288E
8. Install O-ring on end c ap pilot.
9. Install the auxiliary mounting pad adapter on external

pilot on re ar of end c ap.
90000299 90000300
10. Install four new large screws and washers through Install New Char ge Pump Install Screws and Cover
the mounting pad and end cap into the ho using. Cover Retainer
Torque per the accompanying table.
Frame Size Torque

030 -
58 Nm (43 lbf ft)
early 042
late 042 122 Nm (90 lbf ft)
055 122 Nm (90 lbf ft)
075 - 100 256 Nm (189 lbf ft)
100 - 130 298 Nm (220 lbf ft)
180 - 250 580 Nm (429 lbf ft)
T002 290E
90000302 90000303
Install O-rin g on End Cap Install Auxiliary Pad Adapter
11. Install the O-ring and flange cover or auxiliary pump.
Pilot
Auxiliary Pad Conversion
To convert an auxiliary mounting pad to a different size

mounting pad, use the above procedure with the following
additions:
After removing the ch arge pump cover (step 2), remove

the old auxiliary drive coupling.
After removing the four end cap retaining screws, remove

the old auxiliary mounting pad adapter.
90000281 90000305
Install Auxiliary Pad Adapter Torque Pad Adapter Screws
Screws
63
008 911 63 BOMAG 591

17.1 Travel pump
Series 90 Minor Repair

Filtration Options
Suction Filtration Installation
1. Install the hydr aulic fitting to connect the extern al

suction filter to the ch arge pump inlet port.
2. The reducer fitting (pl aced on the charge pressure

gauge port) is installed as follows.
Frame Size Wrench Size Torque
030 - 042 1-1 / 4 inch 70 Nm (52 lbf ft)
055 - 130 1-1 / 2 inch 122 Nm (90 lbf ft)
180 - 250 1-1 / 2 inch 156 Nm (115 lbf ft)
T002 291E
90000310 90000243 The gauge port plug takes a 1/4 inch internal hex
Charge Pump Inlet Reducer Fittin g and
Gauge Port Plug wrench and is torqued to 27 Nm (20 l bf ft).
Remote Charge Pressure Filtration or Integral Charge

Pressure Filtration
Install either of these two filtr ation devices as follows.
1. Remove the reducer fitting, loc ated at ch arge pres-

sure gauge port, from p ump end cap (this p art will not
be used).
2. Install the filter m anifold or filter he ad into the port.

The hydraulic tube should enter its m ating bore in the
90000311 90000314
remote Pressure Filter Integral Pressure Filter Head pump end c ap with a low force.
Manifold
3. After rotating the filter m anifold or filter he ad clock-
wise so that the thre ads engage with the thre ads in
the end c ap, continue to rotate it clockwise between
6 and 7 revolutions. Face manifold or head to the
desired position.
Caution
Failure to install the filter manifold or filter head to a
sufficient depth in the end cap will result in insufficient
engagement of the tube in the end cap bore. This may
allow unfiltered oil to bypass the filter and enter the
90000312 90000315 charge system.
Install Remote Pressure Install Inte gral Pressure S000 021E
Filter Manifold Filter Head
4. While holding the filter m anifold or filter he ad in the

desired position, tighten the swivel lock n ut.
Frame Size Wrench Size Torque
030 - 042 1-3 / 8 inch 70 Nm (52 lbf ft)
055 - 130 1-5 / 8 inch 122 Nm (90 lbf ft)
180 - 250 1-5 / 8 inch 156 Nm (115 lbf ft)
T002 292E
90000313 90000316
Tighten Remote Pressure Tighten Inte gral Pressure 5. After installing the integr al pressure filter he ad as-
Filter Manifold Lock Nut Filter Head Lock Nut sembly, install the filter c anister per the instructions
on the filter c anister.
64
592 BOMAG 008 911 63

Travel pump 17.1

Pump controls
Cover Plate
1. Thoroughly clean external s urfaces prior to remov al

of cover plate.
2. Using a 5 mm intern al hex wrench, remove the eight

cover plate mounting screws. Remove the cover
plate and g asket from housing.
Caution
Protect exposed surfaces and cavities from damage
and foreign material.
S000 022E 90000361
Pump with Cover Plate
3. In preparation for inst alling the cover plate, place a

new gasket on the ho using. Place the cover plate into
position and install the screws. Torq ue the screws to
16 Nm (12 lbf ft).
NOTE
A sealing washer must be installed under the head of
any mounting screws that are installed into "thru"
holes in the housing.
S000 023E
65
008 911 63 BOMAG 593

17.1 Travel pump

Manual Displacement Control (MDC)

of control.

control mounting screws. Remove the control (with
orifice check valve and spring) and control gasket
from housing.
Caution
S000 022E
90000319 90000320
Remove Mountin g Screws Remove Control 3. In preparation for inst alling the control, pl ace a new
gasket on the housing. Inspect to assure that the
control orifice check valve and spring are in their
proper position in the control.
4. While setting the control into position, engage the pin

on the control link age into the m ating hole in the link
attached to the sw ashplate.
5. With the control in position, move control lever both

directions to check proper eng agement of control
linkage pin. Proper eng agement will be indicated by
centering torque as the lever is moved from center.
90000321 90000322 Non-engagement of control link age pin is indic ated
Inner Face of Control Assemble Control to Linka ge by l ack of centering torque as the lever is moved. In
case of non-engagement remove the control and
repeat the above procedure.
6. Align the control g asket and install the screws. Torque

the screws to 16 Nm (12 l bf ft).
NOTE
any mounting screws that are installed into "thru"
S000 023E
90000323 90000324 7. If the control is eq uipped with a ne utral st art switch,
Assemble Control to Torque Mountin g Screws refer to the "MDC Ne utral St art Switch Adjustment"
Pump
instructions.
WARNING
The neutral start switch "neutral" must be read-
justed after reassembling the MDC module.
S000 024E
66
594 BOMAG 008 911 63

Travel pump 17.1

Solenoid Override Valve for MDC

of v alve.
2. Using a 5 mm intern al hex wrench, remove the two

screws and remove solenoid manifold from ho using.
Remove the old gasket.
3. The solenoid may be removed from the valve by

removing the n ut with a 3/4 inch hex wrench. The
solenoid valve may be removed from the m anifold
with a 7/8 inch hex wrench.
4 . When installing the solenoid valve into the manifold,

the valve should be torqued to 24 ± 2.4 Nm (17.7 ± 1.8 90000363
lbf ft). When installing the solenoid onto the v alve, Components of Solenoid Override for MDC
torque the nut to 6 Nm (53 ± 12 l bf in).
5. In preparation for installing the solenoid m anifold,

place a new gasket on the control ho using. Install the
manifold onto the control housing, align the gasket,
a nd inst a ll the screws. Torq u e the screws to
13.5 Nm (10 l bf ft).
Solenoid Override Valve for MDC with Pressure

Released Brake
1. Thoroughly clean external s urfaces prior to removal

of v alve.
2. Using a 4 mm intern al hex wrench, remove the fo ur

solenoid valve mounting screws. Remove the sole-
noid valve (with O-rings) from the adapter plate.
3. Using a 4 mm intern al hex wrench, remove the fo ur

adapter plate mounting screws. Remove the adapter
plate and O-rings from the control ho using.
4. Remove the check valve seat and O-ring from the

control side of the adapter plate. Remove the check
ball and spring.
5. Install a new O-ring on the check valve seat and

reassemble the check valve spring, ball, and seat
into the adapter plate.
6. Install new O-rings on the adapter plate. Place the 90000364

adapter plate into position and install the screws. Components of Solenoid Override with Brake Pressure
Torque the screws to 5.4 Nm (48 l bf in). Defeat for MDC
7. Install new O-rings onto the solenoid v alve assembly

and install the solenoid v alve onto the adapter pl ate.
Install the screws and torque to 5.4 Nm (48 l bf in).
67
008 911 63 BOMAG 595

17.1 Travel pump

Hydraulic and Electric Displacement Controls

of control.
2. Using a 5 mm internal hex wrench, remove the eight

control mounting screws. Remove the control (with
orifice check valve and spring) and control gasket
from housing.
Caution
S000 022E
90000325 90000326
3. In preparation for inst alling the control, pl ace a new
Remove Mountin g Screws Remove Control gasket on the ho using. Inspect to ens ure that the
control orifice check valve and spring are in their
proper position in the control.
4. While setting the control into position, engage the pin

on the control linkage into the m ating hole in the link
attached to the sw ashplate.
5. With the control in position, move control assembly

left and right to check eng agement of pin in the link.
Proper engagement will be indicated by an increas-
ing resistance as the control is moved away from
center position. Non-engagement of pin will be indi-
90000327 90000328
cated by lack of spring force. In c ase of non-engage-
Inner Face of Control Assemble Control to Linka ge ment, remove control and repeat the above proce-
dure.
6. Align the control gasket and install the screws. Torque

the screws to 16 Nm (12 lbf ft).
Caution
A sealing washer must be installed under the
head of any mounting screws that are installed
into "thru" holes in the housing.
S000 023E
Pressure Control Pilot (PCP) for Electric Displace-

ment Control
90000329 90000330
Install Mountin g Screws Torque Mountin g Screws
1. Thoroughly clean external s urfaces of control.
2. Using a 4 mm internal hex wrench, remove the four

screws and remove the PCP.
3. Check surfaces for nicks or damage. Clean internal

screens.
4. Install new O-rings in PCP Housing. Place PCP

against EDC housing and install the screws. Torq ue
to 5.4 Nm (48 l bf in).
90000332 90000334
Note: Do not remove black plastic cover from the
PCP Components Torque PCP Valve Screws aluminum pl ate. This is not a serviceable item
and will void the prod uct w arranty.
68
596 BOMAG 008 911 63

Travel pump 17.1

3-Position (FNR) Electric Control

of control.
2. Using a 4 mm internal hex wrench, remove the four

solenoid valve mounting screws. Remove the sole-
noid valve (with O-rings and orifice) from the adapter
plate.

adapter plate mounting screws. Remove the adapter
plate and g asket from housing.
Caution 90000362
Protect exposed surfaces and cavities from damage 3-Position Electric Control Components
S000 022E
4. Inspect the orifice installed between the valve and

adapter plate. This orifice MUST be installed in the
case drain passage for proper pressure limiter op-
eration.
5. In preparation for installing the adapter plate, place a

new gasket on the ho using. Place the adapter plate
into position and install the screws. Torque the
screws to 16 Nm (12 l bf ft).
NOTE
any mounting screws that are installed into thru“
S000 023E
6. Install new O-rings and the orifice onto the solenoid

valve assembly and install the solenoid v alve onto
the adapter plate. Install the screws and torque to
5.4 Nm (48 lbf in).
Displacement Control Components
Displacement Control Orifices

A
1. Remove the control assembly as described in the
B
instructions for the specific displacement control.
TA P
TB
2 . Orifice plugs may be located in the control assembly,
at the p ump housing face surf ace. Remove the
orifice plugs with a 4 mm intern al hex wrench. Note
the location of e ach plug, do not interch ange plugs.
Torque the orifice pl ugs to 3 Nm (26 l bf in).
3. Assemble the control onto the p ump. Refer to the Orifice Plugs
instructions for the specific control.
Orifice Check Valve
90000849E
Underside of an HDC/EDC Module Showin g Orifice
Locations
69
008 911 63 BOMAG 597

17.1 Travel pump

Displacement Control Orifice Check Valve
1. Remove the control assembly as described in the

instructions for the specific displacement control.
2. The orifice check valve is located in the control

assembly, at the s urface of the p ump housing face.
TA A
B TB Remove the spring retainer and spring from the
orifice check valve cavity and then remove the orifice
P
check valve.
3. Install the desired orifice check valve in the cavity and

then install the spring and spring retainer to hold the
orifice check valve in position.
Orifice Plugs
4. Assemble the control onto the p ump. Refer to the
instructions for the specific control.
Orifice check Valve
90000848E
Underside of an MDC Module Showin g Orifice Locations
Displacement Control Adapter Plate (Early produc-

tion 130 Pumps only)
The screws fastening the control adapter plate to the

housing have retaining compound on the thre ads. They
are removed with a 6 mm intern al hex wrench.
When installing the adapter plate, ensure the O-rings are

in the proper position and torque the screws to 32 Nm
(24 lbf ft).
Displacement Control Filter Screens
If the p ump is equipped with control filter screens in the

pump housing (late production), they should be pressed
into position (with the rounded edge of the filter screens
facing the control until they are flush to 2.0 mm (0.08 inch)
below the surface of the ho using.
90000847
Displacement Control Adapter Plate (Early production
130cc Pumps only)
70
598 BOMAG 008 911 63

Travel pump 17.1

Minor Repair - Motor
Loop Flushin g and Charge Relief Valves
Loop Flushing Valve
1. Using an 1-1/16 inch wrench, remove the hex plugs

and O-rings from both sides of the v alve. Remove the
springs, shoulder washers, and flushing valve shuttle
spool. Note orientation of the w ashers. Remove the
flushing valve spool.
2 . Inspect parts for damage or foreign m aterial.
Note: Early production motors used a small diameter 90000338 90000339

shuttle valve spool. Late production motors use Remove Plugs Springs Remove Flushing Shuttle
a l arger diameter spool. Spool
3. Install fl ushing valve spool in end cap, then inst all the
shoulder washers (with shoulders facing “out”) and
springs on each end of the spool. Inst all the hex pl ugs
with O-rings, and torque to 41 Nm (30 l bf ft) on 030
through 100 motors or 68 Nm (50 l bf ft) on 130
motors.
Motor Charge Relief Valve
1. Remove the shim adjustable charge relief v alve plug

with a 7/8 inch hex wrench. 90000340 90000341
Install Flushin g Shuttle Torque Plugs
Before removing the screw adjustable relief valve Spool
plug, mark the plug, lock nut, and housing so as to be
able to m aint ain the original adjustment when assem-
bling. Remove the screw adjustable charge relief
valve plug by loosening the lock n ut with a 1-1/16 inch
hex wrench for 030 thro ugh 100 units, or a 1-5/8 inch
hex wrench for 130 units, and unscrewing the plug
with a l arge screwdriver or 1/2 inch hex wrench.
2. Remove the spring and v alve poppet.
3. Inspect the poppet and mating seat in the end c ap for

damage or foreign m ateri al. When inspecting shim 90000342 90000343
adjustable valves, do not alter the shims or inter- Remove Shim Charge Relief Remove Screw Charge Relief
change parts with another valve. Valve Valve
71
008 911 63 BOMAG 599

17.1 Travel pump
4. Install the poppet and spring. For shim adjustable

valves, install the plug and torque to 68 Nm (50 l bf ft).
For screw adjustable v alves, install the plug with its
lock nut, aligning the m arks made at disassembly,
and torque the lock n ut to 52 Nm (38 l bf ft).
5. Check and adjust the ch arge pressure.
90000344 90000345
Shim Adjustable Char ge Screw Adjustable Char ge
Relief Valve Relief Valve
Defeating the Loop Flushing Valve

Lock Nut
Plug
Plug 1. Remove loop flushing valve components (these parts
O-ring
O-ring will not be used).
Shims
Spring Spring
2. Install defeating spool into spool bore in end c ap.
Poppet Poppet
Plug with O-ring
(defeat) 3. Install hex plugs provided and torque to 41 Nm
(30 lbf ft).
4. Remove charge relief valve components (these parts

Plug with O-ring are not necessary).
(defeat)
5. Replace with the hex pl ug provided and torque to

Plug
41 Nm (30 lbf ft).
O-ring Spool (defeat)
Spring
Plug with O-ring
(defeat)
Shoulder Washer
Note orientation of washers!

Shoulder OUT (toward spring). Spool
Shoulder Washer
Spring
O-ring
Plug
90000850E
Motor charge Relief Valve and Loop Flushin g Valve Parts
72
600 BOMAG 008 911 63

Travel pump 17.1

Variable Motor Displacement Limiters
1. Remove the tamper-resistant cap from the displ ace-

ment limiter. Me asure and note the length of the
adjustment screw up to the seal lock nut. Using a
19 mm hex wrench, loosen the se al lock nut and
remove the n ut. Remove the limiter screw from the Tamper-Resistant Cap
motor housing with a 6 mm internal hex wrench. Seal Lock Nut
Maximum Displacement
2. Install the limiter screw with the noted length between Limiter Screw
adjustment screw and the seal lock nut. Do not inst all
a new tamper-resistant cap until the limiter h as been
adj usted.
3. Final adjustment of the displ acement limiters should

be performed on a test stand.
Do not turn the limiter screws counterclockwise

beyond their initial adjustment positions.
Caution Limiter Screw
Care should be taken in adjusting displacement Seal Lock Nut
limiters to avoid undesirable speed conditions. The
Tamper-Resistant Cap
seal lock nut must be retorqued after every
adjustment to prevent an unexpected change in SAE Flange Version shown
(cartridge Version simil ar)
S000 026E
90000851E
One full t urn of the displ acement limiter adjustment MV Displacement Limiters
screw will change the displ acement as follows:
Frame Size
Adjusting Screw
055 5.6 cm3 / Rev (0.34 in3 / Rev)
075 7.1 cm3 / Rev (0.43 in3 / Rev)
T002 295E
4. Following the final adjustment, install new t amper

resistant caps.
73
008 911 63 BOMAG 601

17.1 Travel pump

Variable Motor Controls
Electrohydraulic 2-Position Control (Types

NA, NB, NC, and ND)

of the control.
2. Disconnect the external electrical signal connection.

Note: Remove BEFORE removing control.
Install AFTER installing control.
Refer to "Control Orifices" Section
3. Remove the hex nut and solenoid from the control
valve.
4. Remove the orifice check valve for the maximum

angle control cylinder, if eq uipped.
Hydraulic 2-Position
Control Valve
5. Remove the control valve from the motor housing.
6. Remove O-rings from the valve.
7. Install new O-rings on the control v alve.

Electric 2-Position
Control Valve
8. Install the valve into the motor ho using and torque to
47 Nm (35 l bf ft). Do not overtorque the control
valve. Over-torquing may result in the v alve spool
sticking.
9. Install the solenoid onto the v alve and torque the hex
90000852E nut to 5 Nm (44 l bf in). Do not overtorque the nut.
MV Control components
10. If previously removed, reinstall the orifice check
valve. Reconnect the external signal connection.
Hydraulic 2-Position Control (Type PT)
Follow the steps above, except that in step 2 a hydraulic

signal line will be disconnected, and steps 3 and 9 are not
applicable.
1/8 in. int. hex wrench
Torque: 5.4 Nm (48 lbf i n)
Control Plu gs
9/16 in. hex wrench

Remove the control plugs from the housings of earlier
Torque: 34 Nm (25 lbf f t) production motors, if necess ary. Install new O-rings,
reinstall, and torque.
7/8 in. hex wrench
Torque: 68 Nm (50 l bf f t)
90000853E
MV Control Plu gs
74
602 BOMAG 008 911 63

Travel pump 17.1

Variable Motor Control Orifices
Control Suply Orifice
Control Supply Orifice
Screen (pressed in)
1. Remove the control supply orifice from the motor
housing with an 1-1/16 inch hex wrench. O-ring
Backup Washer
2. Remove the O-rings and the backup washers. Check O-ring
that the filter screen is sec ure in the orifice body and Backup Washer
that the screen and the orifice are not plugged.
3. Install new backup washers and O-rings onto the

orifice body. Install the orifice into the motor ho using O-ring
and torque to 37 Nm (27 l bf ft). Backup Washer Backup Washer
Caution
Screen
Do not interchange the control supply orifice with the (pressed in)
minimum displacement orifice (next section).
S000 027E Orifice Body
O-ring
Cross-section View of
Control Supply Orifice Assembly
90000854E
MV Control Supply Orifice
Minimum Displacement Cylinder Orifice or Orifice

Check Valve
Orifice Orifice / Check Valve
Assembly
1. Remove the minimum displacement cylinder drain
orifice or the orifice check v alve from the motor
O-ring
housing with an 1-1/16 inch hex wrench.
Backup Washer
2. Remove the O-rings and the backup washers. Check O-ring

that the orifice is not pl ugged. Check that the check Backup Washer
valve seat is sec ure in the body and that the check
ball is free.
3. Install new backup washers and O-rings onto the

orifice body. Install the orifice into the motor ho using
and torque to 37 Nm (27 l bf ft).
O-ring O-ring
Orifice Body Orifice Body

Caution
Do not interchange the control supply orifice (previous Backup Washer Backup Washer
Spring Pin
section) with the minimum displacement orifice. O-ring O-ring
S000 028E Kugel
Backup Washer Backup Washer
Orifice Seat
(Spot welded)
Cross-Section View of Cross-Section View of
Orifice Assembly Orifice / Check Valve
Assembly
90000855E
MV Minimum Displacement Orifice
75
008 911 63 BOMAG 603

17.1 Travel pump

Maximum Displacement Cylinder Orifice Check Valve
1. Remove the seal lock nut with a 3/4 inch hex wrench.
Housing Plug Remove the maximum displacement cylinder orifice
check valve from the motor ho using with a 1/4 inch
Seal Lock N ut
(seal toward housing) end wrench. Remove the O-ring. The check ball in
the valve must be free.
O-ring
2. Reinstall the check valve and torque to 15 Nm
Orifice / Check V alve Assembly
(11 lbf ft). Install a new O-ring. Install the seal lock
nut with the seal toward the motor ho using.
Seal Lock N ut
(seal toward housing)
Hold the check valve from turning while torquing
the seal lock nut to 34 Nm (25 lbf•ft).
O-ring
3. If no orifice check valve is installed, the housing plug
Orifice Body may be removed with a 9/16 inch hex wrench. Always
install a new O-ring. Reinstall the plug and torque to
Check B all
20 Nm (15 lbf ft).
Spring Pin
Cross-Section View of
Orifice / Check Valve
Assembly
90000856E
MV Maximum Displacement Orifice
76
604 BOMAG 008 911 63

Travel pump 17.1

Speed Sensor
1. Remove the speed sensor by disconnecting the

electrical connector, loosening the lock nut, and Housing Plug
Speed Sensor 1/4 in. int. hex wrench
unscrewing the speed sensor from the p ump or or Torque: 23 Nm (17 lbf f t)
motor housing.
2. Always install a new O-ring before installing the 1-1/16 in. hex wrench
Torque: 13 Nm (10 lbf f t)
sensor. After adjustment!
3. Reinstall the speed sensor (with lock n ut and O-ring)

into the housing. Adjust the gap between the sensor
and the m agnetic speed ring as instructed in Section
"Speed Sensor Adjustment" and torque the sensor
lock nut.
4. If a speed sensor is not installed, the ho using plug

should be torqued as indicated in the accompanying 90000857E
fig ure. Typical Location of Speed Sensor - PV
1-1/16 in. hex wrench

Torq ue: 13 Nm (10 l bf f t)
After adjustment!
or
Housing Plug Speed Sensor

1/4 in. int. hex wrench
Torq ue: 23 Nm (17 l bf f t)
90000858E
Typical Location of Speed Sensor - MF

After adjustment!
or
Speed Sensor
Housing Plug
90000859E
Typical Location of Speed Sensor - MV
77
008 911 63 BOMAG 605

17.1 Travel pump
Series 90 Exploded View Parts Drawings / Parts Lists

Exploded View Parts Drawin gs / Parts Lists
Variable Pumps
Minor Repair Parts
K90 L35
B70 K10 K018 (Early Production
bis 075 Frame Size)
B83 G532 K50 (L70)
K042
OR G536 K70
B83 (L40) L60 L70
G542 K80
G546 (B80)
L40
B82 (B90) L30
P2B_
(B70)
B90
P30 P06
P13
L50
P30
B71
P2A_ P06
P13 G512
G516
G502
G506
G172
G522 G176
G526
B80
(G502
G506) (G502
G506)
(G63)
G63
(CODE 61 OPTION)
(G64)
G64
(CODE 61 OPTION) (K018
BOTH SIDES THRU
K042)
G531
G501
G538
G508
G511
G518
OR
G541
G548
G63
(CODE 61 OPTION)
G521
G528
(G63)
(G501
G508) (G64)
G64
(G501
(CODE 61 OPTION)
G508)
90000860E
78
606 BOMAG 008 911 63

Travel pump 17.1

Parts List
Item Description Qty Item Description Qty
B70 ............... Pl ug ......................................................... 2 G532 ............Pl ug ......................................................... 1

B71 ............... Pl ug ......................................................... 1 G536 ............ O-ring ...................................................... 1
B80 ............... Pl ug ......................................................... 1 G538 ............ O-ring ...................................................... 1
B82 ............... Pl ug ......................................................... 1 G541 ............Pl ug ......................................................... 1
B90 ............... Filter screen ............................................ 3 G542 ............Pl ug ......................................................... 1
G546 ............ O-ring ...................................................... 1
G63 .............. Split fl ange clamp .................................... 4 G548 ............ O-ring ...................................................... 1
G64 .............. Pl ug ......................................................... 4
G172 ............Pl ug ......................................................... 1 K10 ............... Pl ug assembly ......................................... 1
G176 ............ O-ring ...................................................... 1 K50 ............... O-ring ...................................................... 1
G501 ............Pl ug ......................................................... 3 K70 ............... Spring ......................................................1
G502 ............Pl ug ......................................................... 3 K80 ............... Poppet ..................................................... 1
G506 ............ O-ring ...................................................... 3 K90 ............... N ut ........................................................... 1
G508 ............ O-ring ...................................................... 3
G511 ............Pl ug ......................................................... 1 L30 ............... Se al c arrier .............................................. 1
G512 ............Pl ug ......................................................... 1 L35 ............... Se al c arrier .............................................. 1
G516 ............ O-ring ...................................................... 1 L40 ............... Lip se al .................................................... 1
G518 ............ O-ring ...................................................... 1 L50 ............... O-ring ...................................................... 1
G521 ............Pl ug ......................................................... 1 L60 ............... Ret ainer ................................................... 1
G522 ............Pl ug ......................................................... 1 L70 ............... Screw ......................................................3
G526 ............ O-ring ...................................................... 1
G528 ............ O-ring ...................................................... 1 L8 ................. Key .......................................................... 1
G531 ............Pl ug ......................................................... 1 L9 ................. Slotted n ut ............................................... 1
79
008 911 63 BOMAG 607

17.1 Travel pump

Variable Pump Controls
M0DC
M90D M1DC M0DD
M1DD
OR
M11D
M0MA M0ME
M0MB M0MF
M0MC M0MG
M0MD M0M9 M0CA
M9ME M76M M74M M90C
M78M M1CA M87C
M92M M11C
M97M M77M
M95M M98M M75M
M96M S40
M72M
M90M
M71M
M1MA M880 OR
M1MB M7MA
T201
M1MC M7MB
THRU
T001 M1MD M7MC
T209, M0EA
THRU M1ME M7MD
T222 M0EF M91E
T009, M1MF M7ME
T250 M0EP
T022 M1MG M7MF
T050 T301 M7MG
THRU T401
M87M M11M M9EA M98E
T309, THRU
M9EP
T322 T409, M90E M95E
T422 M97E
T350
T450 M1EA M880
M1EF
M870 M1EP M96E
M860
M11E
M850
M840 M87E
M840 M810
REF
M830 M840
M820
REF
(Early Production
130 cc Fr ame Size)
OR
M1HA, M1HC
OR
M1HF, M1HG
M90H
M1HH, M1HJ
M880
M1HK, M1HL M87H
M1HM, M1HN
M11H M0HA, M0HC

M0HF, M0HG
M0HH, M0HJ
M0HK, M0HL
M0HM, M0HN
90000861E
80
608 BOMAG 008 911 63

Travel pump 17.1

Control Parts List
M0CA ........... Cover pl ate kit ......................................... 1 M71M ........... W asher .................................................... 1
M1CA ........... Cover pl ate .............................................. 1 M72M ........... N ut ........................................................... 1
M11C ........... Control g asket ......................................... 1 M80 .............. Control g asket ......................................... 1
M11D ........... Control g asket ......................................... 1 M87M ........... W asher, seal (042) ................................. 1
M87C ........... W asher, seal (042) ................................. 1 M90M ........... Screw ...................................................... 6
M90C ........... Screw ...................................................... 6 S40 ............... Ne utral st art switch kit ............................. 1
M0DC ........... Control kit, 3-position FNR 12V .............. 1 M0MC .......... Control MDC w/ sol. v alve ...................... 1
M0DD ........... Control kit, 3-position FNR 24V .............. 1 M7M ............. Control h andle ......................................... 1
M1DC ........... Control, 3-position FNR 12V ................... 1 M71M ........... W asher .................................................... 1
M1DD ........... Control, 3-position FNR 24V ................... 1 M72M ........... N ut ........................................................... 1
M80 .............. Control g asket ......................................... 1 M74M ........... Solenoid v alve ......................................... 1
M87D ........... W asher, seal (042) ................................. 1 M75M ........... Control manifold ...................................... 1
M90D ........... Screw ...................................................... 6 M77M ........... M anifold gasket ....................................... 1
M78M ........... Screw ...................................................... 2
M0EA ........... Control kit, EDC with M80 .............. Control g asket ......................................... 1
MS connector .......................................... 1 M87M ........... W asher, seal (042) ................................. 1
M0EP ........... Control kit, EDC with M90M ........... Screw ...................................................... 6
Packard connector .................................. 1
M1EA ........... Control, EDC with M0MD .......... Control MDC w/ sol. v alve and
MS-connector .......................................... 1 neutral st art switch .................................. 1
M1EP ........... Control, EDC with M7M ............. Control h andle ......................................... 1
Packard-connector .................................. 1 M71M ........... W asher .................................................... 1
M9EA ........... PCP type 3 oil filled (MS) ........................ 1 M72M ........... N ut ........................................................... 1
M9EA ........... PCP type 3 oil filled (P ackard) ................ 1 M75M ........... Control manifold ...................................... 1
M80 .............. Control g asket ......................................... 1 M76M ........... Solenoid v alve ......................................... 1
M87E............ W asher, seal (042) ................................. 1 M77M ........... M anifold gasket ....................................... 1
M90E ............Screw ...................................................... 6 M78M ........... Screw ...................................................... 2
M91E............ Pl astic cap (MS) ...................................... 1 M80 .............. Control g asket ......................................... 1
M95E ............ O-ring ...................................................... 2 M87M ........... W asher, seal (042) ................................. 1
M96E ............ O-ring ...................................................... 1 M90M ........... Screw ...................................................... 6
M97E ............ O-ring ...................................................... 1 S40 ............... Ne utral st art switch ................................. 1
M98E ............Screw ...................................................... 4
M1MA........... Servovalve kit .......................................... 1 M810 ............ Ad apter plate - Control (130 cc) ............. 1
M820 ............ O-ring (130 cc) ........................................ 1
M0HA ........... Control kit, hydr aulic, HDC ..................... 1 M830 ............ O-ring (130 cc) ........................................ 1
M0HC ........... Control kit, hydr aulic, HDC ..................... 1 M840 ............ O-ring (130 cc) ........................................ 2
M1HA ........... Control, hydraulic, HDC .......................... 1 M850 ............ Pl ug (130 cc) ........................................... 1
M1HC ........... Control, hydr aulic, HDC ..........................1 M860 ............ Screw (130 cc) ........................................ 6
M11H ........... Control g asket ......................................... 1 M870 ............ Pl ug (130 cc) ........................................... 1
M80 .............. Control g asket ......................................... 1
M87H ........... W asher, seal (042) ................................. 1 M9ME........... 4/2 W ay v alve ......................................... 1
M90H ........... Screw ...................................................... 6 M92M ........... Screw ...................................................... 4
M95M ........... O-ring ...................................................... 1
M0MA........... Control MDC M96M ........... O-ring ...................................................... 1
w/o neutral st art switch ........................... 1 M97M ........... O-ring ...................................................... 1
M7M ............. Control h andle ......................................... 1 M98M ........... Screw ...................................................... 4
M71M ........... W asher .................................................... 1
M72M ........... N ut ........................................................... 1 T001-9.......... Control orifice kit .....................................1
M80 .............. Control g asket ......................................... 1 T201-9.......... Orificed check v alve ................................ 1
M87M ........... W asher, seal (042) ................................. 1 T301-9 .......... Spring ...................................................... 1
M90M ........... Screw ...................................................... 6 T401-9.......... Spring ret ainer .........................................1
M0MB........... Control MDC
w/ neutral st art switch ............................. 1
M7M ............. Control h andle ......................................... 1
81
008 911 63 BOMAG 609

17.1 Travel pump

Filter and Options
N40P
N40L
N00M
N00S
N35M
REF N35S
N10M
N10S
N30R N35M N25M Or
N00R N20M
N10R N15M
N31R
N20R OR
N15R
N35R N25R
90000862E
H50L
H50
H40
H05
OR
H30
H60
H50
H40
H30
OR H05
(H30)
J80N
H40
H60 H05
H50 OR
H60
H50
H90L
J40N
J15N
H70 J15_
J30 J10_
J30
H80 J70_
H70
OR
J80_ J50_
J60_
J90_ H80
J00_
J92_
J95_
90000863E
82
610 BOMAG 008 911 63

Travel pump 17.1

Parts List Filter and Options
H05B-H ........ Kit - Charge pump ................................... 1 J80A-V ......... Screw ...................................................... 4
H50L ............Sp acer (No charge pump) ...................... 1 J80N .............Screw ...................................................... 4
H30 .............. Port pl ate ................................................. 2 J90A-V ......... O-ring ...................................................... 1
H40 .............. Pin ........................................................... 1 J92A-V ......... Cover pl ate .............................................. 1
H50 .............. Ch arge pump shaft ................................. 1 J95A-V ......... Screw ...................................................2/4
H60 .............. Key .......................................................... 1
H70 .............. Retaining plate ........................................ 1 N00M ........... Filtr ation manifold kit (Int) ....................... 1
H80 .............. Screw ...................................................... 6 N10M ........... M anifold ................................................... 1
H90L ............Pl ug ......................................................... 1 N15M ........... O-ring ...................................................... 2
N20M ........... N ut ........................................................... 1
J00A ............. A ux. mtg. SAE A fl ange ..........................1 N25M ........... T ube ........................................................ 1
J00B ............. A ux. mtg. SAE B fl ange ..........................1 N35M ........... Pl ug ......................................................... 2
J00C .............A ux. mtg. SAE C fl ange .......................... 1 N40L ............ Filter ........................................................ 1
J00D .............A ux. mtg. SAE D fl ange .......................... 1 N40P ............Filter ........................................................ 1
J00T ............. A ux. mtg. SAE A fl ange (11 T) ............... 1
J00V ............. A ux. mtg. SAE B-B fl ange ....................... 1 N00R ............ Filtration manifold kit (Rmt) ..................... 1
J00N .............A ux. mtg. fl ange - none .......................... 1 N10R ............ M anifold ................................................... 1
J10A-V ......... Co upling .................................................. 1 N15R ............ O-ring ...................................................... 1
J15 ............... Ch arge pump cover assembly ................ 1 N20R ............ N ut ........................................................... 1
J15N .............Ch arge pump cover assembly ................ 1 N25R ............ T ube ........................................................ 1
J30 ............... B ushing ................................................... 1 N30R ............ Pl astic plug .............................................. 2
J50A-V ......... O-ring ......................................................1 N35R ............ Pl ug ......................................................... 1
J60A/T.......... Fl ange adaptor SAE A ............................ 1
J60B/V ......... Fl ange adaptor SAE B ............................ 1 N00S ............ Filtration kit (S uction Flt) ......................... 1
J60C .............Fl ange adaptor SAE C ............................ 1 N10S ............ Red ucer fitting (S uction Flt) .................... 1
J60D .............Fl ange adaptor SAE D ............................ 1 N35S ............ Pl ug ......................................................... 1
J70A-V ......... W asher .................................................... 4
Name Plates
Ames, Iowa, U.S.A. Neumünster, Germany Ames, Iowa, U.S.A. Neumünster, Germany
Model Code Typ Model Code Typ
90L055 EA 1 N 90L055 EA 1 N
6 S 3 C6 C 03 Model Model
Code
6 S 3 C6 C 03 Code
Model No. Ident Nr Model No. Ident Nr
Model Number 94 – 2029 Model Number 687459
Serial N umber Serial N umber
Serial No. Fabr Nr Serial No. Fabr Nr
MADE IN U.S.A. MADE IN GERMANY
Place of Manufacture Place of Manufacture
Name Plate (U.S.A. Production) Name Plate (German Production)
83
008 911 63 BOMAG 611

17.1 Travel pump

Fixed Motor
Minor Repair Parts
H68W
H60W L35
(Early Production
H62W 075 Frame Size) (L70)
H64W
(L40) L60 L70
H66W
H60N L30
L40
(B80)
(H50N)
(G50)
(H50W) (H30W)
L50
(H40W)
(H20W)
G50
G70
H10N (B80)
H50N
H20W
(G63)
B80 H10W H40W
G63
H30W
(CODE 61 OPTION)
H50W
(G64) G64
(CODE 61 OPTION)
B83 B83 OR
B80
G63
(CODE 61 OPTION)
(G63)
G64
(CODE 61 OPTION) (B83)
(G64) (B83)
90000864E
84
612 BOMAG 008 911 63

Travel pump 17.1

Parts List
B80 ............... Pl ug ......................................................... 2 H50W ........... Plug ......................................................... 2

B83 ............... Pl ug ......................................................... 1 H60W ........... Charge relief valve plug .......................... 1
B83 ............... Speed sensor .......................................... 1 H62W ........... O-ring ...................................................... 1
H64W ........... Spring ...................................................... 1
G50 .............. Pl ug ......................................................... 2 H66W ........... Charge relief poppet ............................... 1
G70 .............. Pl ug ......................................................... 1 H68W ........... Lock n ut ................................................... 1
G63 .............. Split fl ange screw .................................... 4
G64 .............. Screw - Shipping Cover .......................... 4 L30 ............... Se al c arrier .............................................. 1
L35 ............... Se al c arrier .............................................. 1
H10N ............ Loop fl ushing spool - defeat.................... 1 L40 ............... Lip se al .................................................... 1
H50N ............ Pl ug ......................................................... 2 L50 ............... O-ring ...................................................... 1
L60 ............... Ret ainer ................................................... 1
H10W ........... Sh uttle valve spool .................................. 1 L70 ............... Screw ......................................................3
H20W ........... Spring g uide ............................................ 2
H30W ........... Spring ......................................................2 L8 ................. Key .......................................................... 1
H40W ........... O-ring ...................................................... 2 L9 ................. Slotted n ut ............................................... 1
Name Plates
Ames, Iowa, U.S.A. Neumünster, Germany Ames, Iowa, U.S.A. Neumünster, Germany
Model Code Typ Model Code Typ
90M055 NC 0 N 90M055 NC 0 N
8 N 0 C6 W 00 Model 8 N 0 C6 W 00 Model
Code Code
NNN 00 00 24 NNN 00 00 24
Model No. Ident Nr Model No. Ident Nr
Model Number 94 – 2029 Model Number 312918
Serial N umber A – 91 – 26 – 67890 Serial N umber N – 91 – 26 – 67890
Serial No. Fabr Nr Serial No. Fabr Nr
MADE IN U.S.A. MADE IN GERMANY
Place of Manufacture Place of Manufacture
Name Plate (U.S.A. Production) Name Plate (German Production)
85
008 911 63 BOMAG 613

17.1 Travel pump

Variable Motor
Minor Repair Parts
Y100 Y102
Y101
L35
Y40 (Early Production
075 Frame Size) (L70)
Y50
Y60 L70
E15 L60
E35 E26 (Y50) (L40)
L30
L40
B83
(B74)
B80
B83 L50
B76
H68W T100
T101
T30
H60W T40
(B74) T50
H62W T60
H64W (T50)
H66W M1PT Y80 Y71

H60N B74 Y72
Y70
M1NA, M1NB P700
(G50) M1NC, M1ND P702
(P400)
(H50N) G50 (B80)
(P401)
(H50W) (P402)
E25 P601 (P403)
(H40W) (B74)
P603
E35
(H30W) H10N
(H20W) (P400) P600
E15
(P401) P602
G70 H50N (P402)
(P403)
H10W
H20W
H30W
(G63) H40W H50W
G63
(G64) (CODE 61 OPTION)
P800
G64
(CODE 61 OPTION)
90000865E
86
614 BOMAG 008 911 63

Travel pump 17.1

Parts List
B74 ............... Pl ug ......................................................... 4 L30 ............... Se al c arrier .............................................. 1

B76 ............... Pl ug ......................................................... 1 L35 ............... Se al c arrier .............................................. 1
B80 ............... Pl ug ......................................................... 2 L40 ............... Lip se al .................................................... 1
B83 ............... Pl ug ......................................................... 1 L50 ............... O-ring ...................................................... 1
B83 ............... Speed sensor .......................................... 1 L60 ............... Ret ainer ................................................... 1
L70 ............... Screw ......................................................3
E15 ............... C ap .......................................................... 1
E25 ............... Set screw ................................................ 1 M1N ............. Control v alve - electric ............................ 1
E35 ............... N ut - Se al Lock ....................................... 1 M1P .............. Control v alve - hydraulic ......................... 1
G50 .............. Pl ug ......................................................... 2 P400............. Pl ug ......................................................... 2

G63 .............. Split fl ange clamp .................................... 4 P600............. Pl ug ......................................................... 1
G64 .............. Shipping cover screw .............................. 4 P601............. PCOR-Valve ............................................1
P700............. Special plug ............................................. 1
G70 .............. Pl ug ......................................................... 1 P800 .............O-ring ...................................................... 1
H10N ............ Loop fl ushing spool - defeat.................... 1 T30 ............... Filter screen ............................................ 1
H50N ............ Pl ug ......................................................... 2 T40 ............... O-ring ...................................................... 1
H60N ............ Pl ug ......................................................... 1 T50 ............... B ackup ring ............................................. 2
T60 ............... O-ring ...................................................... 1
H10W ........... Sh uttle valve spool .................................. 1 T100 ............. Orifice pl ug .............................................. 1
H20W ........... Spring g uide ............................................ 2
H30W ........... Spring ......................................................2 Y40 ............... O-ring ...................................................... 1
H40W ........... O-ring ...................................................... 2 Y50 ............... B ackup ring ............................................. 2
H50W ........... Pl ug ......................................................... 2 Y60 ............... O-ring ...................................................... 1
H60W ........... Ch arge relief valve plug .......................... 1 Y70 ............... Orifice check v alve .................................. 1
H62W ........... O-ring ...................................................... 1 Y71 ............... N ut - Se al Lock ....................................... 1
H64W ........... Spring ......................................................1 Y72 ............... O-ring ...................................................... 1
H66W ........... Ch arge relief poppet ............................... 1 Y80 ............... Pl ug ......................................................... 1
H68W ........... Lock n ut ................................................... 1 Y100............. Orifice pl ug .............................................. 1
Y102............. Orifice check v alve .................................. 1
L8 ................. Key .......................................................... 1
L9 .................Slotted n ut ............................................... 1
Name Plate
Ames, Iowa, U.S.A. Neumünster, Germany

Model Code Typ
90S055 NB 2 0
8 N 4 S1 W 01 Model Code
NNN 01 00 24
Model No. Ident Nr
Model Number 94 – 4002
Serial N umber A – 91 – 26 – 67890
Serial No. Fabr Nr
MADE IN U.S.A.
Place of Manufacture
Name Plate (U.S.A. Production)
87
008 911 63 BOMAG 615

17.1 Travel pump
Hydraulic Power Systems
SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide

SAUER-SUNDSTRAND is a world leader in the design SAUER-SUNDSTRAND specializes in integrating a full
and m anufacture of Hydraulic Power Systems. Research range of system components to provide vehicle designers
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Europe enable SAUER-SUNDSTRAND to offer a wide
range of design solutions utilizing hydraulic power system SAUER-SUNDSTRAND is Your World Source for Controlled
technology. Hydraulic Power Systems
F000 692 F000 691 F000 686
Heavy Duty Axi al Piston Heavy Duty Bent Axis Cartridge Motors/
Pumps and Motors Variable Motors Compact Wheel Drives
F000 685 F000 688 F000 690 F000 684
Medium Duty Axial Piston Microcontrollers and Hydrostatc Transmission

Pumps and Motors Electrohydraulic Controls Packages
F000 717 F000 687 F000 693
Open Circuit Axial Piston Pumps Gear Pumps and Motors Genuine Service Parts
Worldwide Service Support
SAUER-SUNDSTRAND provides comprehensive worldwide service for its

produkts through an extensive network of Authorized Service Centers
strategically located in all p arts of the world.
Look to SAUER-SUNDSTRAND for the best in WORLDWIDE SERVICE.
Original
Ersatzteile http://www.sauer-danfoss.com
Genuine Parts
SAUER-SUNDSTRAND COMPANY SAUER-SUNDSTRAND GMBH & CO.

2800 East 13th Street Postfach 2460 D-24531 Neumünster
Ames IA 50010 U.S.A. Krokamp 35 D-24539 Neumünster Germany
Phone: (515) 239-6000 Fax: (515) 239-6618 Phone: (04321) 871-0 Fax: (04321) 871 122
SM-SPV/SMF/SMV90-E • 10/98 • 300047G
616 BOMAG 008 911 63

17.2 Vibration pump
008 911 63 BOMAG 617

17.2 Vibration pump
618 BOMAG 008 911 63

Vibration pump 17.2
Series 42
Axial Piston
Pumps
Service Instructions
008 911 63 BOMAG 619

17.2 Vibration pump
1. Introduction
1.1 Using This Manual
The Adjustment and Minor Repair procedures de- placed. Lightly lubricate all O-rings with clean petro-
tailed herein may be performed by trained personnel leum jelly prior to assembly. All gasket sealing sur-
without voiding the unit warranty. faces must be cleaned prior to installing new gaskets.
Cleanliness is a primary means of assuring satisfac- All exploded view drawings depict the 28cc frame
tory transmission life. Cleaning parts by using a clean size. For variances in the 41cc frame size, see the
solvent wash and air drying is usually adequate. As outline drawings in section 3. Differences in wrench
with any precision equipment, all parts must be kept size and torquing for the two frame sizes are noted in
free of foreign materials and chemicals. When per- the text. Note that exterior housing screws are mostly
forming service activities, protect all exposed sealing Torx-type T30 or T45.
surfaces and open cavities from damage and foreign
These symbols are used within drawings:
material.
Whenever removing a service component, it is rec- Apply petroleum jelly.
ommended that any gaskets and O-rings be re- Lubricate with clean hydraulic oil.
1.2 Safety Precautions
Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury.
The following general precautions should be taken into consideration whenever servicing a hydrostatic system.
Loss of Hydrostatic Braking Ability Fluid Under High Pressure
WARNING WARNING
When Series 42 units are used in vehicular Use caution when dealing with hydraulic fluid
hydrostatic drive systems, the loss of hydro- under pressure. Escaping hydraulic fluid un-
static drive line power in any mode of opera- der pressure can have sufficient force to pen-
tion (e.g. acceleration, deceleration or “neu- etrate your skin causing serious injury. This
tral” mode) may cause a loss of hydrostatic fluid may also be hot enough to burn. Serious
braking capacity. A braking system which is infection or reactions can develop if proper
independent of the hydrostatic transmission medical treatment is not administered immedi-
must, therefore, be provided which is adequate ately.
to stop and hold the system should the con-
dition develop. Flammable Cleaning Solvents
Disable Work Function WARNING

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

F000719 All rights reserved. Contents sub ject to change. Printed in Germany.
620 BOMAG 008 911 63

Vibration pump 17.2
Contents
1. Introduction ................................................................................................................................ 2
1.1 Using This Manual................................................................................................................................. 2
1.2 Safety Precautions ................................................................................................................................ 2
2. Model Code ................................................................................................................................. 4
3. Component and Port Locations ............................................................................................... 5

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

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

5.1 Shaft Options ...................................................................................................................................... 31
5.2 Filtration, Charge Relief, System Relief, and Loop Flushing ............................................................... 32
5.3 Charge Pump, Auxiliary Pads, and Servo Covers ............................................................................... 33
5.4 Control Options ................................................................................................................................... 34
008 911 63 BOMAG 621

17.2 Vibration pump
Series 42 Model Code
2. Model Code
Refer to the model code exhibited on the unit's name plate for information regarding the configuration of the unit.
Note: Some options listed here may not currently

Ames, Iowa, U.S.A. Neumünster, be available. Some options on your unit may not
Model Code Germany be listed here. This is not an order code. See the
42L28 - C - ANN1 - 01Typ - Model Code Series 42 Price Book for up-to-date ordering infor-
ANA - 2CNB - NN - NN - N - mation.
N - N - NNN - NNN
Model No. Ident Nr
428 2051 Serial No. X XX XX XXXXX
A 93 23 67890
Serial No. Fabr Nr Location Year Week Sequence No.
MADE IN U.S.A. T000 022E
A B C D E F G H J K L M N P
1 2 1234 123 12 34
A Series 42 x1 = Fast
L = CCW E Control Response Time x2 = Medium
B 1 Rotation x3 = Slow
R = CW
28 = 28 cm3 (1.71 in3) F 1 Port Style A,J,P = SAE Threaded O-Ring Boss
2 Displacement
41 = 41 cm3 (2.50 in3) N = None
2 Loop Flushing / Cooling
C = 13T 16 / 32P Spline 2,3 = Loop Flushing / Cooling Shuttle
D = 15T 16 / 32P Spline N = None (Ext. Charge Supply)
C Input Shaft Configurations E = 19T 16 / 32P Spline A = Suction (No Adapter Plate)
3 Filtration
G = 1.000 in. O.D. Straight Keyed C = Remote Pressure (Partial Flow)
K = 1.000 in. O.D. Tapered (1.5 in / ft) G = Suction (Adapter Plate)
N = None N = None
G 1 Charge Pump
A = MDC, Linear, Low Force 2 = 11 cm3 / rev (0.67 in3 / rev)
C = MDC, Non-Linear, Low Force C = 14 bar (205 psi)
D 1 Control Type 2 Charge Relief Setting
E = EDC (Electric Displacmt Contrl) F = 20 bar (280 psi)
F = FNR (3-Pos Forwrd-Neut-Revrs)
G = NFP (Non-Feedback Proport'l) N = None
3 Special Drive Features
1 = NFP
N = None or Not Applicable
1 = NSS / Weatherpack for MDC, N = None
or PCP Style for EDC A = SAE-A, 9 Tooth
4 Rear Auxilliary Mounting Pad
NSS for MDC or 12V Electric for NFP B = SAE-B, 13 Tooth
or PCP for EDC 2 = 12 V DIN for FNR T = SAE-A Special, 11 Tooth
2
or Connector for FNR 3 = NSS+BAS / CW Handle Rot. NN = Check Valve only, No HPRV
or Style for NFP / Weatherpack for MDC 14 = 140 bar (2030 psi)
or Hydraulic for NFP High Pressure Relief Setting - 17 = 175 bar (2450 psi)
H
5 = NSS+BAS / CCW Handle Rot. Port "A" 19 = 190 bar (2755 psi)
/ Weatherpack for MDC 21 = 210 bar (3045 psi)
N = None or Not Applicable 23 = 230 bar (3330 psi)
A = 12V Override / Weather Pack, 25 = 250 bar (3625 psi)
Solenoid Override with MDC 28 = 280 bar (4060 psi)
or EDC Input = 14-85 mA High Pressure Relief Setting -
3 or EDC Input J 30 = 300 bar (4350 psi)
or 400 - 1200 mA or 5-20 bar Port "B"
or Inching / Braking for NFP 34 = 345 bar (5000 psi)
for NFP
E = 12V Override / Brake Port 00 = No HPRV, No Check Valves
N = None or Not Applicable N = None
K Loop Bypass Valve
1,6 = Standard Handle fpr MDC B = Yes
Handle for MDC
or M / S Connector for EDC L Displacement Limiters - Side 1 N, 0 = None
4 or Connector for EDC
or Amp Connector for NFP A, 1 = Yes, Set at Max Disp
or Connector for NFP M Displacement Limiters - Side 2
2,5 = Clevis Handle for MDC
or Weather Pack for EDC N Special Hardware Features NNN = None
P Special Non-Hardware Features NNN = None
622 BOMAG 008 911 63

Vibration pump 17.2
Series 42 Component and Port Locations
3. Component and Port Location s
3.1 Component Locations
A pump with a manual displacement control (MDC) and no filtration adapter is shown. With non-feedback and
automotive controls, the positions of the case drains vary (shown in gray). With a filtration adapter, the porting in
the "Filtration Options" area varies (see section 4.16).
Control Neutral Adjustment Pump Neutral Adjustment

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

Control Module (MDC/EDC)
(MDC Shown)
Servo Piston
Covers
Displacement
Limiters System Check
Relief Valves
Charge
Pump
Shaft Seal
Auxiliary
Mounting Filtration Options
Pad Charge Relief Valve (No Filtration Adapter
(Loop Flushing Valve)
Shown Here)
P100102 E
Series 42 41cc Variable Pump
008 911 63 BOMAG 623

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

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

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

(Non-Feedback Inlet Port S
Controls)
Case Drain
System Pressure
Port L2
Gauge Port M1
P100103 E
28cc Base Unit with MDC and No Filtration Adapter
624 BOMAG 008 911 63

Vibration pump 17.2
System Pressure Servo Pressure

Servo Pressure Charge Pressure
System (Charge Pressure
Pressure Case Drain Supply For
Port B Port L2 No Charge Pump
Option)
System
Pressure
Port A
Case Drain Charge Pump
Port L1 Inlet Port S
System Pressure
Gauge Port M1
Left Side View (Side "2") Right Side View (Side "1") P100104 E
41cc Base Unit with MDC and No Filtration Adapter
To Filter, Port D
(Pressure Filtration)
Charge Pressure
Gauge Port M3
(Full Flow Pressure Filtration)
From Filter, Port E
(Pressure Filtration)
Charge Pressure
Gauge Port M3
(Partial Flow Pressure Filtration)
Charge Pressure
Gauge Port M3
(Suction Filtration)
P100105 E
Filtration Adapter (28cc and 41cc Models)
008 911 63 BOMAG 625

17.2 Vibration pump
Series 42 Adjustments and Minor Repairs
4. Adjustment and Minor Repair Instructions
4.1 Size and Torque for Plugs and Fittings
Plug and fitting sizes are given here. Place a fresh O-ring, lightly lubricated with petroleum jelly, whenever a plug
is removed. Each should be torqued as indicated. A 28cc unit with manual displacement control (MDC) is shown.
Servo Gage
Port M4
11/16 in Hex
27-47 Nm
(20-35 ft lbf)
28cc: 9/16 in Int. Hex

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

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

95-135 Nm
(70-100 ft lbf)
125-250 Nm
(90-190 ft lbf)
11/16 in Hex
System Ports 27-47 Nm
A and B (20-35 ft lbf)
115 Nm (85 ft lbf)
E100001 E
626 BOMAG 008 911 63

Vibration pump 17.2
4.2 Pump “Neutral” Adjustment
The pump neutral adjustment sets the position of the

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

Adjustment Seal
2. Connect a hose between gauge ports M4 and M5 Lock Nut
to equalize the pressures on both ends of the
pump servo piston.
3. Install pressure g auges in gauge ports M1 and
M2 to measure system pressure.
4. Start the prime mover and operate at normal E100002 E
speed.
Pump Neutral Adjustment Screw
5. Loosen the pump "neutral" adjustment seal lock (MDC Control Shown)
nut [28cc 13 mm Hex; 41cc 17 mm Hex]. Turn
the pump "neutral" adjustment screw [28cc 5
mm Hex; 41cc 7 mm Hex] until the system
pressure gauge readings are equal.
6. Turn the adjustment screw clockwise until one of
the gauges registers an increase in system pres-
sure. Note the position of the adjustment screw.
Turn the screw counterclockwise until the other
gauge registers an increase in system pressure.
Note the position of the adjustment screw.
7. Turn the adjustment screw clockwise to a posi-
tion halfway between the positions noted above.
The system pressure gauges should indicate
equal pressures.
8. While holding the adjustment screw in position,
torque the seal lock nut [28cc 20-26 Nm (15-19
ft lbf); 41cc 28-51 Nm (21-37 ft lbf)] .
9. Stop the prime mover and remove the hose
between gauge ports M4 and M5. Remove the
pressure gauges installed in gauge ports M1 and
M2. Reinstall the plugs in the gauge ports.
10. Reconnect work function.
IMPORTANT
If the pump is equipped with an MDC or EDC,
the CONTROL "neutral" adjustment MUST also
be performed before putting the pump into
service (see next section).
008 911 63 BOMAG 627

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

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

external control linkage (for MDC) or control
signal input (for EDC) from the pump.
2. Install pressure g auges in gauge ports M4 and MDC / EDC Control "Neutral"
M5 to measure pressure on the pump servo Adjustment Seal Lock Nut
piston. E100003 E
3. Start the prime mover and operate at normal Control Neutral Adjustment Screw
speed. (EDC Control Shown)
4. Loosen the CONTROL "neutral" adjustment seal
lock nut (see drawing) [17 mm Hex] . Turn the
control "neutral" adjustment screw [5 mm Int.
Hex] until the servo piston pressure gauge read-
ings are as close to equal as possible.
5. Turn the adjustment screw clockwise until one of
the gauges registers an increase in pressure on
the servo piston. Note the position of the adjust-
ment screw.
Turn the screw counterclockwise until the other
gauge registers an increase in pressure on the
servo piston. Note the position of the adjustment
screw.
6. Turn the adjustment screw clockwise to a posi-
tion halfway between the positions noted above.
The servo piston pressure gauges should indi-
cate nearly equal pressures.
7. While holding the adjustment screw in position,
torque the seal lock nut [14-24 Nm (10-18 ft lbf)].
8. Stop the prime mover and remove the pressure
gauges installed in gauge ports M4 and M5.
Reinstall the plugs in the gauge ports.
9. Reconnect the external control linkage (for MDC)
or control signal input (for EDC) to the pump.
Reconnect the work function.
10
628 BOMAG 008 911 63

Vibration pump 17.2
4.4 MDC Control Module
The manual displacement control (MDC) module Nut

provides control of the pump servo piston through a Lock Washer
connection to the summing link pin within the pump Plug for MDC Handle
housing. The following procedure shows how to Visual
Inspection
remove and install the control housing. Section 4.6
explains how to remove and install the control spool
and linkage. Control
Retaining
1. Clean the external surfaces of the pump. If nec- Screws
essary, remove the MDC handle.
2. Remove the seven (7) control retaining screws Control
Gasket
[Torx T30] that secure the control to the pump
housing. Remove the control and control gasket Hold summing link
from the pump. (and control spool)
in position
Note: See section 4.6 for instructions on remov-
ing/installing the control spool and linkage.
3. Clean the sealing surfaces of the control and the
pump housing. Place a new gasket in position on
the housing.
CAUTION E100004 E
The control orifices are part of the control
gasket. Refer to the appropriate Service Parts MDC Control Module Assembly
List to determine the correct gasket.
4. Hold the summing link pin in position while install-

ing the control. (The spring on the control spool
will tend to push the link to an extreme position.)
The link pin MUST engage the slot in the control
cam. A plug is provided on the MDC housing to
permit visual inspection of linkage pin engage- Summing
ment. link pin
MUST enter
Note: It may be easiest to lay the servo piston the slot in
side of the control down first, then watch the link the control
pin engage from the charge pump side of the cam!
E100005 E
pump.
Link Pin Into Cam Slot
5. Install and torque the control screws [15-17 Nm
(11-13 ft lbf)]. Perform Control Neutral Adjust-
ment (Section 4.3).
WARNING
Failure to properly engage the link pin with the
control cam will result in incorrect control
operation, which may lead to loss of control of
the vehicle / machine.
F100201
Link Pin Into Cam Slot
11
008 911 63 BOMAG 629

17.2 Vibration pump
4.5 EDC Control Module
The Electric Displacement Control (EDC) provides a

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

ing the control. (The spring on the control spool
will tend to push the link to an extreme position.)
The link pin MUST engage the hole in the control
piston fork.
Control
Note: It may be easiest to lay the servo piston Gasket Summing
side of the control down first, then watch the link link pin
Hold summing MUST enter
pin engage from the charge pump side of the link (and control the hole in
pump. spool) in the control
position piston fork!
5. Install and torque the control screws [15-17 Nm
(11-13 ft lbf)]. Perform Control Neutral Adjust-
ment (Section 4.3).
WARNING
Failure to properly engage the link pin with
control piston fork will result in incorrect con- E100006 E
trol operation, which may lead to loss of con-
trol of the vehicle / machine. EDC Control Module Assembly
12
630 BOMAG 008 911 63

Vibration pump 17.2
4.6 MDC/EDC Control Spool, Control Linkage, and Control Neutral

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

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

feedback link, and neutral adjustment link. Bore Plug
6. Remove the seal lock nut [17 mm Hex] and the
control neutral adjustment screw [5 mm Int. Hex].
Installation of Spool, Linkage, and Adjustment Housing with
Gasket
Screw Filtration Adapter
1. Install the control neutral adjustment screw and
seal lock nut. Do not tighten the nut.
Control Spool
2. Assemble the "neutral" adjustment link and feed- Bore Cover E100007 E
back link, and install as shown. Install and torque
MDC/EDC Control Spool and Linkage
the linkage pivot screw [8-15 Nm (6-11 ft lbf)].
3. Lubricate and install the control spool and spring
Feedback link
assembly noting proper orientation. must enter slot in
servo piston
WARNING Pivot screw
The control spool and spring assembly MUST
be oriented in the housing as shown for proper
control operation.
4. Install and torque the control spool bore plug [41- Fork on summing link
must engage flats on
94 Nm (30-70 ft lbf)]. Or install the control spool control spool
Slot in "neutral" adjust link
cover (with a new gasket) or plug, and torque the must engage groove in
screws [15-17 Nm (11-13 ft lbf)]. adjusting screw E100008 E
5. Install the summing link. Hold the control spool in Servo Piston Linkage and Control Spool
position while engaging the fork on the summing (Internal Parts Shown with Housing Removed)
link with the flats on the spool. If necess ary, rotate
the spool to engage the summing link.
6. Install a new control gasket. Hold the summing
link and control spool in position while reinstalling
the MDC or EDC (see section 4.4 or 4.5). Perform
Control Neutral Adjustment (section 4.3).
13
008 911 63 BOMAG 631

17.2 Vibration pump
4.7 MDC Neutral Start/Backup Alarm Switch
The Neutral Start Switch (NSS) prevents the engine NSS Cover
and pump from being started when the pump is out of
NSS Control Nut
neutral. The NSS should be wired in series with the NSS Cam
engine starting circuit. The switch contact is closed at
the control handle's neutral position and opens when
the control handle is rotated 1.5 to 2° from neutral.
The Backup Alarm Switch (BUA) outputs an elec- NSS Cavity
tronic signal when the control handle is in a reverse
position. This switch is normally wired in series with
an audio output. The switch cont act is open until the NSS with
control handle is rotated 2.6 to 3.75° in the reverse Weatherpack
direction.
CAUTION
The control handle's neutral position must
NSS with Screw
agree with the pump's neutral position for the Terminals
NSS/BUA to work effectively (see section 4.3).
E100009 E
The Neutral St art / Backup Al arm Switch assembly
can be configured for three different settings. NSS Assembly on MDC
i. A Neutral Start Switch only.
ii. A Neutral Start Switch with Backup Alarm for
units where clockwise (CW) handle rotation re-
sults in "reverse" motion.
iii. A Neutral Start Switch with Backup Alarm for Control
units where counterclockwise (CCW) handle ro- Yolk Cam
tation results in "reverse" motion.
The setting must be in accordance with the configu-
ration of the unit. See the model code (section 2) if
NSS only NSS with BUA NSS with BUA
uncertain of the type of NSS you have.
(CW = Reverse) (CCW = Reverse)
Alignment of the NSS requires a special alignment P100107 E
Top View of NSS Showin g Cam Positions
tool. Dimensions are given at right.
(continued) 9/16 -18UNF 2A THD
.04 x 45 Chamfer
R.125 ø .236–.030
Knurl
35.0
1.250
.306 .354
2.000
Material: .75 DIA x 3 ETD150

(All Dimensions in inches)
P100108 E
Alignment Tool
14
632 BOMAG 008 911 63

Vibration pump 17.2
Adjustment is performed by setting the cam position

within the NSS assembly.
1. The MDC module must be removed from the
NSS Cover NSS
pump housing. Refer to section 4.4.
NSS Control Nut
2. Remove NSS [7/8 in Hex].
NSS Cam
3. Remove the NSS cover by inserting a screw-
driver into the NSS cavity and popping off the
cover with a hammer. Be careful not to damage
the internal hardware.
P100109 E
4. Remove the control nut [8 mm Hex]. Side View of NSS and NSS Cavity
5. Use a screwdriver to pop off the cam.

6. Set cam in proper orientation according to the
unit's configuration (i, ii, or iii above).
7. Screw special alignment tool in NSS cavity to

hold cam in place.
8. On the underside of the MDC module, clamp a
pair of locking pliers around the spring contacts of
the control cam. The pliers should hold the nub on
the control cam to the pin underneath. This will
hold the control cam in neutral position.
9. Screw control nut on cam [4.1-6.8 Nm (3-5 ft lbf)].
10. Press new cover on top of cam cavity. This
requires either an arbor press or a full-sized
punch (punch depth = 1.06 mm (0.0417 in),
punch width = 23.3 mm (0.916 in)). F100202
Underside of MDC Module Showing Where to Clamp
11. Remove the alignment tool and the locking pliers. Locking Pliers
12. Place a new lubricated O-ring on NSS.
13. Reconnect the NSS [25-29 Nm (18-22 ft lbf)] to
the MDC.
14. Reinstall MDC module onto pump housing (refer
to section 4.4).
15
008 911 63 BOMAG 633

17.2 Vibration pump
4.8 MDC Solenoid Override Valve
The solenoid override valve is a s afety feature that

connects both ends of the servo control piston to- Port L4
gether when the solenoid is de-energized. Thus the
Port X7
pump can be put into stroke only when the solenoid
is energized.
The solenoid override with brake release includes
hydraulic control of a safety brake. When de-ener-
gized, a spring-applied, hydraulically-released brake
is drained through port X7. For conditions where case
back-pressure on the spring-applied brake is critical,
an external drain to the reservoir can be connected
through port L4.
The solenoid override valve can be removed to
inspect and remove foreign matter.
Removal Solenoid Override Valve
1. Remove retaining nut [9/16 in Hex]. Assembly E100010 E
Solenoid Override Valve Assembly

2. Remove solenoid housing.
3. Remove retaining ring at base of solenoid. Retaining Nut
4. Remove solenoid. This should be connected to Solenoid

internal spool. Housing
Installation
Washer
1. Replace O-ring. Retaining Ring
2. Place spring and plunger inside of solenoid.
Solenoid
3. Attach spool (male notch) to plunger (female
notch).
O-Ring
4. Insert solenoid/spool assembly in solenoid over- Spring
ride bore. Plunger
5. Snap retaining ring over base of solenoid.
Spool
6. Place washer at base of solenoid.
7. Install housing and retaining nut [2-4 Nm (1.5-3.5
ft lbf)].
E100011 E
Exploded View of Solenoid Override A ssembly
16
634 BOMAG 008 911 63

Vibration pump 17.2
4.9 FNR, NFPE, and NFPH Controls
The 3-position FNR control and the electric and

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

ports for cleanliness.
4. Clean sealing surfaces.
5. Replace locator pin.
6. Install new O-rings.
7. Replace screws [4.7-6.1 Nm (3.5-4.5 ft lbf].
E100013 E
Removal and Installation of FNR and NFPE NFPE Assembly (FNR Similar)
Control Orifices
Note: Future models may contain an orifice plate Non-Feedback
between module and pump housing. This will Control Orifice
take the place of the orifice plugs beneath the
servo piston cover.
1. Remove servo piston cover (see section 4.17).
2. Remove orifice plug [1/8 in Int. Hex].
3. Examine orifice and port for cleanliness.
4. Install orifice plug [2.0-3.4 Nm (1.5-2.5 ft lbf)].
E100014 E
Location of Non-Feedback Control Orifice
17
008 911 63 BOMAG 635

17.2 Vibration pump
4.10 System Check Relief Valves (High Pressure Relief, Charge Check,

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

High Pressure
be replaced by removing the retaining ring and Relief Valve
removing the plunger from the special valve seat Conical Spring
plug. Remove the O-ring from the plunger and
install a new O-ring. Reinstall the plunger and
retaining ring.
5. Install a new outer O-ring, new backup ring, and
new inner O-ring on each valve seat plug.
6. Check that the conical springs are properly re-
tained on the check poppets or relief v alves.
Install the check poppet or high pressure relief
valve assemblies into the pump housing .
CAUTION
The conical springs MUST be correctly posi-
tioned on the check poppets or relief valves
after installation for proper pump operation. E100015 E
System Check Relief Valve Components
7. Install the valve seat plugs or valve seat/ bypass
plugs into the pump housing and torque [40-95
Nm (30-70 ft lbf)].
18
636 BOMAG 008 911 63

Vibration pump 17.2
4.11 Charge Relief Valve
The charge relief valve may be removed for cleaning

and installation of fresh O-rings. The pressure setting
may be changed. However, note that the setting will
vary for different charge flows which depends on
charge pump size and pump speed. The factory
setting is set relative to case pressure at 1800 rpm.
The actual charge pressure will vary at different
speeds.
Shim Adjustable Style
1. Remove the shim adjustable charge relief valve Shim Adjustable
Charge Relief Valve Plug
plug [1 in Hex] from the p ump housing. Remove O-Ring
the O-ring from the plug.
Shims
2. Remove the spring and poppet from the housing. Spring
3. Do not alter the shims which may be installed Poppet
between the spring and valve plug, or inter-
change parts with another valve. Inspect the
poppet and mating seat in the housing for dam-
age or foreign material.
4. If desired, the charge relief valve setting can be

changed. An a pproxim at e rule of thumb is 4 bar
/ 1.25 mm (58 psi / 0.050 in). The effective setting
will vary.
To confirm the charge relief valve setting, mea- E100016 E
sure charge pressure (port M3) with the pump in Shim Adjustable Charge Relief Valve Components
stroke. The charge pressure should level off
when the relief setting is reached.
Approximate Relief Setting vs Shim Thickness
5. Install a new O-ring on the valve plug. Reinstall
the poppet, spring, and plug (with shims and O- 4 bar / 1.25 mm (58 psi / 0.050 in)
T000 023E
ring) into the pump housing [55-135 Nm (40-100
ft lbf)].
(continued)
19
008 911 63 BOMAG 637

17.2 Vibration pump
Screw Adjustable Style Charge Relief Lock Nut

1. Before removing the screw adjustable relief valve O-Ring
plug, mark the plug, lock nut, and housing so as Screw Adjustable
to approximately maintain the original adjust- Charge Relief Valve Plug
Spring
ment when assembling, Remove the screw ad- Poppet
justable charge relief valve plug by loosening the
lock nut [1-1/16 in Hex] and unscrewing the plug
[8 mm Int. Hex]. Remove the O-ring from the plug.
2. Remove the spring and poppet from the housing.
3. Inspect the poppet and mating seat in the hous-
ing for damage or foreign material.
4. Install a new O-ring on the v alve plug. Reinstall
the poppet and spring. Reinstall the plug with its
lock nut [47-57 Nm (34-42 ft lbf)], aligning the E100017 E
marks made at disassembly. Screw Adjustable Charge Relief Valve Components
5. Check and adjust, if necessary, the charge pres-
sure. For screw adjustable "anti-stall" charge
relief valves, an approximate rule of thumb is 2.8 Approximate Relief Setting vs Screw Revolution
bar / quarter turn (40 psi / quarter turn).
2.8 ba r / 1⁄ 4 turn (40 p si / 1⁄ 4 turn)
To confirm the charge relief valve setting, mea- T000 024E
sure charge pressure (port M3) with the pump in
stroke. The charge pressure should level off
when the relief setting is reached.
20
638 BOMAG 008 911 63

Vibration pump 17.2
4.12 Loop Flushing Valve
The loop flushing function consists of the loop flush-

ing shuttle valve and the loop flushing relief valve. The Loop Fl ushing
assemblies may be removed for cleaning and instal- Relief Plug
lation of new O-rings. The relief valve poppet may be Loop Fl ushing Relief
Plug (Defeat) O-Ring
exchanged for one with a different flow rating, but the
O-Ring
relief valve shims should not be changed out unless Shims
specifically instructed so by Sauer-Sundstrand. The Spring
function also can be defeated.
Poppet
Loop Flushing Valve
1. Remove the loop flushing valve plug from the
Loop
pump housing [11/16 in Hex]. Remove the O-ring Loop Fl ushing
Flushing
from the plug. Plug (Defeat)
Plug
O-Ring
2. Remove the loop flushing valve spool assembly O-Ring
from the housing.
Loop
3. Inspect the parts for damage or foreign material. Defeat Flushing
Spool Spool
The centering spring must be securely retained to Assembly
the spool by the washer.
4. Install the loop flushing valve spool assembly into
its bore. Install a new O-ring on the loop flushing
plug and install [27-47 Nm (20-35 ft lbf)].
Loop Flushing Relief Valve
1. Remove the loop flushing relief valve internal hex
plug [5/8 in Hex] from the p ump housing. Remove
the O-ring from the plug.
2. Remove the spring and poppet from the housing.
3. Do not alter the shims which are installed be-
tween the spring and valve plug, or interchange
parts with another valve. Inspect the poppet and
mating seat in the housing for damage or foreign
E100018 E
material. Inspect the orifice in the valve poppet.
Loop Flushing Valve and Loop Flu shing Defeat
4. Install a new O-ring on the valve plug. Reinstall Components
the poppet, spring, shims, and plug (with O-ring)
into the pump housing [15-34 Nm (15-25 ft lbf)].
Defeating Loop Flushing
1. Remove the loop flushing valve from the pump
housing.
2. Install the defeat spool into the spool bore in the
housing. Install the plain plug with O-ring into the
housing [11/16 in Hex], and torque [27-47 Nm
(20-35 ft lbf)].
3. Remove the charge relief valve (these parts are
not necessary).
4. Install the plain hex plug with O-ring into the end
cap [5/8 in Hex], and torque [15-34 Nm (15-25
ft lbf)].
21
008 911 63 BOMAG 639

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

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

the seal carrier. The seal lip must face the outside Sealant may
Seal be used on
of the pump. Be careful not to damage the seal.
outside diameter
The outside diameter of the seal may be coated
with a sealant (e.g. Loctite High Performance Seal Carrier
Inside Lip
(face down)
Sealant #59231) prior to installation. This aids in
preventing leaks caused by damage to the seal
bore in the seal carrier.
(continued)
Press Seal
to bottom of Se al Carrier
E100020 E
Installation of Shaft Seal
22
640 BOMAG 008 911 63

Vibration pump 17.2
If the shaft is not being replaced proceed to step

11. Retaining Ring
8. Remove the shaft and roller bearing assembly Roller Bearing
from the pump or motor. The bearing assembly
can be transferred to the new shaft (steps 9 and
10).
9. Remove the retaining ring that secures roller Key Shaft
bearing assembly with a snap ring plier. Remove
the roller bearing assembly. OR
Shaft Assembly
10. Place roller bearing assembly on new shaft and OR
secure with the retaining ring.
11. Wrap the spline or key end of shaft with thin
plastic to prevent damage to the seal lip during
installation. Lubricate the inside diameter of the
shaft seal with petroleum jelly.
12. Place the O-ring onto the shaft bearing and
lubricate with petroleum jelly.
13. Slide the seal carrier assembly over the shaft and
into the housing bore. Press against O-ring. Hold
inward pressure against the shaft to compress
the cylinder block spring while pressing the seal
carrier into place.
14. Install the retaining ring.
E100021 E
Shaft Components
23
008 911 63 BOMAG 641

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

install a new auxiliary mounting pad or to install a
fresh O-ring for the current auxiliary mounting pad.
Several auxiliary mounting pads are available.
Auxiliary mounting pads are integrated into the charge
pump cover. When nothing is mounted on the pads,
a flange cover is attached to protect the mounting Pad Cover Screws
flange. This cover is removed when mounting a
Aux Mount Pad Cover
pump. Charge
Pump Retaining
Cover
Removal of Auxiliary Mounting Pad Screws
1. Remove the auxiliary pump or remove the two O-Ring
screws retaining the flange cover ["A" Pad 9/16
in Hex; "B" Pad 3/4 in Hex]. Remove the O-ring.
2. Orient pump so that charge pump cover (auxiliary OR
pad) is facing up.
3. Remove the charge pump cover. The auxiliary
pad is integrated into the charge pump cover. OR
Use a Torx T45 male driver to remove the screws. Auxiliary
Mounting
Note: If a different auxiliary pad is being installed, Pad "A"
then a new drive coupling must be installed. To do Gasket
this follow the instructions in the section on re-
moving and installing the charge pump (next
section).
Auxiliary
Note: If the charge pump components come out Mounting
with the charge pump cover refer to section 4.15 Locating
Pad "B"
on how to properly reinstall them. No Charge Pin 1
Pump Defeat
4. Install a new charge pump cover gasket. Charge Pump
Components
5. Install the charge pump cover (auxiliary pump
mounting pad is integrated in cover).
NOTE: The threaded screw holes in the auxiliary Locating
Pin 2
pump mounting pad used on very early produc-
tion pumps with the SAE "A" p ad option are drilled
through into the area between the gerotor cover
and charge pump cover. Any of these holes
which are not used to attach the flange cover or E100022 E
auxiliary pump should be plugged with internal
Auxiliary Pad Options and Component s
hex set screws installed hand tight to prevent the
entrance of water or dirt into this area.
6. Attach the auxiliary pump. If no pump is to be
attached on an auxiliary mounting pad, the pad
should be protected with a flange cover and O-
ring to prevent leakage.
24
642 BOMAG 008 911 63

Vibration pump 17.2
4.15 Charge Pump
The charge pump m ay be disassembled to inspect

and clean, or to change the auxiliary shaft drive
coupling. (Screw used with
Note: For units without integral charge pumps "No Pad" and
"A Pad" Only)
see the last page of this section for additional
information. Cover
Retaining
1. Remove auxiliary pump, if necessary. Screws d
a
2. Remove the screws retaining the charge pump P

y
r
cover to the pump housing [Torx T45] (seven (7) i
l
a
i
x
screws are used with the "no pad" or SAE "A" u
A
auxiliary mounting pad charge pump cover, while r
o
r
six (6) screws are used with the SAE "B" auxiliary e
v
mounting pad charge pump cover). Remove the o
C
charge pump cover, gasket, and the cover locat- p
m
ing pins. u
P
e
g
r
3. Remove the gerotor cover assembly from the Gasket a
h
charge pump cover or the back of the pump C
O-Rings
housing. Remove the gerotor cover O-rings. Two
(2) O-rings are used on the gerotor cover of all
pumps. (An additional O-ring was used on the
gerotor cover of very early production pumps with
the SAE "A" pad option.) Geroter
Cover
s
t
4. Remove the gerotor assembly from the gerotor n
e
cover or pump housing. n
o
Geroter p
5. Remove the gerotor drive pin and drive coupling. Assembly m
o
C
Remove the gerotor cover locating pin from the Drive Coupling p
pump housing. m
u
Geroter Cover Geroter Drive Pin P
e
6. Each part should be inspected separately if they Locating Pin g
r
are to be reused. If either of the gerotor assembly
Charge Pump a
h
Charge Pump Cover Locating
Cover C
parts needs to be replaced, they must both be Pin
Locating
replaced. Always replace the O-rings and charge Pin
pump cover gasket. Inspect the journal bearing in
the gerotor cover for excessive wear.
7. Prior to assembly, lubricate the gerotor assembly
with clean hydraulic oil.
8. Install the gerotor drive pin into the hole in the
drive coupling, and retain with grease or petro-
leum jelly.
9. Install the drive coupling onto the pump shaft with
the smaller outside diameter oriented away from
E100023 E
the pump shaft. Different couplings are used
Charge Pump Components
with the different auxiliary pad options.
10. Install the gerotor assembly onto the coupling.
(continued)
25
008 911 63 BOMAG 643

17.2 Vibration pump
11. Install the gerotor cover locating pin into the

pump housing. Install the gerotor cover assembly
over the gerotor. The locating pin must engage
the slot in the gerotor cover.
NOTE: The charge pump rotation is determined
by the location of the gerotor recess and pressure
balance hole in the gerotor cover. Different
gerotorcovers are used for clockwise and
counterclockwise rotation pumps.
12. Install new pressure balance O-rings onto the
gerotor cover and retain with petroleum jelly or
grease. (An additional O-ring was used on the
gerotor cover of very early production pumps with
the SAE "A" pad option.)
13. Install the charge pump cover locating pins and a
new charge pump cover gasket.
14. Install the charge pump cover. The cover must
engage the gerotor cover and the locating pins. CW CCW
Install the charge pump cover screws and torque P100110 E
evenly [36-43 Nm (26-32 ft lbf)]. Determining Charge Pump Orientation Looking
Inside of Gerotor Pump Cover
15. If necessary, reinstall auxiliary pump.
For units without an integral charge pump see the
next section.
(continued)
26
644 BOMAG 008 911 63

Vibration pump 17.2
Units without Integral Charge Pump

Variable Pumps without an integral charge pump do (Screw used with
not have a gerotor assembly, gerotor drive pin, or "No Pad" and
gerotor cover locating pin installed. The charge pump "A Pad" Only)
inlet port is plugged with an O-ring plug. Cover
For these units that are equipped with housings Retaining d
Screws a
P
without filtration adapters, the gerotor cavity outlet y
r
is plugged with a special plug installed in a housing i
l
a
i
x
passage. The 3/4—16 charge inlet fitting should be u
A
torqued to 68 Nm (50 ft lbf). r
o
r
e
v
For these units that are equipped with housings that o
C
include filtration adapters, the gerotor cavity outlet p
is plugged with an O-ring plug installed in the "To m
u
P
Filter" port of a "Full Filter Flow" (charge relief valve e
g
r
after filter) filter adapter. The 7/8—14 charge inlet a
h
fitting should be torqued to 95 Nm (70 ft lbf). Gasket C
O-Rings
CAUTION
A "Partial Filter Flow" (charge relief valve be-
fore filter) adapter must not be used on variable
pumps without an integral charge pump. If this s
t
n
Geroter e
design adapter is used, the charge relief valve n
o
will be defeated. Cover p
Charge Pump m
o
Cover Locating C
Drive Coupling "
Pin 1 p
Charge Pump m
u
Cover Loc ating P
e
Pin 2 g
r
a
h
C
o
N
"
Geroter
Cavity
Outlet Plug
(Charge Charge
Pump Defeat) Inlet
Charge Pump
Charge Pump Inlet Pl ug Inlet Plug
Charge Inlet
(For Wrench Sizes

and Torquing
See Filtration Section)
E100024 E
No Charge Pump Option Component s No Charge Pump Option Component s

(Housing with Filtration Adapter) (Housing without Filtration Adapter)
27
008 911 63 BOMAG 645

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

697581 and ATI-E 9201 for more information on * Filter ßx-ratio is a measure of filter efficiency defined by ISO
filtration. 4572. It is defined as the ratio of the number of particles greater
than a given size (x) upstream of the filter to number of particles
greater than the same size downstream of the filter. The ßx-ratio
applies to a specific particle size, measured in microns.
28
646 BOMAG 008 911 63

Vibration pump 17.2
4.17 Servo Piston Covers
The servo piston cover can be removed to change the

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

Cover
6. On the right side (side "1"), screw the servo piston
cover on the neutral adjustment screw. Then,
while holding the cover, turn the neutral adjust-
ment screw CCW to engage the cover to the
screw threads.
7. Install servo piston cover screws (15-17 Nm (11-
13 ft lbf)].
8. On the right side (side "1"), loosely install neutral Servo Piston Cover – Left Side (Side "2")
adjustment seal lock nut. Perform pump neutral
adjustment (section 4.2). E100026 E
Servo Piston Cover Components
WARNING
After installing the servo piston cover on right
side (side “1”) of the pump, the pump “neutral”
adjustment and control neutral adjustment
MUST be performed before the vehicle / ma-
chine is put back into service.
CAUTION
Performance of the above procedure may ad-
just the position of the displacement limiter
somewhat.
29
008 911 63 BOMAG 647

17.2 Vibration pump
4.18 Displacement Limiter Adjustment
Displacement limiters can limit the maximum swash- Displacement Limiter

plate position. For Series 42 pumps, displacement Seal Lock Nut
limiters are available on one or both sides of the servo
piston.
Servo Piston
Adjustment of the displacement limiters should be Cover
performed on a test stand.
WARNING
Care should be taken in adjusting displace-
ment limiters to avoid undesirable speed con-
ditions. The limiter screw must have full thread
engagement in the servo piston cover, and the
seal lock nut must be retorqued after every
adjustment to prevent unexpected changes in
operating conditions and external leakage dur-
ing unit operation.
Displacement Limiter – Right Side (Side "1")
1. Mount pump on test stand. (Exploded View, No Need to Remove Limiter or Nut)
2. Loosen displacement limiter seal lock nut [13 mm
Hex]. Do not remove.
3. Adjust displacement limiter [4 mm Int. Hex]. Seal Lock Nut
Tighten the seal lock nut every time the pump
is to be tested [20-26 Nm (15-19 ft lbf)]. Displacement
Limiter
One full t urn of the displacement limiter adjust-
ment screw will change the displacement of the Servo Piston
Cover
pump a pproxim at ely a s follows.
28 cc 3.6 cc / rev 0.22 in3 / rev
41 cc 5.0 cc / rev 0.31 in3 / rev
T000 026E
4. After reaching proper displacement tighten the

Displacement Limiter – Left Side (Side "2")
seal lock nut [20-26 Nm (15-19 ft lbf)]. (Exploded View, No Need to Remove Limiter or Nut)
If necessary, repeat procedure for displacement lim- E100027 E
iter on other side. Displacement Limiters
30
648 BOMAG 008 911 63

Vibration pump 17.2
Series 42 Exploded View Parts Drawings
5. Exploded View Parts Drawings
5.1 Shaft Options
F096
C020
C017
C018
C015
C005
C002
C003
C001
C015 F001
OR
C001
OR
C001
E100028
31
008 911 63 BOMAG 649

Vibration pump 17.2
5.3 Charge Pump, Auxiliary Pads, and Servo Covers
L010
L010A
F020
F020A
G005
G010
(G075)
G015
G002 G020
(G021)
G022
G075 G065
G030 G023
F009
G001
M001
OR
(M001)
OR
(G001)
M005
M010A
G036
M010
(M005) OR
(M010A)
(M010) (G080)
G085
M020
M025
(G001) (G036) G090
(G090)
(G036) (G080)
(G085)
E100030
33
008 911 63 BOMAG 651

17.2 Vibration pump
5.4 Control Options
D038 D039
D081 D037
D003
D003A
(D017)
D080 D082 D019
D016
D002 OR
OR
D056 D017
D040
D010
F035 D012
F035A E001 D070
OR
OR
D011
D013 D004
F036
F035
F034 D081
D081
OR
D060
(F010)
F010
D090
D014
D015
D032A
E100031
D032
34
652 BOMAG 008 911 63

Vibration pump 17.2

Notes
35
008 911 63 BOMAG 653

17.2 Vibration pump
SAUER-SUNDSTRAND Hydraulic Power Sy stems - Market Leader s Worldwide

SAUER-SUNDSTRAND is a world leader in the design SAUER-SUNDSTRAND specializes in integr ating a full
and manufacture of Hydraulic Power Systems. Research range of system components to provide vehicle designers
and development resources in both North Americ a and with the most advanced total-design system.
range of design solutions utilizing hydraulic power system SAUER-SUNDSTRAND is Your World Source for
technology. Controlled Hydraulic Power Systems.
Heavy D uty Axi al Piston Heavy Duty Bent Axis Cartridge Motors/
Medium D uty Axial Piston Mikrocontrollers and Hydrostatic Transmissions

Pumps and Motors Electrohydraulic Controls Pack ages
SAUER-SUNDSTRAND provides comprehensive worldwide service for

its products through an extensive network of A uthorized Service Centers
strategically located in all p arts of the world.
http://www.sauer-danfoss.com

2800 East 13th Street Postfach 2460 D-24531 Ne umünster
Ames, IA 50010 U.S.A. Krokamp 35 D-24539 Neumünster Germany
Phone: (515) 239-6000 F ax: (515) 239-6618 Phone: (04321) 871-0 F ax: (04321) 871 465
SI-SPV42-E • 11/98 • 300 093B
654 BOMAG 008 911 63

17.3 Drum drive
008 911 63 BOMAG 655

17.3 Drum drive
656 BOMAG 008 911 63

Drum drive 17.3

Hydraulikmotoren
MS
Hydraulic motors
Reparaturen
Repairs
02 05 08 11 18
MS
MSE
Störungsbeseitigung
Trouble Shooting
Wartungsarbeiten
Maintenance
Reparaturen
Repairs
5767
Ersatzteile
Spare Parts
5763 5765
0549 5766 0545
5764
0550 0547
Ref : 800378128J POCLAIN HYDRAULICS Industrie

B.P. 106
REPAR MS2-18 D/GB 60411 VERBERIE CEDEX - FRANCE POCLAIN HYDRAULICS
Tel.: 33 3 44 40 77 77
Rev : A - Avr - 00 Fax: 33 3 44 40 77 99
Certifié ISO 9001
www.poclain-hydraulics.com
008 911 63 BOMAG 657

17.3 Drum drive

POCLAIN HYDRAULICS
Dieses Dokument richtet sich an die Hersteller von Maschinen und Sy- This document is provided to machine manufacturers integrating PO-
stemen, die Produkte von POCLAIN-HYDRAULICS einbauen, deren CLAIN-HYDRAULICS products.. It suggests processes that manufac-
Artikelnummer auf der Titelseite genannt sind. Es beschreibt die Instal- turers may utilize to repair products after the warranty period.
lationsangaben und den Inbetriebnahmevorgang, damit ihre optimale
Funktionsweise gewährleistet wird.
Es wird empfohlen, daß sämtliche Arbeiten von Monteuren mit einer an- It is recommended that all operations be performed by technicians
gemessene Ausbildung durchgeführt werden . Sie müssen die Informa- trained accordingly. The technicians should read and understand the
tionen in diesem Dokument gelesen und verstanden haben und vom information given in this document and be authorized by the machine
Hersteller der Maschine bevollmächtigt sein. manufacturer.
Selbstverständlich müssen die Monteure die Richtlinien zur Sicherheit It is essential that the technicians comply with safety instructions to pre-
und zur Unfallverhütung beachten. vent injury.
Dieses Dokument enthält wichtige Hinweise zur Sicherheit. Sie werden This document includes major safety warnings announced in this way:
auf folgende Weise gekennzeichnet:
! Sicherheitshinweis. ! Safety warning.
Additionally, this document includes instructions essential to product

Dieses Dokument enthält weiterhin wesentliche Anweisungen zum Be-
function as well as those providing general information. Both are an-
trieb des Produkts sowie allgemeine Informationen. Sie werden auf fol-
nounced similar to the following examples:
gende Weise gekennzeichnet:
Wesentliche Anweisung. Essential instruction.
General information.
Allgemeine Information.
POCLAIN HYDRAULICS kann nicht für Vorfälle haftbar gemacht wer- POCLAIN HYDRAULICS designs products that are integrated by its
den, die auf die Anwendung der in diesem Dokument empfohlenen Ver- customers in the machines they design.
fahren zurückgehen.
POCLAIN HYDRAULICS ist nicht verantwortlich für die Konstruktion Subsequently POCLAIN HYDRAULICS disclaims liability for conse-
und die Betriebsbedingungen der Maschinen und Systeme, die mit PH- quences of improper integration of its products and of improper set-up
Produkten ausgestattet sind. Ebenso ist POCLAIN HYDRAULICS we- of adjustable devices. In the same way, POCLAIN HYDRAULICS may
der für die Folgen eines falschen Einbaus der Produkte noch für ein fal- not be liable for incomplete or improper operating and maintenance in-
sches Parametrieren einstellbarer Werte, noch für ungültige oder unvoll- structions provided to the end user by the machine manufacturer nor for
ständige Gebrauchs- und Wartungsanweisungen, die den Endverbrau- failures resulting from operations performed by any person using these
chern von den Maschinenherstellern zur Verfügung gestellt worden sind, suggested procedures.
verantwortlich. A re-certification of the machine may be required for every change in
Jegliche Änderung einstellbarer Parameter der PH Produkte kann eine set-up of adjus table devices.
Neuzulassung der Maschinen erforderlich machen.
Mit dem Ziel, den besten Service zu bieten, empfiehlt POCLAIN HY- In order to offer the best quality service, POCLAIN HYDRAULICS rec-
DRAULICS seinen Kunden, jede Anwendung von POCLAIN HY- ommends to its customers to have applications approved by POCLAIN
DRAULICS prüfen und freigeben zu lassen. HYDRAULICS.
Das Öffnen der Produkte führt zum Garantieverlust. Verwenden Sie nur Opening of products voids the warranty contract.
Original-Ersatzteile von POCLAIN HYDRAULICS . Die Montage von Use only POCLAIN HYDRAULICS genuine spare parts. Using parts
Teilen anderen Ursprungs könnte den Betrieb des Bauteils und des Sy- from different sources could reduce the performance of the product and
stems sowie die Sicherheit beeinträchtigen. pose a safety hazard..
Stets um die Verbesserung seiner Erzeugnisse bemüht, behält sich In accordance with its policy of continuous improvement, POCLAIN
POCLAIN HYDRAULICS das Recht vor, ohne vorherige Ankündigung HYDRAULICS reserves the right to modify the specifications of all
alle Änderungen vorzunehmen, die als nützlich für die in diesem Doku- products described herein without prior notice.
ment beschriebenen Produkte bewertet werden.
Dieses Dokument enthält Abschnitte auf deutsch und kursiv gedruckte Ab- This document contains sections written in German and sections
schnitte, die Übersetzung in englischer Sprache darstellen. printed in italics composing the English translation of the French sec-
Im Zweifelsfall ist die französische Version ausschlaggebend. tions. The French sections will be the reference in case of dispute.
Die Maße sind in metrischen Einheiten angegeben. Die Entsprechungen All measures are expressed in metric units. Converted values to other
in anderen Meßsystemen (vor allem angelsächsisch) werden zur Unter- systems (notably US and UK) are given for reference only.
richtung angegeben.
Die Abbildungen haben unverbindlichen Charakter. The illustrations for information only.
POCLAIN HYDRAULICS Industrie 1998. © POCLAIN HYDRAULICS Industrie 1998.

Die Handelsmarke POCLAIN HYDRAULICS ist das Eigentum von PO- The trademark POCLAIN HYDRAULICS is the property of POCLAIN
CLAIN HYDRAULICS SA. HYDRAULICS S.A.
Dieses Dokument ist das Eigentum von POCLAIN HYDRAULICS Indu- This document is the property of POCLAIN HYDRAULICS Industrie.
strie. Es ist streng vertraulich. Es darf ohne unseres vorheriges schriftli- It is strictly confidential. It must not be used, duplicated, copied or dis-
ches Einverständnis weder gesamt noch teilweise verwendet, vervielfäl- closed to a third party in full or in part without our prior written consent.
tigt, kopiert oder an Dritte weitergegeben werden. FACOM is FACOM SA registered trademark.
FACOM ist ein eingetragenes Warenzeichen der FACOM SA. LOCTITE is LOCTITE SA registered trademark.
LOCTITE ist ein eingetragenes Warenzeichen der LOCTITE SA. AUTO-TOP is AGIP SPA registered trademark.
AUTO-TOP ist ein eingetragenes Warenzeichen der AGIP SPA.
2 REPAR MS2-18 D/GB 800378128J
658 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
Inhaltsverzeichnis Contents
INHALTSVERZEICHNIS ............................................. 3 CONTENTS................................................................. 3
SICHERHEIT UND QUALITÄT ................................... 4 SAFETY AND QUALITY ............................................. 4

VOR DEN W ARTUNGSARBEITEN ....................................... 4 B EFORE SERVICING ........................................................ 4
W ÄHREND DER W ARTUNGSARBEITEN............................... 4 D URING SERVICING ......................................................... 4
NACH DEN W ARTUNGSARBEITEN ..................................... 4 AFTER SERVICING ........................................................... 4
IDENTIFIZIERUNG DES BAUTEILS ....................................... 5 I DENTIFICATION OF THE COMPONENT ................................. 5
STÖRUNGSBESEITIGUNG........................................ 6 TROUBLE SHOOTING ............................................... 7
WARTUNGSARBEITEN.............................................. 8 MAINTENANCE .......................................................... 8

AUSTAUSCHEN DES MOTORS........................................... 8 R EPLACING THE MOTOR .................................................. 8
Ausbau..................................................................... 8 Removal................................................................... 8
Einbau...................................................................... 8 Installation................................................................ 8
MECHANISCHE BREMSLÖSUNG ........................................ 9 M ECHANICAL BRAKE RELEASE .......................................... 9
KONTROLLE DER STATISCHE HALTEBREMSE . ................... 10 C HECKING THE PARKING BRAKE EFFICIENCY ..................... 10
REPARATUREN. ...................................................... 11 REPAIRS. ................................................................. 11
AUSWECHSELN DER BREMSKOLBENDICHTUNG................. 11 R EPLACEMENT OF THE O- RING OF THE BRAKE PISTON ....... 11
Demontage ............................................................ 11 Disassembly........................................................... 11
Wiedereinbau......................................................... 13 Reassembly. .......................................................... 13
AUSWECHSELN DES LAGERTEILES (070)......................... 16 R EPLACEMENT OF THE BEARING SUPPORT (070).............. 16
Wiedereinbau......................................................... 18 Reassembly ........................................................... 18
AUSWECHSELN DER BREMSBACKEN ............................... 20 R EPLACING THE BRAKE SHOES ....................................... 20
AUSWECHSELN DES NOCKENRINGS (026)....................... 27 R EPLACEMENT OF THE CAM (026) .................................. 27
AUSWECHSELN DES KOMPLETTEN ZYLINDERBLOCKS (010) 28 R EPLACEMENT OF THE CYLINDERS BLOCK ASSEMBLY (010)28
AUSWECHSELN DES VERTEILERS (047). ......................... 29 R EPLACEMENT OF THE VALVING (047). ........................... 29
AUSWECHSELN DER DECKELDICHTUNG (045).................. 32 R EPLACEMENT OF THE O- RING (045) OF THE END COVER . 32
Wiedereinbau......................................................... 33
Reassembly ........................................................... 33
AUSWECHSELN DES DREHZAHLSENSORS (OPTION).......... 34
R EPLACING THE SENSOR ( OPTIONAL ) .............................. 34
Demontage ............................................................ 34
Disassembly........................................................... 34
Wiedereinbau......................................................... 35
Reassembly ........................................................... 35
WERKZEUG-LISTE .................................................. 36
TOOLING INVENTORY............................................. 36
Standard Werkzeug................................................ 36
Standard tools ........................................................ 36
Spezialwerkzeuge .................................................. 37
Special tools........................................................... 37
ANZIEHDREHMOMENTE NM ± 10%........................... 38
TIGHTENING TORQUES IN [LBF.FT] ± 10% .......... 38
ERSATZTEILE.......................................................... 39
SPARE PARTS LIST ................................................ 39
MOTOREN MIT KONSTANTEM HUBVOLUMEN MS, MSE 02-
S INGLE DISPLACEMENT MOTORS MS, MSE 02-05-08-11-
05-08-11-18. .............................................................. 42
18.............................................................................. 42
MOTOREN MIT UMSCHALTBAREM HUBVOLUMEN MS, MSE
D UAL DISPLACEMENT MOTORS MS, MSE 02-05-08-11-18.44
02-05-08-11-18. ......................................................... 44
800378128J REPAR MS2-18 D/GB 3
008 911 63 BOMAG 659

17.3 Drum drive

POCLAIN HYDRAULICS
Sicherheit und Qualität Safety and Quality

Vor den Wartungsarbeiten Before servicing
• Alle notwendigen Sicherheitsvorkehrungen treffen • Be extremely careful to prevent personal injury and
(Menschen und Material) und die geltenden Sicher- to avoid damage to material. Comply with all safety
heitsvorschriften beachten. regulations.
• Parkbremse bet ätigen und Maschine mit Keilen • Apply the parking brake and prevent the machine
festsetzen. from rolling with tire blocks.
• Energieerzeugung (Motor) des Hydrauliksystems • Stop the hydraulic system power source (engine)
abstellen und die Stromversorgung ausschalten. and disconnect the battery.
• Gegebenenfalls eine Sicherheitszone einrichten. • If necessary, block off the safety area.
• Die Außenflächen der Bauteile reinigen, um • Wash dirt and grease from exterior of the compo-
Schmutz und Fett restlos zu entfernen. nents.
• Warten, bis das Hydrauliksystem vollst ändig abge- • Await the complete cooling down and depressuriza-
kühlt und druckentlastet ist (die Speicher entlasten). tion of the hydraulic system (accumulators must be
purged).
Das heiße oder unter Druck stehende Öl Hot or pressurized hydraulic fluid may
! kann zu schweren Verbrennungen mit
! cause serious burns & infections to the
Entzündung führen. human body.
Bei einem Unfall einen Arzt hinzuziehen. Consult a physician in case of accident.
Während der Wartungsarbeiten During servicing

• Bestimmte Bauteile sind sehr schwer. Sie m üssen • Some hydraulic components are very heavy. Se-
bei der Abnahme vom Rahmen mit einer angemessen cure them with a lifting device of adequate capacity
ausgelegten Hebevorrichtung gehalten werden. when removing from the machine frame.
• Die Sauberkeit ist wesentlich beim Betrieb der Hy- • Cleanliness is essential to functioning of the hy-
draulikbauteile. Die meisten Teile k önnen mit einem draulic components. Most of the parts may be cleaned
sauberen Lösungsmittel gereinigt werden. with a clean solvent.
• Während der Handhabung alle empfindlichen Ober- • During handling, protect all sensitive surfaces from
flächen gegen St öße schützen (Zentrierungen, gleitende shocks (piloting and interface surfaces, thrust & bear-
Teile, Auflagen, Dichtungs- und Lagerauflagen usw.). ings surfaces, seal races, etc...)
• Diese Flächen vor dem Wiederzusammenbau reinigen. • Clean up these surfaces before reassembling.
• Systematisch die demontierten Dichtungen beim
• Always install new O-rings, seals & gaskets dis-
Wiederzusammenbau durch neue ersetzen. Wir emp- carding the old ones. We recommend lubricating all
fehlen, vor der Montage alle Dichtungen zu fetten.
seals prior to assembly.
• Alle gleitenden Flächen durch Aufbringen eines Films • Lubricate all surfaces which have relative motion
sauberer Hydraulikfl üssigkeit ölen, der eine korrekte between parts by coating them with a film of clean hy-
Schmierung beim ersten Neustart gewährleistet. draulic fluid to assure lubrication at first start.
• Niemals die Hydraulikfl üssigkeit, die sich bei hohen • Never heat hydraulic fluid, as it may flame at high
Temperaturen entz ünden kann, erwärmen. Einige L ö- temperature. Some solvents are also flammable.
sungsmittel sind ebenfalls entz ündlich.
W ährend der Arbeiten nicht rauchen. Do not smoke during servicing.
Nach den Wartungsarbeiten After servicing

Die Bauteile wieder einbauen und das Hydrauliksystem Reinstall the components and restart the hydraulic
gemäß den Anweisungen in den folgenden Dokumen- system according to instructions defined in the following
ten wieder in Betrieb nehmen: documents:
• INSTALLATION MS D/GB (ref: 800078173V) • INSTALLATION MS F/GB (ref . 677777844K )
• INSTALLATION CIRCUITS D/GB (ref. 677777853U) • INSTALLATION CIRCUITS F/GB (ref . 677777831V
)
Die Einstellung der Sicherheitsventile
! nicht erhöhen. !
Do not overset relief valves.
4 REPAR MS2-18 D/GB 800378128J
660 BOMAG 008 911 63

Drum drive 17.3

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

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

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

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

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

müssen die Artikelnummer und die chro- serial number must be specified to order
nologische Ordnungsnummer angege- spare parts.
ben werden.
800378128J REPAR MS2-18 D/GB 5
008 911 63 BOMAG 661

17.3 Drum drive

POCLAIN HYDRAULICS
Störungsbeseitigung
BECHÄDIGUNG ABRIEB ERKENNUNG DURCH FILTER VORBEUGUNG……
Störung Ursachen Abhilfe

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

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

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

stand des Filters überprüfen
Dichtungen besch ädigt Die Dichtungen ersetzen
ÄUSSERE ÖLUN-
DICHTIGKEITEN Das Anziehmoment der Monta-
geschrauben, der Entl üftungs-
Fehlerhafte Montage
schrauben und der Anschl üsse
kontrollieren
6 REPAR MS2-18 D/GB 800378128J
662 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
Trouble shooting
DAMAGE IRON PARTICLES DETECTION BY FILTERS PREVENTION ……
Troubles Causes Remedies

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

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

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

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

filter condition
EXTERNAL OIL Seals damaged Replace seals
LEAKS
Check tightening of mounting
Incorrect assembling screws, bleed screws and
unions
800378128J REPAR MS2-18 D/GB 7
008 911 63 BOMAG 663

17.3 Drum drive

POCLAIN HYDRAULICS
Wartungsarbeiten Maintenance
Austauschen des Motors Replacing the motor
Ausbau Removal
• Druck im Arbeitskreis abbauen. • Release the pressure in the supply circuit.
• Leckageleitung am Tank abschrauben, um ein • Disconnect the drain line at the tank level to avoid
Leerlaufen zu verhindern. its siphoning.
• Die Rohre oder Schl äuche, die am Motor ange- • Disconnect and plug the pipes or hoses which are
schlossen sind, abklemmen. connected to the motor.
• Drehzahlsensor abklemmen. • Disconnect the speed sensor.
• Die Befestigungsschrauben demontieren und den • Disconnect the mounting screws, and remove the
Motor ausbauen. motor.
• Das Motorgeh äuse entleeren. • Drain the casing.
Einbau Installation
Die zum Ausbau angegebenen Arbeitsg änge in umge- Execute the removal operations in the reverse order.
kehrter Reihenfolge ausf ühren.
Für weitere Informationen beziehen Sie sich bitte auf Please refer to the following documentation brochures:
folgende Dokumente:
• INSTALLATION MS D/GB (ref: 800078173V) • INSTALLATION MS F/GB (ref : 677777844K )
• INSTALLATION CIRCUITS D/GB (ref: 677777853U) • INSTALLATION CIRCUITS F/GB (ref: . 677777831V )
8 REPAR MS2-18 D/GB 800378128J
664 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
Mechanische Bremslösung Mechanical brake release
Bei bestimmten Reparaturf ällen In certain service situations, it may

oder zum Abschleppen der Maschi- be necessary to release the motor
ne muß die integrierte Parkbremse brake.
gelöst werden.
• Stopfen (142) aus der Schutz- • Extract and release the plug
142
kappe (141) herausziehen. (142) from the brake cover (141).
6499
• Schraube im Kolben festziehen • Tighten the screw in the piston
6556
• Mutter so weit anziehen, bis die • And tighten the nut until the
Welle frei dreht. motor shaft turns freely.
6555
Entsprechendes
Bremsen Brakes Kraft N Force [lbf] Equivalent torque [lbf.ft] Mutter Nut
Drehmoment Nm
F02-F04 18000 [4.000] 42 [30.9] M12
F05-F07 20000 [4.500] 47 [34.6] M12
F08 34000 [7.600] 110 [81.1] M16
F11 45000 [10.000] 140 [103] M16
F12 45000 [10.000] 140 [103] M16
F19 45000 [10.000] 140 [103] M16
Nach Bremslösung, einen neuen Stopfen After brake release, mount a new plug
! (142) einbauen. ! (142) .
800378128J REPAR MS2-18 D/GB 9
008 911 63 BOMAG 665

17.3 Drum drive

POCLAIN HYDRAULICS
Kontrolle der statische Haltebremse. Checking the parking brake efficiency.
Bei fahrbaren Maschinen den Test auf ebenem For a rolling machine, make the test on a hori-
! Grund durchführen. ! zontal ground .
Bremssteuerdruck: mini 12 bar Pilot brake pressure : minimum 12 bar [174 PSI]
Maxi 30 bar. Maximum 30 bar [435 PSI]
• Sich vergewissern, daß der Bremsversorgungs- Make sure that the brake supply pressure is zero,
druck gleich Null ist,
• Die Bremse über die höchstgelegene Schraube • Purge the brake using the screw (112) located at
(112) entl üften, the highest level,
• Den Motor mit Maximaldruck beaufschlagen, • Supply the motor up to the setting pressure.
• Die Motorwelle darf sich nicht drehen, da andern- • The motor shaft must not turn, otherwise it is nec-
falls die Bremse ausgetauscht werden mu ß : essary to replace the brake :
! Mehrscheibenbremsen nicht einfahren. ! Do not run multidisc brakes in.
10 REPAR MS2-18 D/GB 800378128J
666 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
Reparaturen. Repairs.
Auswechseln der Brems- Replacement of the O-ring

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

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

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

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

drücken:
• Mit Hilfe des Dorns und Ab- • Using a mandrel and an ex-
ziehers (siehe Werkzeug Seite tractor (see tools page 36)
36) (fig 6502) (fig 6502)
• Mit Hilfe des Dorns und einer • Using a mandrel and a
Schraube Klasse 12.9 (siehe screw class 12.9 (see tools 6502
Werkzeug Seite 36) page 36)
• Mit Hilfe des Dorns und einer • Using a mandrel and a press
Presse (fig 6503). Die Kraft F (fig 6503). Respect the force F
beibehalten (siehe Schaubild (see table page 9)
Seite 9)
Einsatzrichtung des Si- Mark the mounting di-

cherungsrings markieren. rection of the snap ring .
6503
800378128J REPAR MS2-18 D/GB 11
008 911 63 BOMAG 667

17.3 Drum drive

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

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

106
6511
12 REPAR MS2-18 D/GB 800378128J
668 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
Wiedereinbau. Reassembly.
Vor dem Wiedereinbau ist unbedingt Before reassembling, it is neces-
sicherzustellen, daß alle Teile, Nuten sary to ensure that all parts, the
und Dichtungs-Auflagefl ächen sauber surface condition of the piston seal
sind. contact surface and the grooves are
clean.
Es dürfen keine Rost-,
! Schmutz- oder Wasser-
All traces of rust, mud,
spuren vorhanden sein
! water must be removed.
Mit Korrosionsschutzfett (siehe

Werkzeug Seite 36) einschmieren: Coat with anti-oxidizing grease (see
die Nut, die obere Fl äche des tools page 36), the grooves, the top
Bremskolbens, die Tellerfeder, den of the brake piston, the spring
Sicherungsring und die Auflagefl äche washer, the snap ring and the pis-
der Kolbendichtung im Bremsgeh äuse. ton seal contact surface in the
brake body.
• Neuen O-Ring (106) auf den • Install a new O-ring (106) on
Kolben (107) montieren. the piston (107).
Der Ring muß fest an The ring should be tight

den Kolben gepreßt und
! nicht verdreht werden. ! on the piston and not
twisted. 106
6512
• Bremskolben (107) einsetzen. • Install the brake piston (107).
Achtung, wenn die Take care when passing 107

Dichtung über die Nut
! des Sicherungsrings ! the seal over the snap
ring groove.
geführt wird.
6509
• Tellerfeder (108) einlegen. Install the spring washer (108). 108
6513
800378128J REPAR MS2-18 D/GB 13
008 911 63 BOMAG 669

17.3 Drum drive

POCLAIN HYDRAULICS
• Tellerfeder (108) zusammen- • Compress the spring washer
drücken: (108).
• Mit Hilfe des Dorns und Ab- • Using a mandrel and an ex-
ziehers (siehe Werkzeug Seite tractor (see tools page 36)
36) (fig 6502) (fig 6502)
• Mit Hilfe des Dorns und einer • Using a mandrel and a press
Presse (fig 6503). Die Kraft F (fig 6503). Respect the force F
einbehalten (siehe Schaubild (see table page 9) 6502
Seite 9)
Bei Verwendung der If you use the press do
!
Presse das Lagerteil
nicht auf den Gewinde- ! not place the bearing
support on the studs.
bolzen abstützen.
6503
• Sicherungsring (109) mit Hilfe • Install the snap ring (109) using
einer Zange f ür Innenringe gem äß internal snap ring pliers in line with
der bei der Demontage ange- the mark made during disassembly
brachten Kennzeichnung montie- . (see tools page 36)
ren: (siehe Werkzeuge Seite 36) 6504 6505
• Abzieher und Zange (fig • Extractor and pliers (fig 6504
6504 und 6505) and 6505)
• Presse und Zange (fig 6506 • Press and pliers (fig 6506
und 6507) and 6507)
6506 6507
• Neuen, mit Korrosionsschutzfett • Install a new O-ring (143)

eingeschmierten O-Ring (143) in coated with anti-oxidizing grease in 143
die Nut einsetzen (siehe Werkzeu- its groove. (see tools page 36)
ge Seite 36).
6515
• Neue Schutzkappe (141) auf • Place the new cover (141) on
141
den Anschnitt legen. the entry chamfer .
6516
14 REPAR MS2-18 D/GB 800378128J
670 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
• Schutzkappe mit Hilfe des • Click the cover into place using
Dorns einrasten lassen (siehe the right mandrel. (see tools page
Werkzeug Seite 36). 36).
Sich vergewissern, daß Make sure that the outer

Außenrand
!
der des
Schutzkappe in die Nut ! edge of the cover is en-
gaged in the groove.
eingreift ist.
6517
• Neuen Stopfen (142) einsetzen. • Install a new plug (142).
Sich vergewissern, daß Make sure about the con- 142

zwischen Schutzkappe
! tact between the cover
! und Stopfenrille ein-
wandfreier Kontakt be-
and the plug groove.
steht.
6518
• Motor wieder einsetzen. • Install the motor.
800378128J REPAR MS2-18 D/GB 15
008 911 63 BOMAG 671

17.3 Drum drive

POCLAIN HYDRAULICS
Auswechseln des Lager- Replacement of the bearing

teiles (070) support (070)
Motor herausnehmen. Remove the motor.

Motor auf der Bremse oder Ver- Place the motor on the brake or on
schlussplatte abst ützen (Motor ohne the end cover (motor without
Bremse). brake).
• Position des Lagerteiles • Mark the position of the

(070) in Bezug auf Nockenring bearing support (070) in relation to 070
(026) und Verteilerdeckel (040) the cam (026) and to the valving
kennzeichnen. cover (040).
025
040
6519
• Schrauben (042) heraus- • Remove the screws (042).

nehmen.
042
6520
• Lagerteil (070) herausneh- • Remove the bearing support

men. (070).
070
6521
• Nockenring (026) heraus- • Remove the cam (026).

nehmen. 026
6524
16 REPAR MS2-18 D/GB 800378128J
672 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
• O-Ring (027) vom Verteiler- • Discard the O-ring (027)
deckel (041) entfernen. from the valving cover (041). 027
041
6525
• O-Ring (027) vom Lagerteil • Discard the O-ring (027)

(071) entfernen. from the bearing support (071) 027
071
6522
800378128J REPAR MS2-18 D/GB 17
008 911 63 BOMAG 673

17.3 Drum drive

POCLAIN HYDRAULICS
Wiedereinbau Reassembly
Vor dem Wiedereinbau ist unbe- Before reassembling it is necessary

dingt sicherzustellen, da ß die Nut to ensure that the groove is clean
sauber ist
spuren vorhanden sein.
! water must be removed
• Neuen, mit Korrosions- • Install a new O-ring (027) 027

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

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

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

! Richtung Lagerteil ! towards bearing support
Den Nockenring anhand von zwei Center the cam using two screws 6526
einander gegenüberliegenden (042) diametrically opposite.
Schrauben (042) zentrieren.
18 REPAR MS2-18 D/GB 800378128J
674 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
• Lagerteil montieren • Install the bearing support
Bei Wellenmotoren For shaft motors the

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

einsetzen und mit dem angegebe- screws (042) to the right torque.
nen Drehmoment anziehen. (siehe (see table page 38).
Schaubild Seite 38).
042
6520
• Motor wieder einsetzen. • Install the motor.
800378128J REPAR MS2-18 D/GB 19
008 911 63 BOMAG 675

17.3 Drum drive

POCLAIN HYDRAULICS
Auswechseln der Brems- Replacing the brake shoes.

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

Abnutzung der Bremsbel äge durch to make a visual checking of the
die Inspektionsöffnungen kontrollie- brake pads wear via the inspection
ren. ports.
2055
Das Auswechseln des The same repairs

Bremsbacken und das should be made on
Schleifen der Trommeln each motor of the same
! muß auf allen Motoren ! axle when replacing
der gleichen Achse vor- shoes and brake
genommen werden. drums .
• Befestigungsmuttern der Felge • Loosen the wheel rim retaining

lösen. nuts.
• Maschine auf der H öhe der • Raise the machine on the side
auszubauenden Felge hochheben. of the wheel rim to be removed.
• Rad abnehmen (Reifen). • Remove the wheel rim (tyre).
• Mechanische Bremse l ösen. • Release the mechanical brake.
• Trommel (096) abziehen. • Extract the drum (096).
Reibfläche der Trommel Check the friction sur-

überprüfen, die weder tiefe face condition of the
Rillen (tiefer als 0,2 mm) drum which should show
noch abnormale Abnut- no deep scratches
! zungserscheinungen auf-
! (deeper than 0,2 mm
096
weisen darf, sonst muß [0.0078 in]) nor abnormal
sie geschliffen werden. wear. Otherwise, the
6528
(Ra 1,6 bis 3,2) brake drum should be
replaced. (Ra 1.6 to 3.2)
20 REPAR MS2-18 D/GB 800378128J
676 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
• Rückholfeder (154.a) abbauen. • Remove the return spring
(154.a).
154.a
6529
6530
• Halterungsfedern (154.b) ab- • Remove the retention springs

bauen. (154.b). 1
154.b
2
6531
• Bremsbacken aus der Bet äti- • Release the brake shoes from
gungsvorrichtung l ösen. the regulating mechanism.
6532
• Rückholfedern (154.c) abbau- • Remove the return springs

en. (154.c).
154.c
6533
800378128J REPAR MS2-18 D/GB 21
008 911 63 BOMAG 677

17.3 Drum drive

POCLAIN HYDRAULICS
• Bremsbacke (154.1) abbauen. • Remove the brake shoe (154.1)
154.1
6534
• Den mechanischen Bremshebel • Releasing the mechanical brake

vom Bremsseil l ösen und Brems- control lever from its cable, remove
backe (154.2) entfernen the brake shoe (154.2)
154.2
6535
6536
22 REPAR MS2-18 D/GB 800378128J
678 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
Vorrichtung entstau- Remove all dust from the

ben, sich vergewissern, whole assembly. Make
! daß der Radzylinder ! sure there are no leaks at
dicht ist. the wheel cylinder.
Reibfläche der Trommel überprü- Check the friction surface condition

fen, die weder tiefe Rillen (tiefer als of the drum which should show no
0,2 mm) noch abnormale Abnut- deep scratches (deeper than 0.2 6549
zungserscheinungen aufweisen mm) [0.0078in] nor abnormal wear.
darf, sonst muß sie geschliffen Otherwise, the brake drum should
werden. be replaced.
• Den Bremshebel am Bremsseil • Attaching the control lever on

(098) befestigen und Bremsbacke the brake cable (098), install the
(154.2) einbauen brake shoe (154.2)
098
154.2
6536
6535
800378128J REPAR MS2-18 D/GB 23
008 911 63 BOMAG 679

17.3 Drum drive

POCLAIN HYDRAULICS
• Rückholplatte an die Brems- • Mount the return plate on the
backe (154.2) montieren. brake shoe (154.2)
6537
6538
• Bremsbacke (154.1) einsetzen. • Install the brake shoe (154.1)
6539
• Bremsbacken auf der Bet äti- • Position the brake shoes on the
gungseinrichtung positionieren. regulating mechanism.
6532
• Rückholfedern (154.c) einset- Install the return springs (154.c)

zen.
154.c
6533
24 REPAR MS2-18 D/GB 800378128J
680 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
• Bremsbacken in die Bet äti- • Install the brake shoes in the
gungseinrichtung einbauen. regulating mechanism
6532
• Halterungsfedern (154.b) ein- • Install the retention springs

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

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

Trommel und der eingesetzten Ba- diameter D and that of the brake
cken messen. shoes, which have been installed.
Durchmesser D diameter
6529
800378128J REPAR MS2-18 D/GB 25
008 911 63 BOMAG 681

17.3 Drum drive

POCLAIN HYDRAULICS
• Backendurchmesser anpassen, • Adjust the brake shoes diame-
um bei Bremsen mit mechanischer ter to obtain correct clearance be- 
Einstellvorrichtung mit Hilfe des ei- tween the brake padding and the
  
nen Zahnrads (156.1), oder bei drum using the adjusting wheel
Bremsen mit automatischer Brem- (156.1) for brakes equipped with
sennachstellung mit Hilfe der zwei mechanical adjustment system or
Zahnräder (156.2 und 156.3), das two adjusting wheels (156.2 and
nötige Spiel zwischen Belag und 156.3) for brakes equipped with  
Trommel zu erzielen. In diesem automatic clearance adjustment. In

Fall muß die Wirkung auf die Zahn- this case, the adjusting wheels 6540
räder symmetrisch (a) sein. Den should be adjusted symmetrically
Hebel (156.4) muss zu diesem (a). Release the lever slightly
Zweck freigängig sein. (156.4) to enable this operation to
take place.
Trommeldurchmesser (mm)
Bremsen Drum diameter [in] Total Spiel (mm)
Brake Total clearance [in]
nominal maximum
250 x 60 250 [9.84] 252 [9.92 ] 0.55 [0.02]
270 x 60 270 [10.63] 272 [10.70 ] 0.80 [0.03]
325 x 80 325 [12.79 ] 327 [12.87] 0.80 [0.03]
350 x 60 350 [13.78] 352 [13.85] 0.80 [0.03]
• Trommel aufsetzen und über- • Install the drum, check that it
prüfen, ob sie frei dreht. can turn freely.
6528
• Wenn nötig, den Radzylinder • Bleed the wheel cylinder, if

entlüften. necessary.
• Felge montieren. • Install the wheel rim.
Siehe Dokument INSTALLATION See documentation INSTALLATION
MS D/GB (ref: 800078173V) MS F/GB (ref 677777844 K )
26 REPAR MS2-18 D/GB 800378128J
682 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
Auswechseln des Nocken- Replacement of the cam

rings (026) (026)
Dazu die im Kapitel « Auswechseln Do operations described in chapter
des Lagerteils » unter « Demontage » "replacement of the bearing sup-
beschriebenen Arbeiten ausf ühren, port" section "disassembly" page 16
Seite 16
des Lagerteils » unter " Wiederein- "replacement of the bearing sup-
bau " beschriebenen Arbeiten ausf üh- port" section "reassembly" page 18.
ren, Seite 18. The angular position of the cam
Allerdings muß bei Motoren mit 2 must be respected on dual dis-
Schluckvolumen mit einem placement motors with a displace-
Schluckvolumenverh ältnis über ment ratio different from 2.
oder unter 2 die Winkelposition be-
rücksichtigt werden. Example : Motor MS18 with dis-
Beispiel: Motor MS18, Schluckvolu- placement 1747-1049-698.
3
men 1747-1049-698 Small displacement : 698 cm
3
Kleines Schluckvolumen: 698 cm [42.59 cu.in] letter P
Buchstabe P 3
3
Medium displacement : 1049 cm
Mittleres Schluckvolumen: 1 049 cm [64.01 cu.in] letter M.
Buchstabe M The letter P or M must be located in
Die Buchstaben P oder M m üssen the axis and towards the displace-
sich in der Achse befinden und in ment change spool, with the blind
Richtung des Schiebers f ür das hole towards the fixing of the cam
Wechseln des Schluckvolumens on the bearing support.
zeigen, auf der der Nockenring auf
dem Lagerteil befestigt ist.
M P
M P
MS08
MSE08
A R A R
MS18
MSE18
P M
M P
A R A
MS11
MSE11
P M 2035
800378128J REPAR MS2-18 D/GB 27
008 911 63 BOMAG 683

17.3 Drum drive

POCLAIN HYDRAULICS
Auswechseln des komplet- Replacement of the cylin-

ten Zylinderblocks (010) ders block assembly (010)

des Lagerteils » unter « Demontage » "replacement of the bearing sup-
beschriebenen Arbeiten ausf ühren, port" section "disassembly" page 16
Seite 16
• Nach Demontage des Nocken- • After removing the cam, re-

rings den Zylinderblock ausbauen. move the cylinders block.
6541
• Neuen O-Ring (027) einsetzen. • Install a new O-ring (027).
6542
• Kompletten Zylinderblock (010) • Install the cylinders block as-

einsetzen. sembly (010).
6541
• Dazu die im Kapitel • Do operations described in

« Auswechseln des Lagerteils » unter chapter "replacement of the bearing
"Wiedereinbau" beschriebenen Ar- support" section "reassembly" page
beiten ausf ühren, Seite 18 18
28 REPAR MS2-18 D/GB 800378128J
684 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
Auswechseln des Verteilers Replacement of the valving

(047). (047).

« Auswechseln des kompletten Zy- chapter "replacement of the cylin-
linderblocks (010) » unter ders bloc assembly (010)" section
« Demontage » beschriebenen Ar- "disassembly" page 28.
beiten ausf ühren, Seite 28.
Position des Verteilers Mark location to the

(047) in Bezug auf Ver- valving (047) in relation
! teilerdeckel (041) kenn- ! to the valving cover

(041) (Dual displace-
zeichnen. (Motor mit 2
Hubvolumen). ment motor).
• Den Verteiler (047) durch An- • Separate the valving (047) from
heben an den Ausrichtungszapfen the cover (041) by levering at the
oder am Flansch vom Verteilerdek- indexing pins or at the flange.
kel (041) abmontieren.
2031
Den Verteiler vor Staub Protect the valving from

! schützen. ! dusts.
• Federn (052) ausbauen. • Remove the springs (052).

• Dichtungen und Gegendichtun- • Remove and discard the seals
gen (048) vom Verteilerdeckel and back-up rings (048) from the
(041) herausziehen und beseitigen. cover (041).

spuren vorhanden sein. ! water must be removed .
• Neue Dichtungen und Gegen- • Lubricate and install new seals

dichtungen (048) ölen und einset- and back-up rings (048), ensuring
zen; dabei die Gegendichtungen so the back up rings are twisted as lit-
wenig wie m öglich verformen. tle as possible.
1135
• Die Federn (052) in ihr zuvor • Place the springs (052) in their
mit Fett gef ülltes Gehäuse einset- housings, previously filled with
zen. grease.
• Die Dichtungsauflagefl ächen • Lubricate the faces of the seals
des Verteilers (047) fetten. of the valving (047).
• Press the valving (047) into the
• Den Verteiler(047) in den Ver-
cover (041).
teilerdeckel (041) dr ücken
800378128J REPAR MS2-18 D/GB 29
008 911 63 BOMAG 685

17.3 Drum drive

POCLAIN HYDRAULICS
Die Einbaurichtung des Respect the assembly

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

Do not force when in-
lers (047) in den Vertei-
stalling the valving
! lerdeckel (041) nicht
! (047) into the cover
forcieren. (041).
Montage der Verteileraus- Valving assembly type sin-

führung 1C (konstanter gle displacement motor.
Hubvolumen).
• Keine besondere Montagerich- • No particular assembly sense.
tung.
041
047 2031
Montage der Verteilerausfüh- Valving assembly type Dual

rung 2C (umschaltbarer displacement motor .
Hubvolumen).
• Den gewählten Buchstaben, der • Write the chosen letter indicate

die Drehrichtung anzeigt, gegen- the rotation sense in front of the
über dem Steuerkolben (053) an- displacement change spool (053).
ordnen.
POSITIONIERUNG DES VERTEI- VALVING POSITIONING

LERS
G/ L Links G/L Left
041
 047

053
6758
 
053

30 REPAR MS2-18 D/GB 800378128J
686 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
D/R Rechts D/R Right
047
  041
6757
 
053

• Falls kein Buchstabe vorhanden • If there is no letter, do the in-

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

« Auswechseln des kompletten Zy- chapter "replacement of the cylin-
linderblocks (010) » unter ders block" section "reassembly"
« Wiedereinbau » beschriebenen Ar- page 28 .
beiten ausf ühren, Seite 28.
Motoren SE02 und S05 Situation of SE02 and S05 mo-

tors
SE02 Motor :
SE02 motor : G/L Links D/R Rechts
G/L Left D/R Right
6959

S05 Motor :
S05 motor
G/L Links D/R Rechts
G/L Left D/R Right
053
6948

800378128J REPAR MS2-18 D/GB 31
008 911 63 BOMAG 687

17.3 Drum drive

POCLAIN HYDRAULICS
Auswechseln der Deckel- Replacement of the O-ring

dichtung (045) (045) of the end cover
•
• Motor auf Lagerteil stellen • Place the motor on the bearing
(Muttern sind zum Schutz der Ge- support (fitted with nuts for studs
windebolzen aufgesetzt) protection)
• Schrauben (066) herausneh- • Remove the screws (066)
066
men.
6543
• Verschlussplatte abnehmen. • Remove the end cover
6544
• O-Ring (045) entfernen. • Discard the O-ring (045)

045
057
6545
• Wenn Motor mit 2 Hubvolu- • Discard the O-ring (057) if the

men, O-Ring (057) entfernen motor has 2-displacement
6546
32 REPAR MS2-18 D/GB 800378128J
688 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
• Neuen O-Ring (045) einsetzen. Install a new O-ring (045).
6547
• Wenn Motor mit 2 Hubvolu- • Install a new O-ring (057) if the

men, neuen O-Ring (057) einset- motor has 2-displacement. If not go
zen, andernfalls zum n ächsten to the next section
Schritt übergehen
6548
• Verschlussplatte montieren. • Install the end cover
6544
• Schrauben (066) einsetzen und • Install and tighten the screws

mit entsprechendem Drehmoment (066) to the right torque (see table
anziehen (siehe Schaubild Seite 38) page 38)
6543
800378128J REPAR MS2-18 D/GB 33
008 911 63 BOMAG 689

17.3 Drum drive

POCLAIN HYDRAULICS
Auswechseln des Dreh- Replacing the sensor (op-

zahlsensors (Option) tional)
• Stecker (161.3) abziehen • Disconnect the connector

(161.3)
6550
• Schraube (165) aufschrauben • Unscrew and remove the screw

und ausbauen (165) 165
6551
• Sensor (161) mit dem Tr äger • Extract the sensor (161) with its
166
(166) abziehen support (166)
161
6552
34 REPAR MS2-18 D/GB 800378128J
690 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
Der Dichtung (164) auf Make sure that the seal

Sauberkeit der Auflage- mounting surface (164)
! fläche dem Verteiler- ! on the valving cover
deckel (041) prüfen. (041) is clean.
• Neuen Haltering (163) und • Install the new brake washer

neue Dichtung (164) auf den Sen- (163) and the new seal (164) on the
sor (161) mit seiner Distanzscheibe sensor (161) fitted with its adjusting
(167) schieben. sticker (167).
• Den Sensor in die Halterung • Push the sensor assembly into
(166) stecken, so da ß die Dichtung the support (166) until the seal
(164) korrekt in ihrer Aufnahme (164) is in its housing.
sitzt.
6552
• Sensor (041) in die Bohrung • Push the sensor into the valving
des Verteilerdeckels bis zum Kon- cover (041) until it comes in contact
takt mit dem Zylinderblock (011) with the cylinders block (011),
schieben.
2064
Die Kerbe im Steckeranschluss des the notch of the sensor should be
Sensors muss radial zur Mitte des oriented towards the center of the
Motors (Richtung Welle) zeigen. motor.   
  
6558
• Schrauben (165) einsetzen und • Install and tighten the screw

mit entsprechendem Drehmoment (165) to the right torque (see table
anziehen (siehe Schaubild Seite page 38)
38)
6551
• Stecker (161.3) wieder an- • Reconnect the connector

schließen. (161.3).
6550
800378128J REPAR MS2-18 D/GB 35
008 911 63 BOMAG 691

17.3 Drum drive

POCLAIN HYDRAULICS
Werkzeug-Liste Tooling inventory
Standard Werkzeug Standard tools

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

• Zange f ür Innenringe FACOM 499.32
pliers
• Abzieher FACOM U 20 B Extractor
6553
• Sechskantschl üssel f ür
Hex head wrench 13 17 19 22 24
Innensechskantschraube
• Drehmoment-Schl üssel FACOM J 250 A Torque wrench 6 à 30 N.m [4.4 to 22.1 lbf.ft]
• Drehmoment-Schl üssel FACOM S 250 A Torque wrench 50 à 240 N.m [35 to 175 lbf.ft]
• Drehmoment-Schl üssel FACOM K 250 A Torque wrench 160 à 800 N.m [120 à 600 lbf.ft]
36 REPAR MS2-18 D/GB 800378128J
692 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
Spezialwerkzeuge Special tools
 
 
• Montagewerkzeug
zum Anheben der • Mandrel for reassembling the
  
Schutzkappe oder zum brake cover or to compress the
Komprimieren der Tel- spring washer.
lerfeder.

 
0759
Ø A Ø B Ø C Ø D E F G

mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch] mm [inch]
F02
110 [4.3] 100 [4.0] 125 [4.9] 135 [5.3]
F03
F04 M12 50 [1.96] 10 [0.39] 20 [0.78]
F05 125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25]
F07
F08
125 [4.92] 115 [4.52] 151 [5.94] 159 [6.25] 50 [1.96] 10 [0.39] 20 [0.78]
F09
F11
50 [1.96] 20 [0.78]
F12 M16
F18 190 [7.48] 180 [7.08] 205 [8.07] 215 [8.46] 10 [0.39]
F19 70 [2.75] 30 [1.18]
F21



• Rohr zum Festsetzen Tube to immobi-


  
  
    
des Motors lize the motor 




     
 
   
 
    
• Werkzeuge zur me- Tools for me-

chanischen Bremsl ö- chanical brake 
 
 
sung. release   
    
  


     
800378128J REPAR MS2-18 D/GB 37
008 911 63 BOMAG 693

17.3 Drum drive

POCLAIN HYDRAULICS
Anziehdrehmomente Tightening torques

Nm ± 10% in [lbf.ft] ± 10%
(Gem äß Norm DIN 912) (According to the standard DIN 912)
Größe Size 8.8 10.9 12.9 8.8 10.9 12.9

M6 10 14 17 7.5 10 12.5
M8 25 35 41 18.4 26 30
M10 49 69 83 36 51 61
M12 86 120 145 63.4 88.4 107
M14 135 190 230 100 140 170
M16 210 295 355 155 218 262
M18 290 405 485 214 299 358
M20 410 580 690 302 428 509
38 REPAR MS2-18 D/GB 800378128J
694 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
Ersatzteile Spare parts list

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

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

041 Verteilerdeckel 041 Valving cover part
042 Schraube 042 Screw
043 Dichtungsring 043 Seal washer
047 Verteiler 047 Valving
048 Dichtungssatz 048 Seal kit
050 Stopfen 050 Plug
052 Feder 052 Spring
053 Umschaltkolben 053 Valve spool
054 Scheibe 054 Washer
055 Sicherungsring 055 Snap ring
056 Feder 056 Spring
059 Stift 059 Pin
065 Kompletter Verschlussplatte 065 End cover assembly

067 Dichtring 067 Sealing ring
070 Komplettes Lagerteil 070 Bearing support assembly

071 Lagerteil 071 Bearing support part
072 Innerer Lippendichtring 072 Radial lip seal
073 Rollenlager 073 Roller bearing
074 Rollenlager 074 Roller bearing
075 Scheibensatz 075 Set of shims
076 Stützring 076 Thrust ring
078 Äußerer Dichtring 078 Lip seal
079 Abweiser 079 Deflector
081 Dichtungsträger 081 Seal support
087 Passfeder 087 Key
090 W elle 090 Shaft
091 Radbolzensatz 091 Set of studs
096 Bremstrommel 096 Drum brake
098 Bremsseil 098 Brake cable
154 Komplette Bremsbacke 154 Brake shoe sub-assembly
155 Kompletter Radzylinder 155 Brake cylinder sub-assembly
156 Gegenhalter 156 Brake adjustment
800378128J REPAR MS2-18 D/GB 39
008 911 63 BOMAG 695

17.3 Drum drive

POCLAIN HYDRAULICS
Nummer Bezeichnung Item Description
100 Komplette Bremse 100 Brake assembly
101 Bremsgehäuse 101 Brake body
107 Kolben 107 Brake piston
108 Tellerfeder 108 Spring washer
110 W elle 110 Brake shaft
111 Dichtsatz Bremswelle 111 Seal
113 Dichtungsring 113 Seal washer
135 Satz Bremslamellen 135 Brake kit
141 Schutzkappe 141 Cover
142 Stopfen 142 Plug
150 Drehzahlsensor-Vorbereitung 150 Speed sensor predisposition

160 Kompletter Sensor 160 Speed sensor assembly

161 Sensor 161 Speed sensor part
162 Mutter 162 Nut
164 Dichtung 164 Seal
Als Satz lieferbare Baugruppe Sub-assembly sold assembled
40 REPAR MS2-18 D/GB 800378128J
696 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 41
008 911 63 BOMAG 697

17.3 Drum drive

POCLAIN HYDRAULICS
Motoren mit konstantem Hubvolumen MS, MSE 02-05-08-11-18.
Single displacement motors MS, MSE 02-05-08-11-18.
0987
42 REPAR MS2-18 D/GB 800378128J
698 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
Dichtungssatz
Seal kit 0988
800378128J REPAR MS2-18 D/GB 43
008 911 63 BOMAG 699

17.3 Drum drive

POCLAIN HYDRAULICS
Motoren mit umschaltbarem Hubvolumen MS, MSE 02-05-08-11-18.
Dual displacement motors MS, MSE 02-05-08-11-18.
0990
44 REPAR MS2-18 D/GB 800378128J
700 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
Dichtungssatz
Seal kit
0989
800378128J REPAR MS2-18 D/GB 45
008 911 63 BOMAG 701

17.3 Drum drive

POCLAIN HYDRAULICS
46 REPAR MS2-18 D/GB 800378128J
702 BOMAG 008 911 63

Drum drive 17.3

POCLAIN HYDRAULICS
800378128J REPAR MS2-18 D/GB 47
008 911 63 BOMAG 703

17.3 Drum drive
China España & Portugal

POCLAIN HYDRAULICS BEIJING rep. office POCLAIN HYDRAULICS SPAIN S.L.
Unit A0808, Hui Bin Officies o o a
Gran Via Carlos III n 84 – 1 3
No.8 Beichendong St. 08028 BARCELONA
BEIJING 100101 ESPAÑA
CHINA Tel.: 349 3 409 54 54
Tel.: 86 10 6499 3988 Fax: 349 3 490 21 79
Fax: 86 10 6499 3979 e-mail: info-espana@poclain-hydraulics.com
e-mail: info-china@poclain-hydraulics.com
France
POCLAIN HYDRAULICS SRO POCLAIN HYDRAULICS France SAS

Kší rova 186 B.P. 106
61900 BRNO 60411 VERBERIE CEDEX
FRANCE
Tel.: 420 5 43217830 Tel.: 33 3 44 40 77 77
Fax: 420 5 43217818 Fax: 33 3 44 40 77 91
e-mail: info-ceskarepublika@poclain-hydraulics.com e-mail: info-france@poclain-hydraulics.com
Deutschland Japan
POCLAIN HYDRAULICS GMBH POCLAIN HYDRAULICS KK
Bergstrasse 106 5-4-6 Kugenumashinme
64319 PFUNGSTADT FUJISAWA 251
DEUTSCHLAND JAPAN
Tel.: 49 6157 9474 0 Tel: 81 466 50 4400
Fax: 49 6157 9474 74 Fax: 81 466 50 4422
e-mail: info-deutschland@poclain-hydraulics.com e-mail: info-japan@poclain-hydraulics.com
Italia United Kingdom

POCLAIN HYDRAULICS SRL POCLAIN HYDRAULICS LTD
Via Svizzera 4/A Nene Valley Business Park
41012 CARPI (MODENA) Oundle
ITALIA PETERBOROUGH, Cambs PE8 4HN
ENGLAND
Tel.: 390 59 64 22 44 Tel.: 44 1832 273773
Fax: 390 59 64 20 44 Fax: 44 1832 274990
e-mail: info-italia@poclain-hydraulics.com e-mail: info-uk@poclain-hydraulics.com
Nederland USA
POCLAIN HYDRAULICS BENELUX BV POCLAIN HYDRAULICS INC.
Penningweg 32C 7900 Durand Avenue
4879 AM ETTEN-LEUR P.O. BOX 801
NEDERLAND STURTEVANT, WI 53177
USA
Tel.: 31 76 5021152 Tel.: 1 262 554 6739
Fax: 31 76 5012279 Fax: 1 262 554 4860
e-mail: info-netherlands@poclain-hydraulics.com e-mail: info-america@poclain-hydraulics.com
POCLAIN HYDRAULICS INDUSTRIE S.A.S. au capital de 85 124 000 Francs

B.P. 106 Si è ge social: Route de Saint Sauveur
60411 VERBERIE CEDEX - France VERBERIE (OISE)
Tel.: 33 3 44 40 77 77 R.C.S. Senlis B 414 781 823
Fax: 33 3 44 40 77 99 Siret 414 781 823 00011
e-mail: info@poclain-hydraulics.com
www.poclain-hydraulics.com
704 BOMAG 008 911 63

17.4 Vibration motor
008 911 63 BOMAG 705

17.4 Vibration motor
706 BOMAG 008 911 63

Vibration motor 17.4
A10FM
A10FE
RDE92172-01-R/08.01
ersetzt / replaces 06.99
Reparaturanleitung - A10FM 28 - 60 Baureihe 5

A10FE 28 - 60 Baureihe 5
Repair instructions - A10FM 28 - 60 Series 5
A10FE 28 - 60 Series 5
008 911 63 BOMAG 707

RDE 92172-01-R/08.01
17.4
Hinweis / Inhalt
Vibration motor
Reparaturanleitung A10FM / A10FE
Notice / Contents Repair Instructions A10FM / A10FE
HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen Specifications, descriptions and illustrative material shown
entsprechen dem Informationsstand zum Zeitpunkt der herein were as accurate as known at the time this
Drucklegung dieser Unterlage. publication was approved for printing.
Änderungen können den Service am Produkt beein- BRUENINGHAUS HYDROMATIK reserves the right to
flussen, Verpflichtungen entstehen uns daraus nicht. discontinue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für specifications, materials, or design w ithout notice and
deren Resultat wir keine Haftung übernehmen können. without incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Anga- Optional equipment and accessories may add cost to the
be der Fabrik-Nr. bestellt, sind die Basis guter Reparatu- basic unit, and some options are available only in
ren. combination with certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf For the available combinations refer to the relevant data
dem Teststand vorzunehmen. sheet for the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vor- Adjustment and tests have to be carried out on the test
kehrungen sicherzustellen. bench under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, Protection of personnel and property has to be guar-
vermitteln wir in unseren Schulungskursen. anteed by appropriate measures.
Expert knowledge, the precondition of any service work,
can be obtained in our training courses.
INHALT Seite/ CONTENTS

Page
A10FM / A10FE A10FM / A10FE
Schnittbild 3 Sectional view

Allgemeine Reparaturhinweise 4 General repair guidelines
Triebwelle abdichten 5-7 Sealing the drive shaft
Motor demontieren 8-14 Disassemble the motor
Überprüfungshinweise 15 Inspection hints
Motor montieren 16-19 Motor assembly
Spülventil demontieren 20 Disassembly of the flushing valve
Abstimmung- Lagerung / Hinweise 21 Bearing adjustment / Note
Werkzeuge / Hilfswerkzeuge / Tools / auxiliary tools /
Anziehdrehmomente 27 tightening torques
2 Brueninghaus Hydromatik
708 BOMAG 008 911 63

RDE 92172-01-R/08.01
Vibration motor
Schnittbild
17.4
Reparaturanleitung A10FM / A10 FE
Sectional view Repair Instructions A10FM / A10FE
A10FM
A10FE
Optional Option
Ausführung mit Spülventil Unit with flushing valve
für geschlossenen Kreislauf for closed circuit application
008 911 63 BOMAG Brueninghaus Hydromatik

709 3

RDE 92172-01-R/08.01
17.4
Allgemeine Reparaturhinweise
Vibration motor
General repair guidelines Repair Instructions A10FM / A10FE
Achtung!
Nachfolgend Hinweise bei allen Reparaturarbeiten
an Hydraulikaggregaten beachten!
Attention!
Observe the f ollowing guidelines when carrying out repairs
on hydraulic units!
Alle Öffnungen der Hydraulikaggregate verschließen.
Close off all openings of the hydraulic unit.
Alle Dichtungen erneuern.

Nur original BRUENINGHAUS HYDROMATIK
Ersatzteile verwenden.
Replace all of the seals.

Use only original BRUENINGHAUS HYDROMATIK
spare parts.
Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

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

Att ention: Re-work of the sliding surfaces by using, for
example abrasive paper, can damage the surface.
Hydraulikaggregate vor Inbetriebnahme mit

Hydrauliköl befüllen.
Fill the hydraulic unit with hydraulic oil

before commissioning.
710 BOMAG 008 911 63

RDE 92172-01-R/08.01
Vibration motor
Triebwelle abdichten
17.4
Sealing the drive shaft Repair Instructions A10FM / A10FE
2
1
2 1. Sicherungsring, 2. Wellendichtring
1
1. Circlip, 2. Shaft seal
3 (Paßfeder ausbauen bei Ausführung Paßfeder))

Triebwelle abkleben.
Sicherungsring ausbauen.
(Remove key, version with keyway)

Protect the drive shaft.
Remove the circlip.

711 5

RDE 92172-01-R/08.01
17.4
Vibration motor
4 Nach der Demontage des gelaufenen Wellendichtringes,

einfetten des neuen WDR.(Kontrolle der Laufflächen, Welle,
Gehäuse).
Change the shaft seal and check its sliding surface (drive shaft)
and housing, grease the sealing ring.
5 Welle mit Schutzhülse oder Klebeband versehen.
Use installation tool or plastic strip for assembling seal.
6 Mit geeignetem Rohr den WDRnur so tief montieren,

daß der Sicherungsring montierbar ist (zu tiefes Montieren
führt zum Ausfall: Berührung mit dem Wellenlager! ).
Use a suitable pipe to mount the shaft seal ring, but don't
push it too deap. If t he shaft ring touches the bearing ring
you will damage the seal ring.
7 Sicherungsring einsetzen.
Assemble the snap ring.
8 Sicherungsring ganz einrasten.
Assemble the snap ring in the correct position.
712 BOMAG 008 911 63

RDE 92172-01-R/08.01
Vibration motor
17.4
Hinweis! Note!
Die hier beschriebene Möglichkeit zum Wechsel der This discription showes how th change the drive shaft
Antriebswellen - Abdichtung stellt nicht die serienmäßi- sealing ring but it isn't the way of serial assembly.
ge Montage dar. Für sicheres Dichtungsverhalten ist eine The sealing ring is assembled together with the taper
Montage des Dichtringes zusammen mit dem Kegel- roller bearing from inside the motor housing normally to
rollenlager von innen her durch das Montagegehäuse get a secure sealing condition. If you decide to repair the
durchzuführen. Soll aus Gründen der Vereinfachung im motor in t he shown way be very careful while handling
Reparaturfall die vorgehend beschriebene Vorgehens- so that the drive shaft wouldn't be damaged during
weise durchgeführt werden, so ist beim Ausbau der disassembly of the shaft sealing ring.
Dichtung besonders darauf zu achten, daß die Antriebs-
welle nicht beschädigt wird.

713 7

RDE 92172-01-R/08.01
17.4
Motor demontieren
Vibration motor
Disassemble the mot or Repair Instructions A10FM / A10FE
A10FM
714 BOMAG 008 911 63

RDE 92172-01-R/08.01
Vibration motor
Motor demontieren
17.4
Disassemble the motor Repair Instructions A10FM / A10FE
A10FE
10

715 9

RDE 92172-01-R/08.01
17.4
Motor demontieren
Vibration motor
11 Demontageposition
Lage der Anschlußplatte zum
Gehäuse kennzeichnen.
Disassembly position
Mark the location of the connection plate
on the housing.
12 Anschlußplattenbefestigung über Kreuz lösen.
Remove the connection plate fixing bolts crosswise.
13 Anschlußplatte abheben.

Verteilerplatte
kann herunterfallen - festhalten.
Verteilerplatte abheben.
Remove the connection plate.

Distributor plate
can drop down - hold tight.
Remove distributor plate.
716 BOMAG 008 911 63

RDE 92172-01-R/08.01
Vibration motor
Motor demontieren
17.4
14 Verteilerplatte abheben.
Remove control plate.
15 Lageraußenring mit Abziehvorrichtung ausbauen.

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

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

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

Remove the adjustment shim.

717 11

RDE 92172-01-R/08.01
17.4
Motor demontieren
Vibration motor
17 Triebwerk in horizontaler Lage herausziehen.
Remove the rotary group in a horizontal position.
18 Welle nach hinten herausziehen.
Remove the drive shaft to rear side.
19 Hubscheibe mit Sonderwerkzeug ausbauen (siehe Bild 20).
Remove swash plate with special tool (see picture 20).
20 Der Ausbau der Hubscheibe erfolgt mit einer Schleuder,

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

hook - diameter 6 mm - catches the end of the swash
plate at the bottom).
21 Lager mit Presse abziehen.
Press down bearing.
718 BOMAG 008 911 63

RDE 92172-01-R/08.01
Vibration motor
Motor demontieren
17.4
22 Abziehen des Lageraußenringes im Pumpengehäuse.

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

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

719 13

RDE 92172-01-R/08.01
17.4
Motor demontieren
Vibration motor
25 Feder mit Vorrichtung vorspannen.
Pre-tension the spring using a suitable device.
26 Sicherungsring demontieren.

Feder und Druckstifte ausbauen.
Remove circlip.
Remove spring and pressure pins.
27
720 BOMAG 008 911 63

RDE 92172-01-R/08.01
Vibration motor
Überprüfungshinweise
17.4
Inspection hints Repair Instructions A10FM / A10FE
28 Kontrolle!
Lauffläche (1) keine Kratzer, keine Metalleinlagerungen,
kein Axialspiel (2), (Kolben nur satzweise tauschen).
Check!
Check to see that there are no scratches or metal deposits
on the sliding surface (1), and that there is no axial play (2),
(pistons must only be replaced as a set).
29 Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).
Check!
Cylinder bores (1), splines (2).
30 Riefenfrei, keine Einlaufspuren
Free of grooves, no signs of wear.
31 Kontrolle!
Zylindergleitfläche riefenfrei, nicht eingelaufen, keine
Einlagerungen, Steuerplatte nicht riefig (nur satzweise
austauschen).
Check!
Cylinder sliding surface free of grooves, no wear, no
embedded foreign particles. That there are no scratches
on the control plate. (Only replace them as a set).
32 Kontrolle!
Auflagefläche - Steuerplatte ohne Beschädigung.
Check!
Mounting surface - control plate undamaged

721 15

RDE 92172-01-R/08.01
17.4
Motor montieren
Vibration motor
Motor assembly Repair Instructions A10FM / A10FE
33 Sicherungsring ins Gehäuse montieren.
Fit the circlip into the housing.
34 Wellendichtring und Fixierscheibe gegen

Sicherungsring einsetzen.
Assemble shaft seal ring and shim

against circlip.
35 Montage des Wellendichtringes 1 gegen den Sicherungsring 2,

3 anschließend Fixierscheibe 3 einlegen.
1 Assembly of the shaft seal 1 against the safety ring 2,

back up the shim 3 down to the seal ring.
36 Lageraußenring ins Gehäuse pressen.

Welle mit Lager vormontiert ins Gehäuse einstecken.
Wellendichtring nicht beschädigen.

Wellenverzahnung mit Klebeband umwickeln.
Press outer bearing ring into housing.

Shaft seal with pre-assembled bearing into housing.
Protect splines of the shaft wit h plastic strip

against damage of the seal lip.
722 BOMAG 008 911 63

RDE 92172-01-R/08.01
Vibration motor
Motor montieren
17.4
37 Hubscheibe montieren.
Assemble swash plate.
38 Mit Vorrichtung Druckstifte montieren.
Fit pressure pins using an assembly aid.
39 Feder mit Vorrichtung vorspannen.
Pre-tension the spring using a suitable device.
40
41 Kolben mit Rückzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einölen.
Assemble piston wit h retaining plate.

Note:
Oil piston and slipper pad.

723 17

RDE 92172-01-R/08.01
17.4
Motor montieren
Vibration motor
42 Rotationsgruppemontieren!
Montagehilfe:
Mit O-Ring Kolben f esthalten.
Fit rotary group!
Assembly aid:
Hold the pistons by using an O-ring.
43 Lager (1) in Anschlußplatte montieren.

4 Zylinderstift (2) einsetzen.
O-Ring (3) einsetzen.
Verteilerplatte (4) aufsetzen.
3
Montagehilfe:
Teile mit Fett fixieren.
1
Fit bearing (1) in connection plate.
2 Fit cyilindrical pin (2).
Fit O-ring (3).
Fit distributor plate (4).
Assembly:
Hold the components in place with grease.
724 BOMAG 008 911 63

RDE 92172-01-R/08.01
Vibration motor
Motor montieren
17.4
44 Verteilerplatte montieren.

Montagehilfe: Fett
Fit distributor plate.

Assembly aid: Grease
45 Anschlußplatte aufsetzen und mit Schrauben

über Kreuz anziehen.
Fit t he connection plate and fix it with

the screws crosswise.
A10FM A10FE
46

725 19

RDE 92172-01-R/08.01
17.4
Spülventil demontieren
Vibration motor
Disassembly of the flushing valve Repair Instructions A10FM / A10FE
47 Beidseitig Schrauben 1 lösen und Federn mit Scheiben 2

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

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

the spring and the cartridge.
Montage in umgekehrter Reihenfolge!
Assembling by opposite steps!
726 BOMAG 008 911 63

RDE 92172-01-R/08.01
Vibration motor
Abstimmung- Lagerung / Hinweise
17.4
Bearing adjustment / Note Repair Instructions A10FM / A10FE
Montage - Abstimmung (Kegelrollenlager) / Taper roller bearing initial tension
AA10FM Baureihe 50
AA10FM Series 50
0 .... 0,05 mm
Pos. 12
Abstimmung der Triebwerkslagerung Adjustment of stopper min displacement

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

überhöhten Drehzahlen bis hin zum Ausfall der Bauteile displacement increases the speed of the motor up to a
führen. possible failure of parts of the unit.

727 21

RDE 92172-01-R/08.01
17.4
Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente
Vibration motor
Tools / auxiliary tools / tightening torques Repair Instructions A10FM / A10FE
49 Plastikhammer
Soft hammer
50 Schleuder
...
Anziehdrehmomente /
Tightening torques
Festigkeitsklassen 8,8; 10,9; 12,9
Bolt tensile strength grade:
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
M a 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 (lubricated screws µ = 0,125)
51
728 BOMAG 008 911 63

17.5 Axle drive motor
008 911 63 BOMAG 729

730 BOMAG 008 911 63

Axle drive motor 17.5
saue
Series 51
Bent Axis
Variable Motors
Service Manual
008 911 63 BOMAG 731

saue
Bent Axis Variable Displacement Motor s Series 51
General Description
Series 51 V ariable Displacement Motors are bent Motors equipped with controls norm ally start at maxi-
axis design units, incorpor ating spheric al pistons. mum displacement. This provides maximum starting
torque (high acceleration).
These motors are designed prim arily to be combined
with other prod ucts in closed circuit systems to trans- The controls m ay utilize externally or internally sup-
fer and control hydr aulic power. plied servo press ure. They may be overridden by a
pressure compensator which f unctions when the
Series 51 Motors have a large maximum / minimum motor is operating in motor and pump modes. A
displacement ratio (5 to 1) and high o utput speed defeat option is available to disable the press ure
capabilities. SAE fl ange and cartridge motor config u- compensator override when the motor is r unning in
rations are available. pump mode.
The pressure compensator option fe atures a low
A complete family of controls and regulators is avai- pressure rise (short r amp) to provide optim al power
utilization thro ughout the entire displ acement range
lable to fulfill the req uirements of a wide range of
applic ations.
of the motor. The press ure compensator is also
available as a stand-alone reg ulator.
● The Series 51 - Advanced Technolo gy Today
● The Most Technically Advanced Hydraulic Unit s in the Industry
● SAE Flange and Cartridge Motors
● Cartridge Motors designed for Direct Installation in Compact

Planetary Drives
● Large Displacement Ratio (5:1)
● Complete Family of Control Systems
● Proven Reliability and Performance
● Optimum Product Configurations
● Compact, Lightweight
Front page: Option - hydr aulic two-position control

Copyright 1992-1997, S auer-Sundstrand Company.
All rights reserved. Contents s ub ject to change. Printed in U.S.A. 0992H
2
732 BOMAG 008 911 63


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Contents
Introd uction ......................................................................................................................................................4

Basic Hydraulic Circuits ...................................................................................................................................4
General Description of the Series 51 V ariable Displacement Motors ..............................................................5
Functional Description......................................................................................................................................6
Technical Specifications and Data - Variable Displacement Motors ..............................................................20
Safety Precautions .........................................................................................................................................21
Gauge Installation ..........................................................................................................................................23
Start-Up Procedure and Maintenance ............................................................................................................25
Component Inspection and Adjustment .........................................................................................................27
Troubleshooting .............................................................................................................................................37
Exploded View of the Series 51 V ariable Motor .............................................................................................41
Minor Repair and Replacement - Variable Motor ...........................................................................................51
General .....................................................................................................................................................51
Shaft Seal (SAE Flange Configuration) ....................................................................................................52
Shaft Seal (Cartridge Config uration) .........................................................................................................53
Loop Fl ushing Shuttle Valve (Option)........................................................................................................54
Charge Pressure Relief Valve ...................................................................................................................55
Minimum Angle Servo Cover ....................................................................................................................55
Hydraulic 2-Position Control (Type N2) .....................................................................................................56
Electrohydraulic 2-Position Controls (Types E1•E2 and F1•F2) ...............................................................57
Electric 2-Position Controls (Type S1) ......................................................................................................58
Hydraulic Proportion al Control (Type HZ) .................................................................................................59
Hydraulic Proportion al Control (Type HS) .................................................................................................60
Hydraulic Proportion al Control with M aximum Angle Over-ride (Types H1•H2 or K1•K2) ........................61
Two Connection Hydr aulic Proportion al Control (Type HP) ......................................................................62
Two Connection Hydr aulic Proportion al Control for “D ual Path” Vehicles (Type HC) ...............................64
Electrohydraulic Proportion al Control (Types EP and EQ)........................................................................68
Pressure Control Pilot (PCP) Valve for Electrohydr aulic Proportion al Control (Types EP and EQ)..........70
Multi-function Block ...................................................................................................................................71
Pressure Compensator Regulator (Type PC) ...........................................................................................76
Control Orifices .........................................................................................................................................77
Plug / Fitting Torq ues ................................................................................................................................77
0-1 3
008 911 63 BOMAG 733

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Introduction
The purpose of this m anual is to provide inform ation Dirt or contamination is the gre atest enemy of any
necessary for the norm al servicing of the Series 51 type of hydr aulic equipment. The gre atest possible
family of variable displacement hydrostatic motors. cleanliness is necess ary when starting up the sys-
tem, changing filters, or performing any other service
This manual includes unit and component descrip- procedure.
tion, troubleshooting, adjustments, and minor repair
proced ures. By following the proced ures in this For Technical Information on Series 51 motors, refer
manual, inspections and minor repairs may be per- to publication BLN-10042 or 368753.
formed witho ut affecting the unit warranty.
For Fluid Quality Requirements, refer to p ublication
A Series 51 motor does occ asionally require servic- BLN-9987 or 697581.
ing, and these units are designed to meet this req uire-
ment. Sauer-Sundstrand provides a complete repair serv-
ice for its prod ucts. Contact any Sauer-Sundstrand
Many repairs or adjustments can be completed with- Authorized Service Center for det ails. Sauer-Sund-
out removing the unit from the vehicle or m achine, strand Authorized Service Center loc ations are listed
provided the unit is accessible and can be thoroughly in publication BLN-2-40527 or 698266.
cleaned before beginning any procedures.
Basic Hydraulic Circuit s

CASE Closed Circuit
DRAIN
LINE The main ports of the p ump are connected by hydrau-
lic lines to the m ain ports of the motor. Fl uid flows in
either direction from the p ump to the motor then back
to the p ump in this closed circ uit. Either of the hydr au-
INPUT PV MV OUTPUT lic lines can be under high press ure. The direction
and speed of fl uid flow ( and the motor o utput sh aft
rotation) depends on the position of the p ump swash-
plate. The system press ure is determined by the
machine load.
FLOW (BI-DIRECTIONAL) Open Circuit
RESERVOIR The outlet port of the p ump is connected by a hydrau-
51000001 lic line to a directional control v alve. The working ports
Fig. 0-1 - Basic Closed Circuit of this valve are connected to the m ain ports of the
motor. When the v alve is actuated, fluid flows first
FLOW FLOW from the pump to the v alve. The v alve then directs the
(UNI-DIRECTIONAL) (BI-DIRECTIONAL) fluid to the motor in either direction. The direction of
E fluid flow (and motor output shaft rotation) depends
V on the direction the control v alve is shifted. The speed
L
A
INPUT PUMP V of fluid flow (and motor output shaft speed) depends
L on pump output volume and the dist ance the control
O MV OUTPUT
R valve is shifted. The system press ure is determined
T
N by the m achine load.
O
C
CASE Fluid returning from the motor is ro uted through the
DRAIN
RESERVOIR LINE control valve to the reservoir. Addition al components
may be necessary to provide dyn amic braking and to
51000002 deal with over-r unning loads.
Fig. 0-2 - Basic Open Circuit
4 0-2
734 BOMAG 008 911 63


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General Description of the Series 51 Variable Di splacement Motors

The Series 51 v ariable displacement hydraulic mo- Various hydraulic and electrohydraulic controls may
tors use spherical pistons and piston rings. The angle be mounted on the motor end c ap to control the servo
between the cylinder block and the o utput shaft can piston and the motor displ acement. Servo pressure
be set between 32 ° and 6 °, providing a 5 to 1 oil may either be supplied intern ally from the motor, or
maximum to minimum displacement ratio. externally.
At maximum displacement, the motor will provide a For all controls except the N2 and PC, servo pressure
certain maximum output shaft torque and minimum oil is supplied to a four (4) way spool valve in the motor
speed corresponding to the press ure and flow s up- end cap. When a combination of pilot press ure (or
plied to the motor. Under the s ame input conditions force) from an external control assembly and internal
but at minimum displacement, the shaft speed will be spring force shifts this v alve, servo pressure is routed
approximately five (5) times f aster while the available to move the servo piston and change the motor’s
output torque will decrease to approximately one-fifth displacement.
(1/5) the f ull displacement value. The displ acement
is changed by a servo piston which is connected to A synchronizing shaft, with spheric al rollers, synchro-
the valve segment. nizes the rot ation of the o utput shaft and the cylinder
block. The ball end of e ach piston r uns in a socket
bushing, pressed into the o utput shaft. There are no
other parts used to connect the pistons to the sh aft.
Two tapered roller bearings support the o utput shaft.
Minimum
Hydraulic Pressure Compensator
Proportional Override
Control Valve Segment
Control
Pressure Bearing Plate
Port
Tapered Roller Bearings
Synchronizing
Piston Shaft
Servo Piston
Cylinder
Charge Pressure
Relief Valve
P001 196
Fig. 10-1 - Sectional view of Serie s 51 variable di splacement motor (SAE Flan ge
Configuration) with Hydraulic Proportional Control
10 - 1 5
008 911 63 BOMAG 735

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Functional Description
Loop Flushing
Series 51 motors used in closed circ uit applications
incorpor ate an integr al loop fl ushing valve as st an-
dard equipment. Inst allations that require addition al
fluid to be removed from the m ain hydraulic circuit
because of fl uid cooling req uirements, or circ uits
requiring the remov al of excessive cont amination
from the high press ure circuit, can benefit from loop
flushing. Series 51 motors used in open circ uit appli-
51000003 51000004
Fig. 10-2 - Loop Fig. 10-3 - Loop cations may have the option al loop flushing defeat
components inst alled.
Flushing Flushing Defeat
Components Components Series 51 motors eq uipped with an integral loop
flushing valve also include a charge pressure relief
valve. The setting of the motor ch arge relief v alve
affects the f unction of the fl ushing circuit. Higher
motor charge relief settings red uce the loop fl ushing
flow and increase the flow over the p ump charge
pressure relief v alve when the circ uit is oper ating.
Lower motor ch arge relief settings incre ase the loop
flushing flow and may increase the motor c ase pres-
sure when the circ uit is oper ating.
An appropriate combination of pump and motor charge
pressure settings sho uld be maintained to ins ure the
proper function of the loop fl ushing circuit. Correct
charge pressure must be maintained under all condi-
tions of oper ation to m aintain p ump control perfor-
mance in closed loop systems.
NOTE: An optional orifice m ay be installed between
the motor charge relief and the motor c ase to
limit the m aximum flushing oil flow.
6 10 - 2
736 BOMAG 008 911 63


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Functional Description (Continued)
Displacement Limiter s
All Series 51 motors incorpor ate mechanical dis-
placement limiters. The minim um displacement of
the motor c an be limited within the st andard range by
a set screw in the motor ho using. The m aximum
displacement can be limited with sp acers installed on
the servo piston.
51000005
Fig. 10-4 - Minimum Displacement Limiter
with Tamper Resistant Cap (Cartridge
Motor Configuration Shown)
51000006
Fig. 10-5 - Maximum Di splacement Limiter
Screw
Controls - General
A wide range of control options is available for the
Series 51 motors. These incl ude pilot oper ated
Electrohydraulic 2-Position Controls, Hydr aulic Pro-
portional Controls (single or two [2] connection), and
Electrohydraulic Proportion al Controls. A directly op-
erated Hydraulic 2-Position Control and a Pressure
Compensator regulator are also available.
The Series 51 v ariable motor servo piston (except 5100007
when equipped with N2 control or the PC reg ulator) Fig. 10-6 - Internal Servo Pre ssure Supply
may be operated either by servo pressure oil supplied Screen with Multi-function Block and/or
internally from the main ports of the motor, or by servo Control Removed (Plu g for External
pressure oil supplied from an external source. (The Supply)
N2 control uses servo pressure supplied by an exter-
nal control v alve. The PC reg ulator obtains servo
pressure from the main ports of the motor.)
Orifice plugs are installed in the control spool sleeve
in the end c ap to regulate the flow of oil from the servo
piston to the motor ho using. Orifice plugs m ay be
installed in the end c ap to regulate the flow of servo
pressure supply oil to the control v alve, and to regu-
late the flow of oil from the control v alve to the servo
piston. 51000008
Fig. 10-7 - External Servo Pre ssure Supply
Fitting (Plug for Internal Supply)
10 - 3 7
008 911 63 BOMAG 737

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Hydraulic 2-Po sition Control (Type N2)

This is a two (2) position (m aximum - minimum
displacement) control, consisting of a cover plate
mounted on the end c ap. An external control valve
supplies servo press ure from an external source
directly to the servo piston. PCOR is not available
with the N2 control.
When servo pressure is supplied to port “Y1,” the
51000009 setting piston moves to the m aximum motor displace-
Fig. 10-8 - Serie s 51 Motor with N2 Control ment position. When servo pressure is supplied to
port “Y2,” the setting piston moves to the minim um
motor displacement position.
Orifices may be installed in the extern al control valve
or its connections to reg ulate the speed of servo
piston movement.
51000010
Fig. 10-9 - N2 Control Component s
L2 M6 (M4) Y1 Y2 (M3)
A
M1
max.
disp.
U4 (opt.)
M2
B
L1
51000011
Fig. 10-10 - N2 Control Schematic
8 10 - 4
738 BOMAG 008 911 63


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Electrohydraulic 2-Po sition Control (Types

E1•E2 and F1•F2)
A 12 or 24 VDC solenoid v alve, mounted on the m ulti-
function block, connects the end of the control v alve
spool in the end c ap with pilot press ure (provided by
the shuttle spool in the m ulti-function block) or with
the motor c ase. The control v alve in the end c ap is
biased by a threshold spring, and controls oil flow to
the ends of the servo piston. Servo press ure may be
51000012
supplied from an external source or intern ally by the Fig. 10-11 - Serie s 51 Motor with E1•E2 or
shuttle spool in the m ulti-function block. PCOR is F1•F2 Control
available with these controls.
With the E1 and E2 controls, energizing the solenoid

will cause the motor to shift to minim um displace-
ment. When the solenoid is not energized, the motor
is held at maximum displacement.
With the F1 and F2 controls, energizing the solenoid
causes the motor to shift to m aximum displacement.
When the solenoid is not energized, the motor is held
at minimum displacement.
51000013
Fig. 10-12 - E1•E2 and F1•F2 Control
Components
L2 M6 M4 M3
A
M1
A1
max.
disp.
U4 (opt.) T3
T2 E1•E2
B1
U5
(plug for T7,
ext. servo
T1
T8 M9
press.) X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1
M8 M7
F1•F2
51000014
Schematic
10 - 5 9
008 911 63 BOMAG 739

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Electric 2-Position Control (Type S1)
A 12 VDC solenoid v alve, mounted on the m ulti-
function block, directly oper ates the control v alve
spool in the end c ap. The control v alve in the end c ap
is biased by a threshold spring, and controls oil flow
to the ends of the servo piston. Servo press ure may
be supplied from an extern al source or intern ally by
the shuttle spool in the m ulti-function block. PCOR is
available with this control.
51000162
Fig. 10-14 - Serie s 51 Motor with S1 Control With the S1 control, energizing the solenoid c auses
the motor to shift to m aximum displacement. When
the solenoid is not energized, the motor is held at
minimum displacement.
51000163
Fig. 10-15 - S1 Control Component s
L2 M6 M4 M3
A
M1
A1
max.
disp.
U4 (opt.) T3
T2 S1
B1
U5
(plug for T7,
ext. servo
T1
T8 M9
press.) X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1
51000085
Fig. 10-16 - S1 Control Schematic
10 10 - 6
740 BOMAG 008 911 63


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Hydraulic Proportional Control (Type HZ)

The HZ control consists of a cover plate mounted
directly on the end c ap. A ball type shuttle valve
provides intern al servo pressure supply to the control
valve in the end c ap. PCOR is not available with the
HZ control.
Feedback springs (single spring for 060, 080 and
110) and a threshold spring are installed in the end
cap. The feed back springs and threshold spring 51000015
provide a force on the end of the control spool. The Fig. 10-17 - Serie s 51 Motor with HZ
force of the threshold spring is extern ally adjustable Control
with an adjusting screw. The feedback spring is
positioned between the control spool and a feedback
lug attached to the servo piston. The force of the
feedback spring increases as the motor’s displ ace-
ment decreases.
Pilot oil press ure from an external source is applied to
the end of the control spool opposite the feed back
and threshold springs. An incre ase in pilot press ure
(above the threshold press ure and within the mod u-
lating pressure range) will res ult in a decrease in 51000016
motor displacement, while a decrease in pilot pres- Fig. 10-18 - HZ Control Component s
sure will res ult in an increase in motor displ acement.
L2 M6 M4 M3
A
M1
max.
disp.
U4 (opt.) T3
T2
T7,
U5 (plug for T8 M9
ext. servo press.) T1
X3 (M5)
Servo press,
external
M2
B
Servo
Pressure
internal L1
X1 M7
51000017
Fig. 10-19 - HZ Control Schematic
10 - 7 11
008 911 63 BOMAG 741

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Hydraulic Proportional Control (Type HS)
The HS control consists of a cover plate (with a
hydraulic port) mounted on the m ulti-function block.
Servo pressure may be supplied from an external
source or intern ally by the shuttle spool in the m ulti-
function block. PCOR is available with this control.
The function of the HS control is identic al to the
function of the HZ control.
51000018
Fig. 10-20 - Serie s 51 Motor with HS
Control
51000019
Fig. 10-21 - HS Control Component s
L2 M6 M4 M3
A
M1
A1
max.
disp.
U4 (opt.) T3
T2
B1
T7,
U5 (plug for T8 M9
X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1
M7 X1 HS
H1•H2
M7 X1
K1•K2
M7 X1
51000022
Fig. 10-22 - HS, H1•H2, and K1•K2 Control
Schematic
12 10 - 8
742 BOMAG 008 911 63


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Hydraulic Proportional Control with
Electric Override (Type s H1•H2 and K1•K2)
The function of the H1•H2 and K1•K2 controls is
similar to the f unction of the HS control. A 12 or 24
VDC solenoid v alve is installed between the extern al
pilot press ure source and the control spool.
With the H1•H2 controls, energizing the solenoid
allows the control to f unction as an HS control. When
the solenoid is not energized, pilot press ure is blocked 51000020
and the end of the control spool is dr ained to the motor

Fig. 10-23 - Serie s 51 Motor with H1•H2
case, causing the motor to shift to m aximum displace- Control
ment.
With the K1•K2 controls, energizing the solenoid
blocks pilot press ure and drains the end of the control
spool to the motor c ase, causing the motor to shift to
maximum displacement. When the solenoid is not
energized, the control f unctions as an HS control.
51000167
Fig. 10-24 - Serie s 51 Motor with K1•K2
Control
51000021
Fig. 10-25 - H1•H2 and K1•K2 Control
Components
10 - 9 13
008 911 63 BOMAG 743

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Two Line Hydraulic Proportional Control
(Type HP)
This control consists of a valve block with two (2)
hydraulic ports mo unted on the m ulti-function block.
The valve block incorporates a sh uttle spool and a
pilot piston with centering springs. A pin tr ansmits
force from the pilot piston to the control spool in the
end cap. Feedback springs (single spring for 060,
51000023
080, and 110) and a threshold spring are installed in
Fig. 10-26 - Serie s 51 Motor with HP the end cap. These springs function similar to the HS
Control control. Servo pressure may be supplied from an
external source or intern ally by the shuttle spool in the
multi-function block. PCOR is available with this
control.
Two pilot press ures are provided to the control. The
shuttle spool directs the higher pilot press ure to the
end of the pilot piston opposite the feed back spring,
and the lower press ure to the opposite side of the pilot
piston. The rod transmits a force, proportional to the
difference of the pilot press ures, to the control spool.
51000024 An increase in the difference between the pilot pres-

Fig. 10-27 - HP Control Component s sures will result in a decrease in motor displ acement,
while a decrease will res ult in an increase in displ ace-
ment.
L2 M6 M4 M3
A
M1
A1
max.
disp.
U4 (opt.) T3
T2
B1
T7,
U5 (plug for T8 M9
X3 (M5)
Servo press,
external
M2
Servo B
Press,
internal
L1
X2 X1
51000025
Fig. 10-28 - HP Control Schematic
14 10 - 10
744 BOMAG 008 911 63


saue
for “Dual-Path” Vehicle s (Type HC)
The HC control oper ates in a similar manner to the HP
control, however the HC control is optimized for use
in “dual-path” drive vehicles. This control consists of
a valve block with two (2) hydr aulic ports mo unted on
the end cap. The valve block incorporates a shuttle
spool and a pilot piston with centering springs. A pin
transmits force from the pilot piston to the control
51000158
spool in the end c ap. Fig. 10-29 - Serie s 51 Motor with HC
A bleed valve is provided to elimin ate any air which Control
might become trapped in the pilot piston oil p assages.
Feedback springs are installed in the end c ap. Servo
pressure is supplied intern ally by a ball type shuttle
valve in the control ho using. PCOR is not available
with this control.
Two pilot press ures are provided to the control. The
shuttle spool directs the higher pilot press ure to the
end of the pilot piston opposite the feed back springs,
and the lower press ure to the opposite side of the pilot
piston. The pin tr ansmits a force, proportion al to the
difference of the pilot press ures, to the control spool.
An increase in the difference between the pilot pres- 51000111
sures will result in a decrease in motor displ acement, Fig. 10-30 - HC Control Component s
while a decrease will result in an increase in displ ace-
ment. The feed back springs in the end c ap have L2 M6 M4 M3
differing spring r ates and operate in parallel (060,
A
080, and 110) or series (160 or 250) to provide a linear M1
relationship between motor displ acement and pilot
pressure differenti al. max.
disp.
U4 (opt.) T3
T2
T7,
T8 M9
T1
M5
M2
B
L1
X2 X1
51000160
Fig. 10-31 - HC Control Schematic
10 - 11 15
008 911 63 BOMAG 745

saue
Electrohydraulic Proportional Control
(Types EP and EQ)
This control consists of a valve block and PCP (Pres-
sure Control Pilot) v alve mounted on the m ulti-func-
tion block. The valve block incorporates a pilot piston
with centering springs. A pin tr ansmits force from the
pilot piston to the control spool in the end c ap.
Feedback springs (single spring for 060, 080, and
110) and a threshold spring are installed in the end
51000026
Fig. 10-32 - Serie s 51 Motor with EP Control
cap. These springs f unction similar to the HS control.
Servo pressure may be supplied from an external
(EQ Similar)
source or internally by the shuttle spool in the m ulti-
function block. PCOR is available with this control.
An external pilot press ure source is connected to the
inlet of the PCP v alve, which produces differential
pilot press ures proportion al to the current through it.
These pressures are applied to the pilot piston. The
operation of this control is simil ar to that of the HP
Control, with the motor displ acement being propor-
tional to the c urrent through the PCP v alve.
An increase in current (above the threshold c urrent)
will result in a decrease in motor displ acement, while
a decrease will res ult in an increase in displ acement.
51000027
Fig. 10-33- EQ Control Component s (EP
Similar)
L2 M6 M4 M3
A
M1
A1
max.
disp.
U4 (opt.) T3
T2
B1
T7,
U5 (plug for T8 M9
X3 (M5)
Servo press,
external
M2
Servo B
Pressure
internal
L1
M7 X1 M8
51000028
Fig. 10-34 - EP and EQ Control Schematic
16 10 - 12
746 BOMAG 008 911 63


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Multi-function Block Components
The Multi-function Valve Block includes a shuttle
valve which provides intern ally supplied servo pres-
sure, and an optional Pressure Compensator Over-
Ride (PCOR) f unction with option al brake pressure
defeat.
51000029
Fig. 10-35 - Multi-function Block (Without
Control)
Servo Pressure Supply
For internal supply, the m ulti-function block incorpo-

rates a shuttle spool with intern al check ball valve that
routes oil from the m ain circuit ports of the motor to the
control valve in the end c ap. “High side” press ure is
provided to the servo control v alve in the end c ap.
For external supply, the connection between the
shuttle spool and the servo control v alve is blocked in
51000030
the end c ap. The external pressure supply to the Fig. 10-36 - Multi-function Block with Servo
servo control valve connects to a port (“M5”) on the Pressure Supply Shuttle Spool
end cap.
Pressure Compensator Over-Ride (PCOR)
The Pressure Compensator Over-Ride (PCOR) sys-

tem includes a spool valve located in the PCOR block
which is attached to the m ulti-function block. This
system increases the motor displ acement at system
pressures above the PCOR valve setting. (Pressure
Compens ator Over-Ride is not available with the N2
and HZ controls, or the PC reg ulator.)
For bi-directional PCOR operation, the sh uttle valve

in the multi-function block routes system high pres-
sure to the PCOR spool v alve. For single direction 51000031
PCOR operation, the PCOR spool v alve is connected Fig. 10-37 - Multi-function Block with PCOR
to one (1) side of the closed loop thro ugh passages in Block and Spool Valve (K1•K2 Control
the multi-function block Shown)
When system pressure exceeds the PCOR setting,
the spool v alve moves to connect the displ acement
reducing end of the servo piston to the motor c ase,
and the displ acement incre asing end of the servo
piston to system press ure. This increases the motor
displacement, which reduces the motor o utput speed.
When the PCOR v alve closes, control of the servo
piston returns to the control spool in the motor end
cap.
10 - 13 17
008 911 63 BOMAG 747

saue
An optional “brake pressure defeat” spool may be
installed in the m ulti-function block. When used with
the PCOR, this spool assures that the PCOR does
not cause the motor displ acement to increase during
deceleration (which co uld cause pump overspeed).
Pressure from a source such as the pump servos or
an external valve, shifts the defe at spool to block the
high pressure supply to the PCOR v alve from the
“deceler ation” side of the closed loop. Either bi-
51000032 directional or single direction PCOR oper ation can be
Fig. 10-38 - Multi-function Block with PCOR specified when PCOR defe at is installed.
Defeat Spool Component s
Shuttle Valve Shuttle Valve PCOR Brake Pressure Defeat Operation
A1 T4 A1 Rotation High press ure Control press ure

Defeat
Spool
port on port
CW A XB
T5
CCW B XA
U7 U7
U6 U6
B1 T6
B1
PCOR PCOR
Valve Valve
XA XB
Standard with Defeat
Pressure Compensator Override
51000033
Fig. 10-39 - PCOR and PCOR with Defeat
Schematic
18 10 - 14
748 BOMAG 008 911 63


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Pressure Compensator Regulator (Type
PC)
In this reg ulator, the Press ure Compensator system
in the multi-function block assembly controls the
motor displacement. At system pressures below the
compensator setting, the servo piston is m aintained
in the minim um motor displacement position. When
system pressure exceeds the POR setting, hydr aulic
pressure acts on the servo piston to incre ase the
motor displacement.
With the Press ure Compensator regulator, an in- 51000034
crease in system pressure (above the setting pres- Fig. 10-40 - Serie s 51 Motor with PC
sure) will result in an increase in motor displ acement Regulator
and output torque, and a decrease in motor sh aft
speed.
51000035
Fig. 10-41 - PC Regulator Components
L2 M6 M4 M3
A
M1
max.
disp.
T5
U7
U4 (opt.)
U6 T7
T1
M9
M5
M2
B
L1
51000036
Fig. 10-42 - PC Regulator Schematic
10 - 15 19
008 911 63 BOMAG 749

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Technical Specifications and Data - Variable Di splacement Motors
Design Hydraulic Fluid
Piston motor with v ariable displacement, bent axis Refer to S auer-Sundstrand publication BLN-9887 or
construction. 697581.
Type of Mounting Temperature 1)
SAE fo ur (4) bolt flange – SAE Fl ange Configuration. ϑ min = -40°C (-40°F), intermittent, cold st art
Two (2) bolt flange – Cartridge Motor Configuration. ϑ nominal = 104° C (220°F), continuous
ϑ max = 115° C (240°F), intermittent
Pipe Connections
at the hottest point, norm ally the case drain line.
1)
Main pressure ports: SAE fl ange Hydraulic fluid viscosity must be as shown below.
Remaining ports: SAE O-ring thread
Fluid Viscosity Limits
Direction of Rotation
ν min = 5 mm2 /s (42 SUS) intermittent
Clockwise and counter-clockwise. ν min = 6.4 mm2 /s (47 SUS) min. continuous
Installation Position ν min = 13 mm2 /s (70 SUS) optimum
ν max = 110 mm2 /s (510 SUS) max. continuous
Installation position discretionary. The housing must ν max = 1600 mm2 /s (7400 SUS) intermittent, cold st art
always be filled with hydr aulic fluid.
Filtration
System Pressure Range, Input
Acceptable contamination level: ISO Code 18/13 or
Max: 480 bar (6960 psi) better. Refer to S auer-Sundstrand publication BLN-9887
Min: 10 bar (145 psi) or 697581.
Case Pressure
Max. Continuous: 3 bar (44 psi)
Intermittent (Cold start): 5 bar (73 psi)
Frame Size
Dimension 060 080 110 160 250
Displacement maximum cm3 60.0 80.7 109.9 160.9 250.0
in3 3.66 4.92 6.71 9.82 15.26
minimum cm3 12.0 16.1 22.0 32.2 50.0
in3 0.73 0.98 1.34 1.96 3.05
Continuous speed at max disp min-1 (rpm) 3600 3100 2800 2500 2200
at min disp min-1 (rpm) 5600 5000 4500 4000 3400
Max. speed at max disp min-1 (rpm) 4400 4000 3600 3200 2700
at min disp min-1 (rpm) 7000 6250 5600 5000 4250
Theoretical at max disp Nm / bar 0.95 1.28 1.75 2.56 3.98
torque lbf•in / 1000 psi 583 784 1067 1563 2428
at min disp Nm / bar 0.19 0.26 0.35 0.51 0.80
lbf•in / 1000 psi 117 156 214 313 486
Max. continuous Q max L / min 216 250 308 402 550
flow gal / min 57 66 81 106 145
Max. corner power Pcorner max kW 336 403 492 644 850
hp 450 540 660 864 1140
Mass moment J kg • m2 0.0046 0.0071 0.0128 0.0234 0.0480
of inertia lbf • ft2 0.1092 0.1685 0.3037 0.5553 1.1580
Weight m kg 28 32 44 56 86
(with control N2) lb 62 71 97 123 190
20 10 - 16
750 BOMAG 008 911 63


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Safety Precautions
● When Series 51 units are used in vehicular ● Use caution when dealin g with hydraulic
hydrostatic drive systems, the loss of hy- fluid under pre ssure. Escaping hydraulic
drostatic drive line power in any mode of fluid under pre ssure can have sufficient
operation may cause a loss of hydro static force to penetrate your skin causing seri-
braking capacity. A braking system, redun- ous injury. This fluid may also be hot enou gh
dant to the hydro static transmission must, to burn. Serious infection or reaction s can
therefore, be provided which i s adequate to develop if proper medical treatment i s not
stop and hold the system should the condi- administered immediately.
tion develop.
● Some cleaning solvents are flammable. To
● Certain service procedures may require the avoid possible fire, do not u se cleaning
vehicle/machine to be di sabled (wheels solvents in an area where a source of igni-
raised off the ground, work function di scon- tion may be pre sent.
nected, etc.) while performing them in order
to prevent injury to the technician and by-
standers.
20 - 1 21
008 911 63 BOMAG 751

saue
Notes
22 20 - 2
752 BOMAG 008 911 63


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Gauge Installation
Various pressure gauge readings can be a great Snubbers are recommended to protect press ure
asset in tro ubleshooting pro blems with the Series 51 gauges. Frequent gauge calibration is necessary to
motor or support system. insure accuracy.
Fig. 30-1 - Gau ge Ports, Motor with N2 Control
Port "L1" Port Y2:

Servo press., external
(N2 Control Only) Gauge port M6:
Charge pressure
" X " Gauge port M3; 9/16 — 18 UNF-2B
Servo pressure
min. displacement Gauge port M2:
Port "B" system
pressure
A B
Gauge port M1:

Port "A" system M1
pressure Port Y1: M2
Servo press., external
(N2 Control Only)
Port "L2" Gauge port M4:
Servo pressure
max. displacement
Side Port End Cap Axial Port End Cap
Right Side View View in Direction "X"
51000037
Fig. 30-2- Gauge Ports, Motor with E1•E2, F1•F2, H1•H2, and K1•K2 Control s
Port X3:
servo press., extern al
Gauge port M5:
servo press., internal Control • E1/E2 • F1/F2
XA Control • H1/H2 • K1/K2
Control • E1/E2•F1/F2
Gauge port M8 Gauge port M7
Control • H1/H2 control pressure
Control pressure port X1 View"T"
Control • K1/K2
Control pressure port X1
XA
XB XB
"T" 51000038
Fig. 30-3 - Gau ge Ports, Motor with HS and HZ Controls
Port X3:
servo press., ext.
Gauge port M5: Gauge port M7:
servo press., int. XA Control pressure
Gauge port M7:
Control pressure
View"U" View"U"
(HS) (HZ)
XA XB
Control pressure Control pressure
XB
port X1 port X1
"U"
51000039
30 - 1 23
008 911 63 BOMAG 753

saue
Gauge Installation (Continued)
Fig. 30-4 - Gau ge Ports, Motor with HP Control
Port X3:
servo press., ext.
Gauge port M5:
servo press., int. XA
View"V"
XA XB
XB X1 X2 Ports X1, X2:
Control pressure
9/16 — 18 UNF-2B
"V" 51000040
Fig. 30-5 - Gau ge Ports, Motor with EP•EQ Control
Port X3:
servo press., ext.
Gauge port M5:
servo press., int. XA
View"W"
XA XB
XB
MS-Connector (MS3102C) Packard
Manual override 7/8 — 20 UNEF Connector
Port X1:
External PCP
"W" supply pressure 51000041
Gauge Information
System 600 bar or 10,000 psi G auge Motor 60 bar or 1000 psi G auge
M1 Pressure M6 Charge
Port “A” 9/16 — 18 O-Ring Fitting Pressure 9/16 — 18 O-Ring Fitting
System 600 bar or 10,000 psi G auge M7 Control 60 bar or 1000 psi G auge
M2 Pressure M8 Test Port 9/16 — 18 O-Ring Fitting
Port “B” 9/16 — 18 O-Ring Fitting L1 Case 60 bar or 1000 psi G auge
Servo 600 bar or 10,000 psi G auge L2 Pressure 060, 080, 110:
M3 Pressure 1-1/16 — 12 O-Ring Fitting
(Min. Angle) 9/16 — 18 O-Ring Fitting 160, 250:
Servo 600 bar or 10,000 psi G auge 1-5/16 — 12 O-Ring Fitting
M4 Pressure X1 Control 60 bar or 1000 psi G auge
(Max. Angle) 9/16 — 18 O-Ring Fitting X2 Pressure 9/16 — 18 O-Ring Fitting
Servo 600 bar or 10,000 psi G auge X3
M5 Supply 9/16 — 18 O-Ring Fitting or XA Defeat 60 bar or 1000 psi G auge
(M9) Pressure Tee into Control Press ure Line XB Pressure Tee into Defe at Pressure
Line(s)
24 30 - 2
754 BOMAG 008 911 63


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Start-Up Procedure and Maintenance
Start-Up Precautions Fill the reservoir with recommended hydr aulic fluid,
which should be passed through a 10 micron (nomi-
Cleanliness
nal, no bypass) filter prior to entering the reservoir.
Ensure that all system components, incl uding fittings, The use of contaminated fluid will c ause damage to
pipes, and hoses, are completely clean. If cloths are the components, which m ay result in unexpected
used for cleaning components, they m ust be made of vehicle/machine movement.
lint-free m aterials. The inlet line le ading from the reservoir to the p ump
Follow the g uidelines presented in S auer-Sundstrand must be filled prior to st art up. Check inlet line for
publication BLN-9887 or 697581 for req uired fluid properly tightened fittings and make sure it is free of
cleanliness levels at machine start-up. restrictions and air leaks.
Reservoir and Fluid Level Be certain to fill the pump and motor hou sing with
clean hydraulic fluid prior to start up. Fill the
The reservoir sho uld be designed to accommodate housing by pouring filtered oil into the upper case
maximum volume changes during all system operat- drain port.
ing modes, and to promote de- aeration of the fl uid as
it passes through the tank. The reservoir o utlet (charge Install a 0 to 60 bar or 0 to 1000 psi press ure gauge
pump inlet) and the reservoir inlet (fl uid return) must in the charge pressure gauge port to monitor the
always be below the norm al fluid level. A sight gl ass charge pressure during start-up.
is the preferred method for checking fl uid level. The external control inp ut signal should be discon-
The reservoir inlet (fl uid return) should be positioned nected at the pump control d uring initi al start-up. This
so that flow to the reservoir is directed into the interior will allow the p ump to remain in its ne utral position.
of the reservoir for m aximum dwell and efficient de- “Jog” or slowly rotate prime mover until charge pres-
aeration. A baffle (or baffles) between the reservoir
sure starts to rise. Start the prime mover and run at
inlet and outlet ports will promote de- aeration and the lowest possible RPM until charge pressure is
reduce surging of the fl uid. established. Excess air may be bled from the high
No funnel-shaped eddying at the reservoir o utlet pressure lines through the high press ure gauge ports.
(charge pump inlet) or form ation of fo am at the Once charge pressure is established, incre ase speed
reservoir inlet (fl uid return) is permitted. to normal operating RPM. Note the charge pressure.
Start-Up Procedure If charge pressure is incorrect, sh ut down and deter-
mine cause for improper press ure.
The following st art-up procedure should always be
followed when st arting-up a new Series 51 inst alla- Shut down prime mover and connect extern al control
tion or when rest arting an installation in which either input signal. Start prime mover, checking to be
the pump or motor has been removed from the certain pump remains in ne utral. With prime mover at
system. normal operating speed, slowly check for forw ard and
reverse machine operation.
WARNING
Charge pressure should be maintained during for-
The following procedure may require the ve- ward or reverse oper ation. Contin ue to cycle slowly
hicle/machine to be di sabled (wheels raised off between forw ard and reverse for at least five (5)
the ground, work function di sconnected, etc.) minutes.
while performing the procedure in order to
prevent injury to the technician and by stand- Shut down prime mover, remove g auges, and plug
ers. Take necessary safety precautions before ports. Check reservoir level and add fluid if neces-
operating the vehicle/machine. sary.
Prior to installing the motor, inspect the unit for The transmission is now re ady for operation.
damage incurred during shipping and handling. M ake
certain all system components (reservoir, hoses,
valves, fittings, he at exchanger, etc.) are clean prior
to filling with fl uid.
30 - 3 25
008 911 63 BOMAG 755

saue
Start-Up Procedure and Maintenance (Continued)
Maintenance Changing the Fluid and Filter
Cleanliness
To insure optimum service life on Series 51 prod ucts,
The reservoir breather air filter (if eq uipped) must be regular mainten ance of the fl uid and filter m ust be
kept clean. Clean the area around the filler c ap before performed.
opening the reservoir. The hydr aulic fluid should be The fluid and filter m ust be changed per the vehicle/
filtered before it enters the reservoir. machine manufacturer’s recommendations. In the
Follow the g uidelines presented in S auer-Sundstrand absence of such recommendations, the following
publication BLN-9887 or 697581 for req uired fluid interv als may be used:
cleanliness levels during machine operation. • System with a sealed type reservoir - 2000 hrs.
Recommended Fluids • System with a breathing type reservoir - 500 hrs.
Hydraulic fluids used with S auer-Sundstrand prod- It may be necessary to change the fl uid more fre-
ucts should be carefully selected with assistance quently if the fl uid becomes contaminated with for-
from a reputable supplier, following the g uidelines eign matter (dirt, water, grease, etc.) or if the fl uid has
presented in S auer-Sundstrand publication BLN-9887 been oper ating at temper ature levels gre ater than the
or 697581. maximum recommended. Never reuse fluid.
Checking for Leak s The filter sho uld be changed when changing the fl uid,
or whenever the filter indic ator shows that it is neces-
Check the system components for le akage at regular sary to change the filter.
interv als. Tighten any leaking connections while the
system is not under pressure. Replace any defective
seals and gaskets.
Check hydraulic hoses for damage or aging. When
installing repl acements, be certain that the hoses are
clean and connected properly.
Checking the Fluid Level
Check the reservoir daily for proper fl uid level, the

presence of water (noted by a cloudy or milky appear-
ance, or free w ater in bottom of reservoir), and rancid
fluid odor (indic ating excessive heat).
26 30 - 4
756 BOMAG 008 911 63


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Component Inspection and Adjustment
WARNING
The following procedures may require the ve-

hicle/machine to be di sabled (wheels raised off
the ground, work function di sconnected, etc.)
while performing the adjustments to prevent
injury to the technician and by standers.
Charge Pressure Relief Valve Adju stment

An appropriate combination of pump and motor charge
pressure settings sho uld be maintained to ins ure the
proper function of the loop fl ushing circuit. Correct
charge pressure must be maintained under all
conditions of operation to maintain pump control
performance in closed loop systems.
To measure motor charge pressure, install a 0 to 60

bar or 0 to 500 psi press ure gauge in the motor ch arge 51000042
pressure gauge port. Inst all a gauge to measure case Fig. 30-6 - Adjusting Charge Pressure
pressure. Operate the system with the prime mover Relief Valve
at normal oper ating speed and the p ump at half
stroke (forward or reverse) when me asuring motor
charge pressure.
In most applications, the motor ch arge relief v alve is
set 2 to 4 bar (29 to 58 psi) below the setting of the
pump charge relief v alve (measured with the p ump in
its “neutral” or zero-angle position). This setting as-
sumes a reservoir temperature of 50 ° C (122° F), and
is referenced to c ase pressure.
Series 51 motors are equipped with an external screw 51000043
Fig. 30-7 - Tighten Charge Pressure Relief
adjustable charge pressure relief v alve. To adjust the
charge pressure, loosen the lock n ut (with a 1-1/16" Valve Lock Nut
hex wrench) and turn the adjustment plug with a large
screwdriver. Clockwise rotation of the pl ug increases
the setting, and counter-clockwise rotation decreases
the setting ( at a rate of approximately 3.4 bar [50 psi]
per turn). The lock nut should be torqued to 52 Nm (38
ft•lbsf).
Once the desired ch arge pressure setting is achieved,
remove the g auges and reinstall the port pl ugs.
30 - 5 27
008 911 63 BOMAG 757

saue
Component Adjustment (Continued)
Minimum Displacement Limiter Adju stment
The minimum displacement is set at the factory, and
the adjustment screw is covered with a tamper-
resistant cap
WARNING
Care should be taken in adju sting displace-
ment limiters to avoid unde sirable speed con-
dition s. The sealing lock nut must be retorqued
510000434
Fig. 30-8 - Loosen Minimum Displacement after every adjustment to prevent an unex-
Limiter Lock Nut pected change in operatin g conditions and to
prevent external leakage during unit operation.
NOTE: Changes in motor displ acement can be de-
tected by providing a constant flow of fl uid to
the motor, while m aintaining the motor at
minimum displacement and monitoring the
motor output shaft speed. An incre ase in
displacement will res ult in a decrease in shaft
speed, while a decrease in displacement will
result in an increase in shaft speed.
51000045
To adjust the minimum displacement, first remove
Fig. 30-9 - Rotate Minimum Di splacement and discard the c ap covering the adjusting screw.
Adjusting Screw Using a 17 mm hex wrench for 060 and 080 fr ame
size motors or a 19 mm hex wrench for 110 thro ugh
250 frame size motors, loosen the lock n ut retaining
Approximate Change in the minimum displacement limiter adjusting screw.
Minimum Displacement Using a 5 mm internal hex wrench for 060 and 080
Frame Per Revolution frame size motors or a 6 mm intern al hex wrench for
Size of Adju sting Screw 110 through 250 frame size motors, rotate the adjust-
060 1.5 cc/Rev (.09 in3/Rev) ing screw to limit the minim um displacement of the
080 2.1 cc/Rev (.13 in3/Rev) motor.
110 3.1 cc/Rev (.19 in3/Rev) Rotating the adjusting screw clockwise will incre ase
180 4.0 cc/Rev (.24 in3/Rev) the minimum displacement of the motor, while rot at-
250 6.2 cc/Rev (.38 in3/Rev) ing the adjusting screw counter-clockwise will de-
crease the minim um displacement.
Min. Displacement Screw Size
Frame Range and Length For each full revolution, of the adjusting screw, the
Size cc/Rev (in /Rev)
3
mm (in) displacement will change according to the accompa-
060 12 to 29 (.73 to 1.77) M10x65 (2.56) nying chart.
30 to 40 (1.83 to 2.44) M10x80 (3.15) Different minimum displacements may require differ-
080 16 to 35 (.98 to 2.14) M10x65 (2.56) ent length adjusting screws. The v arious lengths are
36 to 54 (2.20 to 3.20) M10x80 (3.15) shown in the accompanying chart.
110 22 to 46 (1.34 to 2.81 ) M12x70 (2.76) After establishing the desired minim um displacement
47 to 74 (2.87 to 4.52) M12x80 (3.15) setting, tighten the lock n ut on the adjusting screw to
160 32 to 72 (1.95 to 4.39) M12x75 (2.95) 51 Nm (38 ft•l bsf) for 060 and 080 fr ame size motors
73 to 107 (4.45 to 6.53) M12x90 (3.54) or 86 Nm (63 ft•l bsf) for 110 thro ugh 250 fr ame size
250 50 to 90 (3.05 to 5.49) M12x75 (2.95) motors. Install a new tamper-resistant cap on the
91 to 130 (5.55 to 7.93) M12x90 (3.54) adjusting screw.
131 to 167 (7.99 to 10.19) M12x100 (3.94)
28 30 - 6
758 BOMAG 008 911 63


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Maximum Displacement Limiter
Adjustment
The maximum displacement of the Series 51 motors
can be limited by limiting the stroke of the setting
piston, and the resulting movement of the v alve
segment. A displ acement stop screw is inst alled on
the setting piston ( under the minim um angle servo
cover) to limit the stroke of the piston.
Spacers may be installed on the displ acement stop
screw to limit the stroke. A longer or shorter screw
must be used to retain a thicker or thinner sp acer.
WARNING
Care should be taken in adju sting displace-
ment limiters to avoid unde sirable speed con-
ditions. The stop screw must be retorqued
after adjustment to prevent an unexpected
change in operating conditions.
NOTE: Changes in motor displ acement can be de-
the motor, while m aintaining the motor at 51000046
maximum displacement and monitoring the Fig. 30-10 - Remove Minimum An gle Servo
motor output shaft speed. An incre ase in Cover Screws
displacement will res ult in a decrease in shaft
speed, while a decrease in displ acement will
result in an increase in shaft speed. Approximate Change in
Frame Maximum Displacement
To adjust the maximum displacement, first remove Size with Change in Spacer Thickne ss
the screws retaining the minim um angle servo cover cc/mm (in3 /.1 in)
to the end c ap with an 8 mm internal hex wrench (060,
080, 110, and 160 units), or a 10 mm intern al hex 060 0.98 (.15)
wrench (250 units). Remove the minim um angle 080 1.14 (.18)
servo cover and O-rings. Remove the displ acement 110 1.48 (.23)
limiter screw with an 8 mm intern al hex wrench. 160 1.93 (.30)
Installing a thicker spacer on the end of the setting 250 2.63 (.41)
piston will red uce the maximum displacement of the
motor. Installing a thinner sp acer will incre ase the
maxim um displacement. The displ acement will
change according to the accompanying chart.
Torque the displ acement limiter screw to 54 Nm (40
ft•lbsf).
Install the minim um angle servo cover and its O-rings.
Install the cover screws and torque to 78 Nm (58
ft•lbsf) for 060, 080, 110, and 160 motors, or 110 Nm
(81 ft•lbsf) for 250 motors.
51000070
Fig. 30-11 - Torque Maximum Di splacement
Limiter Screw
30 - 7 29
008 911 63 BOMAG 759

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Displacement Control Adju stments
NOTE: A change in motor displ acement can be de-
the motor and monitoring the motor o utput
shaft speed while adjusting the control. An
increase in displ acement will res ult in a de-
crease in shaft speed, while a decrease in
displacement will res ult in an increase in shaft
speed.
Hydraulic 2-Position Control (Type N2)
No adjustments are provided for the N2 control.

A minimum of 25 bar (360 psi) servo press ure is
required to change the motor displ acement with the
motor shaft turning. A minimum of 70 bar (1015 psi)
servo pressure is required to ch ange the motor dis-
placement with the motor sh aft locked.
50000009
Fig. 30-12 - Hydraulic 2-Po sition Control,
Type N2)
Electrohydraulic 2-Position Control (Type s E1•E2

and F1•F2) and Electric 2-Po sition Control (Type
S1)
These controls do not req uire adjustment.

CAUTION
Do not tamper with the adju sting screw in the

end cap (opposite the control).
50000012
Fig. 30-13 - Electrohydraulic 2-Position Pilot pressure for the E1•E2 or F1•F2 electric sole-
Control, Types E1•E2 and F1•F2 noid valve is intern ally supplied. When the solenoid is
energized, motor ch arge pressure should be present
at test ports M7 and M8. When the solenoid is not
energized, test port M8 sho uld drop to c ase pressure.
The S1 control utilizes a direct acting solenoid to
operate the control v alve spool in the end c ap.
Servo pressure s upply oil is usually provided inter-
nally from the m ain system ports of the motor. If
external servo pressure supply is utilized, a minimum
of 25 bar (360 psi) is req uired to change the motor
50000162 displacement with the motor sh aft turning, and a
Fig. 30-14 - Electric 2-Po sition Control, minimum of 70 bar (1015 psi) is req uired with the
Type S1 motor shaft locked.
30 30 - 8
760 BOMAG 008 911 63


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Hydraulic Proportional Control (Type s HZ, HS,
H1•H2, and K1•K2)
The control start pressure for these controls m ay be
adjusted with the adjusting screw on the end c ap
(opposite the control block). Control start is that pilot
pressure at which the motor displ acement starts to
decrease.
To check the control st art setting, inst all a gauge to
monitor the pilot press ure (connect to port M7 or tee 51000015
into the pilot line connected to port X1), and the Fig. 30-15 - Hydraulic Proportional Control,
minimum angle servo press ure (port M3). If adjusting Type HZ
an H1 or H2 control, the override solenoid m ust be
energized. If adjusting a K1 or K2 control, the sole-
noid must not be energized.
NOTE: The pilot signal may be determined by prime
mover speed, other sh aft speeds, or other
control pressures, depending upon the de-
sign of the vehicle / m achine control circ uit.
Increase the pilot sign al to the req uired control start
pressure. An incre ase in minim um angle servo pres-
sure will be noted as the motor displ acement starts to 51000018
decrease. Fig. 30-16 - Hydraulic Proportional Control,
To adjust the control st art pressure, loosen the lock Type HS
nut using a 10 mm hex wrench and turn the adjusting
screw with a 4 mm intern al hex wrench. T urning the
screw clockwise increases the control st art pressure.
Torque the lock nut to 9 Nm (6.6 ft•l bsf) after adjust-
ing.
For the H1•H2 controls, the pilot sign al pressure
supplied to port X1 sho uld also be present at test port
M7 when the solenoid is energized. When the sole-
noid is not energized, test port M7 sho uld drop to c ase
pressure.
51000020
For the K1•K2 controls, the pilot sign al pressure Fig. 30-17 - Hydraulic Proportional Control
supplied to port X1 sho uld also be present at test port with Electric Override, Type H1•H2 (K1•K2
M7 when the solenoid is not energized. When the Similar)
solenoid is energized, test port M7 sho uld drop to
case pressure.
Shut down the prime mover. Remove the g auges and
install the g auge port pl ugs. Return the pump and
motor controls to their norm al operation.
of 25 bar (360 psi) is req uired to change the motor 51000047
displacement with the motor sh aft turning, and a Fig. 30-18 - Adju sting Control Threshold,
minimum of 70 bar (1015 psi) is req uired with the Types HS, HZ, H1•H2, and K1•K2
motor shaft locked.
30 - 9 31
008 911 63 BOMAG 761

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(Type HP)
The differenti al control start pressure for this control
may be adjusted with the adjusting screw on the end
cap (opposite the control block). Control st art is that
differenti al pilot press ure at which the motor displ ace-
ment starts to decrease.
To check the control st art setting, inst all g auges to
51000023 monitor the pilot press ures (tee into the pilot lines
Fig. 30-19 - Two Line Hydraulic connected to ports X1 and X2), and the minim um
Proportional Control, Type HP angle servo press ure (port M3).
NOTE: The pilot sign als may be determined by prime

Increase the pilot sign al differenti al to the req uired
control start pressure. An increase in minim um angle
servo pressure will be noted as the motor displ ace-
51000047 The differenti al control start pressure should be the
Fig. 30-20 - Adju sting Control Threshold same no matter which pilot press ure is higher. Differ-
(Type HP) ences in control oper ation when the pilot press ure
differenti al is reversed indic ate a problem with the
shuttle spool in the control block.
To adjust the control start differenti al pressure, loosen
the lock nut using a 10 mm hex wrench and turn the
adjusting screw with a 4 mm intern al hex wrench.
Turning the screw clockwise incre ases the control
start pressure. Torque the lock n ut to 9 Nm (6.6 ft•l bsf)
after adjusting.

of 25 bar (360 psi) is req uired to change the motor
displacement with the motor sh aft turning, and a
minimum of 70 bar (1015 psi) is req uired with the
motor shaft locked.
32 30 - 10
762 BOMAG 008 911 63


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for “Dual Path” Vehicle s (Type HC)
The differenti al control st art pressure for this control
may be adjusted with the adjusting screw on the
control ho using. Control st art is that differenti al pilot
pressure at which the motor displ acement starts to
decrease.
To check the control st art setting, inst all g auges to
monitor the pilot press ures (tee into the pilot lines 51000158
connected to ports X1 and X2), and the minim um Fig. 30-21 - Two Line Hydraulic
angle servo press ure (port M3). Proportional Control, Type HC
NOTE: The pilot signals may be determined by prime

Increase the pilot sign al differenti al to the req uired
control start pressure. An incre ase in minimum angle
servo pressure will be noted as the motor displ ace-
The differenti al control start pressure should be the 51000159
same no matter which pilot press ure is higher. Differ- Fig. 30-22 - Adju sting Control Threshold
ences in control oper ation when the pilot press ure (Type HC)
differenti al is reversed indic ate a problem with the
shuttle spool in the control block.
To adjust the control st art differenti al pressure, loosen
the lock nut using a 10 mm hex wrench and turn the
adjusting screw with a 4 mm intern al hex wrench.
Turning the screw co unter-clockwise (CCW) increases
the control start pressure. Torque the lock n ut to 9 Nm
(6.6 ft•lbsf) after adjusting.
Servo pressure supply oil is provided intern ally from
the main system ports of the motor.
30 - 11 33
008 911 63 BOMAG 763

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(Types EP and EQ)
The control st art current for the EP and EQ controls
may be adjusted with the adjusting screw on the end
cap (opposite the control block). Control start is that
current supplied to the PCP (Press ure Control Pilot)
valve at which the motor displ acement starts to de-
crease.
51000026 To check the threshold setting, inst all instruments to
Fig. 30-23 - Electrohydraulic Proportional monitor the PCP c urrent, and the minim um angle
Control, Type EP (EQ Similar) servo pressure (port M3).
NOTE: The current supplied to the PCP m ay be
determined by prime mover speed, other
shaft speeds, control press ures, or other elec-
trical signals, depending upon the design of
the vehicle / m achine control circ uit.
Increase the PCP c urrent to the req uired control st art
current. An incre ase in minimum angle servo pres-
sure will be noted as the motor displ acement starts to
decrease.
51000047
Fig. 30-24 - Adju sting Control Threshold To adjust the control start current, loosen the lock n ut
(Type EP•EP) using a 10 mm hex wrench and t urn the adjusting
screw with a 4 mm intern al hex wrench. T urning the
screw clockwise increases the control start current.
Torque the lock n ut to 9 Nm (6.6 ft•l bsf) after adjust-
ing.
PCP supply pressure oil is provided extern ally. PCP
supply pressure must be a minimum of 20 bar (290
psi) and no more th an 70 bar (1015 psi).
of 25 bar (360 psi) is req uired to ch ange the motor
displacement with the motor sh aft turning, and a
minimum of 70 bar (1015 psi) is req uired with the
motor shaft locked.
34 30 - 12
764 BOMAG 008 911 63


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Pressure Compensator Over-Ride (PCOR)
and Pressure Compensator Regulator
(Type PC) Adjustment
The PCOR or PC regulator valve setting may be
adjusted with the adjusting screw on the PCOR/PC
valve block attached to the m ulti-function block. The
regulator start pressure is that system pressure at
which the PCOR or PC reg ulator starts to increase
the motor displ acement.
In order to me asure the reg ulator start pressure
setting of the PCOR or the PC reg ulator, the motor
output shaft must be loaded to incre ase the system 51000031
working pressure. This can accomplished by apply- Fig. 30-25 - PCOR Block on Multi-Function
ing the vehicle’s brakes or by loading the work f unc- Block (K1•K2 Control Shown)
tion.
WARNING
The following procedures may require the ve-

hicle/machine to be di sabled (wheels raised off
the ground, work function di sconnected, etc.)
while performing the adjustment to prevent
injury to the technician and by standers.
Install gauges to monitor system press ure (connect
to ports M1 and M2), the minim um angle servo
pressure (port M3), and the maximum angle servo
pressure (port M4).
51000034
Start the prime mover and operate at normal speed. Fig. 30-26 - Pre ssure Compensator
Provide a signal to the p ump control to provide a
Regulator (Type PC)
constant flow of hydr aulic fluid to the motor. Provide
a signal to the motor control to m aintain the motor at
its minimum displacement.
Increase the load on the motor to incre ase the system
pressure to the req uired regulator start pressure. The
maximum angle servo pressure (M4) will incre ase
and the minim um displacement servo pressure (M3)
will decrease as the PCOR or PC reg ulator operates.
The servo pressures will equalize, and the m aximum
angle servo press ure contin ue to incre ase, as the
motor displacement starts to increase.
51000048
During the tr ansition from minim um to maximum Fig. 30-27 - Sy stem Pressure Gauge Ports
displacement, an additional 10 bar (145 psi) incre ase (Side Port End Cap)
in system pressure may be noted.
Once the motor is at maximum displacement, further
increases in load will res ult in increasing system
pressure until the m aximum system pressure (deter-
mined by the system relief valve or pump pressure
limiter) is re ached.
30 - 13 35
008 911 63 BOMAG 765

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Allow the p ump to return to its ne utral position.
Repeat the proced ure for the other side of the closed
circuit if so config ured. The PCOR or PC reg ulator
must operate at the same start pressure as noted
previously. Any noticeable difference in oper ation
from side to side m ay indicate a problem with the
pressure supply shuttle spool or brake pressure de-
feat spool in the m ulti-function block.
NOTE: Some motors may be configured for the
PCOR or PC reg ulator to function on only
one (1) side of the closed loop. Refer to the
nomenclature on the motor n ameplate.
In order for the PCOR or PC reg ulator to function
properly on motors eq uipped with a brake pressure
defeat spool, the defe at spool must be positioned
correctly. The control press ure for the defe at spool
should be applied to the appropriate port (XA or XB)
as shown in the following t able to shift the defe at
spool and permit PCOR or PC reg ulator operation.
Maximum pressure across the brake pressure defeat
ports XA and XB is 50 bar (725 psi).
51000049 Pressure Compensator Override Defeat Operation
Fig. 30-28 - Loosen PCOR/PC Lock Nut Rotation High system Control
pressure port pressure on port
CW A XB
CCW B XA
The PCOR or PC reg ulator valve is screw adjustable.
To adjust, loosen the lockn ut with a 1-1/16" hex
wrench. Turn the adjusting screw with a large screw-
driver until the desired press ure setting is est ab-
lished. Clockwise rot ation of the adjustment screw
will increase the pressure setting at a rate of approxi-
mately 70 bar (1000 psi) per t urn.
51000050
Fig. 30-29 - Rotate PCOR/PC Adju sting CAUTION
Screw A stop pin is installed in the adjusting screw to
prevent “overtravel” of the PCOR/PC valve
spool. The stop pin mu st protrude (di stance
"X" “X”) 19 mm (.75 in.) from the spring seat for
settings of 270 to 370 bar (3900 to 5350 psi), or
24 mm (.94 in.) for settings of 110 to 260 bar
(1600 to 3750 psi). Refer to the appropriate
Service Parts Manual for further information.
While holding the adjusting screw from t urning, torque
the lock nut to 52 Nm (38 ft•l bsf). Recheck the PCOR
or PC regulator setting.
51000051
Fig. 30-30 - PCOR/PC Adju sting Screw Stop
Pin motor controls to their norm al operation.
36 30 - 14
766 BOMAG 008 911 63


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Troubleshooting
Fault-Logic Diagrams • Closed Circuit
Check Oil Level Check System Check Pump Check Prime Mover
OK OK OK Speed
in Reservoir Relief Valve Inlet Pressure
Pressure
Low Low Low OK
Settings
Fill to Proper Defective Inspect Inlet Filter Adjust

Level and Replace if
Adjust or Necessary
Replace
Replace Check System Check Charge and

Transmission OK Internal Leakage OK Control Pressures
(Pump and Motor)
High Incorrect
Repair as Required Repair as Required

SYSTEM RESPONSE IS SLUGGISH
Check Oil Air in System OK Check Pump Inspect Shaft Inspect Shaft
OK OK OK
Level in Inlet Pressure Couplings Alignment
Reservoir
Loose Fitting Low Defective Defective
Low
Fill to Proper Purge Air and Inspect Inlet Filter Repair or Align Shafts
Level Tighten and Repl ace if Replace
Fittings Necessary
EXCESSIVE NOISE AND/OR VIBRATION
Check Oil Level Inspect Heat Check Charge Check Pump Inlet
OK OK OK
in Reservoir Exchanger Pressure Pressure
Low Defective Incorrect Low OK
Fill to Proper Clean, Repair Repair as Inspect Inlet Filter

Level or Replace Required and Repl ace if
Necessary
Replace Check System Check for Intern al Check System Relief

Transmission OK Pressure OK System Leakage OK Pressure Settings
(Pump and Motor) High High Low
Reduce Load on Repair as Required Adjust or Replace

Transmission
SYSTEM OPERATING HOT
30 - 15 37
008 911 63 BOMAG 767

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Troubleshooting (Continued)
Fault-Logic Diagrams • Closed Circuit (Continued)
Check Charge Check Pump Interchange System Replace

Pressure OK Control System OK Relief Valves and/or OK Transmission
Charge Check (Pump and
Decays in One Defective Valves Motor)
Direction (Forward
Problem Changes
or Reverse) Only
Direction
Inspect and Repair Repair or Repl ace Repair or Repl ace

Loop Flushing Appropri ate Valve
Valve
MOTOR OPERATES NORMALLY IN ONE DIRECTION ONLY
Check Inlet Check Outlet Motor at Incorrect Repair or Repl ace

Pressure at OK Pressure at OK (Minimum) Displacement OK Motor
Motor Motor
Low High / Low Incorrect
Correct System Correct System Check Control Supply

Pressure and/or Repair
LOW MOTOR OUTPUT TORQUE Displacement Control
Check Oil Check Charge Check Pump

Level in OK Pressure OK Output Flow OK Check Motor Displacement
Reservoir
Low Incorrect Improper Incorrect OK
Fill to Proper Repair Charge Repair Pump Check and Repair

Level System Control and/or Control System and
Pump Displacement Controls
(Pump and Motor)
Repair or Replace
Motor
IMPROPER MOTOR OUTPUT SPEED
38 30 - 16
768 BOMAG 008 911 63


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Notes
30 - 17 39
008 911 63 BOMAG 769

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Notes
40 30 - 18
770 BOMAG 008 911 63


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Exploded View of the Serie s 51 Variable Motor
The following inform ation is for gener al parts identi-
fication ONLY. Refer to the applicable Service Parts
List when ordering service p arts.
Base Unit
L35
W10 OPTION
WNNT L40
W50 L50
B71
W25 B80
B71A B80
L70 L80
L75
L40
L50
B70
B70A
B70A
Y10
B70
Y20
W25
Y30
Y20
W50
Y10 Y10
W10 B70A
OPTION Y20
WNNS B70
Y30
Name Plate
saue
Ames, Iowa, U.S.A. Neumünster, Germany
Model Code Typ
51V160 RF1N
E1A2 ANE1 NNN Model Code
050AA210322
Model No. Ident Nr
Model Number 516-40104 786673
Serial Number N 91 25 67890
Serial No. Fabr Nr
MADE IN GERMANY
Place of Manufacture
Name Plate (German Production)
40 - 1 41
008 911 63 BOMAG 771

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Exploded View of the Serie s 51 Variable Motor (Continued)
End Cap
(....) = Applies to the indic ated
G30 frame size(s).
G24
G30A
J70
G26
J60 G38
J50 G36
M18/M98 F10N, F10A–G
M16/M96 F20A–G
K90
K50
J40
K10
OR
K16 K70 OR
(250) K90N
G20
G20A K80
Q40 K90A
K14
K16 G50
(060—160)
G12 G50A G12
G12A G30 G30A K18N
(250) (250)
G80
(060, 080) G12A OR
G80A K18 K16
G30 (060, 080) (060—160) K16
(250)
G30A (250)
G30
(250) G30A K14
G20A
M11/T3A1-A9
T3B0-B6 G20
G12 T3C2-C7
G12A S20 OR
G12 G12A S10
M11/T1A1-A9
T1B0-B6 (060, 080,
T1C2-C7 G30A 110)
G18 (250) OR S10
G90 (160, 250)
G12A G30
Y40 G12 (250)
N1U5 J30
T8A1-A9
Y50 T8B0-B6 J10A-D
T8C2-C7
G30A J20/S70
G30 G42 T7A1-A9
G36 T7B0-B6
T7C2-C7
M11/T2A1-A9 G44
T2B0-B6
T2C2-C7 G38
F33
G38
G38
G42 F32
42 40 - 2
772 BOMAG 008 911 63

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Controls
M28
M30
M24
M38
M36
M10 M30
M18
M28
M32A M32 M26 M14
M32
M24
M26
M30 M28
M1HS
M16 M1HP
M18
M16
M20 M22
M1EP•EQ
M14 M18 M16 M16
M12 M14
M12
EP•EQ M10 HS M18
M10
M36
HP
M16 M1S1
M10
M20 M14
M22
M1E1•E2•E5 M22A S1
M1F1•F2
M1H1•H2
M1K1•K2 M18A
M14
M18
M2E5
E1•E2•E5 / F1•F2 / H1•H2 / K1•K2
44 40 - 4
774 BOMAG 008 911 63


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Controls (Continued)
(....) = Applies to the indic ated
frame size(s).
S50
S30
S20
S40
S60
S11T
(060, 080,
110)
OR
S11T
S10 (160, 250)
(060, 080, S10
110) (160, 250)
S10T S10T
M10 (060, 080, (160, 250)
M12 110)
S70
M44 M32
M34
M34A
M14
M40 M1HC
M1N2 M16
M38 M47
M16A M14 M46
N2
M18
M18A M50A
M50
M10 M34A M48A
M18 M12 M11 M34
M18A (060, 080, 110) M48
M26
M18A M34A
M22 M10
M18 M16A J10 M34
M1HZ M16 M25
HZ
M24
M22
M20
M14
M12
M28 M18
M16
HC
40 - 5 45
008 911 63 BOMAG 775

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PC Regulator
T7
F33
F32
M84
M28
M84A
M28A
M52
M34
M34A
M72 T5
M66 T4
M66A M72A
M34
M34A
M30
M34
M34A
T6 M84
M34A M84A
M34
M34 M34A
M10 M28
M90A M28A
M90 M28A
M26 M28
M26A
M34A
M34
M58
Z10 & Z20
M24 M82 M22 & M20

U7
U6
M1PC & M21
M14
M16
M18
M27A
M27 M29
M23
M27A
M23A
M27
Q60
46 40 - 6
776 BOMAG 008 911 63


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Item Description Quantity Item Description Quantity
B000 COMMON PARTS GROUP (SAE FLNG) J00A-K CONTROL START SETTING
B80 O-RING 1 J10A-K SPRING-HEL COMP- CONT START 1
L35 FLANGE- SAE 1 J20 SEAT-SPRING 1
L40 SEAL- SHAFT 1 J30 SEAT-SPRING 1
L50 O-RING 1 J40 SCREW-ADJUSTING 1
L70 SCREW- SOC HD 8 J50 O-RING 1
J60 NUT-ADJUSTING SCREW 1
C000 COMMON PARTS GROUP (CARTRIDGE) J70 NUT-LOCK 1
L40 SEAL- SHAFT 1
L50 O-RING 1 J00N CONT START N/A (FOR 2 POS CONT)
L75 COVER- SEAL 1
L80 RING- RETAINING 1 M0EP CONTROL- ELHYD PRP, PACKARD
M0EQ CONTROL- ELHYD PRP, MS
F••• MAXIMUM DISPLACEMENT F32 BUSHING- VALVE ASSY 1
F10 SPACER- MAX DISPL LMTR 1 M1EP PCP VALVE, PACKARD CONN 1
F20 SCREW-SOC HD - MAX DISPL LMTR 1 M1EQ PCP VALVE, MS CONN 1
M10 HOUSING- CONTROL 1
G00A END CAP-AXIAL (160-250) M12 SCREW- SOC HD 4
G00B END CAP-AXIAL, CODE 61 (160-250) M14 COVER 1
G00R END CAP-SIDE, LOOP FL M16 GASKET 1
G00S END CAP-SIDE, LOOP FL, CODE 61 M18 SCREW- SOC HD 4
G12 PLUG-STR THD HEX 7 M24 PISTON- SHUTTLE, DELTA P 1
G14 PLUG-EXP 1 M26 SPRING- HEL COMPRESSION 1
G16 PLUG-MANDREL 2 M28 PIN 1
G18 SCREW-SET, FLAT PT 2 M30 O-RING 1
G20 PLUG- SPECIAL 2 M32 PLUG-SOC HD 2
G20N PLUG- STR THD HEX 2 M34 PLUG-MANDREL 6
G24 SCREW-SOC HD 4 M36 O-RING 1
G26 COVER-SERVO PISTON 1 M38 O-RING 1
G30 PLUG-STR THD HEX 3 M40 CONTROL SCREEN FILTER 1
G36 O-RING 2 M42 PLUG-SOC HD 1
G38 O-RING 4 M44 PLUG-PLASTIC 1
G42 O-RING 2 N90 PLUG-STR THD HEX 1
G44 O-RING 1
G50 PLUG-ST THD HEX 2 M0E1/E2 CONTROL- ELHYD 2 POS
G70 COVER-PORT 2 M0F1/F2 CONTROL- ELHYD 2 POS, MAX ANG
G90 CONTROL SCREEN FILTER 1 F32 BUSHING- VALVE ASSY 1
K10 ADJ PLUG ASSY-CHG RLF 1 M1E1 VALVE ASSY- SOLENOID,12V 1
K14 SPRING-HELICAL COMP 2 M1E2 VALVE ASSY- SOLENOID,24V 1
K16 GUIDE-SPRING (060 — 160) 2 M10 HOUSING-CONT, ELHYD, 2 POS (E) 1
K16 GUIDE-SPRING (250) 2 M10 HOUSING-CONT, ELHYD, 2 POS (F) 1
K18 SHUTTLE VALVE SPOOL 1 M12 PLUG-EXP 7
K18N LOOP FLUSH SPOOL- DEFEAT 1 M14 SCREW-SOC HD 4
K50 O-RING 1 M16 O-RING 2
K70 SPRING-HELICAL COMPRESSION 1 M18 PLUG-STR THD HEX 1
K80 POPPET-CHG RELIEF 1 M20 O-RING 1
K90 NUT-HEX LOCK 1 M22 PLUG-STR THD HEX 1
K90N PLUG- ST THD HEX 1 N90 PLUG-STR THD HEX 1
40 - 7 47
008 911 63 BOMAG 777

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M0HC CONTROL- HYD PRPNL 2LN, DUAL PATH M0HS CONTROL- HYD PRP, 1 LN
F32 BUSHING- VALVE ASSY 1 F32 BUSHING-VALVE ASSY 1
M1HC HOUSING- HYD PRPNL (2LN),DUAL 1 M1HS HOUSING- VALVE, HYD PRPRNL 1 LN 1
M10 SCREW-SOC HD 4 M10 SCREW-SOC HD 4
M11 WASHER, FLAT (060, 080, 110) 4 M12 O-RING 1
M12 COVER 1 M14 PLUG-STR THD HEX 1
M14 GASKET 1 M16 PLUG-PLASTIC 1
M16 NUT-SEAL LOCK 1 N90 PLUG-STR THD HEX 1
M18 SCREW-SET, FL PT 1
M20 GUIDE- SPRING 1 M0HZ CONTROL- HYD PRP, 1 LN, CMPCT
M22 SPRING-HELICAL COMPRESSION 1 F32 BUSHING- VALVE ASSY 1
M24 PISTON- DELTA P 1 M1HZ HOUSING- VALVE, HYD PRP, 1 LN, CPT 1
M25 SEAT- SPRING 1 M10 VALVE ASSY- DBL CHECK 1
M26 PIN 1 M12 SCREW- SOC- DRILLED 1
M28 SCREW-SOC HD 4 M14 CONTROL SCREEN FILTER 2
M32 CONTROL SCREEN FILTER 2 M16 PLUG-STR THD HEX 2
M34 PLUG-SOC HD 4 M18 PLUG-STR THD HEX 3
M38 VALVE- BLEED 1
M40 NUT- SEAL LOCK 1 M0H1/H2 CONTROL- HYD PRP, 1 LN, MAX ANG
M44 VALVE, SHUTTLE- DELTA P 1 M0K1/K2 CONTROL- HYD PRP, 1 LN, MIN ANG
M46 SEAT- BALL CHECK 1 F32 BUSHING-VALVE ASSY 1
M47 BALL- SHUTTLE 1 M1H1 VALVE ASSY-SOLENOID,12V 1
M48 PLUG-STR THD HEX 1 M1H2 VALVE ASSY-SOLENOID,12V 1
M50 PLUG-STR THD HEX 1 M10 HSG-CONT,ELHYD, 2 POS 1
M12 PLUG-EXP 8
M0HP CONTROL- HYD PRPNL 2LN, W/BLD M14 SCREW-SOC HD 4
F32 BUSHING- VALVE ASSY 1 M16 O-RING 2
M1HP HOUSING- HYD PRPNL (2LN),W/BLD 1 M18 PLUG-STR THD HEX 1
M10 COVER 1 M20 O-RING 1
M12 GASKET 1 M22 PLUG-PLASTIC 1
M14 PISTON-SHUTTLE, DELTA P 1 N90 PLUG-STR THD,SOC HD 1
M16 SPRING-HELICAL COMPRESSION 1
M18 PIN 1 M0N2 CON-HYD, 2 POS, DIRECT
M24 O-RING 1 M1N2 COVER 1
M26 VALVE SHUTTLE,DELTA P 1 M10 PLUG 1
M28 PLUG-SEALING 1 M11 SCREW- SET,FLT PT 3
M30 O-RING 2 M12 O-RING 1
M32 PLUG-SEALING 1 M14 SCREW-SOC 4
M34 PLUG-EXP 6 M16 GASKET 1
M36 SCREW-SOC HD 4 M18 PLUG 1
N90 PLUG-STR THD HEX 1
48 40 - 8
778 BOMAG 008 911 63


saue
M0PC REGULATOR- PRESS COMP N0A1-6 SVO PRS SPLY, PCOR, DFT
F32 PLUG- VALVE BUSHING BORE 1 N1A1-6 HOUSING-MULTI FUNCTION BLOCK 1
F33 O-RING 1 N11 HOUSING-VALVE 1
M1PC HOUSING- VALVE 1 N14 NUT-HEX LOCK 1
M10 HOUSING- MULTI FUNCTION BLOCK 1 N16 O-RING 1
M14 NUT-HEX LOCK 1 N18 SPRING-HELICAL COMPRESSION 1
M16 O-RING 1 N20 SEAT-SPRING, PCOR 1
M18 SPRING-HELICAL COMPRESSION 1 N21 BUSHING-VALVE 1
M20 SEAT-SPRING, PC 1 N22 SPOOL-PCOR VALVE 1
M21 BUSHING-VALVE 1 N23 PLUG-STR THD HEX 1
M22 SPOOL-PC VALVE 1 N24 O-RING 5
M23 PLUG-STR THD HEX 1 N26 PLUG-SOC HD (W/PCOR) 1
M26 PLUG-SOC HD 1 N26 PLUG-STR THD HEX (WO/PCOR) 1
M27 PLUG-STR THD HEX 10 N27 PLUG-STR THD HEX 17
M28 PLUG-STR THD HEX 4 N28 PLUG-PLASTIC (W/DFT) 2
M29 SCREW-SOC 4 N28 PLUG-STR THD HEX (WO/DFT) 2
M30 SPOOL, BI-DIRECTIONAL CHECK 1 N29 SCREW-SOC 4
M34 PLUG-STR THD HEX 10 N30 SPOOL, BI-DIRECTIONAL CHECK 1
M36 SCREW-SET,FLT PT 5 N32 PISTON 1
M38 PLUG-EXP 11 N34 PLUG-STR THD HEX 10
M50 PLUG-EXP 8 N36 SCREW-SET,FLT PT 5
M52 CONTROL SCREEN FILTER 2 N38 PLUG-EXP (060 - 110 ONLY) 11
M54 PLUG-EXP 1 N50 PLUG-EXP (060 - 110 ONLY) 6
M58 SCREW-SOC HD 4 N52 CONTROL SCREEN FILTER 2
M62 PLUG-EXP 1 N54 PLUG-EXP 1
M66 PLUG-STR THD HEX 2 N58 SCREW-SOC HD 4
M72 PLUG-STR THD,SOC HD 1 N62 PLUG-EXP 1
M82 O-RING 1 N66 PLUG-STR THD HEX (060-110) 2
M84 PLUG-STR THD HEX 2 N66 PLUG-STR THD HEX (160-250) 1
M86 SCREW-FL PT 1 N72 PLUG-STR THD,SOC HD 1
M90 PLUG-STR THD HEX 1 N74 SCREW-SET, FL PT 3
M96 GASKET 1 N82 O-RING 1
M98 PLUG 1 N84 PLUG, SPECIAL 2
N24 O-RING 5 N84 PLUG-STR THD HEX 2
N86 SCREW-SET 1
M0S1 CONTROL- ELECTRIC 2 POS, DIRECT U5 PLUG- SOC (EXT SUPPLY) 1
F32 BUSHING- VALVE ASSY 1 U6 ORIFICE, PCOR DAMPING 1
M1S1 SOLENOID,12V 1 U7 ORIFICE, PCOR DAMPING 1
M10 ADAPTER PLATE- SOLENOID 1
M14 SCREW-SOC HD 4 N0NN SERVO PRESS SPLY- NONE
M16 O-RING 1
M18 O-RING 1 P0AA SYS PRESS PROTECT- NONE
M20 PIN 1
M22 O-RING 1
N90 PLUG-STR THD HEX 1
40 - 9 49
008 911 63 BOMAG 779

saue
S00D-G CONTROL RAMP- HP, HS, H1/H2, K1/K2 Y••• MINIMUM DISPLACEMENT
S10 GUIDE-SPRING (160-250) 1 Y10 SCREW- SET, FLT PT 1
S10D-G CONT RAMP SPRING (060-110) 1 Y20 NUT- HEX, SEAL LOCK 1
S10D-G CONT RAMP SPRING ASSY (160-250) 2 Y30 TAMPER RESISTANT CAP 1
S20 GUIDE-SPRING 1
S70 SEAT-SPRING 1 Z000 PRS COMP SET- N ONE
S00N CONTROL RAMP-NONE Z0•• PCOR / PRESS COMP SETTING

Z10 ADJUSTER- THREADED 1
S00T CONTROL RAMP- HC Z20 PIN-STRAIGHT 1
S10 GUIDE-SPRING 1
S10T CONT RAMP SPRING 1
S11T CONT RAMP SPRING 1
S20 GUIDE-SPRING 1
S30 NUT- ADJUSTING SCREW 1
S40 O-RING 1
S50 NUT- LOCK 1
S60 SCREW- ADJUSTING 1
S70 SEAT-SPRING 1
S00U-Z CONTROL RAMP- EP/EQ

S10 GUIDE-SPRING (160-250) 1
S10U-Z CONT RAMP SPRING (060-110) 1
S10U-Z CONT RAMP SPRING ASSY (160-250) 1
T0A0 CON ORIFICE (A0)- NONE
T0A1 CON ORIFICE (A1)

T1 ORIFICE 1
T2 ORIFICE 2
T3 ORIFICE 1
T4 SCREW 2
T5 ORIFICE 1
T6 SCREW 1
T7 ORIFICE 2
T8 ORIFICE 1
U3 SCREW-FL PT 1
T0A2 CON ORIFICE (A2)

T1 ORIFICE 1
T2 ORIFICE 2
T3 ORIFICE 1
T4 ORIFICE 2
T5 SCREW 1
T6 ORIFICE 1
T7 ORIFICE 2
T8 ORIFICE 1
WNNN SPCL HDW-NONE

A10 SPEED SENSOR 51V 0
B70 PLUG-SOC HD 1
B71 PLUG-PLASTIC 1
50 40 - 10
780 BOMAG 008 911 63


saue
Minor Repair and Replacement - Variable Motor
Charge Pressure
Relief Valve
Loop Fl ushing
Valve
Shaft
Seal
Control
Orifices
Multi-function
Block
Control
Limiter
51000052
Variable Displacement Motor (SAE Flange Configuration)
Fig. 50-1 - Minor Repair s
Minor Repairs may be performed, following the proce- Protect all exposed se aling surfaces and open c avi-
dures in this section, witho ut voiding the unit war- ties from damage and foreign m aterial.
ranty. Although specific products are illustrated,
these procedures apply to all units in the Series 51 It is recommended th at all g askets and O-rings be
family. replaced. All gasket sealing surfaces must be cleaned
prior to inst alling new g asket. Lightly l ubricate all O-
General rings with cle an petrole um jelly prior to assembly.
Cleanliness is a primary means of ins uring satisfac-
tory transmission life, on either new or rep aired units.
Cleaning parts by using a solvent wash and air drying
is adequate, providing cle an solvent is used. As with
any precision eq uipment, the intern al mechanism
and rel ated items must be kept free of foreign m ate-
rials and chemicals.
50 - 1 51
008 911 63 BOMAG 781

saue
Minor Repair and Replacement - Variable Motor (Continued)
Shaft Seal (SAE Flan ge Configuration)

Lip type shaft seals are used on the Series 51 motors.
Replacement of the sh aft seal usually requires re-
moval of the motor from the m achine.
Remove the screws holding the fl ange to the ho using,
using a 6 mm internal hex wrench (060 and 080 units),
an 8 mm intern al hex wrench (110 units), a 10 mm
intern al hex wrench (160 units), or a 12 mm intern al
hex wrench (250 units).
Remove the fl ange from the ho using using a suitable
puller. Care must be taken so as to not d amage the
housing bore or shaft.
51000178 51000179 CAUTION
Fig. 50-2 - Remove Fig. 50-3 - Remove
Screws Holding Flange (SAE) Do not allow the output shaft to move out of the
Flange to Housing housing while removing the flange. After the
(SAE) flange i s removed, do not attempt to remove
the shaft from the hou sing. If the output shaft
moves out of the hou sing, the synchronizing
shaft and roller s could fall out of po sition,
requiring major disassembly of the unit.
Remove the old se al from the fl ange. Once removed,

the seal is not re usable.
Inspect the fl ange and the new se al for any damage
or nicks.
Using an arbor press, press the new se al into the
flange. Be careful not to d amage seal.
NOTE: The outside diameter of the seal may be
51000053 51000054 lightly coated with a sealant (such as Loctite
Fig. 50-4 - Remove Fig. 50-5 - New Seal High Performance Sealant #59231) prior to
Old Seal from Flan ge Installed in Flange installation. This will aid in preventing le aks
(SAE) (SAE) caused by damage to the se al bore in the
flange.
Inspect the se aling area on the sh aft for r ust, wear, or
contamination.
52 50 - 2
782 BOMAG 008 911 63


saue
Install a new O-ring on the fl ange. Prior to assembly,
lubricate the fl ange O-ring and the I.D. of the se al with
petrole um jelly.
Protect the se al lip from d amage during installation by
wrapping the spline or key end of sh aft with pl astic
film, or by using a seal installation tool.
Assemble the fl ange and seal over the shaft and into
the housing bore. Install four (4) of the fl ange screws,
51000055 51000056
and tighten them evenly to p ull the fl ange into posi-
Fig. 50-6 - Install Fig. 50-7 - Torque
tion. Take care to not damage the O-ring or se al lip Flange onto Housing Flange Screws (SAE)
during installation.
(SAE)
Install the fl ange screws and torque evenly to 32 Nm
(24 ft•lbsf) for 060 and 080 motors, 63 Nm (46 ft•l bsf)
for 110 motors, 110 Nm (81 ft•l bsf) for 160 motors,
and 174 Nm (128 ft•l bsf) for 250 motors.
Shaft Seal (Cartrid ge Configuration)

Lip type shaft seals are used on the Series 51 motors.
These seals can be replaced without ma jor disas-
sembly of the unit. However, repl acement of the sh aft
seal requires removal of the motor from the wheel
drive or tr ack drive gearbox.
Remove the seal carrier retaining ring from the ho us-
ing.
Carefully pull the seal cover out of the ho using. Care
must be taken so as not to damage the housing bore
or shaft.
Remove the O-ring from the ho using.
Remove the old se al from the c arrier. Once removed,
the seal is not re usable. 51000057 51000058
Inspect the c arrier and the new se al for any damage
Carrier Retainin g Seal Carrier
or nicks.
Ring (Cartridge) (Cartridge)
Using an arbor press, press the new se al into the
carrier. Be careful not to d amage seal.
NOTE: The outside diameter of the se al may be
lightly coated with a sealant (such as Loctite
High Performance Sealant #59231) prior to
installation. This will aid in preventing le aks
caused by damage to the seal bore in the se al
carrier.
Inspect the se aling area on the sh aft for r ust, wear, or 51000059 51000060
Fig. 50-10 - Seal Fig. 50-11 - Seal
contamination.
Carrier Removed Installed in Carrier
(Cartridge) (Cartridge)
50 - 3 53
008 911 63 BOMAG 783

saue
Install the c arrier O-ring into the groove in the ho us-
ing. Prior to assembly, lubricate the c arrier O-ring and
the I.D. of the se al with petrole um jelly.
Protect the se al lip from d amage during installation by
wrapping the spline or key end of sh aft with pl astic
film, or by using a seal installation tool.
Assemble the carrier and seal over the shaft and into
the housing bore. Take care to not d amage the O-ring
51000061 51000057
Fig. 50-12 - Install Fig. 50-13 - Install or seal lip d uring installation.
Seal Carrier Carrier Retainin g Install the seal carrier retaining ring.
(Cartridge) Ring (Cartridge)
Loop Flushing Shuttle Valve (Option)
Using an 11/16" wrench, remove the hex pl ugs from
both sides of end c ap.
Remove springs and spring seat washers. Note the

orient ation of the w ashers.
NOTE The 250 frame size motors use thicker spring
seat washers.
51000062 51000063 Remove flushing valve spool.
Shuttle Valve Plu gs Valve Spool
Inspect parts for damage or foreign m aterial.
51000066
Fig. 50-16 - Loop Flushing Shuttle Valve
Components
Install flushing valve spool in end c ap, then inst all the
spring seat washers (thick washers on 250 fr ame size
motors) on e ach end of the spool. The step on the
spring seat washers should face out, toward the
springs.
Install the spool springs and hex pl ugs. Torque the
plugs to 41 Nm (30 ft•l bsf).
51000064 51000065
Fig. 50-17 - Install Fig. 50-18 - Install
Valve Spool and Plugs and Sprin gs
Washers
54 50 - 4
784 BOMAG 008 911 63


saue
Charge Pressure Relief Valve
Before removing the screw adjustable relief v alve
plug, m ark the plug, lock nut, and end cap to allow
maintaining the origin al adjustment when assem-
bling. Remove the screw adjustable charge relief
valve plug by loosening the lock n ut (with a 1-1/16"
hex wrench), and unscrewing the pl ug with a l arge
screwdriver.
Remove the spring and relief v alve poppet. 51000067 51000068
Inspect the poppet and mating seat in the end c ap for Charge Relief Valve Charge Relief Valve
damage or foreign m aterial. Plug
Install the poppet and spring. Install the pl ug with its
lock nut, aligning the m arks made at disassembly,
and torque the lock n ut to 52 Nm (38 ft•l bsf).
Check and adjust, if necessary, the charge pressure.
51000069
Fig. 50-21 - Char ge Relief Valve
Components
Minimum Angle Servo Cover

Thoroughly clean external surfaces prior to remov al
of cover.
Remove the fo ur (4) screws retaining the cover to the
end cap with an 8 mm intern al hex wrench (060, 080,
110, and 160 units) or a 10 mm intern al hex wrench
(250 units). Remove the cover. Remove the O-rings
between the cover and end c ap.
51000046 51000006
Install new O-rings on the end c ap and retain with Fig. 50-22 - Remove Fig. 50-23 - In stall
petrole um jelly. Install the cover onto the end c ap and Servo Cover Screw s Servo Cover
install the screws. Torq ue the screws to 78 Nm (58
ft•lbsf) for 060, 080, or 110 units, or 110 Nm (81 ft•l bsf)
for 160 or 250 units.
The plug in the cover m ay be removed with a 7/16"
hex wrench. Torq ue this plug to 9 Nm (7 ft•l bsf).
50 - 5 55
008 911 63 BOMAG 785

saue
Hydraulic 2-Po sition Control (Type N2)

of cover pl ate.
Remove the fo ur (4) screws retaining the cover pl ate
(160 and 250 units). Remove the cover pl ate.
51000071 51000072 Remove the solid pl ug from the v alve sleeve bore in
Fig. 50-24 - Remove Fig. 50-25 - Remove the end cap. (An 8 mm thre aded hole is provided in
Cover Plate Screw s Cover Plate the plug for a puller screw.) Remove the O-ring from
the plug.
Remove the O-rings from the end c ap.
Install new O-rings on the end c ap and retain with
petrole um jelly.
Install a new O-ring on the solid pl ug and install the
solid plug into the end c ap.
51000168
Fig. 50-26 - Remove Valve Sleeve Bore
Plug Install the cover pl ate onto the end c ap and install the
screws. Torque the screws to 78 Nm (58 ft•l bsf) for
060, 080, or 110 units, or to 110 Nm (81 ft•l bsf) for 160
or 250 units.
Set screws are installed in control orifice holes in the
end cap to plug the v alve sleeve bore passages. To
gain access to the screw pl ugs, remove the o uter
plugs from the end c ap with a 7/16" or 11/16" hex
wrench. Remove the screw pl ugs with a 3 mm internal
hex wrench. When inst alling, torq ue the screw pl ugs
51000010
to 4 Nm (35 in•l bsf). Torque the 5/16" o uter plugs to
Fig. 50-27 - N2 Control Component s 9 Nm (7 ft•lbsf), and the 9/16" o uter plugs to 37 Nm (27
ft•lbsf). Refer to the “Control Orifices” topic for addi-
tional information.
The special plug and seal washer on the end c ap
opposite the control m ay be removed with a 13 mm
hex wrench. When inst alling, torq ue this pl ug to 20
Nm (15 ft•lbsf).
51000073 51000074
Fig. 50-28 - Torque Fig. 50-29 - Torque
Cover Plate Screw s Plug in End Cap
56 50 - 6
786 BOMAG 008 911 63


saue
Electrohydraulic 2-Po sition Controls
(Types E1•E2 and F1•F2)
Thoroughly clean external surfaces prior to removing
the control.
The solenoid m ay be removed from the v alve by
removing the n ut with a 3/4" hex wrench. The
solenoid valve may be removed from the control
valve housing with a 7/8" hex wrench.
51000075 51000076
E1•E2 or F1•F2 Solenoid Valve
Control Solenoid
Remove the screws retaining the v alve housing to the
multi-function block with a 4 mm internal hex wrench.
Remove the v alve housing.
The plugs on the control ho using may be removed
with an 11/16" hex wrench. When reinst alling, torq ue
the plugs to 37 Nm (27 ft•l bsf).
51000013
Components
Install new O-rings onto the v alve housing. Install the

valve housing onto the m ulti-function block, and
install the screws. Torque the screws to 6.4 Nm (4.7
ft•lbsf).
51000077
Fig. 50-33 - In stall E1•E2 or F1•F2 Control
Valve Housing
When installing the solenoid v alve into the v alve

housing, the v alve should be torqued to 20 Nm (15
ft•lbsf). When installing the solenoid onto the v alve,
torque the nut to 15 Nm (11 ft•l bsf.).
51000078 51000079
Solenoid Valve Solenoid
50 - 7 57
008 911 63 BOMAG 787

saue
Electric 2-Position Controls (Type S1)
Thoro ughly clean external surfaces prior to removing
the control.
Remove the screws retaining the solenoid and sole-
noid adapter plate to the m ulti-function block with a 4
mm internal hex wrench. Remove the solenoid and
the solenoid adapter plate from the m ulti-function
block.
51000164 51000165
Fig. 50-36 - Remove Fig. 50-37 - Remove Remove the solenoid pin from the m ulti-function
S1 Control Screw s Adapter Plate and block.
Solenoid
Install new O-rings onto the adapter plate and the
solenoid.
51000163
Fig. 50-38 - S1 Control Component s
Install the solenoid pin into the hole in the m ulti-

function block.
51000086
Fig. 50-39 - Install S1 Control Solenoid Pin
Install the adapter plate with O-rings onto the m ulti-

function block.
Install the solenoid with O-ring onto the adapter plate.
Install the screws and torque to 6.4 Nm (4.7 ft•l bsf).
51000165 51000166
Adapter Plate and Control Solenoid
Solenoid Screws
58 50 - 8
788 BOMAG 008 911 63


saue
Hydraulic Proportional Control (Type HZ)

of control.
Remove the fo ur (4) screws ret aining the v alve hous-
ing to the end c ap with an 8 mm intern al hex wrench
(060, 080, and 110 units) or a 10 mm intern al hex
wrench (160 and 250 units). Remove the v alve hous-
ing. Remove the O-rings between the v alve housing
and end c ap, and the O-ring on the v alve spool 51000080 51000081
sleeve. Fig. 50-42 - Remove Fig. 50-43 - Remove

HZ Control Housing HZ Control Housing
The plugs on the control ho using may be removed Screws
with a 7/16" or 11/16" hex wrench. When reinst alling,
torque the 5/16" pl ugs to 9 Nm (7 ft•l bsf), and the 9/16"
plugs to 37 Nm (27 ft•l bsf)
The valve housing is eq uipped with filter screens in
51000016
Fig. 50-44 - HZ Control Component s
the passages between the ho using and the end c ap.

Units with intern al servo pressure supply have a filter
screen installed in the end c ap passage leading to the
valve spool sleeve. These screens sho uld be pressed
into position (with the ro unded edge of the filter
screens facing “out”) until they are flush to 2.0 mm
(0.08 in.) below the machined surface of the valve
housing or end c ap.
Units with extern al servo pressure supply have a plug 51000082 51000083
installed in the end c ap passage leading to the v alve Fig. 50-45 - HZ Fig. 50-46 - End Cap
spool sleeve. This pl ug may be removed with a 2.5 Control Housing O-Rings Installed
mm internal hex wrench. When inst alling this pl ug, Screen s
torque to 2 Nm (18 in•l bsf).
Install a new O-ring onto the v alve spool sleeve in the
end cap. Install new O-rings onto the end c ap.
Install the v alve housing onto the m ulti-function block,
and inst all the screws.
Torque the screws to 78 Nm (58 ft•l bsf) for 060, 080,

or 110 units, or to 110 Nm (81 ft•l bsf) for 160 or 250
units.
51000081 51000084
Fig. 50-47 - In stall HZ Fig. 50-48 - Torque
Control Housing HZ Control Valve
Housing Screws
50 - 9 59
008 911 63 BOMAG 789

saue
Hydraulic Proportional Control (Type HS)
of control.
51000087
Fig. 50-49 - Remove HS Control Hou sing
Screws
The plug on the control ho using may be removed with

an 11/16" hex wrench. When reinst alling, torq ue the
plug to 37 Nm (27 ft•l bsf).
Install a new O-ring onto the v alve housing.
51000019
Fig. 50-50 - HS Control Component s
Install the valve housing onto the m ulti-function block,

and inst all the screws.
Torque the screws to 6.4 Nm (4.7 ft•l bsf).
51000088
Fig. 50-51 - Torque HS Control Hou sing
Screws
60 50 - 10
790 BOMAG 008 911 63


saue
Hydraulic Proportional Control with

Maximum Angle Over-ride (Type s H1•H2 or
K1•K2)
Thoroughly clean external surfaces prior to removing
the control.
The solenoid m ay be removed from the v alve by
removing the n ut with a 3/4" hex wrench.
51000089 51000090
H1•H2 or K1•K2 Solenoid Valve
Control Solenoid
The solenoid v alve may be removed from the control
valve housing with a 7/8" hex wrench.
with an 11/16" hex wrench. When reinst alling, torq ue
the plugs to 37 Nm (27 ft•l bsf).
51000091
Fig. 50-54 - Remove Control Hou sing
Screws
Install new O-rings onto the v alve housing.

Install the v alve housing onto the m ulti-function block,
and inst all the screws. Torque the screws to 6.4 Nm
(4.7 ft•lbsf).
51000021
Fig. 50-55 - H1•H2 and K1•K2 Control
Components
When installing the solenoid v alve into the v alve

housing, the v alve should be torqued to 20 Nm (15
ft•lbsf).
When installing the solenoid onto the v alve, torque
the nut to 15 Nm (11 ft•l bsf.).
51000092 51000093
Solenoid Valve Solenoid
50 - 11 61
008 911 63 BOMAG 791

saue
Two Connection Hydraulic Proportional
Control (Type HP)
Thoro ughly clean external surfaces prior to remov al
of control.
Hold the control ho using in position, and remove the
screws retaining the cover and control ho using to the
multi-function block with a 4 mm intern al hex wrench.
Remove the housing cover and gasket. Remove the
51000094 51000095 valve housing with sh uttle valve assembly and pilot
Fig. 50-58 - Remove Fig. 50-59 - Remove piston from the m ulti-function block.
HP Control Housing Control Housing
Screws Remove the O-rings from the v alve housing. Remove
the pilot piston and spring from the v alve housing.
Remove the pilot piston pin from the m ulti-function
block.
Remove the inner sh uttle spool pl ug from the valve

housing. (A 5 mm thre aded hole is provided in the
inner plug for a puller screw.) Remove the sh uttle
spool from the v alve housing. Remove the o uter
shuttle spool pl ug. Remove the O-rings from the
51000096 51000086 plugs.
Shuttle Spool Plug Pilot Piston Pin
Install new O-rings on the sh uttle spool pl ugs.

Install new O-rings on the v alve housing and retain
with petrole um jelly.
51000024
Fig. 50-62 - HP Control Component s
62 50 - 12
792 BOMAG 008 911 63


saue
Install the pilot piston pin in the m ulti-function block.
Install the o uter (thin) sh uttle piston pl ug with the l arge
chamfer toward the shuttle valve bore. Install the
shuttle spool into its bore and install the inner (thick)
plug with the l arge chamfer toward the sh uttle valve
bore.
51000097 51000098
Fig. 50-63 - Pilot Fig. 50-64 - Install
Piston Pin Installed Shuttle Spool and
Plugs
Position the v alve housing (with O-ring) on the m ulti-
function block.
Install the pilot piston into the ho using and over the
pin. The end of the piston with the cross drilled hole
should engage the pin.
51000099 51000100
Control Housing Pilot Piston
Install the sm all spring in the o uter end of the pilot

piston.
Install the control cover and gasket. Align the control
assembly with the m ulti-function block and install the
four (4) screws.
Torque the control screws to 6.4 Nm (4.7 ft•l bsf).
51000101 51000102
Spring Cover, Gasket, and
Screws
50 - 13 63
008 911 63 BOMAG 793

saue
Two Connection Hydraulic Proportional

Control for “Dual Path” Vehicle s (Type HC)
Bleed Valve
Loosen the seal lock nut on the bleed valve with a 10
mm hex wrench, and remove the v alve with a 4 mm
intern al hex wrench.
Install the bleed valve and torque to 3 Nm (27 in•l bsf).
51000103 51000175
Fig. 50-69 - Remove Fig. 50-70 - In stall
HC Control Bleed HC Control Bleed
Valve Valve
Install the seal lock nut and torque to 19 Nm (14
ft•lbsf).
Servo Pressure Shuttle Valve
Remove the servo pressure shuttle plug with an

11⁄16" hex wrench. Remove the sh uttle ball seat with
a 5 mm intern al hex wrench and remove the ball.
51000176 51000104
Fig. 50-71 - Install Fig. 50-72 - Remove
HC Control Bleed Servo Pressure Ball
Valve Seal Nut Shuttle Valve
Install the servo press ure shuttle ball.
Install the shuttle ball seat and torque to 11 Nm (8
ft•lbsf). Install the sh uttle passage plug and torque to
37 Nm (27 ft•lbsf).
51000123 51000174
Servo Pressure Servo Pre ssure
Shuttle Ball Valve Shuttle Ball Seat
Control Pre ssure Shuttle Valve
Remove the shuttle spool pl ugs with a 1/4" intern al

hex wrench. Remove the control press ure shuttle
spool.
Install the control press ure shuttle spool.
Install the shuttle spool pl ugs and torque to 20 Nm (15
ft•lbsf).
51000105 51000122
Control Pressure Shuttle Spool Plugs
Shuttle Spool
64 50 - 14
794 BOMAG 008 911 63


saue
Pilot Piston and Control Hou sing
Thoroughly clean external surfaces prior to dis as-

sembly of control.
Remove the fo ur (4) screws retaining the cover to the
control ho using with a 4 mm intern al hex wrench.
Remove the housing cover and gasket (with the
adjusting screw and seal lock n ut).
51000177 51000106
HC Control Housing HC Control Housing
Cover Screw s Cover
Remove the control st art adjustor spring seat and
spring from the pilot piston.
Remove the pilot piston from the control ho using.
Remove the pilot piston pin se at and pin from the
control ho using (or pilot piston).
Remove the control st art spring from the control
housing.
51000107 51000108
Adjustment Spring Pilot Piston Pin and
and Pilot Pi ston Control Start Spring
Remove the fo ur (4) screws (and w ashers for 060,
080, and 110 units) retaining the control ho using to
the end cap with an 8 mm intern al hex wrench (060,
(160 and 250 units).
Remove the control ho using from the end c ap. Re-
move the O-rings between the control ho using and
the end c ap, and the O-ring on the v alve spool sleeve.
51000109 51000110
Screws
50 - 15 65
008 911 63 BOMAG 795

saue
with a 7/16" hex wrench or a 1/4" intern al hex wrench.
When reinstalling, torq ue the 5/16" pl ugs to 9 Nm (7
ft•lbsf), and the 9/16" pl ugs to 20 Nm (15 ft•l bsf).
51000111
Fig. 50-83 - HC Control Component s
The control ho using is equipped with filter screens in

the passages between the ho using and the end c ap.
(0.08 in.) below the machined surface of the v alve
housing or end c ap.
51000112 51000113
Fig. 50-84 - HC Fig. 50-85 - End Cap Install a new O-ring onto the v alve spool sleeve in the
Control Housing O-Rings Installed for end cap. Install new O-rings onto the end c ap.
Screen s HC Control
Install the valve housing onto the end c ap, and install
the screws (with fl at washers on 060, 080, and 110
units).
Torque the screws to 78 Nm (58 ft•l bsf) for 060, 080,

and 110 units, or to 110 Nm (81 ft•l bsf) for 160 and
250 units.
51000110 51000114
Screws
66 50 - 16
796 BOMAG 008 911 63


saue
Install the control st art spring into the control ho using.
Install the pilot piston pin. The end of the pin m ust
engage the recess in the end of the control v alve
spool.
51000115 51000116
HC Control Start Pilot Piston Pin
Spring
Install the pilot piston pin se at.
spring and spring se at. The end of the piston with the
deeper bore and the cross drilled hole sho uld engage
the start spring and pin se at.
51000117 51000118
Pilot Piston Pin Seat HC Control Pilot
Piston
Install the adjustor spring in the o uter end of the pilot
piston.
Install the adjustor spring se at.
51000119 51000120
HC Control Start HC Control Start
Adjuster Spring Adjuster Spring Seat
Install the control cover and g asket (with adjusting
screw and seal lock nut).
Torque the control cover screws to 6.4 Nm (4.7
ft•lbsf).
51000106 51000121
HC Control Cover Control Cover
and Gasket Screws
50 - 17 67
008 911 63 BOMAG 797

saue

(Types EP and EQ)
Thoro ughly clean external surfaces prior to remov al
of control.
The Pressure Control Pilot (PCP) v alve may be
removed from the control v alve housing, as de-
scribed under the following he ading.
51000124 51000125 Remove the screws retaining the control ho using
Fig. 50-96 - Remove Fig. 50-97 - Remove cover and control valve housing to the m ulti-function
PCP Valve EP•EQ Control block with a 4 mm intern al hex wrench. Remove the
Housing Screws housing cover and gasket.
Remove the valve housing with the pilot piston from
the multi-function block.
Remove the O-rings from the v alve housing. Remove
the pilot piston and spring from the v alve housing.
Remove the pilot piston pin from the m ulti-function
block.
51000126 51000086
EP•EQ Control Pilot Piston Pin
Housing
Install new O-rings on the v alve housing and retain
with petrole um jelly.
with a 1/4" intern al hex wrench. When reinst alling,
torque the 9/16" pl ugs to 20 Nm (15 ft•l bsf).
51000027
Fig. 50-100 - EQ Control Component s (EP
Similar)
68 50 - 18
798 BOMAG 008 911 63


saue
Install the pilot piston pin in the m ulti-function block.
Position the v alve housing (with O-rings) on the m ulti-
function block.
51000097 51000127
Fig. 50-101 - Pilot Fig. 50-102 - In stall
Piston Pin Installed Control Housing
pin. The end of the piston with the cross drilled hole
should engage the pin.
Install the sm all spring in the o uter end of the pilot
piston.
51000128 51000129
Fig. 50-103 - In stall Fig. 50-104 - In stall
Pilot Piston Spring
Install the control cover and gasket. Align the control

assembly with the m ulti-function block and install the
four (4) screws.
Torque the control screws to 6.4 Nm (4.7 ft•l bsf).
Reinst all the PCP valve, if removed.
51000130 51000131
Fig. 50-105 - Torque Fig. 50-106 - In stall
Cover, Gasket, and PCP Valve
Screws
50 - 19 69
008 911 63 BOMAG 799

saue
Pressure Control Pilot (PCP) Valve for
(Types EP and EQ)
Thoro ughly clean external surfaces of control.
Using a 4 mm internal hex wrench, remove the fo ur
(4) screws and remove the PCP v alve.
Check surfaces for nicks or damage. Clean internal
51000132 51000133 screens.
Fig. 50-107 - Remove Fig. 50-108 - PCP
PCP Valve Screw s Valve Components
Install new O-rings on the PCP ho using and retain

with petrole um jelly. Position the PCP on the control
valve housing and install the screws.
Torque the screws to 5.4 Nm (48 in•l bsf).
51000124 51000131
Fig. 50-109 - In stall Fig. 50-110 - Torque
PCP onto Control PCP Valve Screw s
70 50 - 20
800 BOMAG 008 911 63


saue
Multi-function Block
Removal and Installation
Remove the extern al control assembly as described
in the instr uctions for the specific control.
Remove the fo ur (4) screws (and w ashers for 060,
080, and 110 units) retaining the m ulti-function block
(160 and 250 units). 51000087 51000134
Remove the m ulti-function block from the end c ap. External Control (HS Multi-function Block
Remove the O-rings between the m ulti-function block Shown) Screws
and the end c ap, and the O-ring on the v alve spool
sleeve.
The multi-function block is equipped with filter screens
in the p assages between the block and the end c ap.
(0.08 in.) below the machined surface of the multi- 51000135 51000136
function block or end c ap. Fig. 50-113 - Remove Fig. 50-114 - Multi-
Multi-function Block function Block
Units with extern al servo pressure supply have a plug
Screen s
installed in the end c ap passage leading to the v alve
spool sleeve. This pl ug may be removed with a 2.5
mm internal hex wrench. When inst alling this pl ug,
torque to 2 Nm (18 in•l bsf).
Install a new O-ring onto the v alve spool sleeve in the
end cap.
Install new O-rings onto the end c ap.
Install the m ulti-function block onto the end c ap, and
install the screws. 51000083 51000135
Torque the screws to 78 Nm (58 ft•l bsf) for 060, 080, Fig. 50-115 - End Fig. 50-116 - In stall
or 110 units, or to 110 Nm (81 ft•l bsf) for 160 or 250 Cap O-Rings Multi-function Block
units. Installed
Reinst all the extern al control assembly as described
in the instr uctions for the specific control.
51000137 51000088
Fig. 50-117 - Torque Fig. 50-118 - In stall
Multi-function Block External Control (HS
Screws Shown)
50 - 21 71
008 911 63 BOMAG 801

saue
Servo Pressure Supply Shuttle Spool
Remove the servo press ure supply shuttle spool pl ug

from the multi-function valve with a 9/16" hex wrench.
NOTE: If a pressure compensator valve block is
installed, the opposite end of the sh uttle
spool bore in the m ulti-function valve is
plugged with an internal hex head pl ug lo-
cated under the v alve block. If a pressure
51000138 51000139
Fig. 50-119 - Remove Fig. 50-120 - Remove compensator valve block is not installed, the
opposite end of the sh uttle spool bore is
plugged with a hex head plug.
Supply Spool Plu g Supply Shuttle Spool
Remove the servo press ure supply shuttle spool from
the multi-function valve block.
Inspect the sh uttle spool for burrs or scoring. The
spool must slide free in its bore. The sh uttle ball in the
spool must be free to move.
51000030
Fig. 50-121 - Multi-function Block with
Servo Pre ssure Supply Shuttle Spool
Install the shuttle spool into the m ulti-function block.

Install the hex he ad plug into the m ulti-function valve
and torque to 37 Nm (27 ft•l bsf).
NOTE: If an internal hex head plug was removed

from the opposite end of the sh uttle spool
bore, torque it to 20 Nm (15 ft•l bsf).
51000139 51000140
Fig. 50-122 - In stall Fig. 50-123 - Torque
Supply Shuttle Spool Supply Spool Plug
72 50 - 22
802 BOMAG 008 911 63


saue
Blocking Plate for Multi-function Block Without
PCOR
The blocking plate may be removed by removing the

four (4) screws with a 5 mm internal hex wrench.
Remove the O-rings from the pl ate.
Install new O-rings on the blocking plate and retain
with petrole um jelly. Install the pl ate on the m ulti-
function block and install the screws. Torq ue the
51000170 51000171
screws to 11 Nm (8 ft•l bsf). Fig. 50-124 - Remove Fig. 50-125 - Torque
Blocking Plate (Less Blocking Plate
PCOR) Screws (Less PCOR)
Pre ss ure Compen s ator Valve for Pre ss ure
Compensator Over-Ride (PCOR) and Pre ssure
Compensator Regulator (Type PC)
Loosen the adjusting screw lock nut with a 1-1/16"

hex wrench. Remove the adjusting screw from the
valve block with a large screwdriver.
Remove the press ure compensator valve spring and
the spool assembly from the block.
51000142 51000143
PCOR•PC Adjustor PCOR•PC Spring
and Spool Valve
Remove the v alve block plug with a 1" hex wrench.
Remove the four (4) screws retaining the v alve block
to the multi-function block with a 5 mm intern al hex
wrench. Remove the v alve block and O-rings.
51000144 51000145
PCOR•PC Plug PCOR•PC Valve
Block
Install new O-rings on the press ure compensator
valve block and retain with petrole um jelly. Install a
new O-ring on the adjusting screw.
The plugs on the v alve block may be removed with a
7⁄16" hex wrench. When reinst alling, torq ue the 5⁄16"
plugs to 9 Nm (7 ft•l bsf).
51000146
Fig. 50-130 - Pre ssure Compensator Valve
Block Components
50 - 23 73
008 911 63 BOMAG 803

saue
Install the valve block on the m ulti-function block and
install the screws. Torq ue the screws to 11 Nm (8
ft•lbsf).
Install the valve block plug and torque to 54 Nm (40
ft•lbsf).
51000147 51000148
PCOR•PC Valve PCOR•PC Valve Plu g
Block
Install the press ure compensator spool assembly
and the v alve spring.
Install the adjusting screw and lock nut. Perform the

PCOR or PC regulator pressure adjustment as de-
scribed under “Component Adj ustment."
51000143 51000142
PCOR•PC Spring PCOR•PC Adjusting
and Spool Valve Screw
PCOR and PC Re gulator Orifices
To gain access to the PCOR or PC reg ulator orifices,

remove the three (3) pl ugs located between the
defeat spool stop pl ugs on the m ulti-function block,
using a 7/16" hex wrench. Remove the PCOR brake
pressure defeat spool (if inst alled). Remove the ori-
fice plug(s) and plain plug(s) with a 2.5 mm internal
hex wrench.
51000149
Fig. 50-135 - PCOR and PC Re gulator Refer to the appropri ate Service Parts Manual for
Orifices
inform ation on orifice loc ations and sizes.
Install the orifice pl ug(s) and plain plug(s), and torque
to 4 Nm (35 in•l bsf). Install the outer plugs and torque
to 6 Nm (4 ft•l bsf). Reinstall the PCOR defe at spool (if
removed).
Addition al orifices are installed in the p assages under
the pressure compensator valve block.
51000172
Fig. 50-136 - PCOR and PC Re gulator
Orifices
74 50 - 24
804 BOMAG 008 911 63


saue
PCOR Brake Pressure Defeat Spool
Remove the PCOR defe at spool bore plugs or fittings

with a hex wrench.
Remove the PCOR defeat spool stop pl ugs with a
7⁄16" hex wrench. Remove the defe at spool.
NOTE: The defeat spool m ay be removed from
either end of its bore in the m ulti-function block.
51000150 51000151
PCOR Defeat Spool PCOR Defeat Spool
Plug or Fitting Stop Plug
Inspect the defe at spool for burrs or roughness. The
spool must slide freely in its bore. Inspect the pins in
the stop pl ugs for damage.
51000032
Fig. 50-139 - Multi-function Block With
PCOR Defeat Spool Components
Install the PCOR defe at spool into its bore in the m ulti-
function block.
Install the spool stop pl ugs into the m ulti-function
block. Torq ue the stop pl ugs to 6 Nm (4 ft•l bsf).
Install the defe at spool bore plugs or fittings and

torque to 27 Nm (20 ft•l bsf).
51000152 51000153
PCOR Defeat Spool PCOR Defeat Spool
Stop Plug
50 - 25 75
008 911 63 BOMAG 805

saue
Pressure Compensator Regulator (Type

PC)
The PC regulator utilizes the m ulti-function block and
pressure compensator valve to control the motor
displacement.
Service procedures for these components are in-
cluded in the “M ulti-function Block” section of this
manual.
51000035
Fig. 50-142 - PC Re gulator Components
A valve sleeve bore plug is installed in the motor end

cap in pl ace of the v alve spool sleeve. Remove the
plug from the v alve sleeve bore in the end c ap. (An 8
mm threaded hole is provided in the pl ug for a puller
screw.) Remove the O-ring from the pl ug.
A single servo dr ain orifice is inst alled in the v alve
sleeve bore plug. This orifice limits oil flow from the
maximum displacement end of the servo piston to the
motor case.
51000169 51000173
Fig. 50-143 - Remove Fig. 50-144 - Servo Install a new O-ring on the v alve sleeve bore plug.
Valve Sleeve Bore Drain Orifice (T7) Install the bore plug into the end c ap.
Plug
The special plug and seal washer on the end c ap
opposite the m ulti-function block may be removed
with a 13 mm hex wrench. When inst alling, torq ue this
plug to 20 Nm (15 ft•l bsf).
76 50 - 26
806 BOMAG 008 911 63


saue
Control Orifices
Orifices are installed in the motor end c ap to regulate
oil flow to the servo control v alve and the servo piston.
To gain access to these orifice pl ugs, remove the
three (3) plugs located on the motor end c ap nearest
the multi-function block or control, using a 7⁄16" or
9⁄16" hex wrench. Remove the orifice pl ugs (plain
plugs for N2 control) with a 3 mm internal hex wrench.
51000154 51000155
Install the orifice pl ugs, and torque to 4 Nm (35 Fig. 50-145 - Servo Fig. 50-146 - Servo
in•lbsf). Torque the 5⁄16" o uter plugs to 9 Nm (7 Pressure Supply Orifice for Maximum
ft•lbsf), and the 9⁄16" o uter plug to 37 Nm (27 ft•l bsf). Orifice (T1) Displacement (T2)
Orifices are also installed in the servo control v alve
sleeve to control oil flow from the servo piston to the
motor case.
51000156 51000157
Fig. 50-147 - Servo Fig. 50-148 - Servo
Orifice for Minimum Drain Orifices (T7
Displacement (T3) and T8)
Plug / Fitting Torques
If any plugs or fittings are removed from the unit
during servicing, they sho uld be torqued as indicated
in the accompanying table.
Item Torque
Pressure Gauge Ports 37 Nm
(9/16—18 O-Ring Hex) (27 ft•l bsf)
Construction Plugs 20 Nm
(9/16—18 O-Ring Int. Hex) (15 ft•l bsf)
Construction Plugs 9 Nm
(5/16—24 O-Ring) (7 ft•l bsf)
Screw Plugs 4 Nm
(M6 Int. Hex) (35 in•l bsf)
50 - 27 77
008 911 63 BOMAG 807

Series 51 MV
saue a
Genuine
Service Parts
Sheet 1 of 2

4-Way Valve and Feedback Springs
0
7
s )
l s S
o e
r z 0
1 3
t i J 3 e
n S 0 F s e v
o e 3 2 g e
C m J 3 n l
i
l a F r
- s
a
n F r O e
o
i ] 0 l l v
t s l
r C 0 5 0 7 ) e t
l
a
a v
o H 2 1 S n
i o s n
p t S •
f h s I n o
o p —
r 0 7 h s
P e 1 T c b
l d w
J n e e
r c x 0
6 0
3 e 8 d r
o E 1 r 1 a c
D F [ ( J : ( e s
N t . 8 8 w r r
A n D N 0
2 0 T T x m
e N
h
t l e
l
E e m A S 1
S
d h
n . 2 m u
p
V t a t m r
L s S n
7 i t o o
A j u G 5 f
V d N I 0 T m e
L a R 2 s m u
q
O v e P S m 5 r
R r S e . o
t
e 0 I 2 T
T s 2
N e G N 0 J
1
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C D p L ; ) n 0
o L
L E t A l s ) s h
c i • ! J
3
I y T
T V l o e
r z n f s 2 s ]
N O b S t i : e
r b
l 3 l 2
n S 3 o
U M m N
I o e T w 4 2 T
F ! r N
t
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E E s E E l d x
m n e (
4 m 2 n t
p
s R V a a
V R a e 3
t o e
r a h m I F C c
O E n O L n o ] F 2 , l
a N g m x
n E
M R a F A i n n t o [
E A s E V t r C 0
1 T r 5
, t
i
v I e i
t
i
R S a B L o H
p t 1 1 e o
t o g s
L O
T G e L R r o p — T n e i m l
e n
i o
P !
T
O N v A T P e s
c 0 m q m u r l -
N I o
R m T N r x 6 e m r E t
a 2
r , N
O P e S o E o s S E
N O F ( t
[ 0 I 3 T n
R i o
F L M
D S R I C O T
F R t O
) S
E E • R
f
f T U
0 B T
F s N J D
5 1 A l
b
O A
J T 1 w h 6
m T e r c n m h . C B
e g s r c e N n t R c 6
( N
t
I m O U
l 1 3 n r e m n I T
T T e e i
t
v I r o w 0
2 ) w N e
r T S
- t s x m I
a
n h
r l O
o l e o t S I
0 e c a l j u h t f • x 9 t s O D
4 t n m t l d e f e o j
J n e
i r e s a a m s h t u
P
- T
R I n t s n m r q l m u
u b
e d a 2 O
0 m w n o 3 o 5 m q r R N
6 m x I 1 r e O
J e 1 T ( 0 o t f O
0 4 h 1 T a F D
7
J
78
808 BOMAG 008 911 63

Series 51 MV
saue a
Genuine
Service Parts Sheet 2

4-Way Valve and Feedback Springs - HC Control
s 3
e
z 3
i F e
S s v e
e 0 2 g e
7 3 n l
i
m S F r
- s
r
a
T O e
v
F 0 l l
l
0 1 a
a v
) . 5
2 S ) s t s
0 n
i e n n
l
1 — 0 7
h
•
f o I o
1 1 T s
c b h s
0 S 0 n l d w
— 6 7 e r
0 1 S
T
e 8
r 1 d e
r 0 : w (
8 8 a c
6 o T 1 T T x m e s
D 0 F 1 r r
N ( 1 S e N h
t l e
l
A t n D
N S 0
1
d h
n . 2
E e S a t m u
p
V t m A 0 T 7 n t
i o m r
L s S 2 1 T m e 5 f o
A j u G 1 s m u
V d I N S q
S m 5 r
L a R e . o
t
O e P I 2 T
R v r S 0
T e 2
N s G
e I
N s S
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C D p L
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h n
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t
I E y A S c i •
f !
T V l T e : n e s 2
N O S
b m 3 r l
b
2 3
U M e m N
I ! a T w 4 T F !
r 4
F d x m 2
E E s E E
s R V
V R a n e (
0 a e 3
t
1 , h m I F
O E n O L 1 2 l a N g m
M R a F A n 5 n t
i e
E A s E V — T r
, t
e o v I
R S a B L 0 1 i t o g
T G e L L
O 6 T n e m i
e l n
l
N v A R
O I 0 s m u r
N R o T r m q
o e m r E t
a
m T N F t o s
O P e S N O I 3 T n
R i
D S R I C O
F R )
t
f
E E
T •
f
0 B s
4 1 F l
b
S T A
1 w h 6
m T r e c n m h .
6
e c e c ( t .
t
1 3 I m g s r N n
l e n r w
o x 0 r m n
e
a
n
T T e I i
v t
l
r t
- 2 ) w N e m
0 r h o l s e o f t x 9 t
6 e c a O u h t • s
t m t l j e f e o j
S n n
i e
r e s l d
a a m
s h t u
n t
R I s n m r l m u
u b
q e d
0 m w n
I o 3 o 1 m r 5
a
q r
3 m x e
S e 1 T ( 0 o f t
0 4 h 1 T a
5
S
79
008 911 63 BOMAG 809

saue
SAUER-SUNDSTRAND Hydraulic Power Sy stems - Market Leader s Worldwide

SAUER-SUNDSTRAND is a world leader in the design SAUER-SUNDSTRAND specializes in integrating a f ull
and man u fact ure of Hydraulic Power Systems. Research range of system components to provide vehicle
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products through an extensive network of Authorized Service Centers
strategically located in all parts of the world.

saue 2800 East 13th Street • Ames IA 50010 • U.S.A.
Phone: (515) 239-6000 • FAX: (515) 239-6618
TWX: 9105201150
Postfach 2460 • D-24531 Ne umünster
Krokamp 35 • D-24539 Ne umünster • Germany
Phone: (04321) 871-0 • FAX: (04321) 871 122
SM-VMV51E • 11/97 • 300 043A
BLN-10043 • November 1997
810 BOMAG 008 911 63

17.6 Axle
008 911 63 BOMAG 811

17.6 Axle
Bild 35
812 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 813

17.6 Axle
814 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 815

17.6 Axle
816 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 817

17.6 Axle
818 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 819

17.6 Axle
820 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 821

17.6 Axle
822 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 823

17.6 Axle
824 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 825

17.6 Axle
826 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 827

17.6 Axle
828 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 829

17.6 Axle
830 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 831

17.6 Axle
832 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 833

17.6 Axle
834 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 835

17.6 Axle
836 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 837

17.6 Axle
838 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 839

17.6 Axle
840 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 841

17.6 Axle
842 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 843

17.6 Axle
844 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 845

17.6 Axle
846 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 847

17.6 Axle
848 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 849

17.6 Axle
850 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 851

17.6 Axle
852 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 853

17.6 Axle
854 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 855

17.6 Axle
856 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 857

17.6 Axle
858 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 859

17.6 Axle
860 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 861

17.6 Axle
862 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 863

17.6 Axle
864 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 865

17.6 Axle
866 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 867

17.6 Axle
868 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 869

17.6 Axle
870 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 871

17.6 Axle
872 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 873

17.6 Axle
874 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 875

17.6 Axle
876 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 877

17.6 Axle
878 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 879

17.6 Axle
880 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 881

17.6 Axle
882 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 883

17.6 Axle
884 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 885

17.6 Axle
886 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 887

17.6 Axle
888 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 889

17.6 Axle
890 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 891

17.6 Axle
892 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 893

17.6 Axle
894 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 895

17.6 Axle
896 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 897

17.6 Axle
898 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 899

17.6 Axle
900 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 901

17.6 Axle
902 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 903

17.6 Axle
904 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 905

17.6 Axle
906 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 907

17.6 Axle
908 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 909

17.6 Axle
910 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 911

17.6 Axle
912 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 913

17.6 Axle
914 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 915

17.6 Axle
916 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 917

17.6 Axle
918 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 919

17.6 Axle
920 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 921

17.6 Axle
922 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 923

17.6 Axle
924 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 925

17.6 Axle
926 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 927

17.6 Axle
928 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 929

17.6 Axle
930 BOMAG 008 911 63

Axle 17.6
008 911 63 BOMAG 931

17.6 Axle
932 BOMAG 008 911 63

18 Circuit diagrams
008 911 63 BOMAG 933

934 BOMAG 008 911 63

18.1 Hydraulic diagram 581 202 10

58120210
008 911 63 BOMAG 935

936 BOMAG 008 911 63

Hydraulic diagram 581 202 10 18.1
008 911 63 BOMAG 937

938 BOMAG 008 911 63


58120210
008 911 63 BOMAG 939

940 BOMAG 008 911 63

Hydraulic diagram 581 202 11 18.2
008 911 63 BOMAG 941

942 BOMAG 008 911 63

18.3 Wiring diagram 582 702 09
008 911 63 BOMAG 943

Wiring diagram 582 702 09
Design status: December 2006 to June 2007
944 BOMAG 008 911 63

Wiring diagram 582 702 09 18.3
9
0 1
0
2 0
0
r
e
t
e 7
m 2
o
d 8
e
e
p
s
r
e
t 5
, a
e
n
r h
o M p d h . 1
h C a d 0
g B g r a 0
d i n t ,
e n . n h o g
r r
e a e c i n
p r i
o v . m a n
b
s w , t e t o
i
− . a , m g o , t
e t
n n c h
i c i p a
n O d i i d 1
0
i o d i t a Z a o
n 0
g c n w u q M v r c
n e i s e S s t , r
e g , − t n t i
t , n r m t n i o d
i a a e e t n g r
h a
n l i ,
a
l
u f a s m c a l e g
− , r e a n d t t n
i
m g n i g p s p i o a a
s
t a i
r t n u e u m t e e l i
i
n r t
g a k g s o a h h t
, − n
a t e c n e C
i
a a n n
i n e
u
D s h r
a a
m i i
n
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y
b b b n
u a a o
i i n e d n A l
t
c u p i
c p g k e i o M i . t
c c p
. t . m
n r
i a e t t
u n r p p O p p p o
f
u
C s e b s o B o o o c
.
z
n
A
−
t g
n m
i n l
a
e p r
a
k
g
i h i
u
z
e
f g
d
n
p h i
u a
l
i r t
a
z
g a
a
d
w
h
M o
s m t
i
l c e i n C B h o u
s
h e i o
g t t a , c u
Z r
t c
z G
a e a
r
n T e
e , S i r
h n
e r A
z
, n i
b
m i g
o a c
r e d l
d
r l o .
h r , V , a
. g a a n
o
t a i h n
n c a Z , O R a
o n e t s v g l
t m
i
0 0 g
M i r k n M n
S u K
4 4 , a t
n S ,
a n d h
o
t ,
− − e e h r
t
r c h k
w o n t i n c g n
c u u u
D
/ D / p a s a z k a g l
t i e z
4 4 p n S
n f
a k
i n p n e i
t e
l
a , f c
S
− − r , h m t B h
u u
l z ü n c o , n e
D
g p g n i e C h 5 5
D
c e e t
s n
o
f
u u
a g
e R , e t
f s
H e u s G l n
u i n l
i
e b i s
l
0 0
0 0
9 i l r − i 2
. 2
9
1 1 k t
m o r s t s e A e b
a a e .
2 2 n o s t
r o m h r M M B K K t 1 t 1
1 s
. . r e o r e a A O A A A a u
. g 1
. i
. . u t 6 o 6 e
7 7 F S V M B F Z B Z Z Z B 1 V 1 S
7 7 r
1 1 e
W W m
B B m u .
n o 0 0 0 0 0 0 0 0 0 0 0
9 9 9 9 9 9 9 9 9 9 9
s n 2 2 2 2 2 2 2 2 2 2 2
g − 0 0 0 0 0 0 0 0 0 0 0
n
: g 7 7 7 7 7 7 7 7 7 7 7
u
n i
n 2 2 2 2 2 2 2 2 2 2 2
s : h
i 8 8 8 8 8 8 8 8 8 8 8
n t e w
s c a
i
r
5 5 5 5 5 5 5 5 5 5 5
h n Z d
c t
i e
e
z n
r o c
e
v f : . : .
s o r o
t
l n 1 2 3 4 5 6 7 8 0 1
e N
l
a t t 0 0 0 0 0 0 0 0 0 1 0
e 0 0 0 0 0 0 0 0 0 0 1
9

h b t
l e
n
I t a B h
a
s
008 911 63 BOMAG 945

1
: 1 2
: : 9
:
9
6 : 9 5 5 1
3 : 2
0 7 3 0
1 9 0
3 8
/
1
6 2
8 : 2
: 4 : 0
1 2 1 1
A 3
0 K F 0
1
3 2
K E 9 A
0 S ? ? 0
3
: F
5
3 1 3
:
1 7
1 1 2 X 5 : 6 1
3
2
3 2
X 8
a 1 2 2 5
7 5 : 4 1 1 5
0 8 A 1
: a
7 g f
3 E 7 1 0 8 f
7 2 1 2 t
u
l o
2 1 2 2 2 X 3 4 5 t
a
1 7 1 1 5 1 2 5 h u
1
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s h
K 0 X 4 5 A X 5 2 9 7 1 1 A 8 . 3 s
l
1 1 1
s t u o h t i w 1 2 : 8 b
: F : X X f e
a
2 1 p K 4 f
o f
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o
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c −
t a e
s h
c t i w
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a
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l .
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0 0 a 0 1
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b o
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1 0 Y H
K 4 5 6
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1
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5
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1
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2 2 8 8 8
1
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1 6
1 1 K 1
1 :
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a
3
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5
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0 2
S K r t s
1
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d e e p
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i g n e h c t i w s A . 3
2
9
0 m
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l z h e
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M r e t l a h
c
S
3 r t r
5
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2
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a
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5 3
9
X 7 X 0
5 d −
0 7 B
: 5 7 1 −
r r
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3 1 7 r e
t o i
A
0 1
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K 9
3 : 8
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1
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X K 4 0
3
t
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1
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2
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5
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1
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8
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5 1 5
1 X 5
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1 g t r
1
5 1 0 5 : K X 8 n a
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1
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6 5
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1 2 1 E K :
6 4
1
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+ W
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2 1 6
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:
+ V 2 5 + 1
B 6 5 1 6 D
8 8 W X r r
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n
8
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+ 2 B
B 0
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2 1 r r
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e
s u f n i a m
: 1
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t e 0
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9
1
g
n r e h
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a 1 −
1
3
0
0
A
5
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0
a a
B b
1 V 1 S
A
: 6
3
X F G
e y
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n o
n o
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O i
r e r
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t t e
t
a a i y
b r r
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g n
i t a e
h
c i S 2 1
a
+ − 1 2 B e t

t e
r h c t t
e i
h
c s n l f z i e
H g n r e h
3 t
a u
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l a a
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4
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b
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s
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3
( 4
( e b
r h n
0 7 1 2 T s l
c f a
3 8 n g −
l i n
A
7
6 1
4 9
a
f
1 5 1 z t
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K : R 1 e a
e
3 3 H h
n o
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r e h t o , n o
i s
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v A
S
U 0
4 −
D d
n a 4
−
D 9 1
2 W
B t a y l n o
n o
i t p
O t s n o s , n o i s
r e
V A
S
U 0
4 −
D d n
u 4
−
D 1
9 2 W
B i e r u n
b
946 BOMAG 008 911 63


3
1
: 1
: 0
9 0
4 4 0
7 e 1
3 2
8 g 0
r e t e m o d e e
p s
/ i
1
1
. z n s t i e
a k g
i d
n i w
h
c s e
G e
z e r 7
K n t 2
a e
s
t 8
2
9 + − 3
9
i
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k d
1 1 g
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X X d e
4 n p
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0 w n
P h
c o 1
s i
t
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G o
A
+
T
U
O −
T
U
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: 2
2 : 6
:
t s e
T
5 − 6 6 9
1
r e L 0 X
A X S C
S A
n
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4 5
/ 5 1 ni M M D
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I D E
E E
0 D E P
1
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4 e
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F G p g r
l s o g
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2 h o
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M o 1
: : T t a
m 1 d 1 d d
X e X n
u n
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r e a
r
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d s s e e
h l z e
+ − c x n m
A a A d o
1 4 r r
e − . e
7 7 o d
s w e
1
: 1
: n n h p
1 0 1 e e c s
X 6
B X S s s .
e u
,
G q
k , e
i −
t . r
n n
h z e
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s r e A e m
1
N
S e n h
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D 1
1 2
W
B
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D t a t o
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s − o
t
i
M a e e d
k e
1
N
S e n
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D
1 1 2
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B
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D i e
b t h
c i n
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Z
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V22 b o
r t n s
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n
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n l y w n r
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c o
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1 1 h n
l i e g
1 1
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2 . 4
B X S w

r
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l ,
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n t
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8 2 9

n
5 3
2
4
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1 1 g o
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1 1 1 2 1 X n r
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:
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8 1 A 1 X 7 X 1 o h
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2 2 8 X
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1
4
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1 1 l g
a n
i
h
c n
1 1 1 1 1 2 n n s l
1 g r
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A
2 . 4
X 3 0 X X X B S a n f
−
A
n
r o
h g n
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r a
w . t u
b h
s u p
2 1 w l g
a
F f
n
r o h
l a n g
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r e t s a
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3 z i
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0
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H a
e
− h
r
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t
o i n
M n g
e
n o
i t p o e s i w
r e h
t o , n o i s
r e
v A
S
U 0 4 −
D d
n a 4
−
D 9 1
2 W
B t a y l n o
n o i t p
O t s n o s , n o i s
r e
V A
S
U 0 4 −
D d
n
u 4 −
D 9 1
2 W
B i e r u
b N
e
a r a −
e n
i g n e n i d e
l b m e s s a
9
1
h
c i e r e r o
t o
M m i u n
A
:
b a
b
4
H
Ü
L
G 1 2
4 5 5
e
a r a − e
n i g
n e n
i d
e
l b m e
s s a 1 0 0
h
c i e r e r o t o
M m
i u n
A K 0 0
2
. 2
b a
b
8 5 .
7 7
e g
n l f − g n i t a e
h s i a
l e
r
r 1 t 1 s
. g 1
1 . i
a
1 1 1 6

h c s n l f z i e
a H s i a
l e R
t r
u e 6 o 6 e
X X r
a u 1 V 1 S
4 e t r
7 1 2 6 p a
m e
4 1 e p
t
l
X 7 m
3 1 1
B
2 e e
t
5 i t
t t
m
l l n
2 5 3 1 h l a
5 X ü o
3 K c
1 1
X l o
r t n o c − e
g n l A
a f −
g n i t a e
h l u d o
m
7
g
n r e e
t s h c s n l f z i e H l u d o
M
6 7
u u a
8
/ 8
: 8
/
1 1 5
1 1 0 1
K K K 3
0 0 3 0
2
: 1
: 1
: 2
:
2 2 2 2
008 911 63 BOMAG 947

6 7 7 4

5
: 1
: 1
: 1
: 9
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1 3 8 8 8 5 2 8 1 D 4 i 0
: 1 0 : 0
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h
9
0
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8
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r
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d
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1
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r
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e
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7 : B M n u t
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i s 1 0 1 1 e r e e
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1
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f
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n
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a
1
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s u
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r
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w
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m
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9 8
:
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2 1
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r
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t
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5
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t d
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e 0 0
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a
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: 9 X s 2 .
3 4 2 5 .
1 t 1
1
s
i
1
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6 a
3 7 A 6 6 o 6 S
7 K 7 8 7 8 1 V 1
8 : 8
: /
2 8 8
0 4 4
3 K 6 5
K 8 8
8 a
4 7 5
A
m
5
2 1
K 2 8 0
: K
4 8 1
4 1
n o
i t i s o p −
" 0
" r e v e
l l e v a
r t h
c t i w
s y t i m
i x o
r p 1
: :
E A 0
" l e e
b h
r a
F r o
t a
i t i n
I 1 6 5 2
2 1 2 1 2 X 8 8
9 9
2
1 1 6 2 N K 2 8
A
m 2 1
5
X 5 A X 5 1 B B 1 4
2 1
0
1 X / / X K
7 F : R W 3
8 1 B S 3 :
/ X 4
1 2
1
) n
i e e
s m
e
r B
( n o
i t i s o
P
K 0 n i t e
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B
1
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9
3
1 / 1
:
0 B L 1 0
2 B X 2
: :
3 3
948 BOMAG 008 911 63


5
1
: 1
: 0
9 0
8 6 0
7
t c a t n o
c − t a e
s h
c t i w
s t u o h
t i w 1
3 2
8
/ 0
7
r e t l a h
c s t k a t n o
k
z t i S e n
h o r u
N
1
1
K 2
n
o
i t a
r b
i v l u d o m
n
o i t a
r b
i V l u d o M
8
1
5
6 3 b
6
4 1 : 1
9 X
5 5
0 2
: 2
: 1
1 2 3 S 6 6
E X X
2 3 A A
2 4 S S
3
: 0 3 0 E E
1 F 5 :
1 1 K M M
X X A A
G K 1
G 6 : 9
A
K 7 : 9
A l .
l . n p
i
t p e m
l
c 0 b m
ß a k a
l
r a
e t 6 o g
r e l
t
l n 1
: i
g b n a
r m
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A
3
3 . 3
h c 5 3

1 1 X n /
i l v s
c −
t
s a 1 2 e
l
l
a n i n
o
t
k e 5 7 8 7 k m o
i t
1 X 0 X . t
9
a s
5 Y n s a r
a
t
n h
1
: 1
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i r b
c 1 1 t o r
i o p b
i i
o
k t
i X 3 4 X r a g a V v
t
a m
z w
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i b
b
e g
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S t
t h
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: r v r o b
i 1 e h v n
A
3
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t
l
m w X 1 2 8 c n i
t
i o
y
r l o t
a
X h i
u n
6 6 7 6 c w t r
1 1
: 1 a
N o 0
1 X Y X S s i
1 r b
a
:
1 i v
b
5 X V

3
5 4 S 3
1 1 1 1 n 2
7 1 o
i t a
r b
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s u p 1 4 1 : 1
X
5 1 1
b 9
n i n : X 3

1 n o
i t a
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r e
t s a
T X
o t o 1
i
t 1 S
a r
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i i
b
v
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V 5 4 4
t n o
c −
t a e
s h
c t i w
s 4
5 1 : 1
X
4 / h
a
1 r t c 1 1 8

k z t i S 1
: X X
r e t l a h
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t
l 5
+
D
w 1 S
a s
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c a n r .
s e o b
i
4 1 : 1
X
3 z s
9
1 t
i
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l t i
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k
c u
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u
u
d o
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b
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t
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n
e
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a
8
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t −
1 4 k a
a e
t
n s ,
o
k s
z e
1 1
. 5 t
i g
n
9
6 0 N 0
1 8 2
: / 1 V R 2 V S a
+ 6 4
:
8 4 2
: 2 6
/ A , r
D 0 1 1 A
0 7
8
6 W n −
B K F S / 8 A Z e d
f
T
I e
3 7
6
0 2 S 0 t
u
e
1 1 3
: 0
2 2 8
: K :
9
1 1 s
r p
h s
: : 4 : : :
4 4 2 2 4 4 4
a
3
4
1
4
4
2
F
1
: 1
: 1
: n
1 1 1 e
t
X X A 3 2 . 1 1 2 X e
n l
1 i x
3 h a
2 Y g g
n n
2 3 t i
u
A A 6 0 l h
V 1 a c
S S 1
: h t
i
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s
0 0 3 X s
4 4 2 7 m
− − u
n
D
/ D 5 e n
r
n / s 1 1
2
f o
v
e e 0 t
u
m
n i
i n 4 V 2 4 S g u
h h s 4 4 2 n r
1 2 1 1
c
s s
c e :
1
:
1
:
1 l d
t
u
4 g 2 a g
a a
3 . n X X A 3 2 . 1 1 X h n
i
M m h
c r
a c h
− − 2 s 0 n s c
D D 1 n d e
3
Y 4 4 − o
r m t
i
e e − D u w
r d
d r f
u p D
v
9 g n s
t s e
1 1 f
a a
d d 2 s 9
n
n n 4
S
r
h h c 7 8 2 2 + t
u
l m t
u
t t
a a
t
i 3 3 + 6 a u S
S S a
F w 1 1 6 1 h r
: : 1 c d
s 1 2 1 2 2 s g
X 1 X W W m n
i 5 5
B B h
u
y n t c 0 0
r l e i 0 0
u n f 2
. 2 .
n o t u w 1 t 1 t
S s . g 1
1 . g
6 o 6 o
1 V 1 V
4 4
− − 3 1 4 n
D D 4 4 2 e
t
7 7 1
: 1
: 1
: n e
7 7 3 4 1 1 1 i
1 1 1 1 X X A 3 2 . 1 1 2 X h l x
. a
W W 1 h
B
B /
/ 3 c g
0
0 4 Y s n
i
4 − 2 m h
− 4 u c
D D S t
n i
7 r l
y
s e
g n r d
a e e p
s h c t i w s e w
f
8 u s
/ u n
n o
n
e f u t s
r h F r e t l a h
a c
S t
1 S
1
K 2 1
: 3
5
0 2 0
2
: F 8
: 2
:
4 4 4
008 911 63 BOMAG 949

6
0
f o
r p M
T
B
/ +
M
T
B t a y l n o
1
: 9 0
7 0
f o
r p M
T
B
/ +
M
T
B i e r u n
b
P
O P 1
3 2
B O 0
k B
i
n . 7
h
c m
5
1
5
1 2
e e
r 1
: 9
4
3
: E
: : : 8
t
s u
s
s a
8 :
2
2
4
6
4 : 5
F : 1
5
:
7 7 5
e e 0 X X X 6 2 2 − +
3 4 4 X 3 3
X X
− 1
N
A
C
M m 8 2 A
6
2 : 4 4
X
N N
y y 4 : : A A
l : 2 6 C C
p l 2 4
a a
p 4 −
s
i s X X X 3
N 1
i A
D d : 4
D : C
7 1 6 2
3 3
: 4
4
X
4 : B
: 4 4 2 M
: 2 3
2 4 6
4 3 X X 0 H
2 O
X X X P
R 0
M
E
B t a y l n o 1 6
M
E
B i e r u n −
b 1
N X 3 5
+ 1
N
A
C : 4
4
X
A
7
2 : 4 4
A A − C +
S S 0 3
F F 2 5
: N
A
M M F 2 C
B B X
y +
e a N
g l
i 1 A
e p
s F C
z i
n
A D +
r r
6 e e
t
1
P e t
e M
E E
M
0 + B
I − M m B B
7 − − i t
3 : 4 4
X
: 2 5 V
E B
I I e a
B b
2 : 6 5 2
B
I V
E
X 4 B
: : 8
: 8
: V V y
r l
7 4 2 D 1 7 1 E E u n
r r
e t D
E
: 4
X 4 : 4 7
X X X X x
T X 0
P X n o
e
5 : 4
4
X
k
c i
n
N
G
u r
r
D X
: 4 5 : 4 7
X 8 6
: 4 4
X
D p
4 : 4 4
X
6
6
:
C
: 4
X 3 : 4 7
X
1 4 D
6
: 6
: A x
2 : 6
R
7
6 : 4 4
X
4 4 :
X 1
1 7 X 2
X 2
P X 6
6 : 4 4
X X
1
7
f o
r p M
T
B t a y l n o
:
2 f o
r p M
T
B i e r u n
b
3
X 6
5
6 : 4 4
X
:
2
1
: 4
4
X
X
S
E
M
D
N
G
A
5
5 : 4 4
X X
2
D
N
G
5
:
2
X
.
m
p
i
u
k q
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n t
n h
c n
e
r
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t
s
n s m
s e
e
s r
s e r
u
g a
n r e r b
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0 2 g 0
2 n
e t n
i h . n
f u
A M s
a
u r
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w
s
/ +
g o
7 : 4
4
X
i Z m
n s 7 1
u n : 4
: 9
e e 5 5
l s : 9 2
2 4 6 g
:
2
9 n
h
c
s c
. X X B g l 4 X
X o
i
t
e c / /
b
− g
5
g 5
1 n
e t n
i h . n
f u
A
p
B a o
D
N
G
1 0 3
: 4
4
X
0 2 3 8
: 5
: :
9
6 : 4
:
n 2 9
4
9
4 2 2
e
r X X X X X
o t
s
n o n w
s
/ + r b
/ g
0 2 g
0
2 e n
r o
v . n
f u
A
r
e f 1 3 : 4 4
X
s
s r
g s o 3 1
: : 5
4
n 5
: 8 2 8 5
:
u n 2 4 6 g 4 2
1 4
: 4
4
X
g e
i X X B g l X X
n s
0 5
3 1
. t t / /
b
u c
o
P
o
P − g g
5
1 e n
r o
v . n
f u
A
e c
l a 5 8 3
: 4
4
X
h 1 2 : 4 4
9 X
c
s 6 2 3
e 5 : : 4
: 8 8 5
:
7 3
: 4
4
X
B 2 4 4 2
X X X X
6 3
: 4
4
X
2 3
: 4
4
X
4 1
: 4
4
X
1 2 1 2
3 3 4
5 : 4
4
X
5 6 E A
k i n o
r t k e
l E
4 1 4 4 4 X 5 3
: 4
4
X
1 0 1 3 4 0 6
: 4
4
: : : 8 A 3
:
1 S 8 1 1 F 0
1 1
X 1 X X X
:
5
9 : 4
4
X 5 1
: 4
4
X
2
8 5 : 4 4
X 8 3 5 5
: 4
4
X 0 0
0 0
2
. 2 .
1 t 1 s
7 5
: 4 4
X
. g 1
1 . i
1 2 6 o 6 e
1 V 1 S
6 5
: 4
4
X
t
r i
E A n
g
n u
t s i e
L
5 6 5 e u
3
: 4 A 3 5 n .
1 1 1
5 : 1
: h c
c l
1 7
X F X e a
c
R t
2
: − n
k
8 i e
4 n m
1 h
c e X X
F e r S X
3 t
s s X E E
u S S
E X
8 s a S X M X
S M M X S
A e e E S
1 2 M m M E D E E S E
7
8 2 : 4 4
X M E M H K E M
8
/ C A M
A A E R T L
E A 7 G K P I I R + E
5
1 . t o
P
0 1 3 8 3 5 B 1
3 1 3 A 3
: 4 0 : S D P B D 3
K 1 1 1 : 2
1 X
0 0 X F X 7 7 6 6
2
: 1
: 1
: 1
: 1 : 6
5 : : 0
4
2
2
:
8
:
5 5 3 3 4 2 8 2
:
5
950 BOMAG 008 911 63


7
1
: 0
9 0
8 0
1
3 2
0
7
2
8
5
0 3
7
: G
: : 6
F :
2 4 4 2 1
X X X X
1
: 2
6 :
7 6
7
X X 1
2
−
3
6
: M
:
N 2 4
A
C X X
2
: 5
2 M 2 M 5 0 M M
4 H 5 H
2 O 7 C C
2 O X M B B
R 0 R 0 C i
2 2 B e t a
1 1 1 1 y
b
r l
2
: − + M u n
3 3 n o
8
4 N N + 1
6 7
: . C
t B
1 A A 3 : N
: 5 s 5
F C C
N
2 4 7 t e
7 t c 1
8 i
A
C X X X n f
a P
2 8 8 A h r
c t
: 1
: 1
: e
6 6 6 S I
n
N N
A A
C
− C
−
B B
S S
U U
M M
C C
B B
t t
n n
e e
m m
e e
g g
a a
n n
a a
M M
n n
o i
i
t o
c t c
a a
p p
m m
o o
C C
G G
A A
M M
O O
B B
5 5
0 0
0 0
2
. 2 .
1 t 1 s
. g 1
1 . i
6 o 6 e
1 V 1 S
1
3
0
2
:
6
008 911 63 BOMAG 951

H 8
2 1
: R R 0
: H 9 0
6
r r
9
r
e a
t
, 0
7 0 e t
k o
A
5 7
, 1
1 h
c r e 2
8 3
/ n a
i X 1
1
2 2 X 3 u r 0
1
1
l
B i
c 2
2 3 : 1
X 1 : 1
6
1
: 1
6 X 4 2 3 : 1
e
l t o H 7
K r d
n E k
n i
a
R
V R 2
e i
t
l
i
l c
e t
,
8
h
a c
B d n
i
t
h
n
o 5
h t
i c f r
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952 BOMAG 008 911 63


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954 BOMAG 008 911 63


Name Bl. Pf. Benenn ung title TYP
005 4 MAX. 1,67A

A02 008 17 Blinkrelais indicator relay
A05 003 17 Elektronik Geschwindigkeitsanzeige Electronic system, speedometer MODUL
A12 009 5 Radio Radio
A13 003 3 Ste uergeraet Heizung Control unit, heating
A15 004 16 Ueberwachungsmodul monitoring module
A16 009 7 Elektronik Tachograph Electronic system, tachograph
A51 009 6 Platine Frequenzanzeige Circuit board,frequenzy meter
A68 005 10 Mod ul Sitzkontakt Modul seat contact MAX. 0,12A
A72 010 11 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A83 006 6 Elektronik Messtechnik electronic me asurement−equipment
A87 007 15 USB−CAN Schnittstelle BCM USB−CAN Interface BCM
S 1 V 1
e 6 o 6
i .1 g .1
s
1 t 1 B03 004 15 Unterdr uckschalter Luftfilter Vacuum switch, air cleaner
.2 .2
0 0
B06 004 17 Druckschalter Motoroel Pressure switch, engine oil
0 0 B11 003 9 Signalhorn Warning horn MAX.5A
5 5
B11 003 11 Sign alhorn Warning horn MAX.5A
B13 004 2 Naeherungsinitiator Fahrhebel links Proximity switch, travel lever, lh.
B14 004 6 Naeherungsinitiator Fahrhebel rechts Proximity switch, travel lever, rh.
B21 004 14 Differenzdruckschalter Hydr.−Oelfilter Pressure diff. switch, hydr. oil filter
B30 004 16 Temper aturschalter Motoroel Temperature switch, engine oil
B51 009 5 Lautsprecher Radio Speaker radio
B55 004 17 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B60 003 14 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 006 12 Aufnehmer Verstellzylinder Sensor, a justable zylinder
B62 006 8 Beschle unigungsaufnehmer Acceleration sensor
B62 006 10 Beschle unigungsaufnehmer Acceleration sensor
B103 010 7 Temper aturschalter Klimaanlage Temperature switch, air conditioning
B104 010 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B113 003 3 EMR Temper aturgeber Kuehlmittel EMR Temper ature switch, collant
B124 004 19 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B131 010 10 Temper aturschalter Heizung Temperature switch, heating
E08 008 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
E09 008 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 008 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 008 19 Blinkleuchte hinten rechts Indic ator, rear, rh. MAX. 1,75A
E12 008 7 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 008 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 008 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
c E15 008 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
o E16 008 2 Scheinwerfer links Head light, lh. MAX. 4,6A
m
p B E17 008 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
o a E23 008 11 Ar beitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
n u
e t
e
E23 009 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
n i
l E25 008 12 Ar beitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
t l
i E25 009 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
l s
i
s t
e E27 008 10 Ar beitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
t
i
n E27 009 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
g E28 008 11 Ar beitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 009 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 009 4 Innenleuchte Kabine Inside light, cabin 1,75A
E30 010 13 Heizgeraet Heating unit
E32 009 19 Kennleuchte Warning light 5A
E70 009 15 Nachtleuchte Night lamp 0,83A
E71 009 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 009 16 Beleuchtung Bedienschalter illum. Switches
F00 002 4 Hauptsicherung Batterie Fuse, main, battery 125A

F03 005 18 Sicher ung Vibration Fuse, vibration MAX. 1,23A
F07 008 15 Sicher ung Warnblinker Fuse, hazard light 15A
F08 008 18 Sicher ung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 008 6 Sicher ung Park− u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 008 8 Sicher ung Park− u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 008 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 002 10 Sicherung Startschalter Fuse, starter switch 30A
F14 002 18 Sicherung Hubmagnet Motor Fuse, shut off solenoid, engine 15A
F15 010 18 Sicherung Heizgeraet Fuse, heating unit BOX2
F18 008 5 Vorsicher ung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
F19 008 12 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 30A
F22 008 10 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 30A
F23 003 9 Sicherung Signalhorn Fuse, warning horn 10A
F24 004 10 Sicherung Ueberwachungsmod ul Fuse, monitoring mod ule 10A
F25 004 2 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 10A
F31 010 3 Sicherung Kabinenluefter Fuse, cabin ventilator
F39 002 19 Hauptsicherung Kabine Main fuse, cab 15A
F40 010 13 Sicher ung Kabinenheizung Fuse, heating unit cab BOX2
F41 009 19 Sicherung Rundumkennleuchte Fuse, rotary beacon
F42 009 4 Sicherung Kabineninnenleuchte Fuse, inside light cab
1 F43 009 10 Sicherung Wischermotor hinten F use, wipermotor rear
F44 009 13 Sicherung Wischermotor vorn Fuse, wipermotor front
F48 002 3 Sicher ung Gluehanlage Fuse, glow plug system 125A
F84 006 5 Sicher ung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
FM4 006 11 Platinensicherung Multifuse
6 F105 002 16 Sicher ung Motordrehzahl Fuse, motor speed 20A
F130 009 15 Sicherung Nachtleuchte Fuse, night lamp
F143 009 2 Sicherung Heckscheibenheizung fuse rear screen heating unit
F144 009 20 Sicherung Kabinensteckdose Fuse cabin−socket
5 F146 006 4 Sicher ung Steuerung MESX (Potenti al 30) Fuse Controller (Pot. 30)
8 F148 006 2 Sicher ung Steuerung MESX (Potenti al 15) Fuse Controller (Pot. 15)
2
7
0 G01 002 4 Batterie Battery 103A
2
0
G02 002 5 Gener ator Generator
1 9 G03 002 3 Batterie Battery 103A
0
1
H06 008 15 Meldeleuchte Warnblinker Indicator light, hazard light
H07 004 10 Warnsummer Betriebsstoerung Warning buzzer, breakdown MAX. 0,12A
008 911 63 BOMAG 955


H14 004 8 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer MAX. 0,12A

K04 005 18 Schrittrelais Vibration Toggle relay, vibration MAX. 1,23A
K05 004 3 Rel ais Startstrom Relay, starting current BOSCHW
K06 008 4 Rel ais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 8 Relais Klimageraet Relay, air conditioning BOSCHW
K11 002 10 Rel ais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHW
K14 003 5 Relais Vorgluehen Relay, glow plug system BOSCHL
K16 008 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K22 004 9 Relais Hubmagnet Motor Rel ay, shut off solenoid, engine BOSCHW
K26 004 6 Rel ais Rueckfahrwarneinrichtung Relay, back up alarm BOSCHW
K32 009 2 Relais Kabine Relay, cabin BOSCHW
K35 002 16 Rel ais Selbsthaltung Relay, holding cont act BOSCHW
S 1 V 1
e 6 o 6 K36 002 7 Rel ais Bremskontrolle Relay, brake control BOSCHW
i .1 g .1
s
1 t 1 K48 004 2 Rel ais Fahrhebel 0−Stellung Relay, travel lever 0−position BOSCHW
.2 .2
0 0
K61 002 5 Rel ais Ladekontrolle Relay, charge control BOSCHW
0 0 K114 002 14 Rel ais Motordrehzahl Relay, engine rpm BOSCHW
5 5
K141 009 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW

M01 002 11 St arter Starter 2.3 KW
M04 009 13 Schei benwischermotor vorne Windscreen wiper motor, front 4,7A
M05 009 10 Schei benwischermotor hinten Windscreen wiper motor, re ar 2,9A
M06 009 14 Schei benwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 009 11 Schei benwaschermotor hinten Windscreen w asher motor, rear MAX. 3,8A
M09 010 3 Kabinenluefter Cabin ventilator
P04 003 19 Geschwindigkeitsanzeige Speedometer

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

R10 002 6 Parallelwiderstand Parallel resistor 82 OHM
R19 002 2 Heizflansch heater flange 167A
R20 006 17 Widerstand Resistor 60OHM
R24 007 15 Widerstand Resistor 120 OHM
R80 009 2 Heizung Heckscheibe heating rear screen
c
o S00 002 10 St artschalter Starter switch
m
p B S01 002 18 Sch alter NOT AUS Switch, emergency off
o a S03 003 9 Taster Signalhorn Push button, warning horn
n u
e t
e
S13 005 13 Vi brationsschalter Fahrhebel rechts Switch, vibration, travel lever, rh.
n i
l S14 008 15 Warnblinkschalter Switch, hazard light
t l
i S15 008 4 Bele uchtungsschalter StVZO Switch, lighting StVZO
l s
i
s t
e S20 009 13 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
t
i
n S21 009 10 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
g S28 010 17 Sch alter Kabinenheizung Switch, cabin heating
S30 002 3 Batterietrennschalter Switch, battery disconnect
S35 005 15 Vi brationsschalter klein/gross Switch, vibration low/high
S37 008 18 Sch alter Blinker Switch, indicator
S38 009 19 Schalter Kennleuchte Switch, warning light
S42 005 3 St ufenumschalter schnell−langsam Speed range selector, fast−slow
S42 005 7 St ufenumschalter schnell−langsam Speed r ange selector, fast−slow
S44 010 3 Sch alter Kabinenluefter Switch, cabin ventilator
S45 009 4 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 008 4 Sch alter Arbeitsbeleuchtung Switch, working lights
S58 005 13 Sch alter Aetherstartanlage Push button, ether st arting unit
S86 009 4 Schalter Tuer, links Switch door, lh.
S120 002 14 Sch alter Motordrehzahl Switch, engine speed
S158 009 15 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 009 16 Schalter Heckscheibenheizung switch rear screen heating unit
V01 002 6 Diode Diode 4UF004

V02 005 6 Diode Diode MAX. 1,23A
V04 010 8 Diode Diode FE5B
V06 010 9 Diode Diode
V47 002 15 Diode (A7) Diode (A7) FE5B

X1:1 002 5 WAGO,E−K asten WAGO,E−BOX
X1:2 008 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:3 002 9 WAGO,E−Kasten WAGO,E−BOX
2 X1:4 002 10 WAGO,E−K asten WAGO,E−BOX
2
2
0
1 9 X1:59 002 16 WAGO,E−K asten WAGO,E−BOX
0
956 BOMAG 008 911 63


X1:69 004 13 WAGO,E−KASTEN WAGO, E− box
S 1 V 1
e 6 o 6 X1:77 004 16 WAGO,E−KASTEN WAGO, E− box
i .1 g .1
s
1 t 1 X1:78 003 4 WAGO,E−K asten WAGO,E−BOX
.2 .2
0 0
5 5
c X1:109 004 12 WAGO,E−KASTEN WAGO, E− box
o X1:110 004 14 WAGO,E−KASTEN WAGO, E− box
m
p B X1:111 004 19 WAGO,E−Kasten WAGO,E−BOX
o a X1:112 004 20 WAGO,E−K asten WAGO,E−BOX
n u
e t
e
n i
l X1:114 004 8 WAGO,E−K asten WAGO,E−BOX
t l
i X1:115 005 16 WAGO,E−K asten WAGO,E−BOX
l s
i
s t
e X1:116 005 14 WAGO,E−K asten WAGO,E−BOX
t
i
n X1:117 004 5 WAGO,E−K asten WAGO,E−BOX
g X1:117 004 8 WAGO,E−K asten WAGO,E−BOX
X1:15A 002 10 WAGO,E−K asten WAGO,E−BOX
6 X1:15E 002 10 WAGO,E−K asten WAGO,E−BOX
5 X1:163 010 3 WAGO ZENTRALELEKTRIK WAGO E−BOX
2
2
0
0
008 911 63 BOMAG 957


X1:17E 002 16 WAGO,E−K asten WAGO,E−BOX
X1:18A 008 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:18E 008 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
S 1 V 1
e 6 o 6 X1:22E 008 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
i .1 g .1
s
1 t 1 X1:23A 008 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
.2 .2
0 0
0 0 X1:24A 008 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
5 5
X1:28A 003 9 WAGO,E−Kasten WAGO,E−BOX
X1:28E 003 9 WAGO,E−Kasten WAGO,E−BOX
c X1:313 008 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
o X1:314 008 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
m
p B X1:315 008 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
o a X1:315 008 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
n u
e t
e
n i
l X1:316 008 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
t l
i X1:316 008 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
l s
i
s t
e X1:316 008 19 WAGO ZENTRALELEKTRIK WAGO E−BOX
t
i
n X1:319 008 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
g X1:31A 004 10 WAGO,E−K asten WAGO,E−BOX
X2:47 006 18 WAGO−MESSTECHNIK Wago−measurement equip.
4 X2:58 006 9 WAGO−MESSTECHNIK Wago−measurement equip.
2
2
0
1 9 X2:70 006 15 WAGO−MESSTECHNIK Wago−measurement equip.
0
958 BOMAG 008 911 63


Name Bl. Benenn ung
Pf. title TYP
X3:1 008 11 STECKER ROPS/SD conn. ROPS/SR
X3:1 009 10 STECKER KABINE/ROPS conn. cabin/ROPS
S 1 V 1
e 6 o 6 X3:8 009 2 STECKER KABINE/ROPS conn. cabin/ROPS
i .1 g .1
s
1 t 1 X3:9 010 3 STECKER KABINE/ROPS conn. cabin/ROPS
.2 .2
0 0
X3:10 010 3 STECKER KABINE/ROPS conn. c abin/ROPS
0 0 X3:11 010 4 STECKER KABINE/ROPS conn. c abin/ROPS
5 5
X4:A 006 14 KABINENST. MESST. con. me asurem.equipm.
X4:B 006 14 KABINENST. MESST. con. me asurem.equipm.
X4:C 006 14 KABINENST. MESST. con. measurem.equipm.
X4:D 006 14 KABINENST. MESST. con. measurem.equipm.
X4:E 006 15 KABINENST. MESST. con. me asurem.equipm.
X4:F 007 18 KABINENST. MESST. con. me asurem.equipm.
X4:G 007 18 KABINENST. MESST. con. me asurem.equipm.
X4:M 007 16 KABINENST. MESST. con. me asurem.equipm.
X4:N 007 15 KABINENST. MESST. con. me asurem.equipm.
X6:1 005 14 DEUTSCH DEUTSCH connector
XS 009 1 Steckdose Socket
c X10:2 004 12 AMP SUPERSEAL AMP connector
o X10:3 004 12 AMP SUPERSEAL AMP connector
m
p B X11:1 005 13 DEUTSCH DEUTSCH connector
o a X11:2 005 13 DEUTSCH DEUTSCH connector
n u
e t
e
n i
l X12:2 004 2 DEUTSCH DEUTSCH connector
t l
i X12:3 004 1 DEUTSCH DEUTSCH connector
l s
i
s t
e X13:1 004 6 DEUTSCH DEUTSCH connector
t
i
n X13:2 004 6 DEUTSCH DEUTSCH connector
g X13:3 004 6 DEUTSCH DEUTSCH connector
X14:A 005 13 DEUTSCH DEUTSCH connector
X14:B 005 13 DEUTSCH DEUTSCH connector
X17:1 010 3 STECKER LÜFTER HKL conn. blower
X18:1 010 10 STECKER THERMOFÜHLER conn. sender temp.
X19:1 010 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X19:2 010 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X20:1 010 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X21:1 004 17 STECKER KÜHLMITTEL connector cool ant sensor
X21:2 004 17 STECKER KÜHLMITTEL connector cool ant sensor
X36:A 002 4 EINSPEISUNG SCHALTKAS supply e−box
X36:B 002 4 EINSPEISUNG SCHALTKAS supply e−box
X37:A 002 10 ST. ZÜNDSCHLOß E−KAST connector ignition switch
X37:B 002 11 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X38:A 002 11 ST.STARTER E−KASTEN connector starter e−box
X42:1 006 18 STECKER ADAPTER BOP conector adapter BOP
X44:1 006 13 MESX STECKER MESX Stecker
5 X44:5 006 14 MESX STECKER MESX Stecker
X44: 9 006 12 MESX STECKER MESX Stecker
8 X44:30 006 MESX STECKER MESX Stecker
2 9
2
0
1 9 X44:35 006 5 MESX STECKER MESX Stecker
0
008 911 63 BOMAG 959


S 1 V 1
e 6 o 6 X44:66 006 13 MESX STECKER MESX Stecker
i .1 g .1
s
1 t 1 X44:67 006 14 MESX STECKER MESX Stecker
.2 .2
0 0
0 0 X46:A 006 19 STECKER BOP Connector BOP
5 5
X46:B 006 18 STECKER BOP Connector BOP
X46:D 006 18 STECKER BOP Connector BOP
X46:E 006 19 STECKER BOP Connector BOP
X46:F 006 18 STECKER BOP Connector BOP
X47:A 006 11 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:B 006 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:C 006 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X48:1 006 8 STECKER AUFN. VORNE conn. sender front
X49:1 006 10 STECKER AUFN. HINTEN conn. sender rear
X53:B 010 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:C 010 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:H 010 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:L 010 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:M 010 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X54:1 010 11 STECKER HEIZSTEUERUNG conn. heating controller
c X54:11 010 10 STECKER HEIZSTEUERUNG conn. heating controller
o X54:12 010 11 STECKER HEIZSTEUERUNG conn. heating controller
m
p B X55:1 009 11 STECKER WISCHER HINTE connector wiper rear
o a X55:2 009 10 STECKER WISCHER HINTE connector wiper rear
n u
e t
e
X55:3 009 10 STECKER WISCHER HINTE connector wiper rear
n i
l X55:4 009 10 STECKER WISCHER HINTE connector wiper rear
t l
i X56:1 009 14 STECKER WISCHER VORNE conn. wiper front
l s
i
s t
e X56:2 009 13 STECKER WISCHER VORNE conn. wiper front
t
i
n X56:3 009 13 STECKER WISCHER VORNE conn. wiper front
g X56:4 009 13 STECKER WISCHER VORNE conn. wiper front
X58:2 008 17 STECKER STVZO VL Con. STVZO FL
X59:2 008 19 STECKER STVZO VR Con. STVZO FR
X60:1 008 18 STECKER STVZO HL Con. STVZO BL
X61:1 008 19 STECKER STVZO HR Con. STVZO BR
X74:1 006 14 STECKER DRUCKER con. printer
X75:2 007 16 SUB−D STECKER BCM INT con. SUB−D BCM
X76:1 007 17 STECKER VERS. BCM con. Power−sup. BCM
6 X77:1 010 13 STECKER PUMPE STANDHE Conn. pump add. heater
X77:2 010 13 STECKER PUMPE STANDHE Conn. pump add. heater
Y01 002 12 M agnetventil Startmehrmenge Solenoid v alve, start boost fuel MAX. 3.9A
Y04 004 5 Magnetventil Bremse Solenoid v alve, brake MAX. 1,8A
6 Y07 005 14 Magnetventil Vibration vorne gross Solenoid valve, vibration, front, high MAX. 2,5A
Y08 005 16 Magnetventil Vibration vorne klein Solenoid valve, vibration, front, low MAX. 2,5A
Y13 002 18 Hubmagnet Motor Sh ut off solenoid, engine MAX. 3.8A
Y14 010 13 Kr aftstoffpumpe Heizgeraet Fuel pump, heating unit
5 Y15 010 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
8 Y30 005 6 Magnetventil Stufenumschaltung vorn Solenoid valve, speed r ange sel., front MAX. 1,67A
2
7 Y31 005 3 Magnetventil Stufenumschaltung hinten Solenoid v alve, speed r ange sel., rear MAX. 1,23A
0 Y31 005 8 Magnetventil Stufenumschaltung hinten Solenoid v alve, speed r ange sel., rear MAX. 1,23A
2
0
Y120 002 16 Magnetventil Motordrehz ahl hoch Solenoid v alve, rpm engine high
1 9 Y138 010 10 Magnetveentil Heizung Solenoid valve, heating unit 3,5A
0
6 Y140 006 10 Magnetventil Erreger auf solenoid valve exciter up
Y141 006 11 Magnetventil Erreger ab solenoid valve exciter down
960 BOMAG 008 911 63


9
0
2
0 1
1
0
7 0
2
:
2
:
.
o
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h e e e
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w c
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c
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S a
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0 N l e o
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b a y
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2 6 6 9 4 0 2
.
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.
0 t 0 s
K g 1 i
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9 V 9 S
1 : 1
:
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z m p m
e a e a
G N G N
1
1
K
8
3
X
7
3
X
6
3
X
008 911 63 BOMAG 961


9
0
2
0 1
1
0
7 0
2
:
2
:
.
o
2 .
r
N
N
t
8 t
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e
5 a
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. a
: : f
e e . l
t p
i g s
e a r e
1 S p E R
2
S M
U C
P B 0
O
4
-
D
/ 0
4 4
- -
D
D /
9 4
-
1 D
2
.
. 9
. 1
7 2
7 . .
1 .
7
W 7
1
B
r W
ü
- B
T
n r
e o
t o
s d
a x
k
t o
l b
a -
h e
c
S w
e
t i
h v
c r
i e
r v
s
e o
b
Ü
5 5
0 0
0 0
2 2
.
. 0 s
0 t
g 1 i
. o . e
1
9 V 9 S
1 3 1 : 1
: :
. e
:
. e r
N N z m p m
e a e a
A A G N G N
C C
8
M
8 V
M o
V T
i .
e c
b c g
r a n
u y u
r
N l e
n u
o e
t
3 S
k
8 i
A n
h
c
e
t
s
s
1 e
M
N
A
C
2
F
1
F
962 BOMAG 008 911 63


WAGO smart DESIGNER 4.1
1 05756417
2 05756421
3 2 x 05756425 "L" + 793-501
5 2 x 05756425 "L" + 05756420 + 793-501
7 05756422
8 4 x 05756423 "L" + 05756419 + 793-501
12 18 x 05756436 "R" + 05756419 + 793-501 12 Flachsicherung DIN 72581-C30 / 057 510

99
13 Flachsicherung DIN 72581-C15 / 057 510

98

00

98

98

98

97

97

98

97

98

97

97

98

97

98
Optional1 : Projektgruppe : Walzenzüge-4 Klemmenleist en Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : gezeichnet: :
Optional3 : Obere Ebenen : geprüft: :
Optional4 : Ort :
Tragschiene : Absicherung D-4 Version Lieferadresse :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Optional7 : Größe der Bohrung : 5.20 x 25.00 [mm]
Copyright WAGO. Technische Änderungen vorbehalten.

17.11.2005 07:47:59 Seite 1
008 911 63 BOMAG 963


30 2 x 05756436 "R" + 793-501
32 05756435
33 05756417

Artikelnummer :
Optional4 : Ort :

17.11.2005 07:47:59 Seite 2
964 BOMAG 008 911 63



Artikelnummer :
Optional4 : Ort :

17.11.2005 07:48:52 Seite 3
008 911 63 BOMAG 965



Artikelnummer :
Optional4 : Ort :

17.11.2005 07:48:52 Seite 4
966 BOMAG 008 911 63


1 05756417
2 2 x 05756540 "R" + 793-501 + 05756536
4 2 x 05756540 "R" + 793-501
6 3 x 05756539 "R" + 793-501
9 05756537
10 4 x 05756538 "R" + 793-501
14 05756537
15 3 x 05756538 "R" + 793-501
18 05756537
19 3 x 05756540 "R" + 793-501
22 05756535 "R" + 793-501
23 05756537
24 5 x 05756540 "R" + 793-501
29 05756537
30 2 x 05756538 "R" + 793-501
32 2 x 05756539 "R" + 793-501
34 05756537
35 4 x 05756538 "R" + 793-501
39 05756537
40 4 x 05756540 "R" + 793-501
44 2 x 05756539 "R" + 793-501
46 05756537
47 05756540 "R" + 793-501
48 05756535 "R" + 793-501

Artikelnummer :
Optional4 : Ort :
Tragschiene : Kabelbäume D Version Lieferadresse :

17.11.2005 07:51:17 Seite 1
008 911 63 BOMAG 967


49 05756537
50 2 x 05756538 "R" + 793-501
52 05756537
53 4 x 05756540 "R" + 793-501
57 05756539 "R" + 793-501
58 05756537
59 4 x 05756540 "R" + 793-501
63 05756537
64 05756540 "R" + 793-501
65 05756535 "R" + 793-501
66 05756537
67 05756540 "R" + 793-501
68 05756535 "R" + 793-501
69 05756537
70 05756538 "R" + 793-501
71 2 x 05756540 "R" + 793-501
73 05756539 "R" + 793-501
74 05756537
75 05756417

Artikelnummer :
Optional4 : Ort :

17.11.2005 07:51:17 Seite 2
968 BOMAG 008 911 63



Artikelnummer :
Optional4 : Ort :

17.11.2005 07:51:57 Seite 3
008 911 63 BOMAG 969



Artikelnummer :
Optional4 : Ort :

17.11.2005 07:51:57 Seite 4
970 BOMAG 008 911 63


1 05756417
2 2 x 05756540 "R" + 793-501
4 05756539 "R" + 793-501
5 05756537
6 05756538 "R" + 793-501
7 2 x 05756540 "R" + 793-501
9 05756538 "R" + 793-501
10 05756537
11 2 x 05756540 "R" + 793-501
Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : Messtechnik D Artikelnummer lang :
Optional4 : Ort :
Tragschiene : Klemmenleiste X2 Lieferadresse :

16.11.2005 14:51:24 Seite 1
008 911 63 BOMAG 971


13 05756539 "R" + 793-501
14 05756537
15 05756540 "R" + 793-501
16 05756538 "R" + 793-501
17 05756540 "R" + 793-501
18 05756537
19 05756417

Artikelnummer :
Optional4 : Ort :

16.11.2005 14:51:24 Seite 2
972 BOMAG 008 911 63



Artikelnummer :
Optional4 : Ort :

16.11.2005 14:51:51 Seite 3
008 911 63 BOMAG 973



Artikelnummer :
Optional4 : Ort :

16.11.2005 14:51:51 Seite 4
974 BOMAG 008 911 63


1 05756417 1 Nur bei ZA E2 StvZO Beleuchtung
2 4 x 05756540 "R" + 793-501 2 Nur bei ZA E2 StvZO Beleuchtung
3 Nur bei ZA E2 StvZO Beleuchtung



Artikelnummer :
Optional2 : Projekt : E2 Beleuchtung Artikelnummer lang :
Optional4 : Ort :
Tragschiene : Option E2 StvZO Beleuchtung Lieferadresse :

16.11.2005 14:48:22 Seite 1
008 911 63 BOMAG 975



Artikelnummer :
Optional4 : Ort :

16.11.2005 14:48:52 Seite 2
976 BOMAG 008 911 63


9
0
2
0 1
1
0
7 0
3
:
3
:
.
o
2 .
r
N
N
t
8 t
t e
e
5 a
l
B
h
S
1 1
: :
m
n o
o r
v f
:
s
1 1 : e
c
. a
: : f
e e . l
t p
i g s
e a r e
S p E R
0
0 4
-
4
- /
D
D 4
/
9
1
6 9
0
6
4 -
- D
X X X X
0 1
7 6 6
D 9
X X 7
X X
6
X
6
X 1
9 2
1 . .
2 .
. 7
0 0
.
. 7
8 1
X X
8 1
X X 7 1
7
1
W
W B
B w
t e
h i
v
c r
i
s e
r
e v
o
b r
ü
r t
o
e
k c
c e
n
1 1
e
t n
2
X
2
X S o
C
0
0 2
2 X
X
7 5
7
5 X 5
5 X
X 7
7 3
X X 3 5
X 5 0
2 3 4 0 0
1 1 X 1 2 2 3 4 1 2 0 2
1 1 2
. .
X X 4 X X X X X X X 0 t 0 s
4 g 1 i
1 1 . o . e
1
1 X 6 7 8 4 1 4 9 V 9 S
1 3 3 3 4 1 X 4 1 : 1
: :
X X X X X X X :
. e . e
r
z m p m
2 6 2 6 6 7 8 e a e a
4 4 4 4 3 3 3 G N G N
X X X X X X X
4
5
X
3 7
5 1
X 7 X
1 5
X 7 3 8 9 4
X 6 5 1 1 5
5 6 8 9 7 X X X X
7 7 1 1 4 X
X X X X 7 6 5
5 X 5 X
4 6 X X
7 5
X X
9 8
5 5
9 8 X X
5 5 9
X X 4
2 X 9
2 4
X 8 X 2
4 2
X 8 X
4
X
008 911 63 BOMAG 977

978 BOMAG 008 911 63

008 911 63 BOMAG 979

Design status: June 2007 to February 2008
980 BOMAG 008 911 63


9 1
2 0
2 0
r
e
t 0
a
e
h
7
−
e 2
r
p 8
l
e
u
f
r
e
t 5
, a
n e
r h
o M h . 1
h C p d 0
g B r a d 0
n t g a
d i o g ,
e n g r . n
e r e h n
c i
p a n i
i b
r v . m a n
s w o , g , i
, t e t o
i
− .
e t i h m
p a o t 1
n n
i n t c i n O i
d d 0
g o o i u a Z a n 0
c m w
n e , s e M q t , o
v r c
e g − t n S r
s i
, n r
t m t o d
n i t a
i a n h , m
a e e t
a l
n l g
c a l r
i g
u f
− a s m a e t
t e i
n
m g , r
e p n d s t
a n g p s u i o e a
a s
t
i
i
r t n
i
t
u e s m t h h y
e
s
i
l
n r
g a a k g o a
a C i t t
, − f
u a t
i s e c
a s n
r a e n i n n
i e
n
e
D , h b o r − m G m h n
n t l
y e e , t u b b t
o
i
t i
u p i a e o i c c − o
n k c d n A l
l a a
p
c c p g a i e t
r i M . t
t . t
. t
i m
n i u n r d p O p p p n o
u
f C s e b i n p
s o B o o o a c
g
n 0
u 4 n m
m
r g −
n H a a
l
ä
w
u D
z
h i
p r
f g
r e , u i
o g
v
p h
a z 4 −
a
a d
f
f n
u
r
g t C l
o
t h
s c n C h
M a H
o s m t
i
t
l f a i o t B c Z , u D o u
r
h a
r w t a n
a , 0 t c
r
a K
z , r
h n e b
b
r e T , e 4
o g − S i
c
i
e r Ü V e d m i a D
l
r o , n ,
d
r l
h r . , g a
. a O R a 4
o a i
t h
n c n Z , D a −
o n e t
g r s a t m
v g l
i
0 0 M i n k M S n K m
u , e
4 4 , S
n , a
a n d t
t o n h t
− − e h w r n o t
i c g s
D
t
r c h c u u n y
/ D
e k u s
/ p p
a s a t
t n f z i a
k g l
p
e i
i n n e e u
z t
z
4 4 u n S a k
l c S h m
, f ü u B h h
− − r g
a g
l z
i , c o t
h , n s c e
p n e 7 7
D D n s c e
f n e R n e t C u n n l t
u u H , e f s e i i h l
e
s
i 0 0
0 0
9 9 t
o
i a g
l − e
r r s g
i
u s
t e
G l b b t
A e a a
a l
i 2
. 2 .
1 1 k o o e r
m s m
s
M
z h M B K K
s t
b
e 1 t 1
2 2
. .
n
. F
u
o r t
r
t e o e r n a A O A A A i e u
a
0
. g 0 s
. i
. S V M B A F Z B Z Z Z D B 3 o 3 e
7 7 0 V 0 S
7 7 r
1
1
e
W W m
B B m
u . 9 9 9 9 9 9 9 9 9 9 9 9 9
n o 2 2 2 2 2 2 2 2 2 2 2 2 2
s n 2 2 2 2 2 2 2 2 2 2 2 2
g − 2
n 0 0 0 0 0 0 0 0 0 0 0 0 0
: h u g 7 7 7 7 7 7 7 7 7 7 7 7 7
s : n
i
n 2 2 2 2 2 2 2 2 2 2 2 2 2
i
w 8 8 8 8 8 8 8 8 8 8 8 8 8
n t c
s i
e a
r
5 5 5 5 5 5 5 5 5 5 5 5 5
h n Z d
c t
i e
e n
z o
r c
e f
v : . : .
s o r o
t
l e N t
n 1 2 3 4 5 6 7 8 9 0 1 2 1
0 0 0 0 0 0 0 0 0 1 1 1 0
a l t e 0 0 0 0 0 0 0 0 0 0 0 0 1
h b t e
a h
l
008 911 n
63 a
I t B s
BOMAG 981

2
:
1 0 9
: 9
18.4
0
:
7 1
:
3
7 1
:
1 6 6
Wiring diagram
1
:
3
582 702 29
9
2
0
0
3 8
/
1
6 2
8 : 2
:
: 4 1
2
1 A 2 1
3 F 0 ? ?
1
3 2
K E 9 A
0 3 5 0 K S 0
3
: F
1 3
:
1
7
1 1 2 X 1 2 2
X 5 : 7 3 3
8
a 2 g 5
7
8
5 : 4 1
1
2
1 5
1 a 4 5
u
t
l
a
0 E A : 7 5 5 h f
3 7 1 2 7 2
1 0 8 1 2 c f
2 1 2 X 3
1 1 s o
2 2 b t
1 7 X X a u
A
8 . 3
1 8 1 1 f
f h 1
X X 1 s
K 0
1 4 A
1 1
5 2 7 o l
t
: 5
1
: : 8
2 9 3 s e
t
2 F p 1 f f
1
X S o
t
K 4 Y a u
r
U
S K
A −
.
− g
T r
1 O e 1
0 N m
S E
l
t c a t n o
c − t a e
s h c t i w
s t u o h t i w
r e t l a
h
c s t k a t n
o
k z t i S e
n h o r u n 9 h d
5 m a
m
W 3 z e
q
5
W 6 h e
7 1 8 .
2 H p
e s
r
E A 8 X 5 x
2 A
7 7 + 1 2 D e
1 1 2 1 − X 6 t i
e n
m
m
q 4
1
1 1 0 X 1 n g
n
X 3 6 5 g e
A X
5 0 8 8 X a .
X
U
A A
0 2 a 0 /
1
m l
1 4 8 7 2 0
A
b o
F 1 0
1 7 u s
1 4 6 Y H
K 5 : 7
1
: 3 1 4 3
2 K X V 1
2 1 :
6 2
5
:
1
3 4 1 6 5 X
2 2 8 8 8
1
7 0 X 4
8 8 1
2 1 6
: K 1
1 1 3 :
X 1 2 2
0 1
3 7 e
a 8 g l
7 / n e
4 5 8 5 u
e f
3 0 2 1 m
5
: K
6 0 K r t
s
5 1 h o
1 : 2 A
9 . 3
1 e o
2 1 0 m b
0 S Y t
r t
1
: 3 r
a t
5
d e
e p
s e n
i g n
e h
c t i w
s
2 : t a
l z h e
r d
r o t o
M
r e t l a
h
c
S 1 S s
X l
8 A
: h d
a 1
8
3 a e
2 7 X 7 X 0 z e
:
0 a 0 8 5 r r h p
1 0
5 3 1 A
0
1 / A
0 5
− e t
r e
t e s
r
X M r
a t d −
0 7 B
: 5 7
0
3
t a
S s
e
r n
3
K
1
9 7
3 : 8
0 3 1
o i
t
1
3
X K 4
+
0 o g
n
1 B M M e
:
8 4 2
2
: 6 , ,
5 5 3 8
: 5
: n t
i
:
5 4
:
1
1 2 e n
t
0 4 1
5 9 1 K 2 1 6 5 r u
3 7 X 8 8 a g
t
A
m
5
1 2 n
S t
, i
5 1 5
1 X 5
1 : r
g t
n a
E A A 1
5 3 0 5 :
1 A
1
K X 8
1
: 3 1 7
1 F 1 : 3 3
:
1
1
: u s
,
X X X r h X 2 g
r l
y
t c
e t o p
l i
a
h w
s
r p
c s e u
g n
i n o
i t i d
n o
c r i a o t . c c a y l n
o
0 g
0
S
s n
t
r i
a t
r
e g a
l n a a m
i l K i e b r u n V s
t a
S t a 6 5
s 7
0 8 8
8
3 9
0 8
K 6
1 7 1
:
6 5
: 8 1 7
:
K 2 X 1
6 5 1
M 3 8 8
H 1
: 2
:
0 O 4 7
1 2 2
:
R 8 5 X 6 5
8 S
/ 3 4
1 2 1 E K :
6 M W 4
1 K +
1
: 1
2 1 D 6
0 6
:
+ V 1
B 2 5 + X
6 5 1 6 D W r
8 8 o r
t o
t
1 a
A
m
5
2
1
6 1 1 a
r r
K X X e e
n
8
: e n
e
− 2 G g
+ 2 B
B 0
G
9 : 1
X A
: 6 3
X 7 7 0
0 0
0 2
e y
i 2
. 1 .
2 1 r r 1 t 0 s
e t
e
s u f n i a
m
0 1 : 1
X + − t
t e 0 g . i
. o
a t 3 3 e
g n
u
r e h
c i s t p u
a
H 1 −
1 3
0 1 a 0 V 0 S
0
A
5
2
1
0 B b
B
: 6
3
X F G n o
i t p o
e y
i r
n
o i t p
O r e
e t
t t e
t a i
e g n a
l f −
g n
i t a e
h a b r y
r
c i S 2 1
+ − 1 2 B
r h
e t
t e
c t
a t
h
c s n a
l f z i e
H g n u r e h
8 3 e t
t i a
0 l
4 a w B b
A
5
2
1
F G 0 h s
3 c k
S s a
n e e
) ) n r g
3
( 4
( e b h n
r
0 7 1 2 T s a
l
c f
3 8 n −
a g
l
A
7
6
1
4 9 n
f t
1 5 1 z i
i a
K : R 1 e e
3 3 H h
982 n o
i t p o e
n o BOMAG
s i w
i t p
r e
h t o , n
O t s n o s , n
o
i s
o
r e
i s
v A
r e
V
S
A
U 0
S
4 − D d n
U 0 4 −
a 4 −
D d n
D 9
u 4 −
D
1 2 W
9
B t a y l n o
1 2 W
B i e b r u n 008 911 63

Wiring
1
:
diagram 582 702 29 1
:
18.4
9
3
0
0
4 4 2
7 1
3 2
8
/ 0
1
1 7
K 2
8
5
1
1
e
g a k c a p r e t n i w n o
i t p o
t e
k a p r e t n
i W n o
i t p
O
7 8
1 1
2
: 2
:
E A 1 1
7 1 2 7 X 1 2 X g r
3 3 n e
u t
1 1 m a
X r e
A X
4 5 9 ä h
2 7 −
w e
1 2 R
r
F o r
v p
f l
f
o e
t u
s f
t
f
a
r
K r
e
g t
a
n e
u h
m −
1
N
S e n h o 4 −
D 1
1 2
W
B
/ 0
4 −
D t a t o n
1
N
S e n
h o 4 −
D 1 1
2
W
B
/ 0
4 −
D i e
b t h
c i n r e
ä r
r p
w
V22 o l
e
v u
f
f f
n
r o ,
t
s n
2 1 n o
0 r
o h t r
0 h g f o
1 1 l n
i
a n a
r h
1 n r g
A
2
. 4
1 2 1 g a
i K n
B X S w , i
n n
r r
o a
V21 9 h
l w
8 2 9 a , .
5 3 4 9 0 1 n t
5
2 2 1 2 1 X n
n
r g n
i
1
: 1 1 r o
S o
, c
E A 1 X 7 X 1 o h
8 1 2 8 X 3 4 9 0 1 h g
l
2 2 1 1 1 a i
n n h e
1 1 1 1 1 2 n
g r c g
1 s n
A
2
. 4
X i
A X
3 0 X X S a
B n l
a
n
r o
h g
n
i n
r a
w . t u b h
s u
p
2 1 w
F
n
r o h
l a n
g
i S
r e t s a
T
a f
l
3 f −
0 z g
i
S n
e i
H t
− a
r e
o h
t
o e
n
M i
g
n
e
n o
i t p o e s i w
r e
h t o , n
o i s
r e
v A
S
U 0
4 −
D d n
a 4 −
D 9 1 2 W
B t a y l n o
n o i t p
O t s n o
s , n o i s
r e
V A
S
U 0
4 −
D d
n u 4 −
D 9 1
2 W
B i e b r u
N
a e
r a −
e n
i g n
e n i d e
l b
m
e
s s a
9
1
h
c i e
r e
b
r o t o
M m i u a
b n
A
:
4
H
Ü
L
G 1 2
4 7 7
a
e
r a −
e n
i g
n e n
i d e
l b
m e
s s a 1
K 0 0
h
c i e
r e
b
r o t o
M
m
i u a b n
A
2 0 0
: 2
. 2 .
8 5 2 1 t 1
7 7
e g
n a l f −
g n i t a
e h s i a
l e
r
r 0
. g 0 s
. i
h c s n a
l f z i e
H s i a
l e
R u e
t 3 o 3 e
1 1 1 6 r
a u 0 V 0 S
X X r
4 e t
a
7 1 2 6 p r
m e
4 1 e p
t
X 7 l m
3 1
1
B
2 e t
t e
5 t t
i
2 5 3 1 m n
l a
5 X l
h l
3 ü o
1 1 K c
X l o
r t n
o
c − e g l A
n a f −
g n i t a e
h l u
d o
m
7
g n u
r e u
e t s h
c s n a l f z i e
H l u
d o
M
8 6 7
/ 8
: 8
/
1 1 5
1 1 0 1
K K K 3
0 0 3 0
2
: 1
: 1
: 2
:
008 911 63
2 2 2 BOMAG 2 983

18.4 1
:
5
6 7 7
: 1
: 1
: 1
: 9
:
3 9 9 9 6 2 8
1 0
1 1 2
Wiring diagram 4
− 582 702 29
4 i
1 D : 7 − e 9
4
0
0
6
H
5 7 D h
c
2
R L 6 1 7 2
7 Ü W − − /
− L 1 1 1 7 8 1
3 7 s
b
8
/ L L L 8 X 1 X 0 X W
B 1 a 0
1
1
G B B B 6
A
1 1 1 + − /
0 W
r
e 7
K B
4 / s 2
1 1 8 s r
− 0 8
r e
d
i e
h
c s b
a
r e
s
s a
W
X X X 4 4 a o
2 D W t 5
i − a
1 e r r
B b D o a
t t
a s p
h t n e
s
t c o
i e s l
n
h
c
s
k n n S r
e e
e .
e
r n
i
l t v 1
h
ü
l
l
b
n
r
e
r
e a d l
e
g
r r
a
k
n
i
k
n
i z
t 2 8 1
: 2
: w n k
o l l i
7
: 6 . a c
V W B B S :
1 1
1
2
1
2 s t
s t
o
9 8 2 4 3
6 7 1 n l
1 1 X X X X e s
e t
s i
t t
5 n
m a
d
n a
t s l l ü
f l e t t i m
l h
ü
K
l l
5 h o
1 : 6 0
B 5 Q ü o
e K c 1
B r
u
9 : 6
k s
6 3 c s
6 7 7 u
r
1 1 2 d e
l r
p
k c u
r d
l ö
r o
t o
M
1 1 ö l
r i
X X 6 o o
7 4 0 P t
) ) o e r e
r
n e : 7
7 : B M n u u
i
e d
t 7 1 1 g t t
a
n i X X n a
r r
i s 1 0 1 1 e e e
h k
n c
1 r u t a
r e
p
m
e t l Ö
p p
o a 2 1 2 t 0 m m
1 e
6 : 5 2 : 0
v b 3 _ B
e
t t
r l l
3
B 1 6 : 1
X r o
s n e
S
t m
h o 3 2 1 e Ö i
c f
i r 1 5 7 7
6
r n o
e a
t
n w 4
s 3 1 3 4 l
i e
l
f
t c
A e 5
i 1 r e t l i f t f u L
1 1 7 f r
( v 4 X X 3 5
: u i
L a
e (
g l 1 0 P 1 r r
i e
e u 5 B X e e
t
l n
z d 1 0
1 6
i
f
l a
n o 6 3 0
1 1 3 4 e
ö l
a
l m 1 1 k c
i l
l
e
g 6 7 1 1 7 u i
1 a o
r e t l i f l ö
k i l u
a
r d
y
H
m n X X 1 r
m i
r 1 1
: k
i
d l
i 7
a t
o 8 1 7
8
2 P
B 1 y u
S
r n
1 1 X 0 H a
e o 8 9 1 4 r
d
1 − 0
e
s m
e
r B
k m X A y
c g 9
e u 0 S 7 D 4
i −
h
t
s l
l
2 R
U
9 : 6 + 8
: e
b D
a p O
D 8 3 t t
t n
r i 0 H 9 4 : a
h t
n a 2 4 6 6
: K 4 c o
i
e m − 1 + D 2 n n
Z 1
: 1 5 8
/ 1
6
K 7
1
5 L
X
5 1
: r l g
X E 9
0 0 1 e e n
U
F 2 1 1 2 r l 3 X u
b f u
e
e l
o b e r
g e h
u
g d
e
g
i e
z n
a
k n
a
T
1 1 0 3 0 k d c g
i
e o
X X 1
X
0
R
1
X
n
a n a i
n
z
n m 0 9 1 8 0
e
T s
r r
w o
a g
l n 5
2 1 D
N
G .
N 2
t
e i
b n
1
e i
r 1
4 2
T T .
l
8
5 e
R
9 :
Ü o
/ U
m o A
t
5
U
O O B
A : 1 g
m i 1
L 6
n 1
a o E W X n
u , m
.
S :
m 5
B Z r
ö e r ,
5
T
I
S
t
S r n m
i
2
:
6
8
:
9 9
u
r l
i e r
4 8 e f
a n a
r l
2 1 m r a
1 2 F X 1 + 7 P m e a
X u z w p
0
H
z
s u r
E A 2
: n
r b u
h k
1 4 A 1 4 a a
f
k c
0
3
: 2 1 : 2
3 W
1 F 1 F
c a
5
0 6 8
ü b
X X 9 8
1 ,
X 2 R e
2
K , k
2
: 9 8 a
e r
6 :
6 1
: s b
2
2 m
:
5 A e
r
2 7 r
F 7 8
/
7
1 e m
r
B
8 6 1
: m a
l
0 2 4 1 m
3 K 1 1 2 X u a
1 s p
6 a n u
r
2 7 1 9 + − 9 a k
A
m
0
0 3
K X X 4
1 X c
: 8
6
H
w
r a
4 h b
3 a r
f
k e
5 c z
1 ü z
n o
i t i s o p − " 0 " d
n a s d
r a
w
r o f h c t i w
s y t i m
i x o
r p
: u
l l u
N d n u . w
r o
V
r o t a
i t i n I 1 5 R b
1 2 X 6 8
8
3 N K 3 A
m
5
2
1
6
1 B B 1 2
X / / X K
R W 9 8
B S 3 2 :
1 4
X
U 3 : S
2 1
1 7 E X e e
B
4 / X M s k
1 L 7 0 m a
r
B B 4 5 E 7 e
r b
1 1 K 1 B e
: : A 1 l l
v
1 1 R : i
t
X 1 2 X B 1 n a
1 1 1 2 X e v
A
5 . 2 v i
t d
1 3 4 e o
0 1 0 n n 7 7
7 1
: Y g e 0 0 0
8
3 S
8 1 a l
o 0 2
0 : 9
1 : 1 : X M s 2
. 1 .
3 4 6 2 1 t 0 s
i
0 . e
g 3
. o
6 a A 3 S
3 7
7 K 7 6
8 0 V 0
8 7
: 8 : /
8
0 2 8 8
4
3 4 K 6 5
K 8 8
8 a
4 7 5
A
m
5
2
1
K 0
: 8
2 K
4 8 1
r p 4
1 1
:
n
o
i t i s o
p − " 0 " r e
v e
l l e
v a r t h
c t i w
s y t i m
i x o
E A : 2
9 9
0 " l e b
e h
r a
F r o t a
i t i n I 1 6 5
2 1 2 2 1 2 X 8 8
1 1 6 2 N K 2 8
A
m
5
2
1
X 5 0 X 5 1 B B 1 4
A
2 1 1 X / / X K
7 F : R W 3
8 1 B S 3 :
/ X 4
1 2
1
) n
i e e
s m
e
r B
( n o i t i s o
P
9 1
K 0 n i t e n
f f ö e g
3 U
B
1
X 4 3
1 / 1
:
984 0 B L
B BOMAG 1 0 008 911 63
2
: X 2
:
3 3


e 1
:
18.4
9
5
0
0
6 2
r e t e
m
o
d e
e p
s
g
i
e
. z n
a
s t i e
k g
i d
n
i w
h
c s e
G
2
: z r 1
3 2
4 n e
a t 0
2
F 2 3 s e
t
i m
7
9 + − 9 e o
k d 2
1 1 g e
i 8
X X e
d p 5
4 n
i s
0 w n
P h o
c i
s t
e p
G o 1
A
+
T
U
O −
T
U
O Z
6
:
2
: 2
: 0
− 7 7 1
t s e
T
5 h
0 p
L A X X C h a
p r
S S A
n
r e
a g 1
E E T r o
M M D g h
4
5
/ 5
1 ni o
E h c
I D E
R a
c t
D E
E P a d
T
r P S n
e
t S d a
. e n r
w u t
e
h m
o e e
g
c d i m
s e e o
e e z
G p n d
e
l s A e
u l 2 −
. p
d u 3 7 s
o d 7 1 w . ,
M o 1 : h u
: c
m 1 d 1 s q
X e X e e
G −
t
. e
r , n
i p e k e
i
d s s e n
h l h m
e
+ − c x
a c r
A r t u
e s
1 r e s
7 4 o d s a
1 7 s e e
: 0 1
: n n
e M m
1 6 1 e s .
t
X B X S A p
Z o
i t
e a
b y
r l
u n
n o
r e t e
m y c n e u
q e
r f
e
g i e z n a
z n e u q
e
r
F
− − + +
: : : :
− − 1 1 3 3
+ − − N N N N
1 − 2 − − I I I I
9 9 − − P P P P
1
: 1
:
1 5 1
X 0
P X −
T
U
O 4 0 0 r n s
r
4 4
− − e
e t e o
r
k e 3
O i H H g e
i g t
i
n c e m a
e c
+
T
U
u D /
/ D z
o
r d 1
t 0 4 0 4 n y z i
4
5 1 k
/ 5 s
n
4 − /
/ 4 −
4 C 4 C
a c
z n n d
g
g
w
s
e a
l r −
i E t − H − H 4 n e
e u A i
n
n D D D D − u q
9
8 1 : 1
X
4 3
8 8
1 : 1
X
9 9 6 4 C 4 q e
r
: : 7 7 1 1 r f
e
2 2
2
6
0 1 1 2 2 H −
F n
2
X X A − − − − D D A
o
i
t
7 7 1 3 6 9
7 7 1 1 1 1 Z p
w
s 3
1 2
W
B i e b
s
w l b 7
7
1
W
B i e
b 1
1
2
2
2
2
o
W W W W W W
r
b
l
b B B B B B B
+ −
7 1 : 2
2
X
w l
2 : 2
2 X 0
8 r
b s b 9
1
: 6
3
7 1
7 2 1
:
1 1 1
W
W B 1
X B B
i i X
e e
b b
n o i t a
r b i v r e
c u d
s n a
r t
n
o i t a
r b i V r e m h e n f u
A

8
− 2
e
r u t a
r e p
m e t t n a l l o
c 2
:
K + 6 1
2 X
r u t a
r e p
m e t l e t t i m
l h ü
5 2
:
2
2
: 4 G 1
X
1 1 B 5 1 : 4
X P
2 : 0
3
−
r
e
r u t a
r e p
m e t l i o c i l u a
r d
y h
H + 7 3 u
t
2 2
r u t a
r e p
m e t l ö
k i l u a
r d
y
2 2 4 a .
r
: : 0 e p
G 1 1 R p m
2 X X
0 m e
t 7 7
P e i
l 0 0
t
l 0 0
1 2 o
ö r
. 2
k d
i . 2 .
l 1 t 1
u y 0
. g 0 s
. i
2 r h
a 3 o 3 e
8 d 0 V 0 S
− : y
r e t e
m M
P
R 1 H
r D + X
r e
s s e
m l h
a
z h
e
n
G
3
0
P 0
7
:
1
X
V + V −
r e t e
m t l o
v
W
r e t e
m
t l o
2
:
4 2 6
:
2 1 2 1
F P 3
1 0
1
: 2
4 :
008 911 63 BOMAG 4 985

18.4 1
:
Wiring diagram
1
582 702 29
: 9
6
0
0
9 7 2
7
t c a t n
o c − t a e s h c t i w
s t u o h t i w 1
3 2
8
/ r e t l a h
c s t k a t n
o
k z t i S e n
h o r u
N 0
1
1 7
K 2
n o
i t a
r b i v l u d o m
n o i t a
r b i V l u
d o M
8
1
5
b
6 3
9 4
1 : 1
X
6
5 5
0 2
: 2
: 1
1 2 3 S 7 7
E A X X
2 3 A 2 4 S S
3
: 0 3 0 E E
1 F 5 :
1 1 K M M
X X A A
G K 1
G 6 : 0 1
A
K 7 : 0 1
A l .
l . n p
i
t p e m
l
b a
k l
c
a
r t 0 ß m
a e l
e n 6 o
r g n a
t
l 1
: g i r m
a o / b o
A
3
3 . 3
h c 5 3 4 1 /

n l v s
1 1 X 1 2 i
s
−
c t e l
l a n
n i
o
t a
e 9 5 7 8 7 k m o t
i
k s
a 5 1 X 0
Y
X n s t
a a
l . r r
t 1
: 1
: o n
i ß b
n h
c 1 1 t i
o o p i
r b i
v
o i
t X 3 4 X a t
r g m V
k 2 2 1 a a
b r a
z w
t i e g
i s 6 V b
i n i
S r v r b
t h
i t
i 1
: A
3
3 . 3
e h o
v n
1 t
l t
m w X 1 2 a c
i o
i
n t
r y o a
u l
X h w i
6 6 7 6 c t
8 1
1 : 1
n r
N o 1 X 0
Y
X S s a i
r b
1
: b v
i
5 1 V
3 X
5 S
1 4 3
1 1 1 2
7 1 n
o
i t a
r b
i v n o t t u
b h s u p 1 9 4
1 : 1
X
5 1 3 1
n n 1
: X 1 X
n o
i t a
r b
i V r e t s a
T
o
o i
t t
i 1 S
a a
r 1 X
r b 1
b i
i v
B 3 4 A
/ 8 4
V k z t i S 4
t c a t n o
c − t a e
s h c t i w
s 4 5
1 : 1
X
4 / h
r t 5 1 1
1 c 1
: X 8
r e t l a h
c s t k a t n o
X
e i
t 5
+
D l w 1 S
a t 9 X
h s
c a n .
s e o r
9 4
1 : 1
X
3 z
i s
t i
t b
a i
1 e
S l
k c u
r d
l Ö
l u r v
u d
d o 6 8 i ,
b h
o m 8
2 1 V t
c
1 M
X ,
. i
8 h w
n
e
r h a
F
6 c s
−
A s t
t
1 4 k a
a e
t
n s
o ,
k s
z e
1 1
9 . 5 t
i g
S n
0 N 0
V R 2 V
, a
1
1
6
8 2
2
: 2 6
/ A r
: /
+ 6 4
8 : 1 A
0 7
8
6 W n −
D 0
4
1 S / 8 A Z
T
e d
f e
B K F 6 I u e
0 2 8 9 S
0 t
: K :
2 1
: 1
: s p
r
2 4 h s
3 7 3 0 4
1 : :
: 1 2
:
4
4 4 4 2 a
3
4
1
4
4
2
F
1
: 1
: 1
: n
1 1 1 e
X X 1 2 X t
e
n l
i
A
3
2 . 1
1 h x
2 3 g a
Y g
n n
2 3 u i
t
0 l
A
S
A
S
6
1 V
1 a h
c
t
: h i
U U 1 c w
0 0 3 X s s
4 4 2 7 m
− − u
D n n
/ D
/ 5
1 e
f r
o
n s 1 2 u v
e e 0 t
n i
i n 4
4 V 2
4
4
2 S g m
u
h h s 1 2 1 1 n r
c c e : : : u d
t
s s 1 1 1 l
a a 4
.
g
X X 1
2
X a g
n
M m 3 h n
a h i
c h
− − 2 c r 0 n s c
A
3
2 . 1
s 3 4 4 r t
D D 1 n d Y − o m i
r d
d r e e
f e − D v w
u s
D n
a a t p
u s 9 9 n
g e
d d 2 s 1 1 f
n n
a a
4
S
r
h h
c 7 8 2 2 u t
t
+ l
u
m S
t t t
a i 3 3 + 6 a r
u
S S F w 1 1 6 1 h
1 c d
s :
1 2
:
1 2 2 s g
X 1 X W W m n
B B u i 7 7
0
3 y n h
r l c
t
0 0
0 0
e i
u n f 2
. 2 .
Y n o t w
u s 1 t 1
S 0
. g 0 s
. i
3 o 3 e
0 V 0 S
4 4
− − 3 1 4 n
D D 4 4 2 e
t
7 7 1
: 1
: 1
: n
7 7 3 4 1 1 1 i e
h l
1 1 1 1 X X 1 2 X . x
W W 1 h a
/ B c g
A
3
2 . 1
B / 3 s n
0 0 2 Y i
4 4 4 m
u h
− − S c
n t
7
D D
r y
s e g
n a
r d e e
p
s h c t i w s e i
f w
8
/ u l
n n e f u t s
r h
a
F r e t l a h
c
S u s
t
1 n o S
1
K 2 1
: 3
5
0 2 0
2
: F
8 2
:
:
986 4 4 BOMAG 5 008 911 63

Wiring diagram 582

f o
r p M 702
T
B
/ +
M
T 29
B t a y l n o
1
:
18.4
9
7
0
0
8 2
f o
r p M
T
B
/ +
M
T
B i e b r u n
P
O P 1
3 2
B O 0
k B
i
n .
7
h m
c e
5 5
1
: 1
2
r
e u 1
: 9 3
4 : E
: :
8 8 8
t
s s 9 : 2 6
2 4 4 : 5
F :
1
5
:
5
s a X X X 6 2 2 − +
e e 0 4 4 3 3
M m 3 X
−
1
N
A
C
8 2 X X 6 2 : 4 4
X
N N
: A
y y : 2 :
4 A A
a l
l a
p p 2 4 6
4 − C C
s i
i s X X X 3
N 1
A
D d
: 4
D : C
7 1 6 2
3
3 : 4
4
X
4 : B
: 4 4 2 M
: 2 6 3 X X 0 H
2 4 4 3 2 O
X X X P 0
R 6
1
M
E
B t a y l n
o
M
E
B i e n −
b r u 1
N X 3
+
1
N
A
C
7 2 : 4 4 5 : 4
4
X
A − A
A C 0 +
S S 5
3
N
F F 2 : A
M M F 2 C
B B X
+
e y
a N
g l
i 1 A
e p
s F C
z i
n D +
A r r
6 e t
t e M
1 e e M
P M m E E
+ B −
0 I − − B
i B
3 : 4
4
X
7
: 5 V B e t
2 2
: 6
B
I V
E
5 E 2 I B
I b a
X 4 B
: : 8
: 8
: V V r y
l
7 4 2 D 1 7 1 E E u n
r r X X X T
x
X 0 X n o
E
: 4
X X
4 : 4 7
e e D 5 : 4 4
X P
k t N
c i
n G
u
r r
D
: 4
X 5 : 4 7
X 8
6 : 4
4
X
p
4 : 4 4
X
D 6
6
:
C
: 4
X 3 : 4 7
X
1 4 D 6
2 : A 6 x
: R
4 : 2
7 6 : 4 4
X
1 6
:
X 7 4 2
1 X X X X
P 6 6 : 4 4
X
1
7
f o
r p M
T
B t a y l n
o
:
2 f o
r p M
T
B i e
b r u
n
3
X
5 6 : 4 4
X
6
:
2
1 : 4
4
X
X
S
E
M
D
N
G
A
5 5 : 4 4
X X
2
D
N
G
5
:
2
X
.
9
D
N
G
4
: m
2 p
i
X u
k q
i
n e
h t
n c n
e
r
o e e
t
s s m
n
e s e
r
s r
s a e u
g e
n
5
2 : 4
4
X
M s
a
u r
r b
/ g 0
2 g
0 2 n
e t n
i h . n f u
A
9 A e
w
s
/ +
r
S
P
G
g o
7 : 4 4
X
i 7
n s 7 1
:
2 Z m
u n 5 : : 9
4
e e
l : 9 2 9 5
: X
n
h s
. 2 4 6 l 4 2 o
c c
s
X X B g
g
/ b
/ X X 7
: 4
i
t
e c
a − g g
5 1 n
e t n
i h . n f u
A :
9 9 p
B 5 o
1 .
0
3 : 4
4
X
X l
0 2 : 8
3 O
Z S e O
n
6 :
: 9 9 5
: V E B Z
v
t
e
r
2 4 4 2 T M O
Z S
X X X X S v t
L t
o t
s X E S u
n n o
r b
/ g 0
2 g 0
2 e
n
r o
v . n f u
A
o
r
w
s
/ + S B h
e f 1 3 : 4
4
X
E e t
i
s n
s r 3 1 M h w
g o 5 : : 5
4 o n
n s
n
u e
: 8 2
2 4 6 8 5
: L
E ß o
i
l 4 2 u t
g
i s 0 5 X X B g
g b X X B l c
n . 3
t
1
t / / h e
u c o o
− g c n
s n
g 5
1 e
n
r o
v . n f u
A
P P
e c 5 X 1
4 : 4
4
X
l n o
h a 1
9 2 : 4 4
c A c
s 6 2 3
: 4
e : :
5 8 5
:
2 8
7
3 : 4
4
X
B 4 4 2
X X X X
6
3 : 4
4
X
4
1 : 4
4
X
1 2 1 2
3 3
4 5 : 4 4
X
5 6 E A
k i n
o
r t k e
l E
4 4 X 5
3 : 4
4
X
1 1 1 4 4 4 0
6 : 4 4
: 0 : 3
: 8 A 3
:
1 S 1
8 X 1 F 0
1 1
X 1 X X
:
9
5 : 4
4
X 5
1 : 4
4
X
2
8 5 : 4 4
X 8 7 7
3 : 4
4
X 0 0
0 0
7
5 : 4 4
X 2
. 2 .
1 t 1
0
. g 0 s
. i
1 2 3 o 3 e
0 V 0 S
6
5 : 4
4
X
E A r t
i
e n
g
n u
t s i e L
5 6 5 5 n u
3
: 4 A 3
: 1 .
h c
1 1 1
5
1 : c l
X F X 8 e a
R c
2
: − t
n
k
i e
8 n m
4 h e
1 c r X X
F e u
t S S
3 s s X X E X E
8 s a S S M S M X
A e e E E E E S
1 2 M m M M D K E
7 E M
8 2 : 4 4
X
8
/ A A E R A M
E A 7 G K P I R +
5
1 . t o
P
0 1 3 8 3 5
: S D B D 1
3 1 3
: 4 0
A 3
: 2 3
K 1 1 1 1
X F X
0 0 X 7 7 7 7
2
: 2 1
: 1
: 1
: 1
: : 6
5 : 0
2
:
2 9 4 2 :
008 911 63 BOMAG 6 6 5 5 6 987

18.4 Wiring diagram

1
582 702 29
: 9
8
0
0
9 2
1
3 2
0
7
2
8
5
0 3
7
: G
: : 6
F :
2 4 4 2 1
X X X X
1
: 2
:
6 6
7 7
X X 1
2
−
3
6
: M
:
N 2 4
A
C X X
2
: 5 M
2 M 5 0 M
4 H 7 C C
2 O X M B B
R 0 C i
e t
B b a
1 6 y
r l
2
: − + M u n
8 3 3 C n o
4 N N 1 7
: . B
t
A A
+
3 6
: N s e 5
1 N
2 : 5 t
7 t 1
F C C A
X 4 7 8 i
c
a P
X X n f
C
2 8 8 A h r

: 1 1 c t
e
7 : : S n
7 7 I
N
A N
C A
− C
B −
S B
U S
U
M M
C C
B B
t t
n n
e e
m m
e e
g g
a a
n n
a a
M M
n n
o i
i o
t t
c c
a a
p p
m m
o o
C C
G G
A A
M M
O O
B B
7 7
0 0
0 0
2
. 2 .
1 t 1
0
. g 0 s
. i
3 o 3 e
0 V 0 S
1
3
0
2
:
988 BOMAG 7 008 911 63

Wiring
2
:
diagram 582 702 29 1
:
0
R
H
H
R
18.4
9
9
0
0
7
r r
1 ,
e r
t a
2
7 0 e o
k t
A
5
7 , 1
1
3 h e
c r 2
8 3
/ n a
i X 1
1
2
u r 0
1 l c
i e t
o H 7
2 2
3 : 1
X 1 : 1 6 2 : 1 6 X 4
2 3 : 1
X
1 B d 1 l R
E k a R
K r n
e i n i
i c V , 2
t
l h l
B d e t
t n 8
a t
c
h i A
5
7 , 1 n
i o
h f
c r
5
c w R 1 2 u r
S s 9 0 e
l o
4 R k t
4
1 3 : 1
X 2 : 9
5
X 6 : 9 5 X 6
1 3 : 1
X
1 a
E n i
L H l
i c
3 4 7
0 3 : 1
X
L B
2 2 L H , d n 1
e r i
t
L h a
e
A
5
7 , 1
9 c r
3
1
4
1
4 2 X 1
9
2
u r
e t
o
1
2 3 : 1
X 1 : 0 6 2 : 0
6 X 3 2
3 : 1
X
5
X 0
A 2 1 0 l
H k a
E 6 E L L
6 0 3 : 1
5 8 A A 0
5 3 R
0 8
9
: 9
: V n i
i
, l
c
2 1 2
: 0 5 : L 1 1 e t d
1 F 1 : 1 X t n B n
R 0 1 X o i
h f
X X X c r
A
5
7 , 1
0 3 3 1 2 1
L 8 u r
e o
3 1
3 : 1
X 2 : 8 5
X 6 : 8
5 X 5
1 3 : 1
X
l
L R
0
E k t
a
− − n i
i
l c
7 L L B d
3 B B n
i
S t
r h
9 9 9 g
e l
t i
1
: 1
: W 1 l
4 4 − : a
h d
L 4 c a
r
B s z
k a
3 4 + − n h
i
E X 2 2 b h
n t
r c
9 7 A A a i
8 0
3 : 1
9 6 w
: 0 5 1
1 : 3 4 0 W s
1 F 1 1 1 1 H ,
l . n
X X 4 0
3 : 1
X e o
r B i
t
e
f 1 a
r t n
i
e 0 r h m
w t g
e l
i u
n s
i 1 l l
l
e t 7 7 a i
h h
0 h d
r
c l g 1
i : 1
: c a
s 0 0 s z
s k a
i d
t a
1 1 4
1
n h
i
l ,
e e 1 2 b h
b
r h V V S n t
r c
A e n T T a i
w
ß n t n S S
o i
i W s
i
u b c b
l e a
h a n
c K n c
s i h
t
n e o i
A b C w
4 D
. h
r t n o
r f , s t h g
i l d
a e h g n i k w
r o
s t h
c e
r e n r o
v r e f r e
w n
i e h
c s
s t i e r A 1
b 2
E A 5
A
6 , 4
2 9
1 A 2 5 2
2 5 2 : E
: F 1 : 3 r
1 1 X e
f
X X . h l t n o
r f , s t h g
i l d
a e h g n i k
r o
w r
e O O
r A 1 2
w Z Z
v v
s k n
i l e n
r o
v r e f r e
w n
i e h
c s
s t i e
b
3 n s t
A
6 , 4
i
S t
2 e h t
E h u
d S
a i
c b g
s f l
1 s u D
i A d
t n d
. h
r r a e
r , s t h g
i l d
a e h g n i k
r o
w
:
r A 1 2 3 e e a S u n
g a
s t h
c e
r n e t n
i h r e f r e
w n
i e h
c s
s t i e
b
8 X b D h /
A
6 , 4
a 2 r S S
7
8 E A / n P
o O
S i n n
o
0
3
ß
u P t
l c R u t
t i
5 E e o
h O n h a
. h
l r a e
r , s t h g
i l d
a e h g n i k
r o
w
2 6 r A 1 2 c R n t c i
u n
: 0 7
s k n
i l n e t n
i h r e f r e
w n
i e h
c s
s t i e
b
s i .
1 E 7 n e o c
K 4 8 1 2 A A
A
6 , 4
X : 1 4 2 c
9 2
: 2 5 2 :
: 3 E A b C a e m
l
1 F 1 1 u
e l
l
X X X B i
.
A t
6
8
5
8
Z p
o
3 0
3 : 1
X
6
A
5
2
1 , 0
1 s
t
K h
2
: c
9 e H
r
e R
t ,
h t
s u c h
A
2
4 , 0
X 1
5
2 t H
h l
c R ß
g
e i
l
l
E 0 5 , u i
0
2 3 : 1
X 3 : 1 6 4 : 1 6 X 4
2 3 : 1
X
A A O 1
4 1 1 4 Z E e t
r a
t
2
: F 2 l
−
n d : V e h
g h
1 1 T s t i
A
2
4 , 0
i l c
e e
h h
a X X S X 1
4
2 k H h
n L c g S
u i
2 1
3 : 1
X 3 : 9
5 6 : 9 5 X 6
1 3 : 1
X
c O O X 1 i
l , l n
s g Z S E t e k
e h
s
t Z
i i
v k
v
n t E t r r
k
g a a
e t s h i
A
2
4 , 0
r S M
X 1 2 c l
k u g P p
r S
b o t
e w u L 1 1
3 : 1
X 3 : 8 5 2 6 : 8
5 X 5 X
1 3 : 1 n e n
i
A n o E
8 1 l l i
h
n i
h o B : E e H k
r k
r
ß t 7 t L a
u o i
l t w , P a
h t
A
2
4 , 0
h r
c e
c s
e t X 1
3
2 c h
u g
p
s f
r n E 9 A e l
i
9 1 3 : 1
X 3 : 0 6 4 : 0
6 X 3 2
3 : 1
X
h
n e n g 3 0 A 3 1 1 l
2 1 E ß l
i
A w o i
l : 5 2
1 : : u a
E
6 8
A 3
6 8 c 1 F 1 4 l
h t
2 2 : X X L c
: 1 A : 1 E S
1 F 0
1 1 X B
O
Z
v t S t u o h t i w s t h g i l
X X 3
2 4 d a e h g n i k
r o w n o i t c e n n o c
2
O Z v t S e n h o r e f r e w
1 2 − n i e h
c s s t i e b
r A ß u l h
c s n
A
1 1
1
0 3 : 1
X 2 0
3 : 1
X
7 7
0 0
1 2 3 4 A
5 2
1 , 0
6 5 0 0
O 3 3 1 1 8 8 2
. 2 .
Z O 1 t 1
v Z
t 3 4 X 6 0
. g 0 s
. i
S v
t 5 8
: S 0 3 o 3 e
r S S 1 E K 0 V 0 S
e , 2
t X 0
l h 1 M 1
:
a t
c s t h
g
i l d a e h g
n i k
r o
w , h c t i w s
L 9
h i
c w 0 5 g
n u t h
c u
e l e
b
s t i e
b
r A
r e t l a h
c
S E
S s 1 B s
S 8 t
: h H
7 c R
e t
r
r h
e i
f g
r l
A
6 , 4
s
a
7 X 1
7
2 k
n H
e d
w a
i
0 1
3 : 1
X 5 : 9
5 6 : 9 5 X 6
1 3 : 1
X
8 1 l n e
i
0 E r L e h
7 3 e t
f h
8 r h
A
6 , 4
/ E 6 c
1
1
8 1 A
A 8
1 5 1
7 X 1
6
2
w
g
e l
i S
1 1 K 9 8
9
0 3 : 1
X 5 : 8
5 6 : 8
5 X 5
1 3 : 1
X
K 0 : F 1
3 1 :
1 : 1
E
n d
1 i a
3 e e
X X 9
h h
0 9 0 c
: 1
2 : 2
: S
6 7
008 911 63 BOMAG 8 989

4 2
: 4
1 4 A 1
18.4
n i b a
c t e
k c o
s
: 1 1 5 1 1
: e
t
1 1 F 1
e n
i b a
K e s o
d k c e t S : 1 h
1 1
1 Wiring diagram
1 582
c
u
702 29 0
1
7 F 6
+ − 1 e
l 9 0
5
: 8
:
1 2
1
3
3 n n 2
4 3 S V n o 2
X 2 E e c
F K 1 k a 0
A
5
E 5 5 1 N
I m e 7
+ − B t u b
y
1 A 8 A n n d
r
o r n
r 2
4 0 3 1 2 K o
v f
a
u t 8
F 1 S
2
n
o , R o
r s r 5
i e t
A
6 , 4
5 3 t f
r h
2 E A p e i
g
E Z o l
w
1 2 n d
i a
e e
A
6 , 4
h h n 1
3 c e
s g t
2
E s n n r
t a
i i i e
e k
r h r
1 2 b ,
r s
r o e
A w f t
7
: r h
e i
A
6 , 4
1 8 g
l
1 2 w
E n d
i 1
0 1 2 . e a
e
2 1 3 2 l . m h h
V V 1 7 e l
u c
T T F E
A
6 , 4
b l s g
7 r i s n
t
S S 1 2 2 e h i i
E t c
l e k
r
t
a i b
r o
3 3 h w
1
: 1
: c s A w
9 9 5 S
1 1 n
5 1 3 o
i
e t
I t a
h n
n
i m
3
3 1 t r e g ö z r e v l l a f b A c i
6 4 u m
1 1 e u
l
S K t l
l 2
:
h i 0
c t 1
a h
C 3 1 2 N g
i
3 4 r n
n
o
i t a
n i m
u l l i t h
g
i n e ,
t
l h
A
3 8
, 0
0 0 0 8 a t
c
3
e t h
c u e
l t h c a N
3 A 1 7 5 h i
1 1
0
F E 1 c w
F S 6 S s n t
9 0 r
:
1 : 6 5
X o n
0 M v o
r
1 r f r
4 + − e r a
M h e e
r
c
s h ,
A
8
, 3
a s r
a e
B 2 W w p
e i
2
r w
n
A
7
, 4
5
M o n
2 v e
3 : 6
5
X
4 A : r e
4 1 7 1 6 e r
h c
5
F 0 4 5 s
4 : 6 5
X 0 X c d
W M s i
1
i n h
0 0
W w p
2 a
r h
S g p
o r
h a
n c g
7 e
t a o
0 n r
i T h
a , c
1 : 5
5
X
M h e r
4 + −
r r
e
a
e i a
o t
M h r
e r
, ,
d o
c h r a i
A
8
, 3
s e
a s p
a n i R d
A 1 W e w
w t , a
2
g r
A
9 , 2
5 n n
i
M h e ,
n s
2 r e u t
3 : 5
5
X 2 : 3
X
3 A : e r t
4 5
F 1
7 1
0 5
5
5 h c
s h h
8
4 0 X
X
1 : 3 c d
s i
i n g
c i
l
: 1
4 : 5 5
X
: W M u
1 0
1 1 1
0 1
W w
e d
l a
2 0 2 e e
4 3
F 1
S h h
p
p a B h
,
F 3 9 6 a
r r , n
A 0 A g g e i
+
2 P
+ o o
h h n b
i
A
5
A c
c a
a t
a
b c
T a .
1 3 4 3 K t
A p
A B B C
o
Z
l 6 1 2 3

u 5
d h
o p 6
m a 1 1 y
n r A l c
e g 1 2 u n
A
K 6
o
h h 5
1 : 6 d e
p c 4 5 o u
a 9
, A 5 1 : 3
X
m q
1 7 a t
r a 7 8 4 e
z r
1
: 8 1
g , : , n f
2 0 7
A
G 7
1 o e 3 1 : 6 e ,
3 5 h l C 3 u e
B a
u X A
c d
T
6 1 : 3
X q l u
e d
2 7 5 + − T o D
r
F o
3 2 8 1 o m
E m
:
K 0 + − i o
d i 7 E
1 a d
a 1 P
R r :
5 S
0 1
3 3
4 2
1
: 1 + −
1 A
1
+ −
1
H
: 5 s t h g
i l r o
i r e t n
i s e h c t i w
s
7 7
2 B 0 0
4 r
e h c u e l n e n n I r e t l a h c
S
F e 0 0
t
l 2
. 2 .
− a h 1 t 1
c
h i
t 0 s
H 8 1 2
n I + . g 0
. i
n
i b a
c , t h
g i l e
d
i s n
i
c w 3 o 3 e
e t h
c u
e l n
e n s
t 0 V 0 S
+ − k s
A
5 7
, 1
r
a o
2 A 9 t
4 1 2 r o t a
c i d
n i K n o
F
0
E T 6 o d
k
e t h
c u e
l l o
r t n
o
K
1 8 r
0 S ü
a 1 2 T
7 A 5
8 1 4
G 7 0 7 S
6
: 7
: 8 3 E
:
3 3 3
X X X 3 A 1 e
4 5 4 7 1 2 n i
n
1 1 1 6 8 n e
e
r c s r a e
r g n
i t a e
h i
b b
0 F K 1
: 0 a a
3
e
b
i e h
c s k
c e
H g n u z i e
H
K 0 8 6 5 K c
1 R 8 8 i s
s i
6 a
a l
1 8
: l
1 e e
3
:
3
X
: 2 2 r
2 3 0 3 R 1
K 2
m
r o f t a
l p r o t a
r e p
o t e k c o s + − K 3
: 6
2 :
990 . t s
r e
r h a
F e s o d
k c e t S
S
X
V
2
BOMAG
f o o
r −
n u
s
/ s p
o
R
/ l i a
r −
d
n a h t a y l n
o 0 0
2
: 1
008 911 63
1
D S
/ s p
o
R
/ r e
d n
ä l e
G i e b r u
N
9

Wiring diagram 582 702

1
29 2
1
1
:
2
18.4
9
1
1
0
2
X
0
1 4
1 2
O 1
3 2
B 3 9 0
B 2 1 7
1 8 8 2
7
2
6 8
5 A
1 5
S 5
F 5 2
r e m
i t r e t a e h
g n
u
z i e
H r h u t l a
h c
S 1
1
6 A 5
1 3
,
8 1
=
t
4 r
a
1 A A
7 0
, A A
t
S 4
A 6
, 1 9 8 m
. , i
3 , 0 = 1 2
4 e
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008 911 63
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992 BOMAG 008 911 63

Name Bl. Pf. Benennung title TYP
Wiring
A02
A05 diagram
009 17 Blinkgeber
582 Geschwindigkeitsanzeige
005 17 Elektronik
A06 005 10
702 29
Elektronik Frequenzanzeige vorne
flasher
Electronic system, speedometer
electronic frequency−meter, front
MODUL
MODUL
18.4
A12 010 5 Radio Radio
A13 003 3 Steuergeraet Heizung Control unit, heating
A15 004 16 Ueberwachungsmodul monitoring module
A16 010 7 Elektronik Tachograph Electronic system, tachograph
A51 010 6 Platine Frequenzanzeige Circuit board,frequenzy meter
A66 012 9 Elektronik Steuereinheit Electronic control unit
A67 012 15 Eingabeeinheit Keyboard
A68 006 10 Modul Sitzkontakt Modul seat contact MAX. 0,12A
A72 011 11 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A83 007 6 Elektronik Messtechnik electronic measurement−equipment
S 0 V 0
e 3 o 3 A87 008 15 USB−CAN Schnittstelle BCM USB−CAN Interface BCM
. g 0
i 0
s .
1 t 1
.2 .2
0 0
B03 004 15 Unterdruckschalter Luftfilter Vacuum switch, air cleaner
0 0 B06 004 17 Druckschalter Motoroel Pressure switch, engine oil
7 7
B11 003 9 Signalhorn Warning horn MAX.5A
B11 003 11 Signalhorn Warning horn MAX.5A
B13 004 2 Naeherungsinitiator Fahrhebel links Proximity switch, travel lever, lh.
B14 004 6 Naeherungsinitiator Fahrhebel rechts Proximity switch, travel lever, rh.
B16 005 9 Aufnehmer Vibrationsfrequenz vorne Transducer, vibration frequency, front
B21 004 14 Differenzdruckschalter Hydr.−Oelfilter Pressure diff. switch, hydr. oil filter
B30 004 16 Temperaturschalter Motoroel Temperature switch, engine oil
B55 004 17 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B60 005 14 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 007 12 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 007 8 Beschleunigungsaufnehmer Acceleration sensor
B62 007 10 Beschleunigungsaufnehmer Acceleration sensor
B103 011 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning
B104 011 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B113 003 3 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B124 004 19 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B131 011 10 Temperaturschalter Heizung Temperature switch, heating
E08 009 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
E09 009 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 009 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 009 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 009 7 Parkleuchte links Parking light, lh. MAX. 0,42A
c E13 009 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
o E14 009 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
m
p a B E15 009 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
o u E16 009 2 Scheinwerfer links Head light, lh. MAX. 4,6A
n t E17 009 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
e e
n i l E23 009 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
l
t s
i E23 010 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
l t
i
s e E25 009 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
t
i
n E25 010 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
g E27 009 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 010 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 009 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 010 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 010 4 Innenleuchte Kabine Inside light, cabin 1,75A
E30 011 15 Heizgeraet Heating unit
E32 010 19 Kennleuchte Warning light 5A
E70 010 15 Nachtleuchte Night lamp 0,83A
E71 010 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 010 16 Beleuchtung Bedienschalter illum. Switches
F00 002 4 Hauptsicherung Batterie Fuse, main, battery 125A

F03 006 18 Sicherung Vibration Fuse, vibration MAX. 1,23A
F07 009 15 Sicherung Warnblinker Fuse, hazard light 15A
F08 009 18 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 009 6 Sicherung Park− u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 009 8 Sicherung Park− u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 009 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 002 10 Sicherung Startschalter Fuse, starter switch 30A
F14 002 18 Sicherung Hubmagnet Motor Fuse, shut off solenoid, engine 15A
F15 011 19 Sicherung Heizgeraet Fuse, heating unit BOX2
F18 009 5 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
F19 009 12 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 30A
F22 009 10 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 30A
F23 003 9 Sicherung Signalhorn Fuse, warning horn 10A
F24 004 10 Sicherung Ueberwachungsmodul Fuse, monitoring module 10A
F25 004 2 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 10A
F31 011 3 Sicherung Kabinenluefter Fuse, cabin ventilator
F39 002 19 Hauptsicherung Kabine Main fuse, cab 15A
F40 011 15 Sicherung Kabinenheizung Fuse, heating unit cab BOX2
1 F41 010 19 Sicherung Rundumkennleuchte Fuse, rotary beacon
F42 010 4 Sicherung Kabineninnenleuchte Fuse, inside light cab
F43 010 10 Sicherung Wischermotor hinten Fuse, wipermotor rear
F44 010 13 Sicherung Wischermotor vorn Fuse, wipermotor front
F48 002 3 Sicherung Gluehanlage Fuse, glow plug system 125A
7 F68 002 6 Sicherung Potential 30 Fuse, potential 30 5A
F84 007 5 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
F97 011 13 Sicherung Frischluftluefter fuse, blower fresh air 3A
FM4 007 11 Platinensicherung Multifuse
5 F105 002 16 Sicherung Motordrehzahl Fuse, motor speed 20A
8 F124 003 14 Sicherung Kraftstoffvorwärmung Fuse, fuel pre−heating 25A
2
7 F130 010 15 Sicherung Nachtleuchte Fuse, night lamp
0 F143 010 2 Sicherung Heckscheibenheizung fuse rear screen heating unit
2
2
F144 010 20 Sicherung Kabinensteckdose Fuse cabin−socket
1 9 F146 007 4 Sicherung Steuerung MESX (Potential 30) Fuse Controller (Pot. 30)
0
1 F148 007 2 Sicherung Steuerung MESX (Potential 15) Fuse Controller (Pot. 15)
008 911
G01 63 002 4 Batterie BOMAG
Battery 103A 993

18.4 G02
G03

002 5 Generator
002 3 Batterie
Generator
Battery Wiring diagram 582 702 29
103A
H06 009 15 Meldeleuchte Warnblinker Indicator light, hazard light

H07 004 10 Warnsummer Betriebsstoerung Warning buzzer, breakdown MAX. 0,12A
H14 004 8 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer MAX. 0,12A
H80 012 15 Meldeleuchte Wegfahrsperre Indicator light, anti−theft device LED

K04 006 18 Schrittrelais Vibration Toggle relay, vibration MAX. 1,23A
K05 004 3 Relais Startstrom Relay, starting current BOSCHW
K06 009 4 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 8 Relais Klimageraet Relay, air conditioning BOSCHW
K11 002 10 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHW
S 0 V 0
e 3 o 3 K14 003 5 Relais Vorgluehen Relay, glow plug system BOSCHL
. g 0
i 0
s .
1 t 1 K16 009 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
.2 .2
0 0
K22 004 9 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
0 0 K26 004 6 Relais Rueckfahrwarneinrichtung Relay, back up alarm BOSCHW
7 7
K32 010 2 Relais Kabine Relay, cabin BOSCHW
K35 002 16 Relais Selbsthaltung Relay, holding contact BOSCHW
K36 002 7 Relais Bremskontrolle Relay, brake control BOSCHW
K48 004 2 Relais Fahrhebel 0−Stellung Relay, travel lever 0−position BOSCHW
K61 002 5 Relais Ladekontrolle Relay, charge control BOSCHW
K114 002 14 Relais Motordrehzahl Relay, engine rpm BOSCHW
K141 010 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW

M01 002 11 Starter Starter 2.3 KW
M04 010 13 Scheibenwischermotor vorne Windscreen wiper motor, front 4,7A
M05 010 10 Scheibenwischermotor hinten Windscreen wiper motor, rear 2,9A
M06 010 14 Scheibenwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 010 11 Scheibenwaschermotor hinten Windscreen washer motor, rear MAX. 3,8A
M17 011 13 Zusatzluefter Additional blower
P02 005 5 Temperaturanzeige Hydraulikoel Temperature gauge, hydraulic oil

P03 005 3 Drehzahlmesser Rpm meter
P04 005 19 Geschwindigkeitsanzeige Speedometer
P05 005 11 Frequenzanzeige vorne Frequency meter, front
P07 007 15 Omegameter Omegameter
P09 010 8 Frequenz− und Geschwindigkeitsanzeige Frequency− and Speedometer
P11 007 14 Drucker Printer
P12 005 2 Voltmeter Volt meter
c P14 005 6 Anzeige Kuehlmitteltemperatur Temperature gauge, coolant
o P15 008 16 BCM 03 Bildschirm BCM 03 terminal
m
p a B P16 007 16 Diagnose, Variomatic Diagnostics, varimatic
o u P33 007 18 Opus 21 Opus 21
n t
e e
n i l R03 004 12 Geber Tankanzeige Sender, level gauge
l
t s
i R04 005 4 Geber Hydraulikoeltemperatur Sender, hydraulic oil temp.
l t
i
s e R10 002 6 Parallelwiderstand Parallel resistor 82 OHM
t
i
n R19 002 2 Heizflansch heater flange 167A
g R20 007 17 Widerstand Resistor 60OHM
R79 003 14 Kraftstoffvorwärmung fuel pre−heater 250W
R80 010 2 Heizung Heckscheibe heating rear screen
S00 002 10 Startschalter Starter switch

S01 002 18 Schalter NOT AUS Switch, emergency off
S03 003 9 Taster Signalhorn Push button, warning horn
S13 006 13 Vibrationsschalter Fahrhebel rechts Switch, vibration, travel lever, rh.
S14 009 15 Warnblinkschalter Switch, hazard light
S15 009 4 Beleuchtungsschalter StVZO Switch, lighting StVZO
S20 010 13 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 010 10 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S28 011 19 Schalter Kabinenheizung Switch, cabin heating
S30 002 3 Batterietrennschalter Switch, battery disconnect
S35 006 15 Vibrationsschalter klein/gross Switch, vibration low/high
S37 009 18 Schalter Blinker Switch, indicator
S38 010 19 Schalter Kennleuchte Switch, warning light
S42 006 3 Stufenumschalter schnell−langsam Speed range selector, fast−slow
S42 006 7 Stufenumschalter schnell−langsam Speed range selector, fast−slow
S44 011 3 Schalter Kabinenluefter Switch, cabin ventilator
S45 010 4 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 009 4 Schalter Arbeitsbeleuchtung Switch, working lights
S58 006 13 Schalter Aetherstartanlage Push button, ether starting unit
S86 010 4 Schalter Tuer, links Switch door, lh.
S120 002 14 Schalter Motordrehzahl Switch, engine speed
S158 010 15 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 010 16 Schalter Heckscheibenheizung switch rear screen heating unit
V01 002 6 Diode Diode 4UF004

2 V02 006 6 Diode Diode MAX. 1,23A
V04 011 8 Diode Diode FE5B
7 V09 006 10 Diode Diode MAX. 0,12A
V47 002 15 Diode (A7) Diode (A7) FE5B
5
8 X1:1 002 5 WAGO,E−Kasten WAGO,E−BOX
2
2
2
1 9 X1:7 002 11 WAGO,E−Kasten WAGO,E−BOX
0
994 X1:10 002 4 WAGO,E−Kasten BOMAG
WAGO,E−BOX 008 911 63

Wiring
X1:52
X1:53 diagram
003 2 WAGO,E−Kasten
582 702 29
X1:54 002 18 WAGO,E−Kasten
WAGO,E−BOX
WAGO,E−BOX
WAGO,E−BOX
18.4
S 0 V 0
e 3 o 3 X1:63 002 16 WAGO,E−Kasten WAGO,E−BOX
. g 0
i 0
s .
1 t 1 X1:64 003 3 WAGO,E−Kasten WAGO,E−BOX
.2 .2
0 0
7 7
X1:69 004 13 WAGO,E−KASTEN WAGO, E−box
c X1:89 004 10 WAGO,E−Kasten WAGO,E−BOX
o X1:90 004 9 WAGO,E−Kasten WAGO,E−BOX
m
p a B X1:91 009 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
o u X1:92 005 19 WAGO,E−Kasten WAGO,E−BOX
n t X1:93 005 19 WAGO,E−Kasten WAGO,E−BOX
e e
n i l X1:96 009 17 WAGO ZENTRALELEKTRIK WAGO E−BOX
l
t s
i X1:97 003 9 WAGO,E−Kasten WAGO,E−BOX
l t
i
s e X1:98 003 10 WAGO,E−Kasten WAGO,E−BOX
t
i
n X1:99 003 10 WAGO,E−Kasten WAGO,E−BOX
g X1:100 003 11 WAGO,E−Kasten WAGO,E−BOX
2
2
2
0
008 911
X1:15763 006 13 WAGO,E−Kasten BOMAG
WAGO,E−BOX 995

18.4 X1:158
X1:159
X1:15A
006
006
002
13
16
10
WAGO,E−Kasten
WAGO,E−Kasten
WAGO,E−Kasten
WAGO,E−BOX
WAGO,E−BOX
WAGO,E−BOX
S 0 V 0
e 3 o 3 X1:168 011 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
. g 0
i 0
s .
1 t 1 X1:169 011 7 WAGO ZENTRALELEKTRIK WAGO E−BOX
.2 .2
0 0
0 0 X1:16E 002 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
7 7
c X1:228 005 7 WAGO,E−Kasten WAGO,E−BOX
o X1:22A 009 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
m
p a B X1:22E 009 12 WAGO ZENTRALELEKTRIK WAGO E−BOX
o u X1:23A 009 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
n t X1:23E 009 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
e e
n i l X1:24A 009 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
l
t s
i X1:24E 009 8 WAGO ZENTRALELEKTRIK WAGO E−BOX
l t
i
s e X1:25A 009 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
t
i
n X1:25E 009 18 WAGO ZENTRALELEKTRIK WAGO E−BOX
g X1:26A 009 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
8 X1:32A 006 18 WAGO,E−Kasten WAGO,E−BOX
2
7 X1:32E 006 18 WAGO,E−Kasten WAGO,E−BOX
0 X1:33A 007 2 WAGO ZENTRALELEKTRIK WAGO E−BOX
2
2
1 9 X1:34A 007 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
0
4 X1:34E 007 5 WAGO ZENTRALELEKTRIK WAGO E−BOX
996 X1:35E 007 4 WAGO ZENTRALELEKTRIK BOMAG
WAGO E−BOX 008 911 63

Wiring
X1:37A
X1:37Ediagram
582 702 29
X2:47 007 18 WAGO−MESSTECHNIK
WAGO,E−BOX
WAGO,E−BOX
Wago−measurement equip.
18.4
S 0 V 0
e 3 o 3 X2:57 007 2 WAGO−MESSTECHNIK Wago−measurement equip.
. g 0
i 0
s .
1 t 1 X2:57 007 10 WAGO−MESSTECHNIK Wago−measurement equip.
.2 .2
0 0
0 0 X2:59 007 10 WAGO−MESSTECHNIK Wago−measurement equip.
7 7
c X3:7 010 2 STECKER KABINE/ROPS conn. cabin/ROPS
o X3:8 010 2 STECKER KABINE/ROPS conn. cabin/ROPS
m
p a B X3:9 011 3 STECKER KABINE/ROPS conn. cabin/ROPS
o u X3:10 011 3 STECKER KABINE/ROPS conn. cabin/ROPS
n t X3:11 011 4 STECKER KABINE/ROPS conn. cabin/ROPS
e e
n i l X3:12 011 4 STECKER KABINE/ROPS conn. cabin/ROPS
l
t s
i X3:13 011 7 STECKER KABINE/ROPS conn. cabin/ROPS
l t
i
s e X3:14 011 10 STECKER KABINE/ROPS conn. cabin/ROPS
t
i
n X3:15 010 7 STECKER KABINE/ROPS conn. cabin/ROPS
g X3:16 010 6 STECKER KABINE/ROPS conn. cabin/ROPS
X4:A 007 14 KABINENST. MESST. con. measurem.equipm.
X4:B 007 14 KABINENST. MESST. con. measurem.equipm.
X4:C 007 14 KABINENST. MESST. con. measurem.equipm.
X4:D 007 14 KABINENST. MESST. con. measurem.equipm.
X4:E 007 15 KABINENST. MESST. con. measurem.equipm.
X4:F 008 18 KABINENST. MESST. con. measurem.equipm.
X4:G 008 18 KABINENST. MESST. con. measurem.equipm.
X4:M 008 16 KABINENST. MESST. con. measurem.equipm.
X4:N 008 15 KABINENST. MESST. con. measurem.equipm.
X10:2 004 12 AMP SUPERSEAL AMP connector
X10:3 004 12 AMP SUPERSEAL AMP connector
5 X13:3 004 6 DEUTSCH DEUTSCH connector
X14:A 006 13 DEUTSCH DEUTSCH connector
X14:B 006 13 DEUTSCH DEUTSCH connector
7 X17:3 011 4 STECKER LÜFTER HKL conn. blower
5 X19:1 011 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
8 X19:2 011 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
2
7 X20:1 011 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
0 X20:2 011 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
2
2
1 9 X20:4 011 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
0
5 X21:1 004 17 STECKER KÜHLMITTEL connector coolant sensor
X21:2 004 17 STECKER KÜHLMITTEL connector coolant sensor
008 911
X22:1 63 005 9 ST. VIBRATIONSAUFNEHM BOMAG
connector vibration sensor 997

18.4 X22:2
X22:3
X22:4
005
005
005
9
10
10
ST. VIBRATIONSAUFNEHM
connector vibration sensor
connector vibration sensor Wiring
connector vibration sensor
diagram 582 702 29
X36:A 002 4 EINSPEISUNG SCHALTKAS supply e−box
X36:B 002 4 EINSPEISUNG SCHALTKAS supply e−box
X37:A 002 10 ST. ZÜNDSCHLOß E−KAST connector ignition switch
X37:B 002 11 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X38:A 002 11 ST.STARTER E−KASTEN connector starter e−box
S 0 V 0
e 3 o 3 X44:1 007 13 MESX STECKER MESX Stecker
. g 0
i 0
s .
1 t 1 X44:3 007 15 MESX STECKER MESX Stecker
.2 .2
0 0
0 0 X44:5 007 14 MESX STECKER MESX Stecker
7 7
c X44:59 007 5 MESX STECKER MESX Stecker
o X44:60 007 5 MESX STECKER MESX Stecker
m
p a B X44:65 007 13 MESX STECKER MESX Stecker
o u X44:66 007 13 MESX STECKER MESX Stecker
n t X44:67 007 14 MESX STECKER MESX Stecker
e e
n i l X44:68 007 14 MESX STECKER MESX Stecker
l
t s
i X46:A 007 19 STECKER BOP Connector BOP
l t
i
s e X46:B 007 18 STECKER BOP Connector BOP
t
i
n X46:D 007 18 STECKER BOP Connector BOP
g X46:E 007 19 STECKER BOP Connector BOP
X46:F 007 18 STECKER BOP Connector BOP
X47:A 007 11 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:B 007 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:C 007 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X53:B 011 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:C 011 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:H 011 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:L 011 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:M 011 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X56:1 010 14 STECKER WISCHER VORNE conn. wiper front
6 X56:2 010 13 STECKER WISCHER VORNE conn. wiper front
7 X58:5 009 2 STECKER STVZO VL Con. STVZO FL
5 X59:2 009 19 STECKER STVZO VR Con. STVZO FR
2
2
2
1 9 X59:6 009 19 STECKER STVZO VR Con. STVZO FR
0
6 X60:1 009 18 STECKER STVZO HL Con. STVZO BL
998 X60:3 009 6 STECKER STVZO HL BOMAG
Con. STVZO BL 008 911 63

Wiring
X60:4
X61:1 diagram
009 6 STECKER STVZO HL
582 STVZO
009 19 STECKER
X61:2 009 19
702 HR
29
STECKER STVZO HR
Con. STVZO BL
Con. STVZO BR
Con. STVZO BR
18.4
X65:1 012 5 KEYBOARD Keyboard
S 0 V 0
e 3 o 3 X65:10 012 5 KEYBOARD Keyboard
. g 0
i 0
s .
1 t 1 X65:11 012 5 KEYBOARD Keyboard
.2 .2
0 0
0 0 X68:1 012 15 STECKER LED connector led
7 7
X68:2 012 16 STECKER LED connector led
X69:1 011 13 STECKER FRISCHLUFT LÜ connector fresh air blower
X69:2 011 13 STECKER FRISCHLUFT LÜ connector fresh air blower
Y01 002 13 Magnetventil Startmehrmenge Solenoid valve, start boost fuel MAX. 3.9A
Y04 004 5 Magnetventil Bremse Solenoid valve, brake MAX. 1,8A
Y07 006 14 D*Prop. Ventil Vibration groß E*prop. Valve vibration high MAX. 2,5A
Y08 006 16 D*Prop. Ventil Vibration groß E*prop. Valve vibration high MAX. 2,5A
Y13 002 18 Hubmagnet Motor Shut off solenoid, engine MAX. 3.8A
Y14 011 15 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 011 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y30 006 4 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front MAX. 1,67A
Y30 006 6 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front MAX. 1,67A
Y31 006 3 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
c Y31 006 8 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
o Y120 002 16 Magnetventil Motordrehzahl hoch Solenoid valve, rpm engine high
m
p a B Y138 011 10 Magnetveentil Heizung Solenoid valve, heating unit 3,5A
o u
n t
e e
n i l
l
t s
i
l t
i
s e
t
i
n
g
7
7
5
8
2
7
0
2
2
1 9
0
7
008 911 63 BOMAG 999


9
2
2 1
0 0 0
1 2
7 2
:
:
.
o
2 t
. N
r
N t
8 t e
e
5 B
a h
l
S
2 2
: :
m
n o
o r
v f
:
s
e
1 1 : c
. a
: : f
e e . l
t p
i g s
e a r e
S p E R
0
4
-
D 0
/
4
- 4
-
D D
/
9 4
1 -
. D
2
.
. 9
7 1
7 2
.
.
1 .
W 7
7
n B 1
o
i
t n W
a
n
i
e B
t
m s
O u
l
z l a x
k o
v i d t
e l b
t
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O
S Z t l
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e s c
b S b e
r o
u
N T
g s w
S e
s t i
. 4 n a
5 6 2 5 8 1 1 6 a
c
c
a
0
K
0
K
2
K
3
K
4
K
6
K
1
K
2
K
t i
a h h r
k v
t c c e
y
l t
n i i v
n
o
o w
k s
z t
s
r o
t
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s b
S e
n f
.
e d
n i
e .
c
Ü
g n w c
a o
l r a
0 n c u y
1 r
a i N l
a a n
R o
m o
i
l t 7
K . 7 0
i c
0 0
0 2
e c 2
.
1 t
.
1 s
b a g 0 i
. o . e
0
y
r l 3 V 3 S
u n 0 : 0
. :
:
. e r
: e
N o z m p m
e a e a
G N G N
8
6
A 4
2 6 6 9 0
0 1 3 0
A K K K K
d
t l
e
u b
a
b m
e e
g s
n s
a a
t s
k i
a h
t
1 c
n t
1 o i
K k w
z s
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a
S e
n s
i
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k n
n f
i
n .
e c
w c
r a
y
u l
N n
8 o
3
X
7
3
X
6
3
X
1000 BOMAG 008 911 63


9
2
2 0
0 0 1
1 2
7 2
:
:
.
o
2 N
. N
r
t
8 t
t e
e
5 B S
a h
l
2 2
: :
m
n o
o r
v f
:
s
2 2 : e
c
. a
: : f
e e . l
t p
i g s
e a r e
1 S p E R
2
S M
U C
P B 0
O
4
-
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/
4 4
- -
D
D /
9 4
-
1 D
2
.
. 9
. 1
7 2
7 . .
1 .
7
W 7
1
B
r W
ü
- B
T
n r
e o
t o
s d
a x
k
t o
l b
a -
h e
c
S w
e
t i
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c r
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r v
s
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b
Ü
7 7
0 0
0 0
2 2
.
.
1 t 1 s
g 0 i
. o . e
0
3 V 3 S
1 3 0 : 0
: :
. e
:
. e r
N N z m p m
e a e a
A A G N G N
C C
8
M
8 V
M o
V T
i .
e c
b c g
r a n
u y u
N l r
n e
o u
e
t
3 S
k
8 i
A n
h
c
e
t
s
s
1 e
M
N
A
C
2
F
1
F
008 911 63 BOMAG 1001


WAGO sm art DESIGNER 4.1
1 057 564 17
2 057 564 21
3 2 x 057 564 25 "L" + 793-501
5 2 x 057 564 25 "L" + 057 564 20 + 793-501
7 057 564 22
8 4 x 057 564 23 "L" + 057 564 19 + 793-501
12 18 x 057 564 36 "R" + 057 564 19 + 793-501
30 2 x 057 564 36 "R" + 793-501
32 057 564 35
33 057 564 17
Optional1 : Projek tgruppe : Walzenzüge -4 Klemmenleist en Zeichnungsnummer :

Artikelnummer :
Optional2 : Projekt : D-4/40 Artikelnummer lang :
Zeichnung : gezeichnet: : M. Vogt TEE
Optional4 : Ort :
Tragschiene : Absicherung D-4 komplett Lieferadresse :

03.01.2007 10:21:43 Seite 1
1002 BOMAG 008 911 63



Artikelnummer :
Optional4 : Ort :
Tragschiene : Absicherung D-4 komplett Lieferadresse :

03.01.2007 10:21:46 Seite 2
008 911 63 BOMAG 1003


1 057 564 17
2 2 x 057 565 40 "R" + 793-501 + 057 565 36
4 2 x 057 565 40 "R" + 793-501
6 3 x 057 565 39 "R" + 793-501
9 057 565 37
10 4 x 057 565 38 "R" + 793-501
14 057 565 37
15 3 x 057 565 38 "R" + 793-501
18 057 565 37
19 3 x 057 565 40 "R" + 793-501
22 057 565 35 "R" + 793-501
23 057 565 37
24 5 x 057 565 40 "R" + 793-501
29 057 565 37
30 2 x 057 565 38 "R" + 793-501
32 2 x 057 565 39 "R" + 793-501
34 057 565 37
35 4 x 057 565 38 "R" + 793-501
39 057 565 37
40 4 x 057 565 40 "R" + 793-501

Artikelnummer :
Optional4 : Ort :
Tragschiene : Kabelbäume D-4 komplett Lieferadresse :

03.01.2007 10:10:25 Seite 1
1004 BOMAG 008 911 63


44 057 565 39 "R" + 793-501
45 057 565 35 "R" + 793-501
46 057 565 37
47 2 x 057 565 40 "R" + 793-501
49 057 565 37
50 057 565 40 "R" + 793-501
51 057 565 38 "R" + 793-501
52 057 565 37
53 4 x 057 565 40 "R" + 793-501
57 057 565 39 "R" + 793-501
58 057 565 37
59 4 x 057 565 40 "R" + 793-501
63 057 565 37
64 057 565 40 "R" + 793-501
65 057 565 35 "R" + 793-501
66 057 565 37
67 057 565 40 "R" + 793-501
68 057 565 35 "R" + 793-501
69 057 565 37
70 057 565 38 "R" + 793-501
71 2 x 057 565 40 "R" + 793-501
73 057 565 38 "R" + 793-501
74 057 565 37
75 4 x 057 565 40 "R" + 793-501
79 057 565 37
80 057 565 40 "R" + 793-501
81 057 565 39 "R" + 793-501
82 057 565 37
83 057 565 40 "R" + 793-501
84 2 x 057 565 38 "R" + 793-501
86 057 565 39 "R" + 793-501
87 057 565 37
88 057 564 17

Artikelnummer :
Optional4 : Ort :

03.01.2007 10:10:25 Seite 2
008 911 63 BOMAG 1005



Artikelnummer :
Optional4 : Ort :

03.01.2007 10:11:17 Seite 3
1006 BOMAG 008 911 63



Artikelnummer :
Optional4 : Ort :

03.01.2007 10:11:17 Seite 4
008 911 63 BOMAG 1007


1 057 564 17
2 2 x 057 565 40 "R" + 793-501 + 057 565 36
4 057 565 39 "R" + 793-501
5 057 565 37
6 057 565 38 "R" + 793-501
7 2 x 057 565 40 "R" + 793-501
9 057 565 38 "R" + 793-501
10 057 565 37
11 2 x 057 565 40 "R" + 793-501
13 057 565 39 "R" + 793-501
14 057 565 37
15 057 565 40 "R" + 793-501
16 057 565 38 "R" + 793-501
17 057 565 40 "R" + 793-501
18 057 565 37
19 057 564 21
20 057 564 25 "L" + 793-501
21 057 564 17

Artikelnummer :
Optional4 : Ort :

04.01.2007 10:51:25 Seite 1
1008 BOMAG 008 911 63



Artikelnummer :
Optional4 : Ort :

04.01.2007 10:51:41 Seite 2
008 911 63 BOMAG 1009


1 057 564 17
2 4 x 057 565 40 "R" + 793-501
6 057 565 37
7 2 x 057 565 40 "R" + 793-501
9 4 x 057 565 38 "R" + 793-501
13 2 x 057 565 39 "R" + 793-501
15 057 565 37
16 057 564 17

Artikelnummer :
Optional4 : Ort :

03.01.2007 10:28:28 Seite 1
1010 BOMAG 008 911 63



Artikelnummer :
Optional4 : Ort :

03.01.2007 10:28:30 Seite 2
008 911 63 BOMAG 1011


9
2
2 0
0 0 1
1 3
7 3
:
:
.
o
2 N
. N
r
t
8 t
t e
e
5 B S
a h
l
1 1
: :
m
n o
o r
v f
:
s
e
1 1 : c
. a
: : f
e e . l
t p
i g s
e a r e
S p E R
0
0 4
-
4
- /
D
1 0 D 4
/ -
7
0 1
6 6
9
X
6 9
X X
6
X 4
- D
D 9
X X 7
X X
6
X
6
X 1
9 2
1 . .
2 .
. 7
0 0
.
. 7
8 1 8 1
7
7 1
X X X X
7
6
7
6
1
X X
W
W B
B w
t e
h i
v
c r
i
s
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r
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k c
c e
1 1 t n
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2
X
2
X S o
C
0 0
2 2
X X
7 5
7 5
5 X
5 X
X 7
7 3
X X 3 7
X 7 0
2 3 4 2 3 0 0
1 1 X 1 2 4 1 2 0 2
.
X X 1 1 2
.
X X 4 X X 4 X X X 1 t 1 s
g 0 i
1 1 . o . e
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1 X 6 7 8 4 1 X 4 3 V 3 S
1 3 3 3 4 1 4 0 : 0
: :
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X X X X X X X :
. e r
z m p m
2 6 2 6 6 7 8 e a e a
4 4 4 4 3 3 3 G N G N
X X X X X X X
4
5
X
3 7
5 1
7 X
X 1 5
X 7 3 8 9 4
X 6 5 1 1 5
5 6 8 9 7 X X X X
7 7 1 1 4 X
X X X X 7 6 5 9
5 9 X 5 X 6
4 6 X 6 X X
7 5 X
X X
9 8
5 5
9 8 X X
5 5 9
X X 4
2 X 9
2 4
X 8 X 2
4 2
X 8 X
4
X
1012 BOMAG 008 911 63

008 911 63 BOMAG 1013

Design status: from February 2008
1014 BOMAG 008 911 63


1 1
4 0
2 0
r
e
t 0
a
e
h
7
−
e 2
r
p 8
l
e
u
f
S
P
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n n
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1
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g o i u a Z a n 0
c
n e , w q
s e M t , o
v r c
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s i
, n r
t m t o d
n i t a
i a l a e t n h , m
n l a e g
c a l r
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− a s m a e t
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n
m g , r
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a n g p s u i o e a
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t
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i
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t
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e
s
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l
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g a a k g o a
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, − f
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n r a e n i n n
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n
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D , h b i
r t r m m h n
n t l
y e e o o
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i
t i
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n k i c d n A l
l a a
p
c c p g a o
r i M
n i e t . t
t . t
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n i u n r d p O p p p n o
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f C s e b m n p
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g
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m
r g −
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l
ä
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v
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f , r a h
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g − S i
c
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r V e d l ,
d o ,
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t n h a n Z , a −
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v g l D
g n s
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0 0 M i
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k M
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4 4 n , a t o d
t t
− − e h w r n i t n h
c g s
D
t
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z
4 4 u n S a k
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− − r g
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l z n
i u , c o t
h , n s c e
p n e 7 7
D D n s c e
f n e R h n e t C u n n l t
u u H , c e f s e i i h l
e
s
i 0 0
0 0
9 9 t
o
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l − e
r r s i
u s
a g t
e
G l b b t
A e a a
a l
i 2
. 2 .
1 1 k m s m
w
o o r e r s
M
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s t
b
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n
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u
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t e o e r b n a A O A A A i e u
a
1
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Ü A F Z B Z Z Z D B 6 o 6 e
7 7 0 V 0 S
7 7 r
1
1
e
W W m
B B m
u . 1 1 1 1 1 1 1 1 1 1 1 1 1 1
n o 4 4 4 4 4 4 4 4 4 4 4 4 4 4
s n 2 2 2 2 2 2 2 2 2 2 2 2 2
g − 2
n 0 0 0 0 0 0 0 0 0 0 0 0 0 0
: h u g 7 7 7 7 7 7 7 7 7 7 7 7 7 7
s : n
i
n 2 2 2 2 2 2 2 2 2 2 2 2 2 2
i
w 8 8 8 8 8 8 8 8 8 8 8 8 8 8
n t c
s i
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r
5 5 5 5 5 5 5 5 5 5 5 5 5 5
h n Z d
c t
i e
e n
z o
r c
e f
v : . : .
s o r o
t
l e N t
n 1 2 3 4 5 6 7 8 9 0 1 2 3 1
0 0 0 0 0 0 0 0 0 1 1 1 1 0
a l t e 0 0 0 0 0 0 0 0 0 0 0 0 0 1
h b t e
a h
l
008 911 n
63 a
I t B s
BOMAG 1015

2
:
1 1 9
: 9
18.5 :
8
0
1
:
3
7 1
:
1 7 7
Wiring diagram
1
582 702 41
: 1
2
0
0
3 8
/
1
6 2
8 : 2
:
: 4 1
3 4
1 A 2 1
3 F 0
1
3 2
K E 9 A
0 3 5 0 K S ? ? 0
3
: F
1 3
:
1
7
1 1 2 X 1
5 : 8 3 2
3 2
X 8
a 2 g 5
7
8
5 : 4 1
1
2
1 5
1 a 4 5
u
t
l
a
0 E A : 7 5 5 h f
3 7 1 2 7 2
1 0 8 1 2 c f
2 1 2 X 3
1 1 s o
2 2 b t
1 7 X X a u
A
8 . 3
1 8 1 1 f
f h 1
X X 1 s
K 0
1 4 A
1 1
5 2 2 7 o l
t
: 5
1
: 2 : 8 3 s e
t
2 F p 1 f f
1
X S o
t
K 5 Y a u
r
U
S K
A −
.
− g
T r
1 O e 1
0 N m
S E
l
t c a t n o
c − t a e
s h c t i w
s t u o h t i w
r e t l a
h
c s t k a t n
o
k z t i S e
n h o r u n 9 h d
5 m a
m
W 3 z e
q
5
W 6 h e
7 1 8 .
2 H p
e s
r
E A 8 X 5 x
2 A
7 7 + 1 2 D e
1 1 2 1 − X 6 t i
e n
m
m
q 4
1
1 1 0 X 1 n g
n
X 3 6 5 g e
A X
5 0 8 8 X a .
X
U
A A
0 2 a 0 /
1
m l
1 4 8 7 2 0
A
b o
F 1 0
1 7
6 u s
1 4 6 Y 5 H
K 5 : 7 :
1
: 3 1 4 1 4
2 K X V X 1
2 1 :
2
3 4 1 6 5
2 2 8 8 8
2
: 1
7 0 3 X 4
8 8 1
1 6
1 A K 1
1 7 1 2 :
X 1 2 8
/ 2 e
0 1 5 g l
3 0 n e
a K e f
u
7 m
4 5 8 1 r t
5
: 3 0 s
h o
5 K
6 0 Y A 1 2 e o
1 1
: 2 S m b
2 1 1 t
r t
0
1 S 0 U 0 a r
: d e e p
s e n
i g n
e h c t i w
s 4 0
/ Y t a
t
2 4 4
−
S s
g
− D
l z h e
r d
r o t o
M r e t l a
h
c
S
D n
9 3 u
1 1 4 h l
2 2 − c e
i l
.
. . D u
e f
3 . .
. 1 2
7 l −
g t h d
5
:
1 7
1 7
9 7 n s a e
2 1 2 1
3
1 1
a o z e
:
1 a X 5
4 Y W
s o
u b h p
1 0
5 8 A
: B n
i e s
r
8 M d −
0 7 B
: a
7 1 3
X
0
5 −
r r
e t
e
r n
3
K
1
9 7
3 0 8 X 7 t e
r r o i
t
1
3
X 3 1
X 0
M a t
t a
S s
o g
n
1
: 3 1 M e
8 4 2
2
: 6 5 7 2:6 B+ 0 , ,
5 5 3 8
: : 8
0 3 M n t
i
:
5 4
:
1
1
K 4 e n
t
0 4 1
5 9 1 K 6 5 r u
3 7 X 8 8 a g
t
A
m
5
2
1
1 2 n
S t
, i
5 1 5
1 X 5
1 :
1 r
g t
n a
E A A
5 3 0 5 :
1 A
1
K X 8
1
: 3 1 7
1 F 1 : 3 3
:
1
1
: u s
,
2 g
g n
i n o
i t i d
n o
c r i a o t . c c a y l n
o
X X X r h X r l
y
t c
e t e g a
l n a a m
i l K i e b r u n
o p
l i
a
h w
s
r p
0 c s
g a 6 5 e u
0
S
s n
t
r i
a t
r
0
3
7
8
8 8
V s
t a 9
S t 0 8
s K 6
1 7 1
:
6 6
: 8 1 7
:
K 2 X 2
6 5 1
M 8 8
H 6
: 2
:
0 O 5 8
1 2 2
:
R 8 5 X 6 6
8 S
/ 3 4
1 2 1 E K :
6 M W 4
0 K +
1
: 1
2 1 D 6
0 6
:
+ V 2 1
B 5 + X
6 5 1 6 D W
8 8 r r
o t
t o
1
A
m
5
2
1
6 1 1 a
r a
K X X e r
e
8
: n n
2 e e
− G g
+ 2 B
B 0
G e y
i
r r
e t
t e
t
2 1 e y a t
a
i
e
s u f n
i a m
+ − 1 2 r r B b
g n
u
r e h
c i s t p
u a
H
1 t e
e t r h 7 7
9 : 1
X A
: 6
3
X 0 0 t t e c
t 0 0
0 A a a l t
i 0 2 0
2
: 2 F
5
G b a
n
o i t p
O
: 2
1 0 B h w 2
. 2 .
3 3 3 c s
4 −
D 7 7
1 W
B t a y l n o n o
i t p o
S s k 2 t 1 s
n a . g . i
1
0
1 : 1
X 4 −
D
7
7 1 W
B i e
b r u
N
2
: 2
: n r
e 6 o 6 e
8 9 e b
r 0 V 0 S
5 5
c i S 2 1 T
2 g u
l p w o l g e
s u f
B
: 6
3
X 1 1
F F
2 w
z
r e
k l e
d n
e
w h ü
l G g n u
r e
h
9 A
5 0
2
: 1 5
3 F
2 1
1 g u l p w o
l G e
s u f
2
:
1 e
z
r e
k l e
d n
e w h ü
l G g
n u
r e
h
c i S
8 8
4 5
A
0
F 1 5
F
e y
i
r r
c i S 2 1
e g n
a l f −
g n
i t a e
h e s u f
+ − 1 e
e t
t
t t
h
c s n a
l f z i e
H g n u r e
h
8 3 3 a a
4 A
5 0 B b
F 2
1 G
n
o
i t p
o e s i w
r e
h t o , n o i s
r e
v A
S
U 0 4 −
D d
n a 4 −
D 9 1 2 W
B t a y l n
o
1016 n o i t p
O t s n o
s , n o i s BOMAG
r e
V A
S
U 0
4 −
D d
n u 4 −
D
9 1
2 W
B i e
b r u
n 008 911 63

Wiring
1
:
4
diagram 582 702 41 1
:
4
18.5 3
0
0
7 1
8
/ 1
N
S e n h o 4 −
D 1
1 2
W
B
/ 0
4 −
D t a t o n 3
1
1
1
N
S e n
h o 4 −
D 1 1
2
W
B
/ 0
4 −
D i e
b t h
c i n
K
V22
n
r
2 1 n o
0 r h
0 o 1
1 1 h g
l n
a i
n
1 2 1 n r
1 g a
A
2
. 4
X i
B S w
V21 9 1

8 2 9
3 4 9 0
5 2 2 1 1 n
5 1 1 2 1 X n r
1
: r o
E A 1 X 7 X 1 o h
8 2 8 3 4 9 0 h g
l
2 1 2 X 1 1 1 1
a i
1 1 1 1 1 2 n n
n
1 g r
A
2
. 4
X X X X i
3 0
A B S a
n
r o
h g
n
i n
r a
w . t u b h
s u
p
2 1 w
F
n
r o h
l a n
g
i S
r e t s a
T
3
0
S e
g a k c a p r e t n i t p o
i w n o
t e
k a p r e t n
i W n o
i t p
O
7 8
1 1
2
: 2
:
E A 1 1
7 1 2 7 X 1 2 X g r
3 3 n e
u t
1 1 1
: 2 m a
X : r e
A X
4 5 7 9 7 ä h
2 6 7 6 −
w e
1 2 X R X r
F o r
v p
f l
f
o e
t u
s f
t
f
a
r
K r
e
g t
a
n e
u h
2 m −
e r e
z
r 2
e g
ä r
0 7 1 2 k u
l r p
w
o l
3 8 e l
1 8 0 d p
n w
e
v u
.
4 :
A
7 5 e l
o f
f f
1 9 R w o ,
K 3 h g t
ü
l s n
t r
1 G f o
a
r h
l o
r t n o
c − g
n i w
o l g −
l u d
o
m
e
z g
t ä
r e g
r e u
e t S t i e
z h ü
l G
r 1 K n
0 1 2 e g
k u
l , i
3 H e l n n
r r
d p
0 2 0
A n w o a
5 1 0 5
R
e l
w
o h
l w
K 3 h g a , .
T ü
l n t
3 6 5 7 G g n
i
5
1 1 R 8 8 5
S o
A 1 , c
6 1
. X h e
2 L 4 c g
1 R 2 1 2 s n
K 1
: n l
a
3 a f
l
f −
M
H
O
−
K
0 2
2
4 −
D 7 7
1 W
B t a y l n o z g
i
4 −
D 7 7
1 W
B i e
b r u
N n
e i
H t
− a
r e
o h
t
5 8 o e
n
7 7 H
Ü G 2
L 1 : 5 M i
g
1
X
1
X n
e
a e
r a −
e n i g n
e n i d e
l b
m e
s s a
h c i e
r e b
r o t o
M m i u a
b n
A
1 2
a e
r a − e
n i g
n e n i d
e
l b
m
e s s a
h c i e
r e b
r o t o
M m i u
a b n
A
4 r
1 u e
t
K r
a u
: r t
2
3 e
e
g n a l f − g n i t a
e h s i a
l e
r
1 6 a
p r
e
h
c s n
a l f z i e
H s i a l e
R
4 m p 7 7
5 1 2 6 e
t 0 0
l m 0 0
e t
t e 2
4 3 1
1
B 1
X 7
t
i t . 2 .
7 m n 2 t 2
5 l a 1
. g 1 s
. i
l
h l 6 o 6 e
2 3 1 ü o 0 V 0 S
X K c
r r
3 o o
1 s s
n n
l A e e
S s
l o
r t n
o
c − e g n a f −
g n i t a e
h l u
d o
m
g n u
r e u
e t s h
c s n a l f z i e
H l u
d o
M
2
5
) ) e
1 3 4 h g
X (
0 (
7 c n
1 2 s l
3 8 n a
a f
l −
9 f g
A
7
6
1
7 2
: A 6
2
: 4 1 z
i i
n
8
/ 9 7 8
8 : 2
: 1 e t
1 5 8
/ 1
5 8 K 5
: R
H a
1 1 5 1
1 4 3 1 e
K F 0 K
F F 3 h
K n
o
i t p
o e s i w
r e
h t o , n o i s
r e
v A
S
U 0 4 −
D d n
a 4 −
D 9
1 2 W
B t a y l n
o
0 3 3 4 0 2 0
: : : 1
2 : 1 : 2
n o
i t p
O t s n o
s , n o i s
r e
V A
S
U 0
4 −
D d n
u 4 −
D 9
1 2 W
B i e b r u
N
: :
2 2 2 2
008 911 63 2 2
BOMAG 2 1017

18.5 1
:
Wiring diagram
1
582 702 41
: 1
4
0
0
5 5 4
7 1
3 2
8
/ 0
1
1 7
K 2
8
5
1
1
,
.
r
n ,
i
e m
n r
r l
a a
w a
r
h p
a u
f
k k
c c
a
ü b
R ,
, e
e k
s r
a
m b
e
r
2
B
: 9
7 :
7
2
:
5 A
2 7 7 r
F 7 8
/ 1 e m
8 6 1 m r
0 2 : a
l
4 1 m
3 K 1 1 2 X u a
1 s p
6 a n u
r
2 7 1 9 + − 9 a k
A
m
0
0 3
K X X 4
1 X c
: 8
6
H
w
r a
4 h b
3 a r
f
k e
5 c z
1 ü z
n o
i t i s o p − " 0 " d
n a s d
r a
w
r o f h c t i w
s y t i m
i x o
r p
: u
l l u
N d n u . w
r o
V
r o t a
i t i n I 1 5 R b
1 2 X 6 8
8
3 N K 3 A
m
5
2
1
6
1 B B 1 2
X / / X K
R W 9 8
B S 3 2 :
1 4
X
U 3 : S
2 1
1 8 E X e e
B
4 / X M s k
1 L 7 0 m a
r
B B 4 5 E 7 e b
r
1 1 K 1 B e
: : A 1 l l
v
1 1 R : i
t
X 1 2 X B 1 n a
1 1 1 2 X e v
A
5 . 2 v i
t d
1 3 4 e o
0 1 0 n n 7 7
7 1
: Y g e 0 0 0
8 S
8 1 a l
o 0 2
0 6
: 1
: X M s 2 .
3 5 . 2 s
2 2 t 1
i
1 . e
g 6
. o
6 a A 9 6 S
3 7 7 : 0 V 0
7 K
7 8 7
8 : 8 :
0 2 8
3 4 6 6 5
K 8
/ 8 8
8 a 8
4 7 4 5
A
m
5
2
1
K K 0
: 8
2 K
4 8 1
r p 4
1 1
:
n o i t i s o
p − " 0 " r e
v e l l e v a
r t h
c t i w
s y t i m
i x o
E A : 2
9 9
0 " l e b e h
r a
F r o t a i t i n I 1 6 5
2 1 2 2 1 2 X 8 8
1 1 6 2 N K 2 8
A
m
5
2
1
X 5 0 X 5 1 B B 1 4
A
2 1 1 X / / X K
7 F : R W 3
8 1 B S 3 :
/ X 4
1 2
1
) n
i e e
s m
e
r B
( n o i t i s o
P
9 1
K 0 n i t e n
f f ö e g
3 U
B
1
X 4 3
1 / 1
:
1018
0 B L
B BOMAG 1 0 008 911 63
2
: X 2
:
3 3

Wiring
1
:
diagram 582 702 41 1
:
18.5
1
5
0
0
7 6 4
7 1
3 2
8
/ 0
1
1 7
K 2
8
6 5
2
−
1
:
5 1
X
) )
n e
e d
t i 7 3 9 6
2
n s
i 1 1
h k
c
n a 1
o b
v 5
t m 2
h o
r
c f
i
s w 5
n e
A
( i
v
e (
e
g
i l
u
e d
z 3
n o
a m
l
e g 1
m n
i 2
m r
o
a i
t
S n
r o
e 8 4
1 0
k m 1
c g 2
e l
t u
s
l p
n
a i
r
t
n a
e m
Z
6 6 6

1
: 1
: 1
: 4
7
: 0 0 0 9
: −
3 1 1 1 7 2 8 D 4 i
1 0 − e
1 1 2 7 D h
H 7 c
R L 6 1 7
Ü W − − /
− L 1 1 1 7
X
8 7 s
b
L L L 8 1 X 0 X W
B 1 a
G B B B 6
A
1 1 1 + − / W r
e
0 B s
1 1 8 4 / s
− 0 a r
r e
d
i e
h
c s b
a
r e
s
s a
W
X X X 4 D 4 o
t
2 i − W a
1 e r r
B b D o a
t t
a s p
h t n e
s
t c o
i e s l
n
h
c
s
k n n S r
e e
e .
e
r n
i
l t v
a d l g
h l
ü
l b
n
r
e
r
e e
g
r r
a
k
n
i
k
n
i z
t 2 8 1
: 2
: w n k n g
o l l i
7
: 6 . a c
V W B B S
2 3 9 2 1
:
1 1
1
2
1
2 s t
s o u n
3 4 1 n l t h i
1 1 2 2 X X X X e s
e t
s i
t t c r
o
5
1
d
n a
t s l l ü
f l e
t t i m
l h
ü
K
m
l
n
a
l
a i
t
5 h o w
r n
5 Q e ü o
e o
1 : 6 0
B
B r K c
u b m
9 : 7
k s
c s
1
1
6
7
3
7 u e
r Ü
1 2 d r
l p
k c u
r d
l ö
r o
t o
M
1 1 ö
r l
i
X X 6 o o
4
7 7 0 P t e
7 o e r r
: : B M n u u
i
1 1 g t t
8 X X n r a
a r
1 e e e
r u t a
r e
p
m
e t l Ö
p p
m m
2 : 0 3
B
2 t 0 e
6 : 6
e t
X r o _ 3 t
r l
s n e
S
1 6 : 1
B e i l
1 7 r n Ö o
6 7 6 e a
t
1 3 4 l e
i l
f
t c
r e t l i f t f u L
1 1 7 f r
X X 5
: u i
3 1 L a
0 P r r
B X e e
t
l
0
1 6 f n
i
l a
7 1 0
1 3 4 k
e
ö l
1 i c
l i
1 1 7 u l
a o
r e t l i f l ö
k i l u
a
r d
y
H
X X 1 r
1 1
: k
i
d l
7 2 P 1 y u
4 8 B X H a
0 r
1 4 d
− 0
e
s m
e
r B
X A y
7 D 4 h
S 8
: i −
R e
+
D
U 8 b D
9 : 7
O
9
4 3
K : t t
a
H 0 6 7 4 h t
1 : c o
i
2 n n
5 8
/ 1 6
K
+
D
1 7
X 1
L 9 5 1
: r l
E 0 0 1 e e
U
F 1 1 1 2 r l 3 X u
b f
e o b e r
e l
u
e
g
i e
z n
a
k n
a
T
1 1 0 3 0 g e
k d
g d
i X X 1 0 1 n n
e X R X a
z o T e
s
n m 6 4 3 5 5
2 2 2 2
a g
l 7 7
n 5
D
N
G
e i 1
2 .
l 9 2 0 0
r 1 0 0
4 T
m
5
/
T
U U e : 8
: 2
o A 7 . 2
B
t
i
5
1 O O
L Z 1 g .
m X n 2 t 2
a n : E T u 1
. g 1 s
S o 1 B I
S r
ö e
. i
6 o 6 e
m 6 t r 0 V 0 S
6 5
: S u
2 8 0 9 l
r i
: 1 8 e f
a
4 m r
2 1
1 2 F X 1 + 7 P m e
X u z
0
H
s z
u
E A n
r b
1 4 0
A
1 a
3
: 2 1 3
: W
1 F 1 5
X X 0 6 8
9 8
1 2
X 2
7 K
8
/
1 8
1 1
:
1 2
K 3
0 0
2
: 2
:
008 911 63
4 BOMAG 4 1019

5
18.5 e
:
0
1 Wiring diagram
1
582 702 41
: 1
6
0
0
7 4
r e t e
m o d e e
p s
g
i Z
e
. z n a
s t i e
k g
i d n
i w
h
c s e
G
z r N 1
3 2
n e
a t
A 0
2 3 s e
t
i m
L
E 1 2 7
9 + − 9 e o B 2
1 1
k d
g e 8
X X
i e
d p
1
2 E
:
2 X
5
4 n
i s
X
E P
0 w n
P h o
c i
s t n
e p 1 2 e s
G o g r
i o 1
A e t
Z
1
3 E
: z a
c
+
T
U
O −
T
U
O 7 0
7 n i
6 E P A d
2 : n
g i
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Dokumen - Tips - bw211 212 213d 40 Service Manual e 00891163c08pdf PDF

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BW 211 / 212 / 213 D-40

Single drum roller

008 911 63 BOMAG 3

7.12 Batteries 130

4 BOMAG 008 911 63

12.27 Checking the compression 361

008 911 63 BOMAG 5

16.3 Removing and installing the oscillating articulated joint 508

6 BOMAG 008 911 63

008 911 63 BOMAG 7

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

You should only use genuine BOMAG spare parts.

8 BOMAG 008 911 63

Safety regulations 1.2

by attaching a clearly visible warning tag to the

Workshop equipment and facilities as well as the

008 911 63 BOMAG 9

1.2 Safety regulations

10 BOMAG 008 911 63

Safety regulations 1.2

008 911 63 BOMAG 11

1.2 Safety regulations

12 BOMAG 008 911 63

Safety regulations 1.2

Special safety regulations

008 911 63 BOMAG 13

1.3 General repair instructions

14 BOMAG 008 911 63

General repair instructions 1.3

008 911 63 BOMAG 15

1.3 General repair instructions

16 BOMAG 008 911 63

General repair instructions 1.3

008 911 63 BOMAG 17

1.3 General repair instructions

tion colouring matter makes any warranty claims Fuel hoses

18 BOMAG 008 911 63

General repair instructions 1.3

008 911 63 BOMAG 19

1.3 General repair instructions

Feather keys and keyways Ball and roller bearings

20 BOMAG 008 911 63

General repair instructions 1.3

008 911 63 BOMAG 21

1.3 General repair instructions

Strength classes of metric screws Strength classes of metric nuts

Fig. 8 Identification of nuts

Strength class of Strength class of associated

22 BOMAG 008 911 63

General repair instructions 1.3

Fig. 9 Identification of nuts in clock system

008 911 63 BOMAG 23

1.4 Tightening torques

The values specified in the table apply for screws:

Tightening torques for screws with metric unified thread1

Tightening torques for screws with metric unified fine thread1

24 BOMAG 008 911 63

Tightening torques 1.4

Tightening torques for wheel nuts (fine thread) 1 2

008 911 63 BOMAG 25

1.4 Tightening torques

The values specified in the table apply for screws:

26 BOMAG 008 911 63