Service - Training

BF 300_C
S/N 821 837 57 1001 ....
S/N 821 837 69 1001 ....
S/N 821 837 82 1001 ....
S/N 821 891 03 1001 ....
S/N 821 891 04 1001 ....

Road Finisher

Catalogue number
008 922 07 02/2013
 Table of Contents

General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 13
1.4 Tightening torques 23
Technical data 27
2.1 Technical data 28
Maintenance 35
3.1 General notes on maintenance 36
3.2 Fuels and lubricants 37
3.3 Table of fuels and lubricants 39
3.4 Running-in instructions 40
3.5 Maintenance table 41
E-Plan wiring diagrams 43
4.1 Understanding E-Plan circuit diagrams 44
4.2 Circuit symbols in E-Plan 53
4.3 Identification of switch blocks in the wiring diagram 56
4.4 Designation of components in the wiring diagram 57
4.5 Terminal designations in wiring diagram 58
Electrics 61
5.1 ECOMODE 62
5.2 Glow plugs, R81-R84 65
5.3 Speed sensors, B191 and B192 66
5.4 Oil pressure switch (B06) 67
5.5 Coolant temperature switch (B53) 67
5.6 Air filter vacuum switch (B03) 68
5.7 Coolant float switch (B55) 68
5.8 Charge control light 69
5.9 Glow plugs 69
5.10 Water separator in fuel filter (B124)) 70
5.11 Level sensor in diesel tank (R03) 70
5.12 Fuses 71
5.13 Fuse assignment 72
5.14 Component overview 75
5.15 Overview of wiring looms 78
5.16 Control elements 86
5.17 View of operator's stand 87
5.18 Monitoring modules 88
5.19 View of outside control stand 90
5.20 View of screed control 92
5.21 View of electric heating control panel 93
5.22 Functional block diagram overview of functions, complete 94
5.23 Block diagram components on CAN 95
5.24 Block diagram CAN with control elements 96
5.25 Block diagram of travel circuit 97
5.26 Block diagram material feed 98

008 922 07 BOMAG 3

Table of Contents

5.27 Block diagram screed 99

5.28 Block diagram screed levelling 100
5.29 Block diagram screed heating 101
5.30 Functional block diagram monitoring functions 102
5.31 Block diagram Emergency Stop functions 103
5.32 Checking the voltage supply for the control unit 104
5.33 Diagnostics concept 112
Input codes 115
6.1 Input codes -- display: Functions and operation 116
6.2 Automatic calibration of travel system currents 117
6.3 Automatic calibration of travel system currents 120
6.4 Teaching the E-throttle function: 123
6.5 Teaching the L.C.S. function 124
6.6 Travel signal by button for max. screed relief 126
6.7 Resetting to factory settings 128
6.8 Showing stored faults 129
6.9 Showing saved faults with operating hours 130
6.10 Deleting the fault log 131
6.11 Driving against the closed brake 132
6.12 Adapting the engine speed 133
6.13 Deactivating/activating automatic speed range change when cornering 134
6.14 Deactivating / activating the speed sensor(s) 136
Replacement of components 139
7.1 How to proceed when replacing components? 140
Engine 141
8.1 Features 142
8.2 Cooling system 144
8.3 Removing and installing the thermostat 146
8.4 Checking the thermostat in disassembled state 146
8.5 Check the coolant level 147
8.6 Check the anti-freeze concentration and the condition of the coolant 148
8.7 Change the coolant 148
8.8 Checking radiator hoses and hose clamps 149
8.9 Clean the cooling fins on engine and hydraulic oil cooler 150
8.10 Checking the engine oil level 150
8.11 Changing engine oil and oil filter cartridge 151
8.12 Fuel system 152
8.13 Replace the fuel filter 155
8.14 Checking, cleaning the water separator 156
8.15 Changing the fuel filter, bleeding the fuel system 157
8.16 Check fuel lines and clamps 158
8.17 Check the fuel injection nozzles 158
8.18 Check the fuel injection timing 159
8.19 Check the fuel injection pump 159
8.20 Servicing the generator V-belt 160
8.21 Air filter maintenance 160
8.22 Check the engine mounts 162
8.23 Engine conservation 163

4 BOMAG 008 922 07

 Table of Contents

8.24 Check, adjust the valve clearance 163

8.25 Engine problems 165
Material hopper, description 167
9.1 Material hopper and transport 168
Vibrating screed, description 173
10.1 Screed 174
Travel drive, description 179
11.1 Travel system 180
Cleaning kit, description 187
12.1 Cleaning kit 188
Hydraulics 191
13.1 Hydraulic circuit 192
13.2 Travel pump, A4VG28 EP 194
13.3 Troubleshooting axial piston pumps 201
13.4 Component overview -- hydraulics 204
13.5 Travel circuit 207
13.6 Vibration and tamper drive 210
13.7 Scraper belt drive 212
13.8 Auger drive 214
13.9 Cylinder functions 216
13.10 Check the hydraulic oil level 222
13.11 Changing hydraulic oil and filter 223
Tests and adjustments 225
14.1 Special tools, tests and adjustments 226
14.2 Checking and adjusting the vibration 230
14.3 Checking/adjusting tamping 237
14.4 Checking/adjusting the scraper belts 252
14.5 Checking/adjusting the augers 258
14.6 Checking/adjusting the main screed 264
14.7 Checking/adjusting the screed levelling 270
14.8 Checking/adjusting the hopper wings 276
14.9 Checking/adjusting the mobile screed 282
Central lubrication system 289
15.1 Filling the lubricant container 290
15.2 Electric pump 291
15.3 Integrated electronic control 295
15.4 Progressive distributor 299
15.5 Fault - Cause - Remedy 305
15.6 Repair of a blocked distributor 307
Circuit diagrams 309
16.1 Hydraulic diagram 311
16.2 Electric circuit diagrams 323

008 922 07 BOMAG 5

Table of Contents

6 BOMAG 008 922 07

 1 General

008 922 07 BOMAG 7

1.1 Introduction

1.1 Introduction

This manual addresses the professionally qualified

personnel or the after sales service of BOMAG, and
should be of help and assistance in correct and effi-
cient repair and maintenance work.
This manual describes the disassembly, dismantling,
assembly, installation and repair of components and
assemblies. The repair of components and assem-
blies is only described as this makes sense under due
consideration of working means and spare parts sup-
ply.

Documentation
For the BOMAG machines described in this manual
the following documentation is additionally available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Service information
4 Fundamental electrics

Use only 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 an updating service; for
this reason we would like to draw your attention to our
additional "Technical Service Bulletins".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this 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

These safety regulations must be read and ap-

plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG

8 BOMAG 008 922 07

Safety regulations
Important notes
1.2 Safety regulations
These safety regulations must be read and ap-
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
Repair work shall only performed by appropriately
trained personnel or by the after sales service of
BOMAG.
Workshop equipment and facilities as well as the
use and waste disposal of fuels and lubricants,
cleaning agents and solvent as well as gases and
chemicals are subject to legal regulations, which
are intended to provide a minimum on safety. It is
obviously your own responsibility to know and
adhere to these regulations.
This manual contains headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to inform about and avoid dan-
gers to persons, property and the environment.
i Note
Paragraphs marked like this contain technical infor-
mation for the optimal economical use of the machine.
Caution
! er when working with cranes.
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
Danger
!
Paragraphs marked like this highlight possible
dangers for persons.
Environment
Paragraphs marked like this point out practices
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Observe the regulations for the protection of the
environment.
General
l
For repair and maintenance work move the ma-
chine on a firm base and shut it down.
l
Always secure the machine against unintended roll-
ing.
l Secure the engine reliably against unintentional
starting.
l Mark a defective machine and a machine under re-
pair by attaching a clearly visible warning label to
the dashboard.
008 922 07 BOMAG
1.2
Block the articulated joint with the articulation lock.
l
l Use protective clothes like hard hat, safety boots
and gloves.
l Keep unauthorized persons away from the machine
during repair work.
l Tools, lifting gear, lifting tackle, supports and other
auxiliary equipment must be fully functional and in
safe condition.
l Use only safe and approved lifting gear of sufficient
load bearing capacity to remove and install parts or
components from and to the machine.
l Do not use easily inflammable or harmful substanc-
es, such as gasoline or paint thinners for cleaning.
l Do not smoke or use open fire and avoid sparks
when cleaning or repairing a tank.
l When performing welding work strictly comply with
the respective welding instructions.
Transport work with cranes and lifting
tackle
i Note
Cranes must only be operated by instructed persons
who had been trained in handling cranes.
l Follow the operating instructions of the manufactur-
l Follow the operating instructions of the operator
when working with cranes.
l Always comply with the applicable accident preven-
tion instructions when working with cranes and lift-
ing tackle.
Precautions and codes of conduct for
welding work
Welding work must only be carried out by properly
trained personnel.
Danger
!
Electric shock!
Sparks, fire hazard, burning of skin!
Infrared or ultraviolet radiation (arc), flashing of
eyes!
Health hazard caused by welding work on highly
alloyed work pieces, metal coatings, paint coat-
ings, plastic coatings, oil containing dirt deposits,
grease or solvent residues, etc.!
l Check welding equipment and cables for damage
before use (also the validity of inspection stickers).
l Ensure good conductivity between ground cable
and workpiece, avoid joints and bearings.
9
1.2
l Start the extraction fan before starting work and
guide with the progressing work as required.
l Always isolate the burner when laying it down (re-
move possible electrode residues).
l Protect cables from being damaged, use cables
with insulated couplings.
l Ensure sufficient fire protection, keep a fire extin-
guisher at hand.
l Welding work in areas where there is a risk of fire or
explosion, must only be carried out with welding
permission.
l Remove any combustible materials from the weld-
ing area or cover such items appropriately.
l Name a fire watch during and after welding work.
l Place welding rod holders and inert gas welding
guns only on properly insulated bases.
l Place the inert gas bottles in a safe place and se-
cure them against falling over.
l
Use a protective screen or hand shield with welding
filter, wear welding gloves and clothes.
l
Switch the welding unit off before connecting weld-
ing cables.
l
Check electrode holders and electric cables at reg-
ular intervals.
Behaviour in case of faults
l
In case of faults on the welding unit switch of the
welding unit immediately and have it repaired by ex-
pert personnel.
l
In case of failure of the extraction system switch the
system off and have it repaired by expert personnel.
Maintenance; waste disposal
l
Replace damaged insulating jaws and welding rod
holders immediately.
l
Replace the welding wire reels only in de-energized
state.
What to do in case of accidents; First Aid
l
Keep calm.
l Call first air helpers.
l
Report the accident.
l
In case of an electric accident: Interrupt the power
supply and remove the injured person from the
electric circuit. If breathing and heart have stopped
apply reactivation measures and call for an emer-
gency doctor.
10 BOMAG
Safety regulations
Operation of high-voltage systems
i Note
The rules and statutory regulations valid in the corre-
sponding do apply in addition to the notes given here.
!Caution
The high-voltage system must only be operated
and serviced by qualified and authorized person-
nel.
Before starting operation the operator must check
the proper condition of the system.
!Danger
Possibility of injury or even death caused by elec-
tric shock:
l if persons come into contact with live parts,
l in case of faulty insulation of live parts,
l
inadequate, unsuitable insulation,
l
if melted parts flake off in case of short circuits.
Old oils
Prolonged and repetitive contact with mineral oils will
remove the natural greases from the skin and causes
dryness, irritation and dermatitis. Moreover, used en-
gine oils contain potentially hazardous contaminants,
which could cause skin cancer. Appropriate skin pro-
tection agents and washing facilities must therefore
be provided.
l
Wear protective clothes and safety gloves, if possi-
ble.
l
If there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
full face visor; a facility suitable for rinsing the eyes
should also be available.
l
Avoid longer and repetitive contacts with oils. In
case of open incisions and injuries seek medical ad-
vice immediately.
l
Apply protective cream before starting work, so that
oil can be easier removed from the skin.
l
Wash affected skin areas with water and soap (skin
cleansers and nail brushes will help). Lanolin con-
taining agents will replace natural skin oils that were
lost.
l
Do not use gasoline, kerosene, diesel, thinner or
solvents to wash the skin.
l
Do not put oil soaked cloths into your pockets.
l Avoid clothes getting soiled by oil.
l
Overalls must be washed at regular intervals. Dis-
pose of non-washable clothes environmentally.
l
If possible degrease components before handling.
008 922 07
Safety regulations
Environment
It is strictly prohibited to drain off oil into the soil,
the sewer system or into natural waters. Old oil
must be disposed of according to applicable envi-
ronmental regulations. If in doubt you should con-
sult your local authorities.
Hydraulics
l Always relieve the pressure in the hydraulic system
before disconnecting any lines. Hydraulic oil escap-
ing under pressure can penetrate the skin and
cause severe injury.
l Always make sure that all screw fittings have been
tightened properly and that hoses and pipes are in
mint condition before pressurizing the system
again.
l Hydraulic oil leaking out of a small opening can
hardly be noticed, therefore please use a piece of
cardboard or wood when checking for leaks. When
injured by hydraulic oil escaping under pressure
consult a physician immediately, as otherwise this
may cause severe infections.
l Do not step in front of or behind the drums, wheels
or crawler tracks when performing adjustment work
in the hydraulic system while the engine is running.
Block drums, wheels or crawler tracks with wedges.
Reattach all guards and safety installations after
all work has been completed.
Environment
It is strictly prohibited to drain off oil into the soil,
the sewer system or into natural waters. Oil oil
must be disposed of according to applicable envi-
ronmental regulations. If in doubt you should con-
sult your local authorities.
Fuels
!Danger
Repair work shall only performed by appropriately
trained personnel or by the after sales service of
BOMAG.
Follow the valid accident prevention instructions when
handling fuels.
The following notes refer to general safety precau-
tions for danger free handling of fuel.
Fuel vapours not only are easily inflammable, but also
highly explosive inside closed rooms and toxic; dilu-
tion with air creates an easily inflammable mixture.
The vapours are heavier than air and therefore sink
down to the ground. Inside a workshop they may eas-
ily become distributed by draft. Even the smallest por-
tion of spilled fuel is therefore potentially dangerous.
008 922 07 BOMAG
1.2
l Fire extinguishers charged with FOAM, CO2 GAS
or POWDER must be available wherever fuel is
stored, filled in, drained off, or where work on fuel
systems is performed.
l The vehicle battery must always be disconnected,
BEFORE work in the fuel system is started. Do not
disconnect the battery while working on the fuel
system. Sparks could cause explosion of the fuel
fumes.
l Wherever fuel is stored, filled, drained off or where
work on fuel systems is carried out, all potential ig-
nition sources must be extinguished or removed.
Search lights must be fire proof and well protected
against possible contact with running out fuel.
Hot fuels
Please apply the following measures before draining
of fuel to prepare for repair work:
l Allow the fuel to cool down, to prevent any contact
with a hot fluid.
l
Vent the system, by removing the filler cap in a well
ventilated area. Screw the filler cap back on, until
the tank is finally emptied.
Synthetic rubber
Many O-rings, hoses, etc. are made of synthetic ma-
terial, a so-called fluorocarbon elastomer. Under nor-
mal operating conditions this material is safe and does
not impose any danger to health.
However, if this material becomes damaged by fire or
extreme heat, it may decompose and form highly
caustic hydrofluoric acid, which can cause severe
burns in contact with skin.
l
If the material is in such a state it must only be
touched with special protective gloves. The protec-
tive gloves must be disposed of according to appli-
cable environmental regulations immediately after
use.
l
If the material has contacted the skin despite these
measures, take off the soiled clothes and seek
medical advice immediately. In the meantime cool
and wash the affected area of skin over a sufficient
time with cold water or lime water.
Poisonous substances
Some of the fluids and substances used are toxic and
must under no circumstances be consumed.
Skin contact, especially with open wounds, must be
avoided.
These fluids and substances are, amongst others,
anti-freeze agents, hydraulic oils, fuels, washing addi-
tives, refrigerants, lubricants and various bonding
agents.
11
1.2
Engine
Danger
!
Do not work on the fuel system while the engine is
running. (Danger to life!)
Once the engine has stopped wait approx. 1 min-
utes for the system to depressurize. The systems
are under high pressure. (Danger to life!)
Keep out of the danger zone during the initial test
rung. Danger caused by high pressure in case of
leaks. (Danger to life!)
When performing work on the fuel system make
sure that the engine cannot be started uninten-
tionally during repair work. (Danger to life!)
l Maintenance and cleaning work on the engine must
only be performed with the engine stopped and
cooled down. Make sure that the electric system is
switched off and sufficiently secured against being
switched on again (e.g. pull off ignition key, attach a
warning label).
l Observe the accident prevention regulations for
electric systems (e.g. -VDE-0100/-0101/-0104/-
0105 Electric precautions against dangerous con-
tact voltages).
l Cover all electric components properly before wet
cleaning.
Battery
l Always wear goggles and protective clothing to
service or clean batteries! Battery acid can cause
severe injury by cauterization when coming in con-
tact with skin.
l Work only well ventilated rooms (formation of oxy-
hydrogen gas).
l Do not lean over the battery while it is under load,
being charged or tested (danger of explosion).
l Keep ignition sources away from the battery. Burn-
ing cigarettes, flames or sparks can cause explo-
sion of the battery
l Use battery chargers etc. only in strict compliance
with the operating instructions.
l After an accident with acid flush the skin with a suf-
ficient amount of water and seek medical advice.
l Do not allow children access to batteries.
l When mixing battery fluid always pour acid into wa-
ter, never vice-versa.
Special safety regulations
l Use only genuine BOMAG spare parts for repair
and maintenance work. Genuine spare parts and
original accessories were specially developed, test-
ed and approved for the machine.
12 BOMAG
Safety regulations
l The installation and use of non-genuine spare parts
or non-genuine accessories may therefore have an
adverse effect on the specific characteristics of the
machine and thereby impair the active and/or pas-
sive driving safety. The manufacturer explicitly ex-
cludes any liability for damage caused by the use of
non-original parts or accessories.
l Unauthorized changes to the machine are prohibit-
ed for safety reasons.
l
Do not perform any cleaning work while the engine
is running.
l If tests on the articulated joint need to be performed
with the engine running, do not stand in the articu-
lation area of the machine (danger of crushing!).
l If tests must be performed with the engine running
do not touch rotating parts of the engine (danger of
injury!).
l Always ensure an adequate supply of fresh air
when starting in closed rooms. Exhaust gases are
highly dangerous!
l
Refuel only with the engine shut down. Ensure strict
cleanliness and do not spill any fuel.
l
Always ensure an adequate supply of fresh air
when refuelling in closed rooms.
l
Dispose of used filters in accordance with applica-
ble environmental regulations.
l
When performing repair and maintenance work col-
lect oils and fuels in suitable containers and dispose
of in compliance with applicable environmental reg-
ulations.
l
Do not heat up oils higher than 160 °C because they
may ignite.
l
Wipe off spilled or overflown oil using suitable
cleaning means and dispose of in accordance with
applicable environmental regulations.
l Dispose of old batteries according to applicable en-
vironmental regulations.
l
There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature! Allow
engine and hydraulic system to cool down to a suf-
ficient level.
l Do not exceed the max. permissible tire pressure.
008 922 07
General repair instructions
General
1.3 General repair instructions
l
Before removing or disassembling parts, assem-
blies, components or hoses mark these parts for
easier assembly.
l Before assembling and installing parts, assemblies
or components oil or grease all movable parts or
surfaces as required and in compliance with the
compatibility of materials.
008 922 07 BOMAG
1.3
Electrics
General
Due to the fast technical development electric and
electronic vehicle systems become more intelligent
and more comprehensive day by day, and can hardly
be dispensed with in hydraulic and mechanical vehicle
systems.
Diagnostics according to plan
Well structured trouble shooting procedures can save
time and money.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
l In approx. 10 % of the examined cases the prob-
lems were caused by control units.
l In approx. 15 % sensors and actuators were the
cause of the problems.
By far the highest proportion of all faults could be
traced back to wiring and connections (plugs, etc.).
General:
l
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Knowledge in basic electrics is re-
quired for this purpose. If a fault was diagnosed
without having pulled the plug of the control unit or
inspected the wiring, this should be done before
changing any parts.
l
Check for good cable and ground contacts, there-
fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
l
Always use the machine related wiring diagram for
testing. If one or more faults were detected, these
should be corrected immediately.
l
Do not disconnect or connect battery or generator
while the engine is running.
l
Do not operate the main battery switch under load.
l
Do not use jump leads after the battery has been re-
moved.
l Sensors and electric actuators on control units must
never be connected individually or between exter-
nal power sources for the purpose of testing, but
only in connection with the control unit in question.
l
It is not permitted to pull plugs off while the voltage
supply is switched on (terminal 15 "ON")! Switch the
voltage supply "OFF" first and pull out the plug.
l Even with an existing polarity reversal protection in-
correct polarity must be strictly avoided. Incorrect
polarity can cause damage to control units!
13
1.3 General repair instructions

l Plug-in connectors on control units are only dust Battery

and water tight if the mating connector is plugged
on! Control units must be protected against spray Rules for the handling of batteries
water, until the mating connector is finally plugged When removing a battery always disconnect the mi-
on! nus pole before the plus pole. When installing the bat-
l Unauthorized opening of control electronics (Micro- tery connect the minus pole after the plus pole to avoid
controller MC), modifications or repairs in the wiring short circuits.
can cause severe malfunctions. Fasten the terminal clamps with a little force as possi-
l
Do not use any radio equipment or mobile phones ble.
in the vehicle cab without a proper aerial or in the vi- Always keep battery poles and terminal clams clean to
cinity of the control electronics! avoid high transition resistances when starting and
the related development of heat.
Electrics and welding
Make sure the battery is properly fastened in the vehi-
cle.
!Caution
Before starting welding work you should discon-
nect the negative battery pole or interrupt the
electric circuit with the main battery switch, dis-
connect the generator and pull the plugs off all
control units in order to protect the electrical sys-
tem of the machine.
l Disconnect the minus pole of the battery or interrupt
the electric circuit with the main battery switch.
l Isolate the generator and all control units from the
electric circuit.
l Always fasten the earth clamp of the welding unit in
the immediate vicinity of the welding location.
l When choosing the location for the earth clamp
make sure that the welding current will not pass
through joints or bearings.

14 BOMAG 008 922 07

General repair instructions
Generator
Before removing the generator you must disconnect
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 running, because
this may cause extremely high voltage peaks in the
vehicle wiring system ("Load Dump"), which could
possibly damage control units, radios or other elec-
tronic equipment.
When disassembling the battery cable, the B+-nut un-
derneath on the generator side may also be loosened.
This nut must in this case be retightened.
When connecting e.g. the battery cable to the terminal
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 cir-
cuit and damage to the rectifier elements - the gener-
ator will be out of function.
The generator can only be operated with the battery
connected. Under special conditions emergency op-
eration without battery is permitted, the lifetime of the
generator is in such cases especially limited.
Plus and minus cables must be disconnected during
rapid charging of the battery or electric welding on the
vehicle.
When cleaning the generator with a steam or water jet
make sure not to direct the steam or water jet directly
on or into the generator openings or ball bearings. Af-
ter cleaning the generator should be operated for
about 1 - 2 minutes to remove any deposits of water
from the generator.
008 922 07 BOMAG
1.3
Starter motor
So-called jump starting (using an additional external
battery) without the battery connected is dangerous.
When disconnecting the cables from the poles high in-
ductivities (arcs, voltage peaks) may occur and de-
stroy the electrical installation.
For purposes like e.g. purging the fuel systems, start-
ers may be operated for maximum 1 minute without
interruption. Then you should wait for at least 30 min-
utes (cooling down) until trying again. During the 1
minute starting period this process should not be inter-
rupted.
Starter motors must not be cleaned with high pressure
steam cleaning equipment.
The contacts on starter terminals 30, 45, 50 must be
protected against unintended shorting (jump protec-
tion).
When replacing the starter the ring gear on the engine
flywheel must be checked for damage and its number
of teeth - if necessary replace the ring gear.
Always disconnect the battery before starting assem-
bly work in the starter area of the engine or on the
starter itself.
15
1.3
Hydraulic system
!Caution
Repair work on hydraulic elements shall only per-
formed by appropriately trained personnel or by
the after sales service of BOMAG.
Please note
i Note
Cleanliness is of utmost importance. Dirt and other
contaminations must strictly be kept out of the system.
l Connections and screw fittings, filler neck covers
and their immediate surrounding areas must be
cleaned before removal.
l Before loosening hoses, pipe lines etc. relieve all
pressure from the system.
l During repair work keep all openings closed with
clean plastic plugs and caps.
l Never run pumps, motors and engines without oil or
hydraulic oil.
l When cleaning hydraulic components take care not
to damage any fine machine surfaces.
l Chemical and rubber soluble cleansing agents may
only be used to clean metal parts. Do not let such
substances come in contact with rubber parts.
l Rinse of cleaned parts thoroughly, dry them with
compressed air and apply anti-corrosion oil immedi-
ately. Do not install parts that show traces of corro-
sion.
l Avoid the formation of rust on fine machined caused
by hand sweat.
l Use new O-rings or seal rings for reassembly.
l Use only hydraulic oil as sliding agent when reas-
sembling. Do not use any grease!
l Use only the specified pressure gauges. Risk of
damaging the pressure gauges under too high pres-
sure.
l Check the hydraulic oil level before and after the
work.
l Fill in only clean oil as specified in the maintenance
instructions.
l Check the hydraulic system for leaks, if necessary
find and rectify the cause.
l Before taking new hydraulic components into oper-
ation fill these with hydraulic oil as specified in the
operating and maintenance instructions.
l After changing a hydraulic component thoroughly
flush, refill and bleed the complete hydraulic sys-
tem.
16
General repair instructions
l Perform measurements at operating temperature of
the hydraulic oil (approx. 40 ¯C).
l After changing a component perform a high and
charge pressure test, if necessary check the speed
of the exciter shaft.
l The operating pressure of the exciter shaft to a
great extent depends on the base under the vibrat-
ing drum. On hard ground place the drums on a suit-
able base and check the drum pressure. Do not
activate the vibration on a hard, concreted base,
danger of bearing damage.
l After the completion of all tests perform a test run
and then check all connections and fittings for leaks
with the engine still stopped and the hydraulic sys-
tem depressurized.
Before commissioning
l Fill the housings of hydraulic pumps and motors
with hydraulic oil. Use only hydraulic oils according
to the specification in the maintenance instructions.
l
After changing a component flush the hydraulic sys-
tem as described in the flushing instructions.
Taking into operation
l
Bleed the hydraulic circuits.
l
Start up the hydraulic system without load.
l
Check the hydraulic oil level in the tank, if neces-
sary top up with hydraulic oil as specified in the op-
erating and maintenance instructions or drain oil off
into a suitable container.
After taking into operation
l
Check fittings and flanges for leaks.
l
After each repair check all adjustment data, system
pressures, rotational speeds and nominal values in
the hydraulic system, adjust if necessary.
l
Do not adjust pressure relief valves and control
valves to values above their specified values.
BOMAG 008 922 07
General repair instructions
Fuel hoses
Fig. 1
! Caution
All fuel hoses have two layers of material, a rein-
forced rubber coating outside and an internal Vi-
ton hose. If a fuel hose has come loose one must
make absolutely sure that the internal Viton layer
has not been separated from the reinforced outer
layer. In case of a separation the hose needs to be
replaced.
008 922 07 BOMAG
1.3
Gaskets and mating surfaces
Leaking sealing faces can mostly be traced back to in-
correct assembly of seals and gaskets.
l Before assembling a new seal or gasket make sure
that the sealing surface is free of pitting, flutes, cor-
rosion or other damage.
l Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
l Assemble seals and gaskets only with sealing com-
pound, grease or oil, if this is specifically specified
in the repair instructions.
l If necessary remove any old sealing compound be-
fore assembling. For this purpose do not use any
tools that could damage the sealing surfaces.
l Sealing compound must be applied thin and evenly
on the corresponding surfaces; take care that the
compound does not enter into oil galleries or blind
threaded bores.
l
Examine the contact faces for scratches and burrs,
remove these with a fine file or an oilstone; take
care that no grinding dust and dirt enters into
tapped bores or enclosed components.
l
Blow out lines, ducts and gaps with compressed air,
replace any O-rings and seals that have been dis-
lodged by the compressed air.
Assembly of radial seals
Fig. 2
l
Lubricate the sealing lips (2) (Fig. 2) with clean
grease; in case of double seals fill the space be-
tween the sealing lips with a generous amount of
grease.
l
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.
i Note
If possible, use an assembly sleeve (1 (Fig. 2)), to
protect the lip from being damaged by sharp edg-
es, threads or splines. If no assembly sleeve is avail-
17
1.3 General repair instructions

able, you should use a plastic tube or adhesive tape Feather keys and keyways
to prevent the sealing lip from being damaged.
l Lubricate the outer rim (arrow 3 (Fig. 2)) of the seal Caution
!
and press it flat on the housing seat.
Feather keys may only be reused if they are free of
damage.

Fig. 3
l
Press or knock the seal into the housing, until it is
flush with the housing surface.

i Note
Fig. 4
If possible, use a "bell" (1 (Fig. 3)), to make sure that
the seal will not skew. In some cases it may be ad-
l Clean and thoroughly examine the feather key.
visable to assemble the seal into the housing first, be- l Deburr and thoroughly clean the edges of the key-
fore sliding it over the shaft. Under no circumstances way with a fine file before reassembling.
should the full weight of the shaft rest on the seal.
If you have no proper service tools at hand, use a suit-
able drift punch with a diameter which is about 0,4 mm
smaller than the outer diameter of the seal. Use VERY
LIGHT blows with the hammer if no press is available.

18 BOMAG 008 922 07

General repair instructions 1.3
Ball and roller bearings l Check shaft and bearing housing for discolouration
or other signs of movement between ball or roller
bearing and seats.
!Caution
l Make sure that shaft and housing are free of burrs
Ball and roller bearings may only be reused if they
before assembling the ball or roller bearing.
are free of damage and do not show any signs of
wear. l Always mark the individual parts of separable ball or
roller bearings (e.g. taper roller bearings) to enable
correct reassembling. Never assemble the rollers to
an outer race that has already been used, replace
the complete ball or roller bearing instead.

Fig. 6

!Caution
When assembling the ball or roller 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).

Fig. 5
l If a ball or roller bearing of a bearing pair shows de-
fects, both ball or roller bearings need to be re-
placed.
l
Remove any lubricant residues from the ball or roll-
er bearing to be examined by washing it with gaso-
line or any other appropriate degreasing agent.
Ensure strict cleanliness.
l
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. Replace the ball or roller bearing if
necessary.
l
Check the ball or roller bearing for clearance and re-
sistance between the inner and outer races, replace
if necessary.
l
Lubricate the ball or roller bearing with the recom-
mended type of grease before assembly or reas-
sembly.
l
On greased bearings (e.g. wheel bearings) fill the
space between ball or roller bearing and outer seal
with the recommended type of grease before as-
sembling the seal.

008 922 07 BOMAG 19

1.3 General repair instructions

Screws and nuts Strength classes, metric screws

The strength classes (from 3.6 to 12.9) are specified
Tightening torque
for all strength classes from a nominal diameter of
5mm. The corresponding identification can be found
!Caution where allowed for by the shape of the screw.
Tighten nuts or screws with the tightening tor-
ques specified in the following tables of tighten-
ing torques. Tightening torques deviating from
the ones in the table are specially mentioned in
the repair instructions.
Damaged screws must under no circumstances
be used any longer. Recutting threads with thread
cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
roded thread pitches can cause incorrect torque
value readings.
Self-locking nuts must generally be replaced after
disassembly.
The use of screws with too high strength can
cause damage!
l Nut of a higher strength can generally be used in-
stead of nuts of a lower strength classification.
l When checking or retightening screw joints to the
specified tightening torque you should first relieve
Fig. 7 Identification of screws
by a quarter turn and then tighten to the correct
torque. Example: A screw is identified with 12.9.
l Before tightening you should lightly oil the thread, in The first number corresponds with 1/100 of the nomi-
order to ensure low friction movement. The same nal tensile strength (minimum tensile strength) in N/
applies for self-locking nuts. mm2.
l Make sure that no oil or grease will enter into blind l
The nominal tensile strength is 12 X 100 N/mm2 =
tapped bores. The hydraulic power generated when
1200 N/mm2.
turning in the screw could cause breakage of the ef-
fected part. The second number specifies 10-times the ration be-
tween lower yield point and nominal tensile strength
(yield point ratio).

i Note
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas-
tic deformation).
When exceeding the upper yield point the material will
not restore its original shape after being relieved.
l The lower tensile strength is 9/10 X 1200 N/mm2 =
1080 N/mm2.

i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.

20 BOMAG 008 922 07

General repair instructions 1.3
Strength classes of metric nuts Identification in clock system
Nuts are differentiated by three load groups. Each
load group has a special designation system for the
strength class assigned, so that the load group can be
clearly identified.

Nuts for screw joints with full load capability (4, 5,

6, 8, 10, 12)

Fig. 9 Identification of nuts in clock system

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

Strength class of Strength class of associated

nut screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
6 6.8
8 8.8
9 9.8
10 10.8
12 12.8

Nuts for screw joints with limited load factor (04,

05)
The preceding "0" indicates that, due to their low
height, nuts 2 (Fig. 8) in this group are only able to
withstand the force of a screw to a limited extent.
Nut height below 0,8 d (d = nominal dimension).

Nuts for screw joints without specified load factor

(11H, 14H, 17H, 22H)
This standard contains strength classes (hardness
classes) for nuts 3 (Fig. 8), for which no load values
can be specified, e.g. because of their shape and di-
mensions, but which can only be classified by their
hardness.
Nut height below 0,5 d (d = nominal dimension).

008 922 07 BOMAG 21

1.3 General repair instructions

Identification of UNF-threads Cotter pins

Fig. 11
In places where cotter pins are used, these must be
reassembled. Cotter pins must generally be renewed
after disassembly.
Cotter pins must be assembled as shown in the illus-
tration, unless specified differently.
Fig. 10

Screws
The screw head is marked with a stamped in, round
cavity 3 (Fig. 10).

Nuts
An uninterrupted series of stamped in circles parallel
to the axis of the nut on a hexagon area (2).

Studs and brake rods

At the outmost end a short end of the component is re-
duced to its core diameter (1).

22 BOMAG 008 922 07

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

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

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

Tightening torques for screws with metric unified thread*

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
* Coefficient of friction μ tot. = 0,14

Tightening torques for screws with metric unified fine thread*

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

008 922 07 BOMAG 23

1.4 Tightening torques

Tightening torques for screws treated with anti-seizure paste OKS 240* (copper paste)

Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 X 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
3/4“ - 10 UNC 276 388 464
3/4“ - 16 UNC 308 432 520
* 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) * **

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

24 BOMAG 008 922 07

Tightening torques 1.4
The values specified in the table apply for screws:
l black oiled
l with surface protection A4C
l with surface protection DACROMET

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

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

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

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

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

008 922 07 BOMAG 25

1.4 Tightening torques

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

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

26 BOMAG 008 922 07

 2 Technical data

008 922 07 BOMAG 27

2.1 Technical data

2.1 Technical data

Fig. 12

Dimensions in mm A B H H2 K L W
BF 300 C, S340 2200 1740 3350 2700 170 4950 1700

* BF 300 C, S340
Weights
Operating weight (CECE) kg 8000

Travel characteristics
Travel speed km/h 0 - 4.9
Working speed m/min 0 - 26
Max perm. inclination (ramp) front/rear ° 19/13
Max. theoretical inclination (working/transport % 72/31
speed)

Drive
Engine manufacturer Kubota
Type V 3307 T
Cooling Water
Number of cylinders 4
Rated power ISO 3046 kW (HP) 55,4 (75)
Rated speed rpm 2200

Hopper
Capacity m3 4.8
Width (wings open/closed) mm 3075/1740
Length mm 1660
Filling height (middle) mm 540

Scraper belt / auger

Quantity 2
Width mm 220
Rated speed m/min 30

Conveyor auger

28 BOMAG 008 922 07

Technical data 2.1
*
BF 300 C, S340
Quantity 2
Auger diameter mm 280
Rated speed rpm 100

Screed
Width of screed mm 1700 - 3400
Max. working width mm 4000
Min. paving width with reducing skids mm 750
Mat height mm 250
Smooth plate depth mm 305
Smooth plate thickness mm 12
Heating electric
Crown % -3 to +4.5
Tamper frequency Hz 0 - 30
Vibration frequency Hz 20 - 50
Basic weight kg 1000
Max. weight kg 1200

Filling capacities
Fuel l 100
Hydraulic oil l 80
Engine oil l 11.2
* The right for technical modifications remains reserved

008 922 07 BOMAG 29

2.1 Technical data

Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 950 - 1000
High idle speed rpm 2150 - 2250
Valve clearance intake mm 0.15 ± 0.02
Valve clearance exhaust mm 0.15 ± 0.02
Injection valves opening pressure bar 1. Phase 186 / 2. Phase 225
Valve seat leak tightness injection bar At a pressure of (166. bar, the valve seat must be
valves fuel leak tight
Travel pumps
Manufacturer Bosch-Rexroth
Type A10VG
Quantity 2
System Axial piston/swash plate
Max. displacement cm3/rev 28
Max. flow capacity l/min 109
Maximum pressure bar 370 - 390
Charge pressure bar 24 - 26
High pressure limitation Pressure override valve

Travel motors
Manufacturer Bosch-Rexroth
Type A6VE
Quantity 2
System Axial piston/bent axle
Max. displacement (stage 1) cm3/U 28.1
Min. displacement (stage 2) cm3/U 0

Travel gear
Manufacturer Bonfiglioli
Type 705 C
System Planetary gear with integrated brake
Reduction ratio 1:80
Quantity 2
Continuous torque Nm 6000
Maximum torque Nm 13500
Maximum input speed rpm 5600
Brake: Brake torque Nm 180-220
Brake releasing pressure bar 24 - 26

Service pump
Manufacturer Bosch-Rexroth
Type A10VO
System Gear pump
Quantity 1
Displacement cm3/rev 190
Fastening flange SAE A 2-hole
Nominal pressure bar 276
Maximum speed rpm 3000

Pump --> tamper and vibration

(stage 1)
Manufacturer Haldex
Type WP09
System Gear pump
Quantity 1
Displacement cm3/rev 190

30 BOMAG 008 922 07

Technical data 2.1
Nominal pressure bar 276
Maximum speed rpm 3000

Tamper motor
Manufacturer Sauer Danfoss
Type SNM2
System Gear motor
Displacement cm3/U 14.4
Maximum pressure bar 280
Nominal pressure bar 250
Rated speed rpm 1800 - 2000

Vibration motor
Manufacturer Sauer Danfoss
Type SNM2
System Gear motor
Displacement cm3/U 8.4
Maximum pressure bar 280
Nominal pressure bar 250
Rated speed rpm 2650 - 2850

Pump --> auger drive left (stage 2)

Manufacturer Haldex
Type WP09
System Gear pump
Quantity 1
Displacement cm3/rev 80
Pressure bar 230 - 250
Maximum speed rpm 4000

Motor for augers

Manufacturer Sauer Danfoss
Type OMS 160
System Orbital motor
Max. displacement. cm3/rev 160
Rated speed rpm 80 - 84
Quantity 2

Pump 3-stage (drive of right auger,

as well as conveyor belt left & right)
Manufacturer Haldex
Type WP09
System Gear pump
Quantity 1
Displacement cm3/rev 80
Pressure bar 230 - 250
Maximum speed rpm 4000

Scraper belt motors

Manufacturer Sauer Danfoss
Type OMS 160
System Orbital motor

008 922 07 BOMAG 31

2.1 Technical data

Max. displacement. cm3/rev 160

Rated speed rpm 60 - 64
Quantity 2

Pump for cleaning kit

Manufacturer Flowjet
Type Duplex 2 series
System Dual piston pump
Quantity 1
Displacement (high pressure variant) l/min 8.32
Displacement (medium and low pres- l/min 6.05
sure variant)
Maximum pressure bar 6.8

32 BOMAG 008 922 07

Technical data 2.1
The following noise and vibration data acc. to

- EC Machine Regulation edition 2006/42/EC

- the noise regulation 2000/14/EG, noise protection guideline 2003/10/EC

- Vibration Protection Regulation 2002/44/EC

were determined during conditions typical for this type of equipment and by application of harmonized
standards.

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

Noise value
Sound pressure level on the place of the operator:
LpA = 94 dB(A), determined acc. to ISO 11204 and EN 500

Guaranteed sound power level:

LWA = 104 dB(A), determined acc. to ISO 3744 and EN 500

! Danger
Wear your personal noise protection means (ear defenders) before starting operation.

Vibration value
Vibration of the entire body (driver’s seat)
The weighted effective acceleration value determined acc. to ISO 7096, is≤ 0.5 m/s2.

Hand-arm vibration values

The weighted effective acceleration value, determined acc. to EN 500/ISO 5349, is ≤ 2.5 m/s2.

008 922 07 BOMAG 33

2.1 Technical data

34 BOMAG 008 922 07

 3 Maintenance

008 922 07 BOMAG 35

3.1
3.1 General notes on maintenance
When performing maintenance work always comply
with the appropriate safety regulations.
Thorough maintenance of the machine guarantees far
longer safe functioning of the machine and prolongs
the lifetime of important components. The effort need-
ed for this work is only little compared with the prob-
lems that may arise when not observing this rule.
The terms right/left correspond with travel direction
forward.
l Always clean machine and engine thoroughly be-
fore starting maintenance work.
l Do not touch hot engine parts.
l For maintenance work stand the machine on level
ground.
l Always remove the main battery switch for all main-
tenance work.
l Perform maintenance work only with the engine
shut down.
l
Relieve hydraulic pressures before working on hy-
draulic lines.
l
Before working on electric parts of the machine dis-
connect the battery and cover it with insulation ma-
terial.
Environment
During maintenance work catch all oils and fuels
and do not let them seep into the ground or into
the sewage system. Dispose of oils and fuels en-
vironmentally.
Keep used filters in a separate waste container
and dispose of environmentally.
Catch biodegradable oils separately.
Notes on the fuel system
The lifetime of the diesel engine depends to a great
extent on the cleanliness of the fuel.
l Keep fuel free of contaminants and water, since this
will damage the injection elements of the engine.
l Drums with inside zinc lining are not suitable to
store fuel.
l When choosing the storage place for fuel make
sure that spilled fuel will not harm the environment.
l Do not let the hose stir up the slurry at the bottom of
the drum.
l
The fuel drum must rest for a longer period of time
before drawing off fuel.
l The rest in the drum is not suitable for the engine
and should only be used for cleaning purposes.
36 BOMAG
General notes on maintenance
Notes on the performance of the engine
On diesel engines both combustion air and fuel injec-
tion quantities are thoroughly adapted to each other
and determine power, temperature level and exhaust
gas quality of the engine.
If your engine has to work permanently in "thin air" (at
higher altitudes) and under full load, you should con-
sult the customer service of BOMAG or the customer
service of the engine manufacturer.
Notes on the cooling system
Prepare and check coolant with highest care, since
otherwise the engine may be damaged by corrosion,
cavitation and freezing.
The coolant is prepared by mixing a cooling system
protection agent (ethylene glycol) into the coolant.
Mixing with cooling system protection agent is neces-
sary in all climatic zones. It prevents corrosion, lowers
the freezing point and raises the boiling point of the
coolant.
Notes on the hydraulic system
During maintenance work on the hydraulic system
cleanliness is of major importance. Make sure that no
dirt or other contaminating substances can enter into
the system. Small particles can produce flutes in
valves, cause pumps to seize, clog nozzles and pilot
bores, thereby making expensive repairs inevitable.
l
If, during the daily inspection of the oil level the hy-
draulic oil level is found to have dropped, check all
lines, hoses and components for leaks.
l
Seal external leaks immediately. If necessary in-
form the responsible customer service.
l
Do not store drums with hydraulic oil outdoors, or at
least under a cover. Water can be drawn in through
the bunghole when the weather changes.
l We recommend to use our filling and filtering unit
with fine filter to fill the system. This ensures finest
filtration of the hydraulic oil, prolongs the lifetime of
the hydraulic oil filter and protects the hydraulic sys-
tem.
l
Clean fittings, filler covers and the area around such
parts before disassembly to avoid entering of dirt.
l Do not leave the tank opening unnecessarily open,
but cover it so that nothing can fall in.
008 922 07
Fuels and lubricants 3.2
3.2 Fuels and lubricants pecially at ambient temperatures below -20°C (-4 °F)
and when working at altitudes of 1500 m (5000 ft) and
more.
Engine oil
Diesel fuel specifications: With respect to the percent-
Quality age (ppm) of sulphur the fuel used in the engine must
comply with all relevant exhaust emission regulations
Lubrication oils are classified according to their per-
in the are of use of the engine.
formance and quality class. Oils according to other
comparable specifications may be used. It is highly recommended to use a fuel with a sulphur
content of less than 0,10% (1000 ppm).
Only engine oils of API*-classification
CF and CI-4
must be used in connection with low sulphur fuel ( When using a diesel fuel with a high sulphur content
0.05 %). of 0.50% (5000 ppm) to 1.0% (10.000 ppm), the en-
gine oil change intervals must be halved.
! Caution
Engine oils of API-classification CF-4, CG-4 and ! Caution
CH-4 must not be used. Do not use any fuels with a sulphur content of
more than 1,0% (10000ppm).
Oil viscosity
It is recommended to use diesel fuel that complies
Multi-purpose oils should be generally used. with the specifications EN590 or ASTM D975.
Since lubrication oil changes its viscosity with the tem-
Diesel fuel with the designation no. 2-D is a distillate
perature, the ambient temperature at the operating lo-
fuel with low volatility, which is especially suitable for
cation of the engine is of utmost importance when
industrial engines and heavy-duty commercial vehi-
choosing the viscosity class (SAE-class) .
cles (SAE J313 JUN87).
Optimal operating conditions can be achieved by us- Since this engine complies with the exhaust gas
ing the following oil viscosity chart as a reference. standard acc. to EPA** Stage “TIER 4”, the use of ul-
tra-low sulphur diesel fuel is mandatory, if the engine
is operated within an area where compliance with
Ambient temperature Viscosity
EPA is required.
SAE 30 In order to fulfil these requirements you should, as an
over 25 °C! SAE 10W-30 alternative to no. 2-D, also use diesel fuel no. 2-D
S500 or S15; with ambient temperatures below -10°C
SAE 15W-40
(+14 °F) the diesel fuel no. 1-D S500 or S15 should be
SAE 20 used for no. 1-D.
0°C to 25°C SAE 10W-30 The fuel level should always be topped up in due time
so that the fuel tank is never run dry, as otherwise filter
SAE 15W-40
and injection lines need to be bled.
below 0 °C SAE 10W
Winter fuel
SAE 10W-30
SAE 15W-40 ! Danger
Oil change intervals Fire hazard!

The longest permissible time lubrication oil should re-
main in an engine is 1 year.
If the 500 operating hours are not reached over a pe-
riod of 1 year, the oil change should be performed at
least once per year, irrespective of the operating
hours reached.
Fuels
Quality
Cetan index number: The recommended minimum in-
dex number for the Cetan value is 45. A Cetan index
number higher than 50 should preferably be used, es-
* American Petroleum Institute
Diesel fuels must never be mixed with gasoline.
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At very
low temperatures disturbing paraffin separation can
also be expected when using winter diesel fuel.
Coolant
Always use a mixture of anti-freeze agent and clean,
dehardened water with a mixing ratio of 1:1.
Under particularly extreme temperature conditions
you should consult the service representation of the
engine manufacturer with respect to the anti-freeze
agent to be used.
** United States Environmental Protection Agency

008 922 07 BOMAG 37

3.2 Fuels and lubricants

There are various types of anti-freeze agents availa- Lubrication grease

ble. For this engine you should use ethylene glycol.
For lubrication purposes use an EP-high pressure
Before filling in the coolant mixed with anti-freeze grease, lithium saponified (penetration 2), acc. to DIN
agent the radiator must be flushed with clean water. 51502 KP 2G.
This procedure should be repeated two to three times
to clean the inside of radiator and engine block.
Mixing the anti-freeze agent: Prepare a mixture of
50 % anti-freeze agent and 50 % low mineral, clean
water. Stirr well before filling it into the radiator. The
method for mixing water and anti-freeze agent de-
pends on the brand of the anti-freeze agent. In this re-
spect see standard SAE J1034 and also the standard
SAE J814c.
Add anti-freeze agent: If the coolant level drops be-
cause of evaporation,only clean water is to be used
for topping up. In case of leakages you must always
fill in anti-freeze agents of the same brand and the
same mixing ratio.

! Caution
Do not mix different coolants and additives of any
other kind.
Do not use any radiator cleaning agent after the anti-
freeze agent has been mixed in. The anti-freeze agent
also contains a corrosion protection agent. If this mix-
es with cleaning agent it may cause the development
of sludge, which could damage the cooling system.

Anti-freeze concentration
50% = -37 °C

Environment
Coolant must be disposed of environmentally.

Mineral oil based hydraulic oil

The hydraulic system is operated with hydraulic oil HV
46 (ISO) with a kinematic viscosity of 46 mm2/s at 40
°C and 8 mm2/s at 100 °C. For topping up or for oil
changes use only high-quality hydraulic oil, type
HVLP according to DIN 51524, part 3, or hydraulic oils
type HV according to ISO 6743/3. The viscosity index
(VI) should be at least 150 (observe information of
manufacturer).

Gear oil
For the gearboxes use only ,ulti-purpose gear oils ISO
VG 220 of API-GL5-class with a minimum viscosity of
20 mm2/s at 100 °C.
This is a hypoid lubricant of highest quality class for
extremely loaded transmissions.
The additives in this oil ensure low wear lubrication
under all operating conditions.

38 BOMAG 008 922 07

Table of fuels and lubricants 3.3
3.3 Table of fuels and lubricants

Assembly Fuel or lubricant Quantity

Summer Winter Attention

Observe the level
marks

Motor

- Engine oil Engine oil API: CF or CI-4 approx. 11.2 litres

SAE 10W-40 (-20 °C to +40 °C)

(BOMAG 009 920 06; 20 l)

SAE 10W-30 (-15 °C to +30 °C)

SAE 15W-40 (-15 °C to + 40 °C)

SAE 30 (+5 °C to +30 °C) SAE 10 (-30 °C to -5 °C)

- Fuel Diesel Winter diesel fuel approx. 100 litres

- Coolant Mixture of water and anti-freeze agent approx. 14 litres

(BOMAG 009 940 08; 20 l)
(Specification see "Fuels and lubricants - coolant")

Hydraulic system Hydraulic oil (ISO), HLP 46 approx. 80 litres

(BOMAG PN 009 930 09; 20 l)
or
ester based biodegradable hydraulic oil

Crawler track drive gear Gear oil SAE 80W-140, API GL-5 approx. 3.2 l each
(BOMAG 009 925 07; 20 l)

Lubrication points, general High pressure grease (lithium saponified) as required

008 922 07 BOMAG 39

3.4 Running-in instructions

3.4 Running-in instructions

The following maintenance work must be per-
formed when running in new machines or over-
hauled engines:

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

After a running-in time of 30 minutes

l Retighten the V-belt

After 50 operating hours

l Change engine oil and oil filter cartridge
l Check the tension of the fan V-belt
l Grease the auger drive chain
l Hopper, check scrapers and rubber apron

After 250 operating hours

l Tighten all bolted connections on air intake, ex-
haust, oil sump and engine mounts
l Retighten the bolted connections on the machine.
l Grease the auger drive chain
l Hopper, check scrapers and rubber apron
l Oil change in track drive gear

40 BOMAG 008 922 07

Maintenance table 3.5
3.5 Maintenance table

every 10 operating hours, daily

every 1000 oper. hours

every 2000 oper. hours
every 3000 oper. hours
every 250 oper. hours
every 500 oper. hours
every 50 oper. hours
No. Maintenance work Comment

as required
5.6 Checking the engine oil level Dipstick mark X
5.7 Check the fuel level Instrument cluster X
5.8 Check the coolant level X
5.9 Check the hydraulic oil level Inspection glass X
5.10 Lubricate the machine X
5.11 Check fuel lines and clamps X
5.12 Service the generator V-belt X
5.13 Check the radiator hoses and hose X
clamps
5.14 Service the scraper belt X
5.15 Service the scraper belt drive chain X
5.16 Service the auger X
5.17 Grease the gliding surface of the X
screed mobile section
5.18 Lubricate the machine X
5.19 Check the central lubrication system, X
top up
5.20 Clean the cooling fins on engine and X
hydraulic oil cooler
5.21 Check the oil level in track drive gear X
5.22 Service the battery, check the main pole grease X
battery switch
5.23 Checking the condition and tension of X
the screed heating generator V-belt,
tensioning and if necessary replacing
the V-belt
5.24 Change engine oil and oil filter car- min. 1x per year X
tridge* see foot note
5.25 Check the anti-freeze concentration X
and the condition of the coolant
5.26 Replace the fuel filter X

008 922 07 BOMAG 41

3.5 Maintenance table

every 10 operating hours, daily

every 1000 oper. hours

every 2000 oper. hours
every 3000 oper. hours
every 250 oper. hours
every 500 oper. hours
every 50 oper. hours
No. Maintenance work Comment

as required
5.27 Change the fuel filter, bleed the fuel X
system
5.28 Drain the fuel tank sludge X
5.29 Check track, track drive X
5.30 Check, adjust tamper bar and floor X
plates
5.31 Check, adjust the valve clearance Intake and exhaust valve: X
0.15 mm
5.32 Change hydraulic oil and filter** at least every 2 years X
see foot note
5.33 Check the engine mounts X
5.34 Oil change in track drive gear*** see foot note X
5.35 Checking hopper, scrapers and rubber X
apron
5.36 Change the coolant X
5.37 Check the fuel injection nozzles only by authorized serv- X
ice personnel
5.38 Check the turbo charger only by authorized serv- X
ice personnel
5.39 Check the fuel injection pump only by authorized serv- X
ice personnel
5.40 Air filter maintenance at least 1x every year, X
safety cartridge at least
every 2 years
5.41 Check, clean the water separator X
5.42 Replace heating elements X
5.43 Preparing the machine for a longer X
rest
5.44 Tightening torques X
* Running-in instructions: Oil change after 50 and 500 operating hours, then every 500 operating hours
** Also in case of repair in the hydraulic system.
*** Running-in instructions: Oil change after 250 and 1000 operating hours, then every 1000 operating hours

42 BOMAG 008 922 07

 4 E-Plan wiring diagrams

008 922 07 BOMAG 43

4.1 Understanding E-Plan circuit diagrams

4.1 Understanding E-Plan circuit diagrams

Electric circuit diagrams

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

Structure of a wiring diagram

l Cover sheet, see section "Cover sheet"
l Table of contents, see section "Table of contents"
l Structuring symbol overview, see section "Structuring symbol overview"

i Note
The structuring symbol overview is NOT present in circuit diagrams, which are sorted by systems and local iden-
tification!
l Sheets with illustration of function, see section"Sheets with illustration of function"
l List of fuels and lubricants, see "List of fuels and lubricants"
l Terminal strip overview, see section "Terminal strip overview"
l Plug overview, see section "Plug overview"
l Pin overview, see section "Pin overview"

44 BOMAG 008 922 07

Understanding E-Plan circuit diagrams 4.1
Cover sheet
The cover sheet, see example (Fig. 13), contains general information.

Fig. 13 Example: Cover sheet

008 922 07 BOMAG 45

4.1 Understanding E-Plan circuit diagrams

Table of contents
The table of contents, see example (Fig. 14), lists the individual functions and identifies the corresponding
sheets in the wiring diagram.

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Fig. 14 Example: Table of contents

46 BOMAG 008 922 07

Understanding E-Plan circuit diagrams 4.1
Sheets with representations of functions
l
The main reading direction is sheet by sheet, from top to bottom and from left to right.
l All sheets are successively numbered.
l BOMAG used the resolved type of representation. In this case parts and components with different functions,
which belong to the same components (e.g. relay coil and relay contact), can be represented on different
sheets. Cross-references, which refer to the sheet and current path, serve as linkage between these partial
components (Fig. 15).

Structuring symbols
Relay cross-reference Potential cross-reference

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Mimic diagram of relay Current paths

Fig. 15 Example: Sheet with functions

Current paths (Fig. 15)

l Current paths are successively numbered from 0 to 9.

Potential cross references (Fig. 15)

l Potential cross references serve the purpose of tracking signals, which are transmitted from one representa-
tion of a function to another. Potential cross-references may additionally have structuring symbols assigned
to them.
Example: Potential 15_54 +SEAT/16.1 (on sheet 4, current path 8) continues to the right on sheet 16, current
path 1. +SEAT is the structuring symbol.

008 922 07 BOMAG 47

4.1 Understanding E-Plan circuit diagrams

Relay cross references (Fig. 15)

l 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 relay cross-reference (-K61/4.2) (on sheet 4, current path 4) indicates that the relay coil on sheet
4 is found in current path 2.

48 BOMAG 008 922 07

Understanding E-Plan circuit diagrams 4.1
List of component
The list of components, see example (Fig. 16), is the first evaluation list that follows the representation of func-
tion. This list contains all components used in the wiring diagram, except terminal strips and plugs.

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Fig. 16 Example: List of components

An electric component is a part, assembly or device in an electrical installation.
l
Components are marked with a combination of letters and numbers. The identification with letters follows the
standard DIN - EN 61346 T1-T2. A component identification (BMK), e.g.: “S04“ always identifies the same
component. In this context the term "component" is always considered a function specific assignment and
does not represent a parts or article number. This ensures that the component with the designation "S04" al-
ways refers to the "Brake Switch", irrespective of whether the abbreviation is used in a wiring diagram for a
single drum roller, a tandem roller, a finisher or a milling machine.
l
The component identifications are alphabetically sorted in the list of components. Each component has the
corresponding cross-references assigned, identifying where it can be found in the wiring diagram, which in-
stallation location it is assigned to and to which part of the system it belongs to. Moreover, the functions (func-
tion text) and the technical characteristics are also described.

i Note
Component identifications are used in both the electrical and the hydraulic documentation and are identical.

008 922 07 BOMAG 49

4.1 Understanding E-Plan circuit diagrams

Overview of terminal strips

The overview of terminal strips, see axample (Fig. 17), contains all terminal strips used in the circuit diagram.
Each terminal strip starts on a new page and can be localized via the cross-reference in the wiring diagram.

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Fig. 17 Example: Terminal strip overview X1

50 BOMAG 008 922 07

Understanding E-Plan circuit diagrams 4.1
Overview of plugs
The overview of plugs, see example (Fig. 18), contains all plugs used in the circuit diagram.
The following information is listed for each plug:
l Contact numbering
l Structuring symbols
l Function text
l Use in wiring diagram.

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Fig. 18 Example: Plug overview X0

008 922 07 BOMAG 51

4.1 Understanding E-Plan circuit diagrams

Overview of pins
The overview of pins, see example (Fig. 19), informs about the type of inputs and outputs of the electronic con-
trols (E-BOX) used in the machine, as well as their signals and potentials.

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Fig. 19 Example: Overview of pins, control A66

52 BOMAG 008 922 07

Circuit symbols in E-Plan 4.2
4.2 Circuit symbols in E-Plan

Circuit symbol
Circuit 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).
The standardization serves the purpose of global understanding and fault free connection of appliances, espe-
cially in automobile repairs. Since the wiring diagram is intended to show only the most essential aspects, the
circuit symbol only shows as much of the function, as is needed for easy recognition and for the avoidance of
mistakes.

Fig. 20 Example: Circuit 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
10Fuse
11Terminal strip
12Plug
Different symbols are used to simplify the differentiation of terminal strips 11 (Fig. 20) and plugs (12) in a wiring
diagram.

i Note
Plugs are mainly used to connect two wiring looms or to connect a wiring loom with a component with cable
connection and mating plug.

008 922 07 BOMAG 53

4.2 Circuit symbols in E-Plan

Representation of electric devices

Electronic devices and components are increasingly used in the construction equipment industry. Controls with
software, control elements (e.g. joystics and man / machine interfaces, such as e.g. screens, LC-Displays) are
frequently used to represent and control machine functions. The internal construction of such components is in
most cases protected or just too complex to be illustrated in the wiring diagram within the context of the actual
machine function. There are two different ways to simplify the representation of such devices in the diagram.

Black-Box representation (Fig. 21)

The Black-Box representation shows the device as a Box with the connections required for the machine function.
Connections which are not needed do not need to be represented.
The Blackbox representation is mainly used if there is no differentiated information (e.g. signals from pins) avail-
able from the sub-supplier.

Fig. 21 Example: Central lubrication system

Identification of externally supplied documentation (Fig. 22)

In industrial technology of today it is quite common to integrate externally supplied electric sub-systems into the
projecting of machines. These systems may be composed of various components and wirings. For easier differ-
entiation of BOMAG designation and manufacturer identification the latter appears under the BOMAG designa-
tion with a text frame and a reduced character height.

Fig. 22 Example: Identification of externally supplied documentation

PLC representation (Fig. 23)

The PLC-Box representation of connecting pins uses a table with associated connecting plugs, which are used
in connection with the machine functions. The table symbols can be arranged in a line, if necessary. Connections

54 BOMAG 008 922 07

Circuit symbols in E-Plan 4.2
which are not needed do not need to be represented. The PLC-Box representation enables the representation
of further reaching functional descriptions to the individual component connections.

Fig. 23 PLC representation

The PLC-Box representation is mainly used for controls with BOMAG software, or for electronic devices which
were specified accordingly, and where information on the assignment of signals is available.

Identification of similar, adjacent switching symbols

In wiring diagrams you will frequently find the situation that symbols of the same type appear in a line or are
arranged just next to each other. In such cases it is common practice to reduce the identification on the subse-
quent symbol to the criteria, which are different to the previous symbol to the left.

Example: -X0 36 and -X0 37 (Fig. 23)

In the example illustrated here the component identification "-X0" for the left plug symbol is also valid for the right
plug symbol.

008 922 07 BOMAG 55

4.3 Identification of switch blocks in the wiring diagram

4.3 Identification of switch blocks in the wiring diagram

Switches of modular design

l For normally open contacts the contact symbols "_3/_4" are used.
l For normally closed contacts the contact symbols "_1/_2" are used.
In combination with the contact block numbering described above each individual connection is clearly defined.

5 C 6

3 B 4

1 A 2

travel direction

Fig. 24

Example:
The contact block marked with the "circle" is referred to as "43"/ "44" if it is a normally open contact and "41" /
"42" if it is a normally closed contact.
The contact block marked with "X" is referred to as "23"/ "24" if it is a normally open contact and "21" / "22" if it
is a normally closed contact.
The contact block marked with "Z" is referred to as "13"/ "14" if it is a normally open contact and "11" / "12" if it
is a normally closed contact.
The contact block marked with "Y" is referred to as "53"/ "54" if it is a normally open contact and "51" / "52" if it
is a normally closed contact.

56 BOMAG 008 922 07

Designation of components in the wiring diagram 4.4
4.4 Designation of components in the wiring diagram
The designation of components in the wiring diagram groups several electrical parts of the machine in one
group. The components can be identified by the following table.

Component designa- Meaning

tion
A Interval switch, indicator relay, modules, electronic component
B Pressure, pressure differential, temperature switches and sensors, transducers
C Capacitor
E Headlights, heater, air conditioning condenser
F Fuses
G Battery, generator
H Control lights, warning buzzer, warning light
K Relays
M Starter, pumps, motors
P Operating hour meter, general gauges
R Transducers, resistors
S Switches, momentary contact switches
V Diode
X Terminal
Y Solenoid valves

008 922 07 BOMAG 57

4.5 Terminal designations in wiring diagram

4.5 Terminal designations in wiring diagram

l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a
terminal designation. In Germany the designation of the individual connection terminals is determined by the
standard DIN 72552. The following table shows some examples from this DIN standard.

Terminal designation Meaning

15 Switch plus (after battery) : Output of ignition 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

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

53 Wiper motor input (+)

53a Wiper motor (+) end limit shut down
53b Wiper shunt winding

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

61 Generator control

75 Radio, cigarette lighter

76 Loudspeaker

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

58 BOMAG 008 922 07

Terminal designations in wiring diagram 4.5
Terminal designation Meaning
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 positive
B- Battery minus
D+ Dynamo Plus
D- Dynamo Minus
DF Dynamo field (generator excitation current)
DF1 Dynamo field 1 (generator excitation current)
DF2 Dynamo field 2 (generator excitation current)

008 922 07 BOMAG 59

4.5 Terminal designations in wiring diagram

60 BOMAG 008 922 07

 5 Electrics

008 922 07 BOMAG 61

5.1 ECOMODE

5.1 ECOMODE

Fig. 1
The standard BOMAG ECOMODE ensures a clean environmental balance. Due to the active engine manage-
ment power is made available for the driver when it is needed and is reduced again when permitted by the ap-
plication. Intelligent sensors in connection with an ingenious control immediately detect the actual power
requirement and the engine speed of the well proven KUBOTA engine is automatically adapted. A nice side ef-
fect – the noise sensation inside the cabin is also very pleasant.

62 BOMAG 008 922 07

ECOMODE 5.1

Fig. 2

Caution
!

The actuating mechanism must be set to the correct end stops before initial start-up of the engine. See
chapter "Electrics finisher input codes" section "Input codes E-throttle teaching"
The actuator M39 acts directly on the motor power lever (Fig. 1).
The motor is a permanently controlled DC-motor, which is triggered by the ESX-control A34 via the changeover
relay K176 (1) (Fig. 3).
The position of the drive axle is detected by an integrated potentiometer. The potentiometer is positively con-
nected with the drive shaft of the control element and serves the purpose of feeding back the output shaft posi-
tion.
The gearbox has been designed with three stages. Internal stops protect the gearbox against damage. The gear
on the drive shaft is a toothed segment which determines the internal mechanical stops. The defined limitation
of adjusting speed contributes to the avoidance of smoke when accelerating.

Functional principle of ECO mode

The ESX-control (A34) regulates the control command in dependence on
l travel pressure (travel pressure sensor B112) (Fig. 4)
l selected working power
The following settings result in an increase in engine speed:
l Switching on the screed heating
l Activating the load function
l Extending/retracting the extendable screed left/right
l
Manual operation of the scraper belt left/right in forward
l
Manual operation of the auger left/right in forward
l Opening/closing the hopper wings left/right.

008 922 07 BOMAG 63

5.1 ECOMODE

Fig. 3

Fig. 4

64 BOMAG 008 922 07

Glow plugs, R81-R84 5.2
5.2 Glow plugs, R81-R84 Continuity test
l Remove the glow plug.
During the pre-heating and starting process the glow
plugs are energized through relay K14.
During the preheating process the control lamp is
switched on for 10 seconds and switched off again
when starting.

Fig. 6
l Use a continuity tester to measure the resistance
between glow plug connection and glow plug hous-
ing.
l If the measured value does not correspond with the
factory specification, the glow plug (29 (Fig. 6) is de-
fective.
Fig. 5
1 Glow plugs
2 Glow plug cable
i Note
Factory specification for resistance approx. 0.95 Ohm
in cold condition.

Assembly

i Note
Align the recess to the connecting side when assem-
bling the seal (1) (Fig. 6) to the glow plug (2).
Tightening torque: 7.7 to 9.3 Nm.

008 922 07 BOMAG 65

5.3 Speed sensors, B191 and B192

Fig. 1
The BF300_C is equipped with two speed sensors.
These are installed on the travel motors and feed their
pulses to the ESX machine control.

66 BOMAG 008 922 07

Oil pressure switch (B06) 5.4
5.4 Oil pressure switch (B06) 5.5 Coolant temperature switch
(B53)

Fig. 1
The oil pressure switch is mounted on the cylinder
block and is connected to the lubrication oil channel.
l At a pressure of less than 0.4 bar the oil pressure
switch switches to motor ground.
Fig. 1
The temperature switch is arranged in the coolant cir-
cuit of the engine in such a way, that its tip is surround-
ed by coolant.
l
Should the engine overheat, the temperature switch
will switch to engine ground.

Fig. 1
n red = Engine oil pressure too low, engine is
shut down after 10 seconds. Fig. 1
b red = lights if engine overheats. After 8 sec-
onds the warning buzzer will sound, vi-
bration will be switched off and the travel
speed reduced.

008 922 07 BOMAG 67

5.6 Air filter vacuum switch (B03)

5.6 Air filter vacuum switch (B03) 5.7 Coolant float switch (B55)

Fig. 1 Vacuum switch

l The vacuum switch 1 (Fig. 1) switches to ground at
a vacuum > 50 mbar.

Fig. 1
l In case of a too low coolant level the float switch will
switch to ground.

Fig. 1
a yellow = lights if combustion air filter cartridge is
soiled, clean or replace if necessary.

Fig. 1
o red = flashes when the coolant (filling) level is
too low. Engine is shut down after 10
seconds.

68 BOMAG 008 922 07

Charge control light 5.8
5.8 Charge control light 5.9 Glow plugs

Fig. 1
l The control lamp lights up if a ground signal is ap-
plied to the generator terminal (L).
Fig. 1
During the preheating process the control lamp is
switched on for 10 seconds and switched off again
when starting.

Fig. 1

Fig. 1 l yellow = lights during preheating (for cold start-

ing).
p yellow = Charge control lamp, lights if the battery
is not being charged. Check the V-belt, if
necessary repair the generator.

008 922 07 BOMAG 69

5.10 Water separator in fuel filter (B124))

5.10 Water separator in fuel filter 5.11 Level sensor in diesel tank
(B124)) (R03)

Fig. 1
l With water in the filter the sensor will switch to
ground. Fig. 1
l
The analog level switch is a variable resistance to
ground.

Fig. 1
k yellow = lights when the water proportion in the
transparent section of the fuel pre-filter Fig. 1
reaches the contacts. s = Fuel level gauge

Fig. 2

Main battery switch

Position "I" = Normal position, operation

70 BOMAG 008 922 07

Fuses 5.12
Position "II" = Separates batteries from the on- 5.12 Fuses
board electrics in case of cable fire
and fire in the engine compart-
ment as well as protection against
unauthorized use.

! Caution
Pull out the main battery switch at the earliest 40
seconds after switching off the ignition, except in
cases of emergency.

008 922 07 BOMAG 71

5.13 Fuse assignment

5.13 Fuse assignment

! Danger

Fire hazard!
Do not use fuses with higher ampere ratings and do not bridge fuses.

Central electrics
The central electrics is located on the right hand side under the driver's platform.
l Slide the operator's platform to the left against the stop.
l Remove the cover from the fuse box.

Fig. 3

Terminal Fuse Amperage Designation

X1:1 F13 15 A Start switch

X1:2 F157 30 A Magnetic switch starter

X1:4 F67 15 A Control, potential 30

X1:5 not used

X1:6 F170 40 A Release of hydraulics and travel functions

X1:10 not used

X1:11 not used

X1:12 F05 15 A Socket

X1:13 F23 10 A Warning horn

X1:14 F148 10 A Control, potential 15

X1:15 F182 5A Sensors

X1:16 F175 15 A Screed heating, potential 15

X1:17 not used

X1:18 not used

X1:19 not used

X1:20 F104 15 A Working head lights, front

X1:21 F22 25 A Working head lights, rear

X1:22 F41 10 A Flashing beacon

72 BOMAG 008 922 07

Fuse assignment 5.13
Terminal Fuse Amperage Designation

X1:23 F189 15 A Cleaning system

X1:24 F190 15 A Spraying system

X1:25 F30 15 A Seat heating

X1:26 F16 15 A Central lubrication system

X1:27 F27 15 A Windscreen wiper/washer

X1:30 F180 10 A Sensors

X1:31 F173 15 A Automatic functions

X1:32 F174 15 A Conveyor system

X1:33 F179 10 A Scraper belt

X1:34 F181 10 A Auger

X1:35 F184 10 A Screed height adjustment

X1:36 F171 10 A Travel system

X1:37 F177 10 A Hopper wings

X1:38 F194 10 A Screed mobile section

X1:39 F192 10 A Extraction of asphalt vapours

X1:40 F187 15 A Straight crossfalls/screed

008 922 07 BOMAG 73

5.13 Fuse assignment

Main fuses
The main fuses are located on the left hand side under the driver's platform.
l Slide the operator's platform to the right against the stop.
l Remove the cover from the fuse box.

F48

F00

839107

Fig. 4

Fuse Amperage Designation

F00 125 A Main battery fuse

F48 40 A Preheating system

74 BOMAG 008 922 07

Component overview 5.14
5.14 Component overview

Fig. 5

Pos. Description
1 E-throttle actuator
2 Charge pressure filter
3 Main fuses
4 Batteries
5 Control panel with switches, warning lights, potentiometers, travel lever and multi-function displays
6 Brake releasing valve
7 Generator

008 922 07 BOMAG 75

5.14 Component overview

Fig. 6

Pos. Description
8 Screed heating control panel and Load Control System (LCS)
9 Working hydraulics (valves, etc.)
10 Fuel pre-filter
11 Water separator
12 Fuel pump
13 Hydraulic oil tank
14 Travel pumps
15 Service pump
16 Central electrics with fuse box
17 Travel motor
18 Valve block for hydraulic crown adjustment
19 Valve block for vibration
20 Valve block for tamping
21 Valve block to extend and retract the extendible screed

76 BOMAG 008 922 07

Component overview 5.14

008 922 07 BOMAG 77

5.15 Overview of wiring looms

5.15 Overview of wiring looms

1 Wiring loom, engine BF300

78 BOMAG 008 922 07

Overview of wiring looms 5.15

1 Battery cable, red 35mm2

2 Battery cable, black 70mm2
3 Battery cable, red 70mm2

008 922 07 BOMAG 79

5.15 Overview of wiring looms

1 Wiring loom BF300 -- pre-heating system

80 BOMAG 008 922 07

Overview of wiring looms 5.15

1 Battery cable, red 35mm2

2 Battery cable, black 35mm2
3 Battery cable, red 70mm2
4 Battery cable, black 70mm2
5 Battery cable, black 70mm2

008 922 07 BOMAG 81

5.15 Overview of wiring looms

82 BOMAG 008 922 07

Overview of wiring looms 5.15

1 Wiring loom BF300, hydraulic valves

008 922 07 BOMAG 83

5.15 Overview of wiring looms

1 Wiring loom BF300, hydraulic valves on screed

84 BOMAG 008 922 07

Overview of wiring looms 5.15

1 Wiring loom BF300, screed control panels

008 922 07 BOMAG 85

5.16 Control elements

5.16 Control elements

86 BOMAG 008 922 07

View of operator's stand 5.17
5.17 View of operator's stand

1 2 3 4 5

6
20
15 25

10 30

RPM x100

0
5 35

40
N 7
h

0 1/4 1/2 3/4 1

9
26

10
11
25 4 5 6
3 7

2 8
12
1 9
0 10

+ +

- -
24

23 22 21 20 19 18 17 16 15 14 13 838394

Fig. 7

1 A15 Instrument cluster 18 R07 Rotary switch for working speed

2 not used 19 S217 Operating mode switch transport/work
3 S197 Asphalt fume extraction * 20 S03 Warning horn
4 S225 Switch to reverse the conveyor belt 21 not used
5 A81 Display and warning elements 22 S04, Push button for parking brake
6 S236 Switch for auger height adjustment 23 S120 Rotary switch for engine speed/ ECO-mode
7 not used 24 S261 Control panel for chain control
8 S16 Rotary switch for working lights, front 25 S243, S244 Control panel for levelling
9 S26 Rear working light 26 S220 Speed range selector switch
10 not used 27 A45 Steering wheel
11 Push button for electro-hydraulics 28 Dashboard light
12 S01 Emergency stop switch 29 S237, S238, S239, S240 Screed width control panel
S250 Push button for partial screed load re-
13 30 S247, S248 Control panel for compaction
lief
S230, S231, S232, S233Control panel auger
14 31 S249 Control panel for screed height adjustment
left/right
15 S221 Travel lever
S225, S226, S227Conveyor belt control
16
panel
17 S222, S223 Material hopper control panel
* Optional equipment

008 922 07 BOMAG 87

5.18 Monitoring modules

5.18 Monitoring modules

Fig. 8 Instrument cluster

Pos. Designation
a Display: Clean the combustion air filter
b Warning lamp red engine temperature
c Warning lamp red parking brake closed
d Display travel direction "Neutral"
e Display to replace hydraulic oil filter II
f Warning lamp red hydraulic oil temperature
g Warning lamp red hydraulic oil level
h Warning lamp red fault ESX
i Display engine malfunction
j Display too low fuel level
k Warning lamp water in fuel
l Display engine preheating
m Display replace hydraulic oil filter I
n Warning lamp red low engine oil pressure
o Warning lamp red coolant level
p Charge control light
q Engine RPM-meter
r Operating hour meter/fault codes
s Display of fuel tank filling level

88 BOMAG 008 922 07

Monitoring modules 5.18

Fig. 9 Display and warning elements

Pos. Designation
a not used
b Gearbox 2nd gear, mechanical
c Gearbox 1st gear, mechanical
d right hand conveyor belt
e right hand auger
f Working mode
g not used
h not used
i not used
j Transport mode
k left hand auger
l left hand conveyor belt
m Working speed range
n Transport speed range
o not used
p Warning light parking brake closed

008 922 07 BOMAG 89

5.19 View of outside control stand

5.19 View of outside control stand

i Note
Outside control stand right shown. Left side identical.

Fig. 10

90 BOMAG 008 922 07

View of outside control stand 5.19

i Note
Left outside control stand
1 S125 Emergency stop push button
2 R96 Rotary switch ultrasonic sensor for conveyor belt *
3 S228 Switch for conveyor belt
4 S245 Switch, levelling/mat height
5 Bracket for MOBA control unit
6 S241 Switch, screed width left/right
7 S234 Switch, auger left / right
8 Rotary knob for ultrasonic sensor, auger
9 S213 Warning horn
10Connection, mat thickness control
11Warning light
12Connection, auger sensor

i Note
Right outside control stand:
1 S126 Emergency stop push button
2 R97 Rotary switch ultrasonic sensor for conveyor belt **
3 S229 Switch for conveyor belt
4 S246 Switch, levelling/mat height
5 Bracket for MOBA control unit
6 S242 Switch, screed width left/right
7 S235 Switch, auger left / right
8 Rotary knob for ultrasonic sensor, auger
9 S214 Warning horn
10Connection, mat thickness control
11Warning light
12Connection, auger sensor

* Optional equipment
** Optional equipment

008 922 07 BOMAG 91

5.20 View of screed control

5.20 View of screed control

Fig. 11
1 Pressure gauge for relief pressure
2 R100 Adjustment knob to relieve the screed while the machine is travelling
3 R101 Adjustment knob to relieve the screed with the machine stopped
4 R102 Timer
5 Switch for crown profile adjustment*
6 Vibration speed valve
7 Tamper speed valve

* Optional equipment

92 BOMAG 008 922 07

View of electric heating control panel 5.21
5.21 View of electric heating con-
trol panel

1 8

7
2
6
14 10

11
12

4 5
13
3 838379

Fig. 12

1 Voltage control lamps generator

2 Control lamps thyristor switched
3 Control lamps heating rod
4 Rotary switch for temperature control
5 Push button to acknowledge a fault
6 Push button generator Off
7 Push button generator On
8 Temperature gauge actual value
9 Push button temperature gauge screed left/middle/
right
10Temperature gauge nominal value
11Push button nominal temperature up
12Push button nominal temperature down
13Button Automatic/Manual
14Display switching °C/°F

008 922 07 BOMAG 93

5.22 Functional block diagram overview of functions, complete

5.22 Functional block diagram overview of functions, complete

Moba-Matic

Outside control stands

Main valve block

Ultrasonic sensors
Valve block
Extension extend/
retract
Control paddle

Control panel temperature control

LCS block

Travel motors

Diesel engine
Travel pumps

94 BOMAG 008 922 07

Block diagram components on CAN 5.23
5.23 Block diagram components on CAN

Travel motors

Diesel engine
Travel pumps

008 922 07 BOMAG 95

5.24 Block diagram CAN with control elements

5.24 Block diagram CAN with control elements

Travel motors

Diesel engine
Travel pumps

96 BOMAG 008 922 07

Block diagram of travel circuit 5.25
5.25 Block diagram of travel circuit

Diesel engine
Travel pumps

Travel motors

008 922 07 BOMAG 97

5.26 Block diagram material feed

5.26 Block diagram material feed

Outside control stands

rs
ge
Au

t
el
rb

Control paddle
pe
ra
Sc

Ultr
a so
nic
sen
s
left

ors
right

98 BOMAG 008 922 07

Block diagram screed 5.27
5.27 Block diagram screed

LCS block

Outside control stands

Valve block
Crown profile
control

Valve block
Extension extend/
retract

008 922 07 BOMAG 99

5.28 Block diagram screed levelling

5.28 Block diagram screed levelling

Moba-Matic

Outside control stands

Main valve block

100 BOMAG 008 922 07

Block diagram screed heating 5.29
5.29 Block diagram screed heating

Diesel engine

Control panel temperature control

008 922 07 BOMAG 101

5.30 Functional block diagram monitoring functions

5.30 Functional block diagram monitoring functions

102 BOMAG 008 922 07

Block diagram Emergency Stop functions 5.31
5.31 Block diagram Emergency Stop functions

008 922 07 BOMAG 103

5.32 Checking the voltage supply for the control unit

5.32 Checking the voltage supply for the control unit

Power supply for a control unit, general

All electronic switching and control units require an electric power supply to be able to work. If the plus or minus
supply is faulty, the control unit will work incorrectly or fail.

i Note
The following describes the electric power supply for the ESX-control.
(Fig. 13) shows a simplified representation of how the control unit (ESX, 68 pole) is connected. The complete
representation can be found in the wiring diagram of the machine.
The procedure can also be used for other controls. Pin assignment and voltage supply may be different, but the
procedures for line testing are generally the same.

Fig. 13 Circuitry example

1 = Engine block
ESX = Control unit
F00 = Main fuse
Fx,Fxx = Fuses potential 30
Fxxx = Fuses potential 15
G = Generator
G01 = Battery
GND = Housing earth
H08 = Charge control light
S00 = Ignition switch
S01 = Emergency stop switch
Pin 28 = Voltage supply for control
Pin 54 = if the signal (12/24 Volt) is applied, the control is switched on
Pin 55 = Ground supply for control
Pin 56 to 60 = Voltage supply for outputs
GND = Housing earth

104 BOMAG 008 922 07

Checking the voltage supply for the control unit 5.32
Fault in current supply, general
Clear interruptions in the plus or minus supply are relatively easy to detect. However, the plus and minus sides
of control units are in most cases connected to the vehicle mains supply via several cables, so that several par-
allel current branches exist. Checking the power supply is therefore slightly more difficult than expected. Another
point is the fact that every current branch has several plug connections, which could corrode over the years.
Corroded points are transition resistances and thus cause undesired voltage drops. In case of undesired voltage
drops the control unit is supplied with a lower voltage. This can lead to faulty reactions or even failure of the
control unit.

Fig. 14 Circuitry example

The arrows point to the contact locations, which may be the cause if a control unit only receives a reduced supply
voltage.
The following faults may occur:
l
Line interruption in a plus supply line
l high voltage drop in a plus supply line
l
line interruption on the minus side

008 922 07 BOMAG 105

5.32 Checking the voltage supply for the control unit

Measuring principle for line testing

When a line conducts an electric current, a voltage drop will occur in the line (UV). The size of this voltage drop
UV depends on:
l the available amperage (I) and
l the electric resistance (Rline) of the current branch being checked.
In order to have reliable comparison possibilities at hand one should always work with the same amperage. Iden-
tical marginal conditions are therefore used in all of the following examples:
12 Volt – vehicle battery as voltage source or 24 Volt in a 24 Volt vehicle network.
12 V / 21 W – lamp as load in a 12 Volt vehicle network.
24 V / 21 W - lamp as load in a 24 Volt vehicle network.

Test steps
1. Switch off the ignition.
2. Unplug the control unit from wiring loom.
3. If available connect the Pinbox (Fig. 15) to the plug of the wiring loom, do not connect the control unit with the
Pinbox. If no Pinbox is available, provide measuring cables with appropriate plug-in contacts, e.g. spade-type
plugs.
4. Check with multimeter. If a setpoint is not reached, proceed step by step to identify the weak spot. Repair as
necessary. Repeat the measurement.

! Caution
The plug must not be pulled off or plugged on while the ignition is switched on. Switch off the ignition
first and then pull off or plug on the plug.
Only plug the wiring loom onto the control unit, when the actual value corresponds with the setpoint.

Fig. 15 Pinbox for 68 pole ESX control

106 BOMAG 008 922 07

Checking the voltage supply for the control unit 5.32
General measuring setup to check a supply line (plus side)

Fig. 16 Measuring arrangement 12 Volt

1 = Supply line, plus side
2 = Plug contact in wiring loom plug on control or Pinbox (Fig. 15)
E = Lamp, 12V / 21 Watt
P = Multimeter
G01 = Battery as voltage source, 12V
UV = Voltage drop caused by the lamp current

Setpoint
The voltage drop UV should not exceed 0.5 V => USetpoint ≤ 0.5 V.

008 922 07 BOMAG 107

5.32 Checking the voltage supply for the control unit

General measuring setup to check a return line (minus side)

Fig. 17 Measuring arrangement 12 Volt

1 = Return line, minus side
2 = Plug contact in wiring loom plug on control or Pinbox (Fig. 15)
E = Lamp, 12V / 21 Watt
P = Multimeter
G01 = Battery as voltage source, 12V
UV = Voltage drop caused by the lamp current

Setpoint
The voltage drop UV should not exceed 0.5 V => USetpoint ≤ 0.5 V.

108 BOMAG 008 922 07

Checking the voltage supply for the control unit 5.32
Connection example to check the plus line between battery and plug pin 28

Fig. 18
X = Wiring loom plug disconnected from control unit or Pinbox (Fig. 15)
P = Multimeter
S00 = Ignition switched on. Setpoint : E is bright. UV max. 0.5 Volt
S00 = Ignition switched off. Setpoint : E is dark. UV = 0.0 Volt

008 922 07 BOMAG 109

5.32 Checking the voltage supply for the control unit

Connection example to check the minus line between battery and plug pin 55

Fig. 19
P = Multimeter
X = Wiring loom plug disconnected from control unit or Pinbox (Fig. 15)
E = Setpoint : E is bright. UV max. 0.5 Volt

110 BOMAG 008 922 07

Checking the voltage supply for the control unit 5.32
Test protocol for ESX
E lamp 12V / 21W in 12V vehicle network, to load the current branches.
E lamp 24V / 21W in 24V vehicle network, to load the current branches.
G01, battery
P multimeter, measuring range: DC

Plug pin Note Setpoints

28 Ignition ON
E between plug pin 28 and battery minus E is bright,
P between battery plus and plug pin 28 UV max. 0.5 Volt
28 Ignition OFF
E between plug pin 28 and battery plus E is dark,
P between battery minus and plug pin 28 UV = 0 Volt
54 Ignition OFF, emergency stop not operated
E between plug pin 54 and battery minus E is bright,
P between battery plus and plug pin 54 UV max. 0.5 Volt
54 Ignition OFF, emergency stop operated
E between plug pin 54 and battery minus E is dark,
P between battery plus and plug pin 54 UV = 0 Volt
55 Ignition OFF
E between plug pin 55 and battery minus E is bright,
P between battery plus and plug pin 55 UV max. 0.5 Volt
56, 57, 58, 59, Ignition OFF
60 E between plug pin 56, 57, 58, 59, 60 and battery minus E is bright,
P between battery plus and plug pin 56, 57, 58, 59, 60 UV max. 0.5 Volt

i Note
If one or several setpoint(s) is (are) exceeded, one must make considerations which are related to the wiring
diagram.

Example 1:
In all supply lines to the pins 56, 57, 58, 59 and 60 the voltage drop is too high. There are two possible reasons.
Either all contacts are corroded, or the supply line between battery and fuse Fxx has poor contact.

Example 2:
Only one measuring value exceeds the setpoint. In this case the fault must be located between the last branch
and the corresponding plug pin.

008 922 07 BOMAG 111

5.33 Diagnostics concept

5.33 Diagnostics concept

Introduction
A correct and reliable diagnose is a general prerequisite for the detection of faults in system. For this to count
as a rule several points must be fulfilled. One of these points is the ability of the engine to run a systematic trouble
shooting procedure. However, this is only possible when a diagnostics concept is available and in practice. Trou-
ble shooting can generally be performed in various ways.

Fault description and questioning of the customer

After the customer has explained his complaint(s) the engineer has to ask further questions to track down the
cause of the fault. If the complaint is additionally related to electric/electronic components, the visual examina-
tion and a possible test drive must be subsequently followed by an interrogation of the error log. The further pro-
cedure in this case depends on the outcome of this interrogation.

Description of fault,
Questioning of customer

Visual inspection,
possible test drive

Interrogation of error log

(1)
Fault memorized in
error log
(2)
No fault memorized in
error log

Fig. 20

(1) Fault memorized in error log

Clear cause?
l If the fault message leaves no doubt, repair work may be started immediately.

(2) No fault memorized in the error log at the time of initial questioning
Even if the fault is in the electric/electronic part of the vehicle, a control unit will very often not detect a fault. Right
from the start you should be aware of the fact that a high proportion of faults is caused by contacts. This even
gets worse in case of older and neglected vehicles.
In order to examine the electric/electronic part of an electronic system it is recommended to check the incoming
sensor information and outgoing command values on a control unit. This requires profound knowledge of system
and components.

Consideration, if the error log has not recorded a fault

l
What could be the cause of the complaint?
l
Which measuring possibilities are available?

112 BOMAG 008 922 07

Diagnostics concept 5.33
Localizing faults
Line or component?

Fig. 21
l
In most cases the fault message does not clarify whether the fault is in the sensor or actor, or in one of the
connecting lines (2) between control unit and the mentioned component (1). For this purpose it makes sense
to check the component and the connecting lines between control unit and component separately.
l
Checking the voltage supply for the control unit
l
Checking the sensor lines
l
Checking the actor lines

008 922 07 BOMAG 113

5.33 Diagnostics concept

Sequence after the fault is found

Fault found

Replace component or
repair the connecting line

Delete the error log, test drive

Read out the error log again

No fault memorized in
error log
Prepare the hand-over of the vehicle
Fault memorized in
error log
Check all work again,
rectify the fault

Fig. 22

114 BOMAG 008 922 07

 6 Input codes

008 922 07 BOMAG 115

6.1 Input codes -- display: Functions and operation

Display functions and operation

6.1 Input codes -- display: Functions and operation

The main LC-display (Fig. 23):

l Display of operating hours as well as error and input codes (1)
l Button right (2)
l Button left (3)
l Tool symbol (4) (only visible in Service mode)

Fig. 23 LC-Display

Input of codes (input codes)

i Note
The brake needs to be activated to be able to access input mode!

Calling up input mode

Action Result
-- Press button left and button right at the -- The display shows "0000"
same time for at least two seconds. -- The left "0" is flashing.

i Note
One can change the numerical value of the display by using the buttons one after the other:
The left hand button to change the numbers in ascending mode (0, 1, 2, 3, 4, 5, 6, 7, 8, 9, 0, ...).
The right hand button to move on to the next digit (0000, 0000, 0000, 0000, 0000, ...)
Calling up service mode

Action Result
-- Enter code 0001. -- The system changes to service mode.
-- The display shows the tool symbol.

116 BOMAG 008 922 07

Automatic calibration of travel system currents 6.2
6.2 Automatic calibration of travel system currents

In order to ensure sensitive and exact functioning of the travel system, the start currents of the travel pumps
must be calibrated. This must be carried out for both drive sides for both forward and reverse.
The start currents must always be calibrated:
l after the installation of the travel pumps in the factory.
l after work on the travel pump.
l after replacing a travel pump.
l after replacing the ESX-control.
The procedure is identical for both sides:
Once you have entered the corresponding code, the control current for the solenoid valve on the travel pump is
increased in steps of 5 mA, starting with a predetermined value for minimum current.
After each increase in current the system waits 3 seconds. If a noticeable movement of the machine is sensed
during this time, the current value will be saved. In order to improve this result the measurement is performed
five times. The value finally set by the system is thus the mean value of all previous measurements. The set
value is automatically saved and is valid from the next start of the machine.

! Caution
The following must be ensured before making settings:
- the machine is standing on a level surface.
- there is sufficient space in direction forward and reverse (the machine moves during the calibration
process)

! Caution
During the adjustment procedure:
- Do not leave the machine!
- Watch the area around the machine to exclude any dangers for other persons!

i Note
The calibration must only be made at operating temperature of the machine.

i Note
To stop the machine during the adjustment process:
- Return the travel lever to "Neutral" or
- press the Emergency Stop button or
- switch off the ignition.

Calibrating the travel system currents

i Note
Pay attention to the section "Input Codes Display General"!

i Note
In order to be able to perform the function "Automatic calibration of travel currents" you need to carry out the
following actions:
- Start the engine.
- Turn the rotary button for "ECO mode" to "ECO",

008 922 07 BOMAG 117

6.2 Automatic calibration of travel system currents

- Turn the rotary button "Working speed" at least to position "5"

- Set the travel speed range switch to "fast" (rabbit)
- Move the travel lever forward and move the machine for approx. 5 meters
- shift the travel lever to "Neutral".

Automatic calibration of travel system currents:

Action Result
-- The system changes to service mode.
-- Enter code 0001.
-- The display shows the tool symbol.
-- Make sure that the "ECO mode" switch is
in position "ECO".
-- Set the travel speed range switch to po-
sition "slow" (turtle).
-- Shift the travel lever to "Neutral"
-- The teach function "Travel currents" is activated.
-- The display shows "0 0 0 0".

Note:
-- Enter code 1090.
The machine can no longer be operated with the travel
lever. This is only possible again after the teach proc-
ess has been completed and after the machine has
been restarted!
The "Travel current teach function" for the left side is
-- Enter code 1091. activated.
-- The display shows "4 4 4 4 4".
-- Teaching starts with the first current value.
-- The display shows the actual mA value.
-- Once the machine moves, the corresponding mA
-- Shift the travel lever forward. value is saved.
-- Once the value has been saved the display will
show "1 1 1 1 1".
-- After a short while the display will show 5 5 5 5 5".
-- Teaching starts with the first current value.
-- The display shows the actual mA value.

-- Shift the travel lever reverse. -- Once the machine moves, the corresponding mA
value is saved.
-- Once the value has been saved the display will
show "1 1 1 1 1".

118 BOMAG 008 922 07

Automatic calibration of travel system currents
Automatic calibration of travel system currents:
Action
-- Shift the travel lever to "Neutral"
-- Enter code 1092.
-- Shift the travel lever forward.
-- Shift the travel lever reverse.
-- Shift the travel lever to "Neutral"
i Note
Should the code "2 2 2 2 2" not appear, the calibration was not accepted. In this case the whole procedure must
be repeated.
008 922 07
6.2
Result
-- The display shows "0 0 0 0".
The "Travel current teach function" for the right side
is activated.
-- The display shows "4 4 4 4 4".
-- Teaching starts with the first current value.
-- The display shows the actual mA value.
-- Once the machine moves, the corresponding mA
value is saved.
-- Once the value has been saved the display will
show "1 1 1 1 1".
-- After a short while the display will show 5 5 5 5 5".
-- Teaching starts with the first current value.
-- The display shows the actual mA value.
-- Once the machine moves, the corresponding mA
value is saved.
-- Once the value has been saved the display will
show "1 1 1 1 1".
-- The display shows "3 3 3 3 3" (--> calibration suc-
cessful).
-- This is followed by "2 2 2 2 2" (--> saving complet-
ed).
-- The machine can now be controlled with the travel
lever again.
-- Changes only become effective after a restart of the
machine.
-- END.
BOMAG 119
6.3 Automatic calibration of travel system currents

6.3 Automatic calibration of travel system currents

! Caution
The following must be ensured before making settings:
- the machine is standing on a level surface.
- there is sufficient space in direction forward and reverse (the machine moves during the teaching proc-
ess)

! Caution
During the adjustment procedure:
- Do not leave the machine!
- Watch the area around the machine to exclude any dangers for other persons!

i Note
The calibration must only be made at operating temperature of the machine.

i Note
To stop the machine during the calibration process:
- press the Emergency Stop button or
- return the travel lever to "Neutral" or
- press the parking brake switch. (Parking brake)

Calibrating the travel system currents manually

i Note
Pay attention to the section "Input Codes Display General"!

120 BOMAG 008 922 07

Automatic calibration of travel system currents
Manual calibration of travel system currents:
Action
-- Enter code 0001.
-- Shift the travel lever to "Neutral"
-- Turn the steering wheel to middle posi-
tion. (locks noticeably)
-- Set the speed potentiometer to "0".
-- Enter code 1095.
-- Enter code 1096.
-- Shift the travel lever forward.
-- Set the speed potentiometer between "4"
and "5".
-- Move the steering wheel to left and right.
Once the desired surge current has been
reached:
-- Attention: Hold the steering wheel in
this position!
-- Shift the travel lever to "Neutral"
-- Set the speed potentiometer to "0".
-- Turn the steering wheel to "Neutral"
-- Enter code 1097.
008 922 07
6.3
Result
-- The system changes to service mode.
-- The display shows the tool symbol.
-- The calibration function "Travel currents" is activated.
-- The display shows "0 0 0 0".
-- The LEDs for steering direction are flashing.
Note:
The machine can no longer be operated with the steering
wheel.
-- The calibration function "Travel currents" for forward is
activated.
-- The display shows "4 4 4 4 4".
-- Calibration for forward movement of both track drives
starts.
-- The display shows the surge current correction value in
mA.
-- The display shows the surge current correction value
with respect to the steering wheel displacement.
Note:
Depending on the steering wheel displacement the surge
current correction value will be added to or subtracted from
the basic value.
-- The display shows "1 1 1 1 1".
-- The adjusted value is saved.
-- The display shows "0 0 0 0".
-- The calibration function "Travel currents" for reverse is
activated.
-- The display shows "5 5 5 5 5".
BOMAG 121
6.3
Manual calibration of travel system currents:
Action
-- Shift the travel lever reverse.
-- Set the speed potentiometer between "4"
and "5".
-- Move the steering wheel to left and right.
Once the desired surge current has been
reached:
Attention: Hold the steering wheel in this
position!
-- Shift the travel lever to "Neutral"
-- Set the speed potentiometer to "0".
-- Turn the steering wheel to "Neutral"
i Note
Should the calibration not function correctly, reset the machine to factory settings (see section "Input
codes_Reset to factory settings").
122
Automatic calibration of travel system currents
Result
-- Calibration for reverse movement of both track drives
starts.
-- The display shows the surge current correction value in
mA.
-- The display shows the surge current correction value
with respect to the steering wheel displacement.
Note:
Depending on the steering wheel displacement the surge
current correction value will be added to or subtracted from
the basic value.
-- The display shows "1 1 1 1 1".
-- The adjusted value is saved.
-- The display shows "3 3 3 3 3".
-- The display shows "2 2 2 2 2".
-- The LEDs for steering direction have stopped flashing.
-- The machine can now be controlled with the steering
wheel again.
-- END.
BOMAG 008 922 07
Teaching the E-throttle function: 6.4
6.4 Teaching the E-throttle function:

Teaching the E-throttle function

i Note
Take notice of the section "Input codes Display General"!

Teaching the E-throttle function:

Action Result
-- Switch on the ignition.
Note: Do not start the engine.
-- The system changes to service mode.
-- Enter code 0001.
-- The display shows the tool symbol.
-- The teach function "Teach E-throttle function" is activat-
-- Enter code 5038.
ed.
-- The function E-throttle lower value is activated.
-- The E-throttle actuator in the engine compartment
clicks.
Note: This clicking sound indicates that the coupling of the
-- Enter code 5039.
actuator has been opened.
-- The corresponding position value appears in the display.
Note: The value must be lower than 500. Otherwise you
must adjust the lever of the `E-throttle actuator.
-- Shift the lever of the injection pump fully to
-- The E-throttle actuator in the engine compartment
min (idle speed) and hold it in this position.
clicks.
Note: This makes sure that the lever is ac-
-- A valid value has been taught.
tually in position "min".
-- The function E-throttle upper value is activated.
-- The E-throttle actuator in the engine compartment
clicks.
-- Enter code 5040.
Note: This clicking sound indicates that the coupling of the
actuator has been opened.
-- The corresponding position value appears in the display.
-- Shift the lever of the injection pump fully to -- The E-throttle actuator in the engine compartment
maximum (full speed) and hold it in this clicks.
position. -- A valid value has been taught.
-- The E-throttle function is terminated.
-- Enter code 5041.
-- END.

008 922 07 BOMAG 123

6.5 Teaching the L.C.S. function

6.5 Teaching the L.C.S. function

Teaching the LCS function

The L.C.S. Control panel (Fig. 24):
l Work potentiometer (1)
l Stop potentiometer (2)
l Timer potentiometer (3)

Fig. 24 LCS operation

Fig. 25 Screed adjustment

Caution
!

Lower the screed to be able to teach the L.C.S. function.

The switch “a” (Fig. 25) must be in bottom position “Floating position/draining”.

i Note
Take notice of the section "Input codes Display General"!

i Note
During this teach function the travel lever must always remain in "Neutral".

124 BOMAG 008 922 07

Teaching the L.C.S. function
Teaching the LCS function:
Action
-- Start the engine.
-- Turn all potentiometers on the LCS con-
trol panel to "min".
-- Enter code 0001.
-- Enter code 3006.
-- Enter code 3007.
-- Set the work potentiometer to the desired
pressure (read pressure on pressure gauge
of LCS control panel).
-- Turn the timer potentiometer from "min" to
"max" and back to "min".
-- Turn the work potentiometer to "min".
-- Enter code 3008.
-- Set the stop potentiometer to the desired
pressure (read pressure on pressure gauge
of LCS control panel).
-- Turn the timer potentiometer from "min" to
"max" and back to "min".
-- Turn the stop potentiometer to "min".
-- Enter code 0000.
008 922 07
6.5
Result
-- The system changes to service mode.
-- The display shows the tool symbol.
-- The teach function "Teach LCS" is activated.
-- The display shows "0 0 0 0".
-- The function LCS maximum work pressure is activat-
ed.
-- The display shows "4 4 4 4 4".
-- The display shows the current position of the potentiom-
eter for informative reasons (value between "0" and
"1000").
-- The display shows "1 1 1 1 1".
-- This is followed by "3 3 3 3 3".
-- The display shows "2 2 2 2 2".
-- This is followed by "0 0 0 0".
-- The function LCS maximum stop pressure is activated.
-- The display shows the current position of the potentiom-
eter for informative reasons (value between "0" and
"1000").
-- The display shows "1 1 1 1 1".
-- This is followed by "3 3 3 3 3".
-- The display shows "2 2 2 2 2".
-- This is followed by "0 0 0 0".
-- This quits the service mode.
-- END.
BOMAG 125
6.6 Travel signal by button for max. screed relief

6.6 Travel signal by button for max. screed relief

i Note
This function is a so-called limp home function. It enables the operator to drive the machine, even if the travel
speed potentiometer has reported a fault (codes 1025 or 1026). Activation of the function "Travel signal by push
button for maximum screed relief" is therefore only possible, as long as fault of the travel speed potentiometer
is present.
As long as the function "Travel signal by push button for maximum screed relief" is activated, the button for max-
imum screed relief is not available to the operator! However, the Load Control System (LCS) does still work.

Fig. 26 Push button for maximum screed relief

i Note
Take notice of the section "Input codes Display General"!

Activation of the function "Travel signal by push button for maximum screed relief":

Action Result
-- Switch on the ignition.
Note: Do not start the engine.
-- The system changes to service mode.
-- Enter code 0001.
-- The display shows the tool symbol.
-- Changes to the travel system parameters are now pos-
-- Enter code 1100.
sible.
-- The function "Travel signal by push button for maximum
-- Enter code 1121.
screed relief" is activated.

i Note
To drive the machine the operator must now:
- Shift both travel control lever forward (or backward).
- At the same time press the button for maximum screed relief (Fig. 26) and hold it, until the desired speed has
been reached.

126 BOMAG 008 922 07

Travel signal by button for max. screed relief 6.6
i Note
- Travel lever in "Neutral" stops the machine.

i Note
Once the fault(s) no longer exist (e.g. after a repair) this function deactivates automatically when switching on
the ignition.
There is also the possibility to switch off this function manually.

Deactivation of the function "Travel signal by push button for maximum screed relief":

Action Result
-- Switch on the ignition.
Note: Do not start the engine.
-- The system changes to service mode.
-- Enter code 0001.
-- The display shows the tool symbol.
-- Changes to the travel system parameters are now pos-
-- Enter code 1100.
sible.
-- The function "Travel signal by push button for maximum
-- Enter code 1122.
screed relief" is deactivated.

008 922 07 BOMAG 127

6.7 Resetting to factory settings

6.7 Resetting to factory settings

i Note
Pay attention to the section "Input Codes Display General"!

i Note
The machine will not move as long as the code "7860" is displayed.

Resetting to factory settings:

Action Result
-- Switch on the ignition.
Note: Do not start the engine.
-- The system changes to service mode.
-- Enter code 0001.
-- The display shows the tool symbol.
-- Enter code 7010. -- The display shows "7 8 6 0".
-- Press the right button to confirm "7860". -- The ESX runs a reset.
-- Switch off the ignition.
-- The display shows "7 8 6 0".
-- Switch on the ignition.
-- The system changes to service mode.
-- Enter code 0001.
-- The display shows the tool symbol.
-- Enter code 7010.
-- Use the left hand button to select code
7865 (explanations see below). -- The ESX runs another reset.
-- Press the right button to confirm.
-- Switch off the ignition.
-- The display shows "7 8 6 5".
-- Switch on the ignition.
-- This quits the service mode.
-- Enter code 0000.
-- END.
Explanation of codes:
l 7860 --> "reset"
l 7861 --> "Wheel machine"
l 7865 --> "Track machine"

128 BOMAG 008 922 07

Showing stored faults 6.8
6.8 Showing stored faults

i Note
This function can only be activated / deactivated if the parking brake has been activated!
Do not switch to service mode to show the error log!

Display of logged errors:

Action Result
-- Switch on the ignition.
Note: Do not start the engine.
-- The system changes to the mode "Show logged errors".
-- The error codes logged in the ESX appear flashing in the
display.

Note:
If more than only one error codes has been logged, these
-- Enter code 0700.
codes are displayed in three second intervals. Once the
last error has been displayed, the first error will appear
again.
If there are no error codes present, the display shows "- -
- - -". The mode "Show loggd errors" is in this case termi-
nated after approx. 4 seconds.
-- Enter code 0701. -- The mode "Show logged errors" is terminated.

i Note
Apart from the logged error codes the current faults (if present) are also displayed.

008 922 07 BOMAG 129

6.9 Showing saved faults with operating hours

6.9 Showing saved faults with operating hours

i Note
This function can only be activated / deactivated if the parking brake has been activated!
Do not switch to service mode to show the error log!

Display of logged errors:

Action
-- Switch on the ignition.
Note: Do not start the engine.
-- Enter code 0705.
-- Press the left hand button.
Attention: three possible options!
One error code:
-- Press the left hand button again.
Several error codes:
-- Press the left hand button again.
Showing the operating hours for the error
code:
-- Press the right hand button.
Showing the number of occurrence of this
error:
-- Press the right hand button again.
-- Enter code 0706.
Result
-- The system changes to the mode "Show logged errors
with operating hours".
-- The error codes logged in the ESX appear flashing in the
display.
-- Option 1: No error code logged in the ESX:
--> The display shows "- - - - -". The mode "Show logged
errors with operating hours" is in this case automatically
terminated after approx. 4 seconds.
-- Option 2: Only one error code is logged in the ESX:
--> The display shows the error code. Continue with "One
error code".
-- Option 3: Several error codes logged in the ESX:
--> The display first shows only one error code. Continue
with "Several error codes".
-- The display does not change, the logged error code
flashes. Continue with "Show operating hours of error
code".
-- The display changes. Each actuation of the left hand but-
ton brings you to the next error code, until the first one ap-
pears again. Continue with "Show operating hours of error
code".
-- The operating hours at which the corresponding error
code has been logged are displayed. ("When did the error
occur the last time?")
The display shows the number of occurrence of the corre-
sponding error since the error log had been deleted the last
time. ("How often has the error been detected?")
-- The mode "Show logged errors with operating hours" is
terminated.

i Note
Apart from the logged error codes the current faults (if present) are also displayed.

130 BOMAG 008 922 07

Deleting the fault log 6.10
6.10 Deleting the fault log

i Note
This function can only be activated / deactivated if the parking brake has been activated!
Do not switch to service mode to delete the error log!

Deleting logged errors:

Action Result
-- Switch on the ignition.
Note: Do not start the engine.
-- Enter code 0710.
-- Switch off the ignition.
-- All logged error codes have been deleted.
-- Switch on the ignition.

008 922 07 BOMAG 131

6.11 Driving against the closed brake

6.11 Driving against the closed brake

i Note
Activation of this mode is only possible from software version 0.21!

Activate function "Driving against the closed brake":

Action Result
-- Start the engine.
-- Shift the travel lever to "Neutral"
-- The system changes to service mode.
-- Enter code 0001.
-- The display shows the tool symbol.
-- The mode "Driving against the closed brake" is activated.
-- Enter code 0500.
-- The LED for brake flashes.
-- Shift the travel lever to "forward" ("re-
verse"). -- The display shows "0 0 0 0".
-- Set the speed potentiometer to "> 0".
-- Shift the travel lever to "Neutral"
-- The display shows "0 0 0 0".
-- Set the speed potentiometer to "> 0".
-- The mode "Driving against the closed brake" is deacti-
vated.
-- Enter code 0501.
-- The LED for brake lights.
-- The display shows "0 0 0 0".
-- This quits the service mode.
-- Enter code 0000.
-- END.

132 BOMAG 008 922 07

Adapting the engine speed 6.12
6.12 Adapting the engine speed

i Note
On the finisher BF300 the transmission ratio of the belt drive for the generator (power generation for screed heat-
ing) was adapted from a certain serial number. The diameter of the generator V-belt pulley was thereby
changed. In the software version v0.27 the engine speed during the screed heat up period was adapted.

i Note
Serial numbers, from which the changed V-belt drive has been installed:
l
BF300_P - S340 VE : 821837681008 - ...
l
BF300_P - S340 TVE : 821837811013 - ...
l
BF300_C - S340 TVE : 821837821017 - ...

i Note
The engine speed must be adapted if the software version v0.27 is installed in a finisher which still has the old
belt drive installed.

i Note
Take notice of the section "Input codes Display General"!

Adapting the engine speed:

Action Result
-- Switch on the ignition.
Note: Do not start the engine.
-- The system changes to service mode.
-- Enter code 0001.
-- The display shows the tool symbol.
-- The engine speed is adapted to the original settings (old
-- Enter code 5046.
generator).
-- This quits the service mode.
-- Enter code 0000.
-- END.

008 922 07 BOMAG 133

6.13 Deactivating/activating automatic speed range change when

6.13 Deactivating/activating automatic speed range change when corner-

ing

i Note
The travel speed of the finisher can be changed from transport speed (rabbit = "High") to working speed (turtle
= "Low"with the help of the speed range selector switch (Fig. 25).
Upon delivery the control contains a function that switches automatically from "High" to "Low", if the machine
does not steer in accordance with the steering commands.
The function "Automatic change to working speed" can be disabled.
If the function "Change to working speed" has been deactivated:
l
Automatic switching from "High" to "Low" is ligated.
l
The operator can choose between "High" and "Low".

Fig. 27 Travel speed range switch

i Note
Pay attention to the section "Input Codes Display General"!

Deactivating the function "Change to working speed":

Action Result
-- Switch on the ignition.
Note: Do not start the engine.
-- The system changes to service mode.
-- Enter code 0001.
-- The display shows the tool symbol.
-- The function "Setting the machine type code" is activat-
-- Enter code 1100.
ed.
-- Enter code 1113. -- The function "change to working speed" is deactivated.
-- Switch off the ignition. -- END.

134 BOMAG 008 922 07

Deactivating/activating automatic speed range change when 6.13
Activating the function "Change to working speed":

Action Result
-- Switch on the ignition.
Note: Do not start the engine.
-- The system changes to service mode.
-- Enter code 0001.
-- The display shows the tool symbol.
-- The function "Setting the machine type code" is activat-
-- Enter code 1100.
ed.
-- Enter code 1112. -- The function "change to working speed" is activated.
-- Switch off the ignition. -- END.

008 922 07 BOMAG 135

6.14 Deactivating / activating the speed sensor(s)

6.14 Deactivating / activating the speed sensor(s)

i Note
During operation the control permanently monitors all signals from the connected sensors. Should a speed sen-
sor or part of its cable be defect, the movement of the machine may be affected. This defect will be detected and
shown in the display in form of an error code.
l
1031
l
1032

i Note
In order to be able to continue operation of the machine despite the displayed error code, there is a possibility
to deactivate the monitoring of the speed sensors.

i Note
Pay attention to the section "Input Codes Display General"!

Deactivating the function "Monitoring of speed sensors":

Action Result
-- Switch on the ignition.
Note: Do not start the engine.
-- The system changes to service mode.
-- Enter code 0001.
-- The display shows the tool symbol.
-- The function "Setting the machine type code" is activat-
-- Enter code 1100.
ed.
-- The function "recording of speed signal" is deactivated.
-- Enter code 1009. Note: From now on the system will ignore a missing signal
from the speed sensor.
-- The function "Setting the machine type code" is activat-
-- Enter code 1100.
ed.
-- The function "monitoring the closed electric circuit" is
deactivated.
-- Enter code 1111.
Note: From now on the system will ignore a possible cable
breakage of the speed sensor.
-- Switch off the ignition. -- END.

i Note
Once the defect on the speed sensor has been rectified, the monitoring function must be enabled again.

136 BOMAG 008 922 07

Deactivating / activating the speed sensor(s) 6.14
Activating the function "Monitoring of speed sensors":

Action Result
-- Switch on the ignition.
Note: Do not start the engine.
-- The system changes to service mode.
-- Enter code 0001.
-- The display shows the tool symbol.
-- The function "Setting the machine type code" is activat-
-- Enter code 1100.
ed.
-- The function "recording of speed signal" is activated.
-- Enter code 1008. Note: From now on the system expects a signal from the
speed sensor.
-- The function "Setting the machine type code" is activat-
-- Enter code 1100.
ed.
-- The function "monitoring the closed electric circuit" is
activated.
-- Enter code 1110.
Note: From now on the system will monitor the wiring of
the speed sensor.
-- Switch off the ignition. -- END.

008 922 07 BOMAG 137

6.14 Deactivating / activating the speed sensor(s)

138 BOMAG 008 922 07

 7 Replacement of components

008 922 07 BOMAG 139

7.1 How to proceed when replacing components?

Foreword
7.1 How to proceed when replacing components?

Each machine is adjusted individually ex factory. Should the replacement of machine parts become necessary
during the operating period of the machine, there is always a possibility to repeat these adjustments.
BOMAG thereby does without any expensive special tools, but gives the service personnel the possibility tom
make adjustments and settings easily and simply by just using the display on the machine. The chapter
"Electrics finisher input codes" contains a detailed description of the steps required to correctly adjust the re-
placed component to to re-establish the operability of the machine.

Replacing the contgrol (ESX)

Since the central control (ESX) saves all data and values, all teach procedures listed in the chapter "Electrics
finisher input codes" must be carried out.

i Note
Compliance with the specified sequence of procedures is mandatory!
Carry out the following teach procedure(s):
l
Input codes -- reset to factory settings (Code: 7861 for BF300P. Code: 7865 for BF300C)
l
Input codes - automatic calibration of currents for travel system (only BF300C)
l
If necessary: Input codes - manual calibration of currents for travel system (only BF300C)
l Input codes -- teaching E-throttle function
l If necessary: Input codes - adapt engine speed.

Replacement of travel pump(s)

Carry out the following teach procedure(s):
l Input codes - automatic calibration of currents for travel system (only BF300C)
l If necessary: Input codes - manual calibration of currents for travel system (only BF300C)

Replacement of E-throttle actuator

Carry out the following teach procedure(s):
l Input codes -- teaching E-throttle function

The following components can be replaced without a subsequent teach procedure:

l
The display
l
The diesel engine (Attention: When converting the E-throttle actuator to match the new engine, teaching of
the E-throttle actuator is required).
l
All switches in the instrument panel and the lateral contro, panels.

140 BOMAG 008 922 07

 8 Engine

008 922 07 BOMAG 141

8.1 Features

8.1 Features Engine block

General
All BOMAG finishers BF300 are powered by powerful
4-cylinder KUBOTA engines with direct fuel injection,
turbocharger and 4-valve technology. Engines which
impress by their homogeneous development of power
with low fuel consumption and low CO2 emission, as
well as excellent smoothness of running and reduced
noise. The stringent flue gas standards EPA TIER III
or TIER IV interim as well as EU stage IIA are obvious-
ly fulfilled.

Fig. 29 Engine block

Fig. 28
The standard BOMAG ECOMODE ensures a clean
environmental balance. Due to the active engine man-
agement power is made available for the driver when
it is needed and is reduced again when permitted by
the application. Intelligent sensors in connection with
an ingenious control immediately detect the actual
power requirement and the engine speed of the well
proven KUBOTA engine is automatically adapted. A
nice side effect – the noise sensation inside the cabin
is also very pleasant.
1 Crankcase 1
2 Crankcase 2
The engine has two separate crankcases - crankcase
1 (Fig. 29) with combustion section and crankcase (2)
to support crankcase (1) and for the purpose of noise
reduction.
The cylinders are designed without liners, which en-
sures excellent cooling, lower tensions and good
abrasion resistance.

142 BOMAG 008 922 07

Features
Semi-floating valve cover
A recessed rubber seal ensures a distance of approx.
0.5 mm between valve cover and cylinder head. This
reduces the development of noise on the cylinder
head.
8.1
Cylinder head
The engine has a 4-valve system with one cylinder
head, which is designed with dual intake channels.

Fig. 31
1 Intake
Fig. 30 2 Exhaust
1 Valve cover
2 Rubber seal

008 922 07 BOMAG 143

8.2 Cooling system

Central Direct Injection System (E-CDIS) 8.2 Cooling system

The engines are equipped with the central direct injec-
tion system (E-CDIS = Center Direct Injection Sys-
tem) with the injection nozzle arranged vertically in the
centre of the cylinder.
The system injects the fuel directly into the centre of
the cylinder.
Thermostat
Conventional thermostat valves (type outlet water
temperature) open against the coolant flow. In this de-
sign the pressure (steam pressure + water pump out-
put pressure) influences the opening/closing
performance of the valve.
The valve could thus be delayed at a specified open-
ing temperature and then suddenly open above the
specified temperature. This is referred to as overshoot
phenomenon. The overshoot problem also leads to a
subharmonic phenomenon. Too much water cooled
by the radiator flows through the water channel, caus-
ing the valve to close suddenly below the specified
thermostat closing temperature.
A repetitive cycle of such overshoot and subharmonic
phenomena is referred to as water temperature hunt-
ing. This overshoot problem not only adversely affects
the cooling system components, but also the engine
and related components.
In order to tackle this problem the V3 is equipped with
a flow control thermostat. The valve is provided with a
recess 4 (Fig. 34) to infinitely control the coolant flow
in small steps.

Fig. 32
1 Exhaust valves
2 Piston
3 Injection nozzle
4 Intake valves

Fig. 33
1 Coolant temperature
2 Time
3 Overshooting
4 (Fig. 34) Recess

144 BOMAG 008 922 07

Cooling system 8.2
Lower bypass
The engines of series V3 are designed with lower by-
pass, which ensures better cooling performance of the
radiator. At low coolant temperature in the engine the
thermostat 1 (Fig. 35) remains closed, the coolant is
able to flow through the bypass line and circulate in
the engine.

Fig. 34

Fig. 35 Bypass closed

If the temperature exceeds the thermostat opening
temperature, the thermostat 1 (Fig. 36) will open and
thus prevent hot coolant from passing through the by-
pass line into the engine.
This enhances the cooling power of the radiator.

Fig. 36 Bypass open

008 922 07 BOMAG 145

8.3 Removing and installing the thermostat

8.3 Removing and installing the 8.4 Checking the thermostat in

thermostat disassembled state
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. 74,5°C to 78,5°C the thermostat is closed. Once
the coolant temperature has reached this tempera-
ture, the thermostat will start to open, at about 90° C it
is fully open. In this condition the full coolant flow is
guided through the radiator.

Fig. 1
1 Thermostat cover
2 Thermostat cover seal
3 Thermostat
4 Bore
l Unscrew the thermostat cover fastening screws and
take off the thermostat cover (1) (Fig. 1).
l
Remove the thermostat (3).
Fig. 1
For assembly l Measure and write down the measurement "a" on
l Assemble the thermostat cover (3) with the hole (4) the thermostat (Fig. 1).
facing towards the front cover side.
i Note
"a" = beginning of stroke at approx. 74.5°C to 78.5°C
(T1)
"b" = end of stroke at approx. 90 °C (T2)

Fig. 2
l 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.

146 BOMAG 008 922 07

Check the coolant level 8.5
The temperature increase should not exceed 1°C/ 8.5 Check the coolant level
min, as otherwise the start of opening will be delayed
accordingly.
! Danger

Danger of scalding!
Do not remove the cap from the compensation
tank when the engine is still hot.
Fill up coolant only when the engine is cold.

! Caution
If, during the daily inspection the coolant level is
found to have dropped, check all lines, hoses and
engine for leaks.
Do not use radiator sealant to seal leaks.
Fig. 3 For quality and quantity of coolant refer to the "ta-
ble of fuels and lubricants".
l Measure and write down the measurement "b" on
the thermostat . (Fig. 3). l
Open the engine flap and secure it.
l Calculate the stroke.

Stroke = b - a

i Note
The stroke at the given temperature (T2) should be
approx. 8 mm.

Fig. 4
l
Check the coolant level in the compensation tank
(Fig. 4).
l
Top up coolant, if necessary.

Fig. 5
l To top up unscrew the filler cap (Fig. 5) and fill in
coolant up to the MAX-mark.

008 922 07 BOMAG 147

8.6 Check the anti-freeze concentration and the condition of the

8.6 Check the anti-freeze concen- 8.7 Change the coolant

tration and the condition of the
coolant ! Danger

Danger
! Do not remove the cap from the compensation
Danger of scalding!
Check the anti-freeze concentration only when the
engine is cold.
!Caution
In order to avoid damage to the engine (e.g. by
corrosion, cavitation and freezing), particular at-
tention must be paid to the inspection of the cool-
ant.
For coolant quality refer to the "table of fuels and
lubricants".
Do not mix different coolants and additives, see
section "Fuelds and Lubricants - Coolant".
If the coolant is contaminated by corrosion resi-
dues or other suspended matter, flush the cooling
system, see section "Changing the coolant".
Environment
Catch coolant and dispose of environmentally.
Danger of scalding!
tank when the engine is still hot.
Change the coolant only when the engine is cold.
! Caution
Do not start the engine after draining off the cool-
ant.
Thoroughly flush the engine if the coolant is con-
taminated by corrosion residues or other sus-
pended matter.
When changing the coolant without any signs of
contamination, cleaning of the cooling system is
not necessary.
Do not mix different coolants and additives of any
other kind.
Change the coolant at the latest after two years.
For quality and quantity of coolant refer to the "ta-
ble of fuels and lubricants".
Environment
Catch coolant and dispose of environmentally.

Fig. 6
Fig. 7
l
Unscrew the radiator cap (Fig. 6) and check the
anti-freeze concentration with a conventional tester. l Unscrew the cap (Fig. 7) from the coolant compen-
sation tank.
l Check the condition of the coolant.
l Screw the cover back on again.

148 BOMAG 008 922 07

Checking radiator hoses and hose clamps 8.8
8.8 Checking radiator hoses and
hose clamps

Danger
!

Danger of burning!
Perform inspection work only after the engine has
cooled down and with the engine stopped.

! Caution
If a radiator hose is swollen, hardened or cracked,
Fig. 8
both hose and hose clamp must be replaced im-
mediately.
l Unscrew the plug, let the coolant run out and catch
it (Fig. 8). Take care that no contaminants enter into the air
intake system, since this could damage the en-
l Screw the plug back in once all coolant has run out. gine!
l Check the condition of the coolant.
l Thoroughly flush the engine if the coolant is con-
taminated by corrosion residues or other suspend-
ed matter.
l Fill in clean water.
l Start the engine and flush the cooling system out for
a short while.
l Drain all water off.

Fig. 10
l
Check the condition and tight fit of all radiator hoses
and hose clamps (Fig. 10).
l
Check the condition and tight fit of all air intake lines
and hose clamps.

Fig. 9
l
Fill in coolant up to theMAX mark (Fig. 9) and screw
the filler cap back on.
l Start the diesel engine and run it warm to operating
temperature.
l Let the engine cool down and check the coolant lev-
el again, top up if necessary.

008 922 07 BOMAG 149

8.9 Clean the cooling fins on engine and hydraulic oil cooler

8.9 Clean the cooling fins on en- 8.10 Checking the engine oil level
gine and hydraulic oil cooler
! Caution
Danger
! The machine must be in horizontal position.
Danger of injury! If the engine is warm, shut it down and check the
oil level after five minutes.
Perform cleaning work only after the engine has
cooled down and with the engine stopped. With a cold engine the oil level can be checked im-
mediately.
Caution
! For quality of oil refer to the "table of fuels and lu-
bricants".
Do not damage any cooling fins on the cooler core
when cleaning. l Open and support the engine hood.

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

i Note
Start to blow out from the exhaust side. Fig. 12
l
Pull the dipstick (Fig. 12) out, wipe it off with a lint-
free, clean cloth and reinsert it until it bottoms.
l
Pull the dipstick back out.
l
The oil level must always be between the "MIN"-
and "MAX"-marks. If the oil level is too low, top up
oil to the "MAX" mark immediately.

Fig. 11
l Blow the cooler (Fig. 11) out with compressed air.

Cleaning with cold cleansing agent

Caution
!

Protect electrical equipment such as generator,

regulator and starter against the direct water jet.
l 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.
l Run the engine warm for a while to avoid corrosion.

150 BOMAG 008 922 07

Changing engine oil and oil filter cartridge 8.11
8.11 Changing engine oil and oil fil- l Cover the rubber seal of the new engine oil filter
slightly with clean oil.
ter cartridge l Spin the new fuel filter cartridge on and tighten it
hand tight.
Danger
! l Fill in new engine oil through the oil filler neck (2).
Danger of scalding!
l Screw the cap back on again.
When draining off hot oil.
By hot oil when unscrewing the engine oil filter.

Caution
!

Drain the engine oil only when the engine is warm.

For quality and quantity of oil refer to the "table of
fuels and lubricants".

Environment
Catch running out oil and dispose of environmen-
tally together with the oil filter cartridge.

Fig. 15
l After a short test run check the oil level on the dip-
stick (Fig. 15). The oil level should reach the MAX-
mark, top up oil if necessary.
l Check filter cartridge and drain plug for leaks.

Fig. 13
l
Unscrew the drain hose (Fig. 13) and catch running
out oil.
l Fasten the drain hose again in place.

Fig. 14
l
Unscrew the filter cartridge (1) (Fig. 14) using an
appropriate filter wrench.
l Wipe the sealing face clean.

008 922 07 BOMAG 151

8.12 Fuel system

8.12 Fuel system Governor during starting

If no centrifugal force acts on the governor weights (2)
Regulator (Fig. 17), the low tension of the start spring (1) enables
the governor rack to move to start position, where the
fuel quantity required to start the engine will be sup-
plied.

Fig. 16 Regulator
The engine is equipped with a separate injection
pump, combined with the small mechanical multi-
function governor from Kubota. It also contains a
torque limitation mechanism to control the maximum
peak torque. This mechanism maintains the engine
speed at a constant level, even under load fluctua-
tions, it ensures stable idle speed and regulates the
engine speed by controlling the fuel injection quantity.
The governor is a mechanical governor which controls Fig. 17 Governor during starting
the fuel injection quantity over all speed ranges from
1 Start spring
idle speed to maximum speed by using spring force to
simply compensate the centrifugal force of the gover- 2 Governor weight
nor weights.

152 BOMAG 008 922 07

Fuel system
Governor at idle speed
The throttle lever (2) (Fig. 18) must be turned clock-
wise to set the engine to idle speed. The governor
spring (7) is thereby tensioned and the fork lever (1)
tightened.
When the fork lever (1) is tensioned, both the spring
bolt (3) and the for lever (5) will move in direction of ar-
row A to hold back the governor weights (6). The cen-
trifugal force of the governor weights (6) is
compensated in combination with the start spring (4)
and idle speed is maintained.
8.12
Governor at nominal speed
When the throttle control lever (2) (Fig. 18) swivels
from medium to high speed, the spring force applied
by the governor on the governor spring (7) (Fig. 18)
will increase and move the fork lever (1) (Fig. 18) in di-
rection of arrow A. The fork lever (5) moves, until it
reaches the output power limiting screw (2) (Fig. 19),
in order to maintain the nominal speed and the nomi-
nal output power.
When the engine is overloaded the engine speed will
drop together with the centrifugal force of the governor
weights (6) (Fig. 18). The torsion spring moves the
fork lever (1) (Fig. 18) in direction of arrow A. In order
to increase the output power, the control rack moves
to the direction in which the fuel supply is increased.
This is compensated by the centrifugal force of the
governor weights in order to generate a lower speed
(torque output).

Fig. 18 Governor at idle speed

1 Fork lever Fig. 19 Governor at nominal speed

2 Throttle lever 1 Maximum speed without load

3 Spring bolt 2 Output power limitation screw
4 Start spring 3 Torque limitation screw
5 Fork lever
6 Governor weight
7 Governor spring

008 922 07 BOMAG 153

8.12 Fuel system

Governor when shutting down the engine 2-stage nozzle

Interrupting the electric power to the shut-down sole- The nozzle holder, which is fitted with two springs,
noid (1) will release the centrifugal force of the sole- was designed for the reduction of nitrogen oxide and
noid, whereby the solenoid armature is ejected and particle emissions.
moves the governor rack to position B (Fig. 20), which
shuts down the engine.
In order to shut down the engine manually, the shut-
down lever must be shifted to the left.

Fig. 20 Governor when shutting down the engine

1 Shut-down solenoid
2 Stop lever axle

Fig. 21
1 Nozzle holder body
2 1. stage injection pressure adjustment washer
3 First spring
4 Contact pin
5 Spring seat
6 2. stage injection pressure adjustment washer
7 Second spring
8 Pre-stroke adjustment spring seat
9 Chip pack
10 Maximum stroke adjustment washer
11 Locking nut
12 Nozzle

Characteristics
The nozzle holder with two springs limits the valve
stroke during initial opening of the valve in order to
throttle the injection quantity. Main injection takes

154 BOMAG 008 922 07

Replace the fuel filter 8.13
place when the line pressure has sufficiently in- 8.13 Replace the fuel filter
creased and is able to open the needle valve with full
stroke.
! Danger
This results in the following characteristics.
Fire hazard! Health hazard!
l Improved engine stability at low and medium
speeds. When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
l Reduced speed oscillations and speed jumps.
Do not inhale any fuel fumes.
l
Reduced noise development at idle speed.
l Reduced idle speed due to improved engine stabil-
! Caution
ity.
Ensure strict cleanliness! Thoroughly clean the
l Stabilized fuel injection characteristics of injection area around the fuel filter.
pump and nozzle system and simplified adaptation
of the governor characteristics to the engine re- After work on the fuel system bleed the system,
quirements. perform a test run and check for leaks.

Initial opening pressure

Environment
The force generated by the high pressure of the fuel
supplied by the injection pump presses the needle Any fuel must be caught and disposed of in an en-
valve up. Once this force exceeds the rated force of vironmentally friendly manner.
the first spring the needle valve in the nozzle will move
the first push rod up and open the valve.

Second opening pressure

Once the first push rod has been lifted in the pre-
stroke, it will touch the second push rod. Since the rat-
ed force of the second spring acts on the second push
rod, the combined forces of the first and second
springs will act on the needle valve, which will not lift
up before these forces are overcome.

Fig. 22
l Loosen and unscrew fuel filter cartridge (1) (Fig. 22)
using an appropriate filter wrench.
l Clean the sealing face on the filter carrier from any
dirt.
l Slightly oil the rubber seal on the new filter car-
tridge.
l Turn the new filter cartridge on by hand, until the
seal contacts.
l Tighten the filter element for another half turn.
l Check the filter cartridge for leaks after a short test
run.

008 922 07 BOMAG 155

8.14 Checking, cleaning the water separator

8.14 Checking, cleaning the water

separator

Danger
!

Fire hazard! Health hazard!

When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Do not inhale any fuel fumes.

Environment
Any fuel must be caught and disposed of in an en- Fig. 24
vironmentally friendly manner. l Slacken the drain plug (Fig. 24) for a few turns and
catch running out fuel / water.
i Note l Turn the plug tightly back in. Check for leaks, if nec-
The service intervals for the water separator depend essary use a new seal ring.
on the water content in the fuel and can therefore not
be determined precisely. After taking the engine into
operation you should check the filter bowl initially eve- i Note
ry day, later as required, for signs of water. Once the water separator is empty the warning lamp
for water in fuel must go out.
If a too high quantity is drained off, the filter needs to
be bled, see section "Replacing the fuel pre-cleaner
cartridge".

20
15 25

10 30

RPM x100
5 35

0 40
N
h

b 0 1/4 1/2 3/4 1

838390

Fig. 23
l If the "water in fuel" warning light (b) (Fig. 23) lights
up when starting or during operation, drain the wa-
ter from the fuel filter immediately.

156 BOMAG 008 922 07

Changing the fuel filter, bleeding the fuel system 8.15
8.15 Changing the fuel filter, bleed- Bleed the fuel system
ing the fuel system
i Note
The fuel system is equipped with an electric fuel
Danger
!
pump. Tom purge the system switch on the ignition
Fire hazard! Health hazard! and wait about 15 seconds before starting the engine.
When working on the fuel system do not use open
fire, do not smoke and do not spill any fuel.
Do not inhale any fuel fumes.

Caution
!

Ensure strict cleanliness! Thoroughly clean the

area around the fuel filter.
After work on the fuel system bleed the system,
perform a test run and check for leaks.

Environment
Any fuel must be caught and disposed of in an en-
vironmentally friendly manner.

Fig. 25
l
Tighten the cable on the water separator (Fig. 25).
l (1) Loosen the bleeding screw and drain off fuel
from the bleeding screw.
l (2) Loosen and unscrew the fuel pre-filter cartridge
using an appropriate filter wrench.
l
(3) Unscrew the water separator from the filter car-
tridge.
l (4) Apply a thin coat of oil to the rubber seal of the
water separator.
l (5) Turn the water separator on by hand, until the
seal contacts, then tighten hand-tight.
l (6) Apply a thin coat of oil to the rubber seal of the
filter element.
l (7) Turn the filter cartridge on by hand, until the seal
contacts, then tighten hand-tight.
l Plug the water sensor cable back on.

008 922 07 BOMAG 157

8.16 Check fuel lines and clamps

8.16 Check fuel lines and clamps 8.17 Check the fuel injection noz-
zles
! Danger

Danger of burning! ! Caution

Perform inspection work only after the engine has This work must only be performed by authorized
cooled down and with the engine stopped. service personnel.

! Caution
If fuel lines or hose clamps are found to be dam-
aged, the corresponding parts must be immedi-
ately repaired or replaced.
After replacing lines or hose clamps the fuel sys-
tem needs to be bled.
Removed or new fuel lines must be closed with
clean cloths on both ends, to make sure that no
dirt will enter into the fuel system. Dirt particles
can destroy the injection pump.

Fig. 26
l
Check the condition and tight fit of all hose clamps
(1) (Fig. 26) and fuel lines (2).

158 BOMAG 008 922 07

Check the fuel injection timing 8.18
8.18 Check the fuel injection timing 8.19 Check the fuel injection pump

i Note ! Caution
This work must only be performed by authorized serv- This work must only be performed by authorized
ice personnel. service personnel.

008 922 07 BOMAG 159

8.20 Servicing the generator V-belt

8.20 Servicing the generator V-belt 8.21 Air filter maintenance

Checking the condition and tightness of ! Caution

V-belts
Fig. 27
l Check the entire circumference of the V-belt (Fig.
27) for damage and cracks. Replace damaged or
cracked V-belts.
l Check with thumb pressure (2) whether the V-belt
can be depressed more than 10 to 12 mm between
the V-belt pulleys, retighten if necessary.
Tightening the V-belt
l To retighten loosen the fastening screws (1) (Fig.
27) and move the generator to adjust the V-belt ten-
sion.
l Tighten the V-belt, until it can be depressed no
more than 10 to 12 mm by thumb pressure.
Do not start the engine after having removed the
air filter.
If necessary, the air filter may be cleaned up to six
times. After one year at the latest it must be re-
placed together with the safety element.
Cleaning does not make sense if the air filter ele-
ment is covered with a sooty deposit.
Do not use gasoline or hot fluids to clean the filter
element.
After cleaning the air filter must be inspected for
damage using a torch.
Do not continue to use a damaged air filter ele-
ment. If in doubt use a new air filter.
If the air filter is damaged, the safety element must
be replaced as well.
The safety element must not be cleaned.
i Note
We generally recommend to renew the air filter. A new
filter element is far less expensive than a possible en-
gine damage.
h
20
15 25
10 30

RPM x100
l Finally tighten the fastening screws again. 5 35
N
0 40

h
Replacing the V-belt
0 1/4 1/2 3/4 1
l Loosen fastening screws (1) (Fig. 27).
l
Lift up the generator.
838389
l Take off the old V-belt and install a new one.
Fig. 28
l Tighten the V-belt, until it can be depressed no Service of the air filter is also due when the air filter
more than 10 to 12 mm by thumb pressure. warning light (h) (Fig. 28) lights up.
l Retighten the fastening screws (1).
i Note
Once the air filter warning lamp lights up, work may be
continued until the end of the day.
l
Open the engine hood completely and secure it.

160 BOMAG 008 922 07

Air filter maintenance 8.21
moving the gun up and down inside the element,
until it if free of dust.

Fig. 29
l Loosen both locking hooks (Fig. 29) on the housing
cover and take the cover off.
Fig. 32
l Examine the air filter with a torch for cracks and
holes in the paper bellows (Fig. 32).
l In case of damage replace the air filter and the safe-
ty element.

Fig. 30
l Pull out the main filter element (Fig. 30) with light
turning movements.
l Clean housing, housing cover and dust discharge
valve.
Fig. 33
l
Slide the air filter carefully into the housing (Fig. 33).
Danger
!

Danger of injury!
! Caution
Wear protective clothing (goggles, gloves). The dust discharge valve must point vertically
downwards.
Make sure that the cover locks engage correctly.
l Reassemble the housing cover.

Replacing the safety element

! Caution
The safety element must not be cleaned and
should not be used again after it has been re-
moved.

The safety element must be replaced:

Fig. 31 l
if the air filter is damaged or has been replaced
l
Blow the air filter (Fig. 31) out with dry compressed replaced.
air (max. 2.1 bar (30 psi)) from inside to outside by

008 922 07 BOMAG 161

8.22
l at the latest after 1 year.
l if the air filter warning lamp comes on again af-
ter the air filter has been cleaned.
Fig. 34
l Remove the housing cover and pull out the air filter.
l Pull the safety element (Fig. 34) out by turning it
lightly.
l Push in a new safety filter element.
l Insert the air filter and reassemble the housing cov-
er.
162 BOMAG
Check the engine mounts
8.22 Check the engine mounts
Fig. 35
l
Check the fastening of intake and exhaust tubes
(Fig. 35) on the cylinder heads for tight fit.
l
Check sockets and clamps between air filter, ex-
haust turbocharger and charge air line as well as
the lubrication air line for tight fit and leaks.
l Check fastening screws on oil sump and engine
mounts for tight fit.
l Check condition and tight fit of engine pillow blocks.
008 922 07
Engine conservation 8.23
8.23 Engine conservation 8.24 Check, adjust the valve clear-
If the engine is to be shut down for a longer period of ance
time (e.g. over winter), please consult the service de-
partment of the engine manufacturer for further de-
!Caution
tails.
We recommend to have this work carried out by
trained personnel or our after sales service.
Check the valve clearance only when the engine is
cold.

Fig. 36
l
Loosen the plug connections (4) (Fig. 36) on the
preheating plugs (3) and unscrew the preheating
plugs.
l
Unscrew and take off the injection lines (1).
l
Unscrew and take off the valve cover (2).

Adjustment value for intake and exhaust valves:

0.13 mm to 0.17 mm (0.0051 in to 0.0067 in)

Adjustment Cylinder Intake Exhaust

schematic
1 x x
Cylinder 1 in 2 x
TDC 3 x
4
1
Cylinder 1 2 x
overlapping 3 x
4 x x

008 922 07 BOMAG 163

8.24 Check, adjust the valve clearance

Fig. 37
l 1. Set the cylinder to TDC (Fig. 37) and check the
valve clearance as per adjustment schematic.
Fig. 40
l Check the valve cover gasket for damage, change
if necessary.
l Install the valve cover (2) (Fig. 40) with the valve
cover gasket and tighten it (tightening torque:
10 Nm (7.4 ft.lbs)).

Fig. 38
l A feeler gauge of appropriate thickness (A) must fit
with little resistance between rocker arm (Fig. 38)
and valve. Fig. 41
l If the gap is too narrow or too wide for the feeler l Reinstall the injection lines (1) (Fig. 41) (tightening
gauge, the valve must be adjusted. torque: 30 Nm (22 ft.lbs)).
l
Make sure that the clamps (5) are correctly posi-
tioned.
l
Screw in the preheating plugs (tightening torque:
8 Nm (5.9 ft.lbs)).
l Plug in the plug connections.

Fig. 39
l Loosen the counter nut (4) (Fig. 39).
l Adjust the valve clearance by the adjustment screw
(3) and tighten the counter nut.
l 1. Set the cylinder to overlapping and check the
valve clearance as per adjustment schematic, ad-
just if necessary.

164 BOMAG 008 922 07

Engine problems 8.25
8.25 Engine problems

Fault Possible cause Remedy

Engine does not Starter defective or pinion does not en- Have examined by a specialist.
start gage

Fuel tank empty Fill tank and bleed the fuel system.

Temperature below starting limit tempera- Choose winter fuel and engine oil accord-
ture, fuse defective (engine shut-down so- ing to ambient temperatures.
lenoid)

Fuel filter clogged, in winter due to paraf- Change the filter, use winter fuel.
fin separation

Fuel lines leaking Check all line connections for leaks and
tighten the fittings, bleed the fuel system.

Battery not charged or not connected Tighten the terminal clamps on the bat-
tery, check all cable connections.

Injection valves or injection pump defec- Have examined by a specialist.

tive

Poor starting of Battery power too low, terminal clamps Check the battery charge condition, clean
engine or en- loose or oxidized causing the starter to the terminal clamps, tighten and cover
gine works irreg- turn too slowly. them with acid-free grease.
ularly with poor
power Especially during winter: use of too vis- Use an engine oil compatible for the am-
cous engine oil bient temperatures.

Fuel supply too low, fuel system clogged Change the fuel filter. Check the line con-
by paraffin separation during winter nections for leaks and tighten the fittings.
Use winter fuel under cold conditions.

The specified valve clearance is not cor- Adjust the valve clearance.
rect

Dry air filter cartridge soiled Clean, if necessary use a new one.

Injection lines leaking Check all line connections for leaks and
tighten the fittings, bleed the fuel system.

Turbo charger defective Have examined by a specialist.

Injection valve defective Have examined by a specialist.

Excessive ex- Engine oil level too high Drain the oil down to the top dipstick mark.
haust smoke
Dry air filter soiled Clean, if necessary use a new one.

Injection nozzle defective Have examined by a specialist.

Poor compression because of burned or Have compression rings and pistons ex-
broken compression rings amined by specialist.

The specified valve clearance is not cor- Adjust the valve clearance.
rect

008 922 07 BOMAG 165

8.25 Engine problems

Fault Possible cause Remedy

Engine over- Cooling fins on radiator extremely dirty Clean the cooling fins.
heating, engine (the warning light for engine oil tempera-
must be shut ture lights)
down immedi-
ately! Engine oil level too low Top up engine oil up to the top dipstick
mark.

Coolant level too low Check all lines. hoses and engine for
leaks, fill up coolant. Do not use radiator
sealant to seal leaks.

Thermostat defective Check the thermostat, replace if neces-

sary.

Interior parts of radiator corroded Clean or replace the radiator.

Insufficient cooling air supply to the cool- Remove any clogging from the cooling air
ing fan duct

V-belt loose or broken Tension or replace the V-belt

Engine oil pres- Engine oil level too low (engine oil pres- Top up oil.
sure too low sure warning light comes on, warning
buzzer sounds)

Leaks 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 all
fittings.

The charge con- Generator speed too low Check the V-belt tension, if necessary re-
trol light lights place the V-belt.
during opera-
tion, the warning Generator or regulator defective Have examined by a specialist.
buzzer sounds

166 BOMAG 008 922 07

 9 Material hopper, description

008 922 07 BOMAG 167

9.1 Material hopper and transport

Material flow -- overview

9.1 Material hopper and transport

The material is mainly conveyed by the following components (Fig. 42):

l The material hopper (1)
l The scraper belts (2)
l The augers (3)

Fig. 42 Material flow -- overview

168 BOMAG 008 922 07

Material hopper and transport 9.1
Material hopper

Fig. 43 Material hopper

1 Material hopper
2 Locking system
3 Hydraulic cylinder

Description of function
The material hopper (1) (Fig. 43) receives the material from the truck. The hopper capacity is 4.8 m3 (this is ap-
proximately equivalent to 9 tonnes of asphalt)
The hydraulic cylinders (3) move the wings of the hopper (1) upwards, so that a sufficient amount of material is
fed to the scraper belts at any time. Each wing can be moved independently from the other wing.
Each of the hydraulic cylinders (3) is equipped with locking systems (2) for transporting the finisher. With the
cylinder (3) extended these are folded down and thus protect the piston rod during transport. Moreover, the locks
(2) also make sure that the hopper (1) remains in transport position.

008 922 07 BOMAG 169

9.1 Material hopper and transport

Scraper belts

Fig. 44 Scraper belts

1 Chain tensioner for scraper belt drive
2 Hydraulic motor
3 Chain
4 Drive gear for scraper belt
5 Scraper belt right
6 Scraper belt left
7 Scraper belt tensioner

Description of function
The scraper belts (5) & (6) (Fig. 44) transport the material from the hopper to the augers.
The two scraper belts (5) & (6) made of high-tenacity steel work independently from one another an independ-
ently from the travel speed of the machine.
Two sensors (mechanically (as so-called "Paddles") or ultrasonic*, one each per beam) at the end of the con-
veyor beam control the material flow, so that the correct layer thickness in front of the screed is ensured. The
scraper belts can also be reversed.
The tension of the scraper belts is adjusted with the tensioners (7) at the front of the frame.
Each scraper belt is driven by a hydraulic motor (2). The torque of the hydraulic motor is transferred with the help
of a chaion, which is tensioned by a chain tensioner (1). The chain (3) runs over the drive gear (4), which drives
the scraper belt.

* Option

170 BOMAG 008 922 07

Material hopper and transport 9.1
Augers

Fig. 45 Augers
1 Hydraulic motors
2 Hydraulic cylinder
3 Guide rod
4 Mounting rod
5 Auger

Description of function
The augers (5) (Fig. 45) distribute the material evenly over the full width of the screed. They are thereby guided
by the guide rods (3).
The augers (5) work independently from one another an independently from the travel speed of the machine.
They are hydraulically operated via adjustable mechanical or ultrasonic sensors, by On/Off switches or propor-
tional controls. Each auger (5) is driven by a hydraulic motor (1).
The augers (5) can be adjusted in height with the hydraulic cylinders (2). The augers must be adjusted one step
higher than the front edge of the screed plate (approx. 30-60 mm higher. This depends on the particle size of
the material.)
The assembly flaps (4) prevent material being conveyed beyond the width of the screed.

Care and maintenance work

All parts of the machine that have or had contact with material must be sprayed with a release agent (e.g. "Bitu-
Trennkonzentrat, green") before and after operation.

008 922 07 BOMAG 171

9.1 Material hopper and transport

172 BOMAG 008 922 07

 10 Vibrating screed, description

008 922 07 BOMAG 173

10.1 Screed

Screed -- overview
10.1 Screed

The screed (Fig. 46) of the finisher mainly consists of:

l The drawing arms (1)
l The screed (2)

Fig. 46 Screed -- overview

174 BOMAG 008 922 07

Screed 10.1
Drawing arms

Fig. 47 Drawing arms

1 Scale
2 Drawing arm
3 Hydraulic cylinder (lift-out cylinder)
4 Fastening points of the screed
5 Hydraulic cylinder (levelling cylinder)
6 Hook-in point

Description of function
The drawing arms (2) (Fig. 47) are the connection between screed and finisher. Their position directly influences
the thickness of the paved material.
The hook-in point (6) of the drawing arm (2) can be hydraulically adjusted in height. This provides a possibility
to influence the layer thickness (angle of attack). The scale (1) at the upper end of the hydraulic cylinder (5),
which is responsible for the height adjustment of the hook-in point (6), indicates the paving thickness. The height
of both hook-in points can be adjusted independently from one another.
The complete screed can be lifted with the help of the hydraulic cylinders (3).
Adjusting bolts can be found at the rear fastening point of the screed (4). These can be used to preset the angle
of attack, if the angle to be adjusted can not be achieved via the hydraulic cylinders (5).

008 922 07 BOMAG 175

10.1 Screed

Screed

Fig. 48 Screed
1 Screed
2 Exit flap
3 Heating rod * exit flap
4 Outside control stand
5 Control element for electric heating
6 Vibrator unit central screed
7 Vibrator unit extendable screed
8 Tamper unit** central screed
9 Tamper unit*** extendable screed
10Base plate central screed
11Base plate extendable screed

Description of function
The screed (1) (Fig. 48) is the heart of the finisher. It lays the material and compacts it with its weight. The ma-
terial is additionally compacted by vibration and tamping.
High initial compaction by the finisher has a favourable effect on the evenness of the layer and, at the same time,
enables an early start of compaction, while the mix temperatures are still high. This favourably supports the com-
paction effect of the rollers, and final compaction can be achieved with only a few roller passes.

* Option
** Option
*** Option

176 BOMAG 008 922 07

Screed 10.1
Once the augers have distributed material in front of the screed, the material is pre-compacted by tamper ele-
ments (8), (9). The exit flaps (2) make sure that the material will not flow too far towards the outside. The exit
flaps (2) can be heated by the heating rods (3). This prevents material from sticking to the exit flaps (2).
The crown profile of the screed can also be adjusted, in addition to the angle of attack (see section "Drawing
arms"). This is possible in positive, but also in negative direction. The adjustment is made manually on the
screed itself, or hydraulically by using a switch in the "Control element for the screed" (LCS control).
The base plate (10), (11) skid along the material and compact it again. The base plates (10), (11) carry the vi-
brator units (6), (7). Their vibration causes further compaction of the material. The heating is also mounted on
the base plates (10), (11). This heating can be operated electrically (electricity generation by AC-generator), but
also with gas (propane). Heating the plates prevents material from baking to the plates. The electric heating is
controlled via control element (5).
From the outside control stand (4) the screed personnel is able to control the auger sensor for mix quantity reg-
ulation via a potentiometer. Moreover, the optionally available ultrasonic sensors for the scraper belts, which are
also used to regulate the mix quantity, can also be controlled from here.

Care and maintenance work

All parts of the machine that have or had contact with material must be sprayed with a release agent (e.g. "Bitu-
Trennkonzentrat, geen") before and after operation.

008 922 07 BOMAG 177

10.1 Screed

178 BOMAG 008 922 07

 11 Travel drive, description

008 922 07 BOMAG 179

11.1 Travel system

Track drive -- overview

11.1 Travel system

The crawler track drive (Fig. 49) of the finisher mainly consists of:
l the frame
l the crawler track drive
l the track tensioner
l the drive motor
l the reduction gear

Fig. 49 Track drive

180 BOMAG 008 922 07

Travel system 11.1
Frame
The frame of the track drive (Fig. 50) is the central element of the drive. It carries, among others, the travel gear,
the travel motor and the track tensioner.

Fig. 50 Frame
1 Carrier for travel gear and travel motor
2 Frame tube
3 Carrier for track tensioner

008 922 07 BOMAG 181

11.1 Travel system

Track drive
The track drive consists of two tracks with highly resistant, carriage way protecting polyurethane crawler plates.
The tracks ensure high tractive power of the finisher.

Fig. 51
1 Wheel
2 Track wheel
3 Hydraulic cylinder for track tensioning
4 Crawler plate
5 Supporting roller

182 BOMAG 008 922 07

Travel system 11.1
Crawler track tensioner

Fig. 52 Track tensioner -- excerpt from hydraulic diagram

The crawler track tensioners are controlled via valve (3) (Fig. 52). This valve (3) ensures constant pressure (see
"Hydraulic diagram") in the cylinders (1) of the track tensioner. The valve (3) and the downstream hydraulic cyl-
inders (1) are supplied by the first travel pump.
The valves (3) keep the cylinders (1) for the crawler tracks under tension with a uniform pressure level and thus
realize a chain tensioning device with automatic readjustment.
The so-called "shock limitation" prevents sudden pressure peaks in the hydraulic system caused by external in-
fluences (e.g. when driving against an obstacle). Two check valves (2) inside the valve block prevent overpres-
sure by returning excess hydraulic oil back into the hydraulic circuit. Moreover, the two check valves (2) also
make sure that the track tension is maintained, even when the machine is shut down.

008 922 07 BOMAG 183

11.1 Travel system

Travel motor

Fig. 53 Travel motor

1 Frame
2 Travel motor
The travel motor (2) (Fig. 53) is arranged at the rear end of the frame (1). During operation it is well protected
behind a cover. The motor is bolted to the reduction gear.

i Note
Further information about the travel motor, see chapter "Technical data" and "Hydraulics".

184 BOMAG 008 922 07

Travel system 11.1
Reduction gear

Fig. 54 Travel gear

The travel gears are planetary gears, which are each driven by a flange mounted travel motor (see section "Trav-
el motors").

Function and design

The housing side of the travel gear is rigidly connected with the crawler track drive via a flange. The travel motor
engages directly in the drive shaft. A second flange on the bearing axle side carries a gear, which engages in
the crawler track.
The gearbox transfers the torque generated by the travel motor via the gearing of the gearbox to the gear for the
crawler tracks.
The drive shaft carries an additional hydraulically operated spring accumulator multi-disc parking brake. Pres-
sure is applied to the brake when the brake releasing valve is operated. This pressure works against the discs
of the parking brake and releases the drive shaft for travel movements. If the hydraulic pressure drops, spring
pressure will close the multi-disc parking brake. Travel movements are no longer possible. Creeping of the ma-
chine is also prevented.

Care and maintenance work

All parts of the machine that have or had contact with material must be sprayed with a release agent (e.g. "Bitu-
Trennkonzentrat, green") before and after operation.

008 922 07 BOMAG 185

11.1 Travel system

186 BOMAG 008 922 07

 12 Cleaning kit, description

008 922 07 BOMAG 187

12.1 Cleaning kit

Cleaning kit -- overview

12.1 Cleaning kit

The cleaning kit (Fig. 55) of the finisher mainly consists of:
l the provision container (1)
l the filter (4)
l the pump (2)
l the hose reel (6)
l the spray gun (5)
l the control board (3)

Fig. 55 Cleaning kit

188 BOMAG 008 922 07

Cleaning kit 12.1
Provision container
The provision container takes up the cleaning agent. It has a capacity of 25 litres. For filling the cleaning con-
tainer the driver's stand must be moved fully to the right, so that the filler neck can be accessed.

Filter
The filter protects the spray gun against contamination. It is a wire mesh pre-filter.

Pump
The pump delivers the cleaning agent from the provision container through the filter to the spray gun. The pump
is an electrically driven two-piston pump, which is able to generate a maximum pressure of approx. 6.9 bar.

i Note
Further information about the pump, see chapter "Technical data".

Hose reel
The hose reel holds the hose that leads to the spray gun. After cleaning the reel wind the hose up again. Just
pull the hose to unwind.

Spray gun
The spray gun serves the purpose of cleaning the machine after finishing work, but also as an aid to apply clean-
ing/release agent before work is started. It is stored inside a tube welded into the holder and dispensed from
this tube when it is needed.

Control panel
The cleaning system is switched on and off by the control panel. At the same time one can use the timer to pre-
select a time for the active period of the cleaning system. Once this time has expired, the cleaning system will
switch off. The max. adjustable time is 30 minutes.

008 922 07 BOMAG 189

12.1 Cleaning kit

190 BOMAG 008 922 07

 13 Hydraulics

008 922 07 BOMAG 191

13.1 Hydraulic circuit

13.1 Hydraulic circuit

Open circuit

Fig. 1 Open circuit

Open in this case means that the suction line of a pump) (Fig. 1) normally is situated below the fluid level, the
surface of which is in open contact with atmospheric pressure. Reliable equalization of pressure between the air
in the hydraulic oil tank and the ambient air ensures problem free suction of the pump.
In an open circuit the hydraulic fluid is fed to the consumer (2 or 3) and also returned to the tank through way
valves.

192 BOMAG 008 922 07

Hydraulic circuit 13.1
Closed circuit

Filter

Cooler (option)

Fig. 2 Closed circuit

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

008 922 07 BOMAG 193

13.2 Travel pump, A4VG28 EP

Variable displacement pumps, A10VG28/45/56 EP

13.2 Travel pump, A4VG28 EP

EP control with proportional solenoid

The variable displacement axial piston pump generates, controls and regulates a volumetric pressure fluid flow.
It has been designed for mobile applications, e.g. in construction equipment.
The 10VG is a variable displacement axial piston pump in swash plate design for hydrostatic drives in closed
circuits. The volumetric flow is proportional to the drive speed and the displacement.

Fig. 3 A10VG

1 Drive shaft 8 Valve plate

2 Retracting plate 9 Suction port
3 Control piston 10 High pressure side
4 Control unit 11 Cylinder
5 Pressure override (optional) 12 Piston
6 Low pressure side 13 Slipper pad
7 Auxiliary pump (optional) 14 Swashing cradle

Caution
!

The variable displacement axial piston pump must be filled with pressure fluid and purged during start-
up and operation. This must also be considered for longer periods of rest, because the system may run
empty through the hydraulic lines.

194 BOMAG 008 922 07

Travel pump, A4VG28 EP 13.2
Hydraulic diagram

Control unit

High pressure limitation

Charge valve

High pressure limitation Pressure override valve

Fig. 4 Hydraulic diagram, A10VG EP

A Work connection PS Control pressure inlet

B Work connection R Ventilation
G Pressure port for charge circuit T1 Leak oil
MA Pressure test port, pressure A T2 Leak oil
MB Pressure test port, pressure B X 1 X2 Port for control pressures, pressure in front of
nozzle

008 922 07 BOMAG 195

13.2 Travel pump, A4VG28 EP

Connection overview

Fig. 5

High pressure relief and charge pressure valve

Pressure override valve

HP-valve with bypass

HP-valve with bypass

Charge pressure relief valve

Fig. 6 Valve plate

High pressure relief valves with integrated boost check valves and bypass (only travel pump / for tow-
ing)
Pressure peaks occurring during very fast swashing processes, as well as the maximum pressures are safe-
guarded by superordinate high pressure relief valves, which open when the adjusted value is exceeded and re-
lieve oil into the low pressure side. The fluid quantity always remains constant in the closed hydraulic circuit.
Leakages in pump and motor are compensated by the charge pump.
HP-valves are always adjusted 10% higher than the pressure override.
The boost check valves are integrated in the high pressure relief valves. These valves open to the low pressure
side and let cool and filtered oil flow from the charge oil circuit into the closed hydraulic circuit, in order to com-
pensate leaks and flushing quantities.

196 BOMAG 008 922 07

Travel pump, A4VG28 EP 13.2
Bypass control
In this case the travel system is switched to free circulation. For this purpose the high pressure relief valves in-
tegrated in the variable displacement pump have a so-called bypass function. This means that by turning the
screw (1) (Fig. 7) the valve insert is relieved to such an extent, that the oil is able to circulate freely.

Fig. 7 Bypass control

l Shut down the engine.
l
Loosen the counter nuts by turning them with a hexagon spanner (SW 134) half a turn in anti-clockwise direc-
tion.
l Use an Allen key (SW 4) to turn the screws clockwise, until the screw touches the spring cup, which can be
noticed by the increasing resistance.
l Turn the screw half a turn into the spring cup.

Towing finished
After towing back the screw out again. This resets the high pressure valves to their original setting.

i Note
Tightening torque for counter nut 22 Nm.

Charge pressure relief valve

The charge pressure valve belongs to the group of safety elements in a closed hydraulic circuit. This valve limits
the pressure in the charge circuit to the pre-adjusted value.

Pressure override valve

The pressure override limits the operating pressure. The pressure override is a kind of pressure regulation,
which, when the adjusted nominal pressure is reached, reduces the displacement of the pump to such an extent,
that the adjusted pressure is just maintained.

008 922 07 BOMAG 197

13.2 Travel pump, A4VG28 EP

EP - control

Fig. 8 EP - control

1 Setscrew for mechanical neutral position 5 Proportional solenoid valve

2 Neutral setting spring 6 Valve spool
3 Control piston 7 Feedback lever
4 Control chamber

Fig. 9 EP control
Depending on the pre-selected ampacity "I" on the two proportional solenoids, the control cylinder on the pump
is supplied with control pressure through the EP control unit. This way the swash plate and thus the displacement
of the pump can be infinitely varied. Each proportional solenoid has a flow direction assigned.

! Caution
The spring reset in the control unit is no safety feature.
Internal contamination – like e.g. contaminated hydraulic fluid, abrasion or dirt residues from system
components – can cause blockage of the spool valve in the control unit. The flow volume from the var-
iable displacement pump will in this case no longer follow the instructions of the operator.

198 BOMAG 008 922 07

Travel pump, A4VG28 EP 13.2
Swash plate principle, pump

Fig. 10
The swash plate pump is a positive displacement machine with oil displacing pistons arranged axially to the drive
shaft. The pistons are thereby supported by the swash plate.
Axial piston units based on the swash plate principle with fixed or variable displacement can be used as hydraulic
pumps or hydraulic motors. In pump mode the mechanical energy is converted to hydrostatic energy, when used
in motor mode the hydrostatic energy is converted to mechanical energy. When used as a pump, the flow volume
is proportional to the drive speed and the swashing angle. The available (pump) torque increases with the pres-
sure drop between high and low pressure side.
Variable displacement pumps and motors can be change their displacement, i.e. the pump delivery rate or motor
throughput, by simply changing the angle of the swash plate.

Description of function

Fig. 11

008 922 07 BOMAG 199

13.2 Travel pump, A4VG28 EP

1 Drive shaft 8 Through drive

2 Piston 9 Valve plate
3 Piston area 10 Top dead centre TDC
4 Piston stroke 11 Bottom dead centre BTC
5 Slipping disc 12 Control slots in suction side of swash plate (for
sense of rotation shown)
6 Adjusting angle 13 Control slot on pressure side
7 Cylinder

Driven by the engine, the drive shaft rotates and drives the cylinder via a splined connection. The cylinder rotates
with the drive shaft and drives the 9 pistons. The pistons rest with their slipper pads on the sliding face of the
swashing cradle and perform an axial movement. The slipper pads are held on the sliding face and are positively
guided by a retaining device. During a complete rotation of the cylinder block each piston moves through the
bottom and top dead centre back to its initial position. From dead centre to dead centre is performs a full piston
stroke. During this process the flow volume determined by the stroke is drawn in through the control slots in the
valve plate or pumped out. During the suction stroke the hydraulic fluid is drawn into the increasing piston cham-
ber, i.e. it is actually pressed in. On the opposite side the oil is pressed out of the piston bores into the hydraulic
system during the compression stroke.

200 BOMAG 008 922 07

Troubleshooting axial piston pumps 13.3
13.3 Troubleshooting axial piston pumps
The following table should be of help when performing troubleshooting This table is by no means complete.
In practice you may encounter problems that have not been listed here.

Procedure
l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and
changing of settings can lead to a situation in which the original cause of a fault can no longer be detected.
l Get an overview over the function of the product in connection with the overall system.
l
Try to clarify whether the product was able to deliver the required function within the overall system before the
fault occurred.
l Develop a clear understanding of the troubleshooting process. If necessary ask the direct operator or machine
driver.
Try to detect changes to the overall system, the product is installed in:
l Have conditions or area of application of the product been changed?
l Were changes (e.g. changeovers) or repairs made to the overall system (machine/plant, electrics, control) or
to the product? If yes: What kind?
l Has the product or the machine been operated as intended?
l
How does the fault occur?

Fault Possible cause Remedy

Unusual noises Insufficient suction conditions, e.g.Machine or system manufacturer
air in the suction line, inadequate di-
(e.g. optimize feed conditions, use
ameter of the suction line, excessivesuitable pressure fluid).
viscosity of the pressure fluid, ex- Completely purge the axial piston
treme suction height, too low suctionunit, fill the suction line with pres-
pressure, foreign bodies in the suc- sure fluid.
tion line. Remove foreign bodies from inside
the suction line.
Inappropriate fastening of the axial Check the fastening of the axial pis-
piston unit. ton unit as specified by the machine
or plant manufacturer. Observe the
tightening torques.
Inappropriate fastening of attach- Fasten attachment parts as speci-
ment parts, e.g. coupling and hy- fied by the coupling or fittings manu-
draulic lines. facturer.
Pressure relief valves of the axial Purge the axial piston unit, check
piston unit (charge pressure, high the viscosity of the pressure fluid,
pressure, pressure override). consult the service department.
Mechanical damage to the axial pis- Replace the axial piston unit, con-
ton unit. sult the service department.

008 922 07 BOMAG 201

13.3 Troubleshooting axial piston pumps

Fault Possible cause Remedy

No or insufficient volumetric flow
Faulty mechanical drive (e.g. defec- Check and repair the drive.
tive coupling).
Drive speed too low. Consult the service department.
Insufficient suction conditions, e.g. Completely purge the axial piston
air in the suction line, inadequate di- unit, fill the suction line with pres-
ameter of the suction line, excessive sure fluid.
viscosity of the pressure fluid, ex- Remove foreign bodies from inside
treme suction height, too low suction the suction line.
pressure, foreign bodies in the suc-
tion line.
Pressure fluid not within the optimal Use appropriate pressure fluid.
viscosity range.
External control and setting facilities Check the external control.
defective.
Pilot or control pressure too low. Check pilot and control pressure,
consult the service department.
Functional disturbance in the control Consult the service department.
facility or the regulator on the axial
piston unit.
Wear of the axial piston unit. Replace the axial piston unit.
Mechanical damage to the axial pis- Replace the axial piston unit.
ton unit.

202 BOMAG 008 922 07

Troubleshooting axial piston pumps
Fault
No or insufficient pressure
Fluctuations in pressure/volumetric Axial piston unit not or insufficiently
flow
Pressure fluid too hot.
13.3
Possible cause Remedy
Faulty mechanical drive (e.g. defec- Check and repair the drive.
tive coupling).
Poor drive power. Consult the service department.
Insufficient suction conditions, e.g. Completely purge the axial piston
air in the suction line, inadequate di- unit, fill the suction line with pres-
ameter of the suction line, excessive sure fluid.
viscosity of the pressure fluid, ex- Remove foreign bodies from inside
treme suction height, too low suction the suction line.
pressure, foreign bodies in the suc-
tion line.
Pressure fluid not within the optimal Use appropriate pressure fluid.
viscosity range.
External control and setting facilities Check the external control.
defective.
Pilot or control pressure too low. Check pilot and control pressure.
Functional disturbance in the control Consult the service department.
facility or the regulator on the axial
piston unit.
Wear of the axial piston unit. Replace the axial piston unit.
Mechanical damage to the axial pis- Replace the axial piston unit.
ton unit.
Drive unit defective (e.g. hydraulic Check the drive unit, replace if nec-
motor or cylinder). essary.
Completely purge the axial piston
purged. unit.
Insufficient suction conditions, e.g. Completely purge the axial piston
air in the suction line, inadequate di- unit, fill the suction line with pres-
ameter of the suction line, excessive sure fluid.
viscosity of the pressure fluid, ex- Remove foreign bodies from inside
treme suction height, too low suction the suction line.
pressure, foreign bodies in the suc-
tion line.
Excessive input temperature on axi- Check the system, e.g. malfunction
al piston unit. of the cooler, pressure fluid level in
tank too low.
Malfunction of the pressure control Consult the service department.
valves (e.g. high pressure relief
valve, pressure override, pressure
controller).
Malfunction of the flushing valve Consult the service department.
(not for nominal size 18).
Wear of the axial piston unit. Replace the axial piston unit.

008 922 07 BOMAG 203

13.4 Component overview -- hydraulics

13.4 Component overview -- hydraulics

Tractor

Fig. 12

Pos. Description (if electric connection is available)

1 Brake valve (Y04)
2 Brake releasing valve
3 Valve - activation of hydraulic system (Y194)
4 Valve block - screed up/down (Y226/Y227), floating position (Y227), Load Control System (Y229)
Valve block - auger block up/down (Y214/Y215), hopper wings left open/close (Y202/Y203), right
5
open/close (Y204/Y205), screed left up/down (Y220/Y221), right up/down (Y222/Y223)
6 Valve - conveyor belt right backward/forward (Y208/Y209)
7 Valve - auger right forward/backward (Y212/Y213)
8 Valve - conveyor belt left backward/forward (Y206/Y207)
9 Valve - auger left forward/backward (Y210/Y211)
10 Valve - chain tensioner for drive track

204 BOMAG 008 922 07

Component overview -- hydraulics 13.4
Screed

Fig. 13

Pos. Description (if electric connection is available)

1 Valve block vibration (Y225)
2 Valve block tamper (Y224)
3 Valve block extension screed left extend and retract (Y216/Y217), right extend and retract (Y218/Y219)
4 Valve block for hydraulic crown adjustment. Screed down (Y232), screed up (Y231).

008 922 07 BOMAG 205

13.4 Component overview -- hydraulics

Arrangement of hydraulic pumps

Fig. 14

Pos. Description
1 Gear pump - screed right
2 Gear pump - tamping and vibration
3 Service pump
4 Gear pump - screed left
5 Gear pump - scraper belt right
6 Gear pump - scraper belt left
7 Travel pump - drive track right
8 Travel pump - drive track left

206 BOMAG 008 922 07

Travel circuit 13.5
Travel system
13.5 Travel circuit

The travel system consists of a closed hydraulic circuit. The most important components are the travel pump
with integrated safety elements and control and the travel motors.

Fig. 15 Travel system -- excerpt from hydraulic diagram

1 Travel motor, right

2 Travel motor, left
3 Travel pump stage 1
4 Travel pump stage 2

008 922 07 BOMAG 207

13.5 Travel circuit

The travel pumps are joined together to a tandem unit and flange mo0unted to the flywheel end of the diesel
engine.
The travel pumps deliver the hydraulic oil for the travel circuit, they also supply the track tensioner and the serv-
ice brake.
The hydraulic oil is cleaned by a pressure filter, which is hydraulically arranged directly in front of the travel
pumps.
A charge circuit supplies the closed circuits with cool and filtered hydraulic oil to compensate for leakage and
flushing quantities. The hydraulic oil is additionally needed for the travel system control and for releasing the
parking brake.

Brake control
During operation the closed hydrostatic travel circuit has the function of a service brake.
When the travel lever is returned towards neutral position, the displacement of the travel pujmp is adjusted to-
wards zero accordingly and the machine is hydraulically braked.
To avoid creeping movements, the machine is additionally equipped with multi-disc parking brakes which are
integrated in the travel gears. These close in neutral position of the travel lever and when the machine is
stopped.
The parking brakes are electrically operated by a micro controller and a 3/2-way solenoid valve. In de-energized
state the charge oil supply to the brake pistons is interrupted, allowing the hydraulic oil to return to the tank via
the 3/2-way valve. When moving the travel lever out of neutral position, the connection to the tank is interrupted
and charge oil is directed to the brake piston. This hydraulic pressure works against the spring force applied to
the brake piston by the brake springs and relieves the brake discs.

Releasing the brake mechanically, towing the machine

Fig. 16 Brake releasing valve

i Note
The pump lever extension can be found on the operator's stand, inside the frame at the right hand side (it also
serves the purpose for erecting the wether protection roof hydraulically).
l Press the emergency operation button (2) (Fig. 16) completely down.
l Release the brake by operating the hand pump (1).

After towing
l Pull the emergency operation button (2) completely up.

i Note
After starting the engine the emergency operation button is pushed out by hydraulic pressure.

208 BOMAG 008 922 07

Travel circuit 13.5
Travel motors
The travel motors on the finisher are fixed displacement bent axle axial piston motors.

Fig. 17 Sectional view of travel motor

1 Drive shaft 5 Valve plate

2 Control piston 6 Cylinder
3 Control piston 7 Piston
4 Connecting plate

Travel gears
The travel gears are planetary gears for mobile equipment, which are each driven by a flange mounted travel
motor (see section "Travel motors").

Function and design

The housing side of the travel gear is rigidly connected with the crawler track drive via a flange. The travel motor
engages directly in the drive shaft. A second flange on the bearing axle side carries a gear, which engages in
the crawler track.
The gearbox transfers the torque generated by the travel motor via the gearing of the gearbox to the gear for the
crawler tracks.
The drive shaft carries an additional hydraulically operated spring accumulator multi-disc parking brake. Pres-
sure is applied to the brake when the brake releasing valve is operated. This pressure works against the discs
of the parking brake and releases the drive shaft for travel movements. If the hydraulic pressure drops, spring
pressure will close the multi-disc parking brake. Travel movements are no longer possible. Creeping of the ma-
chine is also prevented.

008 922 07 BOMAG 209

13.6 Vibration and tamper drive

13.6 Vibration and tamper drive

The vibration and tamper drive has been designed as an open hydraulic circuit.
The most essential components are:
l the hydraulic pump
l the valve block for vibration drive
l the valve block for tamper operation
l the vibration motors
l the tamper motors

Fig. 18 Vibration and tamper drive - excerpt from hydraulic diagram

1 Vibration motors (two for the main screed and one each for the mobile screeds)
2 Tamper motors (two for the main screed and one each for the mobile screeds)
3 Valve block for tamper operation
4 Hydraulic pump
5 Valve block for vibration drive

210 BOMAG 008 922 07

Vibration and tamper drive 13.6
Vibration and tamper pump

Fig. 19 Vibration and tamper pump

The vibration and tamper pump (Fig. 19) is driven by the auxiliary drive of the engine. The pump supplies the
hydraulic circuits for vibration and tamper operation with a constant hydraulic oil volume.

Valve blocks
This hydraulic oil supply runs through separate valve blocks for vibration drive (5) (Fig. 18) and tamper drive (3)
(Fig. 18). The latter contains a pressure relief valve and a limitation valve with fixed setting for the pressure over-
ride.

Vibration motor
The vibration motors each engage directly into a flanged on exciter housing with exciter shaft (eccentric shaft).
The eccentric arrangement of the weight of the exciter shaft causes a radial vibration, which works directly on
the screed plates of screed and mobile screeds The generated vibration of the screed plates serves the com-
paction and levelling of the paved material.

Tamper motor*
The tamper motors of screed and mobile screeds each drive a drive shaft which are connected with the corre-
sponding tamper plate by eccentrically mounted connecting rods. This moves the conrods with the attached
tamper plates up and down. This up and down movement pre-compacts the paved material.
The vibration and tamper motors of the screed are additionally linked by a universal shaft, to ensure synchroni-
zation of amplitudes in vibration and tamping. This makes ure that there will be no undesired resonance vibra-
tions or mutual elimination of amplitudes during operation.

* Option

008 922 07 BOMAG 211

13.7 Scraper belt drive

Scraper belt drive

13.7 Scraper belt drive

The scraper belt drive has been designed as an open hydraulic circuit.
The most essential components are:
l the scraper belt pumps
l the scraper belt valve blocks
l the scraper belt motors

Fig. 20 Scraper belt drive - excerpt from hydraulic diagram

1 Scraper belt motor left 4 Valve block for right hand motor
2 Scraper belt motor right 5 Gear pump for scraper belt motor left
3 Valve block for left hand motor 6 Gear pump for scraper belt motor right

212 BOMAG 008 922 07

Scraper belt drive 13.7
Scraper belt pump (gear pump)

Fig. 21 Gear pump for scraper belt drive

The pump for the scraper belt drive (Fig. 21) has been designed as a tandem pump. Each stage of the pump
supplies one hydraulic motor, one each through its own valve block.

Valve blocks
The valve blocks for the scraper belt drive (3), (4) (Fig. 20) contain a pressure relief valve with pre-set pressure
value for pressure override.
The solenoid valve attached to the valve block enables the user to run the scraper belts individually in forward
or reverse mode, depending on the requirements when paving.

Scraper belt motor

The scraper belt motors both drive the scraper belts via a chain drive. Using an intermediate chain drive increas-
es the torque.

Paddle
The end of the scraper belts is equipped with paddles. These touch the material and are thereby moved. If there
is too much material on the scraper belt, the paddle sends a signal through an attached sensor, which forces
the electronics to stop the corresponding scraper belt. If material is required again, the scraper belt will start
again and transport material to the auger.

Ultrasonic sensor*
The material flow on the scraper belt is detected by an ultrasonic sensor. If there is too much material on the
scraper belt, the ultrasonic sensor will generate a signal through an attached sensor, which forces the electron-
ics to stop the corresponding scraper belt. If material is required again, the scraper belt will start again and trans-
port material to the auger. The required amount of material can be set by a rotary switch on the lateral control
stand.

* optional

008 922 07 BOMAG 213

13.8 Auger drive

Auger drive
13.8 Auger drive

The auger drive has been designed as an open hydraulic circuit.

The most essential components are:
l the hydraulic pumps
l the valve blocks
l the auger motors

Fig. 22 Auger drive - excerpt from hydraulic diagram

1 Auger motor left 4 Valve block for right hand motor

2 Auger motor right 5 Gear pump for auger motor left
3 Valve block for left hand motor 6 Gear pump for auger motor right

214 BOMAG 008 922 07

Auger drive 13.8
Pump for auger drive (gear pump)

Fig. 23 Gear pump for auger drive

The auger drive pump (Fig. 23) is part of a tandem pump (left hand auger in combination with the pump for vi-
bration and tamping; right hand auger in combination with the pumps for scraper belt drive). The auger drive
pumps supply one hydraulic motor each, both using their own valve block.

Valve blocks
The valve blocks for the auger drive (3), (4) (Fig. 22) contain a pressure relief valve with pre-set pressure value
fpr pressure override.
The solenoid valve attached to the valve block enables the user to run the augers individually in forward or re-
verse mode, depending on the requirements when paving.

Auger motor
The auger motors both drive the auger shafts via a chain drive. Using an intermediate chain drive increases the
torque.

008 922 07 BOMAG 215

13.9 Cylinder functions

Cylinder functions
13.9 Cylinder functions

The cylinder functions can be sub-divided into the following sections:

l Hopper functions
l Screed functions
l Auger functions
l Track tensioner functions
The cylinders for hopper, screed and auger functions are supplied by the work pump. The track tensioners are
supplied by the return flow from the auger motors (further details on the pump: See chapter "Technical data").

Fig. 24 Work pump - excerpt from hydraulic diagram

216 BOMAG 008 922 07

Cylinder functions 13.9
Hopper
The hopper functions can be sub-divided into two sections:
l Open/close left hand hopper wing
l Open/close right hand hopper wing

"P1" = Pump supply

Fig. 25 Hopper functions -- excerpt from hydraulic diagram

1 Open/close left hand wing 2 Open/close right hand wing

008 922 07 BOMAG 217

13.9 Cylinder functions

Opening / closing the hopper wings

The hopper wings can be adjusted in height. This changes the volume of the material hopper. This adjustment
is accomplished by hydraulic cylinders, which are fastened to the outside of the wings. When paving the hopper
has to take up the material. For transporting the finisher the wings are folded in. (See chapter "Material
hopper_description")

218 BOMAG 008 922 07

Cylinder functions 13.9
Screed
The screed functions can be sub-divided into the following sections:
l Lifting/lowering the left/right hook-in point
l Lifting/lowering the complete screed
l Extending/retracting the extendable screed left/right

"P1" & "P"= Supply

by pump

Option

Fig. 26 Cylinder functions screed - excerpt from hydraulic diagram

1 Lifting/lowering the screed Load Control Sys- 3 Extending/retracting the extendable screed
tem (LCS)
2 Lifting / lowering the hook in points 4 Crown adjustment

008 922 07 BOMAG 219

13.9 Cylinder functions

Lifting/lowering the left/right hook-in point

With their height the hook-in points directly influence the thickness of the material to be applied. For this reason
they are adjustable in height. This is accomplished with hydraulic cylinders (the so-called levelling cylinders)
mounted at the front end of the drawing arms. These cylinders adjust the floating behaviour of the screed and
thus the layer thickness of the material (See chapter "Screed_Description").

Lifting/lowering the complete screed

Lifting/lowering the screed is accomplished by two hydraulic cylinders (the so-called lift-out cylinder) at the rear
ends of both side arms. These cylinders lift/lower or release the screed by means of the screed load control sys-
tem (L.C.S.) intervening in the hydraulic circuit. This combination enables floating operation when paving as-
phalt, with the machine stopped during asphalt application as well as relieving or locking or locking the screed
to avoid flatness faults caused by uncontrolled lowering.

Extending/retracting the extendable screed left/right

Extending and retracting the extendable screed is accomplished by two hydraulic cylinders in the centre of the
screed. The extendable screeds can thereby by infinitely extended or retracted independently from one another.

220 BOMAG 008 922 07

Cylinder functions 13.9
Augers
The auger functions can be sub-divided into two sections:
l Augers up
l Augers down

"P1" = Supply from pump

Fig. 27 Auger functions

1 Lifting / lowering the augers

Lifting / lowering the augers

The augers can be adjusted in height to make sure that a sufficient amount of material is placed in front of the
screed at any time. This adjustment is accomplished by hydraulic cylinders, which are fastened to the auger unit.
The Way valve controls the cylinders, whereby the speed of the movement is determined by the orifices. The
integrated check valves keep the cylinders in position. (See also chapter "Material hopper_description")

008 922 07 BOMAG 221

13.10 Check the hydraulic oil level

Track tensioner - chassis

"P" = Supply from pump

Fig. 28 Crawler track tensioner

13.10Check the hydraulic oil level
1 Tensioning cylinder for crawler tracks
2 Check valves Caution
!
3 Valve In hydraulic systems filled with Panolin HLP
Synth. 46 always use the same oil to top up. With
Tensioning the crawler tracks other ester based oils consult the lubrication oil
The crawler track tensioners are controlled via valve service of the respective oil manufacturer.
(3) (Fig. 28). This valve (3) ensures constant pressure
(see "Hydraulic diagram") in the cylinders (1). The
! Caution
valve (3) and the downstream hydraulic cylinders (1)
are supplied by the return flow from the auger motors. If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped, check
The valves (3) keep the cylinders (1) for the crawler
all lines, hoses and components for leaks.
tracks under tension with a uniform pressure level and
thus realize a chain tensioning device with automatic For quality of oil refer to the "table of fuels and lu-
readjustment. bricants".
The so-called "shock limitation" prevents sudden
pressure peaks in the hydraulic system caused by ex-
Caution
!
ternal influences. Two check valves (2) inside the
valve block prevent overpressure by returning excess Risk of overfilling!
hydraulic oil back into the hydraulic circuit. Moreover, l
Fully open the hopper.
the two check valves (2) also make sure that the track
tension is maintained, even when the machine is shut
l
Fully retract the mobile screed.
down. l
Raise the screed to half height.

222 BOMAG 008 922 07

Changing hydraulic oil and filter 13.11
13.11Changing hydraulic oil and fil-
ter

i Note
See also the notes on the hydraulic system in the
chapter "General notes on maintenance".

! Danger
Danger of scalding!
When draining off hot hydraulic oil!
839106
Fig. 29
l Check the hydraulic oil level in the inspection glass ! Caution
(Fig. 29) . The hydraulic oil must also be changed after ma-
jor repairs in the hydraulic system.
Normal level:
Perform the oil change when the hydraulic oil is
approx. 3 cm below the top edge of the inspection
warm.
glass.
Replace the hydraulic oil filter elements with every
Minimum level: hydraulic oil change.
Middle of inspection glass. Change the filter only after the hydraulic oil
change and after the test run.
Clean the area round hydraulic oil tank, filler
opening and breather filter.
Do not start the engine after draining the hydraulic
oil.
Do not use any detergents to clean the system.
Use only lint-free cleaning cloths.
For quality and quantity of oil refer to the "table of
fuels and lubricants".
When changing from mineral oil based hydraulic
oil to an ester based biologically degradable oil,
838396 you should consult the lubrication oil service of
Fig. 30 the oil manufacturer for details.
l
If necessary fill in hydraulic oil through the filler neck
(Fig. 30). Environment
Any hydraulic oil must be caught and disposed of
in an environmentally friendly manner.

008 922 07 BOMAG 223

13.11 Changing hydraulic oil and filter

Fig. 31
l Unscrew the plug (Fig. 31) and drain off all hydraulic
oil.
l Turn the plug tightly back in.
l Remove the filler cap.
l Fill in new hydraulic oil through the screen.
i Note
We recommend to use our filling and filtering unit with
fine filter to fill the system. This ensures finest filtration
of the hydraulic oil, prolongs the lifetime of the hydrau-
lic oil filter and protects the hydraulic system.
Fig. 33
l Unscrew spigot nut (4) (Fig. 33) and take off filter
bowl (5) with filter element (3).
l Examine the surface of the filter element thoroughly
for any visible dirt.
! Caution
Visible dirt may be an early sign for the failure of
system components and indicate the possible fail-
ure of components. In this case determine the
cause and replace or repair the defective compo-
nents, if necessary. Negligence may cause de-
struction to the entire hydraulic system.
Do not clean or reuse the filter element.
l
Take out the old filter element (3), clean filter bowl
and thread.
l
Reassemble the filter bowl with a new filter element
and new O-rings (1, 2).
l
After a short test run check the filter for leaks.

839106
Fig. 32
l
Check the oil level in the inspection glass (Fig. 32) .

Nominal value:
approx. 3 cm below the upper edge of the inspection
glass

i Note
The breather filter for the hydraulic oil tank is integrat-
ed in the filler cap, you must therefore replace the
complete filler cap.
l Close the tank with a new cover.
l Open the hopper wings and remove the cover to the
engine compartment.

224 BOMAG 008 922 07

 14 Tests and adjustments

008 922 07 BOMAG 225

14.1 Special tools, tests and adjustments

14.1 Special tools, tests and adjustments

1. Vibration reed frequency meter
1000 - 4.000 rpm
17 - 67 Hz
BOMAG part-no.: 300 120 80

Fig. 1
2. Frequency counter
The frequency counter is used for testing the pre-
tension of drive belts by frequency measurement.
10 - 600 Hz
BOMAG part-no.: 079 901 74

Fig. 2
3. Sirometer (frequency meter)
800 - 50.000 rpm
14 - 750 Hz
BOMAG part-no.: 059 710 02

Fig. 3
4. 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. Plastic, temper-
ature range: down to -40 °C

BOMAG part-no.: 050 100 75

Fig. 4

226 BOMAG 008 922 07

Special tools, tests and adjustments 14.1
5. Digital rpm-meter for petrol engines

BOMAG part-no.: 079 948 99

Fig. 5
6. Digital rpm-meter for petrol engines

BOMAG part-no.: 059 711 12

Fig. 6
7. Digital rpm-meter, optical/mechanical, universal
use

BOMAG part-no.: 079 948 98

Fig. 7
8. Infrared hand-held thermometer, -18 to 275°C

BOMAG part-no.: 057 668 06

Fig. 8

008 922 07 BOMAG 227

14.1 Special tools, tests and adjustments

9. Hydraulic test case, large

BOMAG part-no.: 007 610 03

i Note
4 X 600 bar pressure gauges
4 X 60 bar pressure gauges
8 pressure test hoses

Fig. 9
10. Hydraulic test case, small

BOMAG part-no.: 079 930 01

i Note
2X 60 bar pressure gauges
2X 600 bar pressure gauges
4 pressure test hoses

Fig. 10
11. Pressure test hoses
1000 mm BOMAG part-no.: 079 930 02
2500 mm BOMAG part-no.: 079 930 03

Fig. 11
12. Pressure gauge
60 bar BOMAG part-no.: 059 721 07
600 bar BOMAG part-no.: 059 721 04

Fig. 12

228 BOMAG 008 922 07

Special tools, tests and adjustments 14.1
13. Adapter for pressure test hose

BOMAG part-no.: 055 439 02

Fig. 13
14. Gear pump testing device

BOMAG part-no.: 007 610 05

Fig. 14
15. Vacuum pump for hydraulic oil tank
BOMAG part-no.: 007 610 04 (12 Volt)
BOMAG part-no.: 007 610 24 (24 Volt)

Fig. 15

008 922 07 BOMAG 229

14.2 Checking and adjusting the vibration

14.2 Checking and adjusting the vibration

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).

Special tools
Hydraulic test case [BOMAG Part-No.: 079 930
01]
Digital rpm-meter, optical/mechanical, universal
use [BOMAG Part-No.: 079 948 98]

Pressure test vibration

1. Raise and lock the screed (Fig. 1).
2. Fully extend right and left hand mobile screeds.
3. Shut down the engine.

Fig. 1

! Danger
Danger of injury!
Before connecting the pressure gauge make
sure that the engine has been shut down!
4. Connect a high pressure gauge (600 bar) to pres-
sure test port "M" on the pump (Fig. 2).

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
Fig. 2
5. Block the propshaft of the vibration drive with suit-
able means (e.g.: steel bar) (Fig. 3).

! Caution
Rest the steel bar against the screed frame so
that it will not hit the frame when vibration is
switched on!

Fig. 3

230 BOMAG 008 922 07

Checking and adjusting the vibration 14.2
6. Start the engine and set the switch to position
"MAX" (Fig. 4).

Fig. 4
7. Activate the hydraulic system (Fig. 5).

Fig. 5
8. Activate the parking brake (Fig. 6).

Fig. 6
9. Select "Work"-mode (Fig. 7).

Fig. 7

008 922 07 BOMAG 231

14.2 Checking and adjusting the vibration

! Caution
Run the following pressure test only for max.
5 seconds.
10. Switch the vibration on (Fig. 8).

Fig. 8
11. Shift the travel lever to "forward" position (Fig. 9).
12. Read the hydraulic oil pressure in the pressure
gauge.
13. Return the travel lever to "Neutral".

Fig. 9
14. Switch the vibration off (Fig. 10).

Nominal value
See chapter "Technical Data".

i Note
If the nominal pressure relief value is not
reached, adjust the solenoid valve (Fig. 11).

Fig. 10
15. Remove the cap (1) form the pressure relief valve
(PRV) (2) (Fig. 11).
16. Loosen the counter nut (4) and turn the setscrew
(3) in or out, until the nominal value is reached.

i Note
Turning clockwise increases the pressure, turn-
ing anti-clockwise reduces the pressure!
17. Check the pressure once again (see above).
18. Retighten the counter nut (4) and replace the cap
(1).
Fig. 11

232 BOMAG 008 922 07

Checking and adjusting the vibration 14.2
19. Turn the switch to position "MIN" and shut down
the engine (Fig. 12).

! Danger
Danger of injury!
Before disconnecting the pressure gauge
make sure that the engine has been shut
down!
20. Disconnect the pressure gauge.
21. Remove the blockage (prybar) from the shaft.

Fig. 12

008 922 07 BOMAG 233

14.2 Checking and adjusting the vibration

Rotary speed measurement vibration

1. Raise and lock the screed (Fig. 13).
2. Fully extend right and left hand mobile screeds.
3. Shut down the engine.

Fig. 13
4. Fasten a reflex mark (2) on the shaft (1) (Fig. 14).

Fig. 14
5. Completely close the hand wheel for vibration
speed (Fig. 15).

Fig. 15
6. Start the engine and set the switch to position
"MAX" (Fig. 16).

Fig. 16

234 BOMAG 008 922 07

Checking and adjusting the vibration 14.2
7. Activate the hydraulic system (Fig. 17).

Fig. 17
8. Activate the parking brake (Fig. 18).

Fig. 18
9. Select "Work"-mode (Fig. 19).

Fig. 19
10. Switch the vibration on (Fig. 20).

Fig. 20

008 922 07 BOMAG 235

14.2 Checking and adjusting the vibration

11. Shift the travel lever to "forward" position (Fig.

21).
12. Read the shaft speed.

Nominal value
See chapter "Technical Data".
13. Shift the travel lever to "Neutral" position.

Fig. 21
14. Switch the vibration off (Fig. 22).

i Note
If the nominal value is not reached, you must:
1. The vibration pump
2. The vibration motor(s)
.

i
Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
Fig. 22 draulics overview of components".
15. Turn the switch to position "MIN" and shut down
the engine (Fig. 23).

Fig. 23

236 BOMAG 008 922 07

Checking/adjusting tamping 14.3
14.3 Checking/adjusting tamping

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).

Special tools
Hydraulic test case [BOMAG Part-No.: 079 930
01]
Digital rpm-meter, optical/mechanical, universal
use [BOMAG Part-No.: 079 948 98]

Pressure test 1/3 tamper system

i Note
The correct order of the test steps is mandatory,
because otherwise incorrect measuring values
may be obtained!
All test steps must be performed one after the
other!

1. Raise and lock the screed (Fig. 1).

2. Fully extend right and left hand screeds.
3. Shut down the engine.

Fig. 1

! Danger
Danger of injury!
Before connecting the pressure gauge make
sure that the engine has been shut down!
4. Connect a high pressure gauge (600 bar) to pres-
sure test port "M" on the pump (Fig. 2).

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
Fig. 2

008 922 07 BOMAG 237

14.3 Checking/adjusting tamping

i Note
The pressure relief valve (PRV) is located at the
underside of the solenoid valve, which in turn is
mounted to the main screed (Fig. 3).

i Note
Write down the number of revolutions when turn-
ing in the setscrew. This turning in must be re-
versed later during this procedure.
5. On the pressure relief valve loosen the counter
nut (1) and turn the setscrew (2) completely in
(Fig. 3).
Fig. 3
6. Block the propshaft (1) of the tamper motors with
a suitable object (e.g. a prybar) (Fig. 4).

! Caution
Rest the prybar against the screed frame so
that it will not hit the frame when tamper oper-
ation is switched on!

Fig. 4
7. Start the engine and set the switch to position
"MAX" (Fig. 5).

Fig. 5
8. Activate the hydraulic system (Fig. 6).

Fig. 6

238 BOMAG 008 922 07

Checking/adjusting tamping 14.3
9. Activate the parking brake (Fig. 7).

Fig. 7
10. Select "Work"-mode (Fig. 8).

Fig. 8

! Caution
Run the following pressure test only for max.
5 seconds.
11. Switch on the tamper (Fig. 9).

Fig. 9
12. Shift the travel lever to "forward" position (Fig.
10).
13. Read the hydraulic oil pressure in the pressure
gauge.
14. Shift the travel lever to "Neutral" position .

Fig. 10

008 922 07 BOMAG 239

14.3 Checking/adjusting tamping

15. Switch of the tamper (Fig. 11).

Fig. 11
Nominal value

See chapter "Technical Data".

i Note
If the nominal pressure of the pressure relief
valve is not reached:
Adjust the PRV on the tamper motor.
16. Loosen the counter nut and turn the setscrew in
or out, until the nominal value is reached (Fig.
12).

Fig. 12
i Note
Turning clockwise increases the pressure, turn-
ing anti-clockwise reduces the pressure!
17. Check the pressure once again (see above).
18. Retighten the counter nut.
19. Turn the switch to position "MIN" and shut down
the engine (Fig. 13).

! Danger
Danger of injury!
Before disconnecting the pressure gauge
make sure that the engine has been shut
down!
20. Disconnect the pressure gauge.
21. Remove the blockage (prybar) from the shaft.

Fig. 13

240 BOMAG 008 922 07

Checking/adjusting tamping 14.3
test 2/3 tamper extension screed

i Note
The correct order of the test steps is mandatory,
because otherwise incorrect measuring values
may be obtained!

! Danger

Danger of injury!
Before connecting the pressure gauge make
sure that the engine has been shut down!
1. Connect a high pressure gauge (600 bar) to pres-
sure test port "M" on the pump (Fig. 14).

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
Fig. 14
2. Pressure relief valve (Fig. 15).

Fig. 15
3. Loosen the counter nut (1) and back out the set-
screw (2) by the same amount of turns that you
turned it in before (see your own notes) (Fig. 16).

Fig. 16

008 922 07 BOMAG 241

14.3 Checking/adjusting tamping

4. Remove the front covering plate (safeguarding)

of the extension screed (see chapter: "Vibrating
screed repair" section: "Disassembling the
tamper blades").
5. Block the propshaft (1) of the tamper motors with
a suitable object (e.g. a timber block) (Fig. 17).

Fig. 17
6. Start the engine and set the switch to position
"MAX" (Fig. 18).

Fig. 18
7. Activate the hydraulic system (Fig. 19).

Fig. 19
8. Activate the parking brake (Fig. 20).

Fig. 20

242 BOMAG 008 922 07

Checking/adjusting tamping 14.3
9. Select "Work"-mode (Fig. 21).

Fig. 21

! Caution
Run the following pressure test only for max.
5 seconds.
10. Switch on the tamper (Fig. 22).

Fig. 22
11. Shift the travel lever to "forward" position (Fig.
23).
12. Read the hydraulic oil pressure in the pressure
gauge.
13. Shift the travel lever to "Neutral" position .

Fig. 23
14. Switch of the tamper (Fig. 24).

Fig. 24

008 922 07 BOMAG 243

14.3 Checking/adjusting tamping

Nominal value

See chapter "Technical Data".

i Note
If the nominal pressure of the pressure relief
valve is not reached:
Adjust the PRV on the tamper motor (Fig. 25).
15. Loosen the counter nut and turn the setscrew in
or out, until the nominal value is reached.

Fig. 25
i Note
Turning clockwise increases the pressure, turn-
ing anti-clockwise reduces the pressure!
16. Check the pressure once again (see above).
17. Retighten the counter nut.
18. Turn the switch to position "MIN" and shut down
the engine (Fig. 26).

! Danger
Danger of injury!
Before disconnecting the pressure gauge
make sure that the engine has been shut
down!
19. Disconnect the pressure gauge.
20. Remove the blockage (wooden block) from the
shaft.
Fig. 26 21. Reassemble the safeguarding /see chapter: "Vi-
brating screed repair", section "Installing the
tamper blades)

244 BOMAG 008 922 07

Checking/adjusting tamping 14.3
Pressure test 3/3 tamper main protec-
tion (200 bar)

i Note
The correct order of the test steps is mandatory,
because otherwise incorrect measuring values
may be obtained!

! Danger
Danger of injury!
Before connecting the pressure gauge make
sure that the engine has been shut down!
1. Connect a high pressure gauge (600 bar) to pres-
sure test port "M" on the pump (Fig. 27).

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
Fig. 27
2. Block the propshaft (1) of the tamper motors with
a suitable object (e.g. a prybar) (Fig. 28).

! Caution
Rest the prybar against the screed frame so
that it will not hit the frame when tamper oper-
ation is switched on!

Fig. 28
3. Start the engine and set the switch to position
"MAX" (Fig. 29).

Fig. 29

008 922 07 BOMAG 245

14.3 Checking/adjusting tamping

4. Activate the hydraulic system (Fig. 30).

Fig. 30
5. Activate the parking brake (Fig. 31).

Fig. 31
6. Fully extend right and left hand screeds (Fig. 32).

Fig. 32
7. Select "Work"-mode (Fig. 33).

Fig. 33

246 BOMAG 008 922 07

Checking/adjusting tamping 14.3
! Caution
Run the following pressure test only for max.
5 seconds.
8. Switch on the tamper (Fig. 34).

Fig. 34
9. Shift the travel lever to "forward" position (Fig.
35).
10. Read the hydraulic oil pressure in the pressure
gauge.
11. Shift the travel lever to "Neutral" position .

Fig. 35
12. Switch of the tamper (Fig. 36).

Fig. 36
Nominal value

See chapter "Technical Data".

i Note
If the nominal pressure of the pressure relief
valve is not reached:
Adjust the PRV on the "tamper" valve block (Fig.
37).
13. Loosen the counter nut (4) and turn the setscrew
(3) in or out, until the nominal value is reached.

Fig. 37

008 922 07 BOMAG 247

14.3 Checking/adjusting tamping

i Note
Turning clockwise increases the pressure, turn-
ing anti-clockwise reduces the pressure!
14. Check the pressure once again (see above).
15. Retighten the counter nut (1).
16. Turn the switch to position "MIN" and shut down
the engine (Fig. 38).

! Danger
Danger of injury!
Before disconnecting the pressure gauge
make sure that the engine has been shut
down!
17. Disconnect the pressure gauge.
18. Remove the blockage (prybar) from the shaft.

Fig. 38

248 BOMAG 008 922 07

Checking/adjusting tamping 14.3
Tamper speed measurement
1. Raise and lock the screed (Fig. 39).
2. Fully extend right and left hand screeds.
3. Shut down the engine.

Fig. 39
1. Fasten a reflex mark (2) on the shaft (1) (Fig. 40).

Fig. 40
2. Completely close the hand wheel for tamper
speed (Fig. 41).

Fig. 41
3. Start the engine and set the switch to position
"MAX" (Fig. 42).

Fig. 42

008 922 07 BOMAG 249

14.3 Checking/adjusting tamping

4. Activate the hydraulic system (Fig. 43).

Fig. 43
5. Activate the parking brake (Fig. 44).

Fig. 44
6. Select "Work"-mode (Fig. 45).

Fig. 45
7. Switch on the tamper (Fig. 46).

Fig. 46

250 BOMAG 008 922 07

Checking/adjusting tamping 14.3
8. Shift the travel lever to "forward" position (Fig.
47).
9. Read the shaft speed.

Nominal value
See chapter "Technical Data".
10. Shift the travel lever to "Neutral" position.

Fig. 47
11. Switch of the tamper (Fig. 48).

i Note
If the nominal value is not reached, you must:
1. check the tamper pump
2. the tamper motors
.

i
Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
Fig. 48 draulics overview of components".
12. Turn the switch to position "MIN" and shut down
the engine (Fig. 49).

Fig. 49

008 922 07 BOMAG 251

14.4 Checking/adjusting the scraper belts

14.4 Checking/adjusting the scraper belts

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).

Special tools
Hydraulic test case [BOMAG Part-No.: 079 930
01]
Digital rpm-meter, optical/mechanical, universal
use [BOMAG Part-No.: 079 948 98]

Pressure test scraper belt

i Note
The following section describes the test for the
left scraper belt. The position numbers for the
right belt are given in brackets.

! Danger
Danger of injury!
Before connecting the pressure gauge make
sure that the engine has been shut down!
1. Connect a high pressure gauge (600 bar) to the
pressure test port (1) [right: (2)] on the pump (Fig.
1).

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
Fig. 1
draulics overview of components".
2. Block the scraper belt with suitable means.
3. Start the engine and set the switch to position
"MAX" (Fig. 2).

Fig. 2

252 BOMAG 008 922 07

Checking/adjusting the scraper belts 14.4
4. Activate the hydraulic system (Fig. 3).

Fig. 3
5. Activate the parking brake (Fig. 4).

Fig. 4
6. Select "Work"-mode (Fig. 5).

Fig. 5

! Caution
Run the following pressure test only for max.
5 seconds.
7. Push the button "a" ("c") downwards and hold it.
(Fig. 6).
8. Read the hydraulic oil pressure in the pressure
gauge.
9. Release button "a" ("c").

Fig. 6

008 922 07 BOMAG 253

14.4 Checking/adjusting the scraper belts

Nominal value

See chapter "Technical Data".

i Note
If the nominal pressure of the pressure relief
valve is not reached:
1. Adjust the pressure relief valve (PRV) on the
"Scraper belt" valve block (see next step).
2. Solenoid valve (Y206, Y207 (Y208, Y209)) ----
---- Check electric power supply and mechanical
function.
Fig. 7 3. Check the gear pump ("defect?").
4. Check the scraper belt motor ("defect?").

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
10. Remove the cap from the PRV (Fig. 7).
11. Loosen the counter nut (1) and turn the setscrew
(2) in or out, until the nominal value is reached.

i Note
Turning clockwise increases the pressure, turn-
ing anti-clockwise reduces the pressure!
12. Check the pressure once again (see above).
13. Retighten the counter nut (1) and replace the cap.
14. Turn the switch to position "MIN" and shut down
the engine (Fig. 8).

! Danger
Danger of injury!
Before disconnecting the pressure gauge
make sure that the engine has been shut
down!
15. Disconnect the pressure gauge.
16. Remove the blockage from the scraper belt.

Fig. 8

254 BOMAG 008 922 07

Checking/adjusting the scraper belts 14.4
Speed measurement on scraper belt

i Note
The following section describes the test for the
left scraper belt. The position numbers for the
right belt are given in brackets.
1. Fasten a reflex mark (1) on the shaft (2) (Fig. 9).

Fig. 9
2. Start the engine and set the switch to position
"MAX" (Fig. 10).

Fig. 10
3. Activate the hydraulic system (Fig. 11).

Fig. 11

008 922 07 BOMAG 255

14.4 Checking/adjusting the scraper belts

4. Activate the parking brake (Fig. 12).

Fig. 12
5. Select "Work"-mode (Fig. 13).

Fig. 13
6. Push the button "a" ("c") downwards and hold it.
(Fig. 14).

Fig. 14
7. Shift the travel lever to "forward" position (Fig.
15).
8. Read the shaft speed.

Nominal value
See chapter "Technical Data".
9. Shift the travel lever to "Neutral" position.
10. Release button "a" ("c") (Fig. 14).

i Note
If the nominal value is not reached, check the fol-
lowing:
Fig. 15
1. PRV ("defect?")

256 BOMAG 008 922 07

Checking/adjusting the scraper belts 14.4
2. Solenoid valve (Y206, Y207 (Y208, Y209))
(Check electric power supply and mechanical
function)
3. The gear pump ("defect?").
4. The scraper belt motor ("defect?").

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
11. Turn the switch to position "MIN" and shut down
the engine (Fig. 16).

Fig. 16

008 922 07 BOMAG 257

14.5 Checking/adjusting the augers

14.5 Checking/adjusting the augers

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).

Special tools
Hydraulic test case [BOMAG Part-No.: 079 930
01]
Digital rpm-meter, optical/mechanical, universal
use [BOMAG Part-No.: 079 948 98]

Pressure test augers

i Note
The following section describes the test for the
left auger. The right auger must be tested ac-
cordingly.

! Danger
Danger of injury!
Before connecting the pressure gauge make
sure that the engine has been shut down!
1. Connect a high pressure gauge (600 bar) to pres-
sure test port (1) on the pump (Fig. 1).

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
Fig. 1 2. Block the auger with suitable means.
3. Start the engine and set the switch to position
"MAX" (Fig. 2).

Fig. 2

258 BOMAG 008 922 07

Checking/adjusting the augers 14.5
4. Activate the hydraulic system (Fig. 3).

Fig. 3
5. Activate the parking brake (Fig. 4).

Fig. 4
6. Select "Work"-mode (Fig. 5).

Fig. 5

! Caution
Run the following pressure test only for max.
5 seconds.
7. Set the switch “b” (right auger : “c”) downwards.
(Fig. 6).
8. Read the hydraulic oil pressure in the pressure
gauge.
9. Turn switch "b" ("c") to position "0".

Fig. 6

008 922 07 BOMAG 259

14.5 Checking/adjusting the augers

Nominal value

See chapter "Technical Data".

i Note
If the nominal pressure of the pressure relief
valve is not reached:
1. Adjust the pressure relief valve (PRV) on the
"Auger drive" valve block (see next step).
2. Solenoid valve (Y210, Y211 (right auger: Y212,
Y213)) - check electrical control and mechanical
function.
Fig. 7 3. Check the gear pump ("defect?").
4. Check the auger motor ("defect?").

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
10. Remove the cap from the PRV (Fig. 7).
11. Loosen the counter nut (1) and turn the setscrew
(2) in or out, until the nominal value is reached.

i Note
Turning clockwise increases the pressure, turn-
ing anti-clockwise reduces the pressure!
12. Check the pressure once again (see above).
13. Retighten the counter nut (1) and replace the cap.
14. Turn the switch to position "MIN" and shut down
the engine (Fig. 8).

! Danger
Danger of injury!
Before disconnecting the pressure gauge
make sure that the engine has been shut
down!
15. Disconnect the pressure gauge.
16. Remove the blockage from the auger.

Fig. 8

260 BOMAG 008 922 07

Checking/adjusting the augers 14.5
Rotary speed test auger

i Note
The following section describes the test for one
side. The other side must be checked according-
ly.
1. Fasten a reflex mark (2) on the auger (1) (Fig. 9).

Fig. 9
2. Start the engine and set the switch to position
"MAX" (Fig. 10).

Fig. 10
3. Activate the hydraulic system (Fig. 11).

Fig. 11

008 922 07 BOMAG 261

14.5 Checking/adjusting the augers

4. Activate the parking brake (Fig. 12).

Fig. 12
5. Select "Work"-mode (Fig. 13).

Fig. 13
6. Set the switch “b” (right auger : “c”) downwards.
(Fig. 14).

Fig. 14
7. Shift the travel lever to "forward" position (Fig.
15).
8. Read the shaft speed.

Nominal value
See chapter "Technical Data".
9. Shift the travel lever to "Neutral" position.
10. Turn switch "b" ("c") to position "0".

i Note
If the nominal pressure of the pressure relief
valve is not reached:
Fig. 15
1. Check the PRV ("defect?").

262 BOMAG 008 922 07

Checking/adjusting the augers 14.5
2. Solenoid valve (Y210, Y211 (right auger: Y212,
Y213)) - check electrical control and mechanical
function.
3. Check the gear pump ("defect?").

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
11. Turn the switch to position "MIN" and shut down
the engine (Fig. 16).

Fig. 16

008 922 07 BOMAG 263

14.6 Checking/adjusting the main screed

14.6 Checking/adjusting the main screed

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).

Special tools
Hydraulic test case [BOMAG Part-No.: 079 930
01]
Pressure limitation main screeds
! Danger
Danger of injury!
Before connecting the pressure gauge make
sure that the engine has been shut down!
1. Connect a high pressure gauge (600 bar) to the
pressure test port on the service pump (Fig. 1).

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
Fig. 1
2. Start the engine and set the switch to position
"MAX" (Fig. 2).

Fig. 2
3. Activate the hydraulic system (Fig. 3).

Fig. 3

264 BOMAG 008 922 07

Checking/adjusting the main screed 14.6
4. Select "Work"-mode (Fig. 4).

Fig. 4

! Caution
For the following pressure test drive the
screed max. 5 seconds against block.
5. Lift the screed completely and read the pressure
gauge (Fig. 5).

Nominal value
See chapter "Technical Data".

Fig. 5

i Note
If the nominal value of the pressure limitation is
not reached, this may have one of the following
causes:
- Pressure relief setting on the service pump not
correct --> Adjust the pressure relief valve (PRV)
on the service pump.
- Solenoid valve Y194 dirty or defective --> clean
or replace (Fig. 6).

i Note
The arrangement of hydraulic components is
Fig. 6
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
6. Loosen the counter nut (2) and turn the setscrew
(1) in or out, until the nominal value is reached
(Fig. 7).

i Note
Turning clockwise increases the pressure, turn-
ing anti-clockwise reduces the pressure!
7. Check the pressure once again (see above).
8. Retighten the counter nut (2).

Fig. 7

008 922 07 BOMAG 265

14.6 Checking/adjusting the main screed

9. Deactivate the hydraulic system (Fig. 8).

Fig. 8
10. Turn the switch to position "MIN" and shut down
the engine (Fig. 9).

! Danger

Danger of injury!
Before disconnecting the pressure gauge
make sure that the engine has been shut
down!
11. Disconnect the pressure gauge.

Fig. 9

266 BOMAG 008 922 07

Checking/adjusting the main screed 14.6
Time measurement for lifting and low-
ering the main screed
1. Start the engine and set the switch to position
"MAX" (Fig. 10).

Fig. 10
2. Activate the hydraulic system (Fig. 11).

Fig. 11
3. Select "Work"-mode (Fig. 12).

Fig. 12

008 922 07 BOMAG 267

14.6 Checking/adjusting the main screed

4. If necessary lower the screed (1) completely (Fig.

13).
5. Lift the screed completely and measure the re-
quired time.

Nominal value
3-5 seconds
6. Lower the screed completely and measure the
required time.

Nominal value
3-5 seconds
Fig. 13
i Note
If the nominal value is not reached, this may have
one of the following causes:
- Throttle (see hydraulic diagram) dirty --> clean
- Valves Y226, Y237, Y228 dirty or defective -->
clean as necessary, check electric power supply.
Replace if defective.
- Valve Y194 dirty or defective --> clean if neces-
sary, check electric power supply. Replace if de-
fective.
- Flow volume from service pump too low -->
check the pump

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".

i Note
If the nominal value is still not reached despite
these measures you may change the size of the
throttle:
- Bigger throttle: The screed moves faster.
- Smaller throttle: The screed moves slower.

7. Deactivate the hydraulic system (Fig. 14).

Fig. 14

268 BOMAG 008 922 07

Checking/adjusting the main screed 14.6
8. Turn the switch to position "MIN" and shut down
the engine (Fig. 15).

Fig. 15

008 922 07 BOMAG 269

14.7 Checking/adjusting the screed levelling

14.7 Checking/adjusting the screed level-

ling

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).

Special tools
Hydraulic test case [BOMAG Part-No.: 079 930
01]
Pressure test screed levelling
! Danger

Danger of injury!
Before connecting the pressure gauge make
sure that the engine has been shut down!
1. Connect a high pressure gauge (600 bar) to the
pressure test port on the service pump (Fig. 1).

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
Fig. 1
2. Start the engine and set the switch to position
"MAX" (Fig. 2).

Fig. 2
3. Activate the hydraulic system (Fig. 3).

Fig. 3

270 BOMAG 008 922 07

Checking/adjusting the screed levelling 14.7
4. Select "Work"-mode (Fig. 4).

Fig. 4

! Caution
For the following pressure test move the
screed levelling max. 5 seconds against
block.
5. Lift the screed levelling completely and read the
pressure gauge (Fig. 5).

Nominal value
See chapter "Technical Data".

Fig. 5

i Note
If the nominal value of the pressure limitation is
not reached, this may have one of the following
causes:
- Pressure relief setting on the service pump not
correct --> Adjust the pressure relief valve (PRV)
on the service pump.
- Solenoid valve Y194 dirty or defective --> clean
or replace (Fig. 6).

i Note
The arrangement of hydraulic components is
Fig. 6
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
6. Loosen the counter nut (2) and turn the setscrew
(1) in or out, until the nominal value is reached
(Fig. 7).

i Note
Turning clockwise increases the pressure, turn-
ing anti-clockwise reduces the pressure!
7. Check the pressure once again (see above).
8. Retighten the counter nut (2).

Fig. 7

008 922 07 BOMAG 271

14.7 Checking/adjusting the screed levelling

9. Deactivate the hydraulic system (Fig. 8).

Fig. 8
10. Turn the switch to position "MIN" and shut down
the engine (Fig. 9).

! Danger

Danger of injury!
Before disconnecting the pressure gauge
make sure that the engine has been shut
down!
11. Disconnect the pressure gauge.

Fig. 9

272 BOMAG 008 922 07

Checking/adjusting the screed levelling 14.7
Time measurement screed levelling
1. Start the engine and set the switch to position
"MAX" (Fig. 10).

Fig. 10
2. Activate the hydraulic system (Fig. 11).

Fig. 11
3. Select "Work"-mode (Fig. 12).

Fig. 12
4. If necessary lower the drawing arms completely
(Fig. 13).
5. Lift the drawing arms completely and measure
the required time.

Nominal value
27-29 seconds
6. Lower the drawing arms completely and meas-
ure the required time.

Nominal value
23-25 seconds
Fig. 13

008 922 07 BOMAG 273

14.7 Checking/adjusting the screed levelling

i Note
If the nominal value is not reached, this may have
one of the following causes:
- Throttle (see hydraulic diagram) dirty --> clean
- Valves Y220, Y221, Y222, Y223 dirty or defec-
tive --> clean as necessary, check electric power
supply. Replace if defective.
- Valve Y194 dirty or defective --> clean if neces-
sary, check electric power supply. Replace if de-
fective.
- Flow volume from service pump too low -->
check the pump

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".

i Note
If the nominal value is still not reached despite
these measures you may change the size of the
throttle:
- Bigger throttle: The levelling cylinder moves
faster.
- Smaller throttle: The levelling cylinder moves
slower.

7. Deactivate the hydraulic system (Fig. 14).

Fig. 14

274 BOMAG 008 922 07

Checking/adjusting the screed levelling 14.7
8. Turn the switch to position "MIN" and shut down
the engine (Fig. 15).

Fig. 15

008 922 07 BOMAG 275

14.8 Checking/adjusting the hopper wings

14.8 Checking/adjusting the hopper wings

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).

Special tools
Hydraulic test case [BOMAG Part-No.: 079 930
01]
Pressure test for hopper wings
! Danger
Danger of injury!
Before connecting the pressure gauge make
sure that the engine has been shut down!
1. Connect a high pressure gauge (600 bar) to the
pressure test port on the service pump (Fig. 1).

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
Fig. 1
2. Start the engine and set the switch to position
"MAX" (Fig. 2).

Fig. 2
3. Activate the hydraulic system (Fig. 3).

Fig. 3

276 BOMAG 008 922 07

Checking/adjusting the hopper wings 14.8
4. Select "Work"-mode (Fig. 4).

Fig. 4

! Caution
For the following pressure test move the hop-
per wings max. 5 seconds against block.
5. Close the hopper wings completely and read the
pressure gauge (Fig. 5).

Nominal value
See chapter "Technical Data".

Fig. 5

i Note
If the nominal value of the pressure limitation is
not reached, this may have one of the following
causes:
- Pressure relief setting on the service pump not
correct --> Adjust the pressure relief valve (PRV)
on the service pump.
- Solenoid valve Y194 dirty or defective --> clean
or replace (Fig. 6).

i Note
The arrangement of hydraulic components is
Fig. 6
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
6. Loosen the counter nut (2) and turn the setscrew
(1) in or out, until the nominal value is reached
(Fig. 7).

i Note
Turning clockwise increases the pressure, turn-
ing anti-clockwise reduces the pressure!
7. Check the pressure once again (see above).
8. Retighten the counter nut (2).

Fig. 7

008 922 07 BOMAG 277

14.8 Checking/adjusting the hopper wings

9. Deactivate the hydraulic system (Fig. 8).

Fig. 8
10. Turn the switch to position "MIN" and shut down
the engine (Fig. 9).

! Danger

Danger of injury!
Before disconnecting the pressure gauge
make sure that the engine has been shut
down!
11. Disconnect the pressure gauge.

Fig. 9

278 BOMAG 008 922 07

Checking/adjusting the hopper wings 14.8
Testing the hopper wing movement
time
1. Start the engine and set the switch to position
"MAX" (Fig. 10).

Fig. 10
2. Activate the hydraulic system (Fig. 11).

Fig. 11
3. Select "Work"-mode (Fig. 12).

Fig. 12

008 922 07 BOMAG 279

14.8 Checking/adjusting the hopper wings

4. If necessary open the hopper wings completely

(Fig. 13).
5. Close the hopper wing completely and measure
the required time.

Nominal value
4-5 seconds
6. Open the hopper wing completely and measure
the required time.

Nominal value
5-6 seconds
Fig. 13
i Note
If the nominal value is not reached, this may have
one of the following causes:
- Throttles (see hydraulic diagram) dirty --> clean
- Valves Y202, Y203, Y204, Y205 dirty or defec-
tive --> clean as necessary, check electric power
supply. Replace if defective.
- Valve Y194 dirty or defective --> clean if neces-
sary, check electric power supply. Replace if de-
fective.
- Flow volume from service pump too low -->
check the pump

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".

i Note
If the nominal value is still not reached despite
these measures you may change the size of the
throttles:
- Bigger throttle: The hopper wings move faster.
- Smaller throttle: The hopper wings move slow-
er.

7. Deactivate the hydraulic system (Fig. 14).

Fig. 14

280 BOMAG 008 922 07

Checking/adjusting the hopper wings 14.8
8. Turn the switch to position "MIN" and shut down
the engine (Fig. 15).

Fig. 15

008 922 07 BOMAG 281

14.9 Checking/adjusting the mobile screed

14.9 Checking/adjusting the mobile screed

! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (40 °C).

Special tools
Hydraulic test case [BOMAG Part-No.: 079 930
01]
Pressure limitation mobile screeds
! Danger
Danger of injury!
Before connecting the pressure gauge make
sure that the engine has been shut down!
1. Connect a high pressure gauge (600 bar) to the
pressure test port on the service pump (Fig. 1).

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".
Fig. 1
2. Start the engine and set the switch to position
"MAX" (Fig. 2).

Fig. 2
3. Activate the hydraulic system (Fig. 3).

Fig. 3

282 BOMAG 008 922 07

Checking/adjusting the mobile screed 14.9
4. Select "Work"-mode (Fig. 4).

Fig. 4

! Caution
For the following pressure test drive the mo-
bile screeds max. 5 seconds against block.

! Caution
Perform the pressure test by RETRACTING
the mobile screed. In this case the bending
forces acting on the screed are lower!
5. Completely retract the mobile screed and read
the pressure gauge (Fig. 5).

Nominal value
Fig. 5 See chapter "Technical Data".

i Note
If the nominal value of the pressure limitation is
not reached, this may have one of the following
causes:
- Pressure relief setting on the service pump not
correct --> Adjust the pressure relief valve (PRV)
on the service pump.
- Solenoid valve Y194 dirty or defective --> clean
or replace (Fig. 6).

i Note
The arrangement of hydraulic components is
Fig. 6
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".

008 922 07 BOMAG 283

14.9 Checking/adjusting the mobile screed

6. Loosen the counter nut (2) and turn the setscrew

(1) in or out, until the nominal value is reached
(Fig. 7).

i Note
Turning clockwise increases the pressure, turn-
ing anti-clockwise reduces the pressure!
7. Check the pressure once again (see above).
8. Retighten the counter nut (2).

Fig. 7
9. Deactivate the hydraulic system (Fig. 8).

Fig. 8
10. Turn the switch to position "MIN" and shut down
the engine (Fig. 9).

! Danger
Danger of injury!
Before disconnecting the pressure gauge
make sure that the engine has been shut
down!
11. Disconnect the pressure gauge.

Fig. 9

284 BOMAG 008 922 07

Checking/adjusting the mobile screed 14.9
Time measurement for extension and
retraction of mobile screeds
1. Start the engine and set the switch to position
"MAX" (Fig. 10).

Fig. 10
2. Activate the hydraulic system (Fig. 11).

Fig. 11
3. Select "Work"-mode (Fig. 12).

Fig. 12

008 922 07 BOMAG 285

14.9 Checking/adjusting the mobile screed

4. If necessary retract the mobile screed completely

(Fig. 13).
5. Fully extend the mobile screed and measure the
required time.

Nominal value
15-17 seconds
6. Fully retract the mobile screed and measure the
required time.

Nominal value
12-14 seconds
Fig. 13
i Note
If the nominal value is not reached, this may have
one of the following causes:
- Throttle (see hydraulic diagram) dirty --> clean
- Valves Y216, Y217, Y218, Y219 dirty or defec-
tive --> clean as necessary, check electric power
supply. Replace if defective.
- Valve Y194 dirty or defective --> clean if neces-
sary, check electric power supply. Replace if de-
fective.
- Flow volume from service pump too low -->
check the pump

i Note
The arrangement of hydraulic components is
shown in chapter "Hydraulics" under section "Hy-
draulics overview of components".

i Note
If the nominal value is still not reached despite
these measures you may change the size of the
throttle:
- Bigger throttle: The mobile screed moves fast-
er.
- Smaller throttle: The mobile screed moves
slower.

7. Deactivate the hydraulic system (Fig. 14).

Fig. 14

286 BOMAG 008 922 07

Checking/adjusting the mobile screed 14.9
8. Turn the switch to position "MIN" and shut down
the engine (Fig. 15).

Fig. 15

008 922 07 BOMAG 287

14.9 Checking/adjusting the mobile screed

288 BOMAG 008 922 07

 15 Central lubrication system

008 922 07 BOMAG 289

15.1 Filling the lubricant container

15.1 Filling the lubricant container

Fig. 1 Filler coupling

(Fig. 1) Through filler coupling.

Fig. 2 Grease gun

(Fig. 2) With grease gun

Fig. 3 Grease nipple

(Fig. 3) Through grease nipple with hand-operated or pneumatic grease gun

290 BOMAG 008 922 07

Electric pump 15.2
15.2 Electric pump Technical dada

Motor:
Electric pump EP-1 Operating voltage= 12/24 V DC
The central lubrication grease pump is electrically Rated speed = 15 rpm
driven. With a working pressure of max. 280 bar (set-
Power consumption
ting of high pressure relief valve) this pump is suitable
at idle speed = 0.4 A
for pumping conventional greases up to NLGI-Kl. 2.
Power consumption
at full load speed= 1.1 A
Fuse = 3A

Pump:
Max. operating pres-
sure = 280 bar
Permissible operat-
ing temperature= -35°C to +80°C
Container capacity= 1.9 kg, 2.5 kg, 4 kg or 8 kg
Rotation of agitator =counter-clockwise
Installation position= Container vertically upright
Protection class= IP5K9K acc. to DIN 40050

Fig. 4 EP-1 with 4 kg container and integrated electronic control

008 922 07 BOMAG 291

15.2 Electric pump

Working principle

Fig. 5
A DC-motor 10 (Fig. 5) continuously drives the eccen-
tric (5) with thrust ring (6). This eccentricity causes the
suction and pressure stroke of the pump piston (7),
whereby the integrated check valve (8) prevents the
pumped medium from being sucked back in from the
main line.
The agitator (2) forces the lubricant out of the provi-
sion container (1) through a screen plate (4 to the suc-
Fig. 6 Pump element drawing in grease
tion area in the pump housing (3), whereby air
bubbles are eliminated A scraper on the agitator (2)
enables visual inspection of the still available grease
quantity inside the transparent provision container (1).
The pressure relief valve (9) is factory set to 280 bar.

Fig. 7 Pump element pumping

292 BOMAG 008 922 07

Electric pump 15.2
Pump element PE-120V
Max. flow capacity
l Pump element factory set to full stroke
l max. flow capacity 0.12 cm with full stroke
l Reduction of 0.013 cm per detent = 1/2 revolution

Flow capacity regulation:

l Unscrew the plug 2 (Fig. 8)) with an Allen key (SW
5)
l
The setscrew (3) is then regulated with a screwdriv-
er
l Turning clockwise reduces the flow capacity
l Turn anti-clockwise increases the flow capacity
l Max. stroke of setscrew is 2.4 mm = 6 detents.
l 1 turn of the setscrew is 0.8 mm = 2 detents
Fig. 8
l Tighten the plug (2) with the seal ring.

Technical data: Max. flow capacity

F

Max. flow capacity= 0.04 to 0.12 cm3 / stroke

Flow capacity regula-
tion = 6 detents per 1/2 turn
Reduction = 0.013 cm3 per detent
Piston return = forced

Detents
Revolutions

Fig. 9

008 922 07 BOMAG 293

15.2 Electric pump

Installation of pump element

l Installation and removal only with the pump
stopped.
l Assembly of the pump element with the piston (4)
partly pulled out, insert upwards under a slanted an-
gle into the housing bore (Fig. 10)).
l Once the piston head touches the pressing ring -
move the element to horizontal position (Fig. 11).
l The piston head must run in the groove of the guide
ring.
l
Tighten the pump element.
l Disassemble in reverse order.

i Note
When disassembling the pump element make sure
that the piston (4) does not remain in the pump hous-
Fig. 10
ing.

Fig. 11

294 BOMAG 008 922 07

Integrated electronic control 15.3
15.3 Integrated electronic control 2 Green LED to indicate function
3 Red LED to indicate faults
The control unit is equipped with a data memory which
logs the following values: Technical data:
l Control type Supply voltage = 10 to 60 V DC
l Version of control serial number Current load max.= 6.0 A
l Manufacturing date Fuse (not contained
in the unit) = 6.3 A
l
Type of operation (time or speed control)
Output for signal
l Settings (setting ranges). lamp = 0.4 A
Temperature range= -35°C to +75°C
Functional sequence
Protection class= IP 65
After switching on the ignition the green and red LEDs
light up for 1.5 seconds to indicate readiness for oper-
ation (switch-on control), irrespective of the set pro-
gram.
Each initial connection of the control triggers a lubrica-
tion process, the green LED 2 (Fig. 12) in the control
bowl light during the entire lubrication process.
The integrated electronic control unit BEKA-troniX1 is
equipped with a data log. This, among other, serves
the purpose of logging expired times. If the ignition is
interrupted during a lubrication process or within a
pause period, this time is stopped and logged. After
switching the ignition back on the still remaining lubri-
cation or pause times are read out of the log and the
function will be resumed at exactly the point where it
was interrupted.
With the ignition switched on intermediate lubrication
can be triggered at any time by pressing the push but-
ton (1) on the side of the motor housing, this function
also serve the purpose of function testing. The pump
in this case immediately starts a lubrication cycle, the
accumulated or logged lubrication or cycle time is re-
set and starts anew.

Fig. 12
1 Push button to trigger intermediate lubrication

008 922 07 BOMAG 295

15.3
Modes of operation
A) Timer control
With time dependent control of a central lubrication
system both the cycle time and the lubrication time
can be adjusted. Cycle time means the time span be-
tween beginning of a lubrication process to the begin-
ning of the next lubrication process.
Lubrication time
Cycle time
Fig. 13
B) RPM-control
With the integrated electronic control unit one can,
e.g. in case of speed fluctuations caused by low tem-
peratures or high torques, also determine the lubrica-
tion period on the basis of the number of revolutions
of the pump motor.
A sliding contact connects the pump motor with the
control. Each pump revolution sends a signal to the
control, which in turn counts the number of arriving
signals.
If no signals are received from the pump motor over
an adjustable monitoring time (standard 30 sec.) after
the beginning of the lubrication process, the control
will indicate a fault.
The red LED in the inspection window in the bottom
motor shell of the pump or an externally installed sig-
nal lamp (option) will start to flash.
296 BOMAG
Integrated electronic control
Setting parameters
The cycle or lubrication times can be set with the help
of maintained-contact switches in the inspection win-
dow of the control.
Fig. 14
For setting the time disassemble the red frame from
the motor protection housing of the pump using a flat
screwdriver (Fig. 14), loosen four cross-recessed
screws and remove the transparent protection cover.
The cycle or lubrication time can be set with a flat
screwdriver.
! Caution
The cycle time must not be changed.
In case of improper closing of the cover water will
seep into the control and cause damage. In this
case any warranty will become null and void.
Fig. 15
1 Connection of system diagnose
2 Maintained-contact switch to set the lubrication time
3 Maintained-contact switch to set the cycle time
008 922 07
Integrated electronic control 15.3
Lubrication times: a) Functional readiness
1 to 16 min. (16 contacts for 1 min. each)
Functionally ready: 1.5 sec.
2 to 32 min. (16 contacts for 2 min. each)
LED red
2 to 32 sec. (16 contacts for 2 sec. each)
LED green
Cycle times:
0.5 to 8 h (16 contacts for 0.5 h each) Fig. 2 Indication of functional readiness

2 to 32 min. (16 contacts for 2 min. each) b) Lubrication active

2 to 32 h (16 contacts for 2 h each)
LED red
Pump revolutions:
Over the entire lubrication period
1 to 16 revolutions (16 contacts for 1 revolution each)
10 to 160 revolutions (16 contacts for 10 revolution LED green

each)
Fig. 3 Lubrication sequence
170 to 320 revolutions (16 contacts for 10 revolution
each) c) Rotary speed fault

Summary of signal displays

LED red
Two control LEDs (green/red) in the inspection win-
dow of the motor shell show the functions of the pump, LED green
whereby the red LED always indicates a fault in the
program sequence. Fig. 4 Rotary speed fault on pump motor

d) Fault CPU/memory

LED red

LED green

Fig. 5 Fault CPU/memory

Fig. 1 Indication of functional readiness
e) Test lubrication (permanent lubrication)
1 Red LED to indicate faults
2 Green LED to indicate function
LED red

LED green

Fig. 6 Test lubrication

i Note
In order to be able to trigger permanent lubrication for
service purposes in "Timer controlled" mode, the lubri-
cation time must be set to a value that is higher than
the cycle time.

008 922 07 BOMAG 297

15.3 Integrated electronic control

Terminal diagram

Signal lamp green

green (no. 1)

red (no. 2)

Signal lamp red

External signal lamps

orange (no. 4)
Push button

Ignition, terminal 15 black (no. 3)

Ground, terminal 31 brown (ye/gr)

Fig. 7

i Note
(No. ...) = Cable no. for mono-colour cable

298 BOMAG 008 922 07

Progressive distributor 15.4
15.4 Progressive distributor
The progressive distributor can be employed as main
or a secondary distributor.
Progressive piston distributors are distributor units
with a hydraulic sequence control the pistons of which
are controlled by the fed lubricant in such a way that
the lubricant is forced successively to the individual
outlets. In case of disturbances in the sequence of lu-
bricant flow, e.g. blockage of lubrication lines or lubri-
cation points, the distributors will block. This blockage
is used as an aid to monitor the distributors. With au-
tomatic pumps, such as e.g. the electric pump EP-1,
the lubricant emerges from the pressure relief valve.
The progressive distributors are manufactured in a
variable disc design. This has the advantage that the
distributor can be extended or shortened, depending
on the number of lubrication points. This disc design
also provides the possibility to customize individual
distributor discs with different displacements per pis-
ton stroke to one overall progressive distributor.
The different displacements per piston stroke are
achieved by different piston diameters.
For correct functioning a progressive distributor re-
quires at least three pistons, i.e. at lest three pumping
elements.

Technical data:
Operating pressure
at inlet = max. 300 bar Fig. 8 Example: 4 piston elements and 8 outlets

Temperature range= -35°C to + 80°C In detail the progressive distributor consists of a start
element (without piston), a middle element ME and an
Number of ele-
end element EE, which are held together as distributor
ments = Min. 3 piston elements, Max. 12
blocks by tie rods (socket head cap screws) with ser-
piston elements
rated washers. The individual elements are sealed by
O-rings.

Element Max. flow capacity Piston

designation per outlet per ele- ∅
ment
3
MX- F25 25 mm 50 mm3 3 mm
3
MX- F45 45 mm 90 mm3 4 mm
3
MX- F75 75 mm 150 mm3 5 mm
3
MX- F105 105 mm 210 mm3 6 mm

008 922 07 BOMAG 299

15.4 Progressive distributor

Description of function
Lubricant flows into the distributor inlet port through all
distributor discs to piston I (Fig. 1). Piston (I) is dis-
placed to the left and the lubricant from the left pres-
sure chamber of the pumping piston is pressed to
outlet 1 (Fig. 2).
Then the metering pistons (II) and (III) are displaced in
succession and lubricant is delivered to outlets 2 and
3. After displacing piston (III) lubricant is delivered to
the left side of pumping piston (I) (Fig. 3) and dis-
placed out of the right pressure chamber of the pump-
ing piston to outlet 4.
Then the metering pistons (II) and (III) are displaced in
succession and lubricant is pressed to outlets 5 and 6.
After the displacement of pumping piston (III) the lubri-
cant is once again guided to the right side of the
pumping piston (Fig. 1) and a new cycle of the pro-
gressive piston distributor is started. The function de-
scribed above is repeated, as long as the progressive
distributor is supplied with grease.

Fig. 2

Pressure chamber
Fig. 3
Fig. 1

300 BOMAG 008 922 07

Progressive distributor
Connection of 2 outlets
For large lubrication points it may be necessary to join
two or more outlets on the progressive distributor to-
gether.
The individual discs of the progressive distributor
have two outlets.
When connecting two outlets on the progressive dis-
tributor, both outlets of one disc are joined together.
For this purpose the sealing screw, which separates
both sides, is removed and a plug is screwed into the
side to be closed. The metered quantity of the closed
side no emerges from the other side, i.e. the metered
quantity on the open side is doubled.
2 outlets per distributor element (Fig. 4)
single
Fig. 4 2 outlets
1 Sealing screw
1 outlet per distributor element (Fig. 5)
double
Fig. 5 1 outlet
1 Plug
For connecting outlets, plugs are required.
008 922 07 BOMAG
15.4
Connection of several outlets
Connection of outlets with bridging pipes without
outlet
Should the total metering quantity exceed the capacity
of the outlets connected in one disc of the progressive
distributor, e.g. for extremely big lubrication points or
for main distributors, there is a possibility to join the
outlets of several distributor discs with bridging pipes
(Fig. 6).
Fig. 6 Bridging pipe
3 outlets joined together (Fig. 7)
In this case two distributor discs are connected with a
bridging pipe or a distributor bridge without outlet, as
described hereunder. Depending on the element from
which the sealing screw 1 (Fig. 7) had been removed,
three outlets are joined together this way. The me-
tered quantities of the closed outlets then emerge
from one common outlet.
The metered quantity is calculated on the basis of the
metering parameters for all joined piston sides.
tripe
single
Fig. 7 3 outlets
1 Sealing screw
4 outlets joined together (Fig. 8)
With the help of a bridging pipe or a distributor bridge
without outlet you can even join four outlets. For this
purpose the sealing screws must be removed from
both distributor discs and one of the two outlets oppo-
site the bridging pipe or the distributor bridge must be
closed with a plug.
301
15.4 Progressive distributor

Distributor bridge without outlet

Distributor bridge without check valve (Fig. 9)

quadruple

Fig. 8 4 outlets

Fig. 9 without check valve

Distributor bridge with integrated check valve

In order to ensure proper functioning of a progressive
distributor with three delivering elements but only two
outlets (Fig. 10), you must use a distributor bridge
without outlet, but with integrated check valve (Fig.
11).

Fig. 10

Fig. 11 with check valve

302 BOMAG 008 922 07

Progressive distributor 15.4
Connection of outlets with distributor lets in this case emerges from the outlet in the distrib-
bridges with outlet utor disc.

quadruple

Fig. 15 4 outlets

Fig. 12 Distributor bridge with outlet

2 outlets joined together (Fig. 13)

If two outlets (on different, adjacent distributor discs)
are to be joined together, the sealing screws must not
be unscrewed from any of the affected distributor
discs. The delivery from both outlets in this case
emerges from the outlet on the distributor bridge.

single

double

single
Fig. 13 2 outlets

3 outlets joined together (Fig. 14)

If three outlets are to be joined together, the sealing
screw must be unscrewed from one of the two affect-
ed distributor discs and a plug must be screwed into
the free outlet on this distributor disc. The delivery
from all three outlets in this case emerges from the
outlet in the distributor disc.

tripe
single

Fig. 14 3 outlets

4 outlets joined together (Fig. 15)

If four outlets are to be joined together, the sealing
screws must be unscrewed from both distributor discs
the plugs must be screwed into the outlets opposite
the distribuitor bridge. The delivery from all four out-

008 922 07 BOMAG 303

15.4 Progressive distributor

Check valves
The check valves are used in combination with high
pressure hoses, e.g. on lubrication points with high
counter pressure or in main distributors.
There are two versions of check valves available, on
which the pipe socket is screwed in.

Check valve for main distributor (Fig. 16)

Fig. 16
1 Cap screw
2 Duplex ring

Check valve for secondary distributor (Fig. 17)

Fig. 17
1 Cap nut and cutting ring

304 BOMAG 008 922 07

Fault - Cause - Remedy 15.5
15.5 Fault - Cause - Remedy

Fault Cause Remedy

Pump does not work Integrated electronic control defec-
Replace the lower part of the motor
tive protection housing
Electric line interrupted Replace the electric line
Pump defective Replace the pump
Pump works, but does not deliver Air cushion in pumping piston Vent the pump
Min. filling level fallen short of
Fill up the provision container
Pump element defective Replace the pump element
No grease collar at the lubrication Pump does not work See "Pump does not work"
points Pause time too long or lubrication
Reduce pause time or extend lubri-
period too short cation time
System blocked See "Grease emerging from pres-
sure relief valve"
No grease collars at various lubrica- Supply line to secondary distributor Replace the line
tion points burst or leaking
Screw fittings leaking Retighten or replace screw fitting
No grease collar on one lubrication Corresponding grease line burst or Replace the line
point leaking
Screw fitting leaking Retighten or replace screw fitting
Pump speed too low High system pressure or low ambi- Check system / bearing point
ent temperature No damage (perform 1 or 2 interme-
diate lubrication cycles)
Grease emerging from pressure re- System pressure too high Check system
lief valve Progressive distributor blocked Replace the distributor
System blocked Repair blocked / seized bearing
points
Valve spring defective Replace the pressure relief valve
LED-display The LED of the control flashes or is See "Summary of signal displays"
permanently on

Cause for a blockage in the system

l
A crushed or blocked lubricant line
l
A bearing overfilled with lubricant or blocked
l
An unsuitable lubricant for central lubrication systems
l A blocked distributor outlet
l A blocked distributor

Indication of a blockage
l
Grease emerging from pressure relief valve

008 922 07 BOMAG 305

15.5 Fault - Cause - Remedy

Identify the location of the blockage

!Caution
All repair work must be carried out with utmost cleanliness.

Fig. 18
l 1.) Unscrew the main line from the main distributor, operate the pump and check whether lubricant is delivered
properly.
l
2.) Unscrew the cap screws on the distributor one after the other and operate the pump each time a cap screw
is removed. The line (cap screw) at which the pressure drops, is the blocked line or lubrication point.
l 3.) Follow the same principle when checking the associated secondary distributor all the way to the lubrication
point.

Fig. 19 KIT to check central lubrication systems

306 BOMAG 008 922 07

Repair of a blocked distributor 15.6
Repair of a blocked distributor
15.6 Repair of a blocked distributor

Caution
!

All repair work must be carried out with utmost cleanliness.

Fig. 20 Example
Remove the distributor from the system. .
l
Note the sequence of distributor discs.
l
Remove the draw bars 1(Fig. 20)
l Take off the distributor disc(s).

Caution
!

Pistons are not exchangeable among each other .

If piston and bores in the distributor disc show deposits of hardened grease, these deposits must be
removed by washing or blowing out. The bores in the distributor disc must be free of grease residues.

i Note
Grease getting hard indicates that the grease is not suitable for central lubrication systems.
l Unscrew the plugs from the piston bores (2) and slide the pistons from side to side (do not push out).
l Screw the plugs back in.
l Check the next distributor disc, until the blocked piston is found.
l
the piston of the blocked distributor disc out and check the bore in the distributor disc and the surface of the
piston for scratches and damage.

Caution
!

In case of severe damage replace the distributor disc.

l Once all distributor discs have been checked reassemble the distributor in the recorded sequence.
l To prevent jamming of the pistons tighten the draw bars with 12 Nm.
l
Check function of the distributor.

008 922 07 BOMAG 307

15.6 Repair of a blocked distributor

308 BOMAG 008 922 07

 16 Circuit diagrams

008 922 07 BOMAG 309

310 BOMAG 008 922 07
 16.1 Hydraulic diagram
2

008 922 07 BOMAG 311

16.1 Hydraulic diagram

312 BOMAG 008 922 07

008 922 07
Hydraulic diagram

pump
no. PUMPS

1.1 propel left

Kubota 3307-T 1.2 propel right
Ratio eng. /pump: i = 1,16 3 service (all cylinder)
Min. RPM 1000 4 auger left
5 auger right
Max. RPM 2200
6 tamper / vibration
7 conveyor right
8 conveyor left

BOMAG
cylinder operated functions
8 7 4 3 6 5 3.2 screed ext. left
3.3 screed ext. right
3.4 screed up / down
1.1 1.2 3.5 screed load relieving
3.6 screed leveling left
3.7 screed leveling right
3.8 hopper wing left
3.9 hopper wing right
3.10 auger up / down

3.11 crown adjustment

0 1 2 3 4 5 6 7 8 9
drawing number scale
name H. Christ
ed. by 83783111
16.1

313
date 05.03.2009
name BF300C overview page 1
appr. 300C_hy_schematic_2009_03_17.VSD
amendment date name date page 10
314
16.1

BOMAG
0 1 2 3 4 5 6 7 8 9
drawing number scale

008 922 07
Hydraulic diagram

name H. Christ
ed. by 83783111
date 05.03.2009
BF300 C history page
name 2
appr. 300C_hy_schematic_2009_03_17.VSD
amendment date name date page 10
 page
(schematic)

[1] overview

[2] history

008 922 07
[3] legend

pos
no description
1.1/1.2 tandem pump
3 travel motor left
4 travel motor right
Hydraulic diagram

5 speed sensor left

6 speed sensor right
[4]
7 filter
8 different.pressure switch
9 3/2-Way valve (single)
10 brake releasing valve
11 chain tensioner valve

1 connecting block
2 oiltemperature regulator
3 Temperature sensor
[5] 4 check valve
5 cooler
6 manifold
7 manifold

1 pressure relief valve

2 vibration valve block
3 vib motor

BOMAG
[6] 4 variable orifice
5 tamper valve block
6 tamper motor
7 tamper motor (incl DBV)

1 valve block
1 valve block
1 valve block
[7]
1 valve block
2 conveyor motor
3 auger motor

1 -
2 valve block
[8]
3 valve block (option)
4 valve block

1 valve block
[9]
2 Shuttle orifice
1 3/2-Way valve (single)
[10] 2 manifold
3 filter

0 1 2 3 4 5 6 7 8 9
drawing number scale
name H. Christ
ed. by 83783111
16.1

315
date 05.02.2009
name BF300 C legend page 3
appr. 300C_hy_schematic_2009_03_17.VSD
amendment date name date page 10
 A1 A2 MA

316
chain tensioner
37bar
16.1

A1.2
Y 04
A1.1
a1

A1 A2 9
M
180 bar 180 bar 10
T P P1 P2 X T
11
break
left / right

A6VE28EZ1/63W-VAL027FQB
flushing flow: ~3,5l/min
28/12cm³
5 6

BOMAG
Y 197 Y 198
M M M
Y 16 Y 17 Y 72 Y 73
G G
MB MB

B B 4
U T1 U T1

B B

B191 B 192
n Vg min n Vg min

Vg max Vg max

A A
A A
T2 T2

MA MA
3
A10VG28 (left) A10VG28 (right)
cut off: 380 bar M cut off: 380 bar M
high prss.relv. valve: p 380bar 1.2 high press.relv. valve: p 380bar
charge pressure: 25 bar charge pressure valve: BLOCK!
1.1
7
8
Auger left / right

12μm

0 1 2 3 4 5 6 7 8 9

drawing number scale

008 922 07
Hydraulic diagram

name H. Christ
ed. by 83783111
date 05.03.2009
name
BF300 C propel page 4
appr. 300C_hy_schematic_2009_03_17.VSD
page
amendment date name date 10
 (6) suction vibration / tamper
M
page [8] valve-no 4 (T) (LCS)

008 922 07
page [8] valve-no 3 (T) (crown adj.) (7) suction conveyor left

page [8] valve-no 2 (T) (screed ext)

6 (8) suction conveyor right

Hydraulic diagram

page [9] valve-no 1 (T1)

suction A10VO28 service

4
return flow vibation / tamper suction auger left
charge suction auger right

0,5 bar

hot side cold side U

T

Sens. Temp
T (55-
05834005
70°C)

BOMAG
85+-3°C
T A10VG28 tandem pump

leakage service pump

leakage / flushing
T brake / 1/2. gear valve / chain tensioner A6VE28 M
leakage / flushing
A6VE28
T service on/off valve
conveyor left / right
leakage auger motors

leakage conveyor motors

leakage vibration motors

leakage tamper motors

0 1 2 3 4 5 6 7 8 9
drawing number scale
name H. Christ
ed. by 83783111
16.1

317
date 05.03.2009
BF300 C cooling_suction page
name 5
appr. 300C_hy_schematic_2009_03_17.VSD
amendment date name date page 10
 Min. RPM 350
Min. RPM 0
Max RPM 1900
Max RPM 2750

318
16.1

option
100bar 100bar

A B A B
A B
b
A B Y 224
b P T
Y 225
a P T

T P

BOMAG
100bar

P T

screed

tractor M 200bar
see page [01] 1

3 6 5

0 1 2 3 4 5 6 7 8 9
drawing number scale

008 922 07
Hydraulic diagram

name H. Christ
ed. by 83783111
date 05.03.2009
BF300 C vibration / tamper page
name 6
appr. 300C_hy_schematic_2009_03_17.VSD
amendment date name date page 10
 conveyor auger
left right right left

008 922 07
RPM sul RPM sulla
nastro 62+-2 coclea 82+-2
Hydraulic diagram

A B A B A B A B

Y 207 Y 206 Y 208 Y 209 Y 212 Y 213 Y 211 Y 210

a b a b a b a b

1
1
1 1

BOMAG
230 bar 230 bar
230 bar 230 bar

P T P T P T P T

see page [1]

M M M
M
see page [1] see page [1]
8 7 4 3 6 5 8 7 4
CHARGE
hy cooler IN

0 1 2 3 4 5 6 7 8 9
drawing number scale
name H. Christ
ed. by 83783111
16.1

319
date 05.03.2009
BF300 C conveyor / auger page
name 7
appr. 300C_hy_schematic_2009_03_17.VSD
amendment date name date page 10
 Salita 4+-1 sec

320
Discesa 4+-1 sec
4
3.4
16.1

P2 T2
option Screed
raise / lower
A
250bar
250bar A

Y 231 Y 232 Y228 a3

B

250bar 3,0
a1 b1 250bar B
M
Y226
3.11
a1
Crown Y229
P T 3.5
adjustment
3 Y227 a2 M LCS Load
a4
Control
Flow
3 bar System
control
0,1 bar a5
Chiusura 12-14 sec Y230
M
Apertura 15-17 sec
P T 3.2 1,6
Screed ext.
1,2 A
right
P1 T1 T

BOMAG
7 – 105 bar
(0 – 1600 mA)
1,2 B
Y219 A B
0,5 bar

Y218 3.3
a2 P T b2 Screed ext.
1,2 A left
Chiusura 12-14 sec
1,2
Apertura 15-17 sec
B
A B
Y217 2
Y216
a1 P T b1
pump
M see page [1 + 10]
P T
P see page [10]
T see page [5]
3 6 5

0 1 2 3 4 5 6 7 8 9
drawing number scale

008 922 07
Hydraulic diagram

name H. Christ
ed. by 83783111
date 05.03.2009
name BF300 C service (a) page 8
appr. 300C_hy_schematic_2009_03_17.VSD
amendment date name date page 10
 1

008 922 07
Chiusura 4-5 sec
P2 T2 Apertura 5-6 sec

A5
3.9
A B 1,8 B5 Hopper Wing
Y 203
left
Hydraulic diagram

b5 2
1,8
a5 P T Y 202
0,7
A4
Y 221 A B 3.6
Salita 27-29 sec
0,7 Screed leveling left
Discesa 23-25 sec
b4 B4
a4 0,7P T0,7 Y 220

0,7
A3 3.7
A B Screed leveling right Salita 27-29 sec
Y 223
0,7 Discesa 23-25 sec
b3 B3
a3 0,7P T 0,7 Y 222
1,8 A2
3.8

BOMAG
Chiusura 4-5 sec
A B
Hopper Wing
Y 205 1,8 B2 Apertura 5-6 sec
right
b2 3.10
a2 P T
Y 204 Auger
A1
rise / lower
1,5
A B
Y 215
1,5
b1
B1
M a1 P T
Y 214

see page [1 + 10]

P1 T1
P see page [10]
T see page [5]
3

0 1 2 3 4 5 6 7 8 9
drawing number scale
name H. Christ
ed. by 83783111
16.1

321
date 05.03.2009
name BF300 C service (b) page 9
appr. 300C_hy_schematic_2009_03_17.VSD
amendment date name date page 10
322
T

Y 194
16.1

a1
P

Load sensing
signal

M A1.1 A1.2

M
X

service stand by:

25ba

25 bar

M
B 150 bar

BOMAG
see page [1]

page [8] page [8] page [8] page [9]

valve-no 4 (P) valve-no 3 (P) valve-no 2 (P) valve-no 1 (P1)
(LCS) (crown adj.) (screed ext)

S L1 L

0 1 2 3 4 5 6 7 8 9
drawing number scale

008 922 07
Hydraulic diagram

name H. Christ
ed. by 83783111
date 05.03.2009
BF300 C service (c) page
name 10
appr. 300C_hy_schematic_2009_03_17.VSD
amendment date name date page 10
 16.2 Electric circuit diagrams
2

008 922 07 BOMAG 323

16.2 Electric circuit diagrams

324 BOMAG 008 922 07

 %RPDJ*PE+

008 922 07
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