Service - Manual

BW 24 RH
S/N 101 538 01 .... S/N 101 538 30 ....S/N 861 538 21 ....

Rubber tire roller

Catalogue number.
008 915 04 10/2013
 Table of Contents

General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 26
Pneumatic tires rollers 31
2.1 Rubber tire roller 32
Technical data 35
3.1 Technical data 36
Maintenance 41
4.1 General notes on maintenance 42
4.2 Fuels and lubricants 43
4.3 Table of fuels and lubricants 46
4.4 Running-in instructions 47
4.5 Maintenance table 48
Electrics 51
5.1 Level sensor in diesel tank (R03) 52
5.2 Differential pressure switches hydraulic oil filter, B21and B22 52
5.3 Brake oil temperature switch, B148 53
5.4 Brake pressure switches, B12 and B102 53
5.5 Float switch in water tank, B33 54
5.6 Oil pressure switch, B06 55
5.7 Coolant temperature switch, B152 56
5.8 Sensor (B124), water in fuel filter 58
5.9 Air filter vacuum switch, B03 59
5.10 Charge control light, operating hour meter 59
5.11 Fuel preheating, R79 60
5.12 Glow plugs 61
5.13 Engine solenoid to shit down the engine, Y13 62
5.14 Boost fuel solenoid valve, Y01 63
5.15 Engine monitoring 64
5.16 Batteries 66
5.17 Battery service, checking the main battery switch 70
5.18 Main battery switch 71
5.19 Generator 71
5.20 Replacing the voltage regulator 81
5.21 Electric starter 83
5.22 Overview of electric components 89
5.23 Fuse, cabin 106
5.24 Fuses 107
5.25 Main battery fuse 108
5.26 Modules 108
Electronic modules 111
6.1 Module description A04 113
6.2 Electric module A72, old design 123
6.3 Electric module A108 129

008 915 04 BOMAG 3

Table of Contents

Module description A100 133

7.1 Steering column locking module, A100 134
Speedometer Module 137
8.1 Speedometer module 138
Hydraulics 141
9.1 Overview 142
9.2 Hydraulic circuit 144
9.3 Travel pumps, A4VG105 DA 146
9.4 Troubleshooting axial piston pumps 155
9.5 External gear pumps 158
9.6 Travel motor, A6VM 107HA2R1 160
9.7 Trouble shooting, variable displacement axial piston motor 163
9.8 Steering valve 165
9.9 Travel circuit 166
9.10 Steering circuit 172
9.11 Cooling and cross-flushing of the brake housing 175
9.12 Edge cutter 177
9.13 Check the hydraulic oil level 179
9.14 Replace hydraulic oil and breather filter. 180
9.15 Replace hydraulic oil filter 181
9.16 Replacing the bypass filter 182
Brake 183
10.1 Overview 184
10.2 Brake system 185
10.3 Stopping the machine, operating the parking brake 192
10.4 Driving the machine / braking the machine 193
10.5 Multi-disc brake, function test 196
10.6 Towing in case of an engine failure 197
Pneumatics 199
11.1 Overview 200
11.2 Pneumatic system 201
11.3 Operating the tire inflation system 209
11.4 Draining the air pressure vessel 210
11.5 Change the air drier for the brake system 211
11.6 Check the supply lines for the compressor 211
Engine 213
12.1 Description of engine 214
12.2 Lubrication oil circuit TCD 2012 / 2013 217
12.3 Coolant circuit TCD 2012 / 2013 218
12.4 Exhaust gas recirculation 219
12.5 Adjust the valve clearance 220
12.6 Check the engine oil level 221
12.7 Changing engine oil and oil filter 221
12.8 Change the fuel filter, bleed the fuel system 222
12.9 Check, clean the water separator 224
12.10 Checking the coolant level 225
12.11 Check the anti-freeze concentration and the condition of the coolant 226

4 BOMAG 008 915 04

 Table of Contents

12.12 Replacing the coolant 227

12.13 Clean the cooling fins on engine and hydraulic oil cooler 228
12.14 Checking ribbed V-belts and compressor V-belts 229
12.15 Replacing ribbed V-belt and idler pulley 230
12.16 Air filter maintenance 230
12.17 Replace the injection valves 233
12.18 Replace crankcase ventilation valve 233
12.19 Check the engine mounts 234
12.20 General trouble shooting chart TCD 2012 / 2013 235
12.21 Special tools, Deutz engine (TCD 2012 2V) 237
Air conditioning system 253
13.1 Physical basics 254
13.2 Refrigerant R134a 257
13.3 Compressor oil / refrigeration oil 258
13.4 Working principle of the air conditioning system 259
13.5 Monitoring devices 259
13.6 Description of components 260
13.7 Measuring the compressor oil level 266
13.8 Checking the magnetic clutch 266
13.9 Inspection and maintenance work 267
13.10 Checking, replacing the refrigerant compressor V-belt 268
13.11 Service the air conditioning 269
13.12 Drying and evacuation 271
13.13 Emptying in case of repair 272
13.14 Leak test 272
13.15 Filling instructions 273
13.16 Trouble shooting in refrigerant circuit, basic principles 276
13.17 Trouble shooting, refrigerant circuit diagram 280
13.18 Trouble shooting procedure 281
13.19 Steam table for R134a 291
Replacing the cab window panes 297
14.1 Assembly of window panes 298
14.2 Special tools, cabin windows 299
14.3 Auxiliary materials 300
14.4 Removing and installing the window pane 302
Front axle 307
15.1 Repair overview for front axle 308
15.2 Dismantling the front axle 309
15.3 Assembling the front axle 316
Suppliers documentation 339
16.1 Travel pump 341
16.2 Travel motor 383
16.3 Travel gear 437
16.4 Steering valve 511
Circuit diagrams 545
17.1 Hydraulic diagram 538 110 00 547
17.2 Pneumatic diagram 538 120 00 551

008 915 04 BOMAG 5

Table of Contents

17.3 Wiring diagram 538 100 03 555

17.4 Wiring diagram 25 577

6 BOMAG 008 915 04

 1 General

008 915 04 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 008 915 04

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.
008 915 04 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.
008 915 04
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.
008 915 04 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.
Air conditioning system
!Caution
Work on air conditioning systems must only be
carried out by persons who can provide sufficient
evidence of their ability (proof of professionalism)
and only with the appropriate technical equip-
ment.
l
Always wear goggles and protective clothing when
performing maintenance and repair work on air con-
ditioning systems. Refrigerant withdraws heat from
the environment when evaporating, which can
cause injury by freezing when in contact with skin
(boiling point of R134a -26,5 °C at normal pres-
sure).
l Perform maintenance and repair work on air condi-
tioning systems only in well ventilated rooms! Es-
caping refrigerant vapours will mix with the ambient
air and displace the oxygen required for breathing
(danger of suffocating).
l Smoking is prohibited when performing mainte-
nance and repair work on air conditioning systems!
Toxic breakdown products may be generated if re-
frigerant comes into contact with heat.
l Refrigerant should always be extracted and re-
moved by flushing with nitrogen before starting
welding or soldering work near components of the
12 BOMAG
Safety regulations
air conditioning system. The development of heat
may cause the refrigerant to develop toxic and high-
ly corrosive breakdown products.
l Pungent smell! The toxic substances, which are re-
sponsible for the pungent smell, must not be in-
haled, since this may cause damage to the
respiratory system, the lung and other organs. Ex-
tract toxic breakdown products with a suitable ex-
traction system (workshop extraction system).
l
When blowing out components with compressed air
and when flushing with nitrogen the gas mixture es-
caping from the components must be extracted via
suitable extraction facilities (workshop extraction
systems).
Handling pressure vessels
l Since the fluid container is pressurized, the manu-
facture and testing of these pressure vessels is gov-
erned by the pressure vessel directive. The
pressure vessels must be repetitively tested by an
expert as specified in TRB 532 Inspection by Ex-
perts, Repetitive Tests. In this case periodically re-
curring inspections consist of external
examinations, normally on containers in operation.
In combination with the inspection, the refrigerant
collector must be visually examined two times per
year. Special attention must thereby be paid to
signs of corrosion and mechanical damage. If the
container is in no good condition, it should be re-
placed for safety reasons, in order to protect the op-
erator or third parties against the dangers when
handling or operating pressure vessels.
l
Secure pressure vessels against tipping over or roll-
ing away.
l
Do not throw pressure vessels! Pressure vessels
may thereby be deformed to such an extent, that
they will crack. The sudden evaporation and escape
of refrigerant releases excessive forces. This ap-
plies also when snapping off valves on bottles. Bot-
tles must therefore only be transported with the
safety caps properly installed.
l
Refrigerant bottles must never be placed near heat-
ing radiators. Higher temperatures will cause higher
pressures, whereby the permissible pressure of the
vessel may be exceeded.
l Do not heat up refrigerant bottles with an open
flame. Excessive temperatures can damage the
material and cause the decomposition of refriger-
ant.
l
Do not overfill refrigerant bottles, since any temper-
ature increase will cause enormous pressures.
Environment
It is strictly prohibited to release refrigerant into
the atmosphere during operation, maintenance
008 915 04
Safety regulations
and repair work and when taking air conditioning
systems into or out of service.
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.
1.2
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.

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.
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.

008 915 04 BOMAG 13

1.3 General repair instructions

General Electrics
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.
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!

14 BOMAG 008 915 04

General repair instructions 1.3
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.

008 915 04 BOMAG 15

1.3
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.
16 BOMAG
General repair instructions
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.
008 915 04
General repair instructions
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.
008 915 04
1.3
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 17
1.3
Air conditioning system
Chemicals/ozone layer regulation
The chemicals/ozone layer regulation, which became
effective on 01.12.2006, supplements the still directly
applicable regulation (EG) no. 2037/2000 from
29.06.2000 concerning substances, which cause de-
composition of the ozone layer and at the same time
replaces the previously valid German CFC-halon
0prohibition from 06.05.1991.
Work on air conditioning systems must only be carried
out by persons who:
l have proven to have sufficient expert knowledge,
l have the necessary equipment to undertake such
tasks,
l are reliable and
l are not any directives regarding their activities when
carrying out inspection and maintenance work acc.
to § 4 section 2 of the chemical/ozone layer regula-
tion.
The inspection and maintenance tasks, including leak
tests and possible repair activities, must be recorded
in the operating instructions together with information
about the refrigerant quantities used and regained,
whereby the operator is obliged to keep these records
over a period of at least five years.
i Note
Cleanliness is of utmost importance. Dirt and other
contaminations must strictly be kept out of the system.
l Tools used on refrigeration circuits must be of ex-
cellent condition, thus to avoid the damage of any
connections.
l
During repairs on refrigerant lines and components,
these must be kept closed, as far as this is possible,
to prevent the system from being contaminated by
air, moisture and dirt. The operational safety of the
system can only be assured as long as all compo-
nents in the refrigerant circuit are kept internally
clean and dry.
l Connections, screw fittings and their immediate sur-
rounding 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 All parts to be reused should be cleaned with a
gasoline free solvent and blow-dried with clean
compressed air or dried with a lint-free cloth.
l Before opening all components should have
warmed up to ambient temperature, to avoid that
damp air is drawn into the component by the differ-
ence in temperatures.
18 BOMAG
General repair instructions
l Damaged or leaking parts of the air conditioning
must not be repaired by welding or soldering, but
must generally be replaced.
l Do not fill up refrigerant, but extract existing refrig-
erant and refill the system.
l Different types of refrigerant must not be mixed.
Only the refrigerant specified for the corresponding
air conditioning system must be used.
l Refrigerant circuits with refrigerant type R134a
must only be operated with the compressor oil / re-
frigeration oil approved for the compressor.
l Used compressor oil/refrigeration oil must be dis-
posed of in strict compliance with applicable envi-
ronmental regulations.
l Due to its chemical properties compressor oil / re-
frigeration oil must never be disposed of together
with engine or transmission oil.
l Compressor oil / refrigeration oil is highly hydro-
scopic. Oil cans must strictly be kept closed until
use. Oil rests should not be used, if the can had
been opened over a longer period of time.
l
All O-rings/seal rings as well as pipe/ hose fittings
must be oiled with compressor/refrigeration oil bfore
assembly.
l
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil/refrigeration oil
lost by exchanging the components, must be re-
placed with fresh oil.
l
A too high compressor oil / refrigeration oil level ad-
versely affects the cooling performance and a too
low oil level has a negative effect on the lifetime of
the compressor.
l
Use new O-rings or seal rings for reassembly.
l
Always used 2 spanners to work on pipes/hoses to
avoid damages .
l Tighten screw fittings with the specified torque.
l
Check all pipes/hoses, screw fittings or components
for damage, replace if necessary.
l Do not leave the refrigerant circuit unnecessarily
open to the atmosphere.
l
In case of a repair on the refrigeration system you
should first evacuate the air conditioning system for
at least 45 minutes to remove any moisture from the
system, before you start to refill. Moisture bonded in
the compressor oil / refrigeration oil (PAG oil) can
only be removed from the system by changing the
oil.
l Compressor valves must only be opened after the
system has been properly sealed.
l The use of leak detection spray is not permitted. If
such substances are used the WARRANTY will be-
come null and void.
008 915 04
General repair instructions 1.3
l If the air conditioning system had been opened for Fuel hoses
repair work, a new drier should be installed in the re-
frigerant circuit.
l After completion of repair work screw locking caps
(with seals) on all valve connections service con-
nections.
l Before start up of the air conditioning system after a
new filling: - Turn the compressor approx. 10 revo-
lutions by hand using the clutch or V-belt pulley of
the magnetic clutch. - Start the engine with the com-
pressor/control valve switched off. - Once the idle
speed of the engine has stabilized switch on the
compressor and run it for at least 10 minutes at idle Fig. 1
speed and maximum cooling power.
l Never run the compressor with an insufficient ! Caution
amount of refrigerant. 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.

008 915 04 BOMAG 19

1.3 General repair instructions

Gaskets and mating surfaces able, you should use a plastic tube or adhesive tape
to prevent the sealing lip from being damaged.
Leaking sealing faces can mostly be traced back to in-
correct assembly of seals and gaskets. l Lubricate the outer rim (arrow 3 (Fig. 2)) of the seal
l Before assembling a new seal or gasket make sure and press it flat on the housing seat.
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 Fig. 3
threaded bores.
l
Press or knock the seal into the housing, until it is
l
Examine the contact faces for scratches and burrs, flush with the housing surface.
remove these with a fine file or an oilstone; take
care that no grinding dust and dirt enters into
tapped bores or enclosed components. i Note
If possible, use a "bell" (1 (Fig. 3)), to make sure that
l
Blow out lines, ducts and gaps with compressed air,
the seal will not skew. In some cases it may be ad-
replace any O-rings and seals that have been dis-
visable to assemble the seal into the housing first, be-
lodged by the compressed air.
fore sliding it over the shaft. Under no circumstances
Assembly of radial seals 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.

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-

20 BOMAG 008 915 04

General repair instructions 1.3
Feather keys and keyways Ball and roller bearings

Caution
! !Caution
Feather keys may only be reused if they are free of Ball and roller bearings may only be reused if they
damage. are free of damage and do not show any signs of
wear.

Fig. 4
l Clean and thoroughly examine the feather key.
l Deburr and thoroughly clean the edges of the key-
way with a fine file before reassembling.

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.

008 915 04 BOMAG 21

1.3
l Check shaft and bearing housing for discolouration
or other signs of movement between ball or roller
bearing and seats.
l Make sure that shaft and housing are free of burrs
before assembling the ball or roller bearing.
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).
22 BOMAG
General repair instructions
Screws and nuts
Tightening torque
!Caution
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
by a quarter turn and then tighten to the correct
torque.
l Before tightening you should lightly oil the thread, in
order to ensure low friction movement. The same
applies for self-locking nuts.
l Make sure that no oil or grease will enter into blind
tapped bores. The hydraulic power generated when
turning in the screw could cause breakage of the ef-
fected part.
008 915 04
General repair instructions
Strength classes, metric screws
The strength classes (from 3.6 to 12.9) are specified
for all strength classes from a nominal diameter of
5mm. The corresponding identification can be found
where allowed for by the shape of the screw.
Fig. 7 Identification of screws
Example: A screw is identified with 12.9.
The first number corresponds with 1/100 of the nomi-
nal tensile strength (minimum tensile strength) in N/
mm2.
l
The nominal tensile strength is 12 X 100 N/mm2 =
1200 N/mm2.
The second number specifies 10-times the ration be-
tween lower yield point and nominal tensile strength
(yield point ratio).
i Note
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas-
tic deformation).
When exceeding the upper yield point the material will
not restore its original shape after being relieved.
l The lower tensile strength is 9/10 X 1200 N/mm2 =
1080 N/mm2.
i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.
008 915 04 BOMAG
1.3
Strength classes of metric nuts
Nuts are differentiated by three load groups. Each
load group has a special designation system for the
strength class assigned, so that the load group can be
clearly identified.
Nuts for screw joints with full load capability (4, 5,
6, 8, 10, 12)
Fig. 8 Identification of nuts
In a connection with a screw, these nuts 1 (Fig. 8)
must be able to bear the full pre-load at the yield point.
Nut height above 0.8 d (d = nominal dimension).
Strength class of Strength class of associated
nut screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
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).
23
1.3 General repair instructions

Identification in clock system Identification of UNF-threads

Fig. 9 Identification of nuts in clock system

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).
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).

24 BOMAG 008 915 04

General repair instructions 1.3
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.

008 915 04 BOMAG 25

1.4 Tightening torques

The values specified in the table apply for screws:

1.4 Tightening torques

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

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

Tightening torques for screws with metric unified 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

26 BOMAG 008 915 04

Tightening torques 1.4
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

008 915 04 BOMAG 27

1.4 Tightening torques

The values specified in the table apply for screws:

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

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

Tightening torques for screws with UNC thread, * 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

28 BOMAG 008 915 04

Tightening torques 1.4
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

008 915 04 BOMAG 29

1.4 Tightening torques

30 BOMAG 008 915 04

 2 Pneumatic tires rollers

008 915 04 BOMAG 31

2.1 Rubber tire roller

2.1 Rubber tire roller

Flexible and economical compaction

Drive concept: efficient and reliable
BOMAG pneumatic tired rollers BW 24 RH / BW 27 RH combine conventional compaction technology with a
state-of-the-art hydrostatic drive. For this purpose the rear axle is replaced by two hydraulic motors. This is effi-
cient and optimizes operating and maintenance costs.

Automotive control
The pneumatic tired roller is driven via throttle pedal and brake, just like a motor car. The hydrostatic drive ad-
ditionally enables a very sensitive travel control. This is very import for the realization of jerk-free reversing. How-
ever, new trends have also been set with respect to safety: e.g. by the dynamic service brakes. These are
maintenance free, highly durable and supplement the hydrostatic braking effect.

Areas of application
BOMAG pneumatic tired rollers are employed for all typical compaction tasks. These include:
l Earth and asphalt construction
l Compaction of stabilized soil layers
l
Compression of chipping in surface treatment

Kneading and flexing effect of the wheels

With the kneading and flexing effect of their wheels pneumatic tired rollers achieve a special quality in compac-
tion. This achieves a particularly homogeneous compaction with excellent sealing of pores on the surface. The

32 BOMAG 008 915 04

Rubber tire roller 2.1
high weight of the rollers (up to 27 t) generates vertical pressure combined with horizontal forces to all directions
under the wheels.

Fig. 12

Flexible weight adaptation

The BOMAG rollers BW 24 RH and BW 27 RH can be flexibly adapted to the corresponding compaction task.
Various ballasting modes can be used for this purpose. The rollers can be pre-ballasted with individual weight
(which are pushed in below the frame). The large ballast compartment (approx. 3.5 m3) can be filled with sand
or scrap steel for flexible weight adjustment. The version with water tight welded frame (option) can also be filled
with water.

The correct contact pressure

Air pressure too high Correct air pressure Air pressure too low

Fig. 13 Tire pressure

The success of compaction is mainly determined by a correct contact pressure. For this purpose the tire pres-
sure can be varied from 2 - 8 bar. High air pressure for a better depth effect of compaction - important for eco-
nomical processing of thick soil or asphalt layers. For thin surface layers you should considerably lower tire
pressures. The air pressure is generally set in such a way, that a level tire contact are is achieved. An arched
profile should be avoided.

008 915 04 BOMAG 33

2.1 Rubber tire roller

Even weight distribution to each individual wheel.

Tipping resistant design with level compensation

Fig. 14

34 BOMAG 008 915 04

 3 Technical data

008 915 04 BOMAG 35

3.1 Technical data

3.1 Technical data

Fig. 15

Dimensions in A B H H2 K L W
mm
Dimensions in
inches
BW 24 RH 3700 2110 2840 3090 300 4940 2042
145.7 83.1 111.8 121.7 11.8 194.5 80.4

*
BW 24 RH
Weights
Operating weight (CECE) with ROPS-cabin kg (lbs) 8800 (19400)
Max. operating weight kg (lbs) 24300 (53570)
Max. mean Wheel load (CECE) kg (lbs) 3000 (6614)

Travel characteristics
Travel speed (1) km/h (mph) 0-7.1 (0-4.4)
Travel speed (2) km/h (mph) 0-10.5 (0-6.5)
Travel speed (3) km/h (mph) 0-20 (0-12.4)
Max. gradability % 30

Engine
Engine manufacturer Deutz
Type TCD 2012 L04 2V
Cooling Water
Number of cylinders 4
Rated power ISO 14396 kW 74.9
Rated power SAE J 1995 hp 100.4
Rated speed rpm 2300
Electrical equipment V 12
Drive system hydrostatic
Driven axles rear

brakes
Service brake pneumatic/hydraulic

36 BOMAG 008 915 04

Technical data 3.1
*
BW 24 RH
Parking brake Spring accumulator

Steering
Type of steering 2 point pivot steering
Steering operation hydrostatic
Steering angle +/- ° 30
Oscillation of front wheels ° 4
Level compensation mm (in) 100 (3.9)
Inner track radius mm (in) 5320 (209.4)

Tires
Tire size 11.00-20 18 PR
Air pressure min./max. bar (psi) 2-8.1 (29-117.5)

Filling capacities
Water l (us gal) approx. 400 (105.7)
Fuel l (us gal) approx. 250 (66)
Ballast compartment volume m3 (ft3) approx. 3.5 (123.6)
Engine oil l (us gal) approx. 15.5 (4.1)
Hydraulic oil l (us gal) approx. 60 (15.9)
Coolant l (us gal) approx. 20 (5.3)
* The right for technical modifications remains reserved

Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 900
High idle speed rpm 2300 - 2350
Spec. fuel consumption g/kWh 222
Valve clearance intake ° / mm 75° (0.3mm)
Valve clearance exhaust ° / mm 120° (0.5mm)

Replace/repair
Manufacturer Bosch-Rexroth
Type A4VG 105 DA
System Axial piston/swash plate
Max. displacement cm3/rev 105
Max. flow capacity l/min 241.5
High pressure limitation bar 480-20
Pressure override bar 430+10/-20
Charge pressure, high idle bar 30 ± 2
Absolute pressure at control start bar 50
Absolute pressure at control end bar 400

Travel motor
Manufacturer Bosch-Rexroth
Type A6VM107HA2R1
Quantity 2
System Axial piston – bent axle
Displacement (stage 1) cm3/rev 107
Displacement (stage 2) cm3/rev 36.5
Flushing quantity with flushing and l/min 8
charge pressure valve
Control start change-over bar 240
Control end change-over bar 315

008 915 04 BOMAG 37

3.1 Technical data

Perm. leak oil rate l/min 4

Steering/charge pump
Type AZPF-22-016R
System Gear
Displacement cm3/rev 16
Max. steering pressure bar 175 ± 10

Travel gears
Manufacturer Bonfiglioli
Type 606Y
Quantity 2
Reduction ratio 32

Steering valve
Type OSPC 250 LS
System Rotary valve

Front axle
Toe-in mm 2±1

Tables
The following tables show the dependence on area pressure and area for a given load and the adjusted
air pressure for tire size 11.00-20 18PR Compactor Smooth.

Weight of Wheel Tire pressure bar (psi)

machine kg load kg 3 (44) 4 (58) 5 (73) 6 (87) 7 (102) 8 (116)
(lb) (lb)
10400 1300 3,2 (45) 3,4 (48) 3,6 (52) 3,9 (55) 4,2 (60) 4,5 (64)
(22928) (2866)
12000 1500 3,4 (84) 3,6 (51) 3,8 (55) 4,1 (58 4,3 (62) 4,6 (65)
(26455) (3307)
16000 2000 3,8 (54) 4,0 (57) 4,3 (61) 4,6 (66) 4,7 (67) 5,0 (71)
(35274) (4409)
20000 2500 4,1 (59) 4,4 (62) 4,7 (66) 4,9 (70) 5,1 (72) 5,4 (77)
(44092) (5512)
24000 3000 4,4 (62) 4,7 (66) 5,0 (71) 5,4 (76) 5,6 (79) 5,9 (83)
(52911) (6614)
27000 3750 4,5 (64) 4,8 (69) 5,1 (73) 5,5 (79) 5,8 (82) 6,1 (86)
(59525) (3375)

Table of average area pressure kg/cm2 (lb/in2)

38 BOMAG 008 915 04

Technical data 3.1

Weight of Wheel Tire pressure bar (psi)

machine kg load kg 3 (44) 4 (58) 5 (73) 6 (87) 7 (102) 8 (116)
(lb) (lb)
10400 1300 409 (63) 385 (60) 358 (55) 335 (52) 310 (48) 292 (45)
(22928) (2866)
12000 1500 442 (69) 416 (64) 390 (60) 365 (57 345 (53) 328 (51)
(26455) (3307)
16000 2000 530 (82) 495 (77) 464 (72) 434 (67) 425 (66) 398 (62)
(35274) (4409)
20000 2500 605 (94) 570 (88) 537 (83) 507 (79) 495 (77) 463 (72)
(44092) (5512)
24000 3000 688 (107) 642 (93) 600 (93) 560 (87) 540 (84) 512 (79)
(52911) (6614)
27000 3750 748 (116) 700 (109) 660 (102) 610 (95) 585 (91) 555 (86)
(59525) (3375)

Table of effective area cm2) (in2)

008 915 04 BOMAG 39

3.1 Technical data

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 = 77 dB(A), determined acc. to ISO 11204 and EN 500

Guaranteed sound power level:

LWA = 103 dB(A), determined acc. to ISO 3744 and EN 500

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

Hand-arm vibration values

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

40 BOMAG 008 915 04

 4 Maintenance

008 915 04 BOMAG 41

4.1
4.1 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 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 motor
switched off.
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.
42 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.
Coolant is prepared by adding an ethylene-glycol
based anti-freeze agent with corrosion inhibiting prop-
erties to the cooling water.
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.
008 915 04
Fuels and lubricants 4.2
4.2 Fuels and lubricants

Engine oil
Quality
For use in DEUTZ engines the lubrication oils are
classified in DEUTZ Lubrication Oil Quality Classes
(DQC).

Approved engine oils

Deutz ACEA* API** DHD

DQC II-05 or E3-96, CG-4, DHD-1

DQC II-10 E5-02, CH-4,
E7-08, CI-4,
E4-07, CI-4 Plus,
E6-04, CJ-4
E9-08

DQC III-05 or - - -
DQC II-10

DQC IV-05 - - -
or DQC II-10
* Association des Constructeurs European d’Automobiles
** American Petroleum Institute

The list of approved lubrication oils is also available in

the Internet under the following address:
www.deutz.com
de >>SERVICE >> Betriebsstoffe und Addi-
tive >> DeutzQualityClass >> DQC-Freiga-
beliste
en >>SERVICE >> Operating Liquids and Ad-
ditives >> DeutzQualityClass >> DQC Re-
lease List
Consult your local service station if in doubt.
l
Use winter grade engine oil for winter operation!
Oil viscosity
Since lubrication oil changes its viscosity with the tem-
perature, the ambient temperature at the operating lo-
cation of the engine is of utmost importance when
choosing the viscosity class (SAE-class) .
Too high viscosity can cause starting difficulties, too
low ´viscosity can jeopardize the lubrication effect and
result in a high lubrication oil consumption.
Fig. 16
Optimal operating conditions can be achieved by us-
ing the oil viscosity chart (Fig. 16) as a reference.
At ambient temperatures below -40 °C (-58 °F) the lu-
brication oil must be pre-heated (e.g. by parking the
machine indoors).
The viscosity is classified acc. to SAE. Multi-purpose
oils should generally be used.
Oil change intervals
The longest permissible time a lubrication oil should
remain in an engine is 1 year. If the following oil
change intervals are not reached over a period of 1
year, the oil change should be performed at least once
per year, irrespective of the operating hours reached.
DQC II, DQC III, DQC IV: 500 operating hours
! Caution
When using fuels with a sulphur content of more
than 0.5% to 1% or under permanent ambient tem-
peratures below -10 °C (14 °F) and when using bi-
odegradable diesel fuel the oil change intervals
must be halved.

Fuels
You should only use commercially available brand
diesel fuel with a sulphur content of less than 0.5%
and ensure strict cleanliness when filling in. A higher

008 915 04 BOMAG 43

4.2 Fuels and lubricants

sulphur content has a negative effect on the oil

change intervals. Fresh water analysis values

The fuel level should always be topped up in due time Conversion to other units:
so that the fuel tank is never run dry, as otherwise filter
and injection lines need to be bled. - German degree (°dH)] max. 20

Quality - English degree (°eH)] max. 25

The following fuel specifications are permitted: - French degree (°fH)] max. 36.5
l
EN 590
corresponds with the content of max. 356
l
DIN 51628 CaCO3 (mg/l) (ppm)
l
ASTM D975 Grade-No. 1-D and 2-D.
l
JIS K 2204 Grade Fuel 1 and Grade Fuel 2 with lu- Information concerning the water quality can be ob-
brication properties acc. to EN 590 tained from the waterworks.

Winter fuel
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. Diesel
fuels suitable for temperatures down to -44 °C (-47
°F) are available for Arctic climates. At very low tem-
peratures disturbing paraffin separation can also be
expected when using winter diesel fuel.
The admixture of petroleum and the addition of "flow
enhancing additives" (fuel additives) is not permitted.
Coolant
For fluid cooled engines the cooling fluid must be pre-
pared by admixing a cooling system protection agent
to the fresh water and should be checked within the
specified maintenance intervals.
This prevents damage caused by corrosion, cavita-
tion, freezing and overheating.
Fresh water quality
The correct quality of water is highly important when
preparing coolant. Clear and clean water within the
boundaries of the following analysis values should
generally be used.
Fresh water analysis values
pH-value at 20 °C (68 °F) 6.5 - 8.5
Chloride ion content (mg/l) (ppm) max. 100
Sulphate ion content (mg/l) max. 100
(ppm)
Water hardness (ion content of max. 3.56
calcium and magnesium )
(mmol/l)]
If the fresh water analysis values are unknown, these
must be determined with the help of a water analysis.
If the values of the analysis deviate, the water must be
treated accordingly.
l pH-value too low
Adding of caustic lye of soda or caustic potash so-
lution.
l
Water hardness too high:
Mix with soft, distilled or fully demineralized water
l
Chlorides and/or sulphates too high:
Mix with distilled or fully demineralized water
l
Total hardness or carbonate hardness too low:
Mix with hardened water (harder water is in most
cases available in the form of drinking water).
!Caution
Another analysis must be made after the fresh wa-
ter has been prepared.
Cooling system protection agent
As a protection against frost, corrosion and boiling
point anti-freeze agents must be used under any cli-
matic conditions.
Coolant for fluid cooled engines is prepared by adding
an ethylene-glycol based anti-freeze agent with corro-
sion inhibiting properties to the cooling water.
We therefore highly recommend our BOMAG cooling
system protection agent.
If our cooling system protection agent is not available
for any important reasons, you may, in exceptional
cases, use products that have been approved by the
engine manufacturer.
The list of approved cooling system protection agents
is also available in the Internet under the following ad-
dress:

44 BOMAG 008 915 04

Fuels and lubricants
www.deutz.com
de >>SERVICE >> Betriebsstoffe und Addi-
tive >> Kühlsystemschutz >> Kühlsystem-
schutz Technisches Rundschreiben
en >>SERVICE >> Operating Liquids and Ad-
ditives >> Cooling System Conditioner >>
Flyer Cooling System Conditioner Techni-
cal Circular
Products of the same product group (see Deutz Tech-
nical Circular Cooling System Protection Agents) can
be mixed with each other.
The BOMAG cooling system protection agent corre-
sponds with product group A.
! Caution
Do not mix different coolants and additives of any
other kind.
Before changing the product you must clean the
entire cooling system.
Consult your local service station if in doubt.
To ensure proper corrosion protection you must use
the cooling system protection agent all year around,
whereby the following concentration must not be fall-
en short of or exceeded.
Mixing ratio
4.2
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).
Bio-degradable hydraulic oil
The hydraulic system can also be operated with a syn-
thetic ester based biodegradable hydraulic oil.
The biologically quickly degradable hydraulic oil Pan-
olin HLP Synth.46 meets all demands of a mineral oil
based hydraulic oil according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.46
always use the same oil to top up.
When changing from mineral oil based hydraulic oil to
an ester based biologically degradable oil, you should
consult the lubrication oil service of the oil manufactur-
er for details.
! Caution
Check the filter more frequently after this change.
Perform regular oil analyses for content of water
and mineral oil.
Replace the hydraulic oil filter element every 500
operating hours.

Cooling sys- Fresh water Cold protec- Gear oil

tem protection tion down to For the gearboxes use only ,ulti-purpose gear oils ISO
agent VG 220 of API-GL5-class with a minimum viscosity of
20 mm2/s at 100 °C.
min. 35% 65% -22 °C (-8 °F)
This is a hypoid lubricant of highest quality class for
40% 60% -28 °C (-18 °F) extremely loaded transmissions.
The additives in this oil ensure low wear lubrication
45% 55% -35 °C (-31 °F)
under all operating conditions.
max. 50% 50% -41 °C (-42 °F)
Lubrication grease
! Caution For lubrication purposes use an EP-high pressure
A proportion of more than 50% of cooling system grease, lithium saponified (penetration 2), acc. to DIN
protection agent causes a drop in cooling power. 51502 KP 2G.

The use of corrosion protection oils as cooling

system protection agents is not permitted.

i Note
When working at temperature below -41 °C(-42 °F)
you should consult our local service representative.

Environment
Coolant must be disposed of environmentally.

008 915 04 BOMAG 45

4.3 Table of fuels and lubricants

4.3 Table of fuels and lubricants

Assembly Fuel or lubricant Quantity

Summer Winter Attention

Observe the level marks

Engine

- Engine oil ACEA: E3-96, E5-02, E7-08, E4-07, E6-08, E9-08 approx. 15.5 l (4.1 USgal)
API: CG-4, CH-4, CI-4, CI-4 Plus, CJ-4

SAE 10W-40 (-15 °C to +40 °C) (5 °F to 104 °F)

(BOMAG PN 009 920 06; 20 l)

SAE 15W-40 (-5 °C to +40 °C) (23 °F to 104 °F)

SAE 5W-40 (-30 °C to +40 °C) (-22 °F to 104 °F)

- Fuel Diesel Winter diesel fuel approx. 250 l (66 USgal)

- Coolant Mixture of water and anti-freeze agent approx. 20 l (5.3 USgal)

(see "Fuels and Lubricants - Colant")

Hydraulic system Hydraulic oil (ISO), HLP 46 approx. 60 l (15.9 USgal)

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

Travel gear/wheel hubs SAE 80W-140, API GL-5 approx. 7.5 l (2.0 USgal)
(BOMAG PN 009 925 07; 20 l) per side

Sprinkler system Water Anti-freeze mixture* approx. 400 l (106 USgal)

Ballast compartment Water Anti-freeze mixture* approx. 3500 l (925 US-

gal)

Lubrication points High pressure grease (lithium saponified) as required

Air conditioning system Refrigerant R134a approx. 1300 g (2.9 lb)

* Mix water and anti-freeze agent by following the instructions of the manufacturer

46 BOMAG 008 915 04

Running-in instructions 4.4
4.4 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.

Maintenance after 50 operating hours

l Check the engine for leaks
l Retighten bolted connections on intake and exhaust
tubes, oil sump and engine mounts
l Tighten the bolted connections on the machine
l Retighten the wheel studs

Maintenance after 250 operating hours

l Change engine oil and oil filter cartridge.
l 1. Changing oil travel gear/wheel hubs

Maintenance after 500 operating hours

l 2. Changing oil travel gear/wheel hubs

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

* Optional equipment

008 915 04 BOMAG 47

4.5 Maintenance table

4.5 Maintenance table

every 10 operating hours, daily

every 1000 oper. hours

every 2000 oper. hours

every 3000 oper. hours

every 6000 oper. hours

every 250 oper. hours

every 500 oper. hours

No. Maintenance work Comment

as required
5.6 Check 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 Check the water level Instrument cluster X
5.11 Check/adjust the scrapers X
5.12 Multi-disc brake, function test X
5.13 Drain the air pressure vessel X
5.14 Clean the cooling fins on engine and hy- X
draulic oil cooler
5.15 Check the oil level in the drive gear/ see foot note X
wheel hub
5.16 Change engine oil and oil filter cartridge* min. 1x per year X
see foot note
5.17 Check, clean the water separator when the "water in X
fuel" warning light
lights up
5.18 Check the anti-freeze concentration and X
the condition of the coolant
5.19 Drain the fuel tank sludge X
5.20 Battery service, check the main battery pole grease X
switch
5.21 Check, replace the refrigerant compres- X
sor V-belt
5.22 Service the air conditioning X
5.23 Clean the circulation air filter for the X
heating
5.24 Check hydraulic, pneumatic hoses and min. 1x per year X
electric cables
5.25 Change the fuel filter, bleed the fuel sys- X
tem

48 BOMAG 008 915 04

Maintenance table 4.5

every 10 operating hours, daily

every 1000 oper. hours

every 2000 oper. hours

every 3000 oper. hours

every 6000 oper. hours

every 250 oper. hours

every 500 oper. hours

No. Maintenance work Comment

as required
5.26 Check condition, tension of ribbed V- X
belts and compressor V-belt
5.27 Checking the engine mounts X
5.28 Retighten the wheel studs X
5.29 Checking the Roll Over Protective Struc- X
ture (ROPS/FOPS)
5.30 Changing the air drier for the brake sys- min. 1x per year X
tem
5.31 Check the travel control X
5.32 Adjust the valve clearance Intake valve: 75° X
+10°

Exhaust: 120° +10°

5.33 Change the oil in travel gear/wheel min. 1x per year X
hubs** see foot note
5.34 Changing hydraulic oil and breather fil- at least every 2 X
ter*** years
5.35 Replace hydraulic oil filter*** at least every 2 X
years
5.36 Replacing the coolant at least every 2 X
years
5.37 Check the supply lines for the compres- X
sor
5.38 Replace ribbed V-belt and idler pulley X
5.39 Replace the injection valves only by authorized X
service personnel
5.40 Replace crankcase ventilation valve X
5.41 Air filter maintenance when the air filter X
warning light lights
up
min. 1x per year
Safety cartridge at
least every 2 years
5.42 Service the water sprinkling system X
5.43 Maintenance in case of frost X

008 915 04 BOMAG 49

4.5 Maintenance table

every 10 operating hours, daily

every 1000 oper. hours

every 2000 oper. hours

every 3000 oper. hours

every 6000 oper. hours

every 250 oper. hours

every 500 oper. hours

No. Maintenance work Comment

as required
5.44 Fill the windscreen washer system X
5.45 Change the fresh air filter in the cabin X
5.46 Change the tires X
5.47 Check bolted connections for tight fit X
5.48 Temporary taking out of service X
* oil change after 250 and 500 operating hours, then every 500 operating hours
** Running-in instructions: oil change after 250, 500 and 1000 operating hours, then every 1000 operating hours
*** Also after repairs in the hydraulic system.

50 BOMAG 008 915 04

 5 Electrics

008 915 04 BOMAG 51

5.1 Level sensor in diesel tank (R03)

5.1 Level sensor in diesel tank 5.2 Differential pressure switches

(R03) hydraulic oil filter, B21and B22

Fig. 1

Fig. 1 1 B21, differential pressure switch hydraulic oil filter

(brake oil)
l
The analog level switch is a variable resistance to
2 B22, differential pressure switch hydraulic oil filter
ground.
(charge circuit)
3 B148, brake oil temperature switch
l The differential pressure switches (Fig. 1) switch to
ground at a pressure differential of Δ 3.6 bar.
Switching of one of the pressure switches connects
the monitoring board (A15, Pin17) to ground. The
warning light j (Fig. 2) lights.

Fig. 2
n = Fuel level gauge (P01)

Fig. 2 Monitoring board, A15

j yellow = lights when the hydraulic oil filter is con-
taminated. Check the hydraulic system,
change the hydraulic oil filter.

52 BOMAG 008 915 04

Brake oil temperature switch, B148 5.3
5.3 Brake oil temperature switch, 5.4 Brake pressure switches, B12
B148 and B102

Fig. 1 Fig. 1

1 B21, differential pressure switch hydraulic oil filter 1 B12, brake pressure switch (normally closed)
(brake oil) 2 B102, brake light pressure switch (normally open)
2 B22, differential pressure switch hydraulic oil filter
Pressure switch (B12)
(charge circuit)
3 B148, brake oil temperature switch
l
The pressure switch opens at a pressure higher
than 5.6±0.6 bar.
l
The temperature switch switches to ground at a
temperature above 120°C. The monitoring board (A15, pin 18) remains connect-
ed to ground, as long as the pressure is below this
If the brake oil temperature exceeds 120°C, the mon-
switching point. The warning light a (Fig. 2) lights.
itoring board (A15, Pin20) is connected to ground.
Warning lamp l (Fig. 2) flashes.

Fig. 2 Monitoring board, A15

Fig. 2 Monitoring board, A15
l red = flashes when the brake oil temperature
exceeds 120°C. The warning buzzer
sounds.
a red = lights in case of too low pressure in the
brake accumulator. The warning buzzer
sounds. Stop the machine and wait with
the engine running, until the warning light
goes out.

i Note
i Note
The warning buzzer is activated by the monitoring
The warning buzzer is activated by the monitoring
board (Pin23).
board (Pin23).

008 915 04 BOMAG 53

5.5 Float switch in water tank, B33

Pressure switch (B102) 5.5 Float switch in water tank, B33

l At a pressure of 5 bar the pressure switch will
switch to ground.
When the pressure switch (B102) switches, relay
(K36) will switch on the brake lights (E33) and (E34).

Fig. 1 Float switch (normally closed)

In case of a too low water level the float switch will
switch to ground.
With the sprinkling system switched on (relay K104
switched) and a lack of water, the monitoring board
(A15, Pin19) is connected to ground. The water tank
filling level warning light d (Fig. 2) lights.

54 BOMAG 008 915 04

Oil pressure switch, B06 5.6
5.6 Oil pressure switch, B06

Oil pressure monitoring

Fig. 2 Monitoring board, A15

d yellow = Waning light for water tank filling level.
Lights if the water level in the tank is too
low.
Fig. 3 Oil pressure switch (normally closed)
Warning light, engine oil pressure
With a too low engine oil pressure the monitoring
board (A15, Pin17) is connected to ground. Warning
lamp e (Fig. 4)flashes.

Fig. 4 Monitoring board, A15

e red = Warning light, engine oil pressure
Flashes when the engine oil level is too
low, the warning buzzer sounds, the en-
gine is shut down after 10 seconds.

i Note
The warning buzzer is activated by the monitoring
board (Pin23).
The engine is shut down by the monitoring board
(Pin24) via relay (K22).

Disassembling the pressure switch

! Caution
Ensure absolute cleanliness when working in the
lubrication oil system.
Thoroughly clean the area around the affected
component. Dry off wet locations with com-
pressed air.

008 915 04 BOMAG 55

5.7 Coolant temperature switch, B152

Immediately close all connections and openings 5.7 Coolant temperature switch,
with new and clean plugs/caps.
B152
Only remove plugs/caps just before assembling.

Coolant temperature monitoring

Environment
Catch engine oil and dispose of environmentally.

Fig. 7 Coolant temperature switch (normally open)

Warning light, overheating of engine

With a too high coolant temperature the monitoring
Fig. 5
board (A15, Pin17) is connected to ground. Warning
l
Unlock and pull out the cable plug (Fig. 5). lamp i (Fig. 8)flashes.
l
Unscrew the oil pressure switch.

Assembling the pressure switch

Fig. 8 Monitoring board, A15

i red = Warning lamp, overheating of engine
flashes if the engine overheats, warning
Fig. 6 buzzer sounds.
l Insert the oil pressure switch with a new seal ring
and tighten. i Note
The warning buzzer is activated by the monitoring
i Note board (Pin23).
Tightening torque: 40 Nm
l Push on the cable plug.

56 BOMAG 008 915 04

Coolant temperature switch, B152 5.7
Disassembling the temperature switch Installing the temperature switch

Environment
Catch running out fluids in a suitable vessel and
dispose of environmentally.

i Note
Follow the corresponding documentation in the oper-
ating instructions to drain and fill the cooling system.

Fig. 11
l
Screw in the temperature switch (Fig. 11).

i Note
Fig. 9 Make sure that the seal rings are present .
l
Unlock and pull out the cable plug (Fig. 9). Tightening torque: 24 Nm.

Fig. 12
l Push on the cable plug (Fig. 12).

Fig. 10
l
Unscrew the temperature switch (Fig. 10).

008 915 04 BOMAG 57

5.8 Sensor (B124), water in fuel filter

5.8 Sensor (B124), water in fuel fil-

ter

2
2
2

2
Fig. 14 Monitoring board, A15
b yellow = Water in fuel warning light.
Lights when the water content in the fuel
pre-cleaner reaches the sensor contacts.
The warning buzzer sounds.

i Note

1 1 The warning buzzer is activated by the monitoring

board (Pin23).

Fig. 13

Warning light water in fuel filter

With water in the filter the sensor will switch to ground.
The water in fuel warning light b (Fig. 14) lights up.

58 BOMAG 008 915 04

Air filter vacuum switch, B03
5.9 Air filter vacuum switch, B03
Fig. 15 Vacuum switch (normally open)
Air filter warning light
The vacuum switch 1 (Fig. 15) operates at a vacuum
of > 50 mbar.
The switch contact connects the monitoring board
(A15, Pin16) to ground. The air filter warning light h
(Fig. 16) lights.
Fig. 16 Monitoring board, A15
h yellow = Air filter warning light.
Lights when the combustion air filter is
contaminated.
Clean or replace, as necessary.
008 915 04 BOMAG
5.9
5.10 Charge control light, operat-
ing hour meter
Fig. 1 Generator
1 Terminal W
2 Terminal D+
3 Terminal B+
Charge control light, H08
If the battery is not being charged, a ground signal is
applied to D+ terminal 2 (Fig. 1). Current flows from
the monitoring board (A15) through the charge control
light and through (Pin10) to the D+ terminal. The
charge control light g (Fig. 1) lights up.
Fig. 1 Monitoring board, A15
g yellow = Charge control light.
Lights if the battery is not being charged.
Operating hour meter, P00
When battery voltage is applied to the D+ terminal, the
operating hour meter will count the operating hours.
p = Operating hour meter.
Counts the operating hours while the
generator is rotating.
59
5.11 Fuel preheating, R79

RPM-meter* 5.11 Fuel preheating, R79

Terminal "W" on the generator delivers a pulsating di-
rect voltage, which can be utilized to determine the ro-
tary speed of the engine.

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

* Option ** Option

60 BOMAG 008 915 04

Glow plugs 5.12
5.12 Glow plugs Pre-heating control light

R81 to R84
The engines are optionally fitted with glow plugs as
cold starting aids. Preheating the glow plugs in the
combustion chamber of the diesel engine ensures
perfect cold starting and post-heating of the glow
plugs has a positive effect on the emissions from the
still "cold running" diesel engine (e.g. avoidance of
white smoke, noise reduction).

Fig. 2 Monitoring board, A15

c yellow = Pre-heating control light.
Lights when the ignition switch is in posi-
tion "Preheating or Start".

Fig. 1

Triggering of glow plugs

l
When the preheating control unit (K14) is energized
via terminal (17 and 50a) on the ignition switch, it
supplies the glow plugs with battery current and the
control light in the monitoring board (A15, Pin3) with
ground via relay (K86).

i Note
Relay (K14) and glow plug fuse (F48) are mounted on
the battery (G03).

008 915 04 BOMAG 61

5.13 Engine solenoid to shit down the engine, Y13

5.13 Engine solenoid to shit down Assembling the engine solenoid

the engine, Y13

General
When switching the ignition on, the engine solenoid is
supplied with 12 Volt.
Interrupting this power supply shuts down the engine.
The engine shut-down can be triggered through the
ignition switch (S00), the emergency stop button
(S01) or the monitoring board (A15) in case of too low
oil pressure (terminal X6:24).
Technical data: 12 Volt, 4 Ampere

Fig. 3
l Assemble a new O-ring (Fig. 3).
l Cover the O-ring slightly with oil.

Fig. 1

Disassembling the engine solenoid

l Pull the cable of the engine shut-down facility.

Fig. 4

Caution
!

Check the governor rod for light movement.

l Actuate the governor rod between start and stop
position (Fig. 4).

Fig. 2
l
Unscrew fastening screws 1 (Fig. 2).
l Remove the engine shut-down assembly.
l Check the components visually.

62 BOMAG 008 915 04

Boost fuel solenoid valve, Y01 5.14
5.14 Boost fuel solenoid valve, Y01
General
Technical data: 12 Volt, 3.5 Ampere
During the starting process the solenoid valve is sup-
plied with 12 Volt.
This injection adaptation serves the purpose of com-
pensating for condensation and leakage losses and
for rising the engine torque during the acceleration
phase after starting. For this compensation and to as-
sure starting of the cold engine additional fuel needs
to be injected at the time of starting and accelerating.

Fig. 5
l Force the governor rod to stop position and hold it
(Fig. 5).

Fig. 1

Fig. 6
l
Assemble the engine shut-down assembly (Fig. 6).
l Tighten the screws. Tightening torque 21Nm.
l Push the cable plug back onto the engine shut-
down assembly.

008 915 04 BOMAG 63

5.15 Engine monitoring

5.15 Engine monitoring

Fig. 1 Monitoring board, A15
Output warning buzzer, Pin 23: +UB switching.
Output engine shut down, Pin 24: +UB switching.
Tank gauge, Pin 1: (0Ω ⇒ tank full, 65Ω ⇒ tank emp-
ty, 26Ω ⇒ tank ½. If no level switch is connected or the
cable is broken, the gauge will go out.
Water separator, Pin 21 and 22: Resistance <500kΩ .

Pos. Designation Control light Warning Engine Engine Remedy

buzzer shut-down shut-down
time time

10 sec. 2 min.
i H49, control light en- red, flashing X X Run the engine with idle
gine overheating Low-active speed or shut it down if
necessary, clean engine
oil cooler and radiator, if
necessary repair engine.
e H09, engine oil pres- red, flashing X X Check the engine oil lev-
sure control light Low-active el, if necessary repair the
engine.
h H15, engine air filter not used
control light Low-active
g H08, charge control yellow, lights Check V-belt, if neces-
light High-active sary repair the generator
b H70, control light, wa- yellow, lights Check, clean the water
ter in diesel filter separator
c H52, pre-heating con- yellow, lights see chapter "Check heat-
trol light yellow, flash- ing flange control"
es in case of
fault
Low-active
f Option red, flashing X Option Fill up coolant
H73, coolant level Low-active

64 BOMAG 008 915 04

Engine monitoring 5.15
Checking the engine monitoring system l Push the plug back together, the plug interlock
clicks into place.
The following control lights and shut-down functions
can be checked with the engine running: l Check the plug interlock by lightly pulling on the wir-
ing loom.
Air filter
Engine oil pressure

Fig. 2 Pressure differential switch

Fig. 4 Oil pressure switch
l Press on the locking wire and pull the plug off the
differential pressure switch 1 (Fig. 2). l Press on the locking wire and pull off the plug (Fig.
4).
l
Bridge both contacts on the plug of the wiring loom.
l
Apply the contact to engine ground.

i Note
Control light h (Fig. 1) lights up. No audible will sound i Note
and the engine will not be shut down. Control light e (Fig. 1) flashes. An audible warning will
sound and the engine is shut down after 10 seconds.
l Push the plug back on, the plug interlock clicks into
place. l Push the plug back on, the plug interlock clicks into
place.
l Check the plug interlock by lightly pulling on the wir-
ing loom. l
Check the plug interlock by lightly pulling on the wir-
ing loom.
Water separator
Engine overheating

Fig. 3 Sensor plug on water separator

Fig. 5 Coolant temperature switch
l Press the plug interlock and disconnect the plug
(Deutsch plug) (Fig. 3).
l Press on the locking wire (Fig. 5) and pull off the
plug.
l Bridge both contacts on the plug of the wiring loom.
l Bridge both contacts on the plug of the wiring loom.

i Note
Control light b (Fig. 1) lights up.

008 915 04 BOMAG 65

5.16 Batteries

i Note 5.16 Batteries

Control light i (Fig. 1) flashes. An audible warning will
Battery – accumulator
sound and the engine is shut down after 2 minutes.
l
Push the plug back on, the plug interlock clicks into
place.
l Check the plug interlock by lightly pulling on the wir-
ing loom.

Emergency stop switch

Fig. 1
In vehicles batteries are used to start the engine. The
ability to start the engine depends on the charge con-
dition of the batteries.
Lead collectors or accumulators are secondary ele-
ments, i.e they can be recharged after discharging
electric current.
Fig. 6 Emergency stop switch The basic element of a lead accumulator is the cell. It
contains the plate blocks consisting of positive and
l
Press the emergency stop switch (Fig. 6). The en-
negative plates. These plates are separated from
gine should stop immediately.
each other by separators.
All positive plates are arranged parallel to the plus
pole, the negative plates parallel to the minus pole of
the cells.

Fig. 2
All cells are filled with a conductive fluid, the electro-
lyte. For a 12 Volt battery 6 cells are connected in se-
ries.

Capacity
is a synonym for the amount of current taken up and
discharged by a battery over a specified period of
time.

66 BOMAG 008 915 04

Batteries 5.16
Battery maintenance Batteries with screw plugs
Checking the electrolyte level
i Note
Maintenance free batteries are gaining more and
more significance, this freedom from maintenance,
however, is only limited to the fact that no water needs
to be added.
If the battery is not charged and discharged over a
longer period of time, the battery will slowly discharge
by itself.
The accumulator may only be discharged down to a fi-
nal discharging voltage of 10.5 Volt, as otherwise
there is a risk of sulphation, i.e. the generated lead
sulphate forms increasingly coarser crystals, which
will finally not react at all or only very sluggishly during Fig. 3
a subsequent charging process. 1 Upper filling level mark
In the worst case the accumulator can only be dis- 2 Lower filling level mark
posed of after such an exhaustive discharge. l If the electrolyte level only reaches up to the lower
The following therefore applies for longer downtimes: filling level mark (2), fill distilled water into the corre-
l Remove the battery and store it in a cool, dry and sponding cells.
frost protected room.
l Check the open circuit voltage on the battery at reg-
ular intervals (at least once every month).
l Recharge immediately if the open circuit voltage
has dropped to 12.25 Volt (no rapid charging).

i Note
The open circuit voltage of batteries occurs approx. 10
h after the last charging or approx. 1 h after the last
discharge.

Battery test in general

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

008 915 04 BOMAG 67

5.16
Checking the electrolyte density
Fig. 4
The cells are filled with diluted sulphuric acid as elec-
trolyte (approx. 25 Vol% sulphuric acid in distilled wa-
ter), also referred to as accumulator acid, which has a
density of 1.285 kg/dm3 at a temperature of +27° Cel-
sius. This means that one litre of electrolyte has a
weight of 1.285 kg. As the cell is being discharged
lead sulphate (PbSO4) will form on both electrodes
and the electrolyte will increasingly change to water.
Since water has a lower specific weight than diluted
sulphuric acid, the density of the electrolyte will also
drop during the discharge and with a fully discharged
cell and a temperature of 27°C it will only be 1.18 kg/
dm3.
With a lead cell the acid density is therefore a meas-
ure for the charge condition. This characteristic is
used to determine the charge condition of a lead bat-
tery. The so-called electrolyte tester (densimeter) is
used for this purpose.
Fig. 5 Checking the electrolyte density:
1) correct
2) poor
3) poor
i Note
(Hold the pipe of the electrolyte tester vertically, with-
out taking it out of the electrolyte.
68 BOMAG
Batteries
Do not draw too much electrolyte into the pipe.
Make sure that the float is not obstructed in its move-
ment and hold the electrolyte tester at eye level.
The electrolyte tester must be read at the highest
electrolyte level.
l If the electrolyte temperature deviates from the
electrolyte tester calibration temperature, the indi-
cated value for the specific electrolyte weight must
be corrected acc. to the formula (reference) below.
Reference
The specific weight varies slightly with temperature.
To be exact, the specific weight drops by 0.0007 per 1
°C temperature increase (by 0.0004 per 1 °F) and in-
creases by 0,0007 per 1 °C temperature reduction (by
0,0004 per 1 °F) . If e.g. a temperature of 20 °C (68 °F)
is used as reference, the indicated value of the specif-
ic weight must be corrected acc. to the following for-
mula.
l Specific weight at 20 °C = measuring value +
0,0007 × (electrolyte temperature: 20 °C)
l
Specific weight at 68 °F = measuring value + 0,0004
× (electrolyte temperature: 68 °F)
Acid density at 27 °C in kg/dm3
l
1.25 -1.28, open-circuit voltage approx. 12.7 Volt.
Battery is charged.
l
1.20 -1.24, open circuit voltage approx.12.4 to 12.5
Volt, is 50% discharged. Charging is necessary.
l
1.19 and less, open circuit voltage less than 12.3
Volt. Battery is insufficiently charged. The battery
needs to be recharged immediately.
l
If there is a deviation of the specific weight of more
than 0.05 between any of the cells, the battery
needs to be replaced.
l
If the current consumption during charging is not 1/
20 of the nominal capacity (example 100 Ah battery:
100Ah x 1/20 = 5 A) or full recharging of the battery
results in a final electrolyte density of only 1.24 kg/
dm3 or less, the battery shows normal wear by ag-
ing. The battery was insufficient charging or ex-
haustive discharge.
008 915 04
Batteries 5.16
Testing batteries without screw plugs Dark = Charge condition < 65%
On closed batteries the acid density cannot be meas- Light = Electrolyte level too low
ured, we therefore recommend testing with the follow-
ing mobile tester:

Fig. 6 Battery and generator tester

The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) integrated ther-
mal printer.

i Note
Before testing clean the poles and ensure good con-
nection between clamps and poles.
The test program calculates the text messages "good"
or "replace" on the basis of the charge condition (de-
rived from the battery voltage) and the currently avail-
able starting power of the battery. A battery with 45%
starting power may thus be rated good and another
one with 75% starting power as poor ("replace").
The starting power represents the ratio of detected
cold testing current to the entered cold testing current
of the battery.
The starting power can exceed 100%.

Charge condition with hydrometer

! Danger
Danger of explosion!!! If the electrolyte level is too
low, the battery must no longer be charged.

Fig. 7 Charge condition

Green = Charge condition > 65%

008 915 04 BOMAG 69

5.17 Battery service, checking the main battery switch

5.17 Battery service, checking the Caution

!

main battery switch Exhausted batteries (batteries with formation of

sulphate on the plates) are not covered under war-
ranty!
Danger
!
l Open the engine hood and remove the battery cov-
Danger of cauterisation ! Danger of explosion!
er.
When working on the battery do not use open fire,
do not smoke!
The battery contains acid. Do not let acid come in
contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
For recharging remove the plugs from the battery
to avoid the accumulation of highly explosive gas-
es.

Environment
Dispose of the old battery environmentally.
Fig. 8

i Note l
Remove the battery (Fig. 9) and clean the battery
Maintenance free batteries also need care. Mainte- compartment.
nance free only means that the fluid level does not l
Clean the outside of the battery.
need to be checked. Each battery suffers under self- l
Clean battery poles and pole clamps and grease
discharge, which may, in not checked occasionally,
them with pole grease (Vaseline).
even cause damage to the battery as a result of ex-
haustive discharge. l
Retighten the pole clamps.

The following therefore applies for the service life:

l
Check the fastening of the battery.
l
Switch off all consumers (e.g. ignition, light, inside
l
On serviceable batteries check the acid level, if nec-
light, radio). essary top up to the filling mark with distilled water.
l
Check open-circuit voltage of the battery at regular
intervals. At least once per month.
Checking the main battery switch
Reference values: 12.6 V = fully charged; 12.3 V =
50% discharged.
l Recharge the battery immediately after an open-cir-
cuit voltage of 12.25 V or less is reached. Do not
perform quick charging.
The open-circuit voltage of the battery occurs approx.
10 hours after the last charging process or one hour
after the last discharge.
l
After each charging process allow the battery to rest
for one hour before taking it into service.
l
For resting periods of more than one month you
should always disconnect the battery. Do not forget Fig. 9
to perform regular open-circuit voltage measure-
ments.
l
Turn the main battery switch (Fig. 9) to position "0"
and check by voltage measurement (ignition key
test) whether the batteries are disconnected from
the electric system of the machine.

70 BOMAG 008 915 04

Main battery switch 5.18
5.18 Main battery switch 5.19 Generator
General
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve-
hicle with electric current at a steady voltage already
at idling speed.

Terminal designations
l B61, L = charge control
l B+, B = battery plus, also with the designation "30"
l
B- = battery minus, also with the designation "31"
l D+ = dynamo plus corresponds with terminal "61"
and "L"
Fig. 10
l D- = dynamo minus (this designation is only found
No. 1 = Main battery switch
on D.C. generators or A.C. generators with regula-
turn anti-clockwise= Disconnects the battery from the tor removed)
on-board electrics, protects l DF = dynamo field (this designation is only found on
against unauthorized use when
D.C. generators or A.C. generators with regulator
performing welding work on the
removed). Note: The designation DF is also found
machine. Can be removed.
on older alternators with externally arranged regula-
turn clockwise = Operating position, engine can be tor on the connection of the exciting coil to the reg-
started. ulator or on the regulator itself
l
DF1 = dynamo field 1
! Caution l
DF2 = dynamo field 2
In events of emergency do not use the main bat-
tery switch to shut down the engine.
l
IG = "15" ignition switch

This will result in damage to engine and electronic

engine control units.

008 915 04 BOMAG 71

5.19 Generator

Three-phase generator 6 Brush holder

The AC-generator first of all produces AC-voltage / 7 Rectifier
AC-current. 8 Bearing cover
9 Rotor winding
Why does AC-current need to be rectified?
10Rotor
There are a few components for which can either be
operated with alternating current or direct current, be- 11V-belt pulley
cause they work independently from the current flow
direction.
This includes :
l
Incandescent lamps
l
Fluorescent lamps
l Glow lamps
l Electric heating elements.
There are also a few components that could be oper-
ated either with alternating current, direct current or
three-phase current, if the components were designed
accordingly.
This includes :
l
Electric motors
l
Relays.
Fig. 12 Rotor with claw poles
Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc- In the generator the armature windings are located in-
es work with alternating or three-phase current. side the stationary stator (Fig. 13), whereas the excit-
er winding is arranged on the internally revolving rotor
This includes : (Fig. 12).
l
Accumulators
l
Control units
l
All electronics
l
Communication equipment.

Design and function

Fig. 13 Stator
Fig. 11
The three stator windings (Fig. 13) are electrically off-
1 Fan set to each other by 120°. The excitation of the mag-
2 Holding plate netic field requires direct current, which is fed to the
3 Stator core rotor via two carbon brushes and slip rings.
4 Stator winding
5 Brush

72 BOMAG 008 915 04

Generator 5.19
Charge control light
The charge control light has two duties:
l Indication of the correct generator function
l External excitation of the generator during the start-
ing phase

Fig. 15 plus controlled charging regulator

Fig. 14 3-phase current
(Fig. 15) shows the current flow with the ignition
The wiring diagram (Fig. 14) shows the 3 windings in switched on, engine stopped.
Y-connection and the 6 associated rectifier diodes (D1
to D6).
The diodes D1, D2, D3 are also referred to as minus
diodes, because they have B- as common connection
(minus plate). The other diodes are the plus diodes.
The rectifier diodes have the effect that the negative
half-wave is suppressed and only the positive section
of the wave is allowed to pass, resulting in a pulsating
D.C. voltage.

Fig. 16 plus controlled charging regulator

(Fig. 16) shows the current flow with the ignition
switched on, engine running.
1 Battery
2 Charge controller
3 Ignition switch
4 Charge control light
5 Rectifier
6 Rotor
7 Sliprings / carbon brush
8 Auxiliary rectifier
Normally the charge control light lights with the engine
stopped and the ignition switched on and goes out at
low engine speed, but at the latest after a single,
short-term increase in engine speed from idle speed,
because there is no longer a voltage difference on the
lamp.

008 915 04 BOMAG 73

5.19 Generator

Any other behaviour would indicate a defect on the Charge controller

generator (rectifier, carbon brushes, regulator) or a
The charge controller has the following functions
defect on the lamp, presumed the on-board battery is
not discharged. l To regulate the voltage generated by the generator
A far more important function of the lamp is the transi- l To protect against overloads caused by too high
tion and provision of field current. At standstill there is output current
no magnetic field in the de-energized generator. Since l Protection against reverse current
this is necessary for the generation of electric current,
the rotor must be supplied with current, so that a weak If the output voltage or the output current of the gen-
field can build up. erator exceeds the determined maximum values, the
field current and thus the electric power is reduced.
The current flows from the ignition switch via the
charge control light through the generator winding Electronic charge regulator
against ground (terminal 31) and is limited to approx.
300 mA by the light bulb (4 W) (without the lamp the
current flow would be 2 to 5 A). While the rotor is ro-
tating current is induced into the stator winding,
whereby a small part (2–5 A, depending on speed)
flows through the charge regulator into the field wind-
ing of the rotor and the major part flows to the output
terminals (B+), where it can be tapped as useful cur-
rent. If the charge control light is defective or no bat-
tery is available or the battery is discharged, external
excitation is no longer possible at standstill and no
Fig. 17
voltage will be generated, even when the generator is
running. In AC-generators the electrically generated exciter
field of the generator rotor is influenced by an at-
With used, older generators a weak permanent mag-
tached electronic charge regulator. Together with the
netic field may have developed over the lifetime,
holder for the carbon brushes this regulator forms a
which does even exist when no voltage is applied.
unit, which transfers the field current to the sliprings of
This type of machines can even start without charge
the rotor.
control light and produce current during operation.
However, this is an unintended effect and you should The regulator compares the rectified actual current of
not presume that a generator without charge control the generator with the a stable reference voltage in
light or external excitation can be started up. the regulator and matches the strength of the exciter
field (field current) by increasing or reducing the cur-
rent flow (PWM, switching controller) in such a way,
that the actual voltage of the generator remains con-
stant, irrespective of load and speed. The generator
voltage is thereby regulated, the generator current,
however, is not measured, but limited by the construc-
tion dependent internal resistance of the stator coils or
thermal monitoring.

74 BOMAG 008 915 04

Generator 5.19
Checking the generator
First one must check whether the generator is actually
defective.
l This can be easily found out by checking whether
the charge control light in the dashboard lights up. If
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula-
tor, the wiring or the V-belt.
l When the engine is at rest, the charge control light
must light up. If not, the lamp may probably be de-
fective. Defects on generator or wiring are obviously
also possible.

Fig. 18 plus controlled regulator

The following points allow to contain faults in the volt-
age supply within certain limits.
l Cable connections on the generator OK?
l V-belt OK?
l Generator ground (engine ground) OK?
l Pre-excitation from vehicle electronics OK?
Only if all criteria mentioned above are OK, the fault
must be in the generator itself. In this case it must be
replaced or the following trouble shooting procedure
must be performed.

Fig. 19 minus controlled regulator

008 915 04 BOMAG 75

5.19 Generator

Checking the pre-exciter circuit, D+ generator

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

Fig. 20 Connections on the three-phase alternator (exemplary de-

sign)
If the charge control light or LED stays on when the
engine is running, you should proceed as follows:
l Temporarily bridge connections D+ and B+ on the
three-phase alternator (Fig. 20). The bridging must
be made using an insulated cable with a cross-sec-
tion of approx. 1.0 mm, which is stripped for approx.
5 mm on either end. This cable must be fitted with a
consumer (X), e.g. a light bulb of 21 W, 12 V, in
case of a 12 V system.
If this measure does not clear the fault, the alternator
must be defective.

76 BOMAG 008 915 04

Generator 5.19
Checking the rotor Checking the stator

i Note i Note
The rotor coils can only be measured in disassembled The stator coils can only be measured in disassem-
state. bled state.

Fig. 21
l Measure the resistance between the sliprings.
l If the resistance does not comply with the factory
specification, replace the rotor.
l Use the resistance range of the continuity tester to
check the continuity between slipring and core.
l Replace the rotor if no infinite value is indicated.
i Note
Factory specification for resistance: 2.8 to 5 OHM.
Fig. 22
l Use the resistance range of the continuity tester to
measure the resistance between the individual lines
of the stator winding.
l If the measuring value does not comply with the fac-
tory specification, replace the stator.
l Use the resistance range of the continuity tester to
check the continuity between the individual stator
windings and the core.
l Replace the stator if no infinite value is indicated.

i Note
Factory specification for resistance: Less than 1 OHM.

008 915 04 BOMAG 77

5.19 Generator

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

Fig. 23
l Check whether the bearing rotates without obstruc-
tion.
l Replace the bearing if it does not rotate properly.
Fig. 24
The generator test assesses the regulator voltage and
the ripple factor of the generator voltage.
l
All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
l
The generator ground connection must be OK.
l
The battery should be in good condition – the idle
voltage of the battery should be at least 12.6 Volt.
l
If possible switch off all consumers.
l
Perform the measurement at raised engine speed.

78 BOMAG 008 915 04

Generator 5.19
Checking the regulator voltage with the multime- Checking the regulator in disassembled state
ter On a Bosch generator unscrew two fastening screws
for the regulator and lift the regulator off. For this work
the generator does not need to be removed.
The Delco-Remy generator needs to be removed
and partly dismantled, if the regulator needs to be dis-
assembled. Unscrew the housing screws to do so.
Pull rotor with drive bearing and V-belt pulley out of
the stator. Unscrew the ends of the stator winding
from the diode carrier and separate the stator from the
collector ring bearing. Disassemble exciter diodes and
brush holders and remove also the regulator.

Fig. 25
l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
l The generator ground connection must be OK.
l
The battery should be in good condition – the idle
voltage of the battery should be at least 12.6 Volt.
l
If possible switch off all consumers.
l
Perform the measurement at raised engine speed.
l
The voltage (B+) should adjust itself at 13 to 14 Volt.
i Note
When testing the regulator one should be aware that
there are 2 different types of regulators:
l If the carbon brush is not connected to ground the
regulator is a so-called minus controlled regulator.
The exciter winding is positioned between D+ and
DF, the regulator therefore regulates the exciter
winding on the ground side. The other carbon brush
is connected with the cathodes of the exciter di-
odes, terminal D+. This leaves one further terminal,
this is DF.
D+ (vehicle wiring system)
D- (ground contact, mostly located on one of the fas-
tening screws)
DF (Dynamo Field)

Fig. 26
l If the carbon brush is connected to ground the reg-
ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
The basic function of a disassembled regulator can be
easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).

008 915 04 BOMAG 79

5.19 Generator

Replacing carbon brushes

l On a Bosch generator unscrew two fastening
screws for the regulator and lift the regulator off.
Pull out the carbon brushes from underneath. Their
minimum length is 5 mm, shorter carbon brushes
need to be replaced, unsolder both connection litz
wires. Solder the litz wires of the new carbon brush-
es, insert these and fasten the regulator again. For
this work the generator does not need to be re-
moved.
l
For replacing the carbon brushes in the Delco-
Fig. 27
Remy generator the generator needs to be disas-
E.g minus controlled regulator sembled and partly dismantled. The carbon brush
One connects the regulator (Fig. 27) with D+ and D- to holder is located inside the collector ring bearing.
the power source, as shown in the illustration, and the
lamp to both carbon brushes, instead of the exciter
winding. When slowly increasing the voltage the lamp
will first become brighter, because the regulator al-
lows all lamp current (= exciter current) to flow at volt-
age values up to 14.4V. Once the regulator voltage is
reached, the regulator switches the lamp current off.
When returning the voltage back below the control
voltage, the regulator will switch the lamp back on.
With this test the major difficulty is the problem to re-
move the regulator an identify terminals D+, DF and
D-.

Fig. 28

Fig. 29
The illustrations (Fig. 28) and (Fig. 29) show two dif-
ferent regulator types.

80 BOMAG 008 915 04

Replacing the voltage regulator 5.20
5.20 Replacing the voltage regula-
tor

Disassembling the regulator

Fig. 3
l Slacken the screws M3 (A) (Fig. 3).
l Loosen the hexagon nuts M5 (B).
l Remove screw and hexagon nuts.
Fig. 1
l Take off the voltage regulator.
l Loosen the hexagon nuts M5 (Fig. 1).
l Take off hexagon nuts and washers.
Assembling the voltage regulator
l Remove the plastic cover.

i Note
Optional:
Unscrew the hexagon nut M5 from terminal W, take
off washer and flat plug connector.

Fig. 1
l
Check for correct fit of sealing ring on protective
cover (Fig. 1).

Fig. 2
l Check whether washers are present. Take off the
washers (3x) (Fig. 2), to prevent these from falling
into the generator.

008 915 04 BOMAG 81

5.20 Replacing the voltage regulator

Fig. 5
l Assemble the cover (Fig. 5).
Fig. 2 l Install the washers.
l Check whether the rubber seal is present on the l Fasten the protective cover with the hexagon nuts.-
brush holder (Fig. 2). Tightening torque for hexagon nut M5 2.1-3.1 Nm.

i Note
Optional:
Assemble flat plug connector, washer and hexagon
nut M5 to connection W.
Tightening torque for hexagon nut 2.7-3.8 Nm.

Fig. 3
l
Attach the voltage regulator (Fig. 3).
l Tighten the screw M3 (A).- Tightening torque 0.7-
1.0 Nm.
l
Tighten the screw M5 (B).- Tightening torque 3.5-
4.5 Nm.

Fig. 4
l Install the washers (Fig. 4).

82 BOMAG 008 915 04

Electric starter 5.21
5.21 Electric starter Directly acting electric starter
This shows the design of this starter. It consists of a
General
starter motor and a magnetic switch.
Combustion engines need to be started by means of
a special device, because they are not able to start by
themselves. Considerable resistances caused by
compression and friction must thereby be overcome.
The starter converts the electric energy stored in the
battery into mechanical energy. The starter can only
generate its power when a battery with appropriate
capacity is available.
Duties of the starter:
l to accelerate the combustion engine to start speed
with lowest possible current consumption.
l establish the gear connection between starter and
combustion engine.
l to maintain this connection.
Fig. 6
l to switch on the starter current.
1 Magnetic switch
After starting the engine:
2 Armature
l
to return the starter pinion to initial position.
3 Actuating lever
l
to switch off the starter current.
4 Freewheeling clutch
5 Resetting spring
6 Brush
7 Exciting winding
8 Armature
9 Collector

Ignition switch in position "START"

Fig. 7 Magnetic switch open

With the ignition switch (5) in "START" position cur-
rent flows from the battery (10) through the holding
winding (2) and the pick-up winding (3).
The armature (1) is magnetically picked up and forces
the pinion (8) with the actuating lever (6) to engage
with the ring gear (7).
1 Armature
2 Holding winding
3 Pick-up winding
4 Magnetic switch

008 915 04 BOMAG 83

5.21 Electric starter

5 Ignition switch Engine running

6 Actuating lever
7 Ring gear
8 Pinion
9 Freewheeling clutch
10(Battery

Pinion meshes with the ring gear

Fig. 9
Once the engine is running and drives the pinion (1)
via the ring gear (2), the freewheeling clutch (3) will
open and prevent the armature (4) from being driven
by the engine.
1 Pinion
2 (Ring gear
Fig. 8 Magnetic switch closed 3 Freewheeling clutch
When the pinion (3) meshes with the flywheel mount- 4 Armature
ed ring gear (4) and the magnetic switch (2) is closed,
a strong current flows from the battery (7) directly into Ignition switch released
the exciting winding (6) and the armature winding, but
not into the pick-up winding.
This causes the armature (5) to rotate with high speed
and drives the pinion, which in turn drives the ring gear
(4) with a speed of 200 to 300 rpm.
1 Pick-up winding
2 Magnetic switch
3 Pinion
4 Ring gear
5 Armature
6 Exciting winding
7 Battery
Fig. 10
When releasing the ignition switch (6) it will return
from position "START" to "ON" and interrupt the start-
er current circuit. Current will now flow from the bat-
tery (9) through the contact plate in the pick-up
winding (3) and the holding winding (2). Since both
coils generate opposed magnetic fields, the magnetic
field will collapse and the resetting spring (4) takes the
armature (1) back to its initial position.
This opens the current circuit on the contact plate and
the pinion (7) is pulled back from the ring gear (8) and
stops.
1 Armature
2 Holding winding
3 Pick-up winding

84 BOMAG 008 915 04

Electric starter 5.21
4 Resetting spring Magnetic switch
5 Magnetic switch
6 Ignition switch
7 Pinion
8 Ring gear
9 Battery

Fig. 11 Direct acting electric motor

Fig. 12 Geared motor

Armature (4), contact plate (3) and armature guide (6)
form a closed unit. When the ignition switch is turned
to "START", the armature is picked up and causes the
pinion of the clutch to disengage.
This causes the pinion and the ring gear to mesh,
while the contact plate establishes a connection be-
tween the contacts, which enable the main current to
flow into the armature. Once the ignition switch is
opened, the resetting spring (5) will pull the armature
back to initial position.
1 Holding winding
2 Pick-up winding
3 Contact plate
4 Armature
5 Resetting spring
6 Armature guide

008 915 04 BOMAG 85

5.21 Electric starter

Freewheeling clutch Trouble shooting "Starter"

i Note
The most frequent fault is definitely a fully discharged
battery.
If the starter rotates too slowly, either the brushes
are partly worn off, or parts of the exciter or armature
winding is shorted. In some cases oxidized electric
contacts or a soiled ground connection causing ex-
tremely high voltage losses in the overall starter sys-
tem are the cause of problems.
If the starter only emits a clicking sound,- either
the magnetic switch is defect / soiled (dismantle and
clean))- the main contacts on the magnetic switch are
Fig. 13 Freewheeling clutch worn off / soiled (scrape off carefully with a file and
clean)- the starter motor is defective / soiled (remove
The freewheeling clutch is designed in such a way,
armature and clean), cover cleaned, moveable parts
that the flow of force is automatically interrupted if the
with grease.
pinion (5) of the clutch rotates faster than the free-
wheeling ring (1) at higher engine speeds. Frequently a jammed return mechanism is the reason
for a starter failure.
This makes sure that the armature will only drive the
ring gear, but can never be driven by the engine. Occasionally worn contacts are found on the magnetic
return switch
1 Freewheeling ring
2 Roller Defects on the actual starter motor including pinion
and carbon brushes are very rare.
3 Roller spring
With a trouble shooting chart the faults in the starter
4 Splined shaft
system can be narrowed down. The starter system
5 Pinion can only work when many conditions are fulfilled at
6 Pinion the same time.
l Immobilizer deactivated?
l Ignition switch OK?
l Travel lever in correct position?
l Emergency stop not actuated?
l Battery sufficiently charged?
l Battery poles OK?
l Main battery fuse OK?
l Main battery switch closed?
l Main starter cable (terminal 30) OK?
l Starter control cable (terminal 50) OK, voltage
drop?
l Ground cable OK?
l Switching of magnetic switches OK?
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
l the experience of the specialist
l the failure probability of the component to be tested
and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault
must be in the starter itself. In this case it can be re-
paired or replaced.

86 BOMAG 008 915 04

Electric starter 5.21
Testing and measuring the starter Continuity test for the magnetic switch

Function control with the starter removed

Caution
!

Fasten the starter to make sure that it will not

come loose during the test.

Fig. 16
l
Use a continuity tester to check for continuity be-
tween terminal (1) and terminal (29 while holding
the pin depressed.
l Replace the magnetic switch if no continuity is de-
tected.
Fig. 14
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l
Connect a jumper cable instantaneously between
starter housing and battery minus (3).

i Note
If the motor does not start, the starter is defective. Re-
pair or replace the starter.

Checking the magnetic switch

Fig. 15
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l
Connect a jumper cable instantaneously between
starter housing and battery minus (3).

i Note
If the pinion does not disengage, the magnetic switch
is defective. Repair or replace the starter.

008 915 04 BOMAG 87

5.21 Electric starter

Disassembling and assembling the start- Assembling the starter

er
Disassembling the starter

Fig. 17
l
Switch the main battery switch (Fig. 17) to position
“left”. Fig. 19
l Put the starter into place.
l Tighten the screws (arrows) (Fig. 19), tightening
torque 60 Nm.
l Screw on the cable connections (terminal 30 and
50).

Caution
!

To prevent the starter terminals or components

from being damaged you should make sure that
the cable connections are tightened with the fol-
lowing torque values.
Terminal 30, 24±4 Nm
Terminal 50, 1 - 1,3 Nm
Excessively tightened nuts can cause damage to
starter components (e.g. cracks in the cover of the
solenoid switch). Penetrating dampness can
cause short circuit - or even burning of cables.
Fig. 18
Insufficiently tightened nuts can cause loosening
l Unscrew the cable connections (terminal 30 and of cable connections and thus short circuit - or
50). even fire.
l Unscrew screws (arrows) (Fig. 18).
l Remove the starter.

88 BOMAG 008 915 04

Overview of electric components 5.22
5.22 Overview of electric components

1) Wiring loom cabin, flap

008 915 04 BOMAG 89

5.22 Overview of electric components

2) Wiring loom cabin, internal

90 BOMAG 008 915 04

Overview of electric components 5.22

1) Wiring loom cabin, power supply

008 915 04 BOMAG 91

5.22 Overview of electric components

1) Wiring loom wiper blades

2) Wiring loom cabin - battery
3) Wiring loom air conditioning
4) Wiring loom, ground air conditioning compressor

92 BOMAG 008 915 04

Overview of electric components 5.22

1) Wiring loom instruments

008 915 04 BOMAG 93

5.22 Overview of electric components

1) Wiring loom central electrics

Pos. Designation in circuit diagram Designation in circuit diagram

X1 X1:1.... Terminal strip X1
X2 X2:1.... Terminal strip X2
a V41... V48 Diode module, diodes (A1 ....A8)
b A100 Module steering column switch, travel direction
c A04 Module sprinkling system
d R09 Dropping resistor, generator excitation
e K05 ... K149 Relays
f A05 Speedometer electronics

94 BOMAG 008 915 04

Overview of electric components 5.22

1) Wiring loom engine

008 915 04 BOMAG 95

5.22 Overview of electric components

5) Wiring loom front lighting

6) Wiring loom front frame

96 BOMAG 008 915 04

Overview of electric components 5.22

1) Wiring loom, battery (-)

2) Wiring loom rear lighting
3) Wiring loom, battery (+)
4) Wiring loom main battery switch - engine
5) Wiring loom engine - central electrics (-)

008 915 04 BOMAG 97

5.22 Overview of electric components

1) Wiring loom speed transducer - central electrics

2) Wiring loom speed transducer
3) Wiring loom tachograph, cabin - central electrics

98 BOMAG 008 915 04

Overview of electric components 5.22

5) Wiring loom speed transducer - central electrics

6) Wiring loom speed transducer

008 915 04 BOMAG 99

5.22 Overview of electric components

1) Wiring loom, battery (+)

2) Wiring loom, battery (-)
4) Wiring winter package
5) Wiring fuel heating
6) Wiring loom glow plugs
7) Wiring central electrics

100 BOMAG 008 915 04

Overview of electric components 5.22

1) Wiring loom ROPS - battery (+)

2) Wiring loom E1-working lights

008 915 04 BOMAG 101

5.22 Overview of electric components

5) Cable set for loudspeakers

6) Cable set for radio
7) Cable set

102 BOMAG 008 915 04

Overview of electric components 5.22

13) Wiring loom solenoid valve for edge cutter

14) Wiring loom dash board for edge cutter

008 915 04 BOMAG 103

5.22 Overview of electric components

Fig. 20 18 S37 Rotary switch for direction indicators left / right

1 S31 / S184 Travel lever 19 S15 Rotary switch for light system (StVZO)
2 Steering wheel 20 S26 Rotary switch for working lights
3 not used 21 S119 Throttle pedal
4 Tire pressure gauge 22 S00 Ignition switch
5 S01 Emergency stop push button 23 Brake pedal
6 S14 Rotary switch for hazard light system 24 Rotary switch for tire inflation
7 A15 Instrument cluster 25 Rotary switch to relieve tire pressure
* 26 XS Utility socket 12 V
8 P04 / E04 Speedometer
9 H04 EMR Deutz engine (only BW27RH) 27 Rotary switch for cabin heater
10 not used 28 Rotary switch for cabin fan
11 S02 Rotary switch for travel ranges 29 Rotary switch for air conditioning *
12 S185 Rotary switch, dashboard illumination
13 S05 Rotary switch for pressure sprinkler system
14 not used
15 not used
16 S111 Rotary switch for parking brake
17 S03 Push button for warning horn

* Optional equipment

104 BOMAG 008 915 04

Overview of electric components 5.22

Fig. 21 Monitoring board A15

Pos. Designation in circuit diagram Designation in circuit diagram

a H43 Brake pressure control light
b H70 Control light, water in diesel filter
c H52 Control light, preheating monitoring
d H79 Remaining water quantity, sprinkling system
e H09 Engine oil pressure control light
f H73, option Control light, coolant provision
g H08 Charge control light
h H15 Control light for engine air filter
i H49 Control light, overheating of engine
j H23 Hydraulic oil filter control light
k H05 Indicator control light
l H86 Brake oil temperature control light
m H01 Brake control light
n P01 Fuel level gauge
o no function Tank gauge for sprinkling system
p P00 Operating hour meter

008 915 04 BOMAG 105

5.23 Fuse, cabin

5.23 Fuse, cabin

Fig. 22

a = S38, toggle switch for flashing beacon

Fig. 24
b = S20, toggle switch for front windscreen wiper/
f = fuse box in cabin
washer

c = S21, toggle switch for rear windscreen wiper/

! Danger
washer
Fire hazard!
d = S53, toggle switch for working headlights
Do not use fuses with higher ampere ratings and
e = S163, toggle switch for rear windscreen heat- do not bridge fuses.
ing (1), 15A = (F41) Flashing beacon
(2), 15A = (F27) Wiper/washer, front
(3), 15A = (F28) Wiper/washer, rear
(4), 25A = (F31) Cabin fan
(5), 25A = (F110) Working head lights, front/rear
(6), 5A = (F90) Cabin heater
(7), 10A = (F68) Potential 30
(8), 20A = (F40) Cabin heater

Fig. 23

g = E29, reading and dashboard light

h = S158, toggle switch for reading and dashboard

light

i = S45, toggle switch for cabin lamp

j = E70, cabin lamp

106 BOMAG 008 915 04

Fuses 5.24
5.24 Fuses (11) 15A = (F22) Working headlights, rear
(12) 10A = (F23) Warning horn
(13) 10A = (F25) solenoid valve for driving and brak-
ing
(14) 10A = (F26) Solenoid valve for travel speed
range selection
(15) 15A = (F70) Direction indicator
(16) 10A = (F77) Travel
(17) 15A = (F120) Brake light
(17a) 25A= (F124) Fuel pre-heating
(18) 10A = (F09) Parking and tail light, left
(19) 10A = (F10) Parking and tail light, right
Fig. 25 (20) 10A = (F11) Head lights, left hand side
No. 2 = Fuse box ROPS* (21) 10A = (F12) head lights, right hand side
(22) 10A = (F06) Water sprinkling system
! Danger (23) 20A = (F156) Light system (StVZO)
Fire hazard! (24) 10A = (F45) Edge cutter
Do not use fuses with higher ampere ratings and (27) 5A = (F91) Sensors
do not bridge fuses.
(1) 25A = Working head lights

Fig. 26
No. 3 = Fuses in electric junction box

! Danger
Fire hazard!
Do not use fuses with higher ampere ratings and
do not bridge fuses.
(2) 30A = (F01) Main fuse
(3) 15A = (F05) Socket
(4) 20A = (F37) Sprinkler pump
(5) 20A = (F93) Engine control
(6) 15A = (F07) Hazard light
(7) 7.5A = (F119) Engine
(8) 15A = (F129) MD+
(9) 5A = (F04) Gauges
(10) 10A = (F14) Engine solenoid

008 915 04 BOMAG 107

5.25 Main battery fuse

5.25 Main battery fuse 5.26 Modules

In the latest generation of machines BOMAG uses
machine programmable modules. A module mainly
consists of a programmable microprocessor with ad-
ditional circuitry for inputs and outputs.

Fig. 27
No. 4 = Main fuse for battery
125A = (F00)

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

108 BOMAG 008 915 04

Modules 5.26
Signals
Analog signals
Process states are continuous (analog) when they
can be mapped by means of a real number, e.g. tem-
perature = 65.5 °C. The sensor converts a continuous
process status into an analog signal. If the control unit
needs the numerical value of the analog signal, an an-
alog-digital conversion is required.
Analog signals are needed to control, display or mon-
itor limit values. Checking the limit values of physical
quantities leads to the binary information: limit value
reached/not reached.

Binary signals
Process states are bivalent (binary) if they have only
2 possible states of truth, such as e.g. button pressed/
not pressed, object present/not present. The two
states of truth are mapped by means of defined states
of an information carrier, e.g. 'not pressed' equals 0 V,
'pressed' equals 24 V. These states are described
with {0,1} or {false, true}

008 915 04 BOMAG 109

5.26 Modules

110 BOMAG 008 915 04

 6 Electronic modules

008 915 04 BOMAG 111

112 BOMAG 008 915 04
 6.1 Module description A04

008 915 04 BOMAG 113

6.1 Module description A04

114 BOMAG 008 915 04

Module description A04 6.1

Description UPM1
Sprinkling module 27R

- 538 380 02 -

RS 232
LED 2

LED 3

LED 1
LED 4
LED 5

+ - 6 4 3 2 13

30

Version 1.0 from 29.06.2004

A. Hehner Page 1 from 29.06.2004

008 915 04 BOMAG 115
6.1 Module description A04

Table of Contents

1. Version history................................................................................................ 3
2. Description of hardware ................................................................................. 4
2.1. Pin assignment for digital inputs......................................................................................... 4
2.2. Pin assignment for analog inputs........................................................................................ 4
2.3. Pin assignment for outputs .................................................................................................. 4
3. Description of function................................................................................... 6
3.1. Total overview of sprinkling cycle ....................................................................................... 6
4. Software version history ................................................................................ 7

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116 BOMAG 008 915 04
Module description A04 6.1

1. Version history

No. Version Date Description of version Resp.

1 1.0 29.06.04 1. version created Hehner

A. Hehner Page 3 from 29.06.2004

008 915 04 BOMAG 117
6.1 Module description A04

2. Description of hardware

The inputs were changed in such a way, that the following table applies:

Input Behaviour Remark

Input PIN13 LOW-active LED lights when applying ground potential!
Input PIN2 LOW-active LED lights when applying ground potential!
Input PIN3 HIGH-active LED lights when applying positive voltage!
Input PIN4 HIGH-active LED lights when applying positive voltage!

2.1. Pin assignment for digital inputs

Signal name Module Descr.
pin
Emulsion switch 13 Active LOW = Emulsion cycle ON LED on
HIGH = Emulsion cycle OFF LED off
Ground bridge (optional) 2 Active LOW = Sprinkling cycle 6/6 LED on
HIGH = Sprinkling cycle 6/12 LED off
Not used 3 Active HIGH = LED on
LOW = LED off
Not used 4 Active HIGH = LED on
LOW = LED off

2.2. Pin assignment for analog inputs

Signal name Module Descr.
pin
Not used + / -

2.3. Pin assignment for outputs

Signal name Module Descr.
pin
Relay contact 15 + 87 30 + 87 HIGH = Switch on emulsion sprinkling
(normally open) cycle LED on
LOW = Switch off emulsion sprinkling
cycle LED off
BTS 6 HIGH = Switch on emulsion sprinkling
cycle LED on
LOW = Switch off emulsion sprinkling
cycle LED off

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118 BOMAG 008 915 04
Module description A04 6.1

The hardware is available under BOMAG part-no. 057 644 39.

PIN Signal Description

13 IN (Active LOW) Emulsion switch
RS 232 2 IN (Active LOW) Optional (ground bridge)
LED 2

3 IN (Active HIGH) not used

4 IN (Active HIGH) not used
LED 3

LED 1
LED 4
LED 5

6 OUT (BTS) OUT 15/54, 4A

OUT - PWM -
OUT + PWM +
30 Relay - Contact IN 12V, 15 A
+ - 6 4 3 2 13
87
87a
Relay - Contact Normally open
Relay - Contact Normally closed
15/45 Supply voltage 10-39 V
30 Ground


Figure 1: Module

The complete module (including the specific software) is available under

BOMAG part-number 538 380 02.

The following applies when measuring the signal level:

PIN Potential with LED on Potential with LED off

digit. inputs (HIGH active) Operating voltage Voltage < 1V

digit. input (LOW active) Ground Input open

Relay contact 30 +87 Connection between PIN 30 and No connection between PIN
(normally open) 87 30 and 87
Relay contact 30 +87a No connection between PIN 30 Connection between PIN 30
(normally closed) and 87a and 87a
digit. Outputs (BTS) Operating voltage < 1V

A. Hehner Page 5 from 29.06.2004

008 915 04 BOMAG 119
6.1 Module description A04

3. Description of function

The following sequences were realized in the UPM2 Software for realization of sprinkling cycles.

3.1. Total overview of sprinkling cycle

In order to realize a switching interval for the emulsion sprinkling system, the input (PIN 13) and
the output (PIN 6), as well as the relay of the module are used. The emulsion sprinkling system
is activated by the ground signal on input PIN13. If an additional ground signal (bridge) is
applied to input (PIN 2), the interval time is changed to the following values:

Impulse time Pause time

With ground bridge on PIN 2 6 seconds 6 seconds

Without ground bridge on PIN 2 6 seconds 12 seconds

As long as the emulsion sprinkling system is ACTIVE (ground signal on PIN 13), output PIN 6
(LED 5) and relay (LED 6) are cyclically set in intervals for 6 (6) seconds to ON or 12 (6)
seconds to OFF.
During an OFF-pause the emulsion sprinkling system can be triggered by switching input PIN13
short-term to Active LOW, the ON-phase at the output will start immediately from the beginning
for 6 (6) seconds. Triggering is not possible during an ON-phase.
If the emulsion sprinkling system is switched off during an ON-phase, the ON-phase will
continue to the end (6 seconds). An ON-phase cannot be interrupted (or only by switching off
the module).

A. Hehner Page 6 from 29.06.2004

120 BOMAG 008 915 04
Module description A04 6.1

4. Software version history

Version management: BOMAG Sprinkling Module 538 380 02

Module: BM UPM1
Controller: PIC16F84a

Version 1.00 from 29.06.2004:

----------------------------
Checksum: ba02

1. version created.

A. Hehner Page 7 from 29.06.2004

008 915 04 BOMAG 121
6.1 Module description A04

122 BOMAG 008 915 04

 6.2 Electric module A72, old design

008 915 04 BOMAG 123

6.2 Electric module A72, old design

124 BOMAG 008 915 04

Electric module A72, old design 6.2

008 915 04 BOMAG 125

6.2 Electric module A72, old design

126 BOMAG 008 915 04

Electric module A72, old design 6.2

008 915 04 BOMAG 127

6.2 Electric module A72, old design

128 BOMAG 008 915 04

 6.3 Electric module A108

008 915 04 BOMAG 129

6.3 Electric module A108

130 BOMAG 008 915 04

008 915 04
Rotary switch for cabin fan Rotary switch for air conditioning system
Electric module A108

BOMAG
Cabin fan 1 Cabin fan 2
6.3

131
6.3 Electric module A108

132 BOMAG 008 915 04

 7 Module description A100

008 915 04 BOMAG 133

7.1 Steering column locking module, A100

7.1 Steering column locking module, A100

Description UPM03
BW24/27RH

538 380 06 Version 1.0 dated 17.07.06

538 380 12 Version 1.0 dated 09.06.08

Fig. 2

Description of hardware
The module consists of the modified UPM2 module. The inputs were designed in such a way, that the following
table applies:

Input Performance Comment

Input PIN11 HIGH-active LED lights when applying positive voltage!
Input PIN112 HIGH-active LED lights when applying positive voltage!
Input PIN13 LOW-active LED lights when applying ground potential!
Input PIN14 HIGH-active LED lights when applying positive voltage!
Input PIN15 HIGH-active LED lights when applying positive voltage!

134 BOMAG 008 915 04

Steering column locking module, A100 7.1
Pin assignment digital inputs

Signal Name Module Pin Signal on input

Steering column switch left/ 11 Active-HIGH left forward LED on
reverse LOW = left not reverse LED off
Steering column switch left/ 12 Active-HIGH = left forward LED on
forward LOW = left not forward LED off
Parking brake 13 Active-LOW = Parking brake released LED on
HIGH = Parking brake closed LED off
Steering column switch right/ 14 Active-HIGH = right reverse LED on
reverse LOW = right not reverse LED off
Steering column switch right/ 15 Active-HIGH = right forward LED on
forward LOW = right not forward LED off

Pin assignment outputs

Signal Name Module Pin Signal on input

Change of travel direction 4 +UB = forward with delayed switching LED on
0V = reverse with delayed switch off LED off
Solenoid valve, forward trav- 5 +UB = forward travel LED on
el 0V = no forward travel LED off
Output error message / both 6 +UB = error message LED on
steering column switches ac- 0V = no error message LED off
tuated
Solenoid valve, reverse trav- 7 +UB = reverse travel LED on
el 0V = no reverse travel LED off
Start release when both 8 +UB = start release LED on
steering column switches are 0V = no start release LED off
in neutral

The following applies when measuring the signals

PIN Potential to TED on Potential with LED off

digital inputs (HIGH-active) Operating voltage (UB) Voltage < 1V
digital inputs (LOW-active) Ground Input open
digital outputs (HIGH-active) Operating voltage (UB -0.7V) <1V
digital outputs (LOW-active) Ground Operating voltage (UB -0.7V)

Emergency operation
If a bridge is inserted between PIN2 and PIN3, the outputs PIN4 and PIN5 are at HIGH potential and the cor-
responding LED, as well as the red LED on PIN3, will light.

i Note
This function can be used in emergencies (defect), to be able to move the machine for a short time.

Description of function
Switching on
If operating voltage is applied to the module, the Stay-Alive LED will flash in intervals of one second.

Fault signal
If both steering column switches are actuated at the same time, a fault signal is emitted by output PIN 6. This
fault is deactivated by returning both steering column switches to neutral position.
If one steering column switch is actuated while the parking brake is closed, PIN 6 will also emit a fault signal.

Travel direction
When shifting the steering column switch forward (Pin12 or Pin15), output Pin5 will switch.

008 915 04 BOMAG 135

7.1 Steering column locking module, A100

When shifting the steering column switch backward (Pin11 or Pin14), output Pin7 will switch.
Outputs PIN5 and PIN7 will only emit a signal when the parking brake is open (Pin13 active-LOW).

Changing the steering column switch, module 538 380 06, old version
Replacing the steering column switch is only permitted when both travel levers are in neutral position. When the
left hand steering column switch is actuated, the right hand steering column switch is locked (and vice-versa).
Any changes to the locked steering column switch are ineffective).

Changing the steering column switch, module 538 380 12, old version
Replacing the steering column switch is only permitted when both travel levers are in neutral position. When both
steering column switches are actuated, both outputs (Pin5 and Pin7) will switch off and a fault signal will appear
on output Pin6 (LED lights). This fault signal remains present, until both travel levers have been returned to neu-
tral position.

Control of travel direction switchover

When actuating the steering column switch forward, output Pin4 is switched on with a delay of 0.8 seconds.
When actuating the steering column switch backward, output Pin4 is switched off with a delay of 0.8 seconds.

Start release
If no steering column switch is actuated, a signal is submitted through the start release output Pin 8.

136 BOMAG 008 915 04

 8 Speedometer Module

008 915 04 BOMAG 137

8.1 Speedometer module

8.1 Speedometer module

Fig. 1 Speedometer module

Description of function
With the programmable module BM UPM the software
realizes a speedometer function. To ensure that the
tachometer function is not only realized for one spe-
cial roller, there is a possibility to adapt the module to
any machine with the help of a self-teaching mode.
l Whenever the module is switched on the system
runs a self-test by passing through the entire dis-
play range in both directions. The display self-test
takes approx. 15 seconds.
l After this the module changes to measuring mode.
The frequency of the travel pulses of the roller is de-
tected and converted to a proportional output volt-
age that triggers the display.
l The output signal for the display is a PWM-signal.

Manual testing of the speedometer

When the module is in learning mode a manual dis-
play test can be performed via the input "Test". For
this purpose the input "IN" must be energized with 12
Volt, whereupon the speedometer is constantly trig-
gered with 3 Volt.

138 BOMAG 008 915 04

Speedometer module 8.1

Pin-no. module Pin name Description

Test E_ANZEIGENTEST Input HIGH active: Activate manual display test

IN E_WEGIMPULSE Input: Path pulses
Learn E_LERNMODUS Input: HIGH active: Activate teach mode

OUT - Display - Output: Ground connection for speedometer

OUT + Display + Output: Output voltage for speedometer

GND (2X) Ground Input: Module ground connection

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

Teaching the module

In self-teach mode the number of arriving path pulses
is detected at the input (IN). The number of recorded
pulses is referred to as pulse number per 10 or 18 m
(machine dependent) travel distance of the roller.
l Connect the ground cable (-).
l Connect the sensor signal (speed sensor) to fre-
quency input (IN).
l Install a cable bridge from terminal "15/54" to the
connection "Teach".
l Connect potential "Ignition / 15" to connection "15/
54".
l Switch on the ignition, start the engine and travel a
distance of exactly 10 m.

Caution
!

BW24RH, BW27RH, C550H and C560H = travel 18

meters.
All other machines = travel 10 meters.

i Note
If the module is in teach mode the LED on output
"OUT +" will flash with the frequency of the path puls-
es arriving at input (IN).
l
Disconnect the cable bridge from "Teach" to "15/
54“.
l
Switch the ignition off and on again (Reset).

The module has now learned the pulses of the

speed sensor.
l
Connect the speedometer (0 to 6 Volt) to "OUT +"
and "OUT –“.

008 915 04 BOMAG 139

8.1 Speedometer module

140 BOMAG 008 915 04

 9 Hydraulics

008 915 04 BOMAG 141

9.1 Overview

9.1 Overview

Fig. 1

142 BOMAG 008 915 04

Overview 9.1

Fig. 2

Pos. Designation Pos. Designation

1 Steering valve 9 Brake releasing valve
2 Hydraulic oil tank 10 Brake valve
3 Steering pump 11 Priority valve
4 Charge circuit filter 12 Pressure reducing valve
5 Secondary flow filter 13 Travel motor, left
6 Hydraulic cylinder for edge cutter 14 Steering cylinder
7 Return flow filter 15 Control valve block for edge cutter
8 Travel pump 16 Travel motor, right

008 915 04 BOMAG 143

9.2 Hydraulic circuit

9.2 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.

144 BOMAG 008 915 04

Hydraulic circuit 9.2
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.

008 915 04 BOMAG 145

9.3 Travel pumps, A4VG105 DA

Variable displacement pumps, A4VG105 DA

9.3 Travel pumps, A4VG105 DA

DH - Hydraulic control, speed dependent

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 A4VG is a variable displacement axial piston pump in swash plate design for hydrostatic drives in closed
circuits.

Fig. 3 A4VG

1 Drive shaft 7 Auxiliary pump (optional)

2 Retracting plate 8 High pressure side
3 Control piston 9 Cylinder
4 Control unit 10 Piston
5 Valve plate 11 Slipper pad
6 Low pressure side 12 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.

146 BOMAG 008 915 04

Travel pumps, A4VG105 DA 9.3
Hydraulic diagram

Inching valve

Control unit DA-control valve

High pressure limitation Auxiliary pump

High pressure limitation Charge valve Pressure override valve

Fig. 4 Hydraulic diagram, A4VG DA

A Work connection MH Port for balanced high pressure

B Work connection PS Control pressure inlet
G Pressure port for charge circuit R Ventilation
Fa Filter outlet S Suction line for charge oil
Fa1 Filter outlet (attachment filter) T1 Leak oil
Fe Filter inlet T2 Leak oil
FS Port from filter to suction line (cold start) X 1 X2 Port for control pressures, pressure in front of
nozzle
MA Pressure test port, pressure A Z Control pressure port
MB Pressure test port, pressure B

008 915 04 BOMAG 147

9.3 Travel pumps, A4VG105 DA

Connection overview

Fig. 5

High pressure relief, charge pressure and DA-control valve

Pressure override valve

HP-valve with bypass

DA-control valve

Charge pressure relief valve

HP-valve with bypass

Fig. 6 Valve plate

High pressure relief valves with integrated boost check valves and bypass function
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.

148 BOMAG 008 915 04

Travel pumps, A4VG105 DA 9.3

Fig. 7 Bypass function

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.

Activate the bypass function

l Shut down the engine.
l
Loosen the screw (1) by turning them with an outer hexagon spanner (SW 36) a complete turn in anti-clock-
wise direction.

i Note
Once the high pressure relief valve has been loosened, the sealing effect can no longer be guaranteed. Should
pressure fluid leak out of the high pressure relief valve, immediately remove the valve and clean it.

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

Caution
!

The closed hydraulic circuit empties during the towing process with activated bypass. This can cause
undesired functions when later starting operation of the travel drive.
Only start operating the travel drive after the hydraulic circuit has been completely filled and purged.

Charge pressure relief valve

Fig. 8 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.

008 915 04 BOMAG 149

9.3 Travel pumps, A4VG105 DA

Pressure override valve

Fig. 9 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.

DA-control valve
The DA-control valve enables the pump swashing angle to follow the engine speed.

Control valve

Fig. 10 DA-control valve

The speed dependent drive regulation is a purely hydro-mechanical regulation for travel drives in closed hy-
draulic systems. The travel drive regulation enables travel comfort similar to motor vehicles with automatic gear-
box: The more the throttle pedal is kicked down, the bigger the swashing angle and the flow volume from the
travel pump and the higher the travel speed.
With any occurring overload the maximum load control will reduce the flow volume from the pump to a value that
prevents the diesel engine from being extremely overloaded. The DA-control also makes sure that the DA-pump
will adapt the power take-off to the power provided by the diesel engine.

150 BOMAG 008 915 04

Travel pumps, A4VG105 DA 9.3

Control

Charge pressure relief valve Travel direction valve

Inching

Orifice

DA-control valve Diesel

Fig. 11 Automotive travel control

l Kicking down the throttle pedal increases the engine speed.
l An increase in engine speed also causes an increase in pump speed. Since the charge pump is an integral
part of the drive pump, its flow volume will also increase.
l The higher the flow volume through the DA-control valve, the further the pump will swash away from neutral
and thus deliver a correspondingly higher flow volume. The travel speed increases because of the higher en-
gine speed and the larger swashing angle of the travel pump. The travel direction is pre-selected via an inte-
grated way valve (forward - neutral - reverse).
The engine speed dependent drive control protects the engine against unintended "Stalling": The most
important feature of the engine speed dependent drive control (DA) is the sensing of the hydraulic pressure di-
rectly on the driving mechanism of the travel pump. Changes to the system pressure can be caused by the ve-
hicle driving in difficult terrain or approaching a steep gradient.
l Rising pressure in the working lines of the travel pump causes a reduction of its swashing angle.
l
Due to the reduced swashing angle the pump delivers less oil and thus adapts its power consumption to the
power output of the the diesel engine. This protects the engine against "Stalling".
If additional power is needed by other consumers (e.g. steering or working hydraulics), the drive pump will au-
tomatically adapt its swashing angle to these requirements, at which the absorbed hydraulic power is in equilib-
rium with the power offered by the diesel engine.

Inching brake valve

The inching brake valve works in connection with the service brake. This always makes sense when the inching
function is to support the service brake as a measure to reduce the wear on brake linings.
If the driver gently kicks down the brake pedal, the hydrostatic drive is solely braked via the inching function.
When applying high braking pressure, both the hydraulic system and the service brake will work simultaneously.
The pump control unit is in this case directly linked with the service brake circuit. Increasing pressure in the brake
system causes the travel pump to swash back towards neutral.

008 915 04 BOMAG 151

9.3 Travel pumps, A4VG105 DA

Travel direction switch

Throttle pedal Brake pedal

Diesel engine
Inching valve

Fig. 12 Inching valve

Control unit
Depending on the drive speed the DA-control valve generates a control pressure, which is then applied to the
control cylinder of the pump via a 4/3-way valve, which infinitely alters the position of the swash plate, i.e. the
displacement. The 4/3-way valve is equipped with switching solenoids for each flow direction.

Fig. 13 Control unit

1 Setscrew for mechanical neutral position 4 Control chamber

2 Neutral setting spring 5 Solenoid valve
3 Control piston 6 Valve spool

Auxiliary pump
The auxiliary pump permanently delivers a sufficient amount of fluid (charging volume) through a check valve
into the low pressure side of the closed circuit, in order to replace internal leakages in variable displacement
pump and consumers.

152 BOMAG 008 915 04

Travel pumps, A4VG105 DA 9.3
Swash plate principle, pump

Fig. 14
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. 15

008 915 04 BOMAG 153

9.3 Travel pumps, A4VG105 DA

Pos. Designation Pos. Designation

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.

154 BOMAG 008 915 04

Troubleshooting axial piston pumps 9.4
9.4 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.

008 915 04 BOMAG 155

9.4 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.

156 BOMAG 008 915 04

Troubleshooting axial piston pumps
Fault
No or insufficient pressure
Fluctuations in pressure/volumetric Axial piston unit not or insufficiently
flow
Pressure fluid too hot.
9.4
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.

008 915 04 BOMAG 157

9.5 External gear pumps

External gear pumps

9.5 External gear pumps

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

Axial seal Outer pressure field Inner pressure field Radial seal

Sealing zone
Cover Flange Compensation forces
Fig. 16 Axial compensation of gear pump
Internal sealing of the pressure chambers is achieved by flow volume dependent forces. This results in an ex-
cellent rate of efficiency. On the rear side the moveable bearing bushings are pressurized and thus tightly
pressed against the gears. The pressurized pressure fields are thereby limited by special seals. Sealing around
the circumference of the gears to the housing is assured by small gaps, which appears between gears and hous-
ing in dependence on the pressure.

Function

Fig. 17
The increasing volume caused by a tooth exiting a tooth gap results in a vacuum in the suction chamber. The
pressure fluid is transported into the pressure chamber. There the meshing of teeth and tooth gaps displaces
the pressure fluid into the upper supply line.

158 BOMAG 008 915 04

External gear pumps 9.5

Fig. 18

Pos. Designation Pos. Designation

1 Cover 6 Gear (driven)
2 Seals and gaskets 7 Shaft
3 Housing 8 Flange
4 Gear (driving) 9 Bearing plate
5 Displacement chamber 10 Bearing plate

008 915 04 BOMAG 159

9.6 Travel motor, A6VM 107HA2R1

Description of function
9.6 Travel motor, A6VM 107HA2R1

i Note
The travel motors A6VM and A6VE just differ by a different housing.
The A6VM/VE is a variable displacement axial piston motor with a tapered axial piston drive in swash plate de-
sign for hydrostatic drives in open and closed hydraulic circuits. Due to this bent axle design the torque is gen-
erated directly on the drive shaft. The pistons only apply very little transverse forces to the cylinder, which has
a favourable effect on wear, efficiency and starting torque.

! Caution
The 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 hy-
draulic lines.

Fig. 19

Pos Designation Pos Designation

1 Drive shaft 6 Cylinder
2 Control piston 7 Piston
3 Control piston 8 Setscrew for control start
4 Connecting plate 9 Setscrew, Vg min
5 Valve plate

In variable displacement axial piston in bent axle design the pistons (7) are arranged in an inclined position to
the drive shaft (1). The pistons perform an axial movement, which is then converted to a rotary movement by
the piston joint on the drive shaft flange. The cylinder (6) is driven by the pistons.

Motor function
A variable displacement axial piston motor converts the hydrostatic energy into mechanical energy. Pressure
fluid is fed through the connecting plate (4) and the valve plate (5) into the cylinder bores. The pistons (7) inside
the cylinder bores perform an axial movement, which is then converted to a rotary movement by the piston joint
on the drive shaft flange (1). The pistons thereby drive the cylinder (6) and thereby generate the output torque
on the drive shaft. The output torque is generated by the force resulting from pressure and piston area. The out-
put speed is proportionate to the inflowing volume and the displacement, which can be changed by altering the
swashing angle. The output torque increases with the pressure drop between high and low pressure sides and
increasing displacement.

Sensors
The A6VM/VE...U version has been designed with a gearing on the drive. An attached rotary speed sensor en-
ables the detection signals proportional to the motor speed.

160 BOMAG 008 915 04

Travel motor, A6VM 107HA2R1 9.6

Fig. 20
The DSM sensor is fastened to the specially intended connection with a fastening screw

Control
In a variable displacement axial piston motor the angle of the bent axle can be infinitely adjusted within certain
limits. The change in swashing angle of the bent axle causes a difference in stroke length and thus a change in
displacement. The swashing angle of the bent axle is hydraulically changed via the control piston (3). The valve
plate rests light moving in a slideway. Enlarging the swashing angle increases the displacement and the torque,
reducing the angle reduces the values accordingly, while the output speed increases.. Various control facilities
are available to meet different requirements.

HA2R control
HA – Automatic displacement control, high pressure dependent
With the automatic displacement control, high pressure dependent, the adjustment of the displacement is ac-
complished automatically in dependence on the operating pressure.
The control unit measures the internal operating pressure at A or B and when the preset nominal pressure is
reached, the controller swashes the motor from V g min to V g max. as the pressure increases.
l Control start at Vg min (minimum torque, maximum rotary speed)
l
Control end at Vg max (maximum torque, minimum rotary speed)

HA2 - pressure increase

An increase in operating pressure of Δp = 100 bar causes an increase in displacement of from 0 cm3 to Vgmax.

HA.R - control
With this control the high pressure dependent control can be overridden by applying an electrical signal to the
switching solenoid b. In case of override the variable displacement motor swashes to maximum swashing angle,
without any intermediate position.
The travel direction valve makes sure that the preselected pressure side of the hydraulic motor controls the
swashing angle, even when the high pressure side changes (e.g. travel drive when driving downwards). Any
undesired swashing of the variable displacement motor to a higher displacement can thus be prevented.
Depending on the sense of rotation (travel direction) the travel direction valve is actuated by pressure spring or
the control solenoid a.

008 915 04 BOMAG 161

9.6 Travel motor, A6VM 107HA2R1

Qmin Flushing valve (optional)

Stop screw

Qmax Travel direction solenoid

Stop screw
Qmax solenoid
Setscrew
Control start
Fig. 21

Flushing valve
The flushing and charge pressure valve is used to discharge heat from the hydraulic circuit.
l
In the open hydraulic circuit is solely serves the purpose of flushing the housing.
l
In a closed hydraulic circuit it also secures the minimum charge pressure, alongside the flushing of the hous-
ing.
Hot pressure fluid is discharged from the corresponding low pressure side into the motor housing. This fluid is
returned to the tank, together with the leak oil. In the closed circuit this discharged pressure fluid must be re-
placed by cooled pressure fluid from the charge pump.

162 BOMAG 008 915 04

Trouble shooting, variable displacement axial piston motor 9.7
9.7 Trouble shooting, variable displacement axial piston motor
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
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.
Mechanical damage to the axial pis- Replace the axial piston unit
ton unit.
Fluctuations in pressure/volumetric Axial piston unit not or insufficiently Completely purge the axial piston
flow purged. unit.

008 915 04 BOMAG 163

9.7 Trouble shooting, variable displacement axial piston motor

Fault Possible cause Remedy

Operation data are not reached.
Pressure fluid too hot.
Insufficient flow from hydraulic Check the function of the hydraulic
pump pump
Minimum displacement incorrectly Consult the service department.
set
External control and setting facilities Check the external control.
defective.
Control pressure too low Check control pressure, consult the
service department.
Functional disturbance in the control Consult the service department.
facility or the regulator on the axial
piston unit.
Pressure fluid not within the optimal Use appropriate pressure fluid.
viscosity range.
Wear of the axial piston unit Replace the axial piston unit
Mechanical damage to the axial pis- Replace the axial piston unit
ton unit.
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).
Failure of the flushing valve Consult the service department.
Wear of the axial piston unit Replace the axial piston unit

164 BOMAG 008 915 04

Steering valve 9.8
Steering valve
9.8 Steering valve

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

Fig. 22

1 Check valve 8 Outer spool

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

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

008 915 04 BOMAG 165

9.9 Travel circuit

9.9 Travel circuit

The travel circuit is a closed hydraulic circuit.

Hydrostatic travel system

The hydrostatic travel system primarily consists of:
l a travel pump (DA-control pump)
l two travel motors (bent axle variable displacement motors)
l and two travel gears with brakes (reduction gear).

Travel direction switch

Travel speed range selector switch
Throttle pedal Brake pedal

Travel pump
DA-control

Two
Travel motors
parallel
Diesel engine Travel motor
HA-control

Inching valve

Fig. 23 Block diagram of travel circuit

The pneumatic tired roller is driven via throttle pedal and brake.
The speed dependent drive regulation (DA) is a purely hydro-mechanical regulation for travel drives in closed
hydraulic systems. The more the throttle pedal is kicked down, the bigger the swashing angle and the flow vol-
ume from the travel pump and the higher the travel speed. With any occurring overload the maximum load con-
trol will reduce the flow volume from the pump to a value that prevents the diesel engine from being extremely
overloaded. The DA-control also makes sure that the DA-pump will adapt the power take-off to the power pro-
vided by the diesel engine.
The brake pressure is fed into the inching valve of the travel pump in order to reduce brake disc wear. If the
driver gently kicks down the brake pedal (< 20 bar), the hydrostatic drive is solely braked via the inching function.
When applying high braking pressure (> 20 bar), both the hydraulic system and the service brake will work si-
multaneously. Increasing pressure in the brake system causes the travel pump to swash back towards neutral.

166 BOMAG 008 915 04

Travel circuit 9.9

11.2 10.2
11.1 10.1

9.4
9.3
9.6

9.2
9.1
9.5

008 915 04 BOMAG 167

9.9 Travel circuit

9.1 High pressure relief valves 9.6 DA-control valve

9.2 Charge pressure relief valve 10.1 Flushing valve with flushing pressure relief
valve, travel motor left
9.3 Pressure override valve 10.2 Qmax-valve, speed range 1, travel motor left
9.4 Auxiliary pump, charge pump 11.1 Flushing valve with flushing pressure relief
valve, travel motor right
9.5 Inching valve 11.2 Qmax-valve, speed range 1, travel motor right

Tank
Charge oil filter

Travel pump

Brake releasing valve

Brake valve

Pressure reducing valve

Travel gear

Travel motors

Fig. 24 Schematic of travel circuit

Charge circuit
The control oil required for the control of the travel pumps is drawn out of the hydraulic oil tank by the internal
charge pump .

168 BOMAG 008 915 04

Travel circuit 9.9
The charge circuit is fitted with one 12 µm fine filter. The oil flows through this filter to the individual consumers
and functions.
The filter is equipped with a bypass valve. This valve opens at a pressure differential (pressure difference be-
tween filter inlet and filter outlet) of Δp = 3.5 bar. This pressure differential depends on the filter contamination
and the viscosity of the hydraulic oil.

Fig. 1
The differential pressure switch (B21) switches when a differential pressure of Δ p 2.5 bar is reached. The
fault information will therefore already be available before the bypass valve opens.

Travel motors
The motors are bent axle motors A6VM107HA2R1 with variable displacement.

Travel gear

Fig. 2

008 915 04 BOMAG 169

9.9 Travel circuit

1 Travel motor, left 7 Travel motor, right

2 High pressure connections 8 High pressure connections
3 Solenoid for travel direction valve, Y163 9 Solenoid for travel direction valve, Y164
4 Solenoid valve travel speed range selection,
Qmax. Y03 / Y130
5 Flushing valve
6 Pressure test port M1, pilot pressure

Travel gear
The two travel gears are reduction gears with a transmission ration i = 32.2.

Travel motors
Brake unit

Travel gear

Fig. 3

1 Oil filler screw, gear oil
2 Oil level inspection plug, gear oil
3 Oil drain plug, gear oil
4 Gearbox ventilation
5 Oil inlet to release the brake, max. 21 bar
6 Oil inlet from master brake cylinder, max. 81 bar
7 Oil inlet for brake cooling, max. 6 bar
8 Oil outlet for brake cooling
9 Oil drain plug, brake oil

The charge oil flow is additionally needed for releasing the multi-disc brakes in the travel gears of the com-
pactor wheels.

170 BOMAG 008 915 04

Travel circuit 9.9
The gearbox inlet carries the travel motor and the hydro-dynamic multi-disc brake. This brake is statically re-
leased and applied via the brake valve. A second brake connection serves the purpose of hydro-dynamic brak-
ing, the brake pressure is received from a brake cylinder, the brake is applied via the brake valve opening
pressure.
The brake housing is cross-flushed in order to avoid premature wear of brake discs. These two ports are also
located on the brake housing.

008 915 04 BOMAG 171

9.10 Steering circuit

9.10 Steering circuit

Steering valve

Tank

Steering pump

Steering cylinder

Priority valve

Fig. 1
The steering circuit is an open hydraulic circuit and consists mainly of:
l the steering pump,
l
the priority valve
l
the steering valve
l
the steering cylinder
l the pressure resistant connecting hoses

Two steering wheels

The machines are equipped with two steering wheels. However, the machines are fitted with only one steering
valve, which is arranged between the steering wheels. Two circulating roller chains connect both steering wheels
with the steering valve.

172 BOMAG 008 915 04

Steering circuit 9.10
Dual sprocket Steering wheel

Chain guide Roller chain

Steering column

Roller chain Steering valve

Fig. 1

Steering axle

Joint carrier
Tie rod
Body bolster

Steering arm

Wheel bearing Steering cylinder

Fig. 2 Steering axle

Steering pump
The steering pump is a tandem gear pump with fixed displacement. The pump is driven by the diesel engine and
draws the hydraulic oil directly out of the oil tank. The oil then flows to the priority valve and from there to the
steering valve or the brake housings.

Priority valve
Since the steering pump, besides its function of supplying the steering system, also serves the purpose of cross-
flushing the brake, the system is equipped with a priority valve. The priority valve ensures that the steering will
always be prioritized under any condition. The priority valve is triggered by the steering valve through the LS-
line. This valve restricts the oil flow to the brake housings whenever oil is needed for the steering.

008 915 04 BOMAG 173

9.10 Steering circuit

Fig. 3 Priority valve

l When operating the steering the steering valve will generate a load signal "LS", informing the priority valve
that more oil should be directed to the steering.
l When the steering is not operated, the complete oil flow will flow to both brake housings for cross-flushing.

174 BOMAG 008 915 04

Cooling and cross-flushing of the brake housing 9.11
9.11 Cooling and cross-flushing of the brake housing

Oil thermostat
Check valve

Return flow filter

Cooler
Return flow manifold

Tank

Fig. 1

! Caution
The flow direction must not be mixed up.
All return flows pass through the return flow manifold with temperature controlled valve (oil thermostat). This
valve guides the oil flow directly back to the tank, until the operating temperature is reached. At an oil tempera-
ture of 55 °C the valve starts to switch over and at 70 °C the total amount of oil will flow through the hydraulic oil
cooler.

008 915 04 BOMAG 175

9.11 Cooling and cross-flushing of the brake housing

When the steering is not operated, the complete oil flow will flow to both brake housings for cross-flushing. This
cross-flushing is protected by a 6 bar check valve. After the brake housings the oil flows are united and passed
through a return flow filter (12 µ fine filter) back into the tank.
The filter is equipped with a bypass valve. This valve opens at a pressure differential (pressure difference be-
tween filter inlet and filter outlet) of Δp = 3.5 bar. This pressure differential depends on the filter contamination
and the viscosity of the hydraulic oil.
The differential pressure switch (B22) switches when a differential pressure of Δp 2.5 bar is reached. The fault
information will therefore already be available before the bypass valve opens.

Check valve

Fig. 2 Check valve and return flow filter for cross-flushing of brake housing
1 Differential pressure switch, B22
2 Cross-flushing temperature switch, B148

176 BOMAG 008 915 04

Edge cutter 9.12
9.12 Edge cutter

Fig. 1

Pos. Designation Pos. Designation

1 Hydraulic oil tank 3 Poppet
2 Priority valve 4 Hydraulic cylinder

Control valve
The control valve consists of the electro-magnetically operated control valve and two unlockable check valves
(pressure retaining valves).
If the edge cutter is not operated, the complete oil flow is directed through the open channel in the closed valve
to outlet T, from where the complete oil flow is directed to both brake housings for cross-flushing.

008 915 04 BOMAG 177

9.12 Edge cutter

If the control valve is actuated out of neutral to one of the two active positions, the open oil flow passage is closed
and the oil flows through the valve to the corresponding side of the hydraulic cylinder. The unlockable non-
return valves lock the oil in the cylinder chambers, until a new control command opens these valves and allows
the oil to flow out.

178 BOMAG 008 915 04

Check the hydraulic oil level 9.13
9.13 Check the hydraulic oil level

! Caution
In hydraulic systems filled with Panolin HLP
Synth. 46 always use the same oil to top up. With
other ester based oils consult the lubrication oil
service of the respective oil manufacturer.
If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped, check
all lines, hoses and components for leaks.
For quality of oil refer to the "table of fuels and lu-
bricants".

Fig. 2
l
Check the oil level in the inspection glass (Fig. 2).

Normal level
approx. 3 cm (1.2 in) below the top edge of the inspec-
tion glass.

Minimum level
Middle of inspection glass.
l
If necessary fill in hydraulic oil through the filler
neck.

008 915 04 BOMAG 179

9.14 Replace hydraulic oil and breather filter.

9.14 Replace hydraulic oil and

breather filter. WATER-AQUA

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! 538124

Fig. 3
! Caution l Unscrew plug (Fig. 3) . Drain and collect hydraulic
The hydraulic oil must also be changed after ma- oil.
jor repairs in the hydraulic system. l Turn the plug tightly back in.
Perform the oil change when the hydraulic oil is
warm.
Replace the hydraulic oil filter elements with every
hydraulic oil change.
Change the filter only after the hydraulic oil
change and after the test run.
Clean the area round hydraulic oil tank, filler
opening and breather filter.
Do not start the engine after draining the hydraulic
oil.
Do not use any detergents to clean the system.
Use only lint-free cleaning cloths.
For quality and quantity of oil refer to the "table of Fig. 4
fuels and lubricants". l Remove the plug (Fig. 4) from the hydraulic oil tank .
When changing from mineral oil based hydraulic l
Fill in new hydraulic oil through the screen.
oil to an ester based biologically degradable oil,
you should consult the lubrication oil service of
the oil manufacturer for details. i Note
We recommend to use our filling and filtering unit with
fine filter to fill the system. This ensures finest filtration
Environment of the hydraulic oil, prolongs the lifetime of the hydrau-
Any hydraulic oil must be caught and disposed of lic oil filter and protects the hydraulic system.
in an environmentally friendly manner.
l Check the oil level in the inspection glass.

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.

180 BOMAG 008 915 04

Replace hydraulic oil filter 9.15
9.15 Replace hydraulic oil filter

! Danger

Danger of scalding!
Danger of scalding with hot oil when unscrewing
the hydraulic oil filter.

! Caution
If the filter has to be changed together with the hy-
draulic oil, the filter must only be changed after
the oil change and after the test run.
Fig. 6
Always replace both hydraulic oil filters.
l Remove filter bowl (1) (Fig. 6) with filter element (2).
Do not reuse the oil in the filter bowls.
l Remove the old filter element and clean filter bowl
Visible dirt may be an early sign for the failure of
and thread.
system components and indicate the possible fail-
ure of components. In this case determine the l Clean the thread on the filter bowl.
cause and replace or repair the defective compo- l Reassemble the filter bowl with a new filter element
nents, if necessary. Negligence may cause de- and new seals (3).
struction to the entire hydraulic system.
l Run the diesel engine for a maximum of three min-
Do not clean or reuse the filter element. utes at low speed to bleed the hydraulic system.
Apart from the normal oil change intervals, the fil- l Check for leaks after a short test run.
ter element must also be changed after major re-
pairs in the hydraulic system.

Environment
Catch running out oil.
Dispose of oil and filter inserts in compliance with
environmental protection regulations.

i Note
The machine is equipped with two hydraulic oil filters.
The bigger filter filters the oil in the steering hydrau-
lics, the smaller filter cleans the brake flushing oil.

Fig. 5

i Note
If the hydraulic oil filter warning lamp (j) (Fig. 5) in the
instrument cluster lights up during start up or opera-
tion, immediately replace the hydraulic oil filter.

008 915 04 BOMAG 181

9.16 Replacing the bypass filter

9.16 Replacing the bypass filter*

! Danger

Danger of scalding!
By hot oil when unscrewing the filter.

! Caution
If the filter has to be changed together with the hy-
draulic oil, the filter must only be changed after
the oil change and after the test run.
Replace the filter element at the latest after one
year

Environment
Dispose of the old filter element environmentally.
l Open the engine hood.

Fig. 7
l Unscrew the fastening screws (Fig. 7) and take off
the cover.
l
Replace the filter element, attach the cover and fas-
ten it with the screw.

* Optional equipment

182 BOMAG 008 915 04

 10 Brake

008 915 04 BOMAG 183

10.1 Overview

10.1 Overview

Fig. 1

Pos. Designation Pos. Designation

1 Compressor 7 Brake housing
2 Air vessel rear 8 Air vessel front
3 Air drier 9 Diaphragm cylinder with master brake cylinder
4 Brake releasing valve 10 Brake valves
5 Brake valve 11 Shuttle valves
6 Pressure reducing valve

184 BOMAG 008 915 04

Brake system 10.2
10.2 Brake system

Tank

Brake releasing valve

Pressure reducing valve
Travel pump

Brake valve

Brake housing

Fig. 1 Parking brake

The pneumatic tired roller is equipped with two brake systems:
l A static parking brake, which is electrically released and hydraulically applied against the spring force of the
multiple brake discs (Fig. 1).
l A hydro-dynamic service brake, which compresses the brake discs via the compressed air brake pedal and
a hydraulic master brake cylinder by means of hydraulic pressure and swashes the travel pump back towards
neutral by an inching valve (Fig. 2).

008 915 04 BOMAG 185

10.2 Brake system

Air drier

Tank
Cooling

Compressor

Shuttle valve

Tank

Travel pump
Brake valve
Tank

Membrane cylinder

Brake housing
Fig. 2 Service brake

Parking brake
Parking brake closed
The brake solenoid valve (Y04) is electrically triggered by the rotary switch (S111) via the emergency stop switch
(S01).
In de-energized state (Y04) the charge pressure to the brake pistons is interrupted, allowing the hydraulic oil to
return to the tank via the 3/2-way valve. The spring force of the brake discs closes the parking brake.

186 BOMAG 008 915 04

Brake system 10.2
Parking brake released
In energized condition (Y04) the connection to the tank is interrupted and charge oil is directed to the brake pis-
ton. The charge pressure works against the spring force of the brake spring and releases the brake discs.

Fig. 3

1 Pressure reducing valve, 21 bar 3 Brake releasing valve

2 Brake valve (Y04)

Service brake

! Caution
After work in the brake system, the system must be thoroughly purged.
The system pressure in the compressed air system is 8.1 bar.
At a pressure< less than 5.7 bar the pressure switch (B12) will switch, the control light (brake system) will light
up and the warning buzzer will sound.

008 915 04 BOMAG 187

10.2 Brake system

Air tank

Shuttle valve
Membrane cylinder
Master brake cylinder

Hydraulic circuit Brake pedals

Brake

Fig. 1 Service brake, pneumatic section

Shuttle valve, two-way valve

Fig. 2 Two-way valve

Purpose: Alternate ventilation of a line, which can be controlled by two different lines or circuits.

188 BOMAG 008 915 04

Brake system 10.2
Membrane and master brake cylinder

Membrane cylinder

Master brake cylinder

Fig. 3
in combined pneumatic/hydraulic brake systems brake booster (membrane cylinders) are used to amplify the
pedal force generated by the driver
The membrane cylinder is pneumatically controlled via a pneumatic brake pedal and applies pressure to the pis-
ton of the master brake cylinder, so that this cylinder can apply hydraulic pressure to the brake pistons in the
travel gears and thus compress the multiple brake discs.

Inching valve

Inching valve

Fig. 4
The brake pressure is fed into the inching valve of the travel pump in order to reduce brake disc wear. If the
driver gently kicks down the brake pedal (< 20 bar), the hydrostatic drive is solely braked via the inching function.
When applying high braking pressure (> 20 bar), both the hydraulic system and the service brake will work si-
multaneously. Increasing pressure in the brake system causes the travel pump to swash back towards neutral.

008 915 04 BOMAG 189

10.2 Brake system

Brake housing

Fig. 5 Brake housing

1 Gearbox ventilation 7 Brake springs

2 Oil outlet for brake cooling 8 Oil inlet for brake cooling, max. 6 bar
3 Brake discs 9 Oil inlet from master brake cylinder, max. 81 bar
4 Radial seal 10 Oil inlet to release the brake, max. 21 bar
5 Oil inlet to release the brake, max. 21 bar 11 Drive shaft
6 Brake piston

190 BOMAG 008 915 04

Brake system 10.2
Ventilation ports

Fig. 6 on travel pump inching valve

Fig. 7 Pressure test port on right hand brake housing

Fig. 8 on master brake cylinder

008 915 04 BOMAG 191

10.3 Stopping the machine, operating the parking brake

10.3 Stopping the machine, operat-

ing the parking brake

Danger
!

Danger of accident!
Even when leaving the machine just for a short
while you should generally apply the parking
brake and shut the engine down.
l Stop the machine.

538164

Fig. 9
l
Shift the travel lever (Fig. 9) to ”Neutral” position.

538054
Fig. 10
l
Turn the rotary switch/button for parking brake (Fig.
10) to position "left".

192 BOMAG 008 915 04

Driving the machine / braking the machine 10.4
10.4 Driving the machine / braking
the machine

!Danger
Danger of accident!
Wet and loose soils considerably reduce the
ground adhesion of the machine on inclinations
and slopes.
Soil conditions and weather influences impair the
climbing ability of the machine.
Fig. 11 Do not drive up and down inclinations which ex-
ceed the maximum gradability of the machine (see
The parking brake warning light (m) (Fig. 11) in the in-
chapter "technical data").
strument cluster lights up.
Always select lowest speed range when driving
downhill. Risk of overheating the brake!
Driving across slopes should therefore be strictly
avoided, because of the high risk of tipping over
and the related risk of severe or even fatal acci-
dents.
You should therefore always drive straight up or
down a slope.
Do not drive without wearing your seat belt.
Always give way to loaded transport vehicles!
Before starting to drive make sure that the drive
range is absolutely safe.
Switch the lights on if the visibility is poor.
After starting the engine quickly operate the warn-
ing horn and wait for a moment, so that people can
leave the danger zone.

Fig. 12

!Danger
Danger of accident!
If the pressure in the compressed air accumulator
for the brake system drops below 5.7 bar (83 psi),
the warning buzzer will sound and the brake pres-
sure warning lamp (a) (Fig. 12) will light up.

008 915 04 BOMAG 193

10.4 Driving the machine / braking the machine

Do not start to drive before the pressure in the

compressed air accumulator is higher than 5.7 bar
(83 psi) and the warning buzzer has stopped.

Driving the machine

i Note
The machine can be operated from either of the two
operator’s stands.

538005

Fig. 15
l Turn the rotary switch/button for parking brake (Fig.
15) to the "middle position" (parking brake re-
leased).
The parking brake warning light in the instrument clus-
ter goes out.

538140

Fig. 13
l Select the desired speed range (Fig. 13).

N Fig. 16
l Kick the throttle pedal (Fig. 16) slowly down, ac-
cording to the desired travel speed.

R 538161
Braking the machine (service brake)
Kick down half of the
Fig. 14
pedal way = hydrostatic braking (inching valve)
l Pre-select the desired travel direction (Fig. 14).

Caution
!

Danger of engine damage!

Strictly avoid overreving of the engine.

i Note
Hydrostatic braking can cause the engine speed to in-
crease. In this case kick the pedal further down to ac-
tuate the multi disc brake.
longer pedal stroke= additional dynamic service
brake (multi-disc brake)

194 BOMAG 008 915 04

Driving the machine / braking the machine 10.4

538140

Fig. 17
The oil temperature in the service brake (multi-disc
brake) is monitored.
In case of overtemperature the brake temperature
warning lamp (I) (Fig. 17) in the instrument cluster
flashes and the warning buzzer sounds.
Fig. 19
l In case of extreme down slopes turn the rotary
switch for travel speed ranges to the left (Fig. 19), to
prevent overheating of the brake.

Fig. 18
l Brake pedal left or right (Fig. 18), kick down as nec-
Fig. 20
essary for the desired braking effect.
Hydrostatic + dynamic permanent braking power (Fig.
20).
! Danger

Danger of accident!
Always brake very gently on slippery roads, dan-
ger of skidding.
If the operation temperature warning light flashes
and the warning buzzer sounds stop the machine
immediately, run the engine with medium speed
and wait until the light goes out. Then drive on
with low speed and in lowest speed range.
i Note
The diagram shows the maximum downhill slope that
can be driven in permanent operation, in dependence
on machine weight and selected travel speed range.
Example:
Machine weight = 15,000 kg (33000 lbs):
3. travel speed range

Solution:
max. downhill
slope = 12%

Danger
!

Danger of accident!
The specified values refer to permanent operation
and are also dependent on ambient temperature
and degree of soiling of the radiator.

008 915 04 BOMAG 195

10.5
Steeper downhill slopes can also be driven over
shorter distances (<300m (1000 ft)).
Strictly avoid overreving of the engine.
In case of overheating of the brake (indicated by
warning light and warning buzzer) stop immedi-
ately and run the engine with medium speed, until
the oil circuit has cooled down.
The diagram solely refers to the permissible per-
manent braking power. For safe travelling on such
down slopes, the ground surface must have suffi-
cient grip.
196 BOMAG
Multi-disc brake, function test
10.5 Multi-disc brake, function test
! Danger
Life hazard!
Before checking the multi-disc brake make sure
that there are no persons or obstacles in the dan-
ger zone around the machine.
The travel range of the machine must be free of
obstructions.
If the function test of the multi-disc brake fails you
must take the machine out of service until the
brake discs have been replaced.
l Starting the engine
538077
Fig. 21
l
Turn the rotary switch/button for the parking brake
(Fig. 21) clockwise and hold it.
538165
Fig. 22
l Move the travel lever (Fig. 22) forward and kick the
throttle pedal fully down.
l If the machine startsv to drive take it out of service
and have the brake discs replaced.
008 915 04
Towing in case of an engine failure 10.6
10.6 Towing in case of an engine
failure

Danger
!

Danger of accident! Danger of injury!

Before releasing the parking brake secure the ma-
chine against unintended rolling by using appro-
priate means (e.g. metal wheel chocks).
When using towing ropes tow the machine only
uphill.
When towing downhill you must use a rigid towing
Fig. 24
device.
l Press the emergency operation button (Fig. 24)
The machine cannot be steered.
completely down.
Use a towing vehicle with sufficient traction and
braking power for the unbraked towed load.
Do not touch hot engine parts.
i Note
Use a suitable pipe.
After starting the engine the emergency operation but-
Caution
!
ton returns automatically to initial position.
Tow the machine only after having released the
parking brake.
l Insert the pump lever extension and operate the
pump, until the brake is released.
Towing speed 1 km/h (0.6 mph), max. towing dis-
tance 500 m (1640 ft).
After towing
l
Always secure the machine against unintended roll-
ing.
Danger
!
l Open the engine hood.
Before loosening the drawbar secure the machine
against unintended rolling by using appropriate
means (e.g. metal wheel chocks).
l Re-tighten both high pressure relief valves on the
travel pump (Fig. 23) again with 100 Nm (74 ft.lbs).

Fig. 23
l
Slacken both high pressure relief valves (Fig. 23) on
the travel pump for approx. one turn.

! Caution
Turn only the bigger hexagon (arrow). Do not turn
the pressure adjustment screw, as otherwise the
high pressure relief valve need to be adjusted!

008 915 04 BOMAG 197

10.6 Towing in case of an engine failure

198 BOMAG 008 915 04

 11 Pneumatics

008 915 04 BOMAG 199

11.1 Overview

11.1 Overview

Fig. 1

Pos. Designation Pos. Designation

1 Compressor 7 Brake housing
2 Air vessel rear 8 Air vessel front
3 Air drier 9 Diaphragm cylinder with master brake cylinder
4 Brake releasing valve 10 Brake valves
5 Brake valve 11 Shuttle valves
6 Pressure reducing valve

200 BOMAG 008 915 04

Pneumatic system 11.2
11.2 Pneumatic system

Air drier

Tank
Cooling

Compressor

Shuttle valve

Tank

Travel pump
Brake valve
Tank

Membrane cylinder

Brake housing
Fig. 1 Service brake
The compressed air system is needed for:
l
Brake (see chapter on brake system)
l
and the tire inflation system (option)
The system pressure is 8.1 bar.
At a pressure< less than 5.7 bar the pressure switch (B12) will switch, the control light (brake system) will light
up and the warning buzzer will sound.
At a system pressure < 6.5 bar no air pressure will be available for the tire inflation system. Each rubber tire is
fitted with a pressure securing valve, this valve has been set to a residual pressure of 2 bar and thus prevents
the tire from deflating.

008 915 04 BOMAG 201

11.2 Pneumatic system

Components
Compressor and regeneration tank
The compressor is driven via gear drive on the flywheel end of the engine.
Lines connect it to the lubrication oil supply of the engine and the air is supplied by the air filter. I

! Caution
All lines connected with the compressor must be permanently sealed air tight, they should be routed
without tension and must be absolutely clean from inside (free of foreign matter, rust, scale, etc.).

Fig. 2

1 Compressor 4 Cooler - cooling spiral

2 Suction line 5 Regeneration tank
3 Pressure line

202 BOMAG 008 915 04

Pneumatic system 11.2
Air tank

Fig. 3

1 Air tank 4 Tire inflation system

2 Pressure switch brake (B12) switching point 5.7 5 Overflow valve, setting 6.3 bar
bar
3 Output, brake pedal 6 Pressure test port, max. 8.1 bar

3/2-way valve

Fig. 4 3/2-way valve

Purpose: Alternate connection of work lines (consumers) with the pressure line of the ventilation.

008 915 04 BOMAG 203

11.2 Pneumatic system

Tire pressure securing valve and rotary joint

Fig. 5

1 Pressure securing valve, adjustable 2 bar 2 Rotation joint

Air drier

Fig. 6

1 Air drier 4 Input

2 Pressure relief valve, setting 8.1 bar 5 output

204 BOMAG 008 915 04

Pneumatic system 11.2
Air drier
Single-chamber air draier with pressure controller
Atmospheric air taken in by the compressor contains a more or less significant moisture level. This means that
the compressor compresses a gas mixture of air and water vapour. The saturation limit (dew point) of the water
vapour proportion thereby depends on the air temperature and the relative humidity. By heating up the delivered
air the absolute humidity remains constant, but the max. possible absorption of water vapour increases. Vice-
versa, the proportion of water vapour condenses under dropping temperatures and is discharged as water from
the air.

Example
With a relative humidity of 100% and an air temperature of 50°C the proportion of the water vapour quantity is
90 g in 1 m3 drawn in air. If the temperature of the drawn in air quantity drops to 30°C, 60 g of water will be
discharged. This is a total of 0.06 l.

Function
You are to reduce the amount of water vapour generated in the compressed air. This is accomplished by cold
regenerated adsorption drying. This process is achieved by directing the compressed air generated by the com-
pressor through a granulate which is able to take up the air-borne water vapour. The granulate is regenerated
by backwashing with air that has already been dried.

Working principle

Fig. 7
The compressed air entering into the room (A) through port (1) flows through the fine filter (4), the ring channel
(b) to the upper side of the granulate cartridge (2). From here (room a) the compressed air passes through the
cartridge (2), whereby the moisture is absorbed by the granulate surface (3). Dry air then flows through the open-
ing check valve (5) into the port (21) and from there to the downstream equipment in the compressed air system.
At the same time compressed air flows through the throttle bore (c) and port (22) into the regeneration container.
Shut-off pressure is applied to room (D) through bore I and acts on the diaphragm (m). Once the spring force
has been overcome, the inlet (n) will open and the pressurized piston (d) will open the outlet (e). The air delivered
by the compressor now flows through room (A), channel (C) and ventilation (3) to the outside. The piston (d) also

008 915 04 BOMAG 205

11.2 Pneumatic system

has the function of a pressure relief valve. Under overpressure the piston (d) will automatically open the outlet
(e). If the supply pressure in the system drops below the switch-on pressure because of air consumption, the
inlet (n) will close and the pressure in room (B) decreases via the ventilation of the pressure regulator. The outlet
(e) closes and the process of drying is restarted.

Environment
Complete cartridges or granulate must be treated as hazardous waste. Replacement cartridges will be
taken back in case of replacement.

Test
l Check the air drier for leakage and correct regeneration function. For this purpose fill up the compressed air
system until the pressure regulator switches off and shut down the engine.
l Regeneration air should escape from the ventilation of the air drier for approx. 10 seconds.

Compressor
Working principle
The duty of compressors is the generation of compressed air for all compressed air consumers in the machine.

Fig. 8 Compressor
The compressor is driven by the engine. The crankshaft (1), which is connected with the piston (3) via the conrod
(2), controls the piston (3) between the upper and lower dead centres (or vice-versa). Due to the suction effect,
the downwards movement of the piston (3) opens the valve (4). The compressor draws in air through the up-
stream filter. The valve (4) closes again when the lower dead centre is reached. The subsequent upwards move-
ment of the piston (3) compresses the drawn in air. The compression pressure opens the valve (5) and the
generated compressed air flows through the compressed air generation equipment to the connected system.

Overflow valve
Function
Overflow valves separate individual areas of the pneumatic system from one another.

206 BOMAG 008 915 04

Pneumatic system 11.2
Retaining position (Fig. 9)

Fig. 9
The compressed air coming from the main air vessel enters through port (1) into the valve. The compressed air
flows through the bore (a) into the ring channel (b). Since the membrane (3) keeps the bore (c) closed, the com-
pressed air cannot flow through.

Overflow position (Fig. 10)

Fig. 10
Once the force of the adjusting spring (5) can be overcome by the compressed air in the ring channel (b), the
membrane (3) is lifted and air can flow through the bore (c). Once the low spring force (6) has been overcome,
the compressed air will open the check valve (7) and flow through port (2) to the connected secondary consumer.
If the pressure drop in the main air vessel [port (1)] is higher than in the connected secondary consumer, the
pressure in port (2) will predominate, so that the check valve (7) will close immediately and prevent then air from
flowing back.
However, if the pressure in port (2) drops, the pressure in port (1) will also drop, until membrane (3) closes.

008 915 04 BOMAG 207

11.2 Pneumatic system

Test
No compressed air should escape from port (2) up to the value of the set overflow pressure, when port (1) is
vented. After overflowing there should be equal pressure in the connected lines or air vessels. If the pressure
drops in port (1), it should not drop in port (2).

Check valve
Purpose
Protection of pressurized lines against accidental ventilation.

Fig. 11

Working principle
Air flow is only possible in direction of the arrow on the housing. The check valve, which is closed the inlet when
removing pressure in the charge air line, makes sure that no air can flow back. When increasing the pressure in
the charge air line the spring loaded check valve will open the passage again to enable pressure compensation.

208 BOMAG 008 915 04

Operating the tire inflation system 11.3
11.3 Operating the tire inflation*
system

i Note
Changing of the tire pressure is possible during oper-
ation. For correct tire pressure refer to the table at the
end of this manual.

!Caution
Do not switch on both rotary switches /to inflate/
deflate the tires) at the same time.

Inflating the tires

Fig. 12
l
Turn the rotary switch (Fig. 12) clockwise.
The tires will be inflated, the pressure can be read on
the pressure gauge of the tire pressure indicator.

Relieving the tire pressure

Fig. 13
l Turn the rotary switch (Fig. 13) clockwise.
The tires will be deflated, the pressure can be read on
the pressure gauge of the tire pressure indicator.

* Optional equipment

008 915 04 BOMAG 209

11.4 Draining the air pressure vessel

i Note 11.4 Draining the air pressure ves-

A safety device makes sure that the tire pressure does sel
not fall below 2 bar (29 PSI).

i Note
This work can be performed at the end of the working
day when the pressure air vessel is completely full.
l
Shut the engine down and operate the parking
brake.

Fig. 14
l Pull the actuator chain (Fig. 14) for the drain valve
for a short moment.

i Note
During the draining process listen to the sound of the
escaping air.
If the sound changes while draining:
Check whether water or dirt runs out from the breather
valve.
In this case the air drier must be replaced.

210 BOMAG 008 915 04

Change the air drier for the brake system 11.5
11.5 Change the air drier for the 11.6 Check the supply lines for the
brake system compressor
l Shut the engine down and operate the parking
Environment brake.
Dispose of the filter environmentally.
l Run the engine, until the air pressure vessel for the
brake is fully filled (shut-off pressure).
l Shut down the engine.

Fig. 16
l Operate the actuating chain (Fig. 16) of the drain
valve, until the pressure air vessel is empty.

538153

Fig. 15
l
Unscrew the filter cartridge (Fig. 15) using an ap-
propriate 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.
Fig. 17
l Remove the supply lines for the compressor (Fig.
17).

Fig. 18
l Check for deposits inside the pipes and hoses (Fig.
18).

008 915 04 BOMAG 211

11.6 Check the supply lines for the compressor

! Caution
If the value x+x=2 mm (0.08 in) is exceeded, clean
or replace the pipe.
Have the compressor repaired.
l Reconnect the supply lines.
l Start the engine and fill the pressure air vessel.
l Check the pressure air system for leaks.

212 BOMAG 008 915 04

 12 Engine

008 915 04 BOMAG 213

12.1 Description of engine

12.1 Description of engine

Numbering of cylinders

Fig. 1

Cylinder arrangement
The cylinders are successively numbered, starting
with 1 at the flywheel (Fig. 1) .

direction of rotation
Viewed on flywheel.
Turning ccw: Counter-clockwise.

Engine sides
Viewed on flywheel.

214 BOMAG 008 915 04

Description of engine 12.1

Fig. 2 right hand side

1 Crankcase ventilation 6 Lubrication oil filter

2 Lubrication oil filling neck 7 Lubrication oil drain plug
3 Injection pump 8 Fuel filter
4 Oil dipstick 9 V-belt
5 Lubrication oil cooler 10 Generator

008 915 04 BOMAG 215

12.1 Description of engine

Fig. 3 left hand side

1 Combustion air inlet 4 Connections intercooler

2 Coolant outlet 5 Exhaust outlet
3 Coolant inlet 6 Starter motor

216 BOMAG 008 915 04

Lubrication oil circuit TCD 2012 / 2013 12.2
12.2 Lubrication oil circuit TCD
2012 / 2013

25 26 23 22 18 12
12
123 19 20 21 17 15 11
12

8 7 6
5

24

27
Fig. 1 Lubrication oil diagram
1 Lubrication oil sump
2 Lubrication oil suction pipe
3 Lubrication oil pump
4 Pressure relief valve
5 Lubrication oil cooler
6 Return flow check valve (only on 2012)
7 By-pass valve
8 By-pass valve lubrication oil filter
9 Pressure control valve
10 Replaceable lubrication oil filter
11 Main lubrication oil lines
12 Internally switched exhaust gas recirculation
13 Crankshaft bearings
14 Conrod bearings
15 Camshaft bearings
16 Line to spray nozzle
1
1
1 14 13 16 10 9 4 2 3
17 Piston cooling nozzle with pressure maintaining
valve
18 Plunger with rocker arm pulse lubrication
19 Push rod, lubrication oil supply for rocker arm lu-
brication
20 Rocker arm
21 Return line to lubrication oil sump
22 Lubrication oil flow to exhaust turbo charger
23 Exhaust turbo charger
24 Return line from compressor / hydraulic pump to
crankcase
25 Compressor or hydraulic pump
26 Lubrication oil line to crankshaft and camshaft,
compressor / hydraulic pump
27 Return flow from exhaust turbo charger

008 915 04 BOMAG 217

12.3 Coolant circuit TCD 2012 / 2013

12.3 Coolant circuit TCD 2012 /

2013

Fig. 1 Fuel diagram

1 Coolant outlet on radiator

2 Thermostat
3 Coolant - supply to water pump
4 Coolant pump
5 Lubrication oil cooler
6 Cylinder cooling
7 Cylinder liner / head cooling
8 Coolant flow to heater
9 Cabin heater (optional)
10 Coolant to thermostat
11 Connection for cabin heater
12 Compensation line
13 Ventilation line to compensation tank
14 Coolant outlet to radiator
15 Compensation tank
16 Compensation line to heat exchanger

218 BOMAG 008 915 04

Exhaust gas recirculation 12.4
Internal exhaust gas recirculation
12.4 Exhaust gas recirculation

Fig. 1
1 Additional cams for exhaust gas recirculation. The intake valve opens for a moment during the exhaust cycle
and releases part of the exhaust gas flow back into the intake system. With the next intake cycle this partial
quantity is drawn in again.
2 Exhaust valve
3 Intake valve

008 915 04 BOMAG 219

12.5 Adjust the valve clearance

12.5 Adjust the valve clearance

! Caution
We recommend to have this work carried out by
trained personnel or our after sales service.
Before checking the valve clearance let the engine
cool down for at least 30 minutes. The engine oil
temperature must be below 80 °C (176 °F).
After a short test run check the engine for leaks.
l Attach the cranking device over the V-belt pulley
fastening screws.
l Remove the valve covers.
l Crank the engine, until the valves on cylinder 1
overlap.

i Note
Firing order 1-3-4-2
Overlapping of valves: Exhaust valve not yet closed,
intake valve starts to open.
920361
Fig. 3
!Caution l Attach the rotation angle disc (3) (Fig. 3) with the
This engine is equipped with an internal exhaust special spanner to the valve setscrew (2) on the in-
recirculation system. take valve.
With the intake valve opened, the exhaust valve l Fix the magnet (5) of the rotation angle disc.
will temporarily open for about 2 mm (0.08 in). l
Turn the rotation angle disc (3) clockwise against
This is no valve overlap condition! the stop (rocker arm no clearance) and set the scale
to zero.
Valves Cylinder l Turn the rotation angle disc (3) counter-clockwise,
overlapping 1 3 4 2 until the specified angle is reached:
l Hold the rotation angle disc tight, so that it does not
adjustment 4 2 1 3
turn, and tighten counter nut (1) (Fig. 2).
Intake valve clearance: 75° +10° l
After this adjust the clearance of the exhaust valve.
Exhaust valve clearance: 120° +10° l Repeat the adjustment procedure on each cylinder.

920362

Fig. 2
l Loosen the counter nut (1) (Fig. 2).

220 BOMAG 008 915 04

Check the engine oil level 12.6
12.6 Check the engine oil level 12.7 Changing engine oil and oil fil-
ter
! Danger

Danger of injury! Danger

!

Support the engine hood for all maintenance and Danger of scalding!
repair work.
When draining off hot oil.
By hot oil when unscrewing the engine oil filter.
Caution
!

The machine must be in horizontal position.

Caution
!
If the engine is warm, shut it down and check the Drain the oil only when the engine is warm.
oil level after five minutes.
For quality and quantity of oil refer to the ”table of
With a cold engine the oil level can be checked im-
fuels and lubricants”.
mediately.
For quality of oil refer to the "table of fuels and lu-
bricants". Environment
Catch running out oil and dispose of environmen-
tally together with the oil filter cartridge.

Fig. 4
l
Pull the dipstick (Fig. 4) out, wipe it off with a lint-
Fig. 5
free, clean cloth and reinsert it until it bottoms.
l
Unscrew the drain plug (Fig. 5), catch running out
l
Pull the dipstick back out.
oil.
l
The oil level must always be between the "MIN"- l Turn the drain plug tightly back in.
and "MAX"-marks. If the oil level is too low, top up
oil to the "MAX" mark immediately.

Fig. 6
l
Loosen and unscrew the fuel filter cartridge (Fig. 6)
using an appropriate filter wrench.
l Wipe the sealing face clean.

008 915 04 BOMAG 221

12.8 Change the fuel filter, bleed the fuel system

12.8 Change the fuel filter, bleed

the fuel system

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.

Caution
!

Fig. 7 Ensure strict cleanliness! Thoroughly clean the

l Cover the rubber seal of the new filter cartridge (Fig.
7) slightly with clean oil.
l Turn the new filter cartridge on by hand, until the
seal contacts.
l Tighten the filter element for another half turn.
area around the fuel filters.
Never fill filter cartridges beforehand - danger of
contamination!
After work on the fuel system bleed the system,
perform a test run and check for leaks.
Additional bleeding of the fuel system by a 5-
minute test run at idle speed or low load is manda-
tory.

Environment
Any fuel must be caught and disposed of in an en-
vironmentally friendly manner.
l Shut down the engine.
l
Open the engine hood

Replace the fuel filter

Fig. 8
l
Fill in new engine oil (Fig. 8) through the oil filler
neck.
l
Screw the cap back on again.
l After a short test run check the oil level on the dip-
stick .
l
The oil level should reach the MAX-mark, top up oil
if necessary.
l
Check filter cartridge and drain plug for leaks.

538122
Fig. 9
l Close the fuel valve (Fig. 9) on the fuel pre-cleaner.

222 BOMAG 008 915 04

Change the fuel filter, bleed the fuel system 12.8
Replace the fuel filter cartridge

Fig. 10
l Loosen and unscrew the fuel filter cartridge (Fig.
Fig. 12
10) using an appropriate filter wrench.
l (2) Pull the cable off the water separator (Fig. 12).
l Clean the sealing face on the filter carrier from any
Loosen the bleeding screw and drain off fuel from
dirt.
the bleeding screw.
l (3) Loosen and unscrew the fuel pre-filter cartridge
using an appropriate filter wrench.
l (4) Unscrew the water separator from the filter car-
tridge.
l (5) Apply a thin coat of oil to the rubber seal of the
water separator.
l (6) Turn the water separator on by hand, until the
seal contacts, then tighten hand-tight.
l (7) Apply a thin coat of oil to the rubber seal of the
filter element.
l (8) Turn the filter cartridge on by hand, until the seal
Fig. 11 contacts, then tighten hand-tight. Plug the cable of
l Slightly oil the rubber seal (Fig. 11) on the new filter the water sensor back on.
cartridge.
Bleed the fuel system
l
Turn the new filter cartridge on by hand, until the
seal contacts.
l
Tighten the filter element for another half turn. i Note
Air in the fuel system causes irregular running of the
engine, a drop in engine power, stalls the engine and
makes starting impossible.
Therefore bleed the fuel system after changing the
fuel pre-filter or working on the fuel system.

008 915 04 BOMAG 223

12.9
1 tor
538123
Fig. 13
l Slacken the bleeding screw (1) (Fig. 13) on the fuel
pre-filter for two to three turns.
l Open the fuel shut-off valve.
l Operate the hand pump manually, until fuel flows
out of the slackened bleeding screw without air
bubbles.
l Then tighten the bleeding screw while pumping.
l Start the engine and let it idle for five minutes.
224
Check, clean the water separator
12.9 Check, clean the water separa-
Danger
!
Fire hazard!
When working on the fuel system do not use open
fire, do not smoke.
Environment
Any fuel must be caught and disposed of in an en-
vironmentally friendly manner.
i Note
The service intervals for the water separator depend
on the water content in the fuel and can therefore not
be determined precisely. After taking the engine into
operation you should check the filter bowl initially eve-
ry day, later as required, for signs of water.
If a too high quantity is drained off, the filter needs to
be bled, see section "Replacing the fuel pre-cleaner
cartridge".
Fig. 14
l
If the warning light for water in the fuel (b) (Fig. 14)
in the instrument cluster lights up during operation,
drain the water from the fuel prefilter.
l Open the engine hood.
BOMAG 008 915 04
Checking the coolant level 12.10
12.10Checking the coolant level

! Danger

Danger of scalding!
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.

Fig. 15 Do not use radiator sealant to seal leaks.

l Slacken the drain plug (Fig. 15) for a few turns and For coolant quality refer to the "table of fuels and
catch running out fuel / water. lubricants".
l Turn the plug tightly back in. Check for leaks, if nec-
essary use a new seal ring.

i Note
Once the water separator is empty the warning light
for water in fuel must go out.

Fig. 16

i Note
A too low coolant level is indicated by the coolant level
warning light (f) (Fig. 16) in the instrument cluster.

Fig. 17
l
Check the coolant level (Fig. 17) only when the en-
gine is cold.
l
To top up unscrew the filler cap and fill in coolant up
to the MAX-mark.

008 915 04 BOMAG 225

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

12.11Check the anti-freeze concen- l Check the condition of the coolant.

tration and the condition of the l If the coolant is contaminated by corrosion residues
or other suspended matter, flush the cooling sys-
coolant tem, see section "Changing the coolant".

Danger
!

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 quality and quantity of coolant refer to the "ta-
ble of fuels and lubricants".
Do not mix different coolants and additives, see
section "Fuelds and Lubricants - Coolant".
In case of lubrication oil entering into the cooling
system or a suspicious turbidity caused by corro-
sion residues or other suspended matter, the
coolant must be drained off and the complete
cooling system needs to be cleaned. Lubrication
oil can damage the sealing materials used in the
engine.

Environment
Catch coolant and dispose of environmentally.

Fig. 18
l Unscrew the radiator cap (Fig. 18) and check the
anti-freeze concentration with a conventional tester.

! Caution
The anti-freeze concentration (additive) must be at
least 35 Vol% and maximum 45 Vol%.

226 BOMAG 008 915 04

Replacing the coolant 12.12
12.12Replacing the coolant
WATER-AQUA

! Danger

Danger of scalding!
Change the coolant only when the engine is cold.

! Caution
Do not start the engine after draining off the cool-
ant.
In case of lubrication oil entering into the cooling 538127
system or a suspicious turbidity caused by corro- Fig. 20
sion residues or other suspended matter, the
coolant must be drained off and the complete
l Unscrew the plug, let the coolant run out and catch
cooling system needs to be cleaned. Lubrication it (Fig. 20).
oil can damage the sealing materials used in the l Check the condition of the coolant.
engine.
When changing the coolant without any signs of ! Caution
contamination, cleaning of the cooling system is
Thoroughly flush the cooling system if the coolant
not necessary.
is contaminated by corrosion residues or other
suspended matter.
!Caution
If lubrication oil has entered you must add a
For quality and quantity of coolant refer to the "ta- cleansing agent in order to remove any residues
ble of fuels and lubricants". from the system. Follow the instructions of the
Do not mix different coolants and additives, see manufacturer. If in doubt consult your local serv-
section "Fuels and Lubricants - Coolant". ice station or the engine manufacturer.
l
Remove the thermostat.
Environment l
Fill in clean water.
Catch coolant and dispose of environmentally. l
Start the diesel engine and run it warm to operating
temperature.
l
Allow the engine to cool down to approx. 50 °C
(122 °F).
l
Drain all water off.
l
When using a cleansing agent repeat the flushing
process twice with clear water.
l Screw the plug back in once all coolant has run out.
l
Reinstall the thermostat .

! Caution
The anti-freeze concentration (additive) must be at
Fig. 19 least 35 Vol% and maximum 45 Vol%.
l Unscrew the cover (Fig. 19) from the compensation
tank.

008 915 04 BOMAG 227

12.13 Clean the cooling fins on engine and hydraulic oil cooler

12.13Clean the cooling fins on en-

gine and hydraulic oil cooler

Danger
!

Danger of injury!
Perform cleaning work only after the engine has
cooled down and with the engine stopped.
Wear safety goggles.

Caution
!

Fig. 21 Do not damage any cooling fins on the cooler core

l Fill in coolant (Fig. 21) up to the MAX-mark and
screw the filler cap back on.
l Start the diesel engine and run it warm to operating
temperature.
when cleaning.
i Note
Dirt on fan blades and oil cooler reduce the cooling ef-
fect. Dirt deposits in these areas are substantially sup-
ported by oil and fuel on these surfaces. For this
reason you should always seal any oil or fuel leaks in
the vicinity of the cooling fan or the oil cooler and clean
the cooling surfaces after.

Cleaning with compressed air

Fig. 22
l
Check the coolant level (Fig. 22) again, top up if
necessary.

Fig. 23
l Remove the cover plate (Fig. 23).

i Note
Start to blow out from the exhaust side.
l Blow the radiator 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.

228 BOMAG 008 915 04

Checking ribbed V-belts and compressor V-belts 12.14
12.14Checking ribbed V-belts and Checking the condition and tension of the
compressor V-belt*
compressor V-belts*

Danger
!

Danger of injury!
Perform this work only with the engine shut down.

Check condition and tension of ribbed V-

belt.

Fig. 26
l Inspect the entire circumference of the compressor
V-belt (Fig. 26) visually for damage and cracks. Re-
place a damaged or cracked V-belt.
l Check with thumb pressure whether the V-belt can
be depressed more than 10 to 15 mm (0.4 – 0.6
inches) between the V-belt pulleys, retighten if nec-
essary.

Fig. 24
l Inspect the entire circumference of the ribbed V-belt
(Fig. 24) visually for damage and cracks. Replace
damaged or cracked ribbed V-belts.

Fig. 25
l Check the distance between the tongue of the
moveable tensioner arm and the stop on the fixed
tensioner housing .
l If the distance "a" (Fig. 25) is smaller than 3 mm
(0.12 in), replace the ribbed V-belt.

* Optional equipment

008 915 04 BOMAG 229

12.15 Replacing ribbed V-belt and idler pulley

12.15Replacing ribbed V-belt and 12.16Air filter maintenance

idler pulley
! Caution
l Remove the compressor V-belt*.
Perform cleaning, maintenance and repair work
only with the engine shut down. Do not start the
engine after removing the filter element.
Do not use gasoline or hot fluids to clean the filter
element.
After cleaning the filter element must be inspected
for damage using a torch.
Air filter elements with damaged paper bellows or
seal lips must be replaced in any case.
The main filter element must be replaced after 3
times cleaning, but at the latest after one year, ir-
respective of the operating hours.
Each cleaning interval must be marked with a
Fig. 27
cross on the cover of the filter element.
l Press idler pulley (1) (Fig. 27) in direction of arrow
Cleaning does not make sense if the air filter ele-
using a socket wrench (3), until the locking pin (4)
ment is covered with a sooty deposit. Use a new
engages in the assembly bore.
filter element.
l Take the ribbed V-belt (2) first off the smallest pul-
Incorrectly handled inserts may become ineffec-
ley.
tive because of damage (e.g. cracks) and cause
l Unscrew fastening screws (5) and take off idler pul- damage to the engine.
ley.
l
Install a new idler pulley and tighten the fastening
screw with 80 Nm (59 ft.lbs)
l Install the new ribbed V-belt.
l Counter the idler pulley with a ratchet and remove
the locking pin.
l
Check whether the ribbed V-belt is correctly seated
in the guides.
l
Install and tighten the compressor V-belt.

Fig. 28
Maintenance of the air filter is due when air filter con-
trol light (h) (Fig. 28) in the instrument cluster lights
permanently when the engine is running, but at the lat-
est after one year.

i Note
Once the air filter warning light lights up, work may be
continued until the end of the day.
l Open the engine hood completely and secure it.

* Optional equipment

230 BOMAG 008 915 04

Air filter maintenance 12.16
Removing the main filter element

Fig. 31
l Blow the filter cartridge out from inside to outside
Fig. 29
with dry compressed air (max. 5 bar) (Fig. 31), until
l Loosen both locking hooks (Fig. 29) on the housing all dust has been removed.
cover and take the cover off.

Fig. 32
Fig. 30 l Examine the filter cartridge with a torch for cracks
l Pull out the main filter element (Fig. 30) with light and holes in the paper bellows (Fig. 32).
turning movements.
Caution
!
Cleaning the main filter element Do not continue to run the machine with a dam-
aged main filter element. If in doubt use a new
Caution
! main filter element.
Replace the safety cartridge if the main filter ele-
ment is defective!

008 915 04 BOMAG 231

12.16 Air filter maintenance

Cleaning the dust bowl

Fig. 34
l Pull the safety element (Fig. 34) out by slight turning
Fig. 33
movements.
l Pull the internal part (Fig. 33) out and remove the l Push in a new safety filter element.
dust from the cover.
l Reassemble main filter element and cover.
l Reinsert the inner part.

Caution
!
!Caution
Make sure that the cover locks engage correctly.
When assembling the inner part make sure that
the notch in the cover engages in the opening of
the inner part.

Installing the main filter element

l
Slide the main filter element carefully into the hous-
ing.
When closing the housing cover the main filter ele-
ment is automatically forced in the correct position.

Changing the safety filter element

! Caution
The safety filter element must not be cleaned and
should not be used again after it has been re-
moved.
Break the seal only to replace the safety filter ele-
ment.
The safety filter element must be replaced:
If the main filter element is defective.
after three service intervals of the filter cartridge,
at the latest after 2 years,
if the warning light comes on again after servicing
the main filter cartridge.
l
Remove the housing cover and pull the main filter
element off.

232 BOMAG 008 915 04

Replace the injection valves 12.17
12.17Replace the injection valves 12.18Replace crankcase ventilation
valve
! Caution
This work must only be performed by authorized
service personnel.
Injection lines must be renewed after they have
been loosened three times.

Fig. 35
l Replace the ventilation valve (Fig. 35).

008 915 04 BOMAG 233

12.19 Check the engine mounts

12.19Check the engine mounts

Fig. 36
l Retighten intake and exhaust tube fastenings (Fig.
35) on the cylinder head.
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 Retighten the fastening screws for oil sump and en-
gine mounts.

234 BOMAG 008 915 04

General trouble shooting chart TCD 2012 / 2013 12.20
12.20General trouble shooting chart TCD 2012 / 2013

Faults Causes Action

Temperature below starting limit Check
Oil level too low Fill up lubrication oil
Lubrication oil level too high Check the lubrication oil level, drain off if nec-
essary
Lubrication oil cooler defective Check
Exhaust gas counter pressure too high Check
Engine does not
V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose
start or starts
Engine oil with wrong SAE viscosity class Change the lubrication oil
poorly
Fuel quality not as specified in the operating Change the fuel
instructions
Air in the fuel system Bleed the fuel system
Battery defective or not charged Check the battery
Cable to starter loose or oxidized Check cable connection
Starter defective or pinion does not engage Check starter
Engine does not Engine electronics prevent starting Check fault by fault code, repair as necessary
start and diag-
nostic lamp flash-
ing
Engine starts, but V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose
runs irregularly or Incorrect valve clearance Adjust
misfires Injector defective replaced
Glow plugs defective replace
Air in the fuel system bleed
Fuel pre-filter/fuel pre-cleaner soiled Clean
Fuel quality not as specified in the operating Change the fuel
instructions
Injection line leaking Check the injection line
Injection valve defective Check / replace the injection valve
Speed changes Engine electronics detected a system fault Check fault by fault code, repair as necessary
are possible and and activates a substitute speed
diagnostic lamp
lights
Bleeding line clogged Clean
Engine shut-down lever still in stop position Check/replace
(shut-down solenoid defective)
Injector defective replace
Coolant heat exchanger soiled Clean
Coolant pump defective (V-belt torn or loose) check, whether torn or loose
Lack of coolant top up
Charge air pipe leaking Check the charge air pipe
V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose
Engine overheat-
Lubrication oil filter on air or lubrication oil replace
ing. Temperature
side soiled
warning system
Lubrication oil level too low Fill up lubrication oil
responds
Lubrication oil level too high Check the lubrication oil level, drain off if nec-
essary
Air filter clogged / exhaust turbocharger de- Check/replace
fective
Air filter service switch / indicator defective Check/replace
Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary
Short circuit of heat in cooling system Check the cooling system
Resistance in cooling system too high / flow check
quantity too low

008 915 04 BOMAG 235

12.20 General trouble shooting chart TCD 2012 / 2013

Faults Causes Action

Engine oil level too high Check the oil level
Engine shut-down lever still in stop position Shut-down solenoid defective
Fuel quality not as specified in the operating Change the fuel
instructions
Air filter clogged / exhaust turbocharger de- Check/replace
Insufficient en- fective
gine power Air filter service switch / indicator defective Check/replace
Charge air pipe leaking Check the charge air pipe
Intercooler soiled Clean
Injection line leaking Check the injection line
Injector defective replace
Injection valve defective Check the injection valves
Insufficient en- Engine electronics reducing the output power Check fault by fault code, repair as necessary
gine power and
diagnostic lamp
lights
Engine does not Injection line leaking Check the injection valve / replace if neces-
work with all cyl- sary
inders Injection valve defective Check the injection valve / replace if neces-
sary
Oil level too low Fill up lubrication oil
Engine has to low Extremely slanted position of engine Check engine pillow blocks / reduce the en-
or no oil pressure gine inclination
Engine oil of wrong SAE class or quality Change the lubrication oil
Engine has ex- Engine oil level too high Check oil level, drain off if necessary
cessive oil con- Extremely slanted position of engine Check engine pillow blocks / reduce the en-
sumption gine inclination
Blue engine ex- Engine oil level too high Check oil level, drain off if necessary
haust smoke Extremely slanted position of engine Check engine pillow blocks / reduce the en-
gine inclination
Temperature below starting limit
Fuel quality not as specified in the operating Change the fuel
White engine ex-
instructions
haust smoke
Injection valve defective Check the injection valve / replace if neces-
sary
Air filter clogged / exhaust turbocharger de- Check / replace if necessary
fective
Air filter service switch / indicator defective Check / replace if necessary
Black engine ex-
Charge air pipe leaking Check the charge air pipe
haust smoke
Injection valve defective Check the injection valve / replace if neces-
sary
Injector defective replace

236 BOMAG 008 915 04

Special tools, Deutz engine (TCD 2012 2V) 12.21
12.21Special tools, Deutz engine (TCD 2012 2V)


TCD 2012 2V Standard tools

8002
Pressure pump
Checking fuel system for leak-tightness

057 250 66

© 35409-2

8005
Compression pressure tester
for diesel engines
10 - 40 bar

057 250 67

© 35410-3

8024
Assembly pliers
Removing valve stem gaskets

057 250 68

© 37509-2

008 915 04 BOMAG 237

12.21 Special tools, Deutz engine (TCD 2012 2V)

Standard tools TCD 2012 2V

8113
Socket wrench insert
Torx - E 14

057 250 69

© 43022-0

8114
Socket wrench insert
Torx - E 20

057 250 70

© 35415-1

8115
V-belt tension meter
150 to 600 N
for checking the V-belt tension

079 947 09

© 35416-3

238 BOMAG 008 915 04

Special tools, Deutz engine (TCD 2012 2V) 12.21


TCD 2012 2V Standard tools

8189
Torx tool set
Case containing: 
- Double-ended ring spanner E6/E8
- Double-ended ring spanner E10/E12
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)

079 947 01

© 39432-1

8190
Rotation angle disc
with magnet
Setting valve clearance

057 250 72

© 43528-0

8191
Screwdriver insert
for slotted screw
Valve clearance setting

057 250 74

© 43060-0

008 915 04 BOMAG 239

12.21 Special tools, Deutz engine (TCD 2012 2V)

Standard tools TCD 2012 2V

8192
Bowl wrench
Fuel pre-filter (type: Racor)

057 250 73

© 43193-1

8194
Screwdriver insert
with hexagonal socket (size 4 mm),
1/2 inch, long version
(in conjunction with rotation angle disc 8190)

057 250 75

© 43183-0

8196
Open end wrench adapter
Size 13, 
for torque wrench
Tightening of lock nut of the valve clearance setting
screw

057 250 71

© 43019-0

240 BOMAG 008 915 04

Special tools, Deutz engine (TCD 2012 2V) 12.21


TCD 2012 2V Standard tools

8198
Pricker
Removing rotary shaft lip seal

057 250 76

© 43206-0

8199
Crowfoot wrench
Size 15
3/4 inch
(in connection with rotation angle disc 8190)

057 250 77

© 44309-0

9017
Assembly lever
Example: Removing and installing the valves

057 250 78

© 37511-2

008 915 04 BOMAG 241

12.21 Special tools, Deutz engine (TCD 2012 2V)


TCD 2012 2V Special tools

100 190
Connection piece
(in conjunction with compression pressure tester 8005)

057 250 79

© 42524-1

100 320
Turning gear
flywheel side

057 250 80

© 35422-1

100 330
Turning gear
V-belt pulley
Turning crankshaft on torsional vibration damper

079 947 19

© 35423-1

3/12

242 BOMAG 008 915 04

Special tools, Deutz engine (TCD 2012 2V) 12.21

Special tools TCD 2012 2V

100 400
Dial gauge with fixing wheel
Measuring range 0 -10mm / 0.01mm

057 250 81

© 35424-1

100 410
Digital gauge
Measuring range 0 -30 mm / 0.01 mm

057 250 82

© 43205-0

100 750
Measuring apparatus
Measuring bar with two spacing washers
(in conjunction with 100 400 or 100 410)
Checking valve lag dimension
Checking piston projection

057 250 83

© 39402-1

008 915 04 BOMAG 243

12.21 Special tools, Deutz engine (TCD 2012 2V)


TCD 2012 2V Special tools

103 050
Socket wrench insert
Size 15
for valve clearance setting with removed exhaust return
module
(in connection with 8190)

057 250 84

© 43023-0

103 220
Special pliers
for removing the roller tappet

057 250 85

© 43010-0

110 500
Special wrench
Size 17
Removing and installing high-pressure lines

057 250 86

© 35436-1

244 BOMAG 008 915 04

Special tools, Deutz engine (TCD 2012 2V) 12.21

Special tools TCD 2012 2V

110 700
Socket wrench insert
long
Assembling/disassembling pressure sensors
(rail pressure, oil pressure, fuel pressure)

057 250 87

© 43198-2

110 900
Assembly case
Case for O-rings, complete with:
Disassembly tool 110 901 and three assembly sleeves
with guide:
- High pressure pump (Ø 36), 110 902
- Injector, 2V motor (Ø 16), 110 903
- Injector, 4V motor (Ø 23), 110 904
Disassembling/assembling O-rings

057 250 88
© 43208-0

120 430
Assembly tool
Removing and installing the heating plugs

057 250 89

© 43020-0

008 915 04 BOMAG 245

12.21 Special tools, Deutz engine (TCD 2012 2V)


TCD 2012 2V Special tools

120 900
Support bracket
pivoting
Clamping cylinder head

057 250 90

© 35438-3

120 910
Base plate for support bracket
(in conjunction with support bracket 120 900 if support
bracket is not screwed tightly)

057 250 91

© 35439-3

121 410
Assembly tool
Assembling valve stem gaskets

057 250 92

© 37614-2

246 BOMAG 008 915 04

Special tools, Deutz engine (TCD 2012 2V) 12.21

Special tools TCD 2012 2V

121 420
Assembly sleeves
Set of assembly sleeves for valve stem gasket

057 250 93

© 43210-0

130 300
Universal piston ring pliers
Removing and installing the piston rings

057 250 94

© 43021-0

130 440
Trapezoidal groove wear gauge
for piston diameter 101 mm
Check piston ring groove

057 250 95

© 36461-2

008 915 04 BOMAG 247

12.21 Special tools, Deutz engine (TCD 2012 2V)


TCD 2012 2V Special tools

130 450
Trapezoidal groove wear gauge
for piston diameter 98 mm
Check piston ring groove

057 250 96

© 36461-2

130 660
Piston ring tensioning band
Piston diameter 98 mm

057 250 97

© 39408-1

130 670
Piston ring tensioning band
Piston diameter 101 mm

057 250 98

© 39408-1

248 BOMAG 008 915 04

Special tools, Deutz engine (TCD 2012 2V) 12.21

Special tools TCD 2012 2V

142 670
Assembly tool
Assembling crankshaft sealing ring
(opposite side to flywheel)

079 947 26

© 35445-1

142 830
Assembly tool
for crankshaft (flywheel side)

079 947 27

© 35446-1

144 800
Counter support
Torsional vibration damper

057 250 99

© 35453-1

008 915 04 BOMAG 249

12.21 Special tools, Deutz engine (TCD 2012 2V)


TCD 2012 2V Special tools

170 050
Special wrench
Unscrew the filter cartridges

079 947 28

© 37629-2

170 160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system

079 947 29

© 43663-0

6066
Assembly block
Engine clamping, double-sided

079 947 30

© 35451-2

250 BOMAG 008 915 04

Special tools, Deutz engine (TCD 2012 2V) 12.21

Special tools TCD 2012 2V

6066/158
Clamping bracket
consisting of:
1 holder 6066/158-1 rear right,
1 holder 6066/158-2 rear left,
1 holder 6066/158-3 front right,
1 holder 6066/158-4 front left
(in connection with assembly block 6066)
Clamping of the engine, double-sided

079 947 31

© 35452-1

008 915 04 BOMAG 251

12.21 Special tools, Deutz engine (TCD 2012 2V)

252 BOMAG 008 915 04

 13 Air conditioning system

008 915 04 BOMAG 253

13.1 Physical basics

13.1 Physical basics A - heat absorption

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

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

1. gaseous (invisible)

2. vaporous

3. liquid

4. solid

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

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

254 BOMAG 008 915 04

Physical basics 13.1
Pressure and boiling point 4. If a fluid evaporates it requires a lot of heat, i.e. the
fluid thereby cools down the surrounding environment
The boiling point is the temperature at which fluid
(e.g. alcohol on skin)
changes to gaseous state.
Changing the pressure above a fluid also changes the
boiling point. It is a well known fact, that e.g. the lower i Note
the pressure applied to water, the lower the boiling At absolute pressure 0 bar correspond with an abso-
point. lute vacuum. The normal ambient pressure (overpres-
sure) corresponds with 1 bar absolute pressure. On
When looking at water, the following values do apply:
the scales of most pressure gauges 0 bar corre-
l Atmospheric pressure, boiling point 100°C sponds with an absolute pressure of 1 bar (indicated
l Overpressure 0.4 bar, boiling point 126°C by the statement -1 bar below the 0).
l Vacuum -0.6 bar, boiling point 71°C
For an optimal exchange of heat, liquid refrigerants
must have a low boiling point, so that they can absorb
and dissipate heat quickly.

Fig. 4 Pressure - Temperature Diagram

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

008 915 04 BOMAG 255

13.1 Physical basics

Excerpt from the wet steam table * R134a

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

256 BOMAG 008 915 04

Refrigerant R134a
13.2 Refrigerant R134a
General
The evaporation and condensation process is the
method commonly used in mobile air conditioning sys-
tems. The system in this case works with a substance
that boils at low temperature, a substance referred to
a refrigerant. The refrigerant used is tetrafluoroethane
R134a, which boils at a temperature of -26.5°C and
under a steam pressure of 1 bar.
Although the refrigerant circuit is a hermetically closed
loop, the system loses approx. 100g of refrigerant
over the course of 1 year by diffusion through hoses,
pipes and seals, even though the system is free of
leaks. If too much refrigerant is lost the cooling power
of the system will drop.
Physical data of the refrigerant R134a
Chemical formula:
CH2F-CF3 or CF3-CH2F
Chemical designation:
Tetrafluoroethane
Boiling point at 1 bar:
- 26.5 °C
Solidification point:
-101.6 °C
Critical temperature:
100,6 °C
Critical pressure:
40.56 bar (absolute)
Critical point:
Critical point (critical temperature and critical pres-
sure) means that above this point there is no separat-
ing interface between liquid and gas. Above its critical
point any substance is gaseous. At temperatures be-
low the critical point all refrigerant types in pressure
containers have a liquid and a gaseous phase, i.e. a
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature.
008 915 04 BOMAG
13.2
Characteristics of the refrigerant R134a:
Refrigerant R134a is currently available under the fol-
lowing trade marks.
H-FKW 134a
SUVA 134a
KLEA 134a
Colour:
Refrigerant in form of vapour or liquid is colourless as
water. The gas is invisible. Only the bordering layer
between gas and liquid is visible. (Fluid level in rising
pipe of filling cylinder or bubbles in inspection glass).
In the inspection glass the liquid refrigerant R134a
may appear coloured (milky). This turbidity results
from partially dissolved refrigeration oil and is no indi-
cator for a fault.
Steam pressure:
In an incompletely filled, closed container, vaporous
refrigerant will volatilize from the surface in the same
quantity that will turn liquid in combination with steam
particles. This state of equilibrium occurs under pres-
sure and is frequently referred to as steam pressure.
The steam pressure is independent from the temper-
ature.
Physical properties of R134a:
The steam pressure curves of R134a and other refrig-
erants are partly very similar, making a clear differen-
tiation solely by pressure impossible. With R 134a the
compressor is lubricated by special synthetic refriger-
ation oils, e.g. PAG-oils (polyalkylene glycol oils).
Behaviour with metals:
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
compounds, leads to aggressiveness against certain
metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.
Critical temperature / critical pressure:
Up to a gas pressure of 39.5 bar overpressure (this
corresponds with a temperature of 101 °C) the refrig-
erant R134a remains chemically stable, above this
temperature the refrigerant decomposes (see com-
bustibility).
Water content:
In liquid refrigerant water can only be dissolved in very
low quantities. In contrast to this refrigerant steam
mixes with water steam at any ratio. If the dryer in the
257
13.3
liquid container has absorbed approx. 8 gr. of water,
the refrigerant circuit transports possibly existing wa-
ter in form of droplets. This water flows to the nozzle
of the expansion valve and turns to ice. The air condi-
tioning system stops cooling. Water destroys the air
conditioning system, because under high pressures
and temperatures and in connection with other con-
taminants it forms acids.
Inflammability:
Refrigerant is not inflammable. On the contrary, it has
fire inhibiting or fire extinguishing properties. Refriger-
ant is decomposed by flames or glowing surfaces. Ul-
traviolet light also cracks refrigerant (caused by
electric welding). This results in toxic fission products,
these must not be inhaled. However, irritation of the
mucous membranes is an early and in-time warning.
Filling factor:
In a container there must be a steam space above the
liquid space. The liquid expands with increasing tem-
perature. The steam filled space becomes smaller.
From a certain time on the container will be filled with
just liquid. After this only a minor temperature in-
crease is enough to generate very high pressures in
the container, because the liquid would like to expand,
but there is no more room. The related forces are high
enough to cause the container to burst. In order to
avoid overfilling of a container the pressure gas direc-
tive clearly specifies how many kilograms of refriger-
ant may be filled into the container per litre volume.
Multiplied with the internal volume this "filling factor"
determines the permissible filling capacity For refrig-
erants used in motor vehicles it is 1.15 kg/l.
Environmental aspects
The contribution of R134a to the greenhouse effect is
by factor 10 smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for
newly produced construction equipment were succes-
sively converted to refrigerant R134a. This refrigerant
does not contain any chlorine and is thus harmless for
the ozone layer. Until approx. 1992 air conditioning
systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decompo-
sition potential and also a potential to amplify the
greenhouse effect. Conversion programs for existing
old systems with the ozone damaging R12 are in ef-
fect. For reasons of protecting the environment refrig-
erant must not be discharged into the atmosphere.
258 BOMAG
Compressor oil / refrigeration oil
13.3 Compressor oil / refrigeration
oil
The compressor oil lubricates the movable parts in the
compressor, seals e.g. the gap between piston and
cylinder inside the compressor to prevent refrigerant
loss and prevents other seals in the system from dry-
ing up.
Part of the compressor oil dissolves in the refrigerant
until saturation is reached, so that a gas mixture of re-
frigerant, water steam, compressor oil and contrast
agent circulates through the system.
Compressor oil (the oil quantity should be 10 % of the
refrigerant weight) mixes with the refrigerant and cir-
culates permanently through the system.
In connection with R134a- air conditioning systems
special synthetic compressor oils, e.g. polyalkylene
glycol (PAG) oils, are used. This is necessary, be-
cause e.g. mineral oil does not mix with R134a. Apart
from this, the materials in the R134a air conditioning
system may be attacked when the mixture is flowing
through the refrigerant circuit under high pressure and
at high temperatures or if the lubrication film in the
compressor tears off. The use of non-permitted oils
can cause damage to the air conditioning system, you
should therefore only used the approved oils.
Properties of compressor oil / refrigeration oil:
The most important properties are high solvency in
connection with refrigerants, good lubrication charac-
teristics, that they are free of acids and their low water
content. For this purpose only certain oils can be
used. PAG-oils suitable for use with refrigerant R134a
are highly hygroscopic and will not mix with other oil.
As a protection against the invasion of moisture drums
must immediately be closed again after they had been
opened. Compressor oil ages under the effect of
moisture and acids, becomes dark, viscous and ag-
gressive against metals.
008 915 04
Working principle of the air conditioning system
13.4 Working principle of the air
conditioning system
All air conditioning systems are based on the same
principle. They extract heat from the surrounding en-
vironment. Everybody knows the effect: if a sweating
body is exposed to wind it will cool down, because
heat is extracted. For this purpose a refrigerant circu-
lates in a closed circuit inside the vehicle. This refrig-
erant thereby continuously changes its physical state
between liquid and gaseous.
Fig. 1 Principle sketch of an air conditioning system
An engine driven compressor (1) draws in gaseous re-
frigerant from the evaporator (5) and compresses it.
During this process the temperature of the refrigerant
increases tremendously.
The refrigerant vapour is then pumped to the con-
denser (2). This condenser is arranged directly in front
of the vehicle radiator, so that a sufficient air flow is as-
sured. In the condenser (2) the gas is cooled down
and consequently liquefied.
In the dryer / liquid container (3) the refrigerant is then
collected and freed of moisture and contaminants.
The expansion valve (4) regulates the flow rate from
the dryer / liquid container (3) back to the evaporator
(5) and the circuit starts again.
008 915 04 BOMAG
13.4
13.5 Monitoring devices
Pressure switch
The pressure switch (8) is used as monitoring feature
for too high and too low pressures. The switching con-
tacts (4 and 5) effect the magnetic clutch of the com-
pressor via a relay (6).
If the system pressure increases excessively, e.g. be-
cause of a excessively soiled condenser, a failed fan
or a defective expansion valve, the high pressure con-
tact (5) will cut off the electric power supply to the
magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off
pressure by the set differential pressure, the magnetic
clutch of the compressor is switched on again.
The low pressure contact (4) interrupts the electric
power supply to the magnetic clutch when the set
pressure is fallen short of (possible causes: lack of re-
frigerant, defective expansion valve, too low heat
load, defective evaporator fan, ...). Since the refriger-
ant R134a has an evaporation temperature of 0 °C at
an overpressure of 2 bar, the low pressure contact (4)
is set to approx. 1.5 bar to avoid icing. The switch on
pressure is 0.5 to 2 bar higher than the shut-off pres-
sure (depending on system, see description of com-
ponents.)
Thermostat
A frost protection thermostat (3) protects the evapora-
tor against icing. Similar to the pressure switch, the
thermostat activates or deactivates the magnetic
clutch for the compressor. Depending on the design,
the feeler of the temperature control is mounted be-
tween the fins of the evaporator or attached to the
evaporator outlet (suction side). With fixed tempera-
ture controls the control switches the compressor off
at about 1 °C and back on again at about 2.5°C to 5.5
°C (depending on system, see description of compo-
nents.)
With adjustable temperature regulators the switching
point can be changed so that the compressor is al-
ready shut down at higher temperatures. This enables
regulation of the air temperature.
259
13.6 Description of components

Monitoring chain 13.6 Description of components

Compressor

Fig. 2 Monitoring chain consisting of:

l 1 Switch
l 2 Fuse
l 3 Thermostat
Fig. 3 Refrigerant compressor
l 4 Low pressure switch contact
The compressor is mounted to the engine and has the
l 5 High pressure switch contact
duty to build up the refrigerant pressure required for
l
6 Relay the function of the system. Coupling and decoupling is
l
7 Connection for magnetic clutch accomplished by an electromagnetically controlled
l
8 Pressure switch mechanical clutch, which is integrated in the V-belt
pulley of the compressor.

Compressor data
Displacement: 155 cm²
Weight: 6.9 kg
max. rpm: 6000
Sense of rotation: clockwise
Refrigerant: R134a
Oil quantity (scope of delivery): 207 gr
Oil: PAG SP-20 (H14-003-404)
The service valves are installed directly on the com-
pressor. These are used to e.g. evacuate and fill the
system.

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

Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.

260 BOMAG 008 915 04

Description of components 13.6
The following table shows how much compressor oil / Condenser
refrigeration oil will be lost in connection with various
types of work on the air conditioning system.

Reason of oil loss Amount of oil lost

Loss when emptying approx. 15 gr
Defective A/C hose approx. 30 gr
Replacement of condenser approx. 15 gr
Replacement of evaporator approx. 30 gr
Replacement of liquid con- approx. 30 gr
tainer
Replacement of expansion approx. 15 gr
valve

! Caution
Please bear in mind, that the new compressor is Fig. 4
delivered with a filling of 207 gr. compressor oil. The condenser is located in front of the the radiator for
To avoid excessive oil in the A/C-system and thus the machine. It emits heat energy from the system into
a poor cooling effect, the oil level in the A/C-sys- the surrounding air and liquefies the gaseous refriger-
tem must be adjusted accordingly. ant.
The quantity depends on the amount of oil that
may have been lost in connection with the possi- i Note
ble replacement of other components. The fins must be free of dirt and damage.
The compressor oil quantity must be 10% of the
refrigerant quantity in the complete system.
! Caution
With a refrigerant filling of 1100 gr. the system re- When replacing a heat exchanger, e.g. evaporator
quires a compressor oil / refrigerant oil filling of or condenser, any compressor oil lost by ex-
110 gr. changing the components, must be replaced with
Procedure: fresh oil.
Drain and measure the compressor oil from the
old compressor.
Drain the compressor oil from the new compres-
sor and only fill in the exact quantity that had been
drained out of the old compressor. The compres-
sor oil from the new compressor can be used for
this purpose.

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

008 915 04 BOMAG 261

13.6 Description of components

Dryer / filter / fluid container / inspection glass Pressure relief valve

Fig. 5 Fig. 6
The fluid container is equipped with a safety valve.
Dryer / filter
Response pressure 32 +/- 4 bar
The fluid container collects the fluid drops and passes
these then as a constant flow to the expansion valve. Tightening torque 10 - 15 Nm
Moisture that has entered during assembly of the re-
Inspection glass
frigerant circuit is absorbed by a dryer in the fluid con-
tainer.
At evaporation temperatures below zero the refriger-
ant will deposit previously absorbed moisture on the
expansion valve, where this water turns into ice and
thus adversely affects the controllability of the expan-
sion valve. Moreover, moisture in the refrigerant cir-
cuit causes corrosion, forms acids and enters into
chemical compositions.
Inside the refrigerant container the heavy liquid refrig-
erant collects in the lower part of the container, flows
through a rising pipe to the outlet marked "A" and thus
ensures bubble free operation of the expansion valve.

i Note
Since the absorbing capacity of this filter/dryer is lim-
ited, it must be changed within certain service inter-
vals. We recommend to replace it 1 x per years,
before the start of the season.
! Caution
The filter/dryer must generally be replaced when-
ever opening the refrigerant circuit, because
moisture will enter in such a case.
This requires emptying the air conditioning sys-
tem!
Installation position:
Fig. 7
During operation the refrigerant must flow through the
inspection glass without air bubbles. In most cases
the presence of air bubbles is a sign for a too low re-
frigerant level in the system. Apart from this, the refrig-
erant may not sufficiently condense as a result of a
soiled evaporator or a defective condenser fan and
the fluid level in the refrigerant container may drop
down to a level, at which gaseous refrigerant could
flow through the rising tube to the inspection glass.
This results in abnormally high temperatures in and on
the fluid lines (between refrigerant container and ex-
pansion valve), as well as very high pressures in the
pressure side.

The arrow marks on the filter/dryer must point in
flow direction, i.e. towards the expansion valve.
Filter/dryer cannot be treated for further use!
However, incorrect evacuation or filling may also be
the reason for air entering into the system and since
air cannot be condensed, one will not be able to get
rid of these bubbles by topping up refrigerant. In this
case the air conditioning system needs to be evacuat-
ed and refilled.

262 BOMAG 008 915 04

Description of components 13.6
Pressure switch
i Note
Air in the system is characterized by high pressures
and temperatures.
On R134a refrigeration systems the inspection glass-
es are equipped with moisture indicators. In addition
to the float, the dryer/collector/inspection glass combi-
nation has an indicator pearl integrated in the inspec-
tion glass, which changes its colour when absorbing
moisture.
The refrigerant level should be inside the inspection
glass and should only be checked after approx. 5 min-
utes continuous operation, because the refrigerant
must first evenly distribute all over the system.

! Danger
In case of mechanical damage or corrosion on
this pressure container this collector unit must be
replaced, to avoid bursting and further damage.
Fig. 8
After a minimum pressure is reached in the low pres-
sure side or a maximum pressure in the high pressure
side, the pressure switch (B75) will switch of the mag-
netic clutch of the compressor, thus to avoid destruc-
tion of system components by excessive pressure or
drawing in external gases and foreign matter as a re-
sult of too low pressure.

Working pressure:
Low pressure off: 1,5 ±0,5 bar
Low pressure on: 3.5 bar
Overpressure off: 25,0 ±1,5 bar
Overpressure on: 18,0 ±1,5 bar

008 915 04 BOMAG 263

13.6
Expansion valve
Fig. 9
The expansion valve is mounted inside the HKL-mod-
ule in the cabin. The expansion valve always allows a
small amount of the high pressure liquefied refrigerant
to flow into the evaporator, which has a much lower
pressure. This lower pressure causes these liquid re-
frigerant to expand and to evaporate to gaseous state.
The heat required for this evaporation process is tak-
en from the ambient air through the lamellas and sup-
plied to the refrigerant. This is the so-called cooling
effect.
The thermostatic expansion valve operates with an
external pressure compensation. This type of expan-
sion valve works with high accuracy, because it uses
pressure and temperature at the evaporator outlet and
adjusts and overheating of approx. 7 K. The already
installed expansion valves and the ones delivered as
spare parts have this overheating value pre-set. In or-
der to prevent a loss in performance or compressor
damage you should only use original expansion
valves, because adjusting expansion valves takes a
lot of time and care.
i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+
264 BOMAG
Description of components
Evaporator
Fig. 10
The evaporator is mounted inside the HKL-module in
the cabin. It consists of a heat exchanger (inside air -
refrigerant), with refrigerant flowing to a pipe system
with cooling flanges.
As with the condenser, correct operation of all fans
and cleanliness of the fins must be assured.
Air conditioning systems have a circulation air filter
mounted in the air flow in front of the evaporator,
which should be cleaned or changed by the operator,
depending on the amount of dirt.
A condensation water filter is mounted in the air flow
after the evaporator. This filter has the function to col-
lect the water that has condensed from the air in the
evaporator block and to discharge this water into the
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.
! Caution
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.
008 915 04
Description of components 13.6
Thermostat Pipes and hoses

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

Recommended tightening torques for O-ring

sealed fittings
Fig. 11
The feeler of a defroster thermostat to switch off the Thread Spanner width Torque
magnetic clutch in case of icing up or to switch the 5/8“ 17 or 19 13,6 - 20,3 Nm
clutch back on after defrosting, is mounted on the 3/4“ 32,5 - 39,3 Nm
evaporator. 7/8“ 27 35,3 - 42,0 Nm
1 1/16“ 32 40,7 - 47,5 Nm
With fixed temperature controls the control switches
M30X2 36 105,0 - 115,0 Nm
the compressor off at about +1 °C and back on again
M36X2 41 165,0 - 175,0 Nm
at about +2.5°C to +5.5 °C.

Adjustable thermostat Bending radii for air conditioning hoses

With adjustable temperature regulators the switching

point can be changed so that the compressor is al- Hose type Nominal Bending radius
ready shut down at higher temperatures. This enables width
regulation of the air temperature. GH 134 NW8 min. 50 mm
GH 134 NW10 min. 65 mm
GH 134 NW12 min. 75 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm

Fig. 12 adjustable temperature controller

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

008 915 04 BOMAG 265

13.7 Measuring the compressor oil level

13.7 Measuring the compressor oil 13.8 Checking the magnetic clutch
level l Measure the voltage.

!Caution i Note
The compressor oil level must be checked after Nominal value = vehicle voltage
replacing a system component or if a leak in the l
Check the magnetic coil locking ring for secure fit.
system is suspected. Use only compressor oil / re-
frigeration oil PAG SP-20 (H14-003-404). l
Check the current consumption.
l Run the compressor for 10 minutes at engine idle
speed.
l remove the refrigerant from the air conditioning sys-
tem.

Fig. 1

Fig. 1 i Note
l
Turn the compressor, as shown in (Fig. 1), if neces- at 12 Volt vehicle voltage approx. 3.5 Amp.
sary remove V-belt and hoses.
at 24 Volt vehicle voltage approx. 1.75 Amp.
l
Remove the oil plug.
Overcurrent indicates a short circuit inside the mag-
netic coil.
i Note No current indicates an interrupted electric circuit.
The oil level must reach the bottom edge of the bore,
top up or drain off oil if necessary.
l
Close the oil plug again.

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

Fig. 2 Measuring the air gap

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

266 BOMAG 008 915 04

Inspection and maintenance work
i Note
The gap should be 0.4 to 0.8 mm.
l
Take off the drive V-belt and rotate the V-belt pulley
by hand while the magnetic clutch is disengaged.
i Note
In case of excessive flatness faults or deviations the
magnetic clutch needs to be replaced.
Cross-section of magnetic clutch
Fig. 3 shows a cross-section of the magnetic clutch. If
the coil (7) is not supplied with operating voltage,
there is no contact between the front plate of the
clutch (1) and the V-belt pulley (2). A spring presses
the front plate away from the belt pulley. The V-belt
pulley rotates with the bearing (3) in idle speed, the
compressor does not work. When the coil is supplied
with operating voltage (12 or 24 V), a magnetic field is
generated and pulls the front plate of the clutch. Both
front plate and compressor shaft (8) are then driven by
the V-belt pulley, the compressor works.
Fig. 3 Cross-section of magnetic clutch
008 915 04 BOMAG
13.9
13.9 Inspection and maintenance
work
l Visual inspection of the complete system for dam-
age.
l Check the compressor mounting bracket on the ve-
hicle engine for tight fit and damage.
l Check the condition, alignment and tightness of the
V-belt.
l
Check the routing of refrigerant hoses and cables in
the area of the vehicle engine and transmission, as
well as on the chassis for chafing and rectify any de-
tected faults. Ensure sufficient clearance to hot
parts, such as the exhaust; install a protective
shield, if necessary.
l Check the routing of hoses and hoses on the at-
tachment box or in the cabin.
l Check all hose and screw fittings for leaks.
l Check the fastening of the condenser unit.
l
Clean the condenser fins, replace the condenser
block if damaged fins are found.
l
Check the fastening of the evaporator unit.
l
Check the function of evaporator and condenser
fans.
l
Check the electric control panel. If discolorations on
conductors are found, these should be replaced
and possibly also the corresponding relays.
l
Switch on the cooling system and check the refrig-
erant level.
l
Filter/dryer and filter/dryer/fluid container combina-
tions must always be replaced after opening the re-
frigerant circuit. If these are in service for more than
1 year, there is a risk that they may be clogged by
excessive absorption of moisture! The filter/dryer
should be replaced in regular intervals.
l Measure the temperature on the evaporator: Meas-
ure the intake air temperature - Measure the blow
out air temperature - The temperature difference
should be at least 8-10 K.
l
Measuring the pressure in the refrigerant circuit
267
13.10 Checking, replacing the refrigerant compressor V-belt

13.10Checking, replacing the refrig- l Press the compressor in direction of arrow, until the
correct V-belt tension is reached.
erant compressor V-belt* l Retighten all fastening screws.

Danger
! Changing the V-belt
Danger of injury! l Slightly slacken the fastening screws 1, 2 and 3.
Work on the V-belt must only be performed with l Press the compressor against the direction of arrow
the engine shut down. completely against the engine.
Wear safety goggles. l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
Check the V-belt
l Tension the V-belt as previously described.

Caution
!

Check the V-belt tension after a running time of 30

minutes.

Fig. 4
l
Inspect the entire circumference of the V-belt (Fig.
4) visually for damage and cracks. Replace dam-
aged or cracked V-belts.
l Check with thumb pressure whether the V-belt can
be depressed more than 10 to 15 mm (0.4 – 0.6
inches) between the V-belt pulleys, retighten if nec-
essary.

Tighten the V-belt.

Fig. 5
l
Slightly slacken fastening screws 1, 2 and 3 (Fig.
5).

* Optional equipment

268 BOMAG 008 915 04

Service the air conditioning 13.11
13.11Service the air conditioning*

! Caution
Under very dusty conditions clean every day in or-
der to maintain the cooling power of the air condi-
tioning system.

Danger
!

Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
Fig. 7
age or explosion of the system.
l Turn the rotary switch for the cab ventilator (Fig. 7)
Clean the condenser to position "1".

Fig. 8
Fig. 6
l Choose a cooling temperature with the rotary switch
l Clean the condenser fins with compressed air or for the air conditioning system (Fig. 8) in the blue
cold water (Fig. 6). section.
l
Open the air outlet nozzles.
!Caution l
Check, whether the out flowing air is noticeably
During cleaning work do not damage the cooling cooler.
fins and realign bent fins.

Checking the refrigerant level i Note

The adjusted temperature must be below the actual
l Start the engine. temperature inside the cabin, so that the compressor
will be switched on.
l Open the engine hood.

* Optional equipment

008 915 04 BOMAG 269

13.11 Service the air conditioning

Checking the moisture level of the drying

agent

Fig. 9
l Check whether the white float (Fig. 9) inside the in-
spection glass of the drier/collector unit floats right
at the top. Fig. 11
l Check the moisture indication pearl (Fig. 11) inside
the inspection glass of the drier/collector unit.
i Note
The refrigerant level is correct. orange = Drying agent o.k.
colourless= moisture level of drying agent too high.
l Inform the service department. Replace drier/col-
lector unit, check air conditioning system.

Caution
!

Have the drier/collector unit replaced by the serv-

ice department every year before the operating
season.

Checking the condition of the drier/col-

lector unit

Fig. 10
l
If the white float (Fig. 10) inside the inspection glass
of the drier/collector unit floats at the bottom, inform
the service department.
i Note
The refrigerant level is not correct.
l Refrigerant must be filled up, if necessary check the
air conditioning system for leaks.
!Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeatedly
inspected by a specialist. In this sense repeated
inspections are external examinations, normally
on pressure reservoirs in operation. In connection
with this inspection the drier/collector unit must
be visually examined twice every year. During
these inspections special attention must be paid
to corrosion and mechanical damage. If the reser-
voir is not in proper condition it must be replaced
for safety reasons, as a precaution to protect op-
erators and third parties against any danger aris-
ing from the handling and operation of pressure
reservoirs.

! Danger

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

270 BOMAG 008 915 04

Drying and evacuation 13.12
13.12Drying and evacuation
Evacuation of air conditioning systems using R-type
refrigerants not only has the purpose of emptying the
system of all air before filling in refrigerant, but also to
verify the leak tightness over a longer lifetime in the
achieved vacuum. However, the most important factor
in this work step is the drying of the system.
Any water residues in the refrigerant circuit will com-
bine with the refrigerant, which will lead to the previ-
ously described consequential damage.
Vacuum pumps with a capacity of more than 100 l/min
and a final pressure of less than 30 micron, i.e. 0.039
Fig. 12 mbar should be used to evacuate the refrigeration
l Check the drier/collector unit (Fig. 12) for mechani- system.
cal damage or rust. The refrigerant compressor is not suitable for the pur-
pose of evacuation, because it is not able to achieve
a sufficient final vacuum and, apart from this, may be
mechanically damaged because of a lack of lubrica-
tion when running empty during evacuation.
It is common practice to evacuate the refrigeration
system to a final vacuum of 1 Torr, i.e. 1.33 mbar.
An exact time for evacuation and drying cannot be
predicted. It can only be determined by means of a
vacuum meter. However, if there is no vacuum meter
at hand it is generally better to evacuate 1 hour longer
than 1 hour too less.

Function drying:
Under normal ambient pressure (1.013 mbar) evapo-
rates absolute at 100° C. If the pressure is reduced,
water will already evaporate, e.g. under a pressure of
10 mbar, at an ambient temperature of almost 7°C,
but the water will not evaporate all at once. Since it is
very difficult to separate the steam from the vacuum in
the system, the evacuation process is supported by
the co-called vacuum breaking (filling the circuit with
dried nitrogen). With vacuum breaking the filled in
dried nitrogen absorbs the moisture in the refrigerant
circuit, which can then be easily discharged together
with the nitrogen.

008 915 04 BOMAG 271

13.13
13.13Emptying in case of repair
For repair work the air conditioning systems must very
often be emptied of all refrigerant.
Especially with expensive refrigerants and larger
amounts of oil it may be necessary to keep the refrig-
erant for later use.
For later use these refrigerants must be drawn out
with suitable equipment and intermediately stored in
collecting containers.
Environment
Contaminated refrigerant must be disposed of en-
vironmentally
Releasing refrigerant into the atmosphere is pro-
hibited (see restrictive injunction concerning
CFC, day of enforcement 01. 08. 1991, § 8)
! Danger
For draining refrigeration systems you should not
simply use any delivery containers, but only ap-
propriate pressure bottles, which must be special-
ly marked and should comply with the pressure
gas directive.
When transferring refrigerant you must make sure
that the bottle does not contain more than the per-
mitted amount of refrigerant in litres and has suf-
ficient gas space for expansion (filling factor: 0,7).
In order to reduce the evacuation period in case of
short repairs, you may fill the refrigerant circuit with
approx. 0.5 bar nitrogen when opening. This ensures
that nitrogen will flow out of the refrigerant circuit while
it is open and no air or moisture can enter. However,
the necessity for vacuum generation and a dryer
change remains.
272 BOMAG
Emptying in case of repair
13.14Leak test
! Caution
The use of leak detection colouring matter is not
permitted, because its chemical composition is
unknown and its effect on compressor oil and rub-
ber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Before starting the evacuation process, the refrigerant
circuit is filled with nitrogen through a pressure reduc-
er valve (approx. 22 bar). After this all connections in
the air conditioning system are checked with the help
of a suitable leak detection spray. A leak is thereby in-
dicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air con-
ditioning system with refrigerant.
Leak test with electronic leak tester
Fig. 1 Electronic leak tester
Small leaks with only very low amounts of refrigerant
escaping can be detected, e.g. with an electronic leak
tester. Such equipment is able to detect leaks of less
than 5 gr. per year.
The leak tester used must be specially designed for
the refrigerant composition in the air conditioning sys-
tem. For example, leak detectors for refrigerant R12
are not suitable for R134a, because the refrigerant
R134a is free of chlorine atoms, meaning that this leak
detector will not respond.
Leak test with soap bubbles
Fig. 2 Soap bubble test
Points susceptible for leakage are sprayed with a
soapy solution. Bubbles indicate the leak. The detec-
tion limit for R 134a is 250 g/year.
008 915 04
Filling instructions 13.15
13.15Filling instructions

Filling of refrigerant into the dried, vented and oil filed

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

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

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

008 915 04 BOMAG 273

13.15 Filling instructions

Fig. 1

Pos. Designation Pos. Designation

1 High pressure - gaseous 13 Manual shut-off valve (not used)
2 High pressure - liquid 14 Pressure switch with high and low pressure contacts
3 Low pressure - gaseous 15 Defroster thermostat
4 Compressor 16 Vacuum meter
5 Compressor pressure switch (not 17 Low pressure gauge
used)
6 not used 18 High pressure gauge
7 Evaporator 19 Pressure reducing valve
8 Expansion valve 20 Vacuum pump
9 Inspection glass 21 Nitrogen bottle
10 Filter dryer 22 Refrigerant bottle
11 Fluid container 23 Pressure gauge bar
12 Capacitor

274 BOMAG 008 915 04

Filling instructions
Filling instructions
1 Connect the service adapter with the blue hand
wheel in the suction side.
2 Connect the service adapter with the red hand
wheel in the pressure side (the hand wheels on
the service adapters must be fully backed out - left
hand stop)
3 Connect the blue suction hose below the blue
hand wheel on the pressure gauge bar to the blue
service adapter.
4 Connect the red pressure hose below the red
hand wheel on the pressure gauge bar to the red
service adapter.
5 Connect the yellow hose below the yellow hand
wheel on the manometer bar to the 2-stage vacu-
um pump.
6 Connect the last hose below the black hand wheel
on the nitrogen bottle via the pressure reducing
valve.
7 Check on the pressure gauge bar that all hand
wheels are closed.
8 Turn the hand wheels on both service adapter
clockwise. This opens the valves (right hand
stop).
9 Open the valve on the nitrogen bottle (only via
pressure reducer); pressure approx. 20 bar.
10 Open the black and red hand wheels on the pres-
sure gauge bar and fill nitrogen into the system,
until a pressure of approx. 3.5 to 5.0 bar is indicat-
ed on the suction side.
11 Then open the blue hand wheel and raise the
pressure in the suction side (max. 10 bar). Check
for leaks with a leak detection fluid or soapsuds.
12 If the system is leak tight, release the nitrogen
from the system. For this purpose disconnect the
hose from the nitrogen bottle and open the red,
blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand
wheels on the pressure gauge bar. In case of a
leak no or only an insufficient vacuum will be
reached. In this case proceed as described under
point 9-12. Once the leak is sealed continue with
point 14.
15 Once a sufficient vacuum is reached, both pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.
16 Switch off the vacuum pump, watch the pressure
gauges to see whether the vacuum is maintained.
17 Open the valve on the refrigerant bottle and open
the black and red hand wheels on the pressure
gauge bar. Fill refrigerant into the system, until a
pressure equilibrium between suction and pres-
008 915 04 BOMAG
13.15
sure side is reached (reading of pressure gaug-
es).
18 Close the red hand wheel.
19 Perform a leak test with the electronic leak detec-
tor.
20 Start the engine and switch on the system.
21 Open the blue hand wheel and continue filling in
refrigerant until the inspection glass is free or air
bubbles (in fluid container/dryer combinations the
white pearl should float in the upper third of the in-
spection glass). Then close the refrigerant bottle.
22 Close the blue hand wheel on the pressure gauge
bar.
23 Preparing the test run: -Close windows and doors
-Fan on full speed stage -Mount measuring feel-
ers to air discharge and air intake.
24 Run the system for approx. 20 minutes with medi-
um engine speed.
25 The temperature difference between air discharge
and air intake should be (depending on type of air
condition) 8-10°C. Ambient temperature in this
case approx. 20 °C. (These data are only refer-
ence values, which may be influenced by possible
insolation)
26 Switch off system and engine and check for leaks
again.
27 Turn out (left hand stop) and remove the hand
wheels on both service adapters.
28 Fit all valves with dust caps.
29 Perform a leak test.
30 Mark the system with the corresponding type
plates and information decals, such as type of oil
and refrigerant.
275
13.16 Trouble shooting in refrigerant circuit, basic principles

13.16Trouble shooting in refriger-

ant circuit, basic principles

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

Technical equipment
Pressure gauge and thermometer are the most impor-
tant auxiliary means for trouble shooting. The refriger-
ant states, such as overheating and undercooling,
provide important information when performing trou-
ble shooting. Even your own senses should not be un-
derrated in trouble shooting. Bubbles in the inspection
glass, contamination and white frost are visible indica-
tors. If the compressor draws in wet steam, this is vis-
ible in the suction line and may also be audibly Fig. 2 Pressure gauge
perceptible. An overloaded compressor can even be
Example:
smelled.
A totally empty air conditioning system holds an at-
The following tools and auxiliary means should be
mospheric pressure of approx. Pambp = 1 bar.
available for trouble shooting:
Filling the system with refrigerant causes an overpres-
l
Service station
sure of Pe = 3 bar.
l
Pressure gauge
l
Thermometer Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
l
dry nitrogen Evacuating the system down to Pe = -0.6 bar, creates
a "vacuum" (negative overpressure).
l
Refrigerant bottle for new refrigerant
l
Container for old oil Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
l
Vacuum pump
l
Hoses
l Scales
l Suction station
l Leak detector
The measuring equipment must be checked at regular
intervals. Calibration can only be made by an ap-
proved testing authority.

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

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

276 BOMAG 008 915 04

Trouble shooting in refrigerant circuit, basic principles
Pressure gauge with saturation temperature scale
Fig. 3 Absolute pressure gauge
Temperature scales on the pressure gauges always
refer to the absolute pressures Pabs. Please note that
it is not possible to measure a temperature directly
with a pressure gauge. The indicated temperatures
are just reference values. Only the saturation temper-
ature is assigned to the measured pressure.
If the refrigerant is fluid, the temperature is below the
saturation temperature.
If the refrigerant is gaseous, the temperature is above
the saturation temperature.
Pressure gauges must indicate 0 bar when not con-
nected to the system.
Low pressure gauges have a blue, high pressure
gauges a red border.
Thermometer
The thermometers used are normally digital thermom-
eters with surface or attachment sensors. Good heat
insulation of the measuring location must be assured,
especially in case of big temperature differences. An
economical use of heat-conduction paste is recom-
mended. If the measuring location is excessively con-
taminated, it needs to be cleaned and possibly treated
with a fine emery cloth. Only the temperature of the
sensor is measured. Temperature differences be-
tween the measured and the actual values of a few
degree Kelvin may be caused by missing heat insula-
tion and by insulating oxide layers on the cable.
Overheating
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are
008 915 04 BOMAG
13.16
not compressible and must therefore not enter into the
compression chamber of the compressor.
If the suction condition of the compressor is directly on
the dew line, an e.g. incorrect evaporator load can
cause "wet suction". This can lead to two processes,
which are destructive for the compressor. The liquid
refrigerant washes off the lubricating film between pis-
ton and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in
the cylinder causes a direct energy transfer from pis-
ton to cylinder cover during compression. The valve
plate may then be damaged by so-called fluid strokes.
Apart from protecting the compressor against fluid,
overheating has further advantages. Since the fluid
proportions in the drawn in steam reduces the flow
rate of the compressor, it may be increased by a over-
heating. Overheating also improves the oil recircula-
tion.
Common overheating values
The optimal overheating value is approx. 5 - 8 Kelvin.
With this overheating the maximum system power is
reached. However, the thermostatic expansion valve
is unable to regulate this value exactly. Depending on
design and operating conditions overheating fluctu-
ates within a range between 4 and 12 Kelvin. The in-
fluence of the ambient air on the suction line causes
an additional overheating effect.
Overheating is calculated as follows:
Δ to2h = to2h - to
Δ to2h, overheating at evaporator outlet in K
to2h, temperature at evaporator outlet in °C
to, evaporation temperature in °C
"h" represents "overheated"
Supercooling
It is the function of the expansion valve to reduce the
refrigerant to a lower pressure level (evaporation
pressure) after it has been liquefied. For an optimal
function of the valve pure fluid must be applied to its
inlet port.
The refrigerant must "squeeze" (literally speaking)
through a throttle gap inside the expansion valve.
When comparing a certain mass of refrigerant in liquid
and vaporous condition (under constant pressure),
the vaporous refrigerant requires a much higher vol-
ume. That's why the vaporous refrigerant needs a
much longer time to "squeeze" through the throttle
gap.
Vaporous refrigerant in front of the expansion valve
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
277
13.16 Trouble shooting in refrigerant circuit, basic principles

If the refrigeration system is operated with the "expan-

sion valve inlet" condition directly on the boiling curve,
slightest fluctuations in operating condition may cause
a formation of bubbles in front of the expansion ele-
ment.
For this reason one shifts the condition "Expansion
Valve Inlet" away from the boiling curve into the fluid
area and refers to this condition as Supercooling. This
supercooling ensures a fluid supply in front of the ex-
pansion valve.

Common supercooling values

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

Supercooling is calculated as follows:

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

278 BOMAG 008 915 04

Trouble shooting in refrigerant circuit, basic principles 13.16

Fig. 1 Refrigerant circuit with t, h- diagram

Pos Designation Pos Designation

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

008 915 04 BOMAG 279

13.17 Trouble shooting, refrigerant circuit diagram

13.17Trouble shooting, refrigerant

circuit diagram

Fig. 1 Refrigerant circuit diagram

Pos. Designation Pos. Designation

1 Cold air 9 Pressure switch with high and low pressure contacts
2 Evaporator 10 Dryer
3 Thermostat 11 Fluid container
4 Warm air 12 Hot air
5 Gebläse 13 Compressor
6 Inspection glass 14 Condenser
7 Expansion valve 15 Cooling air
8 Pressure gauge, high pressure 16 Pressure gauge, low pressure

280 BOMAG 008 915 04

Trouble shooting procedure 13.18
13.18Trouble shooting procedure l Evaporator and heating (with highest fresh air fan
speed) do not draw leak air.
l The fresh air fan runs when the engine is running
Procedure
and the air conditioning system is set to max. cool-
Knowledge ing power.
Trouble shooting is not possible with exact knowledge
l Ambient temperature above 15 °C.
about the system design, the installed components l The thermostat is correctly installed and the switch-
and their function in the system trouble shooting is not ing temperatures are correct.
possible:

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

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

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

008 915 04 BOMAG 281

13.18
Measuring points and measurements
Fig. 2 Flow diagram with measuring points
l C, condenser measuring points
l E, expansion valve measuring points
l O, evaporator measuring points
l V, compressor measuring points
The flow diagram contains "Minimum Requirements"
which must be fulfilled to be able to check the system
or perform trouble shooting.
Temperature and pressure at the evaporator outlet
can be used to derive the overheating of the evapora-
tor. Overheating is a clear indicator for the evaporator
filling level. In case of excessive overheating the re-
frigerant quantity fed into the evaporator is too low, in
case of insufficient overheating it is too high. In indi-
vidual cases one must then check if this situation is
caused by the expansion element or by insufficient fill-
ing. A differentiation is only possible if there is a clear
indicator for the refrigerant filling quantity.
Pressure and temperature at the condenser outlet can
be used to derive the supercooling. This can be used
282 BOMAG
Trouble shooting procedure
to assess the filling quantity. In systems with fluid con-
tainer the inspection glass is most suitable to check
the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
The hot gas temperature can be used to check wheth-
er the compressor runs in the permissible operating
range.
Example: Measurement of overheating
l a) Which measuring equipment is required?
l b) Where to measure with which size?
l c) A pressure gauge connected to the evaporator
indicates "Peo2 = 1.7 bar". How high is the evapora-
tor pressure "Po" ?
l
d) How high is the evaporator temperature "to" ?
l e) A thermal sensor attached to the evaporator out-
let measures the temperature "to2h = +3 °C". How
high is the overheating „Δto2h“ ?
l
f) Evaluation of the measured overheating.
008 915 04
Trouble shooting procedure 13.18
Solution: be a defect in the expansion valve or problems in the
l a) Pressure gauge, thermometer, steam table oil recirculation.
l b) Evaporation pressure "Peo2" and temperature The following list contains pressure values in a sys-
"to2h" are measured at the same point on the evap- tem, that can be expected at various ambient temper-
atures (measured at medium speeds).
orator outlet.
l c) Po = Peo2 + Pamb, "Evaporation pressure = Suction pressure (low pressure gauge)
pressure on evaporator + atmospheric pressure" =
Ambient temperature in °C Excess pressure in bar
1.7 bar + 1 bar = 2.7 bar.
25 approx. 2,0
l
d) "Pc" = 2,7 bar can then be used to derive an con- 30 approx. 2,5
densing temperature "to" of -2,2 °C from the steam 35 approx. 3
table for R134a. High pressure (high pressure gauge)
l e) Δto2h = to2h - to, „Overheating at evaporator out-
Ambient temperature in °C Excess pressure in bar
let = evaporator outlet temperature - evaporation
temperature" = 3 °C - (-2.2 °C) = 5.2 Kelvin. 25 approx. 8,0
35 approx. 13
l f) The determined overheating is within the usual
40 approx. 16
range of 4 - 12 Kelvin.
45 approx. 18
Example: Measuring supercooling
l a) Which measuring equipment is required?
l
b) Where to measure with which size?
l
c) A pressure gauge connected to the condenser in-
dicates "Pec2 = 15 bar". How high is the condensing
pressure "Pc" ?
l
d) How high is the condensing temperature "tc" ?
l
e) A thermal sensor attached to the condenser out-
let measures the temperature "tc2u = 58 °C". How
high is the supercooling "Δtc2u" ?
l
f) Evaluation of the measured supercooling.

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

Typical faults and possible causes

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

008 915 04 BOMAG 283

13.18 Trouble shooting procedure

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

284 BOMAG 008 915 04

Trouble shooting procedure 13.18
Suction pressure too low (1), high pressure too
low to normal (2)

Fig. 3

Cause Possible effect Remedy

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

008 915 04 BOMAG 285

13.18 Trouble shooting procedure

Suction pressure normal (1), high pressure too

high (2)

Fig. 4

Cause Possible effect Remedy

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

286 BOMAG 008 915 04

Trouble shooting procedure 13.18
Suction pressure too high (1), high pressure too
low to normal (2)

Fig. 5

Cause Possible effect Remedy

Compressor defective Cooling power too low Replace the compressor

008 915 04 BOMAG 287

13.18 Trouble shooting procedure

Suction pressure too high (1), high pressure too

high (2)

Fig. 6

Cause Possible effect Remedy

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

288 BOMAG 008 915 04

Trouble shooting procedure 13.18
Other faults

Symptom Cause Possible effect Remedy

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

Noise in system

Faults Possible cause Remedy

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

008 915 04 BOMAG 289

13.18 Trouble shooting procedure

Inspection glass

Faults Possible cause Remedy

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

Monitoring devices

Faults Possible cause Remedy

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

290 BOMAG 008 915 04

Steam table for R134a 13.19

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

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

008 915 04 BOMAG 291

13.19 Steam table for R134a

292 BOMAG 008 915 04

Steam table for R134a 13.19

008 915 04 BOMAG 293

13.19 Steam table for R134a

294 BOMAG 008 915 04

Steam table for R134a 13.19

008 915 04 BOMAG 295

13.19 Steam table for R134a

296 BOMAG 008 915 04

 14 Replacing the cab window panes

008 915 04 BOMAG 297

14.1 Assembly of window panes

Fig. 1

1 Glass panes
2 Fastening element
3 Fixing washer and spacer
4 Washer
5 Hexagon nut, self locking
6 Protective cap

298 BOMAG 008 915 04

Special tools, cabin windows 14.2
14.2 Special tools, cabin windows
1. Locking handle for fastening element

BOMAG part-no.: 055 705 84

Fig. 1
2. Suction lifter

commercial

Fig. 2
3. Cutter

Commercial

Fig. 3

008 915 04 BOMAG 299

14.3 Auxiliary materials

14.3 Auxiliary materials

Safety gloves
4. Cutter

Commercial

Fig. 1
5. Window glass bonding agent

BOMAG part-no.: 009 780 32

Fig. 2
6. Activator

BOMAG part-no.: 009 780 33

Fig. 3

300 BOMAG 008 915 04

Auxiliary materials 14.3
7. Silicone sealant

BOMAG part-no.: 009 700 36

Fig. 4

008 915 04 BOMAG 301

14.4 Removing and installing the window pane

14.4 Removing and installing the window

pane
Environment
Environmental damage
Dispose of glass splinters fro0m machine and
cabin or inside cabin in an environmentally
friendly way.

! Danger

Danger of cutting
Wear safety gloves.
1. Pull large glass rests off the bonding strip (Fig. 1).

Fig. 1
2. Clean the sealing surfaces from any adhesive
material (Fig. 2).
3. Use a cutter to remove adhesive residues with
glass rests.
4. Cover places without adhesive residues with an
activator.

Fig. 2
5. Insert the fastening element with washer into the
bore in the glass pane (Fig. 3).

Fig. 3

302 BOMAG 008 915 04

Removing and installing the window pane 14.4
6. Turn the fixing and spacer washer hand-tight onto
the thread of the fastening element (Fig. 4).

i Note
Do not overtighten the thread.

Fig. 4
7. Lay an approx. 1 cm high triangular bead of glass
pane bonding agent on the inside of the pane, ap-
prox. 1.5 cm away from the edge (Fig. 5).

i Note
Apply window pane bonding agent only to the
sides (sealing areas) which have contact with the
cabin.

Fig. 5
8. Attach the suction lifter to the outside of the pane
(Fig. 6).
9. Install the window pane so that the fastening ele-
ments fit into the bores of the fastening bars.
10. Press the glass pane against the sealing surface.

Fig. 6
11. Assemble the washer and the self-locking hexa-
gon nut.
12. Fasten the window pane to the fastening bar us-
ing a locking handle and a ring spanner (Fig. 7).

i Note
Only use the locking handle to counter.
13. Press the protective cap onto the hexagon nut.

Fig. 7

008 915 04 BOMAG 303

14.4 Removing and installing the window pane

14. Remove the suction lifter (Fig. 8).

Fig. 8
15. Clean the joining edges on the window pane (Fig.
9).

i Note
The joint flanks must be solid, dry and free of dirt,
dust, grease, oil and other foreign substances.
16. Mask the upper and lower contact areas to the
cabin.

Fig. 9
17. Apply silicone sealant evenly and under pressure
first to the inside joint edge (Fig. 10).

Fig. 10
18. Then apply silicone sealant evenly and under
pressure to the outside joint edge (Fig. 11).

Fig. 11

304 BOMAG 008 915 04

Removing and installing the window pane 14.4
19. Then spray the joints from inside and outside with
water containing washing up liquid (Fig. 12).

Fig. 12
20. Treat the inside joint (Fig. 13)

Fig. 13
21. and the outside joint (Fig. 14) with a scraper or a
spattle.

i Note
Once the silicone sealing agent has cured it can
only be removed mechanically.

Fig. 14

008 915 04 BOMAG 305

14.4 Removing and installing the window pane

306 BOMAG 008 915 04

 15 Front axle

008 915 04 BOMAG 307

15.1 Repair overview for front axle

15.1 Repair overview for front axle

Fig. 1 6 Tie rods

1 Joint carrier 7 Rotation joint
2 Body bolster 8 Steering axle
3 Steering leg 9 Joint bolt with bearing
4 Wheel bearing 10 Wheel discs
5 Steering cylinder 11 Bearing bushes for steering axle

308 BOMAG 008 915 04

Dismantling the front axle 15.2
15.2 Dismantling the front axle
!Danger
Danger of squashing!
Do not stand or work under suspended loads!
1. Disassemble the front axle.
2. Attach the lifting tackle to the front axle (Fig. 1).

Fig. 1
3. Place the front axle with the top side down safely
on a assembly trestle (Fig. 2).

Fig. 2
4. Remove the locking plates from the steering arms
(Fig. 3).
5. Drive bolt (1) out with a suitable drift punch and
pull out the tie rods (2).

Fig. 3
Disassembly of wheel bearing units
6. Remove the wheel discs (Fig. 4).

Fig. 4

008 915 04 BOMAG 309

15.2 Dismantling the front axle

7. Remove the rear bearing cover (Fig. 5).

8. Disassemble the front bearing cover with Bel-
leville springs, shims and backing discs.

Fig. 5
9. Attach the lifting tackle to the wheel bearing unit.
10. Turn impact puller 1 (Fig. 6) into the thread (M24)
and extract the bearing bolt with the bearing.

iNote
Remove also the joint bolt from the opposite side.

Fig. 6
11. Lift the bearing unit out of the body bolster (Fig.
7).

Fig. 7
12. Bend the lug if the locking plate open and un-
screw the grooved nut 1 (Fig. 8).

Fig. 8

310 BOMAG 008 915 04

Dismantling the front axle 15.2
13. Take off the locking plate (Fig. 9).

Fig. 9
14. Take off the shim (Fig. 10).
15. Extract the wheel bearing using a suitable puller.

Fig. 10
Disassembling the steering arm
16. Disassemble the left hand holding plate (Fig. 11).
17. Disassemble the right hand holding plate .
18. Attach the lifting tackle to the body bolster.

Fig. 11
19. Lift both steering arms out of the steering axles
(Fig. 12).
20. Unscrew the steering cylinder fastening screws
and disassemble the steering cylinder (1).

Fig. 12

008 915 04 BOMAG 311

15.2 Dismantling the front axle

21. Lay the steering arms on the workbench (Fig. 13).

Fig. 13
22. Knock out the bearing bushings 1 (Fig. 14).

Fig. 14
Disassembling the body bolster
23. Attach the lifting tackle to the body bolster.
24. Remove the rear bearing cover (Fig. 15).
25. Disassemble the front bearing cover with Bel-
leville springs, shims and backing discs.

Fig. 15
26. Press the body bolster against the joint recepta-
cle to the stop (Fig. 16).

i Note
The outer race (1) of the rocker bearing is thereby
stripped off.
If the outer race is not stripped off completely, it
may need to be destroyed.
It may be helpful to weld a flat steel bar to the out-
er race so that it can be pulled off with a puller.

Fig. 16

312 BOMAG 008 915 04

Dismantling the front axle 15.2
27. Force inner race 1 (Fig. 17) of the rocker bearing
off the bolt.

i Note
If the inner race cannot be levered off, it may
need to be destroyed.
It may be helpful to weld a flat steel bar to the in-
ner race so that it can be pulled out with a puller.

28. Remove backing disc (2).

Fig. 17
29. Unscrew the socket head cap screws (Fig. 18).

Fig. 18
30. Turn in the forcing screws and force the joint bolt
out of the body bolster (Fig. 19).

Fig. 19
31. Take the joint bolts out of the body bolster (Fig.
20).

Fig. 20

008 915 04 BOMAG 313

15.2 Dismantling the front axle

32. Press the body bolster against the joint recepta-

cle to the stop (Fig. 21).

i Note
The outer race (1) of the rocker bearing is thereby
stripped off.
If the outer race is not stripped off completely, it
may need to be destroyed.
It may be helpful to weld a flat steel bar to the out-
er race so that it can be pulled off with a puller.

Fig. 21
33. Force inner race 1 (Fig. 22) of the rocker bearing
off the bolt.

i Note
If the inner race cannot be levered off, it may
need to be destroyed.
It may be helpful to weld a flat steel bar to the in-
ner race so that it can be pulled out with a puller.

34. Remove backing disc (2).

Fig. 22
35. Unscrew the socket head cap screws (Fig. 23).

Fig. 23
36. Turn in the forcing screws and force the joint bolt
out of the body bolster (Fig. 24).

Fig. 24

314 BOMAG 008 915 04

Dismantling the front axle 15.2
37. Take the joint bolts out of the body bolster (Fig.
25).

Fig. 25
38. Take the joint receptacle out of the body bolster
and lay it safely to the side (Fig. 26).

Fig. 26
Disassembling the steering axles

i Note
The steering axles 1 (Fig. 27) cannot be disas-
sembled without being destroyed.
The steering axles were assembled with the help
of liquid oxygen at -20°C.

Fig. 27

008 915 04 BOMAG 315

15.3 Assembling the front axle

15.3 Assembling the front axle

! Caution
Ensure strict cleanliness.

! Danger

Danger of squashing!
Do not stand or work under suspended loads!
1. Lay the body bolster with the top side down on the
assembly trestle (Fig. 1).

Fig. 1
Assembling the steering axles
2. Spray the receiving bores with sliding lacquer
OKS 571 to ease assembly (Fig. 2).

Fig. 2

! Danger

Persons handling liquid oxygen must learn

the following safety instructions:
Safety instructions, handling low temperature
liquid gases
Safety instructions, lack of oxygen.
Safety instructions, oxygen enrichment.
Safety instructions, frost bites and congela-
tion.
3. Cool the steering axles down to at least -20°C
with liquid oxygen.
Fig. 3 4. Press the steering axles 1 (Fig. 3) into the body
bolster until they bottom.

i Note
The steering axles must slide into the body bol-
ster.

316 BOMAG 008 915 04

Assembling the front axle 15.3
Assembling the joint receptacle
5. Lay the joint receptacle 1 (Fig. 4) on the assembly
trestle.

! Caution
Do not apply any load to the steering axles be-
fore the bottom section is free of ice.
6. Attach lifting tackle to steering axles with body
bolster (2).

Fig. 4
7. Assemble new seal rings (Fig. 5).
8. Oil the seal rings.

Fig. 5
9. Oil the receiving bores for the joint bolts (Fig. 6).

Fig. 6
10. Insert the body bolster into the joint receptacle
(Fig. 7).

Fig. 7

008 915 04 BOMAG 317

15.3 Assembling the front axle

Assembling the joint bolts

11. Screw in the front guide pins (M10) (Fig. 8).
12. Screw in the rear guide pins (M10) .

Fig. 8
13. Oil and attach the front and rear joints bolts (Fig.
9).

! Caution
Avoid skewing of the joint bolts.
14. Attach the assembly tool (1).

Fig. 9
15. Pull both joint bolts in against the stop (Fig. 10).
16. Remove the assembly tool.

Fig. 10
17. Remove the guide pins (Fig. 11).

Fig. 11

318 BOMAG 008 915 04

Assembling the front axle 15.3
18. Screw in the socket head cap screws from both
sides (Fig. 12) and........

Fig. 12
19. ..... tighten (Fig. 13).

Fig. 13
Assembling the rocker bearings
20. Assemble the front backing disc (Fig. 14).
21. Assemble the rear backing disc.

Fig. 14
22. Spray the bearing seats and the inner bearing
races with sliding lacquer OKS 571 to ease as-
sembly (Fig. 15).

! Caution
Do not use any grease.

Fig. 15

008 915 04 BOMAG 319

15.3 Assembling the front axle

23. Attach the inner rocker bearing races with the

wide outer rim forward (Fig. 16) and.....

! Caution
Do not skew.

Fig. 16
24. .... drive in with a suitable mandrel (Fig. 17)

Fig. 17
25. Spray the bearing seats and the outer bearing
races with sliding lacquer OKS 571 to ease as-
sembly (Fig. 18).

! Caution
Do not use any grease.

Fig. 18
26. Attach the outer bearing races with the wide outer
rim facing outside and drive them in with a plastic
hammer (Fig. 19).

! Caution
Do not skew.

Fig. 19

320 BOMAG 008 915 04

Assembling the front axle 15.3
27. Assemble the rear bearing cover.
28. Tighten the hexagon screws (Fig. 20) cross-wise.

Fig. 20
Adjusting the bearing preload

! Caution
The bearings must be fully pressed in!
29. Insert backing disc 1 (Fig. 21) and Belleville
springs (2) into the front cover.

i Note
Lay the Belleville springs into the cover with the
curvature pointing down.

Fig. 21
30. Attach the front bearing cover with backing disc
and Belleville springs and locate the assembly
with two fastening screws (Fig. 22).

! Caution
Adjust the bearing preload with an axial
preload of 40KN.
With threaded rod M12-8.8 = 77 Nm tightening
torque
With threaded rod M16-8.8 = 90 Nm tightening
torque.
31. Push the threaded rod through joint receptacle
Fig. 22
and body bolster.
32. Tighten the threaded rod with the specified torque
(Fig. 23).

Fig. 23

008 915 04 BOMAG 321

15.3 Assembling the front axle

33. Measure the gap (measurement „Y“) between

cover and joint receptacle with a feeler gauge
(Fig. 24).

i Note
Shim thickness "S" = 3.4 mm - "Y"
34. Remove the cover again.

Fig. 24
35. Insert shim 2 (Fig. 25) of appropriate thickness
and backing disc (1) into the cover.

Fig. 25
36. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 26).

Fig. 26
37. Assemble the cover (Fig. 27) with Belleville
springs, shims and backing disc.
38. Turn in and tighten the fastening screws.

Fig. 27

322 BOMAG 008 915 04

Assembling the front axle 15.3
39. Turn in protection plug 1 (Fig. 28).

Assembling the steering cylinders

40. Insert the steering cylinder with fastening clamps
into the grooves (2) in the body bolster.
41. Turn in and tighten the screws.

Fig. 28
Steering arm

i Note
The work steps (Fig. 29) to (Fig. 45) apply for both
body bolsters.
42. Lay the steering arm on the workbench (Fig. 29).

Fig. 29
43. Attach the bottom bearing bushing (Fig. 30).

Fig. 30
44. Attach the top bearing bushing (Fig. 31).

Fig. 31

008 915 04 BOMAG 323

15.3 Assembling the front axle

45. Attach the assembly tool 1 (Fig. 32).

46. Pull both bearing bushings fully in with the as-
sembly tool.

Fig. 32
47. Assemble new seals and apply a thin coat of oil
(Fig. 33).

Fig. 33
48. Apply some grease to the friction disc contact
surface (Fig. 34).

Fig. 34
49. Assemble the friction disc (Fig. 35).

Fig. 35

324 BOMAG 008 915 04

Assembling the front axle 15.3
50. Apply some grease to the friction disc seal ring
(Fig. 36).

Fig. 36
51. Assemble and grease the seal (Fig. 37).

Fig. 37
52. Clean the steering axle (Fig. 38).

Fig. 38
53. Spray the steering axle with sliding agent OKS
571 (Fig. 39).

Fig. 39

008 915 04 BOMAG 325

15.3 Assembling the front axle

54. Apply some grease to the body bolster contact

surface (Fig. 40).

Fig. 40
55. Attach the lifting tackle to the body bolster (Fig.
41).

Fig. 41
56. Fit body bolster and steering axle together (Fig.
42).

Fig. 42
57. Assemble the holding plate (Fig. 43).

Fig. 43

326 BOMAG 008 915 04

Assembling the front axle 15.3
58. Tighten the screw (Fig. 44).

Fig. 44
59. Oil the receiving bores for the bearing bolts (Fig.
45).

Fig. 45
Assembling the wheel bearings

i Note
The work steps (Fig. 46) to (Fig. 53) apply for both
bearing shafts.
60. Attach lifting tackle to the bearing shaft (Fig. 46)
and..........

Fig. 46
61. ......... stand the shaft in a hydraulic press (Fig.
47).
62. Assemble spacer (1).
63. Spray the bearing mounting surfaces with sliding
agent OKS 571 .

Fig. 47

008 915 04 BOMAG 327

15.3 Assembling the front axle

64. Press the wheel bearing in until it bottoms (Fig.

48).

Fig. 48
65. Turn the bearing shaft by 180° (Fig. 49).
66. Assemble spacer (1).
67. Spray the bearing mounting surfaces with sliding
agent OKS 571 .

Fig. 49
68. Press the wheel bearing in until it bottoms (Fig.
50).

Fig. 50
69. Attach shim and locking plate (Fig. 51).

Fig. 51

328 BOMAG 008 915 04

Assembling the front axle 15.3
70. Attach the grooved nut with the bevelled side
down and tighten it hand tight with a sickle span-
ner (Fig. 52).

Fig. 52
71. If necessary loosen the grooved nut again, until a
lug of the locking plate matches a groove in the
grooved nut (Fig. 53).
72. Bend the lug down.
73. Perform the work steps (Fig. 51), (Fig. 52) and
(Fig. 53) on both sides of the wheel bearing unit.

Fig. 53
Assembling the wheel bearing units

i Note
The work steps (Fig. 54) to (Fig. 70) apply for both
bearing units.
74. Attach the lifting tackle to the wheel bearing unit
(Fig. 54).
75. Oil the receiving bores for the bearing bolts.

Fig. 54
76. Fit wheel bearing unit and body bolster together
(Fig. 55).

Fig. 55

008 915 04 BOMAG 329

15.3 Assembling the front axle

77. Oil and attach the front and rear joints bolts (Fig.
56).

! Caution
Avoid skewing of the joint bolts.
78. Attach the assembly tool (1).

Fig. 56
79. Pull both joint bolts in against the stop (Fig. 57).
80. Remove the assembly tool.

Fig. 57
81. Assemble the backing discs on both sides (Fig.
58).

Fig. 58
82. Spray the bearing seats and the inner bearing
races with sliding lacquer OKS 571 to ease as-
sembly (Fig. 59).

! Caution
Do not use any grease.

Fig. 59

330 BOMAG 008 915 04

Assembling the front axle 15.3
83. Attach the inner rocker bearing races with the
wide outer rim forward (Fig. 60) and.....

! Caution
Do not skew.
84. ...... drive in with a suitable mandrel.

Fig. 60
85. Spray the bearing seats and the outer bearing
races with sliding lacquer OKS 571 to ease as-
sembly (Fig. 61).

! Caution
Do not use any grease.

Fig. 61
86. Attach the outer bearing races with the wide outer
rim facing outside and drive them in with a plastic
hammer (Fig. 62).

! Caution
Do not skew.

Fig. 62
87. Assemble the rear bearing cover (Fig. 63).
88. Tighten the hexagon screws cross-wise.

Fig. 63

008 915 04 BOMAG 331

15.3 Assembling the front axle

Adjusting the bearing preload

! Caution
Bearings and bearing bolts must be fully
pressed in!
89. Insert backing disc 1 (Fig. 64) and Belleville
springs (2) into the front cover.

i Note
Lay the Belleville springs into the cover with the
curvature pointing down.
Fig. 64
90. Attach the front bearing cover with backing disc
and Belleville springs and locate the assembly
with two fastening screws (Fig. 65).
91. Push the threaded rod through joint receptacle
and body bolster.

! Caution
Adjust the bearing preload with an axial
preload of 40KN.
With threaded rod M12-8.8 = 77 Nm tightening
torque
With threaded rod M16-8.8 = 90 Nm tightening
Fig. 65
torque.
92. Tighten the threaded rod with the specified
torque.
93. Measure the gap (measurement „Y“) between
cover and joint receptacle with a feeler gauge
(Fig. 66).

i Note
Shim thickness "S" = 3,2 mm - "Y"
94. Remove the cover again.

Fig. 66

332 BOMAG 008 915 04

Assembling the front axle 15.3
95. Insert shim 2 (Fig. 67) of appropriate thickness
and backing disc (1) into the cover.

Fig. 67
96. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 68).

Fig. 68
97. Assemble the cover (Fig. 69) with Belleville
springs, shims and backing disc.
98. Turn in and tighten the fastening screws.
99. Press in the protection plug (1).

Fig. 69
100. Assemble the wheel discs (Fig. 70).

Fig. 70

008 915 04 BOMAG 333

15.3 Assembling the front axle

Assembling the tie rods

i Note
Perform work steps (Fig. 71) to (Fig. 74) on the
left and right hand steering arms.
101. Spray the mating surfaces with sliding lacquer
OKS 571 to ease assembly (Fig. 71).
102. Drive the bearing into the tie rod with a suitable
drift punch.

Fig. 71
103. Apply both tie rod seals 2 (Fig. 72).
104. Slide tie rod (1) and seals (2) into the receptacle
on the steering arm.

Fig. 72
105. Spray the bolts with sliding lacquer OKS 571 to
ease assembly (Fig. 73).

i Note
Insert the bolt so that groove (2) is in line with
tapped bores (1).
106. Knock the bolt in with a plastic hammer.

Fig. 73
107. Fasten the locking plate (Fig. 74).

Fig. 74

334 BOMAG 008 915 04

Assembling the front axle 15.3
Adjusting the toe-in

i Note
Toe-in occurs when the front ends of the wheels
are closer together than the rear ends. With toe-
in the right hand wheel steers slightly to the left,
while the left hand wheel steers slightly to the
right (Fig. 75).

Fig. 75
108. Align both steering arms to each other (Fig. 76).

Fig. 76
109. Apply both tie rod seals 4 (Fig. 77).
110. Slide both tie rods (1) with seals (4) into the fork
heads (2) of the steering cylinder (5).
111. Insert a special tool (3, bolt with undersize) into
the fork heads of the cylinder.

Fig. 77
112. Measure the distance of the outer wheel discs at
the front (Fig. 78).
113. Measure the distance of the outer wheel discs at
the rear.

i Note
Nominal value for toe-in: 2 +/- 1 mm.

Fig. 78

008 915 04 BOMAG 335

15.3 Assembling the front axle

i Note
The toe-in is adjusted by turning the fork head (2)
accordingly. Adjust the left and right hand fork
heads as uniformly as possible.
114. Remove the special tool 3 (Fig. 79).
115. Pull the tie rods (1) out of the fork heads (2).
116. Turn the fork heads (2) into or out of the cylinder
(5).

i Note
Turning the for heads out reduces the toe-in.
Fig. 79
117. Slide both tie rods (1) with seals (4) into the fork
heads (2) of the steering cylinder (5) again.
118. Assemble the special tool (3) again.
119. Repeat the measurement (Fig. 80).

i Note
Repeat work steps (Fig. 79) and (Fig. 80), until
the toe-in is correctly adjusted.

Fig. 80
Assembling the steering bolts
120. Remove the special tool (Fig. 81).

Fig. 81

336 BOMAG 008 915 04

Assembling the front axle 15.3
i Note
Perform work steps (Fig. 82) to (Fig. 84) on the
left and right hand fork heads.
121. Spray the bolts with sliding lacquer OKS 571 to
ease assembly.

i Note
Insert the bolt so that groove (2) is in line with
tapped bores (1).
122. Drive the bolts (2) in with a plastic hammer.

Fig. 82
123. Fasten the locking plate 2 (Fig. 83).
124. Push the screws 1 through the fork head and turn
on the nuts.

Fig. 83
125. Tighten the fork head (Fig. 84).

Fig. 84
Turning the front axle around
126. Attach the lifting tackle to the front axle (Fig. 85).

Fig. 85

008 915 04 BOMAG 337

15.3 Assembling the front axle

127. Lay the front axle safely in front of the machine

(Fig. 86).
128. Assemble the front axle.

Fig. 86

338 BOMAG 008 915 04

 16 Suppliers documentation

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Electric Drives Linear Motion and
16.1
and Controls Hydraulics Assembly Technologies Pneumatics Service

Verstellpumpe A4VG 71–180 RDE 92 003-21-R/01.06

Variable Pump A4VG 71–180

Baureihe/Series 32 R1
Reparaturanleitung / Repair Manual
Baugruppen / Assembly Groups

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Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Vermeidung von Gefahren
Für einen sicheren Betrieb und um Schäden bei der Reparatur
zu vermeiden, lesen Sie diese Reparaturanleitung sorgfältig
und aufmerksam durch!
Für Personen- oder Maschinenschäden, die durch Nichtbe-
achtung dieser Reparaturanleitung entstehen, verfällt jegliche
Gewährleistung von Bosch Rexroth AG.
1 Zu dieser Anleitung
Diese Anleitung unterstützt Sie bei der Reparatur, den Über-
prüfungen und der Wiederinbetriebnahme von Rexroth A4VG
Verstellpumpen, NG 71–180. Diese Anleitung umfasst die
folgenden Kapitel:
x „Sicherheit“ auf Seite 7
Hier erhalten Sie grundsätzliche Hinweise zum sicheren
Umgang mit Verstellpumpen und zu deren Betrieb.
Lesen Sie dieses Kapitel bevor Sie anfangen zu arbeiten.
x „Produktbeschreibung“ auf Seite 11
Hier erfahren Sie, wie Sie den Typ einer Verstellpumpe
feststellen. Ferner finden Sie hier eine Übersicht über die
Funktionsweise und Informationen zur bestimmungsgemäßen
Verwendung der Verstellpumpe.
Lesen Sie dieses Kapitel, um Ihr Grundwissen über die
Verstellpumpe aufzufrischen.
x „Austausch externer Baugruppen“ auf Seite 15
Dieses Kapitel erklärt Ihnen, wie Sie Baugruppen einer Ver-
stellpumpe austauschen.
x „Überprüfungen“ auf Seite 33
Dieses Kapitel erklärt Ihnen, wie Sie die Einstellarbeiten an
einer Verstellpumpe vornehmen.
344
Travel pump
Avoiding Dangers
To ensure safe operations and avoid damages during repairs,
read this complete repair manual carefully and attentively.
Bosch Rexroth AG accepts no responsibility for personal
injuries or damages to the machine that arise from disregarding
this repair manual.
1 About this Manual
This manual supports you in the repair, adjustment and recom-
missioning of Rexroth A4VG variable pumps, sizes 71–180.
The manual is structured as follows:
x “Safety” on page 7
This chapter provides you with basic hints and tips regarding
working with and operating variable pumps.
Read this chapter before you start working.
x “Product Description” on page 11
This chapter explains how you identify the variable pump.
Addtionally, it provides you an overview of the how the vari-
able pump and information regarding the correct usage.
Read this chapter to refresh your knowledge of the variable
pumps.
x “Exchanging Extermnal Assembly Groups” on page 15
Rexroth provides various replacement parts for repairs. This
section provides you an overview of the available spare parts
subassemblies.
x “Checking” on page 33
Read this chapter to be able to restore the settings on an
variable pump after a repair.
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16.13/40
Bosch Rexroth AG

1.1 Inhaltsverzeichnis 1.1 Contents

1. Zu dieser Anleitung 2 1. About this Manual 2

1.1 Inhaltsverzeichnis 3 1.1 Contents 3
1.2 Gültigkeitsbereich dieser Anleitung 4 1.2 Validity of this Manual 4
1.3 Wichtige Unterlagen 5 1.3 Important Documents 5
1.4 Gefahrenkennzeichnungen und Pictogramme 6 1.4 Danger Labels and Pictograms 6
2. Sicherheit 7 2. Safety 7
2.1 Grundlegende Sicherheitshinweise 7 2.1 Basic Safety Information 7
2.2 Anforderungen an das Personal 10 2.2 Requirements on the Personnel 10
3. Produktbeschreibung 11 3. Product Description 11
3.1 Typschild 11 3.1 Name Plate 11
3.2 Funktionsbeschreibung 11 3.2 Functional Description 11
3.3 Technische Daten 14 3.3 Technical Data 14
4. Austausch externer Baugruppen 15 4. Exchanging External Assembly Groups 15
4.1 Wellendichtring austauschen 16 4.1 Exchanging the Shaft Seal 16
4.2 Dichtungen austauschen 18 4.2 Exchanging Seals 18
4.3 Hilfspumpe austauschen 24 4.3 Exchanging the Backing Pump 24
4.4 Steuergerät austauschen 26 4.4 Exchanging the Control Unit 26
5. Überprüfungen 33 5. Checking 33
5.1 Niederdruck (Speisedruck) überprüfen 34 5.1 Checking Low Pressure (Charge Pressure) 34
5.2 Hochdruck überprüfen 34 5.2 Checking High Pressure 34
5.3 Mechanische Nulllage überprüfen 35 5.3 Checking the Mechanical Zero Stroke 35
5.4 Hydraulische Nulllage überprüfen 36 5.4 Checking the Hydraulic Zero Stroke 36

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1.2 Gültigkeitsbereich dieser 1.2 Validity of this Manual

Anleitung
Diese Reparaturanleitung gilt für die Axialkolben-Verstellpumpe
A4VG NG 71–180 der Bosch Rexroth AG. Informationen zu
zugelassenen Druckflüssigkeiten entnehmen Sie den Angaben
des Anlagenherstellers.
Diese Reparaturanleitung richtet sich an:
x Anlagenbetreiber,
x den autorisierten Fachbetrieb bzw. Händler,
x den Anlagenhersteller.
Für den Anlagenhersteller sind zusätzlich auch die jeweilige
Einbauzeichnung, das technische Datenblatt, die Betriebsan-
leitung und die Auftragsbestätigung der Bosch Rexroth AG
verbindlich.
This manual is valid for the Bosch Rexroth axial piston variable
pump A4VG NG 71–180. Refer to the system manufacturer for
information about the allowed hydraulic fluids.
This repair manual is directed at:
x the system operator
x authorized dealers
x the system manufacturer
For the system manufacturer, the installation drawing, the
catalog sheet, the manual, and the confirmation of order from
the Bosch Rexroth AG are also obligatory.

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1.3 Wichtige Unterlagen
Bevor Sie mit den in dieser Anleitung beschriebenen Arbeiten
anfangen, stellen Sie sicher, dass Sie folgende Unterlagen
griffbereit haben:
x Auftragsbestätigung
Die Auftragsbestätigung enthält die voreingestellten techni-
schen Daten. Die Axialkolbenmaschine darf nur unter den in
der Auftragsbestätigung angegebenen Werten und Bedin-
gungen betrieben werden.
x Einbauzeichnung
Die Einbauzeichnung der Axialkolbenmaschine enthält die
Außenabmessungen, sämtliche Anschlüsse und den Schalt-
plan.
x Technisches Datenblatt
Das technische Datenblatt RD 92 003 enthält u.a. die zuläs-
sigen technischen Daten für die Axialkolbenmaschine.
x Gesamtschaltplan der Maschine bzw. Anlage
Der Hydraulikschaltplan und der elektrische Schaltplan der
Maschine bzw. Anlage enthalten die Informationen zu den
hydraulischen bzw. elektrischen Anschlüssen. Diese Daten
brauchen Sie, um mit der Axialkolbenmaschine als Teil der
Maschine bzw. Anlage zu arbeiten. Die Unterlagen erhalten
Sie vom Maschinen- bzw. Anlagenhersteller.
x RD 90 300-B: Allgemeine Betriebsanleitung für Axialkol-
benmaschinen
Die allgemeine Betriebsanleitung unterstützt Sie bei Installa-
tion, Inbetriebnahme und Betrieb von Rexroth-Axialkolbenma-
schinen.
x Produktspezifische Betriebsanleitung
Die produktspezifische Betriebsanleitung enthält spezielle,
für die Axialkolbenmaschine gültige Informationen. Informie-
ren Sie sich bei Rexroth, ob es zu Ihrer Axialkolbenmaschine
eine produktspezifische Betriebsanleitung gibt.
Folgende Rexroth-Druckschriften geben Ihnen weitere Informa-
tionen zu Installation und Betrieb der Axialkolbenmaschine:
x RD 90 220: Druckflüssigkeiten auf Mineralölbasis
Beschreibt die Anforderungen an eine Druckflüssigkeit auf
Mineralölbasis für den Betrieb mit Rexroth-Axialkolbenma-
schinen und unterstützt Sie bei der Wahl einer Druckflüssig-
keit für Ihre Anlage.
x RD 90 221: Umweltfreundliche Druckflüssigkeiten HEES,
HEPG, HETG für Axialkolbenmaschinen
Beschreibt die Anforderungen an eine umweltfreundliche
Druckflüssigkeit für den Betrieb mit Rexroth-Axialkolbenma-
schinen und unterstützt Sie bei der Wahl einer Druckflüssig-
keit für Ihre Anlage.
x RD 90 223: Axialkolbenmaschinen für den Betrieb mit
HF-Druckflüssigkeiten
Enthält zusätzliche Informationen zum Einsatz von Rexroth-
Axialkolbenmaschinen mit HF-Druckflüssigkeiten.
x RD 90 300-03-B: Hinweise zum Einsatz von hydrauli-
schen Antrieben bei tiefen Temperaturen
Enthält zusätzliche Informationen zum Einsatz von Rexroth-
Axialkolbenmaschinen bei tiefen Temperaturen.
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1.3 Important Documents
Before you start any of the procedures described in this manu-
al, make sure you have the following documents:
x Confirmation of order
The confirmation of order contains the values set during the
commissioning by Rexroth. Before you can recommission the
axial piston unit after a repair, you have to restore the values
originally set by Rexroth.
x Installation drawing
The installation drawing of the axial piston unit contains the
sizes of all connections.
x Technical data sheet
The technical data sheet RE 92 003 contains the maximum
allowed performance data.
x Hydraulic diagramWiring diagram
The hydraulic diagram and the wiring diagram of the unit
or system contain the information related to the respective
machine.You need this data to work with the axial piston as
part of the machine or system. You can get this information
from the unit or system manufacturer.
x RE 90 300-B: General Manual for Axial Piston Units
The general manual supports you during the installation,
initiation, and operation of Rexroth axial piston units.
x Product Specific Manual
The product-specific manual contains information specially
designed for the axial piston unit. Get in touch with Rexroth
to find out if there is any product-specific information on your
specific axial piston unit.
The following Rexroth publications provide additional informati-
on to the installation and operation of axial piston units:
x RE 90 220: Mineral-oil Based Pressure Fluids
This publication describes the requirements on a hydraulic
fluid for operation in an axial piston unit and supports you in
the selection of a hydraulic fluid for your installation.
x RE 90 221: Environmentally Acceptable Hydraulic Fluids
HEES, HEPG, HETG for Axial Piston Units
Describes the demands on environmentally compatible, rea-
dily biodegradeable hydraulic fluids HEPG, HEES that can
be used in Rexroth axial piston units and supports you by the
choice of a hydraulic fluid for your system.
x RE 90 223: Axial Piston Units for Use with HF Fluids
Provides additional information for the use of Rexroth axial
piston units with HF hydraulic fluids.
x RE 90 300-03-B: Instructions on the Use of Hydrostatic
Drives at Low Temperatures
Provides additional information for the use of Rexroth axial
piston units for low temperatures.
347
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Travel pump

1.4 Gefahrenkennzeichnungen 1.4 Danger Labels and Pictograms

und Piktogramme
Diese Anleitung unterscheidet zwischen Kategorien von Gefah- This manual differentiates between the following categories of
ren gemäß ISO Guide 37: danger according to ISO Guide 37:
! GEFAHR ! DANGER

Weist auf hohes Risiko und die Gefahr von Tod oder schwe- Indicates high risk, mortal danger and serious injuries.
ren Verletzungen hin.

! WARNUNG ! WARNING

Weist auf mittleres Risiko und die Gefahr von Verletzungen Indicates middle risk, injuries or serious material damage.
und schweren Sachschäden hin.

! VORSICHT ! CAUTION

Weist auf geringes Risiko und Sachschäden hin. Indicates low risk or material damage.

Hinweis Note

Kennzeichnet Informationen, die zum besseren Verständnis Indicates information that contributes to a better understan-
der Maschinenabläufe beitragen oder weist auf einen beson- ding of the machine processes or indicates important informa-
deren bzw. wichtigen Sachverhalt hin. tion.

Tipp Tip

Kennzeichnet Informationen, die zum effizienteren Arbeiten Indicates information that contributes to more efficient work.
beitragen.

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2 Sicherheit
Lesen Sie dieses Kapitel sorgfältig durch, bevor Sie mit Arbei-
ten an der Verstellpumpe beginnen.
Die Rexroth-Verstellpumpen sind im Sinne der Maschinenricht-
linie 98/37/EG Komponenten, die zum Einbau in eine Anlage
bestimmt sind. Die Sicherheitsrichtlinien in dieser Anleitung be-
ziehen sich nur auf die Verstellpumpe. Beachten Sie zusätzlich
die Sicherheitsrichtlinien des Anlagenherstellers.
Informieren Sie sich an Hand der allgemeinen Betriebsanlei-
tung für Axialkolbenmaschinen über die bestimmungsgemäße
Verwendung und die Sorgfaltspflicht des Betreibers und
Bedieners.
2.1 Grundlegende
Sicherheitshinweise
Befolgen Sie die folgenden Sicherheitshinweise und die des
Anlagenherstellers genau, um Verletzungen und Gesundheits-
schäden sowie Sach- und Umweltschäden auszuschließen.
! GEFAHR
Lebensgefahr
Das Arbeiten an nicht stillgelegten Maschinen bzw. Anlagen
stellt eine Gefahr für Leib und Leben dar.
Die in diesem Dokument beschriebenen Arbeiten dürfen nur
an stillgelegten Maschinen bzw. Anlagen vorgenommen
werden. Bevor Sie mit den Arbeiten beginnen:
x Stellen Sie sicher, dass der Antriebsmotor nicht eingeschal-
tet werden kann.
x Stellen Sie sicher, dass sämtliche kraftübertragenden Kom-
ponenten und Anschlüsse (elektrisch, pneumatisch, hydrau-
lisch) gemäß den Herstellerangaben ausgeschaltet sind und
nicht eingeschaltet werden können. Falls möglich, entfernen
Sie die Hauptsicherung der Maschine bzw. Anlage.
x Stellen Sie sicher, dass die Maschine bzw. Anlage komplett
hydraulisch entlastet ist (drucklos). Folgen Sie hierzu den
Angaben des Maschinen- bzw. Anlagenherstellers.
! WARNUNG
Verletzungsgefahr
Um Verletzungen zu vermeiden, beachten Sie bitte folgende
Empfehlungen betreffend Sicherheitskleidung:
x Tragen Sie bei Arbeiten an Maschine bzw. Anlage Sicher-
heitsschuhe mit Stahlkappen.
x Tragen Sie bei Arbeiten mit gefährlichen Stoffen (beispiels-
weise Druckflüssigkeiten) Schutzhandschuhe und Schutz-
brille.
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2 Safety
Read through this chapter carefully before you start any work
on the variable pump.
The Rexroth variable pump are in the sense of the machine gui-
deline 98/37/EG components of a larger machine or system.
The safety guidelines in this manual only cover the variable
pump. You must additionally follow the system manufacturer’s
safety guidelines.
Read the general manual for axial piston units to get more infor-
mation on the designated use and the operator‘s obligation to
exercise dilligence.
2.1 Basic Safety Information
Pay exact attention to the following safety information and that
of the system manufacturer to eliminate injuries and health
damages as well as damages to material or the environment.
! DANGER
Danger to Life
Working on systems that have not been shut down is life-thre-
atening.
The work described in this document can only be carried out
on a shut down system. Before you start any of the tasks:
x Make sure that the engine / motor cannot be switched on.
x Make sure that all components and connections that carry
energy (electrical, pneumatic, hydraulic) have been shut
down according to the manufacturer’s instructions and
cannot be switched on. If possible, disable the main fuse.
x Make sure that the system is completely unloaded. Follow
the instructions of the the system manufacturer.
! WARNING
Danger of injuries
To avoid injuries, pay attention to the following regarding
safety clothing.
x When working on the system, wear steel-toed safety shoes.
x When working with dangerous substances (for example,
certain hydraulic fluids), wear protective gloves and protec-
tive glasses.
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! GEFAHR
Vergiftungs- und Verletzungsgefahr
Der Kontakt mit Drückflüssigkeiten ruft Gesundheitsschäden
hervor (z.B. Augenverletzungen, Haut- und Gewebeschädi-
gungen, Vergiftungen beim Einatmen).
x Überprüfen Sie vor jeder Inbetriebnahme die Leitungen auf
Verschleiß bzw. Beschädigungen.
x Tragen Sie dabei Schutzhandschuhe und Schutzbrille.
x Wenn dennoch Druckflüssigkeit in die Augen gelangt oder
in die Haut eindringt, konsultieren Sie unmittelbar einen
Arzt.
x Beachten Sie beim Umgang mit Druckflüssigkeiten unbe-
dingt die Sicherheitsangaben des Druckflüssigkeitsherstel-
lers.
! WARNUNG
Verbrennungsgefahr
Die Axialkolbenmaschine erwärmt sich während des Betriebs.
Auch die Magnete an der Axialkolbenmaschine werden im
laufenden Betrieb heiß. Bei Berührung der Axialkolbenma-
schine oder der Magnete können schwere Brandverletzungen
entstehen.
x Lassen Sie die Axialkolbenmaschine vor jedem Kontakt
abkühlen.
x Schützen Sie sich mit hitzebeständigen Handschuhen und
Schutzkleidung.
! GEFAHR
Vergiftungs- und Verletzungsgefahr
Beim Suchen nach Leckstellen kann entweichende Druckflüs-
sigkeit in die Haut eindringen und schwerste Vergiftungen und
Verletzungen hervorrufen.
x Suchen Sie nur bei abgestellter und druckloser Maschine
nach Leckstellen.
! WARNUNG
Verletzungs- und Beschädigungsgefahr
Durch falsch angeschlossene Komponenten können erhebli-
che Fehlfunktionen entstehen.
x Achten Sie auf korrekte Verrohrung gemäß Schaltplan.
x Führen Sie komponentenorientierte Funktionstests durch.
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Travel pump
! DANGER
Danger of poisoing or injuries
Contact with hydraulic fluids can cause health damage (eye
injuries, skin damage, poisoning due to inhalation).
x Always check the hydraulic lines for wear and damage prior
to putting the unit into operation.
x Always wear protective gloves and safety glasses.
x Should pressure fluid come into contact with your eyes or
skin: Get medical help immediately!
x When handling hydraulic fluids, pay exact attention to the
manaufacturer’s safety instructions.
! WARNING
Danger of burns
The variable pump heats up during operation. The unit’s sole-
noids get hot during operation. Touching the variable pump or
solenoids can lead to severe injuries.
x Let the variable pump cool down prior to any contact.
x Protect yourself from burns by wearing safety gloves and
protective clothing.
! DANGER
Danger of poisoning
When looking for leaks, escaping hydraulic fluid can break
into the skin and cause serious poisoning.
x Always use a piece of cardboard or paper to look for leaks.
! WARNING
Danger of injuries or damage
Incorrectly connected components can considerably impair
the functionality of a hydraulic system.
x Make sure that the hydraulic lines are connected properly.
x Check the correct functioning of all components.
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! GEFAHR
Feuergefahr
Hydraulische Druckflüssigkeit ist brennbar.
x Halten Sie offenes Feuer von der Verstellpumpe fern.
! WARNUNG
Gehörschäden
Die Geräuschemission von Axialkolbenmaschinen ist u.a. von
Drehzahl, Betriebsdruck und Einbauverhältnissen abhängig.
Es ist damit zu rechnen, dass der Schalldruckpegel bei nor-
malen Einsatzbedingungen über 70 dBA steigt. Dies kann zu
Gehörschäden führen.
x Schützen Sie sich stets mit Gehörschutz bei Arbeiten in
der Nähe der Axialkolbenmaschine während des laufenden
Betriebs.
! WARNUNG
Umweltschäden
Druckflüssigkeiten sind wassergefährdende Flüssigkeiten.
Das Austreten von Druckflüssigkeiten kann zu Grundwasser-
vergiftung und Bodenverseuchung führen.
x Bringen Sie unter der Axialkolbenmaschine eine Auffang-
wanne an.
x Beseitigen Sie Leckstellen unverzüglich.
x Es sind stets die nationalen Gesetze und Vorschriften zu
beachten. In Deutschland sind hydraulische Maschinen bzw.
Anlagen „Anlagen zum Umgang mit wassergefährdenden
Stoffen im Sinne des Wasserhaushaltsgesetzes (WHG)“.
Beachten Sie in diesem Zusammenhang besonders §1 und
§19 WHG (§19g, 19i, 19l).
x Weitere Informationen zum richtigen Umgang mit Rexroth-
Hydraulikprodukten finden Sie in unseren Druckschriften
„Allgemeine Produktinformationen für Hydraulikprodukte“,
RD 90 220 und „Umweltschonende, biologisch schnell
abbaubare Druckflüssigkeiten HEPG, HEES für Axialkol-
benmaschinen“, RD 90 221.
008 915 04 BOMAG
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! DANGER
Danger of fire
Hydraulic fluid is inflammable.
x Keep open fires away from the variable pump.
! WARNING
Danger of hearing loss
The noise emission produced by axial piston units depends
on speed, operating pressure, and installation. During normal
application conditions, over 70 dBA can be anticipated. This
can lead to hearing damage.
x Always wear hearing protection when working in the vicinity
of the variable pump during operation.
! WARNING
Risk of damage to the environment
Hydraulic fluid leakage leads to contamination of the ground
and ground water.
x A basin for catching any hydraulic fluid must be placed
under the variable pump.
x Leaks must be cleaned up immediately.
x In Europe, hydraulic systems are considered “Systems
using water-threatening substances” in the sense of the
Water Management Law (WHG).Therefore, pay special
attention to §1 and §19 WHG( §19g, 19i, 19l). Additionally
pay attention to any national regulations and norms.
x For further information regarding the correct use of Bosch
Rexroth hydraulic products, see the publications RE 90 220
“Mineral-oil Based Pressure Fluids” and RE 90 221 “En-
vironmentally Acceptable Hydraulic Fluids HEES, HEPG,
HETG for Axial Piston Units“, RD 90 221.
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2.2 Anforderungen an das Personal
Diese Reparaturanleitung richtet sich an Fachkräfte mit
Hydraulik-Fachwissen, die an einer Service-Schulung bei
Rexroth teilgenommen haben.
Als Fachkraft gilt, wer aufgrund seiner fachlichen Ausbildung
und Erfahrung ausreichende Kenntnisse hat, sowie mit den
einschlägigen Bestimmungen so weit vertraut ist, dass er
x die ihm übertragenene Arbeiten beurteilen kann,
x mögliche Gefahren erkennen kann,
x die notwendigen Maßnahmen zur Beseitigung von Gefahren
ergreifen kann,
x Kenntnisse über die möglichen Gesundheitsgefahren von
Druckflüssigkeiten hat
x und die erforderlichen Reparatur- und Montagekenntnisse
hat.
Hydraulik-Fachwissen bedeutet, das Personal muss,
x in der Lage sein, die Hydraulikpläne zu lesen und vollständig
zu verstehen,
x insbesondere die Zusammenhänge bezüglich der eingebau-
ten Sicherheitseinrichtungen vollständig verstehen
x und Kenntnisse über Funktion und Aufbau von hydraulischen
Bauteilen haben.
352
Travel pump
2.2 Requirements on the Personnel
This repair manual is directed at qualified personnel with
specialized hydraulics know-how who have taken part at a
service training at Rexroth.
Qualified personnel is defined as persons who have sufficient
knowledge on the basis of specialized training and experience,
and are familiar with the relevant regulations, so that they are
able to
x judge the delegated tasks,
x recognize possible dangers,
x take the necessary measures for the elimination of dangers,
x judge the possible health risks from hydraulic fluids,
x and have the required repair and installation know-how.
Specialized hydraulics know-how means that these persons
must:
x be able to read and completely understand hydraulic plans,
x especially understand the connections regarding the in-
stalled safety equipment,
x and are familiar with the function and structure of hydraulic
components.
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Bosch Rexroth AG

3 Produktbeschreibung 3 Product Description

Dieses Kapitel gibt Ihnen einen allgemeinen Überblick über die This chapter provides a general overview of the functionality of
Funktionalität der Rexroth A4VG Verstellpumpe. the A4VG variable pump.
Machen Sie sich mit den Inhalten dieses Kapitels vertraut, You should be familiar with the contents of this chapter before
bevor Sie mit Arbeiten an einer Verstellpumpe beginnen. starting any work on the variable pump.

3.1 Typschild 3.1 Name Plate

Die Verstellpumpe ist am Typschild zu identifizieren: The variable pump can be identified on its name plate:

1 3FYSPUI
D-89275 Elchingen

2 TYP: A4VG90DA2D2/32R-NZF02F001SP 7
3 MNR: R90XXXXXXX
7202 8
4 SN: 12345678
5 FD: 05W28 Rotation:
9
6 n = XXXX min -1
P = XXX kW

Made in Germany 10

Folgende Informationen finden Sie auf dem Typschild: The following information can be found on the name plate:
1 Hersteller 1 Manufacturer
2 Typschlüssel 2 Ordering code
3 Materialnummer der Axialkolbenmaschine 3 Material number of the axial piston unit
4 Seriennummer 4 Serial number
5 Fertigungsdatum 5 Date of manufacturing
6 Drehzahl 6 Speed
7 interne Werksbezeichnung 7 Internal manufacturing code
8 Drehrichtung (bei Blick auf die Welle; hier: rechts) 8 Direction of rotation (when facing the shaft; here: clockwi-
se)
9 vorgesehener Platz für Prüfstempel 9 Designated space for certification stamp
10 Leistung 10 Power
Stellen Sie sicher, dass Typ und Nenngröße der zu reparieren- Ensure that the variable pump to be repaired is of the type and
den Verstellpumpe mit dieser Anleitung übereinstimmen. size covered by this manual.

3.2 Funktionsbeschreibung 3.2 Functional Description

Damit Sie in der Lage sind, Probleme an der Verstellpumpe
zu identifizieren und gezielt Reparaturen durchzuführen, sind
Kenntnisse der Funktionsweise und des Aufbaus erforderlich.
Dieser Abschnitt gibt Ihnen eine grobe Übersicht.
Die A4VG Verstellpumpe ist eine Axialkolben-Verstellpum-
pe in Schrägscheibenbauart für hydrostatische Antriebe im
geschlossenen Kreislauf. Der Volumenstrom ist proportional zu
der Antriebsdrehzahl und dem Verdrängungsvolumen. Durch
die Verstellung der Schrägscheibe ist eine stufenlose Volumen-
stromänderung möglich.
To make sure that you are able to identify problems with a vari-
able pump and to carry out specific repairs, familiarity with how
the unit functions and its assembly are required. This section
provides you with a rough overview.
The variable displacement axial piston pump type A4VG in
swashplate design is designed for closed circuit hydrostatic
drives. The flow is proportional to the input drive speed and
displacement. By adjusting the swashplate, it is possible to
infinitely vary the flow.

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3.2.1 Schnittzeichnung 3.2.1 Sectional Drawing

Die folgenden Schnittzeichnungen zeigen das Zusammenspiel The following drawings show the interrelation of the compon-
der Komponenten der A4VG Verstellpumpe. ents of the A4VG variable pump.

Seitenansicht / Side View Steuergerät (siehe unten) /

Control unit (see below)

Schwenkwiege /
Cradle

Antriebswelle /
Drive Shaft
Anschlussplatte
mit Hilfspumpe /
Port Plate with
Auxiliary Pump
Wellendichtring /
Shaft Seal Ring

Triebwerk /
Rotary Group
Draufsicht Verstellungen/
Top View with Controllers
Steuergerät
HWD Control unit DAD

Antriebswelle
Antriebswelle Drive Shaft
Drive Shaft

Verstellkolben
Control Piston

EPD HDD

Antriebswelle
Drive Shaft
Antriebswelle
Drive Shaft

Steuergerät
Control unit

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Ansicht Anschlussplatte /
View Port Plate

HWD / EPD / HDD

DAD

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3.3 Technische Daten 3.3 Technical Data

Die technischen Daten der Verstellpumpe finden Sie in der Auf- You can find the technical data for the variable pump in the
tragbestätigung. Ergänzend dazu ist das jeweilige technische Confirmation of Order. This is supplemented by the unit‘s data
Datenblatt. Für die A4VG Verstellpumpe gilt das technische sheet. For the A4VG variable pump, the valid data sheet is
Datenblatt RD 92 003. RE 92 003.

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4 Austausch externer
Baugruppen
Dieses Kapitel beschreibt den Austausch von extern zugängli-
chen Baugruppen der Verstellpumpe A4VG.
Der Austausch folgender Baugruppen wird beschrieben:
x Wellendichtring
x Dichtungen
x Hilfspumpe
x Steuergerät
Hinweis
Alle in nachfolgenden Zeichnungen dargestellten Steuergerä-
te sind nur stellvertretend und müssen nicht der Konfiguration
Ihrer Axialkolbenmaschine entsprechen.
! WARNUNG
Gefahr von Verschleiß und Funktionsstörungen
Die Sauberkeit der Druckflüssigkeit und die Lebensdauer der
Hydraulikanlage stehen in unmittelbarem Zusammenhang.
Verschmutzung der Druckflüssigkeit führt zu Verschleiß und
Funktionsstörungen. Insbesondere harte Fremdkörper in den
Hydraulikleitungen, wie z.B. Schweißperlen und Metallspäne,
können die Axialkolbenmaschine beschädigen.
Beachten Sie daher unbedingt folgende Hinweise:
x Achten Sie auf äußerste Sauberkeit. Die Axialkolbenmaschi-
ne muss schmutzfrei eingebaut werden. Verunreinigungen
in der Druckflüssigkeit können die Funktion und Lebensdau-
er der Axialkolbenmaschine erheblich beeinträchtigen.
x Achten Sie besonders bei der Installation darauf, dass
Anschlüsse, Hydraulikleitungen und Anbauteile (z.B. Mess-
geräte) sauber sind. Reinigen Sie diese gründlich, bevor
Sie Anschlüsse öffnen. Stellen Sie sicher, dass auch beim
nachfolgenden Verschließen der Anschlüsse keine Verunrei-
nigungen eindringen.
x Verwenden Sie für die Beseitigung von Schmiermitteln und
anderen starken Verschmutzungen geeignete flüssige Reini-
gungsmittel. Es darf kein Reinigungsmittel in das Hydraulik-
system eindringen.
x Verwenden Sie zur Reinigung keine Putzwolle oder fasern-
de Putzlappen.
x Verwenden Sie als Dichtungsmittel keinesfalls Hanf oder
Kitt.
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4 Exchanging External
Assembly Groups
This chapter describes the replacement of the externally acces-
sible assembly groups of the variable pump A4VG.
The exchange of the following assembly groups is described:
x Shaft seal
x Seals
x Auxiliary pump
x Control unit
Note
All the following illustrations are only examples and do not
have to completely correspond with the configrations of your
axial piston unit.
! WARNING
Danger of wear and malfunction
The durability of the hydraulic unit depends to a great extent
on how clean the unit is kept. Dirt in the hydraulic fluid can
lead to malfunctions. Especially hard foreign matter in the
hydraulic conduits, for example, welding beads and cuttings,
can damage the axial piston unit.
Therefore you should observe the following instructions:
x Make sure everything is kept extremely clean. The axial pis-
ton unit must be installed in a dirt-free environment. Conta-
mination of the hydraulic fluid can lead to considerable wear
and malfunctions of the axial piston unit.
x Espacially during the istallation, you should make sure that
ports, hydraulic conduits, and mounting components (for
example, gauges) are clean. Clean these thoroughly before
you open connections. After that, when sealing the ports,
make sure that contaminating elements cannot enter the
system.
x When removing grease and other dirt you should use ap-
propriate liquid cleaning agents. Cleaning agents must not
enter the hydraulic system.
x Do not use cotton waste or rags which lose threads.
x Never use hemp or putty as a sealant.
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4.1 Wellendichtring austauschen 4.1 Exchanging the Shaft Seal

Dieser Abschnitt erklärt, wie Sie den Wellendichtring austau- This section explains how you can replace the shaft seal.
schen.
Benötigtes Sonderwerkzeug: Required Special Tools:
x Montagehülse x Mounting sleeve
Die Materialnummern sind je nach Pumpenmodell verschie- The material number depends on the pump model.
den:
– A4VG71: Mat.-nr. R909877509 – A4VG71: Mat. no. R909877509
– A4VG90: Mat.-nr. R909877510 – A4VG90: Mat. no. R909877510
– A4VG125: Mat.-nr. R909877511 – A4VG125: Mat. no. R909877511
– A4VG180: Mat.-nr. R909877512 – A4VG180: Mat. no. R909877512
NG 71, 90, 125

NG 180

b
a
a: Sicherungsring Circlip
b: Wellendichtring Shaft Seal
c: Triebwelle Drive Shaft

Um den Wellendichtring auszutauschen: To exchange the shaft seal:

1 Kleben Sie die Triebwelle (c) ab, um Beschädigungen am 1 Mask the drive shaft (c) for protection against damage of the
Wellendichtring (b) zu vermeiden. shaft seal (b).
2 Entfernen Sie den Sicherungsring (a). 2 Remove the safety ring (a).

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3 Drehen Sie Blechschrauben in die mit Gummi gefüllten 3 Screw the tapping screw into the rubber lined holes of the
Löcher des Wellendichtrings (b) und ziehen Sie den Wellen- shaft seal (b), and use pliers to pull the shaft seal out.
dichtring mit einer Zange heraus.

4 Fetten Sie den Wellendichtring zwischen Dicht- und Staub- 4 Grease the shaft seal between the seal and dust lip to avoid
lippe leicht ein, um Trockenlauf zu vermeiden. a dry run.
5 Pressen Sie den Wellendichtring mit Hilfe der Montagehülse 5 Using the mounting sleeve (special tool), press the shaft seal
(Sonderwerkzeug) auf Anschlag ein. until it is in stop position.

6 Führen Sie den Sicherungsring so ein, dass er in die dafür 6 Place the safety ring so that it locks into place in the respec-
vorgesehene Nut einrastet. tive slot.
7 Entfernen Sie die Abklebung an der Triebwelle. 7 Remove the mask on the drive shaft.

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4.2 Dichtungen austauschen 4.2 Exchanging Seals

Die Baugruppe „Dichtungssatz komplett“ enthält Dichtungen The assembly group "complete seal set" contains seals for the
für folgende Komponenten: following components:
x Stellkolbendeckel x Positioning piston covers
x Ventile x Valves
x Druckabschneidung x Pressure cut-off
x Hilfspumpe (siehe „Hilfspumpe austauschen“) x Auxiliary pump (refer to "Exchanging the Auxiliary Pump")
x Steuerung (siehe „Steuergerät austauschen“) x Control unit (refer to "Exchanging the Control Unit")

Benötigtes Sonderwerkzeug: Keines Required Special Tools: none

Dichtung an den Stellkolbendeckeln austauschen
Die beiden Seiten des Stellkolbens sind mit zwei unterschiedli-
chen Deckeln abgedeckt. Die nötigen Schritte zum Austausch
der Deckeldichtungen unterscheiden sich daher.
a
Exchanging the valve positioning piston covers
Both sides of the positioning piston have their own different
covers. The required steps to exchange the covers are threre-
fore different.

c
d

c c
b

e
f
a: Linker Deckel Left cover
b: Rechter Deckel Right cover
c: O-Ring O-ring
d: Stellschraube Adjustment screw
e: Kontermutter Counter nut
f: Befestigungsschrauben Fastening screw

Um die Dichtung an den Stellkolbendeckeln auszutauschen:
1 Kennzeichnen Sie die Lage des linken Deckels (a) und ent-
fernen Sie die Befestigungsschrauben (f).
2 Verdrehen Sie den Deckel (a) und lösen Sie ihn vorsichtig
mit leichten Hammerschlägen (Gummihammer).
To exchange the valves of the positioning pistons:
1 Mark the position of the left cover (a) and remove the faste-
ning screws (f).
2 Twist the cover (a) and carefully loosen it by tapping it with a
(rubber) hammer.

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3 Entfernen Sie den alten O-Ring (c). Kontrollieren Sie die 3 Remove the old o-ring (c). Check the slot (h) and the
Nut (h) und das Gehäuse (g) auf Verschleiß und Verunreini- housing (g) for wear and dirt.
gungen.
c

h g

4 Setzen Sie einen neuen O-Ring ein und schrauben Sie den
linken Deckel fest.
5 Markieren Sie die Lage des rechten Deckels (b), damit Sie
ihn nach dem Abdichten wieder lagerichtig aufsetzen kön-
nen.
Messen und notieren Sie das Maß X der Kontermutter (e) für
die spätere Montage.
Entfernen Sie die Kontermutter (e). Halten Sie dazu die
Stellschraube (d) fest.
4 Install a new o-ring and screw the cover shut.
5 Mark the position of the right cover (b) so that you can set it
back to its original position after sealing.
Measure and write down the dimension X of the counter
nut (e). You need this for the subsequent assembly.
Remove the counter nut (e). To do so, grip the positioning
screw (d).
b

e
X
d
X

6 Schrauben Sie den Deckel von der Stellschraube durch 6 Unscrew the cover from the positioning screw.
Drehen ab.

7 Entfernen Sie die beiden O-Ringe (c). Kontrollieren Sie die 7 Remove the two o-rings (c). Check the slots (h) and housing
Nuten (h) und das Gehäuse (g) auf Verschleiß und Verunrei- (g) for wear and dirt.
nigungen.
c

g h
h

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8 Kleben Sie das Gewinde ab, um Beschädigungen des O- 8 Mask the screw thread to avoid damaging the o-ring, and
Rings zu vermeiden, und schieben Sie den kleinen O-Ring push the smaller o-ring up to the designated slot.
bis zur vorgesehenen Nut auf.

9 Setzen Sie den großen O-Ring ein, entfernen Sie die Abkle-
bung und schrauben Sie den Deckel fest.
10 Schrauben Sie die Kontermutter (e) per Hand ein. Blockie-
ren Sie die Stellschraube (d) während Sie die Kontermutter-
festziehen.
Kontrollieren Sie das Maß X nach der Montage.
9 Insert the larger o-ring, remove the masking and screw the
cover back on.
10 Screw in the counter nut (e) manually. Block the adjusting
screw (d) while you tighten the counter nut.
Check the dimension X after assembly.
b

e
X
d
X

Hinweis Note

Nach dem Einbau im Gerät bzw. Prüfstand muss die korrekte After the installation of the unit or the test rig, the correct
mechanische Nulllagen-Einstellung erfolgen, siehe „Überprü- mechnical zero stroke must be adjusted, refer to "Checking",
fungen“ auf Seite 29. page 29.

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Ventildichtungen austauschen Exchanging the valve seals

Hinweis Note

Möglicherweise sind nicht alle in den Zeichnungen gezeigten It is possible that the valves displayed in these illustrations are
Ventile an Ihrer Einheit vorhanden. not all present in your unit.

Hochdruckventil /
High-pressure valve

Niederdruckventil
Low-pressure valve

Um die Ventildichtungen auszutauschen: To exchange the valve seals:

1 Schrauben Sie das Niederdruckventil heraus. 1 Unscrew the low pressure valve.
2 Kleben Sie die Gewinde der Niederdruckventile ab, um 2 Mask the screw thread to avoid damage to the o-rings.
Beschädigungen der O-Ringe zu vermeiden.

3 Setzen Sie die neuen O-Ringe ein, entfernen Sie die Abkle- 3 Insert the new o-rings, remove the masking from the screw
bungen an den Gewinden und schrauben Sie das Nieder- thread, and screw the low pressure valve back in.
druckventil wieder ein.
Ziehen Sie es mit einem Drehmoment von 70 Nm fest. Tighten it with a torque of 70 Nm.
4 Schrauben Sie die Hochdruckventile heraus. 4 Unscrew the high-pressure valves.
Beachten Sie: Bei NG 71–90 gibt es zwei O-Ringe und Note: NG 71–90 have two o-rings and one There are two
einen Stützring, bei NG 125 und 180 nur einen O-Ring. types of this valve: with or without bypass function.
Sicherungskappe / Tamper prof cap

O-Ring
O-Ring

Stützring /
Support ring

O-Ring

NG 71–90 NG 125, 180

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5 Entfernen Sie die O-Ringe und den Stützring (NG 71–90)
und kontrollieren Sie das Gehäuse auf Verschleiß und Verun-
reinigungen.
6 Bauen Sie das Hochdruck-Ventil ein und ziehen Sie es mit
einem Drehmoment von 150 Nm (NG 71–90) bzw. 200 Nm
(NG 125, 180) fest.
Hinweis
Nach dem Einbau muss eine Überprüfung des Hochdrucks
erfolgen, siehe „Überprüfungen“ auf Seite 29.
Dichtung der Druckabschneidung austauschen
Um die Dichtung der Druckabschneidung auszutauschen:
1 Notieren Sie das Einstellmaß X der Dichtmutter für die späte-
re Montage.
2 Bauen Sie die Dichtmutter (a) und die Verschlussschraube
(b) aus.
Entfernen Sie den O-Ring (c).
a
b X
3 Setzen Sie einen neuen O-RIng (c) ein.
4 Setzen Sie die Verschlussschraube (b) ein und ziehen Sie
sie mit einem Drehmoment von 35 Nm fest.
5 Bauen Sie eine neue Dichtmutter (a) ein und stellen Sie das
notierte Einstellmaß X ein.
Ziehen Sie die Dichtmutter mit 25 Nm fest.
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5 Remove the o-rings and the supprot ring (NG 71–90) and
check the housing for wear and dirt.
6 Install the high-pressure valve and tighten it with a torque of
150 Nm (NG 71–90) or 200 Nm (NG 125, 180).
Hinweis
Nach dem Einbau muss eine Überprüfung des Hochdrucks
erfolgen, siehe „Überprüfungen“ auf Seite 29.
Exchanging the seals of the pressure cut-off
To exchange the seal of the pressure cut-off:
1 Write down the sealing nut's setting dimension X for the
subsequent assembly.
2 Extract the sealing nut (a) and the locking screw (b).
Remove the o-ring (c).
3 Install a new o-ring (c).
4 Install the locking screw (b) and tighten it with a torque of 35
Nm.
5 Install the new sealing nut (a) and adjust to the setting
measure X that you wrote down previously.
Tighten it with a torque of 25 Nm.
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Dichtung des Regelventils austauschen Exchanging the control valve

b
a

a: Regelventil Control valve

b: O-Ring O-ring

Um die Dichtung am Regelventil auszutauschen: To exchange the control valve:

1 Schrauben Sie das Regelventil (a) aus. 1 Unscrew the control valve (a).
2 Kleben Sie das Gewinde zur Vermeidung von Beschädigun- 2 Mask the screw thread to avoid damaging the o-ring.
gen des O-Rings ab.

3 Schieben Sie den neuen O-Ring auf. 3 Slide the new o-ring on.
4 Entfernen Sie die Abklebung und schrauben Sie das Regel- 4 Remove the masking and screw the control valve back on.
ventil ein.
Ziehen Sie sie mit einem Drehmoment von 50 Nm fest. Tighten them with a torque of 50 Nm.

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4.3 Hilfspumpe austauschen
Die nachfolgenden Schritte gelten sowohl für den Austausch
einer Hilfspumpe als auch für den Austausch eines O-Rings.
Benötigtes Sonderwerkzeug: Keines
Um die Hilfspumpe auszutauschen:
1 Markieren Sie die Lage des Deckels (a), damit Sie ihn nach
dem Abdichten wieder lagerichtig aufsetzen können.
2 Entfernen Sie die vier Befestigungsschrauben (b).
3 Drücken Sie den Deckel wie gezeigt ab.
4 Entfernen Sie die Hilfspumpe und untersuchen Sie die Teile
der Hilfspumpe auf Verschleiß und Verunreinigungen.
Markieren Sie vorher die Lage der Hilfspumpe, damit Sie sie
später wieder lagerichtig einbauen können (sofern Sie die
alte Hilfspumpe weiter verwenden).
Hinweis
Die Hilfspumpe kann nur komplett ausgetauscht werden.
5 Setzen Sie zwei neue O-Ringe (c) ein.
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4.3 Exchanging the Auxiliary Pump
The following steps apply to the exchange of an auxiliary pump
as well as to the exchange of an o-ring.
Required Special Tools: none
To exchange the auxiliary pump:
1 Mark the position of the cover (a), so that you can replace it
in its original position after the sealing.
2 Remove the four fastening screws (b).
3 Press the cover off as illustrated.
4 Remove the auxiliary punp and check the part for wear and
dirt.
Mark the position of the auxiliary pump beforehand, so that
you can return it to its original position afterwards (if you
keep the old auxiliary pump in use).
Note
The auxiliary pump can only be exchanged as a whole.
5 Install two new o-rings (c).
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6 Setzen Sie die (neue) Hilfspumpe ein. 6 Install the (new) auxiliary pump.
Achten Sie darauf, dass die angefaste „Seite“ (d) zum De- Pay attention that the chamfered "side" (d) is assembled
ckel (a) montiert wird. facing the cover (a).

d a
d

Hinweis Note

Die Hilfspumpe wird mit Haltestopfen (e) geliefert. Diese wer- The auxiliary pump is delivered with fixing plugs (e). These are
den bei der Montage auf die Anschlussplatte in die entspre- pressed into the bore of the port plate during assembly.
chenden Bohrungen eingepresst.

7 Schrauben Sie den Deckel (a) fest. Beachten Sie dabei die 7 Screw the cover (a) back on. Pay attention to the marking
vorher angebrachte Markierung. made previously.

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4.4 Steuergerät austauschen 4.4 Exchanging the Control Unit

Die nachfolgenden Schritte gelten sowohl für den Austausch The following steps apply to the exchange of the whole control
des ganzen Steuergeräts als auch für den Austausch eines O- unit as well as to the exchange of an o-ring.
Rings am Steuergerät.
Benötigtes Sonderwerkzeug: Required Special Tools:
x NG 71: Keines x NG 71: none
x NG 90–180: 2 Hilfsschrauben (Mat.-nr. R02774871) x NG 90–180: 2 auxiliary screws (Mat. no. R02774871)
Hinweis Note

Es gibt eine Vielzahl von Steuergeräten (siehe Abbildung). There exists a multitude of control units (as illustrated).
Bitte beachten Sie, dass hier exemplarisch nur der Austausch Please pay attention to the fact that only the example of an
eines HW Steuergeräts gezeigt wird. HW controller is described here.

alt / old

DA

neu / new alt / old

HD

neu / new
EP
HW alt / old

neu / new

Polrohr
Anziehmoment 19 Nm /
Pole tube
Tightening torque 19 Nm

Anziehmoment 5+1 Nm
Steckschlüssel SW 26 /
Tightening torque 5+1 Nm
26 A/F socket spanner

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Austausch des Steuergeräts bei NG 71 Exchanging the Control Unit with NG 71
Um das Steuergerät bei NG 71 auszutauschen: To exchange the control unit:
1 Entfernen Sie die fünf Befestigungsschrauben (a). 1 Remove all five fastening screws (a).

2 Drücken Sie das Steuergerät (b) wie gezeigt ab. 2 Press the control unit (b) off as illustrated.

3 Entfernen Sie den O-Ring (c) und die Flachdichtung (e). 3 Remove the o-ring (c) and the gasket (e). Check the sealing
Kontrollieren Sie die Dichtflächen (d) auf Beschädigungen surfaces (d) for wear and dirt.
und Verunreinigungen.
Tauschen Sie das Steuergerät bei Bedarf aus. Exchange the control unit if required.

Hinweis Note

Das Steuergerät kann nur komplett ausgetauscht werden. The control unit can only be exchanged as a whole.

d
e
e
d

4 Setzen Sie einen neuen O-Ring (c) und eine neue Flachdich- 4 Insert the new o-ring (c) and the new gasket (e).
tung (e) ein.

008 915 04 BOMAG 369

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28/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

5 Setzen Sie das (neue) Steuergerät ein.
6 Zentrieren Sie die Dichtung (e) mit zwei Befestigungsschrau-
ben (a) und bauen Sie das Steuergerät ein.
Ziehen Sie alle vier Befestigungsschrauben mit halbem
Drehmoment an.
a
5 Insert the new control unit.
6 Center the seal (e) with two fastening screws (a) and install
the control unit.
Screw all four fastening screws tight with half the torque.

a: Befestigungsschraube Fixing screw

b: Steuergerät Control unit
e: Dichtung Seal

7 Setzen Sie die fünfte Schraube (f) ein und ziehen Sie sie mit 7 Insert the fifth screw (f) and tighten it with a torque of
einem Drehmoment von 10,4 Nm fest. 10.4 Nm.
Ziehen Sie die anderen vier Schrauben (a) nach Drehmo- Tighten the other four screws (a) crosswise and according
ment über Kreuz fest. to torque.

Hinweis Note

Nach der Montage des Steuergeräts muss die hydraulische After installing the control unit, the hydraulic zero stroke must
Nulllage neu eingestellt werden (gilt nicht für DA-Regelung), be re-established. This does not apply to DA-control. Please
siehe „Überprüfungen“ auf Seite 33. refer to "Checking", page 33.

370 BOMAG 008 915 04

 RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180 Bosch Rexroth AG
16.129/40
Austausch des Steuergeräts bei NG 90–180 Exchanging the Control Unit with NG 90–180
Hinweis Note

Die folgende Handlungsanweisung behandelt exemplarisch The following instructions show how to exchange an HD
den Austausch eines HD-Steuergeräts. control unit, exemplarily.

Um das HD-Steuergerät bei NG 90–180 auszutauschen: To exchange the HD control unit with NG 90–180:
1 Entfernen Sie die vier Befestigungsschrauben (a). 1 Remove all four fastening screws (a).
Entfernen Sie den Deckel (g) und die Flachdichtung (d). Remove the cover (g) and the gasket (d).

g
d
a

2 Entfernen Sie die zwei Zylinderschrauben (f). 2 Remove the two assembly screws (f).
f

3 Drücken Sie das Steuergerät (b) wie gezeigt ab. 3 Press the control unit (b) off as illustrated.

008 915 04 BOMAG 371

 16.1
30/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

4 Entfernen Sie die O-Ringe (c). Kontrollieren Sie die Dichtflä- 4 Remove the o-rings (c). Check the sealing surfaces for wear
chen auf Beschädigungen und Verunreinigungen. and dirt.
Tauschen Sie Steuergerät bei Bedarf aus. Exchange the control unit if required.
Hinweis Note

Das Steuergerät kann nur komplett ausgetauscht werden. The control unit can only be exchanged as a whole.

c
d

5 Setzen Sie neue O-Ringe (c) und eine neue Flachdichtung
(d) ein.
6 Setzen Sie das (neue) Steuergerät (b) ohne Deckel auf.
Schrauben Sie das Steuergerät diagonal mit zwei Hilfs-
schrauben (e) (Sonderwerkzeug) an (mit 7 Nm).
Schrauben Sie es mit zwei Zylinderschrauben (f) an (mit
10,4 Nm).
5 Insert the new o-rings (c) and the new gasket (d).
6 Insert the (new) control unit (b) without cover.
Tighten the control unit with two auxiliary screws (e) (special
tools) diagonally (with a torque of 7 Nm).
Fix it with two assembly screws (f) (with a torque of
10,4 Nm).
f e

7 Entfernen Sie die Hilfsschrauben (e) wieder. 7 Remove the auxiliary screws (e).
8 Kontrollieren Sie, ob die Zugfedern richtig in den Kerben des 8 Make sure that both spring catches are hooked to the pair of
Hebelpaares eingehängt sind. leavers.

372 BOMAG 008 915 04

 RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180 Bosch Rexroth AG
16.131/40
9 Setzen Sie den Deckel (g) mit der Dichtung (d) auf und 9 Put on the cover (g) with the gasket (d) and fix it with the
schrauben Sie ihn mit den vier Befestigungsschrauben fest. four fastening screws.
Ziehen Sie die schrauben mit 10,4 Nm fest. Tighten the screws with a torque of 10,4 Nm.
a

g
d

Hinweis Note

Nach der Montage des Steuergeräts muss die hydraulische After installing the control unit, the hydraulic zero stroke must
Nulllage neu eingestellt werden (gilt nicht für DA-Regelung), be re-established. This does not apply to DA-control. Please
siehe „Überprüfungen“ auf Seite 33. refer to "Checking", page 33.

008 915 04 BOMAG 373

 16.1
32/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

374 BOMAG 008 915 04

 RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180 Bosch Rexroth AG
16.133/40
5 Überprüfungen 5 Checking
Bei der ersten Inbetriebnahme nach einer Reparatur müssen When starting up for the first time after a repair, you must
Sie die ursprünglichen Einstellungen der Verstellpumpe kontrol- check the original settings of the variable pump. This chapter
lieren. Dieses Kapitel erklärt folgende Überprüfungen: describes the following checkings:
• Niederdruck • Low pressure
• Hochdruck • High pressure
• Mechanische Nulllage • Mechanical zero stroke
• Hydraulische Nulllage • Hydraulic zero stroke
Hinweis Note

Führen Sie alle Überprüfungen bei Betriebstemperatur durch. Carry out checkings at operating temperature.

Hinweis Note

Wenn die überprüften Werte von den ursprünglichen Einstel- If the checked values differ from the original settings, please
lungen abweichen, setzen Sie sich bezüglich der Einstellung contact Rexroth in terms of adjusting the settings.
bitte mit dem Rexroth-Service in Verbindung.

! WARNUNG ! WARNING

Verletzungsgefahr Danger of injuries

Arbeiten an der Verstellpumpe bei Betriebstemperatur sind Working on the variable pump at operating temperature is
gefährlich. dangerous.
x Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“ x Pay exact attention to the safety advice (refer to "Safety",
auf Seite 7). page 7).

! WARNUNG ! WARNING

Gefahr von Verschleiß und Funktionsstörungen Danger of wear and malfunction

Die Sauberkeit der Druckflüssigkeit und die Lebensdauer der
Hydraulikanlage stehen in unmittelbarem Zusammenhang.
x Achten Sie bei Überprüfungen darauf, dass Messanschlüs-
se, Schläuche und Messgeräte sauber sind. Reinigen Sie
diese gründlich bevor Sie die Messpunkte öffnen und mit
den Einstellarbeiten beginnen.
x Stellen Sie sicher, dass auch beim nachfolgenden Verschlie-
ßen der Messpunkte keine Verunreinigungen eindringen.
The durability of the hydraulic unit depends to a great extent
on how clean the unit is kept.
x When checking settings, you should make sure that gauge
ports, hydraulic conduits, and und gauges are clean. Clean
these thoroughly before you open gauge ports and begin
adjusting settings.
x After that, when sealing the ports, make sure that contami-
nating elements cannot enter the system.

008 915 04 BOMAG 375

34/40
16.1
Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

5.1 Niederdruck (Speisedruck) überprüfen
Dieser Abschnitt erklärt, wie Sie ND-Ventile überprüfen.
Um den Niederdruck zu überprüfen:
1 Schließen Sie wie gezeigt ein Manometer an Anschluss G
an.
5.1 Checking Low Pressure (Charge Pressure)
This section describes how to check the low pressure valves.
To check the low pressure:
1 Connect a manometer to connection G as displayed.

bei DA-
Ausführung /
with DA
version

2 Überprüfen Sie den Niederdruck (G). 2 Check the low pressure (G):

Hinweis Note

Die genauen Einstelldaten entnehmen Sie dem Technischen Refer to the catalog sheet RE 92 003 and your specification
Datenblatt RD 92 003 und Ihrer Spezifikation. for the detailed setting data.

5.2 Hochdruck überprüfen 5.2 Checking the High Pressure

Die Begrenzung des Hochdrucks erfolgt über die Druckab-
schneidung. Zusätzlich ist ein Hochdruckbegrenzungsventil
(Sicherheitsventil) überlagert. Der Druckwert der Druckab-
schneidung liegt ca. 10 % unter dem Wert des Hochdruckbe-
grenzungsventils.
Es kann also nur der Druckwert der Druckabschneidung über-
prüft werden.
Hinweis
The limitation of the operating pressure is performed by a high
pressure relief valve. Additionally, a high pressure relief valve
(safety valve) is in superposition. The pressure value of the
pressure cut-off is 10 % below that of the high pressure relief
valve.
Therefore, only the pressure value of the pressure cut-off can
be measured.
Note

Die genauen Einstelldaten entnehmen Sie Ihrer Spezifikation. Refer to your specification for the detailed setting data.

376 BOMAG 008 915 04

 RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180
16.135/40
Bosch Rexroth AG

5.3 Mechanische Nulllage überprüfen 5.3 Checking the Mechanical Zero Stroke
Dieser Abschnitt erklärt, wie Sie die mechanische Nulllage bei This section describes how to check the mechanical zero stro-
HW-, HD-, EP- und DA-Steuergeräten überprüfen. ke for HW, HD, EP, and DA controllers.

HW HD EP DA

! WARNUNG ! WARNING

Verletzungsgefahr Danger of injuries

Die im Folgenden beschriebenen Arbeiten an der Verstellpum-
pe sind gefährlich.
x Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“
auf Seite 7).
x Blockieren Sie das Fahrzeug bzw. entlasten Sie die Anlage
bevor Sie die Einstellarbeiten durchführen.
The following procedures carried out on the variable pump are
dangerous.
x Please pay attention to the safety advice (refer to "Safety",
page 7).
x Block the machinery or unit before you carry out the installa-
tion.

mind. / at least
Nennweite 6 / Nominal Width 6

MA

Messbereich/
Metering range
0 ... 600 bar

MB

Um die mechanische Nulllage zu überprüfen: To check the mechanical zero stroke:

1 Verbinden Sie beide Stellkammern über einen Schlauch mit
mindestens Nennweite NW6.
Dadurch stellen Sie sicher, dass ein Restsignal aus dem
Steuergerät keine Auswirkung auf die Einstellung der me-
chanischen Nullage hat.
2 Schließen Sie an die Messanschlüsse MA und M B Manome-
ter an.
3 Überprüfen Sie, ob bei blockiertem Antrieb beide Manometer
den gleichen Druckwert anzeigen.
1 Connect the two position chambers with a hose (with at
least nominal width NW6).
Thus, you ensure that a residual signal from the controller
has no influence on the setting of the hydraulic zero stroke.
2 Connect manometers to the measuring ports MA and M B.
3 Check if both manometers show the same pressure value
when the unit is blocked.

008 915 04 BOMAG 377

 16.1
36/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

5.4 Hydraulische Nulllage überprüfen 5.4 Checking the Hydraulic Zero Stroke
Dieser Abschnitt erklärt, wie Sie die hydraulische Nulllage bei This section describes how to check the hydraulic zero stroke
HW-, HD- und EP-Steuergeräten überprüfen. for HW, HD, and EP controllers.

! WARNUNG ! WARNING

Verletzungsgefahr Danger of injuries

Die folgenden Arbeiten an der Verstellpumpe sind gefährlich.
x Beachten Sie die Sicherheitshinweise (siehe „Sicherheit“
auf Seite 7).
x Blockieren Sie das Fahrzeug bzw. entlasten Sie die Anlage
bevor Sie die Einstellarbeiten durchführen.
The following procedures carried out on the variable pump are
dangerous.
x Pay attention to the safety advice (refer to "Safety",
page 7).
x Block the machinery or unload the unit before you procede
with the installation.

HW HD EP

Messbereich/
Metering range
0 ... 60 bar

X1

X2

Um die hydraulische Nulllage zu überprüfen: To check the hydraulic zero stroke:

1 Schließen Sie an die Anschlüsse X1 und X2 Manometer an. 1 Connect manometers to the ports X1 und X2.
2 Überprüfen Sie, ob bei blockiertem Antrieb beide Manometer 2 Check if both manometers show the same pressure value
den gleichen Druckwert anzeigen. when the unit is blocked

Hinweis Note

Verdrehen Sie die Exzenterjustierung (a) am Steuergerät nicht Never turn the eccentric calibration (a) of the controller over
über ±90°. ±90 degrees.

378 BOMAG 008 915 04

 RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180
16.137/40
Bosch Rexroth AG

008 915 04 BOMAG 379

 16.1
38/40Bosch Rexroth AG Reparaturanleitung/Repair Manual A4VG 71–180 RDE 92 003-21-R/01.06
Travel pump

380 BOMAG 008 915 04

 RDE 92 003-21-R/01.06
Travel pump Reparaturanleitung/Repair Manual A4VG 71–180
16.139/40
Bosch Rexroth AG

008 915 04 BOMAG 381

16.1
© This document, as well as the data,
specifications and other information
set forth in it, are the exclusive proper-
ty of Bosch Rexroth AG. It may not be
reproduced or given to third parties
without its consent.
The data specified above only serve to
describe the product. No statements
concerning a certain condition or
suitability for a certain application can
be derived from our information. The
information given does not release
the user from the obligation of own
judgment and verification. It must be
remembered that our products are
subject to a natural process of wear
and aging.
Subject to change.
382 BOMAG
Travel pump
Bosch Rexroth AG
Hydraulics
Produktsegment
Axialkolbenmaschinen
Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72-74
info.brm-ak@boschrexroth.de
www.boschrexroth.com/brm
© Alle Rechte bei Bosch Rexroth AG,
auch für den Fall von Schutzrechtsan-
meldungen. Jede Verfügungsbefugnis,
wie Kopier- und Weitergaberecht,
bei uns.
Die angegebenen Daten dienen
allein der Produktbeschreibung.
Eine Aussage über eine bestimmte
Beschaffenheit oder eine Eignung für
einen bestimmten Einsatzzweck kann
aus unseren Angaben nicht abgeleitet
werden. Die Angaben entbinden
den Verwender nicht von eigenen
Beurteilungen und Prüfungen. Es ist
zu beachten, dass unsere Produkte
einem natürlichen Verschleiß- und
Alterungsprozess unterliegen.
Änderungen vorbehalten.
Printed in Germany
RDE 92 003-21-R/01.06
008 915 04
 16.2 Travel motor

008 915 04 BOMAG 383

16.2 Travel motor

This repair manual describes the fixed displacement motor A6VM, which is identical with the travel motor A6VE,
which differs only by a different housing design.

384 BOMAG 008 915 04

Travel motor 16.2
Industrial Electric Drives Linear Motion and Service Mobile
Hydraulics and Controls Assembly Technologies Pneumatics Automation Hydraulics

RDE 91 604-01-R/03.03
Verstellmotor A6VM 28...200 ersetzt/replaces 08.01

Variable Displ. Motor A6VM 28...200

Reparaturanleitung / Repair Instructions

008 915 04 BOMAG 385

16.2 Bosch Rexroth AG | Mobile Hydraulics
2 A6VM | RDE 91 604-01-R/03.03
Travel motor

Typschlüssel
Typschlüssel A6V M / 6 3 W
Axialkolbenmaschine
Schrägachsenbauart, verstellbar A6V
Betriebsart
Motor (Einschubmotor A6VE siehe RD 91606) M
Nenngröße
≅ Schluckvolumen Vg max (cm3) 28 55 80 107 140 160 200
NG 28...200: Fertigung Werk Elchingen
Regel- und Verstelleinrichtung 28 55 80 107 140 160 200
Hydraulische Verstellung Steuerdruckanstieg 10 bar HD1 HD1 *
steuerdruckabhängig 25 bar HD2 HD2 *
35 bar HD3 – – – – – – – HD3 *
Hydraulische Zweipunktverstellung HZ – – – – – – – HZ .
HZ1 – – – HZ1 *
HZ3 – – – – HZ3
Elektrische Verstellung, Steuerspannung 12 V EP1 EP1 *
mit Proportionalmagnet 24 V EP2 EP2 *
Elektrische Steuerspannung 12 V EZ1 – – – EZ1 *
Zweipunktverstellung, 24 V EZ2 – – – EZ2 *
mit Schaltmagnet 12 V EZ3 – – – – EZ3
24 V EZ4 – – – – EZ4
Automatische Verstellung, ohne Druckanstieg HA1 HA1 *
hochdruckabhängig mit Druckanstieg Δp = 100 bar HA2 HA2 *
Hydraulische Verstellung, drehzahlabhängig DA – – – – – – – DA *
pSt/pHD = 5/100, hydraulisches Fahrtrichtungsventil DA1 DA1 *
elektrisches Fahrtrichtungsventil 12 V DA2 DA2 *
+ elektrische Vg max-Schaltung 24 V DA3 DA3 *
pSt/pHD = 8/100, hydraulisches Fahrtrichtungsventil DA4 DA4 *
elektrisches Fahrtrichtungsventil 12 V DA5 DA5 *
+ elektrische Vg max-Schaltung 24 V DA6 DA6 *
Druckregelung (nur für HD, EP) 28 55 80 107 140 160 200
ohne Druckregelung (kein Zeichen)
Druckregelung, direktgesteuert D
direktgesteuert, mit 2. Druckeinstellung E
fernsteuerbar – – – – – – – G
Übersteuerung der HA-Verstellung (nur für HA1, HA2)
ohne Übersteuerung (kein Zeichen)
hydraulische Übersteuerung T
elektrische Übersteuerung Steuerspannung 12 V U1
24 V U2
elektrische Übersteuerung Steuerspannung 12 V R1
+ elektrisches Fahrtrichtungsventil 24 V R2

* Differentialkolben Gleichgangkolben

386 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.23
Type code
Type code A6V M / 6 3 W
Axial piston unit
Bent axis design, variable displacement A6V
Mode of operation
Motor (plug-in motor A6VE see RE 91606) M
Size
≅ Displacement Vg max (cm3) 28 55 80 107 140 160 200
Sizes 28...200: production plant Elchingen
Control device 28 55 80 107 140 160 200
Hydraulic control pilot pressure increase 10 bar HD1 HD1 *
pilot pressure related 25 bar HD2 HD2 *
35 bar HD3 – – – – – – – HD3 *
Hydraulic two-position control HZ – – – – – – – HZ .
HZ1 – – – HZ1 *
HZ3 – – – – HZ3
Electrical control, control voltage 12 V EP1 EP1 *
with proportional solenoid 24 V EP2 EP2 *
Electrical control voltage 12 V EZ1 – – – EZ1 *
two-position control, 24 V EZ2 – – – EZ2 *
with switching solenoid 12 V EZ3 – – – – EZ3
24 V EZ4 – – – – EZ4
Automatic control, without pressure increase HA1 HA1 *
high pressure related with pressure increase Δp = 100 bar HA2 HA2 *
Hydraulic control, speed related DA – – – – – – – DA *
pSt/pHD = 5/100, hydraulic valve for travel direction DA1 DA1 *
electrical valve for travel direction 12 V DA2 DA2 *
+ electrical Vg max-switch 24 V DA3 DA3 *
pSt/pHD = 8/100, hydraulic valve for travel direction DA4 DA4 *
electrical valve for travel direction 12 V DA5 DA5 *
+ electrical Vg max-switch 24 V DA6 DA6 *
Pressure control (only for HD, EP) 28 55 80 107 140 160 200
without pressure control (no code)
Pressure control, direct control D
direct control, with 2nd pressure setting E
remote control – – – – – – – G
Override of HA-control (only for HA1, HA2)
without override (no code)
Hydraulic override T
Electrical override control voltage 12 V U1
24 V U2
Electrical override control voltage 12 V R1
+ el. valve for travel direction 24 V R2

* Differential piston Synchronizing piston

008 915 04 BOMAG 387

16.2 Travel motor

388 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.25
Schnittbild
Sectional drawing

A6VM 55-107 HZ3

A B

max. min.

X T

A6VM 55-107 EZ3

A B

max. min.

A6VM 55-107 HA3

A B

max. min.

A6VM 55-107 HA3U

A B

max. min.

008 915 04 BOMAG 389

16.2 Bosch Rexroth AG | Mobile Hydraulics
6 A6VM | RDE 91 604-01-R/03.03
Travel motor

Schnittbild
Sectional drawing

A6VM 28-200 HD

A B

max min

X
G

M1 T(T1)

A6VM 28-200 HD
mit Spülventil / with flushing valve

A B

max min

M1 T(T1)

A6VM 28-200 HD1D

mit Druckregelventil / with pressure
control valve

A B

max min

X
G

M1 T(T1)

390 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.27
Schnittbild
Sectional drawing

A6VM 28-200 EP

A B

max min

M1 T(T1)

A6VM 28-200 EP./..A

A B

max min

T(T1) M1

A6VM 28-200 EP./..A

A B

max min

Sa

T(T1) M1

008 915 04 BOMAG 391

16.2 Bosch Rexroth AG | Mobile Hydraulics
8 A6VM | RDE 91 604-01-R/03.03
Travel motor

Schnittbild
Sectional drawing

A6VM ... DA1

A B X1 X2

max min
G
X3

M1 T(T1)

A6VM ... DA3 A B

X1

X3
max min
G

M1 T(T1)

392 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.29
Schnittbild
Sectional drawing

A6VM 28-200 HA2U

mit Bremsventil / with braking valve

A
S

max min

T(T1) M1

A6VM 28-200 HA1R

mit Spülventil / with flushing valve

A B

max min

T(T1) M1

A6VM ... HA1U

mit Spülventil / with flushing valve

A B

max min

T(T1) M1

008 915 04 BOMAG 393

16.2 Bosch Rexroth AG | Mobile Hydraulics
10 A6VM | RDE 91 604-01-R/03.03
Travel motor

Allgemeine Reparaturhinweise
General repair instructions

Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!

Attention!
Observe the following notices when carrying out
repair work at hydraulic aggregates!

Alle Öffnungen der Hydraulikaggregate

verschließen.

Close all ports of the hydraulic aggregates.

Alle Dichtungen erneuern.

Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.

Replace all seals.

Use only OR IG I NAL B R U E N I NG HAUS
HYDROMATIK spare parts.

Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.

Check all seal and sliding surfaces for wear.

Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.

Hydraulikaggregate vor Inbetriebnahme mit

Betriebsmedium befüllen.

Fill up hydraulic aggregates with medium

before start- up.

394 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
11

Dichtsätze und Baugruppen

Seal kits and sub assembly groups

Dichtsatz für Triebwelle.

Seal kit for drive shaft.

Äußerer Dichtsatz.

External seal kit.

Gehäuse

Housing

Triebwerk komplett
Hinweis: Pos. 1 - Für Anschlußplatte mit
Pos. 2 Differentialkolben
Pos. 2 - Für Anschlußplatte mit
Gleichgangkolben

Complete rotary group

Note: Pos. 1 - For port plate with differential
piston
Pos. 2 - For port plate with
synchronizing piston
Pos. 1

Pos. 1 Pos. 2 Anschlußplatte mit Stellkolben

Hinweis: Pos. 1 - Für Anschlußplatte mit
Differentialkolben
Pos. 2 - Für Anschlußplatte mit
Gleichgangkolben

Port plate with control piston

Note: Pos. 1 - For port plate with differential
piston
Pos. 2 - For port plate with
synchronizing piston

008 915 04 BOMAG 395

16.2 Bosch Rexroth AG | Mobile Hydraulics
12 A6VM | RDE 91 604-01-R/03.03
Travel motor

Dichtsätze und Baugruppen

Seal kits and sub assembly groups

Schaltmagnet / Proportionalmagnet

Solenoid

Deckel mit * Drosselstift.

* Drosselstift "Auftragsbezogen".
* Cover with * throttle pin.
* Throttle pin "as to order requirement".
*
*

*
*
Deckel mit Spül- und Speisedruckventil
* und * Drosselstift
* Drosselstift "Auftragsbezogen".
Cover with flushing and boost pressure valve
and * throttle pin.
* Throttle pin "as to order requirement".

396 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
13

Baugruppen / Steuerteile
Component groups / Control components

z. B. HA EP

HA2
Auftrags-
bezogen *
"as to order
DA
requirement".

HD

008 915 04 BOMAG 397

16.2 Bosch Rexroth AG | Mobile Hydraulics
14 A6VM | RDE 91 604-01-R/03.03
Travel motor

Baugruppen / Steuerteile
Component groups / Control components

z. B. HZ3 / EZ3

HA3 / HA3U

398 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
15

Dichtmutter austauschen
Replace seal nut

Dichtmutter austauschen.
Zuerst Maß X messen und festhalten.

Replace seal nut.

First measure and record setting height.

Maß X

Beim Anziehen Einstellschraube gegenhalten,

anschließend Einstellhöhe kontrollieren.

When tightening, counterhold setting screw, then

check setting height.

008 915 04 BOMAG 399

16.2 Bosch Rexroth AG | Mobile Hydraulics
16 A6VM | RDE 91 604-01-R/03.03
Travel motor

Triebwelle abdichten
Sealing of the drive shaft

Triebwelle abkleben.
Sicherungsring und Scheibe ausbauen.

Protecting the drive shaft.

Remove retaining ring and shim.

Blechschraube in die mit Gummi gefüllten

Löcher eindrehen.
Mit Zange WDR herausziehen.

Screw in sheet metal screw into the holes

fitted with rubber.
Pull out seal with pliers.

Wellendichtring und Scheibe mit Montagehülse

einpressen.
Zwischen Dicht- und Staublippe, Wellendichtring
* leicht einfetten
Einpresstiefe beachten! * Marke für Einpresstiefe.
Sicherungsring einbauen.

Press in shaft seal ring and shim with bush to stop.

Take note of press-in depth!
Lightly grease the seal, dust lips and shaft seal ring.
Install * mark for press-in depth of safety ring.

400 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
17

Steuerteile abdichten
Sealing of the control parts

Achtung!
Federvorspannung

1 Attention!
Spring load

1. Deckel / Cover
2. Steuerteil / Control part
1
Kontrolle
Bohrung im Gehäuse, O-Ring, Nut.

Inspect
Drilling in housing, O-ring, groove.

Einstellschraube nicht ausbauen.

2 Kontrolle
O-Ring, O-Ring-Nut, Gehäuse

Do not remove adjustment screw.

Inspect
O-ring, O-ring groove, housing

Montagehilfe
Stift mit Fett einkleben.

2 Assembly aid
Insert pin with grease.

008 915 04 BOMAG 401

16.2 Bosch Rexroth AG | Mobile Hydraulics
18 A6VM | RDE 91 604-01-R/03.03
Travel motor

Verstellung abdichten
Sealing the hydraulic control

Beispiel: A6VM ... HD Verstellung

Demontageposition:
Deckel Pos. 1 abbauen.

Example: A6VM ... HD control

Pos.1 Disassembly position:
Remove cover pos. 1

1
1. O-Ring
2
2. Stellölzulauf
3. Drosselstift
Einbaulage je nach Steuerteil verschieden.

1. O-ring
2. Input flow of oil control
3. Throttle pin
Installation position differs according to the
3 control components

1
5
1. Stellölzulauf / Input flow of oil control
2 3 2. Hochdruck bzw. Niederdruck / High pressure /
low pressure
3. Hochdruck bzw. Niederdruck / High pressure /
low pressure
4. Lecköl / Leckage oil
4 5. Stellkolben / Control piston

402 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
19

Verstellung abdichten
Sealing the hydraulic control

Pos. 2

Beispiel: A6VM ... Verstellung - Differentialkolben

Demontageposition: Deckel Pos. 2 abbauen.
Achtung! Federvorspannung.
Maß x: Maß festhalten (Regelbeginn).
x
Example: A6VM... control - differential piston
Disassembly position: Remove cover pos. 2.
Attention! Spring load.
Dimension x: Note dimension (begin of regulation).

1. O-Ring Kontrolle

1. Check of O-ring

1
2 1. Hochdruck - kleine Stellkolbenseite
* 2. Stelldruck
3. Hochdruck - Rückschlagventil
4. Hochdruck - Rückschlagventil
* siehe Serviceinfo

1. High pressure - small control piston side

2. Control pressure
3
4 3. High pressure - check valve
4. High pressure - check valve
* see serviceinfo

008 915 04 BOMAG 403

16.2 Bosch Rexroth AG | Mobile Hydraulics
20 A6VM | RDE 91 604-01-R/03.03
Travel motor

Abschlußplatte demontieren
Disassembly of the port plate

x Differentialkolben:
Maß X festhalten.

Differential piston:
Note dimension x

Bei "Demontage" der Anschlußplatte

"Triebwerk" immer auf Null schwenken.
Kolbenringe hängen aus der Zylinder-
bohrung aus.

For disassembly of the port plate, swivel

always rotary group to zero position.
Piston rings to hang out of the cylinder
boring.
Qmin-Schraube
Qmin-screw

Qmin-Schraube ausbauen.
Triebwerk auf 0o schwenken.

Remove Qmin-screw.
Swivel rotary group to 0o.

404 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
21

Abschlußplatte demontieren
Disassembly of the port plate

x Gleichgangkolben:
Maß X festhalten.

Synchronizing piston:
Note dimension x.

Bei "Demontage" der Anschlußplatte "Triebwerk"

immer auf Null schwenken.
* Kolbenringe hängen sonst aus der Zylinder-
bohrung aus.
Qmin-Schraube
For disassembly of the port plate, swivel always
Qmin-screw
rotary group to zero position.
* Piston rings to hang out of the cylinder boring.

Qmin-Schraube und Verschlußschraube ausbauen.

Remove Qmin-screw and plug.

Mit Schraube Qmin Triebwerk auf 0o schwenken.

Swivel rotary group to zero position with screw Qmin

.

008 915 04 BOMAG 405

16.2 Bosch Rexroth AG | Mobile Hydraulics
22 A6VM | RDE 91 604-01-R/03.03
Travel motor

Abschlußplatte demontieren
Disassembly of the port plate

Anschlußplatte
Lage markieren. Schrauben lösen.
Abbauen

Port plate
Mark position. Loosen screws.
Removal

O-Ring austauschen.
Neuer O-Ring mit etwas Fett einkleben.
Triebwerk nicht ausschwenken.
Kolbenringe hängen aus der Zylinderbohrung aus.

Check O-ring.
Stick new O-ring with some grease.
Do not swivel rotary group.
Piston rings to hang out from the cylinder boring.

Steuerlinse in Gleitbahn mit Fett einkleben.

Fertigmontage in umgekehrter Reihenfolge.
Anschlußplatte aufsetzen.
Triebwerk senkrecht.

Stick control lens in sliding surface with grease.

Assembly in reversal order.
Mount port plate.
Rotary group vertical.

406 BOMAG 008 915 04

Travel motor 16.2

008 915 04 BOMAG 407

16.2 Travel motor

408 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
25

Triebwerk ausbauen
Remove rotary group

Gewindestift in Mittelzapfen einschrauben,

mit Schutzscheibe und Mutter Zylinder befestigen.
Qmax - Anschlagschraube ausbauen.

Screw in threaded pin into center pin.

Fix the cylinder with disc and locknut.
Remove Qmax -stop screw.

Nenngröße / Size 28 : M4 x 60 mm
55 : M5 x 80 mm
80 : M6 x 90 mm
107 : M6 x 100 mm
140 : M8 x 110 mm
160 : M8 x 110 mm
200 : M8 x 110 mm

Triebwerk auspressen!
Bei Wiederverwendung der Lager nicht schlagen.

Press out rotary group!

If the bearings are used again do not hit on the drive
shaft.

008 915 04 BOMAG 409

16.2 Bosch Rexroth AG | Mobile Hydraulics
26 A6VM | RDE 91 604-01-R/03.03
Travel motor

Triebwerk ausbauen
Remove rotary group

Oder mit Abziehvorrichtung ausdrücken.

Or press-out with extraction device.

410 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
27

Triebwerk austauschen
Exchanging of the rotary group

eingepresst
pressed in
Triebwerk komplett
Abstimmung hydraulischer
Teil notwendig.

Complete rotary group

Setting of hydraulic part
necessary.

Triebwerk Baugruppe
1.Mechanischer Teil: Triebwelle mit Lager abgestimmt.
2.Hydraulischer Teil: Abstimmung notwendig *.

Rotary group
1. Mechanical part: Adjust drive shaft with bearing.
2. Hydraulic part: Adjustment necessary *.

Triebwerk: Alle Bauteile

* Abstimmung
Abstimmwerte, Drehmomente siehe Serviceinfo.

Rotary group: All parts

* Setting
Setting value, torque see service information.

008 915 04 BOMAG 411

16.2 Bosch Rexroth AG | Mobile Hydraulics
28 A6VM | RDE 91 604-01-R/03.03
Travel motor

Triebwerk austauschen
Exchanging of the rotary group

Befestigungsschraube (Zylinder) ausbauen.

Zylinder abheben.

Remove fixing screw (cylinder).

Remove cylinder.

Rückzugplatte demontieren.
Schrauben sind eingeklebt. Nach Erwärmen auf
max 120o C mit Torx-Werkzeug demontieren.

Disassemble retaining plate.

Screws are glued. Warm it up to max. 120o C
and remove with Torx-tools.

412 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
29

Überprüfungshinweise
Inspection notes

Kein Passungsrost, nicht ausgeschlagen.

Free of corrosion, erosion or fretting;

no damage to splines or keyways.

Kolben
Riefenfrei und keine Pittings.

Pistons
No scoring and no pittings.

1 2

Mittelzapfen
Riefenfrei und keine Pittings.

Center pin
No scoring and no pittings.

Rückzugplatte
Riefenfrei und keine Ausbrüche.

Retaining plate
No scoring and no evidence of wear

Zylinder / Steuerlinse
1 Bohrungen riefenfrei, nicht ausgelaufen.
2 Gleichmäßiges Tragbild, riß- und riefenfrei.

Cylinder block / control lens

1 Bores free of scoring, no evidence of wear.
2 Faces smooth and even, free of cracks
and scoring.

008 915 04 BOMAG 413

16.2 Bosch Rexroth AG | Mobile Hydraulics
30 A6VM | RDE 91 604-01-R/03.03
Travel motor

Überprüfungshinweise
Inspection notes

Reglergehäuse
Gleitbahn und Seitenführung riefenfrei,
nicht ausgelaufen.

Control housing
Sliding surface and side guides free of scoring
and no wear.

Sichtkontrolle:
Im Lagerbereich riefenfrei und keine Einlaufspuren.

Visual check:
Bearing areas free of scoring and no evidence
of wear.

414 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
31

Triebwerk montieren / siehe Serviceinformation

Rotary group assembly / see service information

Triebwelle: mechanischer Teil

Rotary group: mechanical part

1 Abstimmung Maß * und Lagerdrehmomente

siehe Serviceinfo.

2
* Adjustment dimension * and bearing torque
see service infoprmation.

Lager aufpressen.
Beim Aufpressen Lagerdrehmoment nicht
überschreiten.

Press on bearing.
Do not exeed bearing torque during press-on.

BOJH
GG
DRTT
GHE

000
000
BOJH
GG
DRTT
GHE

Lager mit Montagehülse vorspannen und laufende Drehmomentenkontrolle.

Preload bearing with assembly sleeve and steady control of the torque.

008 915 04 BOMAG 415

16.2 Bosch Rexroth AG | Mobile Hydraulics
32 A6VM | RDE 91 604-01-R/03.03
Travel motor

Triebwerk montieren
Rotary group assembly

Sicherungsring 1 montieren.
Maß * für Abstimmscheibe mit Endmaß ermitteln
(überkreuz).
Abstimmscheibe einbauen.
Sicherungsring montieren.

1 Assemble safety ring.

Determine dimension * for adjustment disc with fi-
* nal dimensions (crossover)
Install adjustment shim.
Assemble safety ring.

Triebwelle einbaufertig.

Drive shaft ready for assembly.

416 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
33

Triebwerk montieren
Rotary group assembly

Rückzugplatte mit Kolben und Mittelzapfen

einsetzen.
Schrauben mit Precote-Beschichtung verwenden.
(Anziehdremoment siehe Seite 42).

Insert retaining plate with piston and center pin.

Use screw with Precote-coating.
(Tightening torque see page 42).

Auf richtige Schichtung aller Teile achten.

Make sure all parts are fitted in correctly.

Triebwerk auf Null schwenken und Zylinder mit

Gewindestift befestigen. (siehe Seite 25)

Swivel cylinder block to zero position and fix the

cylinder with a threaded pin (see page 25)

008 915 04 BOMAG 417

16.2 Bosch Rexroth AG | Mobile Hydraulics
34 A6VM | RDE 91 604-01-R/03.03
Travel motor

Triebwerk montieren
Rotary group assembly

Triebwerk komplett zum Einbau fertig.

Rotary group completely assembled ready

for assembly.

Montagehülse montieren.

Place assembly sleeve.

Gehäuse auf 80oC erwärmen.

Warm up housing to 80oC.

418 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
35

Triebwerk montieren
Rotary group assembly

Triebwerk ins Gehäuse auf Anschlag einsetzen.

Insert rotary group into housing to seat position.

Nach Einbau des Triebwerks im Gehäuse ist die

Triebwelle bis auf Anschlag nach vorne zu ziehen.

Pull the drive shaft after rotary groupassembly into

housing to seat position.

2 1

Zylinder in Nullposition
ausrichten.
1. Zylinderbefestigungsschraube
demontieren.
2. O-Ring einsetzen.

Fix zero position of cylinder

with Qmax-screw.
1. Disassemble cylinder
fixing screw.
2. Insert O-ring.

008 915 04 BOMAG 419

16.2 Bosch Rexroth AG | Mobile Hydraulics
36 A6VM | RDE 91 604-01-R/03.03
Travel motor

Triebwerksabstimmung (siehe Serviceinfo)

Rotary group adjustment (see service information)

Mit Schraube Zylinderausschwenkung

vermitteln.

Determine cylinder swivel range to

max. angle with screw.

* * Scheibe
* Disc

Zentrierscheibe aufsetzen.

Place centering disc.

Meßvorrichtung aufbauen.

Mount measuring device.

Maß X überprüfen.

Check dimension X.

420 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
37

Abschlußplatte montieren
Assembly of the port plate

1. Anschlußplatte mit Differential-

* kolben montieren.
Montageausführung beachten!
Befestigungsschrauben mit
Drehmoment anziehen.
2. Triebwerk in "Ausgangsstellung"
schwenken.
3. Qmin -Schraube auf
Maß * einstellen.
4. Verschlußschraube einbauen.
5. Montagehülse demontieren.

1. Assemble port plate with

differential piston.
Take care of assembly design!
Tighten fixing screws
with torque.
2. Swivel rotary group to "starting
position".
3. Set Qmin -screw to
dimension*.
4. Assemble plug.
5. Remove assembly sleeve.

Deckel montieren.

Assemble cover.

Steuerteil montieren.
x
Assemble control components.

008 915 04 BOMAG 421

16.2 Bosch Rexroth AG | Mobile Hydraulics
38 A6VM | RDE 91 604-01-R/03.03
Travel motor

Anschlußplatte montieren
Assembly of the port plate

1. Anschlußplatte mit Gleichgang-

kolben montieren.
Montageausführung beachten!
Befestigungsschrauben mit
* Drehmoment anziehen.
2. Triebwerk in "Ausgangsstellung"
schwenken.
3. Qmin -Schraube auf Maß * einstellen.
4. Verschlußschraube einbauen.
5. Montagehülse demontieren.

1. Assemble port plate with

synchronizing piston.
Take care of assembly design!
Tighten fixing screws
with torque.
2. Swivel rotary group to "starting
position".
3. Set Qmin -screw to dimension*.
4. Assemble plug.
5. Remove assembly sleeve.

Wellendichtring, Scheiben und Sicherungsring

montieren.
Mit Montagehülse einpressen.
Dicht- und Staublippe, Wellendichtring leicht
einfetten.
Einpresstiefe beachten!

Assemble shaft seal, disc and safety ring.

Press-in with assembly sleeve.
Lightly grease the seal, dust lips and shaft seal ring.
Take care of press-in depth.

422 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
39

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

1. Schaftschrauben (nach N 08.001) 1. Bolts (to N 08.001)

Die Werte gelten für Schaftschrauben mit metrischen
ISO-Gewinde nach DIN 13 Teil 13, sowie Kopfauflage-
maßen nach DIN 912 Zylinderschrauben, DIN 931
Sechskantschrauben mit Schaft bzw.
DIN 933 Sechskantschrauben mit Gewinde bis Kopf.
The values stated are valid for bolts with metric ISO threads
to DIN 13 part 13, as well as head areas to DIN 912 socked
head cap screws, DIN 931 hexagon bolt or
DIN 933 hexagon bolts with threads up to the head.

Festigkeitsklassen / Tensile strength class

Gewinde / Thread 8.8 10.9 12.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240

008 915 04 BOMAG 423

16.2 Bosch Rexroth AG | Mobile Hydraulics
40 A6VM | RDE 91 604-01-R/03.03
Travel motor

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

2. Verschlußschrauben mit Innensechskant und 2. Plugs with internal hexagon and profile seal ring
Profildichtring (nach N 02.009). (to N 02.009).

G
EOLASTIC-
Dichtung / Seal

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G1 A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300

424 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
41

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

5. Verschlußschrauben mit Innensechskant, 5. Plugs with internal hexagon, O-ring and UNF-,
O-Ring und UNF-, UN-Gewinde nach SAE J 514 UN- threads to SAE J 514 (nach N 02.106)
(nach N 02.106)

G
O-Ring / O-ring seal
Dichtung / Thread

Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment

Thread Tightening torque Thread Tightening torque
MA in Nm MA in Nm
7/16 - 20 UNF 15 M12 x 1,5 20
1/2 - 20 UNF 20 M14 x 1,5 30
9/16 - 18 UNF 25 M27 x 1,5 90
3/4 - 16 UNF 72
7/8 - 14 UN 127
1 1/16 -12 UN 147
1 3/16 -12 UN 173
1 5/16 -12 UN 198
1 5/8 -12 UN 320
1 7/8 -12 UN 390

008 915 04 BOMAG 425

16.2 Bosch Rexroth AG | Mobile Hydraulics
42 A6VM | RDE 91 604-01-R/03.03
Travel motor

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

6. Linsenschrauben mit Innen-TORX, Gewindevor- 6. Oval head screw with inner TORX, thread precoated with
beschichtung mit "precote" "precote"

precote 80 - Rot / Red

Standard / Standard

precote 86 - Blau / Blue

Variante / Variant
* * mit Unterkopfbeschichtung - farblos
Ι 2602493 M5 x 16
Ι 2602395 M6 x 20
* with head bottom coating - colorless
siehe Stückliste / as to parts list

Festigkeitsklassen / Tensile strength class

Gewinde / Thread 10.9
Anziehdrehmoment / Tightening torque M A in Nm
M3 2,1
M4 4,7
M5 9,1
M6 15,8
M8 37,7

7. SEAL-LOCK-Dichtmuttern (nach N 02.100) 7. SEAL-LOCK - sealing nuts (to N 02.100)

Gewinde / Anziehdrehmoment MA in Nm
Thread Tightening torque MA in Nm

M6 10
M6 x 0,5 11
M8 22
M8 x 1 24
M10 40
M10 x 1 44
M12 69
M12 x 1,5 72
M14 110
M14 x 1,5 120
M16 170
M16 x 1,5 180

426 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
43

Montageanweisung für Anziehdrehmomente

Assembly guidelines for tightening torques

A6V - Stellkolben / positioning piston

für / for A6V / A7V / A7F / A8V)

Anziehdrehmoment MA für Gewindestift (1) / Anziehdrehmoment MA für Schraube (2) /

Tightening torque MA for threaded pin (1) Tightening torque MA for shaft bolts (2)
(Verbindung: Stellkolben und Stellzapfen / (Verbindung: Stellkolben und Stellzapfen für A6V
Connection: Positioning piston and positioning trunnion Connection: Positioning piston and piston for A6V

M6 : 8,5 Nm M14 x 1,5 : 120 Nm

M8 : 14,0 Nm
M10 : 30,0 Nm
M12 : 52,0 Nm

008 915 04 BOMAG 427

16.2 Bosch Rexroth AG | Mobile Hydraulics
44
Sicherheitsbestimmungen
Safety regulations
Allgemein
● Machen Sie sich mit der Ausstattung der Maschine
vertraut.
● Fahren Sie die Maschine nur, wenn Sie sich völlig mit den
Bedien- und Steuerelementen sowie der Arbeitsweise der
Maschine vertraut gemacht haben.
● Benutzen Sie Ihre Schutzausrüstung wie Schutzhelm,
Sicherheitsschuhe und Gehörschutz.
● Machen Sie sich mit Ihrem Arbeitsgebiet vertraut.
● Benutzen Sie die Maschine nur für den ihr zugedachten
Zweck.
Beachten Sie bitte die Richtlinien der Berufsgenossenschaft
und des Maschinenherstellers
Vor dem Start
● Beachten Sie die Bedienungshinweise vor dem Starten.
● Prüfen Sie die Maschine auf auffällige Fehler.
● Fahren Sie die Maschine nicht mit defekten Instrumenten,
Kontrolleuchten oder Steuerorganen.
● Alle Schutzvorrichtungen müssen fest auf ihrem Platz sein.
● Nehmen Sie keine losen Gegenstände mit bzw. befestigen
Sie diese an der Maschine.
● Halten Sie die Maschine von öligem und zündfähigem
Material frei.
● Prüfen Sie vor dem Besteigen der Maschine, ob sich
Personen oder Hindernisse neben oder unter der Maschine
befinden.
● Vorsicht beim Besteigen der Maschine, benützen Sie
Treppen und Griffe.
● Stellen Sie vor dem Start Ihren Sitz ein.
428 BOMAG
A6VM | RDE 91 604-01-R/03.03
Travel motor
General advice
● Make yourself familiar with the equipment of the
machine.
● Only operate the machine if your are completely familiar with
the operating and control elements as well as the functioning
of the machine.
● Use your safety equipment like helmet, safety shoes and
hearing protection.
● Make yourself familiar with your working field.
● Only operate the machine for its intended purpose.
Please observe the guidelines of the Professional
Association and the machine manufacturer.
Before starting
● Observe the operating instructions before starting.
● Check the machine for remarkable faults.
● Do not operate the machine with defective instruments,
warning lights or control elements.
● All safety devices must be in a secure position.
● Do not carry with you movable objects or secure them to the
machine.
● Keep oily and inflammable material away from the machine.
● Before entering thc driver’s cabin, check if personsor
obstacles are beside or beneath the machine.
● Be careful when entering the driver’s cabin, use stairs and
handles.
● Adjust your seat before starting.
008 915 04
RDE 91 604-01-R/03.03
Travel motor | A6VM
Sicherheitsbestimmungen
Safety regulations
Starten
● Beim Starten müssen alle Bedienhebel in “Neutralstellung”
stehen.
● Die Maschine nur vom Fahrersitz aus Starten.
● Prüfen Sie die Anzeigeinstrumente nach dem Start, um
sicher zu gehen, daß alles ordnungsgemäß funktioniert.
● Lassen Sie die Maschine nicht unbewacht, während
der Motor läuft.
● Beim Start mit Batterieverbindungskabeln verbinden Sie Plus
mit Plus und Minus mit Minus. Massekabel (Minus) immer
zuletzt anschliesen und zuerst abtrennen.
Vorsicht
● Auspuffgase sind lebensgefährlich. Bei Start in
geschlossenen Räumen für ausreichende Luftzufuhr
sorgen!
Hydraulikanlage
1. Hydraulikanlage steht unter hohem Druck!
Unter hohem Druck austretende Hochdruck- Flüssig-
keiten (Kraftstoff, Hydrauliköl) können die Haut durch-
dringen und schwere Verletzungen verursachen. Daher
sofort einen Arzt aufsuchen, da anderenfalls schwere
Infektionen entstehen können!
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr
geeignete Hilfsmittel verwenden!
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt
drucklos machen und angebaute Geräte absenken!
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor
abstellen und Traktor gegen Wegrollen sichern
(Feststellbremse, Unterlegkeil)!
5. Beim Anschließen von Hydraulikzylindern und -motoren ist
auf vorgeschriebenen Anschluß der Hydraulikschläuche zu
achten!
6. Bei Vertauschen der Anschlüsse umgekehrte Funktionen
(z.B. Heben/Senken) - Unfallgefahr!
7. Hydraulikschlauchleitungen regelmäßig kontrollieren und bei
Beschädigung und Alterung austauschen! Die Austausch-
schlauchleitungen müssen den technischen Anforderungen
des Geräteherstellers entsprechen!
Öle, Kraftstoffe und Filter ordnungsgemäß
entsorgen!
008 915 04 BOMAG
Mobile Hydraulics | Bosch Rexroth AG 16.2
45
Start
● When starting all operating levers must be in “neutral position”.
● Only start the machine from the driver’s seat.
● Check the indicating instruments after start to assure that all
functions are in order.
● Do not leave the machine unobserved when the motor is
running.
● When starting with battery connection cables connect plus
with plus and minus with minus. Always connect mass cable
(minus) at last and cut off at first.
Attention
● Exhaust gas is dangerous. Assure sufficient fresh air when
starting in closed rooms!
Hydraulic equipment
1. Hydraulic equipment is standing under high pressure.
High pressure fluids (fuel, hydraulic oil) which escape
under high pressure can penetrate the skin and cause
heavy injuries. Therefore immediately consult a doctor as
otherwise heavy infections can be caused.
2. When searching leakages use appropriate auxiliary devices
because of the danger of accidents.
3. Before working at the hydraulic equipment, lower pressure
to zero and lower working arms of the rnachine.
4. When working at the hydraulic equipment, absolutely stop
motor and secure tractor against rolling away (parking brake,
shim)!
5. When connecting hydraulic cylinders and motor pay attention
to correct connection of hydraulic flexible hoses.
6. In case of exchanging the ports, the tunctions are vice versa
(f. ex. lift-up/lower) - danger of accidents!
7. Check hydraulic flexible hoses regularly and replace them in
case of dammage or wear! The new hose pipes must comply
with the technical requirements of the machine manufacturer!
Orderly disposal or recycling of oil, fuel and
filters!
429
16.2 Bosch Rexroth AG | Mobile Hydraulics
46 A6VM | RDE 91 604-01-R/03.03
Travel motor

Inbetriebnahme
Operating instruction

Einstellüberprüfung Setting test

(Regelbeginn von Vg max - Vg min ) (Begin of regulation of Vg max - Vg min )
z.Beispiel HD e.g HD

X - 10 bar

Einstellschraube - Regelbeginn / P
Set screw - begin of control
Vg min

G
X
Betriebsdruck /
Operating
pressure

~ P/2

1:2

M1

Stelldruck /
Control pressure
Sicherheitsbestimmungen beachten! Observe safety regulations!
Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake).

A6VM - HD Vg max - Vg min A6VM - HD Vg max - Vg min

● Manometer "G" = 600 bar ● Pressure gauge "G" = 600 bar

● Manometer "M1" = 600 bar ● Pressure gauge "M1" = 600 bar
● Manometer "X" = 60 bar ● Pressure gauge "X" = 60 bar

Regelbeginn / Einstellung Begin of regulation / Setting

Beispiel: 10 bar Steuerdruck an X Example: 10 bar pilot pressure at X

Manometer an M1 beachten! Observe pressure gauge at M1!

Druckwert an X erhöhen bis an M1 die Hälfte Increase pressure value at X till half the pressure is generated
des Druckes von G ansteht ♦ Regelbeginn from G ♦ Begin of regulation

Einstellschraube im Uhrzeigersinn ♦ Regelbeginn Setscrew turned clockwise ♦ Begin of regulation earlier

früher
Setscrew turned anti-clockwise ♦ Begin of regulation later
Einstellschraube gegen Uhrzeigersinn ♦ Regelbeginn
später

430 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
47

Inbetriebnahme
Operating instruction

Einstellüberprüfung Setting test

(Regelbeginn von Vg max - Vg min ) (Begin of regulation of Vg max - Vg min )
z.Beispiel EP e.g EP

Einstellschraube - Regelbeginn /
Set screw - Begin of control
P

Vg min

Betriebsdruck /
Operating pressure

~ P/2

1:2

M1

Stelldruck /
Control pressure

Sicherheitsbestimmungen beachten! Observe safety regulations!

Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake).

A6VM - EP Vg max - Vg min A6VM - HD Vg max - Vg min

● Manometer "G" = 600 bar ● Pressure gauge "G" = 600 bar

● Manometer "M1" = 600 bar ● Pressure gauge "M1" = 600 bar
● Magnet = Multimessgerät ● Solenoid = multi measuring device

Regelbeginn / Einstellung Begin of regulation / Setting

Beispiel: 200/400 mA Example: 200/400 mA

Manometer an M1 beachten! Observe pressure gauge at M1!

Strom erhöhen bis an M1 die Hälfte Increase current till half the pressure is generated
des Druckes von G ansteht ♦ Regelbeginn from G ♦ Begin of regulation

Einstellschraube im Uhrzeigersinn ♦ Regelbeginn Setscrew turned clockwise ♦ Begin of regulation earlier

früher
Setscrew turned anti-clockwise ♦ Begin of regulation later
Einstellschraube gegen Uhrzeigersinn ♦ Regelbeginn
später

008 915 04 BOMAG 431

16.2 Bosch Rexroth AG | Mobile Hydraulics
48 A6VM | RDE 91 604-01-R/03.03
Travel motor

Inbetriebnahme
Operating instruction

Einstellüberprüfung Setting test

(Regelbeginn von Vg min - Vg max ) (Begin of regulation of Vg min - Vg max )
z.Beispiel HA z.Beispiel HA

Vg min X M1

Stelldruck /
Control
pressure
1:2

Einstellschraube - Regelbeginn / G
Set screw - Begin of control Betriebsdruck /
Operating
pressure
Sicherheitsbestimmungen beachten! Observe safety regulations!
Einstelldaten nach Werksauftrag! Setting data as to production order
Blockzustand (Straßengang und festgebremst). Blocked condition (travel mode and manual brake)
Manometer 600 bar an G und M1 anschließen. Connect pressure gauge 600 bar at G and M1
Beispiel 1: Example 1:
Regelbeginn 200 bar, Begin of regulation 200 bar
Betriebsdruck langsam erhöhen bis Manometer an G 200 bar Increase service pressure slowly till pressure gauge at
Stelldruck Manometer M1 G = 200 bar
1 /2 des Betriebsdruckes = ca. 100 bar Positioning pressure gauge M1
♦ Regelbeginn 1/2 of the sevice pressure = approx. 100 bar.
Nachjustierung des Stelldruckes an ♦ Begin of control
Einstellschraube - Regelbeginn Readjust positioning pressure at set screw - start of control
Hinweis: Note:
Drehen im Uhrzeigersinn - Regelbeginn früher. Clockwise turning - begin of regulation earlier
Drehen gegen Uhrzeigersinn - Regelbeginn später. Anti-clockwise turning - begin of regulation later
Beispiel 2: Example 2:
Bei Anlagen mit zwei oder mehr Motoren z. B. Raupenfahrzeuge In systems with two or more motors, e.g. tracked vehicles,
kann folgende Einstellung zusätzlich erfolgen. the following setting may be carried out additionally.
Kontermutter von Einstellschraube Vgmin lösen - Remove safety cap from the setscrew Vg min - do not disturb
Einstellschraube nicht verdrehen. Maß X festhalten. setscrew.
Betriebsdruck langsam erhöhen bis Manometer an G 200 bar Increase service pressure slowly till pressure gauge is indicating
anzeigt. 200 bar at G.
Kontrolle: Einstellschraube Vg min "fest" (Steuerlinse wird gegen Verification: Vg min "fixed" (lens plate is pressed against setscrew).
die Einstellschraube gedrückt). Up from 200 bar service pressure the screw is becoming
Ab 200 bar Betriebsdruck wird die Schraube "lose" "movable".
(Steuerlinse schwenkt Richtung Vg max). (lens plate is stroking to direction Vg max).
♦ Regelbeginn ♦ Begin of control
Achtung! Attention
Einstellwert Vg min -Schraube nicht verändern. Do not modify setting data of Vg min screw.
Hinweis: Nachjustierung an Einstellschraube- Regelbeginn Note: Readjustment at the set screw - begin of regulation

432 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
49

Inbetriebnahme
Operating instruction

Einstellüberprüfung (Regelbeginn) G1
DA1/4, DA2,3,4,5,6 X3 Einstellschraube - Regelbeginn
Vg min
5/8

100

1:2

M1
DA1, DA2, DA3 = PST / PHD 5 / 100
DA4, DA5, DA6 = PST / PHD 8 / 100 Stelldruck

Beispiel: Betriebsdaten nach Geräteblatt

Verstellbeginn Vg min - Vg max bei 20 bar Steuerdruck X3
und 220 bar Betriebsdruck

● Manometer G = 600 bar Betriebsdruck

● Manometer X3 = 60 bar Steuerdruck
● Manometer M1 = 600 bar Stelldruck G
Fahrzeug beladen, Straßengang, Fahren (max. Geschwindigkeit
= max. Steuerdruck)
Manometer M1 beobachten, anbremsen für Druckaufbau an
"G", ab 220 bar Betriebsdruck baut sich Druck an M1 ab.
♦ Regelbeginn P/2.

DA1, DA2, DA3 PSt / PSt 5/100

X3 G M1 = 1/2 Betriebsdruck (Regelbeginn)

20 bar 200 bar 200 bar = Vg min
20 bar 220 bar 110 bar = Regelbeginn Vg min
♦ Vg max
20 bar 240 bar 0-50 bar = Vg max
* Einstellschraube - Regelbeginn - Drehen im Uhrzeigersinn - Regelbeginn später

nur 1/8 Umdrehung verstellen ♦ kontrollieren

DA4, DA5, DA6 PSt / PSt 8/100

X3 G M1
20 bar 207,5 bar 207,5 bar = Vg min M1
20 bar 220 bar 110 bar = Vg min ® Vg max
20 bar 225 bar 0 bar = Vg max Stelldruck

008 915 04 BOMAG 433

16.2 Bosch Rexroth AG | Mobile Hydraulics
50 A6VM | RDE 91 604-01-R/03.03
Travel motor

Inbetriebnahme
Operating instruction

Setting test (Begin of Regulation) G1

DA1/4, DA2,3,4,5,6 X3
Setscrew - Begin of control
Vg min
5/8

100

1:2

M1
DA1, DA2, DA3 = PST / PHD 5 / 100
DA4, DA5, DA6 = PST / PHD 8 / 100 Control
pressure
X3
Example: Operation data as to machine specification sheet
Begin of regulation Vg min - Vg max at 20 bar pilot pressure
and 220 bar service pressure
G
● Pressure gauge G = 600 bar service pressure
● Pressure gauge X3 = 60 bar pilot pressure
● Pressure gauge M1 = 600 bar positioning pressure
Load vehicle, travel mode, travel (max. speed = max. pilot pressure
Observe pressure gauge M1, declarate at "G" for pressure generation,
up from 220 bar service pressure pressure at M1 is dropping.
♦ begin of regulation P/2.

DA1, DA2, DA3 PSt / PSt 5/100

X3 G M1 = 1/2 service pressure (begin of regulation)
20 bar 200 bar 200 bar = Vg min
20 bar 220 bar 110 bar = begin of regulation Vg min ♦ Vg max
20 bar 240 bar 0-50 bar = Vg max
* Setscrew - begin of regulation - turn clockwise - begin of regulation later

displace by 1/8 turn only ♦ verification

DA4, DA5, DA6 PSt / PSt 8/100

X3 G M1
20 bar 207,5 bar 207,5 bar = Vg min M1
20 bar 220 bar 110 bar = Vg min ♦ Vg max
20 bar 225 bar 0 bar = Vg max Control
pressure

434 BOMAG 008 915 04

RDE 91 604-01-R/03.03
Travel motor | A6VM Mobile Hydraulics | Bosch Rexroth AG 16.2
51

008 915 04 BOMAG 435

16.2
© 2003 by Brueninghaus Hydromatik
GmbH, 89275 Elchingen
All rights reserved. No part of this
document may be reproduced or
stored, processed, duplicated or
circulated using electronic systems, in
any form or by any means, without the
prior written authorization of Bosch
Rexroth AG. In the event of
contravention of the above provisions,
the contravening party is obliged to
pay compensation.
The data specified above only serve to
describe the product. No statements
concerning a certain condition or
suitability for a certain application can
be derived from our information. The
given information does not release the
user from the obligation of own
judgement and verification. It must be
remembered that our products are
subject to a natural process of wear
and aging.
436 BOMAG
Travel motor
Brueninghaus Hydromatik GmbH
Werk Elchingen
Glockeraustraße 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
info.brm@boschrexroth.de
www.boschrexroth.com/brm
© 2003 by Brueninghaus Hydromatik
GmbH, 89275 Elchingen
Alle Rechte vorbehalten. Kein Teil des
Werkes darf in irgendeiner Form ohne
vorherige schriftliche Zustimmung der
Brueninghaus Hydromatik GmbH
reproduziert oder unter Verwendung
elektronischer Systeme gespeichert,
verarbeitet, vervielfältigt oder verbreitet
werden. Zuwiderhandlungen
verpflichten zu Schadensersatz.
Die angegebenen Daten dienen allein
der Produktbeschreibung. Eine
Aussage über eine bestimmte
Beschaffenheit oder eine Eignung für
einen bestimmten Einsatzzweck kann
aus unseren Angaben nicht abgeleitet
werden. Die Angaben entbinden den
Verwender nicht von eigenen
Beurteilungen und Prüfungen. Es ist zu
beachten, dass unsere Produkte einem
natürlichen Verschleiß- und
Alterungsprozess unterliegen.
Printed in Germany
RDE 91 604-01-R/03.03
008 915 04
 16.3 Travel gear

008 915 04 BOMAG 437

16.3 Travel gear

438 BOMAG 008 915 04

Travel gear 16.3

RIDUTTORE PER COMANDO RUOTA

WHEEL DRIVE

6 06 Y 3 LB S011 B 32 I3 5EW90-S02 VAM

CODICE
CODE 2T255608241A

Manuale di installazione, uso

e manutenzione

Installation, operation and maintenance

manual

Emissione:
02/2007
Issue:

Aggiornamento - data:
Revision - date: 0.0 - 14/02/2007

Compilatore:
Ufficio tecnico commerciale: Prepared by: .............................................................
Technical and commercial dept: Approvato da:
Approved by: ............................................................

008 915 04 BOMAG 439

16.3 Travel gear

-2-
440 BOMAG 008 915 04
 Travel gear 16.3

INDICE INDEX

1. INFORMAZIONI GENERALI 1. GENERAL INFORMATIONS

1.1. Scopo del manuale ........................................... 2 1.1. Manual aim ...................................................... 2
1.2. Identificazione del prodotto ............................... 3 1.2. Product identification........................................ 3
1.3. Modalità di richiesta assistenza ........................ 3 1.3. Requesting assistance ..................................... 3
1.4. Informazioni sulla sicurezza.............................. 4 1.4. Informations on safety...................................... 4
1.5. Modalità di consegna ........................................ 5 1.5. Delivery methods ............................................. 5
1.6. Modalità di imballaggio ..................................... 5 1.6. Packaging methods ......................................... 5
1.7. Sollevamento e movimentazione ...................... 6 1.7. Lifting and handling ......................................... 6
1.8. Modalità di magazzinaggio ............................... 7 1.8. Storage methods.............................................. 7

2. INFORMAZIONI TECNICHE 2. TECHNICAL INFORMATIONS

2.1. Descrizione del prodotto ................................... 8 2.1. Product description .......................................... 8

3. INFORMAZIONI SULL’INSTALLAZIONE 3. INSTALLATION INFORMATIONS

3.1. Procedure per l’installazione........................... 11 3.1. Installation procedure..................................... 11
3.2. Installazione del motore idraulico.................... 12 3.2. Hydraulic motor installation ............................ 12
3.3. Installazione del motoriduttore 3.3. Installation of the wheel drive
sulla macchina 13 on the machine ............................................... 13
3.4. Fissaggio ruota al motoriduttore ..................... 13 3.4. Fixing of the wheel to the gearmotor.............. 13
3.5. Collegamento del freno................................... 14 3.5. Connecting the brake..................................... 14
3.6. Caratteristiche olio lubrificazione 3.6. Characteristics of oil forced
forzata freno 15 brake lubrication 15
3.7. Riempimento olio lubrificante del riduttore...... 16 3.7. Filling-up the gearbox with lubricating oil ....... 16
3.8. Prima messa in esercizio e rodaggio .............. 18 3.8. First start up and running in ........................... 18

4. INFORMAZIONI SULLA MANUTENZIONE 4. MAINTENANCE INFORMATIONS

4.1. Manutenzione periodica.................................. 19 4.1. Periodic maintenance .................................... 19
4.2. Sostituzione dell'olio lubrificante ..................... 20 4.2. Changing the lubricating oil............................ 20
4.3. Ricerca guasti ................................................. 21 4.3. Troubleshooting ............................................. 21
4.4. Smontaggio del motoriduttore......................... 22 4.4. Motorgearbox disassembly ............................ 22
4.5. Fasi di smontaggio.......................................... 25 4.5. Disassembling method................................... 25
4.6. Fasi di smontaggio riduttore............................ 25 4.6. Gearbox disassembly method ....................... 25
4.7. Fasi di smontaggio gruppo riduttore ............... 29 4.7. Gearbox kit disassembly method ................... 29
4.8. Fasi di smontaggio gruppo freno .................... 36 4.8. Brake kit disassembly method ....................... 36
4.9. Valutazione dei pezzi da sostituire.................. 41 4.9. Evaluating that pieces to replace ................... 41
4.10.Fasi di rimontaggio gruppo freno .................... 42 4.10.Brake kit reassembling method...................... 42
4.11.Fasi di rimontaggio gruppo riduttore ............... 48 4.11.Gearbox kit reassembling method ................. 48
4.12.Fasi di rimontaggio riduttore ........................... 57 4.12.Gearbox reassembling method ...................... 57
4.13.Controllo finale e reinstallazione ..................... 64 4.13.Final test and reinstallation ............................ 64
4.14.Dismissione e rottamazione del prodotto........ 65 4.14.Dismantling and destroying the product......... 65

INDICE -1- INDEX

008 915 04 BOMAG 441
16.3
1. INFORMAZIONI GENERALI
1.1. Scopo del manuale
Questo manuale è stato realizzato dal costruttore per
fornire le informazioni necessarie a coloro che sono
autorizzati ad interagire con il prodotto: dai progettisti,
agli installatori, manutentori e riparatori.
Oltre ad adottare le regole della buona tecnica di
costruzione, le informazioni devono essere lette
attentamente ed applicate in modo rigoroso.
La non osservanza di dette informazioni può essere
causa di rischi per la salute e la sicurezza delle
persone e danni economici.
Queste informazioni sono state realizzate dal
costruttore nella propria lingua originale (italiano) e
possono essere tradotte in altre lingue per soddisfare
le esigenze commerciali e/o legislative.
Informazioni
La completa e costante osservanza delle indicazioni
contenute nel presente manuale tecnico garantisce
la migliore economia di esercizio ed una più lunga
durata di funzionamento del motoriduttore.
La documentazione fotografica ed i disegni sono forniti
a scopo esplicativo, in modo da descrivere
esaurientemente le operazioni da eseguire sul riduttore.
Anche se il riduttore in vostro possesso si discostasse
in parte dalle illustrazioni contenute in questo manuale
tecnico, le caratteristiche e la sequenza delle operazioni
descritte sono sempre garantite.
INFORMAZIONI GENERALI -2-
442 BOMAG
Travel gear
1. GENERAL INFORMATIONS
1.1. Manual aim
This manual has been realized by the manufacturer to
give necessary information to those authorised to work
on this product for example the design engineers,
installers, repair and maintenance technicians.
Besides helping one understand the rules of good
manufacturing techniques used, the information given
must be read attentively and strictly put into action.
Failure to observe this information may lead to health
and safety risks to persons as well as economic loss.
This information was compiled by the Italian
manufacturer in his original language (Italian) and can
be translated into other languages to satisfy
commercial and/or legal needs.
Information
A strict and consistent compliance with the
specifications of this technical manual ensure the
minimum operating costs and a longer unit life.
Photographic documentation and drawings are
supplied for educational purposes, so as to safely and
properly carry out maintenance operations.
Minor deviations from pictures of this manual may
appear on the actual gearbox. However, these
discrepancies are not relevant to the main parameters,
or maintenance functions.
GENERAL INFORMATIONS
008 915 04
 Travel gear 16.3

1.2. Identificazione del prodotto 1.2. Product identification

I dati per l'identificazione del prodotto sono riportati in The data to identify the product are shown on the
una targhetta applicata su di esso. identification plate attached to it.

Informazioni
Per la richiesta di informazioni, ricambi,
assistenza, ect, fornire sempre i dati identificativi.
La targhetta va mantenuta integra per tutta la vita del
prodotto. L'illustrazione evidenzia la disposizione dei
dati.
Information
For all enquiries regarding general information on
the product, spare parts, assistance etc, always
give the identification data stamped on the ID
plate.
The plate must not be removed or damaged during the
life of the product. The following illustration shows how
the data is set out.

Identificazione del Costruttore Codice del montatore

Manufacturer’s identification Assembler code

Designazione del prodotto: Rapporto di riduzione

composizione alfanumerica che Reduction ratio
consente di identificare il prodotto.
Product designation: Data di produzione
alphanumeric composition which Date of production
allows identification of the product.

Codice prodotto Codice del prodotto cliente

Trasmital Bonfiglioli Customer product code
Trasmital Bonfiglioli
product code Numero di matricola
Serial number
Codice a barre (tipo 39)
Bar code (type 39)
IDM-15220100300.tif

1.3. Modalità di richiesta assistenza 1.3. Requesting assistance

Per qualsiasi richiesta di assistenza rivolgersi For all requests for assistance please contact the
direttamente alla rete di vendita del costruttore manufacturers’ sales network, directly.

INFORMAZIONI GENERALI -3- GENERAL INFORMATIONS

008 915 04 BOMAG 443
16.3
1.4. Informazioni sulla sicurezza
Leggere attentamente le istruzioni riportate in questo
manuale e eventualmente quelle applicate
direttamente sul prodotto, in particolare rispettare
quelle riguardanti la sicurezza.
Il personale che effettua qualsiasi tipo di intervento in
tutto l’arco di vita del prodotto, deve possedere precise
competenze tecniche, particolari capacità ed
esperienze acquisite e riconosciute nel settore
specifico. La mancanza di questi requisiti può causare
danni alla sicurezza e alla salute delle persone.
Eseguire la movimentazione del prodotto rispettando
le informazioni riportate in questo manuale nei
paragrafi "Modalità di imballaggio" e "Sollevamento e
movimentazione" oppure applicate direttamente
sull’imballo (se presenti).
Utilizzare il prodotto solo per gli usi previsti dal
fabbricante. L’impiego del prodotto per usi impropri
può recare rischi per la sicurezza e la salute delle
persone e danni economici, nonché il decadere della
garanzia da parte del costruttore.
Mantenere il prodotto in condizioni di massima
efficienza effettuando le operazioni di manutenzione
programmata previste dal costruttore. Una buona
manutenzione consentirà di ottenere le migliori
prestazioni, una più lunga durata di esercizio e un
mantenimento costante dei requisiti di sicurezza.
Per eseguire interventi di manutenzione in zone non
facilmente accessibili o pericolose, predisporre
adeguate condizioni di sicurezza per sé stessi e per gli
altri rispondenti alle leggi vigenti in materia di
sicurezza sul lavoro.
Sostituire i particolari usurati utilizzando i ricambi
originali. Usare gli oli e i grassi consigliati dal
costruttore. Tutto questo potrà assicurare la
funzionalità del prodotto ed un livello di “sicurezza
accettabile”.
INFORMAZIONI GENERALI
444 BOMAG
Travel gear
1.4. Informations on safety
Carefully read the instructions given in this instruction
manual as well as the ones attached to the product and
make sure to follow the information concerning safety.
Personnel, which perform any type of work on the
product during its life span, must possess precise
technical qualifications as well as recognised skills and
experience gained in the specific sector. Failure to do
so may lead to health and safety risks to persons.
It is recommended that when handling the product
attention is paid to the information given in this manual
and particularly in the sections: “Packaging Methods”
and “Lifting and handling” or simply follow the
instructions given on the packaging (if present).
Utilise the product only for the use specified by the
manufacturer. Improper use of the product could lead
to health and safety risks to persons as well as
economic loss and furthermore will invalidate the
guarantee given by the manufacturer.
Keep the product in perfect working order by following
the scheduled maintenance procedure set out by the
manufacturer. Good maintenance will ensure the best
performances, a longer period of operation and a
constant safeguard towards security requirements.
To undertake maintenance procedures in areas which
are hard to reach or otherwise dangerous it is
important to follow adequate safety conditions for one
self and for others in compliance with the rules and
regulations that govern safety in the workplace.
When replacing worn parts, use original spare parts.
Use oils and greases recommended by the
manufacturer. Doing this, will ensure that the product
works properly and that the safety level is
“acceptable”.
-4- GENERAL INFORMATIONS
008 915 04
 Travel gear
1.5. Modalità di consegna
I riduttori vengono forniti dalla BONFIGLIOLI
TRASMITAL nelle seguenti condizioni standard:
– Già predisposti per essere installati nella posizione
di montaggio come definito in fase d’ordine.
– Le parti interne, per garantirne l’integrità, sono
preventivamente lubrificate con un velo d’olio usato
per il collaudo finale del riduttore. Non viene
eseguito il riempimento dell’olio lubrificante
(come segnalato da cartellino).
– Le parti grezze e le superfici di accoppiamento
vengono opportunamente trattate con antiossidanti.
– Le superfici esterne sono protette con smalto di
fondo antiossidante all'acqua di colore grigio e
successivamente finite con smalto di colore grigio (i
dati di verniciatura sono riportati nel disegno di
installazione). Le superfici di accoppiamento non
sono verniciate. Il tappo di sfiato se presente, non
deve essere verniciato.
– Collaudati secondo specifiche interne.
– Appositamente imballati per agevolarne la
movimentazione, il trasporto e lo stoccaggio.
IMBALLO SU PALLET CON TERMORETRAIBILE
PACKAGED ON A PALLET WITH
THERMOSHRINKING FILM
Cartellino che informa
“privo di lubrificante”
Card which states: “does not
contain lubricating oil”
1.6. Modalità di imballaggio
Le illustrazioni raffigurano i tipi di imballo più frequenti.
Informazioni
Al ricevimento del prodotto, accertarsi che
corrisponda alle specifiche di acquisto e che non
presenti danni o anomalie. Per qualsiasi
inconveniente rivolgersi direttamente alla rete di
vendita del costruttore.
INFORMAZIONI GENERALI -5-
008 915 04 BOMAG
16.3
1.5. Delivery methods
Gearboxes are supplied by BONFIGLIOLI
TRASMITAL at the following standard conditions:
– Ready for installation in the mounting position
specified when ordering.
– To guarantee their reliability, the internal parts are
properly lubricated with a layer of oil, the same as
the one used in the final test of the gearbox.
Lubricating oil has not been added (as shown on
the card).
– All unmachined parts and surfaces to be coupled
are appropriately treated with antioxidants.
– External surfaces are protected with an antioxidant
water resistant grey color and painted with a grey
sinthetic finish coat (painting data are shown on the
installation drawing). Machined surfaces are not
painted. The breather plug must not be painted, if
available.
– Tested to in-house specifications.
– Appropriately packaged to facilitate handling,
transport and storage.
IMBALLO CON CASSA
PACKAGED IN A CASE
IDM-15220600100.tif
1.6. Packaging methods
The illustrations show the more common types of
packaging.
Information
When the product arrives, ensure that it meets the
information contained in the purchase agreement
and that there are no damages or irregularities. If
there are any problems contact the manufacturers’
sales network directly.
GENERAL INFORMATIONS
445
16.3
1.7. Sollevamento e movimentazione
Se la movimentazione avviene quando il prodotto è
imballato, è sufficiente attenersi alle indicazioni
applicate direttamente sull'imballo e/o comunque
utilizzando i normali mezzi di sollevamento.
Cautela - Precauzione
Considerando che la massa e la forma del prodotto
non ne consentono lo spostamento a mano, in
particolari movimentazioni (es: installazione), è
necessario utilizzare accessori che consentono di
garantire la sicurezza delle persone ed evitare
danni al prodotto.
Per sollevare e movimentare il prodotto, dopo aver
aperto l'imballo, attenersi alle seguenti indicazioni:
1. Avvitare n° 2 golfari M20 UNI ISO 3266 nei fori
filettati del corpo angolare.
2. Servendosi di un paranco sollevare e movimentare
con la massima cautela evitando gli urti.
Golfare M20 UNI
ISO 3266
Eyebolt M20 UNI
ISO 3266
INFORMAZIONI GENERALI
446
Travel gear
1.7. Lifting and handling
If the handling occurs when the product is still
packaged, simply follow the instructions given on the
packaging and/or use normal hoisting means.
Caution
Considering that the size and form of the product
does not allow manual shifting, in particular
handlings, (e.g. installation) it is necessary to use
accessories that guarantee human safety and
which also avoid damages to the product.
To lift and handle the product, after having opened the
packaging, follow the information given below:
1. Tighten nos. 2 eyebolts M20 UNI ISO 3266 into the
thread holes of the right angle housing.
2. By using a tackle lift and handle with care avoiding
impacts.
IDM-15220600200.tif
-6- GENERAL INFORMATIONS
BOMAG 008 915 04
 Travel gear
1.8. Modalità di magazzinaggio
In fase di magazzinaggio del prodotto adottare le
precauzioni di seguito indicate.
1. Evitare ambienti con eccessiva umidità ed esposti
ad intemperie ed escludere aree all'aperto.
2. Evitare il contatto diretto del prodotto con il suolo.
3. Disporre il prodotto in modo che abbia una base di
appoggio stabile e verificare che non sussistano
rischi di spostamenti imprevisti.
4. Accatastare il prodotto imballato (se consentito)
seguendo le indicazioni riportate sull'imballo stesso.
Per periodi di magazzinaggio previsti superiori a 6
mesi, verificare ed eventualmente eseguire le seguenti
operazioni.
5. Per evitare ossidazioni, ricoprire tutte le parti
esterne lavorate con grasso.
6. Riempire completamente i riduttori di olio
lubrificante.
Informazioni
I riduttori, prima del loro utilizzo, dovranno essere
riempiti con la corretta quantità e tipo di
lubrificante previsto.
INFORMAZIONI GENERALI
008 915 04
16.3
1.8. Storage methods
In the storage process of the product follow the safety
measures given below.
1. Avoid environments with excessive humidity and
exposed to changing weather conditions and make
sure that open areas are excluded.
2. Make sure that the product does not lie directly on
the ground.
3. Make sure that the product is placed on a stable
base thereby avoiding that the product moves
about unexpectedly.
4. Stack the packaged product (if allowed) following
the indications given on the packaging itself.
For storing periods that go beyond 6 months, check
and consult the following procedures.
5. To avoid oxidation, cover all the worked external
parts with grease.
6. Fill completely the gearboxes with lubricant oil.
Information
Before use, the gearboxes should be filled with the
proper amount of lubricant of the recommended
type.
-7- GENERAL INFORMATIONS
BOMAG 447
16.3 Travel gear

2. INFORMAZIONI TECNICHE 2. TECHNICAL INFORMATIONS

2.1. Descrizione del prodotto 2.1. Product description

I riduttori BONFIGLIOLI TRASMITAL della serie
descritta in questo manuale sono stati progettati e
costruiti per essere applicati su rulli gommati per il
comando ruota.
Una importante raccomandazione è di progettare “a
regola d’arte” l’impianto idraulico di comando.
L’illustrazione mostra le parti e le principali funzioni di
un riduttore.
The BONFIGLIOLI TRASMITAL gearboxes of the
series described in this manual are designed and built
for wheel drive of pneumatic tyred roller machines.
An important piece of advice given is “to perfectly”
design the main hydraulic system.
The illustrations show the parts and the main functions
of the gearbox.

Gruppo riduttore
Gearbox kit
Gruppo riduzioni
Reduction kit

Gruppo riduzione angolare

Right angle reduction kit

Gruppo riduzioni
Reduction kit

Gruppo freno
Brake kit

IDM-15220600600.tif

INFORMAZIONI TECNICHE -8- TECHNICAL INFORMATIONS

448 BOMAG 008 915 04
 Travel gear 16.3

Gruppo riduzioni
Reduction kit

IDM-15220600700.tif

Gruppo freno
Brake kit

IDM-15220600800.tif

INFORMAZIONI TECNICHE -9- TECHNICAL INFORMATIONS

008 915 04 BOMAG 449
16.3 Travel gear

Posizione dei tappi olio sul riduttore/ Oil plugs position on the gearbox

IDM-15220600900.tif

Legenda: Legend:
1 1
M18x1,5 ......................................... Tappo carico olio M18x1,5 .............................................. Oil filling plug
2 2
M14x1,5 ......................................... Tappo livello olio M14x1,5 ............................................... Oil level plug
3 3
M18x1,5 ....................................... Tappo scarico olio M18x1,5 ......................................... Oil draining plug
4 4
M14x1,5 .............................................. Tappo chiuso M14x1,5 ................................................ Closed plug
5 5
G 1/4” (n° 2) ..................................... Comando freno G 1/4” (nos. 2) ............................. Brake release port
6 6
G 1/4” (n° 2) ........................ Comando azionamento G 1/4” (nos. 2) ............................. Dynamic operated
dinamico del freno brake port
7 7
G 3/4” .......... Entrata olio lubrificazione forzata freno G 3/4” ............. Forced oil brake lubrication inlet port
8 8
G 3/4” ............ Uscita olio lubrificazione forzata freno G 3/4” ........... Forced oil brake lubrication outlet port
9 9
G 3/8” .................................. Tappo scarico olio freno G 3/8” ................................... Oil brake draining plug

INFORMAZIONI TECNICHE - 10 - TECHNICAL INFORMATIONS

450 BOMAG 008 915 04
 Travel gear
3. INFORMAZIONI SULL’INSTALLAZIONE
3.1. Procedure per l’installazione
Prima dell'installazione eseguire le seguenti operazioni.
1. Pulire accuratamente il prodotto dai residui
dell'imballaggio e di protezione.
2. Predisporre le parti di accoppiamento facendo
riferimento al disegno di installazione.
Le fasi principali di installazione sono di seguito
elencate. Nei paragrafi successivi sono indicate, in
dettaglio, le operazioni da eseguire.
– Installazione del motore idraulico (paragrafo 3.2.)
– Installazione del prodotto sulla macchina
(paragrafo 3.3.)
– Fissaggio ruota al motoriduttore (paragrafo 3.4.)
– Collegamento del freno (paragrafo 3.5.)
– Riempimento e livello dell'olio lubrificante riduttore
(paragrafo 3.7.).
INFORMAZIONI SULL’INSTALLAZIONE
008 915 04
16.3
3. INSTALLATION INFORMATIONS
3.1. Installation procedure
Before proceeding with installation, follow the
instructions given below.
1. Properly clean the product removing packaging
and all remains of protection padding.
2. Prepare the parts to be coupled using the
installation drawing as a guide.
The main installation processes are given below. In the
following sections, the procedures to follow are given
in detail.
– Hydraulic motor installation (section 3.2.)
– Mounting the product to the machine (section 3.3.)
– Fixing of the wheel to the gearmotor (section 3.4.)
– Connecting the brake (section 3.5.)
– Filling-up the gearmotor with lubricating oil and level
of oil to maintain in the gearbox (section 3.7.).
- 11 - INSTALLATION INFORMATIONS
BOMAG 451
16.3
3.2. Installazione del motore idraulico
Assicurarsi che le superfici di accoppiamento ed il
centraggio dove va inserito il motore idraulico siano
pulite ed esenti da bave.
Informazioni
Prima di montare il motore idraulico, verificare,
con un calibro per interni, il corretto assemblaggio
del riduttore controllando la quota assiale indicata
nello schema seguente.
1. Montare la guarnizione O-ring (A) nella propria
sede nel motore idraulico ed assemblare
quest'ultimo al riduttore facendo attenzione a non
danneggiare la guarnizione precedentemente
montata.
2. Serrare le n° 4 viti M16 (B), classe di resistenza
8,8, con una chiave dinamometrica alla coppia di
215 Nm.
Informazioni
Togliere i tappi in plastica a protezione degli
attacchi solamente al momento del collegamento
dei tubi, per evitare l’immissione di qualsiasi corpo
estraneo all’interno del motore idraulico.
B A
Legenda:
B B
n° 4 viti ...............................M16 classe 8,8 - 215 Nm
INFORMAZIONI SULL’INSTALLAZIONE
452
Travel gear
3.2. Hydraulic motor installation
The mating areas and the pilot diameter of the gearbox
where the motor is to be mounted must be clean and
without burrs.
Information
Before assembling the hydraulic motor, verify by a
depth slide gauge the correct assembly of the unit
checking the axial distance as shown in the
scheme below.
1. Fit the O-ring seal (A) in its seat in the hydraulic
motor, and assemble it to the gearbox being
careful not to damage the seal already fitted.
2. Tighten the nos. 4 screws M16 (B), grade 8,8, by a
torque wrench at 215 Nm torque.
Information
Only when it is necessary to attach pipes, remove
the plastic caps protecting the connections, this
will ensure that no foreign body goes inside the
hydraulic motor.
IDM-15220601000.tif
Legend:
n° 4 screws......................... M16 grade 8,8 - 215 Nm
- 12 - INSTALLATION INFORMATIONS
BOMAG 008 915 04
 Travel gear
3.3. Installazione del motoriduttore sulla macchina
1. Spostare il motoriduttore nella zona di
installazione sollevandolo come indicato nel
paragrafo 1.7.
2. Pulire le zone di accoppiamento da protettivi o
vernice ed installare il motoriduttore sul telaio
macchina (per il corretto orientamento fare
riferimento al disegno di installazione).
3. Fissare il motoriduttore al telaio macchina con n° 8
viti M20 (C), classe di resistenza 10,9, serrate con
una chiave dinamometrica alla coppia di 585 Nm.
3.4. Fissaggio ruota al motoriduttore
1. Pulire le zone di accoppiamento da protettivi o
vernice ed assemblare la ruota al motoriduttore.
2. Fissare le ruote al motoriduttore con n° 20 viti
M20x1,5 (D), classe minima di resistenza 10,9,
serrate con una chiave dinamometrica alla coppia
di 635 Nm.
Telaio macchina
Machine frame
C Wheel
Legenda:
C C
n° 8 viti .............................M20 classe 10,9 - 585 Nm
D D
n° 20 viti ....................M20x1,5 classe 10,9 - 635 Nm
INFORMAZIONI SULL’INSTALLAZIONE
008 915 04
16.3
3.3. Installation of the wheel drive on the machine
1. Move the wheel drive in the mounting area
applying lifting methods shown in section 1.7.
2. Clean the mating surfaces from oils or paint and fit
the wheel drive on the machine frame (for the
correct orientation refer to the installation drawing).
3. Fix the wheel drive to the machine frame by using
nos. 8 screws M20 (C), grade 10,9, tightened by a
torque wrench at 585 Nm.
3.4. Fixing of the wheel to the gearmotor
1. Clean the mating surfaces from oils or paint and
assemble the wheel to the gearmotor.
2. Fix the wheels to the wheel drive by using nos. 20
screws M20x1,5 (D), grade 10,9, tightened by a
torque wrench at 635 Nm.
D
Ruota
IDM-15220601100.tif
Legend:
n° 8 screws ...................... M20 grade 10,9 - 585 Nm
n° 20 screws ............. M20x1,5 grade 10,9 - 635 Nm
- 13 - INSTALLATION INFORMATIONS
BOMAG 453
16.3 Travel gear

3.5. Collegamento del freno 3.5. Connecting the brake

Il riduttore è provvisto di un freno negativo a dischi
multipli di sicurezza con sblocco a comando idraulico
(freno di stazionamento).
Per informazioni riguardanti le caratteristiche del freno,
fare riferimento al disegno di installazione.
The gearbox is fitted with a negative multi disk safety
brake with hydraulic control release (parking brake).
For information regarding the characteristics of the
brake refer to the installation drawing.

DATI FRENO / BRAKE TECHNICAL DATA

Pressione minima di completa apertura/minimum brake release pressure (bar) 19

Pressione massima di comando freno/ Maximum operating pressure brake (bar) 50

Coppia frenante/ Braking torque (Nm) 900 ± 10%

Informazioni
Togliere i tappi in plastica a protezione degli
attacchi solamente al momento del collegamento
dei tubi, per evitare l'immissione di qualsiasi corpo
estraneo all'interno del motore idraulico.
1. Effettuare i seguenti collegamenti al freno (per
dimensione e tipo, fare riferimento al disegno di
installazione).
– Comando apertura freno; porte “5”.
– Comando azionamento dinamico freno; porte “6”.
– Entrata olio lubrificazione forzata freno; porta “7”.
– Uscita olio lubrificazione forzata freno; porta “8”.
Information
Only when it is necessary to attach pipes, remove
the plastic caps protecting the connections, this
will ensure that no foreign body goes inside the
hydraulic motor.
1. Pipe the brake as shown below (for hose sizes and
dimensions refer to the installation drawing).
– Brake release ports: “5”.
– Dynamic operated brake ports: “6”.
– Forced oil brake lubrication inlet port: “7”.
– Forced oil brake lubrication outlet port: “8”.

IDM-15220601200.tif

Caratteristiche olio lubrificazione forzata freno / Forced oil brake lubrication characteristics

Portata olio nominale / Nominal oil flow (l/1') 23

Portata olio max intermittente / Max intermittent oil flow (l/1') 33

Contropressione massima intermittente alla porta "9"

(bar) 6
Intermittent max back pressure at drain port "9"

Temperatura max olio in uscita porta "8"

(°C) 100
Max oil output temperature port "8"

INFORMAZIONI SULL’INSTALLAZIONE - 14 - INSTALLATION INFORMATIONS

454 BOMAG 008 915 04
 Travel gear
3.6. Caratteristiche olio lubrificazione forzata freno
L’olio deve rispondere alle caratteristiche ISO VG 46.
L’olio deve essere filtrato con grado massimo di
50 μm.
È opportuno non mescolare fra loro olii con proprietà
differenti.
È consigliato usare un filtro con indicatore visivo
d’intasamento visibile dall’esterno, con una valvola
limitatrice che blocchi il flusso dell’olio quando il filtro
sia intasato.
Qualora si dovesse lavorare a basse temperature
(climi artici) sono necessarie norme specifiche
(contattare il costruttore).
Il controllo della temperatura dell’olio idraulico è una
delle costanti più critiche nel sistema idraulico.
Alte temperature di esercizio, causano un degrado
della resistenza all’ossidazione ed accelerano il
deterioramento dell’olio idraulico.
INFORMAZIONI SULL’INSTALLAZIONE
008 915 04
16.3
3.6. Characteristics of oil forced brake lubrication
Lubrication must reflect the ISO VG 46 characteristics.
It must be filtered with a maximum grade of 50 μm.
It is advised not to mix together oils with different
properties.
It is advised to use a filter with a led indicator that can
be seen externally, with a flow control valve that blocks
the flow of oil when the filter is clogged.
If it is necessary to work in low temperatures (artic
climates) it is essential to use specific guidelines
(contact the manufacturer).
Checking the temperature of the hydraulic oil is one of
the most critical aspects of the hydraulic system.
High operational temperatures will cause a
degradation of the oxidation resistance level and will
accelerate the deterioration process of the hydraulic
oil.
- 15 - INSTALLATION INFORMATIONS
BOMAG 455
16.3 Travel gear

3.7. Riempimento olio lubrificante del riduttore
La lubrificazione è separata fra motore e riduttore.
La lubrificazione del riduttore è a sbattimento in
bagno d'olio. L'olio consigliato è del tipo per
trasmissioni ad ingranaggi, con viscosità
SAE 80W/90 oppure SAE 85W/140 con
caratteristiche EP rispondente a: MIL-L-2105 C &
API GL 5.
Nella tabella seguente sono riportate le marche più
diffuse di lubrificanti con i tipi di olio consigliati.
3.7. Filling-up the gearbox with lubricating oil
The motor and the gearbox have separate lubrication.
The gearbox is lubricated by oil splashing.
The recommended type of oil is SAE 80W/90 or
SAE 85W/140 with EP features complying with
MIL-L-2105 C & API GL5.
In following table the most common brands of lubricant
and the types recommended are shown.

Informazioni Information
Durante l'esercizio e solo per brevi momenti l'olio During operation the oil temperature must not
può raggiungere, ma non superare, la temperatura exceed 85-90°C intermittent.
di 85-90°C intermittente.

Elenco olii consigliati a Norme SAE 80W/90 e SAE 85W/140 con caratteristiche API GL5
Lubricant oils suggested according SAE 80W/90 and SAE 85W/140 API GL5 grade

Temperatura ambiente
-20°C / +30°C +10°C / +45°C
Ambient temperature
SAE 80W/90 SAE 85W/140
Viscosità olio / Oil viscosity
Produttori / Manufacturers Tipo olio / Oil Brand

SHELL SPIRAX HD SPIRAX HD

AGIP ROTRA MP ROTRA MP

ARAL GETRIEBEOL HYP GETRIEBEOL HYP

BP-MACH HYPOGEAR EP HYPOGEAR EP

CASTROL HYPOY HYPOY

CHEVRON UNIVERSAL GEAR LUBRICANT UNIVERSAL GEAR LUBRICANT

ELF TRANSELF B TRANSELF B

ESSO GEAR OIL GX PONTONIC MP GEAR OIL GX PONTONIC MP

I.P. PONTIAX HD PONTIAX HD

MOBIL MOBILUBE HD MOBILUBE HD

TOTAL TRASMISSION TM TRASMISSION TM

Informazioni
In caso di lubrificazione con olii sintetici, è consigliato
utilizzare solo quelli a base Polialfaolefine (PAO).
Non mescolare olii di marca o caratteristiche diverse.
Information
In case of lubrication with syntetic oils, is
recommended to use only oils with PAO base.
Do not mix together oils of different brands or
characteristics.

INFORMAZIONI SULL’INSTALLAZIONE - 16 - INSTALLATION INFORMATIONS

456 BOMAG 008 915 04
 Travel gear
Informazioni
Il riduttore viene fornito privo di olio ma
predisposto con tappi di carico, scarico e livello.
Prima della messa in funzione occorre eseguire il
riempimento.
Eseguire questa operazione come di seguito indicato.
1. Con l'asse del riduttore in orizzontale, ruotare il
corpo fino a che il tappo di scarico (3) si trovi in
basso sull'asse verticale del coperchio di chiusura.
2. Svitare i tappi di carico e livello olio (1-2).
3. Riempire dal foro (1) fino a che l'olio lubrificante
non fuoriesca dal foro (2).
4. Avvitare i tappi di carico e livello olio (1-2) e
mettere in funzione il riduttore; attendere qualche
istante, poi verificare nuovamente il livello dell'olio.
5. Aggiungere olio lubrificante se necessario.
INFORMAZIONI SULL’INSTALLAZIONE
008 915 04
16.3
Information
The gearbox is supplied without oil; anyway it has
filling, draining and oil level plugs. Before putting
the gearbox into operation, it is necessary to fill it
with oil.
This procedure is undertaken following the indications
given below.
1. Check that the gearbox axis is horizontal. Rotate
the gearbox housing until the drain plug (3) is on
the bottom of the vertical axis of the end cover.
2. Unscrew the fill and level oil plugs (1-2).
3. Fill from the hole (1) until the lubricant oil flows out
from the hole (2).
4. Tighten the fill and level oil plugs (1-2) and let the
gearbox run. After a few minutes, stop and check
the oil level.
5. If necessary, refill with lubricant oil.
IDM-15220601600.tif
- 17 - INSTALLATION INFORMATIONS
BOMAG 457
16.3
3.8. Prima messa in esercizio e rodaggio
In questa prima fase, si raccomanda di adottare alcune
precauzioni come di seguito indicato.
1. Eliminare eventuale aria residua dal circuito
idraulico e aggiungere olio nel serbatoio se
necessario.
Informazioni
La presenza di aria residua nel circuito idraulico si
manifesta con la presenza di schiuma nel
serbatoio e causa un funzionamento a strappi del
motore ed un eccessiva rumorosità del motore e
delle valvole.
2. Avviare il motoriduttore a bassa velocità ed
incrementare gradualmente, dopo avere verificato
che il funzionamento sia corretto, in assenza di
rumore e vibrazioni.
Informazioni
Non arrivare alla massima pressione sino a
quando tutto l'impianto non sia stato filtrato per
l'eliminazione di eventuali particelle di impurità.
Durante il rodaggio eseguire le operazioni di seguito
indicate.
3. Controllare che il numero dei giri ed il senso di
rotazione siano corretti.
4. Controllare che il funzionamento sia regolare ed in
assenza di rumore eccessivo e vibrazioni.
5. Controllare che la temperatura dell’olio non superi
i 90°C.
Al termine di questo primo rodaggio eseguire le
operazioni di seguito indicate.
6. Controllare che non vi siano perdite d’olio. In caso
contrario provvedere alla loro eliminazione
7. Controllare il livello dell’olio lubrificante del
motoriduttore.
8. Durante il primo avviamento, causa l’eventuale
presenza di aria, l’apertura del freno potrebbe
risultare ritardata. Ripetere alcune volte il
comando di apertura e chiusura del freno.
9. Controllare che non vi siano altri problemi.
INFORMAZIONI SULL’INSTALLAZIONE
458
Travel gear
3.8. First start up and running in
In this first stage it is advised to follow the measures
given below.
1. Bleed air from every part of the hydraulic circuit
and add oil in the tank if necessary.
Information
The presence of residual air in the hydraulic circuit
will manifest itself with the presence of foam in the
tank and will lead to a jerking of the motor as well
as excessive noise coming from the motor and the
valves.
2. Start the gearmotor at a low speed and gradually
increase it after having verified that it is functioning
correctly without any noises or vibrations.
Information
Do not reach maximum pressure unless the entire
system has been filtered to eliminate any particles
of dirt that may be present.
During the running-in stage follow the steps given
below.
3. Make sure that the speed and direction of rotation
are correct.
4. Make sure that the functioning is regular and
without any excessive noises and vibrations.
5. Make sure that the oil temperature does not
exceed 90°C.
After having terminated this first running-in follow the
steps given below.
6. Check that there are no oil leakages. If present,
proceed to remove them.
7. Check the level of lubricating oil in the gearmotor.
8. It could happen that due to the presence of air,
during the first start up, the opening action of the
brake could be slowed down. It is advised to repeat
the opening and closing function of the brake.
9. Check that there are no other problems in general.
- 18 - INSTALLATION INFORMATIONS
BOMAG 008 915 04
 Travel gear 16.3

4. INFORMAZIONI SULLA MANUTENZIONE 4. MAINTENANCE INFORMATIONS

4.1. Manutenzione periodica 4.1. Periodic maintenance

Il riduttore necessita solamente delle operazioni di The gearbox only requires the scheduled maintenance
manutenzione programmata prevista dal costruttore procedures set out by the manufacturer (see Table
(vedi tabella). below).

Una buona manutenzione consentirà la continuità di Good maintenance will ensure an on going functioning
funzionamento nel tempo con la massima affidabilità. in time as well as maximum reliability.

Nel caso in cui insorgano anomalie di funzionamento Should irregularities in function arise, it will be
sarà necessario consultare la check-list della ricerca necessary to consult the troubleshooting checklist to
guasti per trovare una soluzione adeguata. find the most adequate solution.

In caso contrario potrebbe essere necessario If unsuccessful, it may be necessary to disassemble a

effettuare lo smontaggio parziale o completo del partially or completely the motorgearbox (see
motoriduttore (vedi paragrafo 4.4.) section 4.4.)

Controllo / Inspection Frequenza / Frequency Azione / Action

Serraggio viti Dopo le prime 50 ore Verifica serraggio viti

Tightening screws After the first 50 hours Screws tighening torque check

Livello olio Ogni 100 ore Rabboccare l’olio

Oil level Every 100 hours Refill oil

Primo cambio olio A 150 ore Sostituire olio

1st oil change At 150 hours Oil replacement

Cambi olio successivi Ogni 1000 ore o 1 anno Sostituire olio

Following oil changes Every 1000 hours or 1 year Oil replacement

INFORMAZIONI SULLA MANUTENZIONE - 19 - MAINTENANCE INFORMATIONS

008 915 04 BOMAG 459
16.3
4.2. Sostituzione dell'olio lubrificante
1. Con l'asse del riduttore in orizzontale, ruotare il
corpo fino a che il tappo di scarico (3) si trovi in
basso sull'asse verticale del coperchio di chiusura.
2. Svitare i tappi (1-3) e fare defluire l'olio in un
recipiente sufficientemente capiente; per
agevolare l'operazione di scarico è bene operare
con olio caldo.
3. Attendere qualche minuto affinché tutto l'olio sia
uscito, quindi avvitare i tappi (1-3).
4. Effettuare il riempimento dell'olio seguendo le
modalità predefinite (vedi paragrafo 3.7.).
Informazioni
Si raccomanda di non miscelare oli a base
minerale con oli a base sintetica e viceversa.
Cautela - Precauzione
Non disperdere l'olio nell'ambiente ma smaltirlo
rispettando le leggi vigenti in materia.
INFORMAZIONI SULLA MANUTENZIONE - 20 -
460 BOMAG
Travel gear
4.2. Changing the lubricating oil
1. Check that the gearbox axis is horizontal. Rotate
the gearbox housing until the drain plug (3) is on
the bottom of the vertical axis of the end cover.
2. Unscrew the plugs (1-3) and let the oil flow in a
large enough container; in order to facilitate the
draining must be oil still warm.
3. Wait a few minutes until all the oil is drained and
then proceed to screw on the plugs (1-3).
4. Proceed with the oil fill-up following the procedures
given (see section 3.7.).
Information
Never mix mineral oils with synthetic oils and vice
versa.
Caution
Do not dispose of the oil in the natural
environment but be careful to eliminate it in
compliance with the relative rules and regulations
that govern locally.
IDM-15220601700.tif
MAINTENANCE INFORMATIONS
008 915 04
 Travel gear 16.3

4.3. Ricerca guasti 4.3. Troubleshooting

La seguente tabella è stata realizzata per una The following table is realized to localize troubles in the
individuazione dei guasti nei riduttori per traslazione. gearbox.

Anomalie / Anomalies Cause / Causes Rimedi / Remedies

Perdita olio esterna / External oil leakage:
Dalla tenuta frontale a)Tenuta frontale danneggiata a)Sostituzione tenuta frontale
From the lifetime seal Lifetime damaged Replace lifetime seal

Dal coperchio a)Guarnizione O-ring danneggiata a)Sostituzione guarnizioni O-ring

From the end cover O-ring seal damaged Replace O-ring seals

a)Guarnizione tappo danneggiata a)Sostituzione guarnizione tappo

Plug seal damaged Replace plug seal
Dai tappi
From the plugs
b)Tappi o viti allentate b)Serrare tappi/viti
Plugs or screws loose Tighten the plugs/screws
Eccessiva rumorosità / Too much noise:
Rumore idraulico (in fase a)Impianto idraulico a)Verificare l'impianto idraulico
di rallentamento malfunzionante
velocità motore) Hydraulic circuit malfunctioning Verify hydraulic circuit
Hydraulic noise (during the
slowing down of the motor
speed)

Interno al riduttore (zona a)Danneggiamento interno a)Verificare riduttore

ingranaggi) Internal damage Check the gearbox
Inside the gearmotor
(reductions)
Altro / Other:
a)Livello olio scarso a)Verificare livello olio e aggiungerne
se necessario
Insufficient oil level Check the oil level and refill if
necessary
Surriscaldamento
Overheating b)Olio idraulico troppo caldo b)Verificare circuito idraulico
Hydraulic oil too warm Check the hydraulic circuit

c)Incompleta apertura freno c)Verificare pressione apertura freno

Brake not fully released Check brake release pressure

Malfunzionamento freno di stazionamento

Parking brake malfunctioning
Coppia frenante
a)Dischi freno usurati a)Sostituzione dischi freno
insufficiente
Brake discs worm Replace brake disc pack
Insufficient braking torque
b)Parti danneggiate b)Verifica componenti freno
Damaged parts Check brake components

a)Freno bloccato a)Verifica completa apertura freno

Parking brake locked Check the complete brake release
Rotazione ruota bloccata
b)Componenti meccanici b)Sostituzione parti danneggiate
Wheel locked
danneggiati
Mechanical components Replace damaged parts
damaged

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008 915 04 BOMAG 461
16.3
4.4. Smontaggio del motoriduttore
Nel caso in cui sia necessario effettuare una revisione
(parziale o totale) è necessario smontare il riduttore
dalla macchina. Considerando che questo è un
intervento di manutenzione straordinaria, è opportuno
che venga realizzato da personale con competenze
specifiche e capacità acquisite.
E' altresì importante che tale intervento sia effettuato in
una officina opportunamente attrezzata. Oltre ai
normali attrezzi, è necessario disporre delle
attrezzature speciali che possono essere costruite
(vedi allegati attrezzature speciali) oppure richieste
direttamente al costruttore.
Attrezzature speciali
Anello montaggio
tenuta frontale .......................... Codice/: 6689960610
Moltiplicatore di coppia............ Codice/: ATZ.09.003.1
Per la realizzazione di queste attrezzature vedi disegni
costruttivi in fondo al manuale.
INFORMAZIONI SULLA MANUTENZIONE - 22 -
462 BOMAG
Travel gear
4.4. Motorgearbox disassembly
In the case that it was necessary to undergo a (partial
or total) revision, it will be necessary to dismount the
gearbox from the machine. As this is known as an out
of the ordinary maintenance procedure, it is important
that only personnel with specific skills and experience
undertake it.
It is also important that this procedure is undertaken in
a workshop that is adequately tooled. As well as normal
workshop tools it will be necessary to use special tools
that can be made (see special tools attachment) or may
be requested from the manufacturer.
Special Tools
Tool for lifetime seal
assembly ...................................... Code/: 6689960610
Torque multiplier......................... Code/: ATZ.09.003.1
To be able to produce these equipments refer to the
production drawings at the end of this manual.
MAINTENANCE INFORMATIONS
008 915 04
 Travel gear 16.3

Nelle pagine seguenti vengono riportate tutte le fasi di
smontaggio e rimontaggio del riduttore: rispettarle
scrupolosamente.
Eseguire questi interventi adottando tutte le
necessarie precauzioni, come ad esempio:
1. chiudere tutti gli attacchi all'impianto oleodinamico
sul riduttore per evitare l'introduzione accidentale
di corpi estranei nel circuito e nel riduttore.
2. fare attenzione che le superfici di accoppiamento
non vengano danneggiate.
3. eseguire la movimentazione in modo che non crei
pericoli per la sicurezza delle persone e garantisca
l'integrità del riduttore.
4. predisporre la zona di lavoro al fine di rispettare le
leggi in materia di sicurezza e salute nei posti di
lavoro.
In the following pages all the procedures for
disassembling and reassembling the gearbox are
given, it is important to strictly adhere to them.
Proceed with these operations using all the necessary
safety measures, like for example:
1. Plug all the Hydraulic ports on the gearbox to avoid
the introduction of any foreign particles in the
circuit and the gearbox.
2. Making sure that the coupling surfaces are not
damaged.
3. Following the handling so as to be sure that there
are no risks for human safety and to guarantee the
reliability of the gearbox.
4. Making available a work area that is in line with
work and health safety in the workplace guidelines.

NOTA: di seguito sono indicate tutte le fasi per NOTE: Below are all the steps to follow during these
eseguire questi interventi. I numeri fra parentesi nel operations. Numbers in brackets in the text correspond
testo, corrispondono ai riferimenti riportati nel to the references in the exploded view.
seguente disegno esploso.

Gruppo riduttore
Gearbox kit A1
A2
A3
A4
A5

A4

A3
A11 A2
A1
A6

A7
A8
A9
A10

A12

A7
A13
A14
A15

IDM-15220600300.tif

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008 915 04 BOMAG 463
16.3 Travel gear

Gruppo riduzioni
Reduction kit

B1
B2
B3
B4
B5
B6

B16
B13
B17
B14 B15
B18

B7
B8
B9
B10
B11
B12
IDM-15220600400.tif

Gruppo freno
Brake kit

C7
C8

C11 C1
C12 C2
C13 C3
C14 C4
C5
C6

C9
C15 C10
C16
C17
C18
C19
C20
C7
C8

C21
C22
C23

IDM-15220600500.tif

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464 BOMAG 008 915 04
 Travel gear
4.5. Fasi di smontaggio
Informazioni
Per eseguire lo smontaggio del riduttore occorre
smontarlo dalla macchina e recarsi in un'officina
opportunamente attrezzata.
Per dare inizio alla fase di smontaggio, fare defluire
completamente l'olio lubrificante dal riduttore secondo
quanto descritto al paragrafo 4.2.
Svitare e sfilare le n° 4 viti M16, classe di resistenza
8,8, e togliere il motore idraulico e la propria
guarnizione O-ring.
4.6. Fasi di smontaggio riduttore
INFORMAZIONI SULLA MANUTENZIONE
008 915 04 BOMAG
16.3
4.5. Disassembling method
Information
For starting the gearbox disassembly it is now
necessary to remove it from the machine and
move it to a properly equipped workshop.
Before wheel drive disassembling, make sure that the
oil is discharged according to instructions specified in
section 4.2.
Unscrew and remove the nos. 4 screws M16, grade
8,8, and remove the hydraulic motor and its O-ring
seal.
4.6. Gearbox disassembly method
1. Svitare le n° 16 viti M12x40 (A3), classe di
resistenza 12,9, dal 1° gruppo riduttore (A2).
Unscrew the nos. 16 screws M12X40 (A3), grade
12,9, from the 1st gearbox kit (A2).
2. Servendosi di un paranco sfilare il 1° gruppo
riduttore (A2).
Informazioni
Fare attenzione a non daneggiare il tubo (A6)
durante questa fase.
By using a tackle remove the 1st gearbox kit (A2).
Information
Taking care not to damage the tube (A6) during
this step.
3. Sfilare il tubo (A6).
Remove the tube (A6).
- 25 - MAINTENANCE INFORMATIONS
465
16.3 Travel gear

4.6. Fasi di smontaggio riduttore 4.6. Gearbox disassembly method

4. Svitare le n° 16 viti M12x40 (A3), classe di

resistenza 12,9, dal 2° gruppo riduttore (A2).

Unscrew the nos. 16 screws M12X40 (A3), grade

12,9, from the 2nd gearbox kit (A2).

5. Servendosi di un paranco sfilare il 2° gruppo

riduttore (A2).

By using a tackle remove the 2nd gearbox kit (A2).

6. Svitare le n° 8 viti M10x30 (A12), classe di

resistenza 8,8, dal gruppo freno (A15).

Unscrew the nos. 8 screws M10X30 (A12), grade

8,8, from the brake kit (A15).

7. Sfilare il gruppo freno (A15).

Remove the brake kit (A15).

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 Travel gear 16.3

4.6. Fasi di smontaggio riduttore 4.6. Gearbox disassembly method

8. Sfilare l’albero scanalato (A13) dal gruppo

freno (A15).

Remove the splined shaft (A13) from the brake

kit (A15).

9. Togliere le guarnizioni O-ring (A14) dalle proprie

sedi nell’albero scanalato (A13).

Remove the O-ring seals (A14) from their seats in

the splined shaft (A13).

10. Svitare le n° 16 viti M10x30 (A12), classe di

resistenza 8,8, dalla riduzione angolare (A5).

Unscrew the nos. 16 screws M10X30 (A12), grade

8,8, from the right angle reduction (A5).

11. Sfilare la flangia di collegamento (A10).

Remove the connecting flange (A10).

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16.3 Travel gear

4.6. Fasi di smontaggio riduttore 4.6. Gearbox disassembly method

12. Togliere le guarnizioni O-ring (A7) dalle proprie

sedi nella flangia di collegamento (A10).

Remove the O-ring seals (A7) from their seats in

the connecting flange (A10).

13. Sfilare il giunto di collegamento (A8).

Remove the coupling (A8).

14. Servendosi di pinze sfilare l'anello elastico (A9)

dalla propria sede nel giunto di collegamento (A8).

By using pliers remove the circlip (A9) from its seat

in the coupling (A8).

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 Travel gear 16.3

4.7. Fasi di smontaggio gruppo riduttore 4.7. Gearbox kit disassembly method

15. Sfilare il solare di 1° riduzione (B1).

Remove the 1st stage sun gear (B1).

16. Estrarre, contemporaneamente, la 1°

riduzione (B2) e il solare di 2° riduzione (B10).

Remove, at the same time, the 1st reduction

assembly (B2) and the 2nd stage sun gear (B10).

17. Sfilare il solare di 2° riduzione (B10).

Remove the 2nd stage sun gear (B10).

18. Togliere la guarnizione O-ring (A4) dalla propria

sede nel mozzo flangiato (B3).

Remove the O-ring seal (A4) from its seat in the

flanged hub (B3).

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16.3 Travel gear

4.7. Fasi di smontaggio gruppo riduttore 4.7. Gearbox kit disassembly method

19. Capovolgere il riduttore e svitare il tappo di livello

olio (B17) con chiave esagonale maschio.

Turn the gearbox upside down and unscrew the

level oil plug (B17) by a male hex head wrench.

20. Svitare i tappi di carico-scarico olio (B16) con

chiave esagonale maschio.

Unscrew the draining-filling oil plugs (B16) by a

male hex head wrench.

21. Svitare le n° 10 viti M10x20 (A1-B12), classe di

resistenza 8,8, dal coperchio di chiusura (B15).

Unscrew the nos. 10 screws M10x20 (A1-B12),

grade 8,8, from the end cover (B15).

22. Sfilare il coperchio di chiusura (B15).

Remove the end cover (B15).

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 Travel gear 16.3

4.7. Fasi di smontaggio gruppo riduttore 4.7. Gearbox kit disassembly method

23. Togliere la guarnizione "X-ring" (B14) dalla propria

sede nel coperchio di chiusura (B15).

Remove the "X-ring" seal (B14) from its seat in the

end cover (B15).

24. Togliere la guarnizione O-ring (B11) dalla propria

sede nel corpo riduttore (B6).

Remove the O-ring seal (B11) from its seat in the

gearbox housing (B6).

25. Servendosi di pinze sfilare gli anelli elastici (B9)

dalle proprie sedi situate nei perni del mozzo
flangiato (B3).

By using pliers remove the circlips (B9) from their

seats in the flanged hub’s pins (B3).

26. Servendosi di un estrattore sfilare i gruppi planetari

di 2° riduzione (B8).

By using a puller remove the planet assemblies of

the 2nd reduction (B8).

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16.3 Travel gear

4.7. Fasi di smontaggio gruppo riduttore 4.7. Gearbox kit disassembly method

27. Servendosi di un trapano eliminare le cianfrinature

presenti sulla ghiera (B7).

By using a drill remove the calkings on the ring

nut (B7).

28. Posizionare il moltiplicatore di coppia

(ATZ.09.003.1) sulla ghiera (B7). Servendosi del
moltiplicatore di coppia svitare la ghiera (B7).

ATZ.09.003.1
Place the torque multiplier (ATZ.09.003.1) on the
ring nut (B7). By using the torque multiplier loosen
the ring nut (B7).

29. Rimuovere la ghiera (B7).

Take out the ring nut (B7).

30. Servendosi di una pressa e di un tampone

metallico, sfilare il mozzo flangiato (B3) dal corpo
riduttore (B6).

By using a press and a metal stopper, remove the

flanged hub (B3) from the gearbox housing (B6).

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 Travel gear
4.7. Fasi di smontaggio gruppo riduttore
Informazioni
Può essere necessario in caso di perdite olio,
dover provvedere al controllo ed alla eventuale
sostituzione della tenuta frontale (B4), cioè di
entrambe le parti metalliche e delle guarnizioni
O-ring.
INFORMAZIONI SULLA MANUTENZIONE
008 915 04
16.3
4.7. Gearbox kit disassembly method
31. Servendosi di un paranco sfilare il mozzo
flangiato (B3) dal corpo riduttore (B6).
By using a tackle remove the flanged hub (B3)
from the gearbox housing (B6).
Information
In case of oil leakages, it might be necessary to
check and eventually replace the lifetime
seal (B4), which means both the metal rings parts
and the O-ring seals.
32. Sfilare la 1° semitenuta frontale (B4) dal mozzo
flangiato (B3).
Remove the 1st half-seal (B4) from the flanged
hub (B3).
33. Sfilare la 2° semitenuta frontale (B4) dal corpo
riduttore (B6).
Remove the 2nd half-seal (B4) from the gearbox
housing (B6).
- 33 - MAINTENANCE INFORMATIONS
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16.3 Travel gear

4.7. Fasi di smontaggio gruppo riduttore 4.7. Gearbox kit disassembly method

34. Servendosi di un estrattore e di un tampone

metallico, smontare l’anello interno del cuscinetto
dal mozzo flangiato (B3).

By using a puller and a metal stopper, remove the

bearing inner raceway from the flanged hub (B3).

35. Sfilare l'anello interno del cuscinetto dal mozzo

flangiato (B3).

Remove the bearing inner raceway from the

flanged hub (B3).

36. Servendosi di pinze estrarre l’anello di

spallamento (B5) dal corpo riduttore (B6).

By using pliers remove the elastic ring (B5) from

the gearbox housing (B6).

37. Sfilare i supporti in plastica e le sfere dal corpo

riduttore (B6).

Remove the plastic supports and the balls from the

gearbox housing (B6).

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4.7. Fasi di smontaggio gruppo riduttore 4.7. Gearbox kit disassembly method

38. Sfilare l'anello interno del cuscinetto dal corpo

riduttore (B6).

Remove the bearing inner raceway from the

gearbox housing (B6).

Informazioni Information
Per lo smontaggio del secondo gruppo For the 2nd gearbox kit (A2) disassembly follow
riduttore (A2) seguire le stesse fasi descritte nel the same steps shown in section 4.7.
paragrafo 4.7.

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16.3 Travel gear

4.8. Fasi di smontaggio gruppo freno 4.8. Brake kit disassembly method

39. Posizionare il gruppo freno (A15) su di un

distanziale.

Place the brake kit (A15) on a spacer.

40. Svitare le n° 8 viti M10x60 (C23), classe di

resistenza 8,8, dalla flangia predisposizione
motore (C22).

Unscrew the nos. 8 screws M10x60 (C23), grade

8,8, from the motor adaptor flange (C22).

Pericolo - Attenzione Danger - Warning

Svitare gradualmente le n° 8 viti (C23) in egual Loose the nos. 8 screws (C23) gradually by equal
misura in modo da bilanciare il carico delle molle amount each to balance the springs load on the
sulla flangia predisposizione motore (C22). motor adaptor flange (C22).

41. Sfilare la flangia predisposizione motore (C22).

Remove the motor adaptor flange (C22).

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 Travel gear 16.3

4.8. Fasi di smontaggio gruppo freno 4.8. Brake kit disassembly method

42. Togliere la guarnizione O-ring (C21) dalla propria

sede nella flangia predisposizione motore (C22).

Remove the O-ring (C21) from its seat in the motor

adaptor flange (C22).

43. Contrassegnare la posizione delle molle (C20) allo

scopo di avere un riferimento per il rimontaggio.

Mark the position of the springs (C20) as a

reference for the reassembling step.

44. Sfilare le molle (C20) dalle proprie sedi nel pistone

freno (C19).

Remove the springs (C20) from their seats in the

brake piston (C19).

45. Avvitare nei fori filettati di estrazione del pistone

freno (C19) n° 2 viti M5 e sollevarlo.

Tighten nos. 2 screws M5 in the extraction thread

holes of the brake piston (C19) and lift it.

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008 915 04 BOMAG 477
16.3 Travel gear

4.8. Fasi di smontaggio gruppo freno 4.8. Brake kit disassembly method

46. Sfilare il pistone freno (C19).

Remove the brake piston (C19).

47. Togliere la guarnizione O-ring (C14) dalla propria

sede nel corpo freno (C6).

Remove the O-ring seal (C14) from its seat in the

brake housing (C6).

48. Sfilare il distanziale (C17).

Remove the spacer (C17).

49. Togliere la guarnizione O-ring (C18) dalla propria

sede nel distanziale (C17).

Remove the O-ring seal (C18) from its seat in the

spacer (C17).

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4.8. Fasi di smontaggio gruppo freno 4.8. Brake kit disassembly method

50. Togliere le guarnizioni O-ring (C13) dalle proprie

sedi nel corpo freno (C6).

Remove the O-ring seals (C13) from their seats in

the brake housing (C6).

51. Sfilare, contemporaneamente, l’albero

freno (C16), il pacco dei dischi freno (C11-C12) e
il cuscinetto (C4).

Remove, at the same time, the brake shaft (C16),

the brake discs pack (C11-C12) and the
bearing (C4).

52. Sfilare il pacco dei dischi freno (C11-C12).

Remove brake discs pack (C11-C12).

53. Servendosi di un estrattore e di un tampone

metallico, sfilare il cuscinetto (C4) dall’albero
freno (C16).

By using a puller and a metal stopper, remove the

bearing (C4) from the brake shaft (C16).

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008 915 04 BOMAG 479
16.3 Travel gear

4.8. Fasi di smontaggio gruppo freno 4.8. Brake kit disassembly method

54. Servendosi di pinze sfilare l'anello elastico (C15)

dalla propria sede nell’albero freno (C16).

By using pliers remove the circlip (C15) from its

seat in the brake shaft (C16).

55. Servendosi di pinze sfilare l'anello elastico (C1)

dalla propria sede nel corpo freno (C6).

By using pliers remove the circlip (C1) from its seat

in the brake housing (C6).

56. Sfilare il disco spingimolle (C2).

Remove the spring retainer disc (C2).

57. Togliere la guarnizione O-ring (C5) dalla propria

sede nel corpo freno (C6).

Remove the O-ring seal (C5) from its seat in the

brake housing (C6).

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 Travel gear
4.8. Valutazione
4.9. Fasi di smontaggio
dei pezzigruppo freno
da sostituire
Informazioni
Lo smontaggio del riduttore termina con
quest'ultima operazione: tutti i particolari sono ora
a disposizione per le verifiche necessarie.
4.9. Valutazione dei pezzi da sostituire
I componenti soggetti ad usura sono i seguenti.
– Ingranaggi.
– Cuscinetti.
– Tutte le guarnizioni.
Sostituire i componenti usurati o guasti rispettando le
seguenti indicazioni:
1. Rimuovere accuratamente lo sporco, in particolare
pulire le sedi delle guarnizioni, dei cuscinetti e degli
anelli di bloccaggio.
2. Lubrificare i componenti prima di montarli.
3. In caso di ingranaggi danneggiati, esempio un
planetario, non sostituire il singolo ingranaggio ma
tutta la riduzione.
4. Sostituire sempre tutte le guarnizioni interessate
alla parte da rimontare. Aggiungere uno strato di
grasso sulle sedi di montaggio e sulle guarnizioni
nuove per facilitarne il montaggio.
5. Sostituire le parti danneggiate con ricambi originali
e rispettando le indicazioni fornite dal costruttore
nel paragrafo 4.10.
INFORMAZIONI SULLA MANUTENZIONE
008 915 04
16.3
4.8. Evaluating
4.9. Brake kit disassembly method
that pieces to replace
58. Togliere l’anello di tennuta (C3) dalla propria sede
nel disco spingimolle (C2).
Informazioni
Eseguire questa fase solo in caso di sostituzione.
Remove the seal ring (C3) from its seat in the
spring retainer disc (C2).
Information
Carry out this step only in case of replacement.
Information
The gearbox disassembly ends with the above
operation. All items are now available for the
necessary inspections.
4.9. Evaluating that pieces to replace
The pieces that are subject to general wear and tear
are the following:
– Gears.
– Bearings.
– All the seals
Replace the used or irregular parts respecting the
following steps:
1. Accurately remove dirt, and in particular properly
clean the seals, bearings and locking rings
seating.
2. Lubricate the parts before connecting them.
3. In the case of damaged gears, for example a
planetary, do not proceed to replace the individual
gear but the entire reduction assembly.
4. When reconnecting a part always replace all the
seals involved. Add some grease on the seats and
on the new seals to make easier the reassembly.
5. Replace all the damaged parts with original spare
parts and doing so follow all the steps given by the
manufacturer in Section 4.10.
- 41 - MAINTENANCE INFORMATIONS
BOMAG 481
16.3 Travel gear

4.10.Fasi di rimontaggio gruppo freno 4.10.Brake kit reassembling method

1. Montare l’anello di tenuta (C3) nella propria sede

nel disco spingimolle (C2).

Assemble the seal ring (C3) into its seat in the

spring retainer disc (C2).

2. Servendosi di un martello in gomma e di un

tampone metallico, spingere l’anello di tenuta (C3)
in battuta nella propria sede.

By using a rubber hammer and a metallic stopper,

push the seal ring (C3) against the seat shoulder.

3. Montare la guarnizione O-ring (C5) nella propria

sede nel corpo freno (C6).

Assemble the O-ring seal (C5) into its seat in the

brake housing (C6).

4. Inserire il disco spingimolle (C2).

Insert the spring retainer disc (C2).

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4.10. Fasi di rimontaggio gruppo freno 4.10. Brake kit reassembling method

5. Servendosi di un martello in gomma spingere il

disco spingimolle (C2) in battuta nella propria
sede.

By using a rubber hammer push the spring retainer

disc (C2) against the seat shoulder.

6. Servendosi di pinze, montare l’anello elastico (C1)

nella propria sede nel corpo freno (C6).

By using pliers, assemble the circlip (C1) into its

seat in the brake housing (C6).

7. Servendosi di pinze, montare l’anello

elastico (C15) nella propria sede nell’albero
freno (C16).

By using pliers, assemble the circlip (C15) into its

seat in the brake shaft (C16).

8. Inserire il cuscinetto (C4) sull’albero freno (C16).

Insert the bearing (C4) on the brake shaft (C16).

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4.10. Fasi di rimontaggio gruppo freno 4.10. Brake kit reassembling method

9. Servendosi di un martello in gomma e di un

tampone metallico, spingere il cuscinetto (C4) in
battuta nella propria sede.

By using a rubber hammer and a metal stopper,

push the bearing (C4) against the seat shoulder.

10. Montare l'albero freno (C16) all'interno del corpo

freno (C6).

Assemble the brake shaft (C16) inside the brake

housing (C6).

11. Montare il pacco dei dischi freno secondo il

seguente ordine: inserire per primo un disco in
bronzo sinterizzato (C11) a dentatura esterna.

Assemble the brake discs package according to

the following order: firstly, insert one sintered
bronze disc (C11) with external teeth.

12. Inserire successivamente un disco in acciaio (C12)

a dentatura interna. Ripetere l'operazione sino ad
ottenere una successione di n° 9 dischi in bronzo
sinterizzato e n° 8 in acciaio.

Then insert, an internally toothed steel disc (C12).

Repeat the operation until all nos. 9 sintered
bronze discs and nos. 8 steel discs have been
assembled.

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4.10. Fasi di rimontaggio gruppo freno 4.10. Brake kit reassembling method

13. Lubrificare la sede della guarnizione all'interno del

distanziale (C17) e montare la guarnizione
O-ring (C18).

Lube the seal seat into the spacer (C17) and

assemble the O-ring seal (C18).

14. Lubrificare le sedi delle guarnizioni all'interno del

corpo freno (C6) e montare le guarnizioni
O-ring (C13).

Lube the seal seats into the brake housing (C6)

and assemble the O-ring seals (C13).

15. Montare il distanziale (C17) all'interno del corpo

freno (C6), facendo attenzione a non danneggiare
le guarnizioni precedentemente montate.

Assemble the spacer (C17) inside the brake

housing (C6), paying attention not to damage the
seals already fitted.

16. Lubrificare la sede della guarnizione all'interno del

corpo freno (C6) e montare la guarnizione
O-ring (C14).

Lube the seal seat into the brake housing (C6) and
assemble the O-ring seal (C14).

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16.3 Travel gear

4.10. Fasi di rimontaggio gruppo freno 4.10. Brake kit reassembling method

17. Inserire il pistone freno (C19) all'interno del corpo

freno (C6), facendo attenzione a non danneggiare
le guarnizioni precedentemente montate.

Insert the brake piston (C19) inside the brake

housing (C6), paying attention not to damage the
seals already fitted.

18. Inserire le molle (C20) nelle sedi del pistone

freno (C19) rispettando le posizioni segnate in
precedenza.

Insert the springs (C20) into the holes in the brake

piston (C19) marked previously.

19. Montare la guarnizione O-ring (C21) nella propria

sede nella flangia predisposizione motore (C22).

Assemble the O-ring seal (C21) into its seat in the

motor adaptor flange (C22).

20. Posizionare la flangia predisposizione

motore (C22) sul corpo freno (C6).

Place the motor adaptor flange (C22) on the brake

housing (C6).

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4.10. Fasi di rimontaggio gruppo freno 4.10. Brake kit reassembling method

21. Serrare le n° 8 viti M10x60 (C23), classe di

resistenza 8,8, con una chiave dinamometrica alla
coppia di 50 Nm.

Tighten the nos. 8 socket head screws

M10x60 (C23),grade 8,8, by a torque wrench at
50 Nm torque.

50 Nm

Pericolo - Attenzione Danger - Warning

Avvitare gradualmente le n° 8 viti (C23) in egual Tighten the nos. 8 screws (C23) gradually by equal
misura in modo da bilanciare il carico delle molle amount each to balance the springs load on the
sulla flangia predisposizione motore (C22). motor adaptor flange (C22).

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4.11.Fasi di rimontaggio gruppo riduttore 4.11.Gearbox kit reassembling method

22. Montare l’anello interno del cuscinetto nel corpo

riduttore (B6).

Assemble the bearing inner raceway in the

gearbox housing (B6).

23. Assemblare il primo giro di sfere al corpo

riduttore (B6).

Assemble the 1st ball row to the gearbox

housing (B6).

24. Assemblare il supporto in plastica al primo giro di

sfere.

Assemble the plastic support to the 1st ball row.

25. Servendosi di un paranco posizionare il corpo

riduttore (B6) su di un distanziale.

By using a tackle place the gearbox housing (B6)

on a spacer.

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4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

26. Montare il 2° supporto in plastica nel corpo

riduttore (B6).

Assemble the 2nd plastic support in the gearbox

housing (B6).

27. Assemblare il secondo giro di sfere al supporto in

plastica.

Assemble the 2nd ball row to the plastic support.

28. Montare l’anello interno del cuscinetto nel corpo

riduttore (B6).

Assemble the bearing inner raceway in the

gearbox housing (B6).

29. Servendosi di pinze, montare l’anello di

spallamento (B5) nella propria sede nel corpo
riduttore (B6).

By using pliers, assemble the elastic ring (B5) into

its seat in the gearbox housing (B6).

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4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

Preparazione della tenuta frontale: Make ready of the lifetime seal:

1. Effettuare una accurata pulizia degli
alloggiamenti (A e B) facendo uso, se
necessario, di spazzole metalliche o solventi (le
superfici a contatto con gli anelli di gomma (C)
devono essere perfettamente pulite ed asciutte).
2. Assicurarsi che le superfici di tenuta (D) degli
anelli (E) siano esenti da qualsiasi rigatura,
ammaccatura o corpi estranei e che le
superfici (F) degli stessi anelli siano
perfettamente pulite ed asciutte. Si raccomanda
l'immersione degli anelli metallici in solvente
volatile o alcool bianco.
3. Togliere dalle superfici lappate (D) degli
anelli (E) ogni traccia di polvere o impronte digitali
e umettarle poi con un leggero strato di olio,
avendo cura di non ungere le rimanenti parti.
1. Carefully clean the seats (A and B) using, if
necessary, metallic brushes or solvent (surfaces in
contact with or (C) must be perfectly clean and
dry).
2. Make sure that sealing surfaces (D) of metal
rings (E) are free from scratches, dinges or foreign
substances; metallic ring surfaces must be
perfectly clean and dry. We suggest to dip the
metallic rings in volatile solvent or industrial
degreasing alcohol.
3. Carefully clean the lapped surface (D) of metal
rings (E) and remove dust or fingerprints. Then
lubrificate them with a thin oil film, taking care not
to oil the other components.

D D

A B

F F

C C

E E

IDM-1521530040

30. Montare la 1° semitenuta frontale (B4) sull'attrezzo

(6689960610).

6689960610 Assemble the 1st half seal (B4) on the tool

(6689960610).

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4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

31. Eseguire il montaggio della 1° semitenuta

frontale (B4) sul corpo riduttore (B6).

Assemble the 1st half seal (B4) on the gearbox

housing (B6).

32. Montare la 2° semitenuta frontale (B4) sull'attrezzo

(6689960610).
6689960610
Eseguire il montaggio della 2° semitenuta
frontale (B4) sul mozzo flangiato (B3).

Assemble the 2nd half seal (B4) on the tool

(6689960610).
Assemble the 2nd half seal (B4) on the flanged
hub (B3).

B4
Informazioni
Controllo corretto assemblaggio tenuta
frontale (B4).

B3
Information
Correct lifetime seal assembly check (B4).

B4

B6

IDM-15220601500.tif

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4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

33. Pulire accuratamente le superfici metalliche della tenuta

frontale (B4).

Cautela - Precauzione
Applicare un leggero strato di olio su una o entrambe le
superfici metalliche facendo attenzione a non ungere le
altre parti della tenuta frontale.

Clean carefully the seal faces (B4).

Caution
Apply a thin oil film on the entire metallic face of one or
both seals. Oil must not contact surfaces other than the
sealing faces.

34. Posizionare il mozzo flangiato (B3) all'interno del

corpo riduttore (B6).

Place the flanged hub (B3) inside the gearbox

housing (B6).

35. Servendosi di una pressa e di un tampone

metallico, spingere il mozzo flangiato (B3) in
battuta nel corpo riduttore (B6) fino ad ottenere il
completo assemblaggio del gruppo.

By using a press and a metallic stopper, push the

flanged hub (B3) against the shoulder in the
gearbox housing (B6) until assembling of the unit
is complete.

Cautela - Precauzione
Avvitare parzialmente la ghiera (B7) per evitare la
fuoriuscita del mozzo flangiato (B3) dal corpo
riduttore (B6) durante le fasi successive.

Caution
Screw the nut (B7) partially in order to avoid the
out coming of the flanged hub (B3) from the
gearbox housing (B6) during the following steps.

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4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

36. Posizionare il moltiplicatore di coppia (ATZ.09.003.1)

sulla ghiera (B7). Servendosi del moltiplicatore di
coppia, serrare la ghiera (B7) con una chiave
dinamometrica con coppia in ingresso al moltiplicatore
ATZ.09.003.1 di 113,5±3,5 Nm, corrispondente ad una coppia in
uscita dal moltiplicatore di 3500±100 Nm.

Place the multiplier (ATZ.09.003.1) on the ring

nut (B7). By using the multiplier, tighten the ring
nut (B7), by a torque wrench with an input
multiplier torque of 113,5±3,5 Nm corresponding to
an output multiplier torque of 3500±100 Nm.
3500±100 Nm

37. Cianfrinare la ghiera (B7) in corrispondenza dei 2

incavi del mozzo flangiato (B3).

Stake the ring nut (B7) near 2 seats of the flanged

hub (B3).

Informazioni
Cianfrinare Ø 4÷5 mm (profondità 1÷1,5 mm).

Information
Stake Ø 4÷5 mm (depth 1÷1,5 mm).

IDM-15217301600.tif

38. Posizionare i 4 gruppi planetari di 2° riduzione (B8)

nei perni del mozzo flangiato (B3).

Place the 4 planet assemblies of the 2nd

reduction (B8) in the flanged hub’s pins (B3).

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4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

39. Servendosi di un martello in gomma e di un

tampone metallico, spingere i gruppi planetari di 2°
riduzione (B8) in battuta fino ad ottenere il
completo assemblaggio.

By using a rubber hammer and a metal stopper

push the planet assemblies of the 2nd
reduction (B8) against the shoulder until assembly
is complete.

40. Servendosi di pinze montare gli anelli elastici nelle

sedi dei perni del mozzo flangiato (B3).

By using pliers assemble the circlips in the flanged

hub pin seats (B3).

41. Montare la guarnizione O-ring (B11) nella propria

sede nel coperchio di chiusura (B15).

Assemble the O-ring seal (B11) into its seat in the

end cover (B15).

42. Applicare uno strato di grasso RETINAX HD-2 o

prodotto similare sulla guarnizione "X-ring" (B14).
Inserire la guarnizione "X-ring" (B14) nella propria
sede nel coperchio di chiusura (B15).

Apply a coat of grease RETINAX HD-2 or similar

product on the "X-ring" seal (B14).
Insert the "X-ring" seal (B14) in its seat in the end
cover (B15).

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4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

43. Posizionare il coperchio di chiusura (B15) sul

corpo riduttore (B6).

Place the end cover (B15) on the gearbox

housing (B6).

44. Serrare le n° 10 viti M10x20 (A1-B12), classe di

resistenza 8,8, con una chiave dinamometrica alla
coppia di 50 Nm.

Tighten the nos. 10 socket head screws

M10x20 (A1-B12), grade 8,8, by a torque wrench
at 50 Nm torque.

50 Nm

45. Capovolgere il riduttore e montare la guarnizione

O-ring (A4) nella propria sede nel mozzo
flangiato (B3).

Turn the gearbox upside down and assemble the

O-ring seal (A4) into its seat in the flanged
hub (B3).

46. Inserire il solare di 2° riduzione (B10) nel mozzo

flangiato (B3).

Insert the 2nd stage sun gear (B10) in the flanged

hub (B3).

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4.11. Fasi di rimontaggio gruppo riduttore 4.11. Gearbox kit reassembling method

47. Montare la 1° riduzione (B2).

Assemble the 1st reduction assembly (B2).

Informazioni Information
Per per il rimontaggio del secondo gruppo For the 2nd gearbox kit (A2) reassembly follow the
riduttore (A2) seguire le stesse fasi descritte nel same steps shown in section 4.11.
paragrafo 4.11.

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4.12.Fasi di rimontaggio riduttore 4.12.Gearbox reassembling method

48. Inserire il solare di 1° riduzione (B1) nella riduzione

angolare (A5).

Insert the 1st stage sun gear (B1) in the right angle
reduction (A5).

49. Servendosi di un paranco montare il 1° gruppo

riduttore (A2).

By using a tackle assemble the 1st gearbox

kit (A2).

50. Applicare LOCTITE tipo 243 sulla filettatura delle

n° 16 viti M12x40 (A3), classe di resistenza 8.8.

Apply LOCTITE type 243 on the thread of the

nos. 16 screws M12x40 (A3), grade 8.8.

51. Serrare le n° 16 viti M12x40 (A3), classe di

resistenza 12,9, con una chiave dinamometrica
alla coppia di 145 Nm.

Tighten the nos. 16 socket head screws

M12x40 (A3), grade 12,9, by a torque wrench at
145 Nm torque.

145 Nm

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4.12. Fasi di rimontaggio riduttore 4.12. Gearbox reassembling method

52. Smontare il coperchio di chiusura (B15) del 2°

gruppo riduttore (A2) e, servendosi di un paranco,
montare il 2° gruppo riduttore (A2).

Remove the end cover (B15) of the 2nd gearbox

kit (A2) and, by using a tackle, assemble the 2nd
gearbox kit (A2).

53. Applicare LOCTITE tipo 243 sulla filettatura delle

n° 16 viti M12x40 (A3), classe di resistenza 8.8.

Apply LOCTITE type 243 on the thread of the

nos. 16 screws M12x40 (A3), grade 8.8.

54. Serrare le n° 16 viti M12x40 (A3), classe di

resistenza 12,9, con una chiave dinamometrica
alla coppia di 145 Nm.

Tighten the nos. 16 socket head screws

M12x40 (A3), grade 12,9, by a torque wrench at
145 Nm torque.

145 Nm

55. Inserire il tubo (A6) nel 2° gruppo riduttore (A2).

Insert the tube (A6) in the the 2nd gearbox kit (A2).

INFORMAZIONI SULLA MANUTENZIONE - 58 - MAINTENANCE INFORMATIONS

498 BOMAG 008 915 04
 Travel gear 16.3

4.12. Fasi di rimontaggio riduttore 4.12. Gearbox reassembling method

56. Montare la guarnizione O-ring (B11) nella propria

sede nel coperchio di chiusura (B15).

Assemble the O-ring seal (B11) into its seat in the

end cover (B15).

57. Applicare uno strato di grasso RETINAX HD-2 o

prodotto similare sulla guarnizione "X-ring" (B14).
Inserire la guarnizione "X-ring" (B14) nella propria
sede nel coperchio di chiusura (B15).

Apply a coat of grease RETINAX HD-2 or similar

product on the "X-ring" seal (B14).
Insert the "X-ring" seal (B14) in its seat in the end
cover (B15).

58. Posizionare il coperchio di chiusura (B15) sul 2°

gruppo riduttore (A2).

Place the end cover (B15) on the 2nd gearbox

kit (A2).

59. Serrare le n° 10 viti M10x20 (A1-B12), classe di

resistenza 8,8, con una chiave dinamometrica alla
coppia di 50 Nm.

Tighten the nos. 10 socket head screws

M10x20 (A1-B12), grade 8,8, by a torque wrench
at 50 Nm torque.

50 Nm

INFORMAZIONI SULLA MANUTENZIONE - 59 - MAINTENANCE INFORMATIONS

008 915 04 BOMAG 499
16.3 Travel gear

4.12. Fasi di rimontaggio riduttore 4.12. Gearbox reassembling method

60. Inserire i tappi (B16) nei fori di carico e scarico olio

del coperchio di chiusura (B15). Serrare i tappi con
una chiave dinamometrica alla coppia di 25±5 Nm.

Insert the plugs (B16) into the oil draing-filling

holes of the end cover (B15).Tighten the plugs by
a torque wrench at 25±5 Nm torque.

25±5 Nm

61. Inserire il tappo (B17) nel foro di livello olio del

coperchio di chiusura (B15). Serrare il tappo con
una chiave dinamometrica alla coppia di 10±2 Nm.

Insert the plug (B17) into the oil level hole of the
end cover (B15).Tighten the plug by a torque
wrench at 10±2 Nm torque.

10±2 Nm

62. Servendosi di pinze montare l’anello elastico (A9)

nella propria sede nel giunto di collegamento (A8).

By using pliers assemble the circlip (A9) into its

seat in the coupling (A8).

63. Montare il giunto di collegamento (A8) sulla

riduzione angolare (A5).

Assemble the coupling (A8) on the right angle

reduction (A5).

INFORMAZIONI SULLA MANUTENZIONE - 60 - MAINTENANCE INFORMATIONS

500 BOMAG 008 915 04
 Travel gear 16.3

4.12. Fasi di rimontaggio riduttore 4.12. Gearbox reassembling method

64. Montare la guarnizione O-ring (A7) nella propria

sede nella flangia di collegamento (A10).

Assemble the O-ring seal (A7) into its seat in the

connecting flange (A10).

65. Montare la flangia di collegamento (A10) sulla

riduzione angolare (A5).

Assemble the connecting flange (A10) on the right

angle reduction (A5).

66. Applicare LOCTITE tipo 243 sulla filettatura delle

n° 16 viti M10x30 (A12), classe di resistenza 8.8.

Apply LOCTITE type 243 on the thread of the

nos. 16 screws M10x30 (A12), grade 8.8.

67. Serrare le n° 16 viti M10x30 (A12), classe di

resistenza 8,8, con una chiave dinamometrica alla
coppia di 50 Nm.

Tighten the nos. 16 socket head screws

M10x30 (A12), grade 8,8, by a torque wrench at
50 Nm torque.

50 Nm

INFORMAZIONI SULLA MANUTENZIONE - 61 - MAINTENANCE INFORMATIONS

008 915 04 BOMAG 501
16.3 Travel gear

4.12. Fasi di rimontaggio riduttore 4.12. Gearbox reassembling method

68. Montare le guarnizioni O-ring (A14) nelle proprie

sedi nell’albero scanalato (A13).

Assemble the O-ring seals (A14) into their seats in

the splined shaft (A13).

69. Inserire l’albero scanalato (A13) nel giunto di

collegamento (A8).

Insert the splined shaft (A13) in the coupling (A8).

70. Montare la guarnizione O-ring (A7) nella propria

sede nella flangia di collegamento (A10).

Assemble the O-ring seal (A7) into its seat in the

connecting flange (A10).

71. Montare il gruppo freno (A15) sulla flangia di

collegamento (A10).

Assemble the brake kit (A15) on the connecting

flange (A10).

INFORMAZIONI SULLA MANUTENZIONE - 62 - MAINTENANCE INFORMATIONS

502 BOMAG 008 915 04
 Travel gear 16.3

4.12. Fasi di rimontaggio riduttore 4.12. Gearbox reassembling method

72. Applicare LOCTITE tipo 243 sulla filettatura delle

n° 8 viti M10x30 (A12), classe di resistenza 8.8.

Apply LOCTITE type 243 on the thread of the

nos. 8 screws M10x30 (A12), grade 8.8.

73. Serrare le n° 8 viti M10x30 (A12), classe di

resistenza 8,8, con una chiave dinamometrica alla
coppia di 50 Nm.

Tighten the nos. 8 socket head screws

M10x30 (A12), grade 8,8, by a torque wrench at
50 Nm torque.

50 Nm

Informazioni
Prima di montare il motore idraulico, verificare,
con un calibro per interni, il corretto assemblaggio
del riduttore controllando la quota assiale indicata
nel disegno a fianco.

Information
Before assembling the hydraulic motor, verify by a
depth slide gauge the correct assembly of the unit
checking the axial distance as shown in the
IDM-15220601300.tif
scheme.

INFORMAZIONI SULLA MANUTENZIONE - 63 - MAINTENANCE INFORMATIONS

008 915 04 BOMAG 503
16.3
4.13.Controllo finale e reinstallazione
Verificare il prodotto reinstallandolo sulla macchina.
Verificare la funzionalità della trasmissione eseguendo
tutti i controlli indicati nel paragrafo 3.8.
Qualora si sia eseguito un intervento sul freno, è
necessario controllare che non ci siano perdite d’olio.
Procedere come segue:
1. Collegare al foro comando freno (porta 5) un
manometro (con fondo scala a 100 bar) e la
relativa valvola di comando afflusso olio.
2. Aprire la valvola di comando afflusso olio e
sbloccare il freno, raggiungendo la pressione di
50 bar.
3. Chiudere la valvola di comando afflusso olio e
mantenere la pressione nel freno per un periodo di
almeno 3 minuti.
4. Verificare con il manometro che la pressione
rimanga costante.
5. Ripetere le stesse operazioni (1-2-3-4) per il
comando di azionamento dinamico del freno
(porta 6).
Informazioni
Se la pressione diminuisce significa che le
guarnizioni del freno non fanno tenuta, in tal caso si
dovrà procedere alla loro sostituzione, oppure che il
rimontaggio non è stato eseguito in modo corretto.
INFORMAZIONI SULLA MANUTENZIONE - 64 -
504 BOMAG
Travel gear
4.13.Final test and reinstallation
Check the product by remounting it to the machine.
Check the function of the transmission following all the
checks shown in section 3.8.
If work on the brake was undertaken, it is important to
check that there are no oil leakages. Follow the
procedure below:
1. Connect the pressure pilot line with the manometer
(with a base scale of 100 bars) to the brake release
port (port 5).
2. Open the flow valve and release the brake with the
pilot pressure of 50 bar.
3. Close the flow valve and keep the brake released
3 minutes or longer.
4. Using the manometer, check that the pressure
remains constant.
5. Follow the same steps (1-2-3-4) for the dinamic
operated brake port (port 6).
Information
If the pressure drops it may mean that the brake
seals are not tight and consequently they must be
replaced or it may mean that the reassembling was
not completed properly.
IDM-15220601400.tif
MAINTENANCE INFORMATIONS
008 915 04
 Travel gear 16.3

6. Al termine delle operazioni rimontare il motore 6. After having reassembled the gearbox, fit the
idraulico come indicato nel paragrafo 3.2. hydraulic motor, as shown in section 3.2.
7. Effettuare il riempimento dell'olio lubrificante come 7. Fill the gearmotor with the lubricant oil as shown in
illustrato al paragrafo 3.7. section 3.7.

4.14.Dismissione e rottamazione del prodotto 4.14.Dismantling and destroying the product

La dismissione del riduttore va effettuata rispettando le
seguenti indicazioni:
1. Smontare il riduttore dalla sua sede e svuotare
l'olio lubrificante.
2. Smontare completamente il riduttore e rimuovere
l'olio e il grasso dai componenti.
3. Avviare i materiali pericolosi e/o inquinanti ai
rispettivi centri di smaltimento, come richiesto dalle
leggi vigenti in materia.
When dismantling the gearbox follow the indications
given below:
1. Dismount the gearbox from its seating and empty
the lubricating oil.
2. Completely dismount the gearbox and remove all
oil and grease from its parts.
3. Send all dangerous and/or polluted parts to the
authorised demolishing centres whilst keeping in
line with respective local rules and regulations.

INFORMAZIONI SULLA MANUTENZIONE - 65 - MAINTENANCE INFORMATIONS

008 915 04 BOMAG 505
16.3 Travel gear

INFORMAZIONI SULLA MANUTENZIONE - 66 - MAINTENANCE INFORMATIONS

506 BOMAG 008 915 04
Travel gear 16.3

008 915 04 BOMAG 507

16.3 Travel gear

508 BOMAG 008 915 04

 Travel gear 16.3

Data / Date

Revisioni manuale
Manual revisions

Rev. 01 02 03 04 05 06 07 08 09 10
- Paragrafo / Paragraph
- Fase / Step

- Disegno / Drawing
sostituito dal
replaced by

Questa pubblicazione annulla e sostituisce ogni precedente edizione This publication replaces and supersseds any previous issue and
o revisione. la BONFIGLIOLI TRASMITAL si riserva il diritto di revision. BONFIGLIOLI TRASMITAL reserves the right to implement
apportare modifiche senza preavviso. E' vietata la riproduzione modifications without notice. This manual cannot be reproduced,
anche parziale senza specifica autorizzazione. even partially, without prior written consent.

008 915 04 BOMAG 509

16.3 Travel gear

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Fax 0058.212.2424552 - Tlx 24780 Maica V
www.maica-ve.com - maica@telcel.net.ve

510 BOMAG 008 915 04

 16.4 Steering valve

008 915 04 BOMAG 511

16.4 Steering valve

512 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic
Steering Unit Type
OSPB, OSPC and
OSPF

Service Manual

008 915 04 BOMAG 513

 16.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
Table of Contens

Table of contens 
%XPLODED VIEW /30B  3
%XPLODED VIEW /30#  /30F 4
Tools  
$ISMANTLINg 
$ISMANTLING THE PRESSURE RELIEF VALVE FOR /30C
!SSEMBLINg
!SSEMBLY PATTERN FOR STANDARD BEARINg 
)NSTALLATION INSTRUCTION FOR / RING  ROTO 'LYd 
!SSAMBLY OF THE PRESSURE RELIEF VALVE FOR /30C
!SSAMBLY OF THE SHOCK VALVES FOR /30#/30# ,3/30# ,32 
-AX TIGHTENING TORQUE AND HYDRAULIC CONNECTIONs 

¹  3AUER $ANFOSS !LL RIGHTS RESERVED 0RINTED IN %UROPA

3AUER $ANFOSS ACCEPTS NO RESPONSIBILITY FOR POSSIBLE ERRORS IN CATALOGS BROCHURES AND OTHER PRINTED MATERIAL
3AUER $ANFOSS RESERVES THE RIGHT TO ALTER ITS PRODUCTS WITHOUT PRIOR NOTICE4HIS ALSO APPLIES TO PRODUCTS
ALREADY ORDERED PROVIDED THAT SUCH ALTERATIONS ARENT IN CONmICT WITH AGREED SPECIlCATIONS !LL TRADEMARKS IN
THIS MATERIAL ARE PROPERTIES OF THEIR RESPECTIVE OWNERS 3AUER $ANFOSS AND THE 3AUER $ANFOSS LOGOTYPE ARE
TRADEMARKS OF THE 3AUER $ANFOSS 'ROUP
&RONT COVER ILLUSTRATIONS & & &
$RAWING  FA

2 520L0066 s 2EV "" s -AY 

514 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
%XPLODED 6IEW /30"

 $UST SEAL RING

 (OUSING SPOOL SLEEVE
 "ALL  MM ; IN=
 4HREAD BUSHING
 / RING WITH KIN RING OR
2OTO 'LYD
 "EARING ASSEMBLY  $ISTRIBUTOR PLATE
 2ING FOR SPRINGS  'EARWHEEL
 #ROSS PIN  s  MM  / RING  s   MM ; s  IN=
; s  IN=  %ND COVER
 .EUTRAL POSITION SPRINGS  7ASHER  s   s  MM ; s  s  IN=
 #ARDAN SHAFT  3PECIAL SCREW
 3PACER  3CREW
 / RING   s   MM  .AME LABEL
; s  IN=  3PACER

520L0066 s 2EV "" s -AY  3

008 915 04 BOMAG 515
 16.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
%XPLODED 6IEW /30#  /30&

 $UST SEAL RING  3PACER  .AME PLATE

 (OUSING SPOOL AND SLEEVE  #ARDAN SHAFT  #OMPLETE RELIEF VALVE
#HECK VALVE AND THE SEATS FOR RELIEF  3ET OF SPRINGS  3PRING WIRE
AND SHOCK VALVES ARE LOCKTITED  / RING  #OMPLETE SHOCK VALVE
 "ALL  MM ; IN=  $ISTRIBUTOR PLATE 33 Ball 3 in
 4HREAD BUSHING  'EARWHEEL SET  3PRING
 / RING USED WITH KIN RING ITEM   / RING  2OLLED PIN
 +IN RING  %ND COVER  "USHING
 "EARING ASSEMBLY  7ASHER  "ALL
 2ING  3PECIAL SCREW  +IN RING
 #ROSS PIN  3CREW  / RING

4 520L0066 s 2EV "" s -AY 

516 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
Tools

Tools Holding tool

#ODE NUMBER 3*   

&

'UIDE RING
#ODE NUMBER 3*   

&

!SSEMBLY TOOL FOR / RING AND KIN RING 

2OTO 'LYD
#ODE NUMBER 3*   
#ODE NUMBER 3* . 

&

!SSEMBLY TOOL FOR LIP SEAL

#ODE NUMBER 3*   

&

520L0066 s 2EV "" s -AY  5

008 915 04 BOMAG 517
 16.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
Tools

Tools !SSEMBLY TOOL FOR CARDAN SHAFT

#ODE NUMBER 3*   

&

!SSEMBLY TOOL FOR DUST SEAL

#ODE NUMBER 3*   

&

4ORQUE WRENCH   .M

 MM SOCKET SPANNER
 AND  MM SOCKETS
 MM SCREWDRIVER
 MM ; IN= SCREWDRIVER
 MMRING SPANNER
 AND  MM SOCKET SPANNERS
0LASTIC HAMMER
4WEEZERS

4HE TOOLS ARE NOT AVAILABLE FROM 3AUER

&
$ANFOSS

6 520L0066 s 2EV "" s -AY 

518 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING

Dismantling $ISMANTLE STEERING COLUMN FROM STEERING

UNIT AND PLACE THE STEERING UNIT IN THE
HOLDING TOOL
3CREW OUT THE SCREWS IN THE END COVER
 OFF PLUS ONE SPECIAL SCREW 

&

2EMOVE THE END COVER SIDEWAYS

&

,IFT THE GEARWHEEL SET WITH SPACER IF

lTTED OFF THE UNIT4AKE AUT THE TWO /
RINGS

&

2EMOVE THE CARDAN SHAFT

&

520L0066 s 2EV "" s -AY  7

008 915 04 BOMAG 519
 16.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING

Dismantling 2EMOVE DISTRIBUTOR PLATE

&

3CREW OUT THE THREADED BUSH OVER THE

CHECK VALVE

&

2EMOVE / RING

&

/30" /30" ,3 /30"8 ,3

3HAKE OUT THE CHECK VALVE BALL ’ MM

/30# ,3 /30# ,32

3HAKE OUT THE CHECK VALVE BALL AND
SUCTION VALVE PINS AND BALLS

/N SOME PINS IN THE /30# THERE ARE

TWO SPRINGS SEE PAGE  POS  
2EPLACE THIS PINS PRIOR TO THE REASSEMBLY

&

8 520L0066 s 2EV "" s -AY 

520 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING

Dismantling 4AKE CARE TO KEEP THE CROSS PIN IN THE

SLEEVE AND SPOOL HORIZONTAL4HE PIN
CAN BE SEEN THROUGH THE OPEN END
OF THE SPOOL 0RESS THE SPOOL INWARDS
AND THE SLEEVE RING BEARING RACES
AND NEEDLE BEARING WILL BE PUSHED
OUT OF THE HOUSING TOGETHER

&

4AKE RING BEARING RACES AND NEEDLE

BEARING FROM SLEEVE AND SPOOL
4HE OUTER THIN BEARING RACE CAN
SOMETIMES hSTICKv IN THE HOUSING
THEREFORE CHECK THAT IT HAS COME OUT

&

0RESS OUT THE CROSS PIN 5SE THE

SPECIAL SCREW FROM THE END COVER
.OTE NEXT POINTPARAGRAPH

&

/30" #. AND /30# #.

#. OSPF
! SMALL MARK HAS BEEN MADE WITH
A PUMICE STONE ON BOTH SPOOL AND
SLEEVE CLOSE TO ONE OF THE SLOTS FOR THE
NEUTRAL POSITION SPRINGS SEE DRAW m
ING 
)F THE MARK IS NOT VISIBLE REMEMBER
TO LEAVE A MARK OF YOUR OWN ON SLEEVE
AND SPOOL BEFORE THE NEUTRAL POSITION
SPRINGS ARE DISMANTLED

&OR /30& BOTH MARKS SHOULD BE

PLACED OPPOSITE EACH OTHER
&

520L0066 s 2EV "" s -AY  9

008 915 04 BOMAG 521
 16.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING

Dismantling #AREFULLY PRESS THE SPOOL OUT OF THE

SLEEVE

&

0RESS THE NEUTRAL POSITION SPRINGS OUT

OF THEIR SLOTS IN THE SPOOL

&

2EMOVE DUST SEAL AND / RING  +IN

RING  2OTO 'LYD

&

2EMOVE PLUGS FROM SHOCK VALVES

USING A  MM IHEXAGON SOCKET
spanner

&

10 520L0066 s 2EV "" s -AY 

522 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING

Dismantling 2EMOVE SEAL WASHERS  OFF 

&

5NSCREW THE SETTING SCREWS USING A

 MM I HEXAGON SOCKET SPANNER

&

3HAKE OUT THE TWO SPRINGS AND TWO

VALVE BALLS INTO YOUR HAND4HE VALVE
SEATS ARE BONDED INTO THE HOUSING
AND CANNOT BE REMOVED

&

4HE SHOCK VALVES ARE NOW DISMANTLED

&

520L0066 s 2EV "" s -AY  11

008 915 04 BOMAG 523
 16.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING THE 0RESSURE 2ELIEF 6ALVE FOR /30#

Dismantling 3CREW OUT THE PLUG USING AND

 MM IHEXAGON SOCKET SPANNER
2EMOVE SEAL WASHERS

&

5NSCREW THE SETTING SCREW USING AN

 MM IHEXAGON SOCKET SPANNER

&

3HAKE OUT SPRING AND PISTON4HE

VALVE SEAT IS BONDED INTO THE HOUSING
AND CANNOT BE REMOVED

&

4HE PRESSURE RELIEF VALVE IS NOW

DISMANTLED

&

12 520L0066 s 2EV "" s -AY 

524 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING THE 0RESSURE 2ELIEF 6ALVE #ARTRIDGE

Dismantling the Pressure 3CREW OUT THE PRESSURE RELIEF VALVE

Relief Valve (Cartridge) USING AND  MM IHEXAGON SOCKET
for OSPC LS / OSPC LSR SPANNER 2EMOVE THE SEAL RING )F THE
VALVE IS DEFECTIVE IT MUST BE REPLACED

&

4HE PRESSURE RELIEF VALVE IS NOW

DISMANTLED

&

4HE STEERING UNIT /30" IS NOW COM

PLETELY DISMANTLED

&

4HE STEERING UNIT /30" ,3 IS NOW

COMPLETELY DISMANTLED

&

520L0066 s 2EV "" s -AY  13

008 915 04 BOMAG 525
 16.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
$ISMANTLING THE 0RESSURE 2ELIEF 6ALVE #ARTRIDGE

Dismantling the Pressure 4HE STEERING UNIT /30# IS NOW

Relief Valve (Cartridge) COMPLETELY DISMANTLED
for OSPC LS / OSPC LSR 2EPLACE THIS PINS PRIOR TO THE REAS
SEMBLY

&

4HE STEERING UNIT /30# ,3 IS NOW

COMPLETELY DISMANTLED
2EPLACE THIS PINS PRIOR TO THE REAS
SEMBLY

&

Cleaning Lubrication
#LEAN ALL PARTS CAREFULLY IN 3HELLSOL + "EFORE ASSEMBLY LUBRICATE ALL PARTS WITH
OR THE LIKE HYDRAULIC OIL

Inspection and replacement

2EPLACE ALL SEALS AND WASHERS
#HECK ALL PARTS CAREFULLY AND MAKE
ANY REPLACEMENTS NECESSARY

14 520L0066 s 2EV "" s -AY 

526 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
!SSEMBLING

Assembling

0LACE THE TWO mAT NEUTRAL POSITION

SPRINGS IN THE SLOT
0LACE THE CURVED SPRINGS BETWEEN
&
THE mAT ONES AND PRESS THEM INTO
PLACE

! 

,INE UP THE SPRING SET

&

'UIDE THE SPOOL INTO THE SLEEVE -AKE

SURE THAT SPOOL AND SLEEVE FOR /30"
,3 /30"8 ,3 /30# ,3 /30# ,32 AND
OSPF are placed correctly in relation
TO EACH OTHER SEE PAGE  

&

520L0066 s 2EV "" s -AY  15

008 915 04 BOMAG 527
 16.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
!SSEMBLING

Assembling !SSEMBLE SPOOL AND SLEEVE

OSPB LS, OSPBX LS, OSPC LS, OSPC

LSR and OSPF

7HEN ASSEMBLING SPOOL AND

SLEEVEONLY ONE OF TWO POSSIBLE WAYS
OF POSITIONING THE SPRING SLOTS IS
CORRECT 4HERE ARE THREE SLOTS IN THE
SPOOL AND THREE HOLES IN THE SLEEVE IN
THE END OF THE SPOOLSLEEVE OPPOSITE
&
TO THE END WITH SPRING SLOTS 0LACE
THE SLOTS AND HOLES OPPOSITE EACH
OTHER SO THAT PARTS OF THE HOLES IN THE
SLEEVE ARE VISIBLE THROUGH THE SLOTS IN
THE SPOOL

OSPB CN and OSPC CN

!SSEMBLE THE SPOOLSLEEVE AND MAKE
SURE THE MARKS ON SPOOL AND SLEEVE
ARE OPPOSITE EACH OTHER SEE DRAWING
PAGE  
&

0RESS THE SPRINGS TOGETHER AND PUSH

THE NEUTRAL POSITION SPRINGS INTO
PLACE IN THE SLAVE

&

,INE UP THE SPRINGS AND CENTRE THEM

&

16 520L0066 s 2EV "" s -AY 

528 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
!SSEMBLING

Assembling 'UIDE THE RING DOWN OVER THE SLEEVE

4HE RING SHOULD BE ABLE TO MOVE

FREE OF SPRINGS

&

&IT THE CROSS PIN INTO THE SPOOLSLEEVE

&

Fit bearing races and needle bearings

AS SHOWN ON THE DRAWING NEXT PAGE

&

&

520L0066 s 2EV "" s -AY  17

008 915 04 BOMAG 529
 16.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
!SSEMBLY 0ATTERN FOR 3TANDARD "EARING

Assembling for Assembly pattern for standard bearing

Standard Bearing
 /UTER BEARING RACE
 .EEDLEBEARING
3 Inner bearing race
4 Spool
 3LEEVE

! 

Assembly pattern for double bearing

 7ASHER FOR AXIAL BEARING

 /UTER NEEDLEBEARING
3 Outer bearing race
4 Spool
 3LEEVE
 )NNER NEEDLEBEARING
 )NNER BEARING RACE

! 

4HE INSIDE CHAMFER ON THE INNER BEARING RACE MUST FACE THE INNER SPOOL

18 520L0066 s 2EV "" s -AY 

530 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
)NSTALLATION )NSTRUCTION FOR / RING  +IN RING  2OTO 'LYD

Installation 4URN THE STEERING UNIT UNTIL THE BORE

Instructions for IS HORIZONTAL 'UIDE THE OUTER PART OF
O-ring / Kin-ring THE ASSEMBLY TOOL INTO THE BORE FOR
Roto glyd THE SPOOLSLEEVE

&

'REASE O RING AND KING RINGROTO

'LYD WITH HYDRAULIC OIL AND PLACE
THEM ON THE TOOL

&

(OLD THE OUTER PART OF THE ASSEMBLY

TOOL IN THE BOTTOM OF THE STEERING
UNIT HOUSING AND GUIDE THE INNER
PART OF THE TOOL RIGHT TO THE BOTTOM

&

0RESS AND TURN THE O RINGKIN RING

INTO POSITION IN THE HOUSING

&

520L0066 s 2EV "" s -AY  19

008 915 04 BOMAG 531
 16.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
)NSTALLATION )NSTRUCTION FOR / RING  +IN RING  2OTO 'LYD

Installation $RAW THE INNER AND OUTER PARTS OF

Instructions for THE ASSEMBLY TOOL OUT OF THE STEERING
O-ring / Kin-ring / UNIT BORE LEAVING THE GUIDE FROM THE
Roto Glyd INNER PART IN THE BORE

&

20 520L0066 s 2EV "" s -AY 

532 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
)NSTALLATION )NSTRUCTION FOR ,IP 3EAL

Installation ,UBRICATE THE LIP SEAL WITH HYDRAULIC

Instructions for OIL AND PLACE IT ON THE ASSEMBLY TOOL
Lip Seal

&

'UIDE THE ASSEMBLY TOOL RIGHT TO THE

BOTTOM

&

0RESS AND TURN THE LIP SEAL INTO PLACE

IN THE HOUSING

&

7ITH A LIGHT TURNING MOVEMENT

GUIDE THE SPOOL AND SLEEVE INTO THE
BORE

&IT THE SPOOL SET HOLDING THE CROSS PIN

HORIZONTAL

&

520L0066 s 2EV "" s -AY  21

008 915 04 BOMAG 533
 16.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
)NSTALLATION )NSTRUCTION FOR ,IP 3EAL

Installation 4HE SPOOL SET WILL PUSH OUT THE

Instructions for ASSEMBLY TOOL GUIDE4HE O RING
Lip Seal AND KIN RINGROTO 'LYD ARE NOW IN
POSITION

&

4URN THE STEARING UNIT UNTIL THE BORE

IS VERTICAL AGAIN 0UT THE CHECK VALVE
BALL INTO THE HOLE INDICATED BY THE
ARROW

&

3CREW THE THREADED BUSH LIGHTLY INTO

THE CHECK VALVE BORE4HE TOP OF THE
BUSH MUST LIE JUST BELOW THE SURFACE
OF THE HOUSING

&

0LACE A BALL IN THE TWO HOLES INDICATED

BY THE ARROWS

&

22 520L0066 s 2EV "" s -AY 

534 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
)NSTALLATION )NSTRUCTION FOR ,IP 3EAL

Installation 0LACE A NEW PIN IN THE SAME TWO

Instructions for HOLES
Lip Seal

&

)N SOME CASES A SPRING HAS TO BE

lTTED SEE PAGE  POS  ON THE PIN
BEFORE IT IS PLACED IN THE
HOUSING

&

'REASE THE O RING WITH MINERAL OIL

APPROX VISCOSITY  MMS ;353=
AT ²# ; ²&=

&

0LACE THE DISTRIBUTOR PLATE SO THAT THE

CHANNEL HOLES MATCH THE HOLES IN THE
HOUSING

&

520L0066 s 2EV "" s -AY  23

008 915 04 BOMAG 535
 16.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
)NSTALLATION )NSTRUCTION FOR ,IP 3EAL

Installation 'UIDE THE CARDAN SHAFT DOWN INTO THE

Instructions for BORE SO THAT THE SLOT IS PARALLEL WITH
Lip Seal THE CONNECTION mANGE

&

0LACE THE CARDAN SHAFT AS SHOWN

SO THAT IT IS HELD IN POSITION BY THE
MOUNTING FORK

&

'REASE THE TWO O RINGS WITH MINERAL

OIL APPROX VISCOSITY  MMS ;353=
AT ²# ;²&= AND PLACE THEM IN THE
TWO GROOVES IN THE GEAR RIM &IT THE
GEARWHEEL AND RIM ON THE CARDAN
SHAFT

&

Caution

&IT THE GEARWHEEL ROTOR AND CARDAN

SHAFT SO THAT A TOOTH BASE IN THE ROTOR
IS POSITIONED IN RELATION TO THE SHAFT
SLOT AS SHOWN4URN THE GEAR RIM SO
THAT THE SEVEN TROUGH HOLES MATCH
THE HOLES IN THE HOUSING

&

24 520L0066 s 2EV "" s -AY 

536 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
)NSTALLATION )NSTRUCTION FOR ,IP 3EAL

Installation &IT THE SPACER IF ANY

Instructions for
Lip Seal

&

0LACE THE END COVER IN POSITION

&

&IT THE SPECIAL SCREW WITH WASHER AND

PLACE IT IN THE HOLE SHOWN

&

&IT THE SIX SCREWS WITH WASHERS

AND INSERT THEM
#ROSS TIGHTEN ALL THE SCREWS AND THE
ROLLED PIN WITH A TORQUE OF 
   .M ;   LBFIN=
4HE /30" /30" ,3 AND /30"8 ,3 CAN
NOW BE FUNCTION TESTED

&

520L0066 s 2EV "" s -AY  25

008 915 04 BOMAG 537
 16.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
!SSAMBLY OF THE 0RESSURE 2ELIEF 6ALVE FOR /30#

Assembly of the Pressure &IT THE PISTON

Relief Valve for OSPC

&

&IT THE SPRING

&

3CREW IN THE SETTING SCREW WITH AN

 MM HEXAGON SOCKET SPANNER
-AKE THE PRESSURE SETTING ON A PANEL
OR THE VEHICLE

&

3CREW PLUG WITH DUST SEAL INTO THE

HOUSING USING AN  MM IHEXAGON
SOCKET SPANNER
4IGHTENING TORQUE    .M
;   LBFIN=

&

26 520L0066 s 2EV "" s -AY 

538 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
!SSAMBLY OF THE 3HOCK 6ALVES FOR /30#/30# ,3/30# ,32

Assambly of the Shock 0UT A BALL IN THE TWO HOLES INDICATED

Valves for OSPC/OSPC LS/ BY THE ARROWS
OSPC LSR

&

Place springs and valve cones over

THE TWO BALLS

4HE BLUE SPRING APPLIES TO SETTING

RANGE   BAR ;  PSI=4HE
untreated spring applies to setting
RANGE   BAR ;  PSI=

&

3CREW IN THE TWO SETTING SCREWS USING

A  MM IHEXAGON SOCKET SPANNER
-AKE THE PRESSURE
SETTING ON A PANEL OR THE VEHICLE

&

3CREW PLUG WITH SEAL RING INTO THE

TWO SHOCK VALVES AND TIGHTEN THEM
WITH A TORQUE OF  
  .M ;  LBFIN= USING
A  MM IHEXAGON SOCKET SPANNER
3TEERING UNIT TYPE /30# /30# ,3 OR
/30# ,32 IS NOW ASSEMBLED

&

520L0066 s 2EV "" s -AY  27

008 915 04 BOMAG 539
 16.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
!SSAMBLY OF THE 3HOCK 6ALVES FOR /30#/30# ,3/30# ,32

Assambly of the Shock 0LACE THE DUST SEAL RING IN THE

Valves for OSPC/OSPC LS/ HOUSING7ITH THE /30# /30# ,3 AND
OSPC LSR /30# ,32 THE DUST SEAL RING MUST BE
PLACED ONLY AFTER THE PRESSURE RELIEF
VALVE AND SHOCK VALVES HAVE BEEN
lTTED

&

&IT THE DUST SEAL RING IN THE HOUSING

USING SPECIAL TOOL 3*   
SEE PAGE  AND A
PLASTIC HAMMER

&

0RESS THE PLASTIC PLUGS INTO THE

CONNECTION PORTS
$O NOT USE A HAMMER

&

28 520L0066 s 2EV "" s -AY 

540 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
-AX4IGHTENING 4ORQUE AND (YDRAULIC #ONNECTIONS

Max. Tightening Torque 4 4ANK

and Hydraulic Connec-
tions , ,EFT PORT

0 0UMP

2 2IGHT PORT

Max. tightening torque N.m [lbf.in]

Screwed With cooper With aluminium

With cutting edge With O-ring
connection washer washer
' 4  ;=  ;=  ;=
3
'  ;=  ;=  ;=
'   ;=  ;=  ;=

  5.&  ;=
3
4  5.&  ;=
-  s   ;=  ;=  ;=  ;=
- s   ;=  ;=  ;=  ;=
- s   ;=  ;=  ;=  ;=

520L0066 s 2EV "" s -AY  29

008 915 04 BOMAG 541
 16.4 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
.OTES

30 520L0066 s 2EV "" s -AY 

542 BOMAG 008 915 04

Steering valve 16.4
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
.OTES

520L0066 s 2EV "" s -AY  31

008 915 04 BOMAG 543
 16.4
Our Products
(YDROSTATIC 4RANSMISSIONS
(YDRAULIC 0OWER 3TEERING
%LECTRIC 0OWER 3TEERING
%LECTROHYDRAULIC 0OWER 3TEERING
#LOSED AND /PEN #IRCUIT !XIAL 0ISTON
0UMPS AND -OTORS
'EAR 0UMPS AND -OTORS
"ENT !XIS -OTORS
Orbital Motors
4RANSIT -IXER $RIVES
0ROPORTIONAL 6ALVES
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(YDROSTATIC 4RANSAXLES
)NTEGRATED 3YSTEMS
&AN $RIVE 3YSTEMS
%LECTROHYDRAULICS
-ICROCONTROLLERS AND 3OFTWARE
%LECTRIC -OTORS AND )NVERTERS
*OYSTICKS AND #ONTROL (ANDLES
$ISPLAYS
Sensors
520L0066 s 2EV "" s -AY 
544
Steering valve
Sauer-Danfoss Mobile Power and Control Systems
– Market Leaders Worldwide
3AUER $ANFOSS IS A COMPREHENSIVE SUPPLIER PROVIDING COMPLETE
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3AUER $ANFOSS 53 #OMPANY 3AUER $ANFOSS !P3
 %AST TH 3TREET $+  .ORDBORG $ENMARK
!MES )!  53! 0HONE   
0HONE     &AX   
&AX    
3AUER $ANFOSS 'MB(  #O /(' 3AUER $ANFOSS $AIKIN ,4$
0OSTFACH  $  .EUMàNSTER 3ANNOMIYA 'RAND "LDG &
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&AX     0HONE    
&AX    
WWWSAUER DANFOSSCOM
BOMAG 008 915 04
 17 Circuit diagrams

008 915 04 BOMAG 545

546 BOMAG 008 915 04
 17.1 Hydraulic diagram 538 110 00

008 915 04 BOMAG 547

17.1 Hydraulic diagram 538 110 00

548 BOMAG 008 915 04

Hydraulic diagram 538 110 00 17.1

008 915 04 BOMAG 549

17.1 Hydraulic diagram 538 110 00

550 BOMAG 008 915 04

 17.2 Pneumatic diagram 538 120 00

008 915 04 BOMAG 551

17.2 Pneumatic diagram 538 120 00

552 BOMAG 008 915 04

Pneumatic diagram 538 120 00 17.2

008 915 04 BOMAG 553

17.2 Pneumatic diagram 538 120 00

554 BOMAG 008 915 04

 17.3 Wiring diagram 538 100 03

008 915 04 BOMAG 555

17.3 Wiring diagram 538 100 03

S/N Wiring diagram 538 100 03

S/N 101 538 011 001 ⇔ 101 538 011 388 BW 24 RHl

556 BOMAG 008 915 04

Inhaltsverzeichnis: BW 24 RH TIER 3

008 915 04
table of contents: BW 24 RH TIER 3
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing  no.
001 538 100 03 Stromlaufplan Circuit Diagram
002 538 100 03 Versorgung, Starten, Steckdose supply, starting unit, socket
003 538 100 03 Bremse, NotAus, Warnsummer brake, emergency off, warning buzzer
004 538 100 03 Überwachung monitoring unit
005 538 100 03 Berieselung, Signalhorn sprinkler system, warning horn
Wiring diagram 538 100 03

007 538 100 03 Blinkbegrenzung, Arbeitsbeleuchtung (StVZO) illumination, working light (StVZO)
009 538 100 03 Fahrtricht., Fahrstufenumschalt., Rückfahrwarnsum. traveling directon, speed selection, warning buzzer,
012 538 100 03 Tachograph, Geschwindigkeitsanzeige tachograph, speedometer
013 538 100 03 Heizung, Klimaanlage heating, air conditioning
014 538 100 03 Kabine cab
015 538 100 03 Arbeitsscheinwerfer ROPS worklamp RORS
016 538 100 03 Diebstahlschutz System anti  theft system
017 538 100 03 Kantenschneidgerät edge cutter
101 538 100 03 Bauteilliste component listing

BOMAG
18.4.2008
001 001
Nallin Stromlaufplan 538 100 03
18.4.2008
17.3

557
circuit diagram 001
Seis
558
X2:31
X2:12 X2:11
X2:21
17.3

F01
X2:41 F37
5:2 30A
Sicherung F05
fuse
X2:22 Sicherung
fuse
15A
X2:51 30
7:5 30 X2:32
30 X13:A K11
P0123
P01 2:18
S00

X89:B

X89:A
87 87a

Zündstartschalter
K32 14:1 ignition switch 15 54 58 19 17
50a
X1:13

F124 X13:B X13:C

7:2 15 3:1 K11 3:6
X2:61
2 ZA/option Sicherung F119
F00
X2:241 fuse 7,5A
125A Sicherung Battrie
fuse, battery Sicherung F124 X2:62 F119
1 F119 2:15 2:12 F119 14:6
25A
X1:17
X2:242 1 ZA/option X1:129
(6) V46
X2:261
1 2 Meldeleuchte Ladekontrolle
Sicherung indicator light, charge control Sicherung F195
X1:163 30
fuse 5A X6:+
G01+ 2:8 F48 86 1 X6:+ 2:16 K05 X6:+
125A 9:13 X2:262
B+ 2 K62 R09 H08 2:12 4:6
2:8 87 87a
X6:14 H52

BOMAG
(8) 30 85 2
2
+ G01 102AH X1:106
K14 2:13 X6:3

X1:23
+ G03 P00
W D+ X14:A X14:B
 Batterie (9) 87 G02 Betriebsstundenzähler X1:21
battery
 2.Batterie Generator operating hour meter
2.battery generator X6:
4:18 3:5
B B+ X1:166 X1:165
2:5 M 2:7 2
ZA/option

R81
R82
R83
R84
S30 G01+ K11
Batterietrennschalter Glühstifkerzen 14 2:1 4 3 86 + XS
switch battery disconnect pen. type glow plug 14 B+ K14
2:1 2 Y01 12V
2 1 5 85 
30 50
X51:C br X63:3 V01 X1:167
R79 87a 87
M01 1
X91:B K31 1 86
13:1 K86 K86 2:15 K 3:9
 X1:28
M 2:7 2:7 M M 3:3 85 30
X1:164 X1:168 X1:168 X1:125 31 3:1

4:1 Startmehrmenge 2:5 2:17 2:15 Steckdose

start boost fuel
socket
Kraftstoffvorheizung
fuel, preheating Starter Relais/Steuergerät Glühstiftkerzen Kontrollampe Glühüberwachung
starter
relay/controll unit, glow plugs indicator light, glow plug

29.04.2008
1 1
Wiring diagram 538 100 03

008 915 04
Nallin Versorgung, Starten, Steckdose 538 100 03
18.06.2008
Seis supply, starting unit, socket 002
 2:12 15 15 4:1
2:19 K11 K11 5:1
X2:71 F14
Sicherung 10A
fuse F25 X2:131
Sicherung 10A
X2:72 fuse

008 915 04
X2:132

X1:8
S111 9:12

X1:1

B0T 12 21 31
S111
B0

Bremsschalter
switch brake A15
11 22 32
Wiring diagram 538 100 03

X1:9

K22 30

3:17
87 87a X6:24 X6:23

X1:44 X1:46

3:3
9:7
X1:144
11 21 31

X1:145 S01 12 22 32 A100:6

9:2
K112 30 NotAusSchalter
21 switch, emergency off

BOMAG
S01 3:9
X1:14
NotAusSchalter 87 87a
switch, emergency off 3:12
22 X1:97
X30:1
86
K22 +
X1:15
X1:98 H07
X1:48 
X1:47 86 Relais Motor Stop 85
K112
X6:12 X6:11 relay, engine stop
2 Y13 1 + H20 + H01 Y04 1 2

  85
V41 1 2 X30:2
(1) 2 V42 1
2:12 M M 3:11 2:12 X6: X6: 4:18 3:4 M M 4:11 (2)
2:19 K K 3:17 3:10 K K 9:6
X1:49
31 X1:49 X1:49 X1:49
2:20 31 4:1
Hubmagnet Motor 3:7 Bremsventil 3:3 Warnsummer
shut off solenoid, engine solenoid valve, brake warning buzzer
Meldeleuchte Bremskontrolle
indicator light, brake Meldeleuchte Bremse Überwachungsmodul
indicator light brake monitoring module

22.04.2008
1 1 538 100 03
Nallin Bremse, NotAus, Warnsummer
18.06.2008
17.3

559
Seis brake, emergency off, warning buzzer 003
 560
3:20 15 15
X2:91
F129
X2:81 F04 5A
17.3

15A
Sicherung Sicherung
fuse
fuse
X2:82 X2:92
F04 F04 7:13

X1:51
F120
7:19
X6:26
Bremsdruck Meldeleuchte Motoröl
brake pressure indicator light, engine oil pressure

Bremsöltemp. Meldeleuchte Motorüberhitzung

brake oil, temp. idicator ligh, engine overheating
Wasserrestmenge Meldeleuchte Luftfilter
water reserve indicator light, air cleaner
Kühlmittelvorrat Motor Differenzdruck Hy.
X6:+ indicator light, eng. coolant res. idicator ligh, hydr.oil filter X6:+
2:17
H86 H79 H73 H09 H49 H15 H23
H43
R20

X6:15 X6:11 X6:8 X6:16 X6:17

X6:18 X6:20 X6:19
X1:45 X1:25 X1:26 X1:24 X1:22
X1:108 X1:109 X1:107 X1:105
X1:155
R21
R22

H70
Tankanzeige
X1:157 level gauge
X1:156
X6:21 X6:22 P01
X1:142 Q

BOMAG
X1:20 X1:19
X1:153
86 X1:103 X1:102 X6:1
30 K36 30 X98:1 B22 1
K62 K104 X1:42
5:5
2:8
X1:126
87 87a 85 3 B55 p 2 1
87 87a
B124 X10:2 X10:1
X1:151 X1:91 X1:128 4
X27:1 2
B102 3 Fußbremse geplant B03 31 B21
B12 1 B148 1 X98:2 projected 1 B06 3 B152
foot brake 1 B33
P P R03
P P P _t
5 BAR 4 42 p
2 120_GC 2 2 4
2
M M
MD+ 5:1 X27:2 2:11 X6: X6:25
3:12 7:1 X10:3
X1:158 X1:125 X1:154 X1:49 X1:159
31

5.7+/0.6BAR
3:20 31 5:1
Meldeleuchte Wasser im Diesel
7:19 indicator light, water in fuel

Geber Kraftstofftank
sender, level gauge

29.04.2008
1 1
Wiring diagram 538 100 03

008 915 04
Nallin Überwachung 538 100 03
18.06.2008
Seis monitoring unit 004
 3:20 K11 K11 7:1

4:2 MD+

F37 X2:221
2:5 Sicherung
fuse F06

008 915 04
10A
X2:121
X2:222

Sicherung F37
fuse 20A
Sicherung
F23 fuse
10A

X2:42
86
K104
X2:122

85

Berieselung
Wiring diagram 538 100 03

sprinkler system

23 13
1 0 2
S05 10

24 14 X1:52

13
X1:12 S03
13
Taster Signalhorn
15/54 14

BOMAG
A04 switch warning horn
30 Modul Berieselung
modul, sprinkler system
87
X1:43
X1:132

X17:1
+ X1:127

M02 2
+
11A V02
 B11
1
X17:2 
Signalhorn
X1:133 X1:111 X1:49 warning horn
31 X1:125 31
4:20 7:1
4:9
Berieselungspumpe
sprinkler pump

20.07.2006
1 1 538 100 03
Nallin Berieselung, Signalhorn
04.08.2006
17.3

561
Werner sprinkler system, warning horn 005
 562
5:20 K11 K11 9:1
30 X2:151 4:20 F04 F04 12:1 X2:231 X2:171
X2:111 2:5 F70 F120
2:7 F124 F07 F156
Sicherung 20A Sicherung
17.3

Sicherung 15A 15A 15A

F22 Sicherung fuse fuse 1 fuse
15A S185
fuse X2:52 X2:152 X2:232 X2:172
X2:112 X1:41 Überwachungsmodul X1:4
X1:146 monitoring module Schalter Beleuchtung
13 23 2 F120
L0R A15 switch head lights 11 23 4:3
S37 X6:8 012
13
S26 Schalter Nachtbeleuchtung
Schalter Blinker 14 24 switch, night lamp
switch indicator S15 12 24
14 X1:6 X1:7 X1:2 X1:3

X1:147
E61 49L 49R
+ 30 X2:181 X2:191
Blinkgeber X2:201 X2:211
flasher F09 Sicherung Sicherung F10
A02 10A fuse fuse 10A

X1:93
 31 Sicherung F12 Sicherung
fuse fuse
E04 X2:182 X2:192 10A
F11 10A
+ 82
X2:202 X2:212

switch, working head lights

X1:54 A42
L R 14:6


Schalter Arbeitsbeleuchtung
X6:19
30
X6:18 X1:31 X1:121 X1:122 X1:32 X1:130 X1:131 K36
13 4:3
01 23 X1:55 X1:123 X95:22
X1:33 X1:124 X95:12 87 87a
X1:34 V12
S14
X95:12
X95:23

X1:50
+ + + +
E12 E14 E16 E17

X96:12
X96:27

14 24 V13
   X1:94
+  +

X95:11
X96:11
X95:21
X96:21
X96:13
E13 E15

BOMAG
H05 ZA
X96:23 2 1  option
X97:1 X97:1 
1 1
1 1 H()
H06 7:7 E41 E43
X95:16
X95:26

56b 56b
X96:17
X96:77

E08 E10
E18 E19 1 1 2 2 1 1

switch, hazard light

2 2

Schalter Warnblinker
31 31 E09 E11 E33 E34
X97:2 X97:2
X95:14 2 2 2 2
X96:15
X96:25

X95:24 X95:15 X95:25

links/left
X96:16 X96:14 X96:24

rechts/right
X96:26 X6:7
H06 MV 7:13 7:8 MV MV 7:17 7:16 MV

4:16 M M 7:8 H() 7:11 7:3 M M 9:8

31

X1:49

X1:111
5:20 X1:125 31 9:1

Arbeitsscheinwerfer
working head light
Bel. Reifendruckanz.
illum. wheel pressure
Bel. Geschwindigkeitsanz..
illum. speedometer
X1:49
Meldeleuchte Blinker Scheinwerfer links
indicator light, indicators Parkleuchte links
Meldeleuchte Warnblinker Blinkleuchte VL Blinkleuchte VR head light LH
indicator light, hazard light indicator front,lh. indicator front,rh. parking light lh.
Schlußleuchte links Parkleuchte rechts Scheinwerfer rechts
Blinkleuchte HL tail light,lh parking light rh. head light RH
indicator rear,lh
Blinkleuchte HR Schlußleuchte rechts Bremsleuchte links
indicator rear,rh. tail light,rh brake light lh
Bremsleuchte rechts
brake light rh

18.04.2008
1 1
Wiring diagram 538 100 03

008 915 04
Nallin Blinkbegrenzung, Arbeitsbeleuchtung (StVZO) 538 100 03
18.06.2008
Seis illumination, working light (StVZO) 007

Meldeleuchte Warnblinker
7:20 K11 K11 17:1

F77 X2:161 X2:141

Sicherung 10A F26 10A
fuse Sicherung
X2:162 fuse X2:142

008 915 04
X1:143
31 X1:53
S01 Schalter, NOT AUS
3:12 switch, emergency off
32
X1:5
K42
9:9

+ br/brn X1:81 + br/brn

Wiring diagram 538 100 03

X11:1 X12:1
r0v r0v 13 21
S31 S184
123 S02
123
Fahrtrichtungsschalter R V Fahrtrichtungsschalter

bl/blu
sw/blk
rt/red
switch, travel direction R V switch, travel direction Fahrstufenschalter

rt/red
sw/blk
bl/blu
X11:2 X11:3 X11:4 X12:4 X12:3 X12:2 14 22 speed range selector

X1:82 X1:83 2 3 X1:148 X1:149 1

11 12 15/54 14 15 15/54 X1:16 X1:27
A100 () X1:99 X1:110
6 7 5 4 Modul Lenkstocker Fahrtrichtung 9 13 10 8
A100:6 modul, lever switch, travel direction
3:20

BOMAG
K42
86 9:6 Beide Fahrhebel in 0Stellung:
K42 S111
Out K05 high = Startfreigabe
3:14
30
K42
X1:95 X1:96 85 9:7
87 87a
Y16
X3:1 1 Y03 1 Y130 1
X1:92
+ 85
Y17 2 2
H14 1 2 2
 Y163 1 Y164 1 V45
X3:2 1 K05
2 2 2 86
3:18 K M
X1:133 7:20 M 13:6
X1:49 X1:111 X1:111
7:20 31 31 12:1

Warnsummer Rückfahrwarneinrichtung 9:10 Mag.ventile Fahrtri 2:13 Mag.ventil Fahrstufe, links

warning buzzer back up alarm solenoid valves travel dir. switch over sol.valve speed range, l.h.

Mag.vent. Fahren, vorw. Mag.ventil Fahrstufe, rechts

sol.valve speed range, r.h.
solenoid valve traveling, forw.
Relais Startstrom
Mag.vent. Fahren, rückw. relay starting current
solenoid valve traveling, backw.

17.04.2008
1 1 538 100 03
Nallin Fahrtricht., Fahrstufenumschalt., Rückfahrwarnsum.
18.06.2008
17.3

563
Seis traveling directon, speed selection, warning buzzer, 009
564
7:15 F04 F04 16:1
17.3

Lernmodus
to learn
Anzeigetest
diagnose
Tachographenmodul

B15.1
module, tachograph Lern Test

15/54
15/54
12:12
X1:61
5 A16 4 A05
IN
2 1 6 3 7.8.9
12:12
OUT+ 1

OUT
X1:10 + X1:11

B15.1
P04
P09.A2
14:6
P09.A1 
14:6
X1:73 X1:71 ZA
option

B4 B3 A2 A3 A1

BOMAG
X24:4
P09 C3

SW/BK X24:3
BR/BR X24:1
Anzeige
indicator
A5 A6
B15

X24:2

BL/BU
Rexroth

G02 X1:72
14:8
31 X1:111
9:20 31 13:12
Aufnehmer Geschwindigkeit Geschwindigkeitsanzeige
transducer speed
speedometer

ZA
option

09.01.2007
1 1
Wiring diagram 538 100 03

008 915 04
Nallin Tachograph, Geschwindigkeitsanzeige 538 100 03
09.01.2007
Werner tachograph, speedometer 012
 F31
14:2
D
F31 F68:G
Box 1 G 14:2
4 F68 H F F15 14:2

008 915 04
B Box 1
F40 F15
0123 Schalter Kabinenlüfter 7 F68:7 14:6
BOX 1 BOX 1
switch, cabin ventilator Schalter Kabinenheizung
8 switch, cab heating 6
3
S44
L M H C 4 5
A72 2 A72:2
14:6
Steuergerät

low
mid
high
control unit
S28
1

6 11 12 6 2 1 3

ZA

X65:3

X65:2
30 option

X65:4
Wiring diagram 538 100 03

K85 X63:7 X63:4 X63:6 X53:6

14:19
X52:1 15 1 4 7 6
87 87a 1
Diagnose
B103 X49:1 diagnostics
Thermofühler Klimaanlage _t
temperature sensor 2
X52:2

X40:1
X50:1 1 P18

X40:3

X40:2
E30
X43:1 _t B131 Heizung
4 2 heater timer
Thermofühler Heizung
temperature sensor, heating
B104 P
Überwachung Kühlmitteldruck LP HP X49:2
3
monitoring coolant pressure

BOMAG
X43:3 X43:4
5 8 10
X53:3
X53:5

X43:2

X45:3

X42:3
X45:2

X42:2
X45:4

X42:4
ge rt or ge rt or X55:1 X54:1

X21:1 Y15 1 E30 13:18 13:14 E30

M09 M09
2 1 1 Y14
br br V09 Y138 2
V10
1 2 2
X42:1 X45:1 X54:2
9:10 M Magnetventil Heizung 12:20 31 31 16:1
solenoid valve, heating unit
X40:4 X55:2
2:4 K31 K31 14:1

Kabinenlüfter
cab ventilator indicator light, air conditioning Kraftstoffpumpe
fuel pump heating unit
Klimakompressor
air conditioning compr.

ZA ZA
option option

12.01.2007
1 1 538 100 03
Nallin Heizung, Klimaanlage
12.01.2007
17.3

565
Werner heating, air conditioning 013
 566
K32 X91:A
2:6 K32 15:1
X51:B
17.3

F68:G 7:14 A42 A42

13:19 15:7
30
K32 2:19 F119 X51:A

14:16 X63:8 14:1 E72+ F143 14:17 14:15 F143

A72:2
87 13:11

Wischer vorne Wischer hinten 15A

F143
windscreen wiper, front windscreen wiper, rear InlineFuse
13:19 F15
E A B C
F31 13:11 F68:7 F27 F28 X63:5
13:19 F110 F41
25A Box 1 15A Box 1
Box 1 Box 1 P09.A1 X67:A X67:A 15A S163 5
15A 12:5
5 1 2 3
option Tachograph K141 30
E72+ X67:B
14:11 P09.A2
12:5 14:18 1
X67:B 87 87a
S20 7 S21 7
1 1 1
0 2 2 0 2 2
1 1 1 1 X66:1 X67:B X67:A 01 S53
01
E72
S53 2 2 2 2 1 +
S45 5 4 5 4
30 S38 A12 Radio R80 1 5
K118 E71 1
S20 S21 S38 radio
switch, worklamp

14:20
Schalter Arbeitsscheinwerfer

5 15 30
87 87a X64:4 + 2
indicator

S158 2 X64:2
Kontrolleuchte

X63:1
X62:1
X63:2

X62:2

E72

X64:5
X64:3
X64:6
X64:8
14:7 B51 31 B51
Auffindbeleuchtung option X61:C X61:A

BOMAG
X64:7
E70
+
 X67:C
X46:31b

X46:53

X44:31b

X44:53
X46:53a

X44:53a
E32 
G02
12:5 X46
+ + X67:C +

53
53a
31b
53
53a
31b
Abfallverzögert
3 min

E29 +
E23 E25 XS option X44
+ X67:C 86 K32 86 K118
53a

+ + 12V  Tachograph I 15 86 K85

  M04 M06 M05 M07

53a
E28 E27 K141
31b 53
31

 2,5A
31  31  31 85
  85 85

31b 53
31
E72 X61:B X61:B
14:1 14:15 14:13
X64:1 X44:31 X46:31 X61:B

13:19 K31 K31 15:1

Arbeitsscheinwerfer vorne Steckdose Heizung Heckscheibe
working lights, front socket Wascher vorn heating rear screen
washer motor,front
Arbeitsscheinwerfer hinten Kennleuchte Nachtbeleuchtung Wischermotor vorn Wischermotor hinten 14:4 14:17 13:2 14:4
working lights, rear
rotary beacon night lamp wiper motor front wiper motor rear
Wascher hinten
Kabinenleuchte washer motor,rear
cabin inside light

20.07.2006
1 1
Wiring diagram 538 100 03

008 915 04
Nallin Kabine 538 100 03
04.08.2006
Werner cab 014
14:20 K32

008 915 04
14:20 A42

13 A
S53
F108

1
14
30
K135
15:14
Wiring diagram 538 100 03

87 87a

BOMAG
+ +
E23 E25
 
86
K135
+ +
E28 E27
85  

14:20 K31

Arbeitsscheinwerfer vorne
working head lights, front

15:16 Arbeitsscheinwerfer hinten Arbeitsscheinwerfer hinten

working head lights, rear working head lights, rear

ZA
option

20.07.2006
1 1 538 100 03
Nallin Arbeitsscheinwerfer ROPS
04.08.2006
17.3

567
Werner worklamp RORS 015
568
17.3

A67 1 2 3
Keyboard
keyboard
4 5 6

7 8 9

* 0

X22:1

X22:2
A66
Steuereinheit
control unit

BOMAG
13:15 31 31 17:1

ZA
option

20.07.2006
1 1
Wiring diagram 538 100 03

008 915 04
Nallin Diebstahlschutz System 538 100 03
04.08.2006
Werner anti  theft system 016
 9:20 K11 K11

X2:251

1
F45 10A
Sicherung

008 915 04
2

X2:252

X1:181

0 13 23
S34 0
Wiring diagram 538 100 03

14 24

X1:182 X1:183
X1:185 X1:186

BOMAG
1 1
Y20
Y21
2
2

X1:184 31
16:12 31
Mag.ventil/solenoid valve
Kantenschneidgerät ab
edge cutter down
Mag.ventil/solenoid valve
Kantenschneidgerät hoch
edge cutter up

07.04.2008
Nallin Kantenschneidgerät 538 100 03
07.04.2008
17.3

569
Seis 0558 edge cutter 017
 Name Bl. Pf. Benennung title TYP

17.3 A02
A04
A05
007
005
012
9
7
15
Blinkgeber
Modul Berieselung
Elektronik Geschwindigkeitsanzeige
Flasher
modul sprinkler system
Electronic system, speedometer
4X21WATT
Wiring diagram 538 100 03
A12 014 9 Radio Radio
A15 003 18 Ueberwachungsmodul monitoring module
A15 007 10 Ueberwachungsmodul monitoring module
A16 012 6 Elektronik Tachograph Electronic system, tachograph
A66 016 9 Elektronik Steuereinheit Electronic control unit
A67 016 15 Eingabeeinheit Keyboard
A72 013 7 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A100 009 8 Modul, Lenkstockschalter Fahrrichtung modul, lever switch, travel direction

B03 004 15 Unterdruckschalter Luftfilter neu Vacuum switch, air cleaner new
B06 004 12 Druckschalter Motoroel Pressure switch, engine oil
29.4.08
Nallin
29. 4. 8

B11 005 16 Signalhorn Warning horn

B12 004 6 Druckschalter Bremse Pressure switch, brake 5.7+/0.6BAR
B15 012 10 Aufnehmer Geschwindigkeit Transducer, speed
B21 004 15 Differenzdruckschalter Hydr.Oelfilter Pressure diff. switch, hydr. oil filter
B22 004 16 Differenzdruckschalter Hydr.Oelfilter Pressure diff. switch, hydr. oil filter
B33 004 9 Sensor Wassertankrestmenge Sensor, water tank residual quantity
B51 014 9 Lautsprecher Radio Speaker radio
B51 014 10 Lautsprecher Radio Speaker radio
B55 004 10 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B102 004 3 Druckschalter Bremsleuchten Pressure switch, brake lights 5 BAR
B103 013 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning 4_GC
B104 013 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B124 004 17 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B131 013 9 Temperaturschalter Heizung Temperature switch, heating 110_GC
B148 004 8 Temperaturschalter Bremsoel Temperature switch, brake oil 120_GC
B152 004 13 Temperaturgeber Kuehlmittel temperature switch, collant

E04 007 4 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer 2W

E08 007 8 Blinkleuchte vorne links Indicator, front, lh. 21W
E09 007 9 Blinkleuchte hinten links Indicator, rear, lh. 21W
E10 007 9 Blinkleuchte vorne rechts Indicator, front, rh. 21W
E11 007 10 Blinkleuchte hinten rechts Indicator, rear, rh. 21W
E12 007 14 Parkleuchte links Parking light, lh. 5W
E13 007 13 Schlussleuchte links Tail light, lh. 5W
E14 007 15 Parkleuchte rechts Parking light, rh. 5W
E15 007 17 Schlussleuchte rechts Tail light, rh. 5W
E16 007 17 Scheinwerfer links Head light, lh. 55 W
E17 007 18 Scheinwerfer rechts Head light, rh. 55 W
E18 007 1 Arbeitsscheinwerfer links Working head light, lh. 55W
component listing

E19 007 2 Arbeitsscheinwerfer rechts Working head light, rh. 55 WATT

E23 014 2 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55W
Bauteilliste

E23 015 17 Arbeitsscheinwerfer vorne links Working head light, front, lh. 55 WATT
E25 014 3 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55W
E25 015 18 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 55 WATT
E27 014 3 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55W
E27 015 19 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 55 WATT
E28 014 1 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55W
E28 015 16 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 55 WATT
E29 014 7 Innenleuchte Kabine Inside light, cabin 21W
E30 013 13 Heizgeraet Heating unit
E32 014 5 Kennleuchte Warning light 55W
E33 007 19 Bremsleuchte links Brake light, lh. 21W
E34 007 20 Bremsleuche rechts Brake light, rh. 21W
E41 007 13 Umrissleuchte vorne links Contour illumination front, lh. 5W
E43 007 16 Umrissleuchte vorne rechts Contour illumination front, rh. E43
E61 007 3 Beleuchtung Reifendruckanzeige Illumination 2W
E70 014 7 Nachtleuchte Night lamp 5W
E71 014 17 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 2W
E72 014 1 Beleuchtung Bedienschalter illum. Switches 2W, 24V
E72 014 2 Beleuchtung Bedienschalter illum. Switches 2W, 24V
E72 014 2 Beleuchtung Bedienschalter illum. Switches 2W, 24V
E72 014 2 Beleuchtung Bedienschalter illum. Switches 2W, 24V

F00 002 1 Hauptsicherung Batterie Fuse, main, battery 125A

F01 002 12 Hauptsicherung Fuse, main 30A
F04 004 18 Sicherung Instrumente Fuse, gauges 5A
F05 002 20 Sicherung Steckdose Fuse, socket 15A
F06 005 5 Sicherung Berieselung Fuse, sprinkler system 10A
F07 007 6 Sicherung Warnblinker Fuse, hazard light 15A
F09 007 13 Sicherung Park u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 007 16 Sicherung Park u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 007 17 Sicherung Scheinwerfer links Fuse, head light, lh. 10A
F12 007 18 Sicherung Scheinwerfer rechts Fuse, head light, rh. 10A
F14 003 3 Sicherung Hubmagnet Motor Fuse, shut off solenoid, engine 10A
F15 013 17 Sicherung Heizgeraet Fuse, heating unit 5A
F22 007 2 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 15A
F23 005 16 Sicherung Signalhorn Fuse, warning horn 10A
F25 003 9 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 10A
1

F26 009 17 Sicherung Magnetv. Fahrstufenumsch. Fuse, sol. valve, speed range sel. 10A
F27 014 12 Sicherung Wischer u. Wascher vorne Fuse, windscr. wiper and washer, fr. 15A
F28 014 14 Sicherung Wischer u. Wascher hinten Fuse, windscr. wiper and washer, re. 15A
F31 013 1 Sicherung Kabinenluefter Fuse, cabin ventilator 25A
F37 005 2 Sicherung Berieselungspumpe Fuse, sprinkler pump 20A
6

F40 013 14 Sicherung Kabinenheizung Fuse, heating unit cab 20A

F41 014 5 Sicherung Rundumkennleuchte Fuse, rotary beacon 15A
F45 017 7 Sicherung Kantenschneidgeraet Fuse, edgecutter 10A
F48 002 5 Sicherung Gluehanlage Fuse, glow plug system 125A
538 100 03

F68 013 9 Sicherung Potential 30 Fuse, potential 30 10A

F70 007 9 Sicherung Blinker Fuse, indicators 15A
F77 009 7 Sicherung Fahren Fuse, traveling 10A
F108 015 16 Sicherung Scheinwerfer mitte Fuse, head lights middle 25A
F110 014 4 Sicherung Scheinwerfer aussen Fuse, head lights outside 25A
101

F119 002 12 Sicherung Motor Fuse, motor 7,5A

F120 007 19 Sicherung Bremsleuchte Fuse, brake light 15A
570 F124 002 6 Sicherung Kraftstoffvorwaermung BOMAG
Fuse, fuel preheating 25A 008 915 04
 Name Bl. Pf. Benennung title TYP
F129

F156
004
Wiring diagram 538 100 03
F143 014
007
1
17
17
Sicherung, MD+
Sicherung Heckscheibenheizung
Sicherung StvzO
Fuse, MD+
fuse rear screen heating unit
Fuse, StvzO
15A
15A
20A
17.3
F195 002 15 Sicherung Steuergeraet Vorgluehen Fuse, glow plug control 5A

G01 002 1 Batterie Battery 102AH

G02 002 7 Generator Generator 90A
G03 002 3 Batterie Battery 102AH

H01 003 7 Meldeleuchte Bremse Indicator light, brake LED IN A15

H05 007 11 Meldeleuchte Blinker Indicator light, indicators LED IN A15
H06 007 6 Meldeleuchte Warnblinker Indicator light, hazard light LED IN A15
H06 007 6 Meldeleuchte Warnblinker Indicator light, hazard light LED S14, 18MA
H07 003 18 Warnsummer Betriebsstoerung Warning buzzer, breakdown 930V CA70MA
29.4.08
Nallin
29. 4. 8

H08 002 11 Meldeleuchte Ladekontrolle Indicator light, charge control LED IN A15
H09 004 12 Meldeleuchte Oeldruck Motor Indicator light, engine oil pressure LED IN A15
H14 009 2 Warnsummer Rueckwaertsfahrt Backup alarm buzzer 815V CA0,3A
H15 004 15 Meldeleuchte Motorluftfilter Indicator light, engine air filter LED IN A15
H20 003 6 Meldeleuchte Sitzkontaktschalter Indicator light, drivers seat contact LED IN A15
H23 004 16 Meldeleuchte Hydraulikoelfilter Indicator light, hydr.oil filter LED IN A15
H43 004 6 Meldeleuchte Bremsdruck Indicator light, brake pressure LED IN A15
H49 004 13 Meldeleuchte Motorueberhitzung Indicator light, engine overheating LED IN A15
H52 002 17 Anzeige Gluehueberwachung Glow plug indicator LED IN A15
H70 004 18 Anzeige Wasser im Diesel Indicator water in fuel
H73 004 10 Meldeleuchte Kuehlmittelvorrat Indicator light, eng. coolant res. LED IN A15
H79 004 9 Meldeleuchte Wasserrestmenge Indicator light, Water res. LED IN A15
H86 004 8 Meldeleuchte Bremsöltemperatur Indicator light, brake oil temperature LED IN A15

K05 009 13 Relais Startstrom Relay, starting current BOSCHW

K11 002 18 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHW
K14 002 13 Relais Vorgluehen Relay, glow plug system BOSCHL
K22 003 17 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K32 014 16 Relais Kabine Relay, cabin BOSCHL
K36 004 3 Relais Bremskontrolle Relay, brake control BOSCHW
K42 009 7 Umschaltrelais Relay, switch over BOSCHW
K62 002 8 Relais D+ Relay, D+ BOSCHW
K85 014 19 Umschaltrelais Relay, switch over BOSCHW
K86 002 15 Umschaltrelais Relay, switch over BOSCHW
K104 005 5 Relais, Stoermeldungen Relay, failure indication BOSCHW
K112 003 9 Relais, Meldeleuchte Bremse Relay, indicator light brake BOSCHW
K118 014 20 Relais Arbeisscheinwerfer Relay, working lights BOSCHW
K135 015 14 Relais Arbeisscheinwerfer Relay, working lights BOSCHW
K141 014 18 Relais Heckscheibenheizung relay, heating rear screen BOSCHW
component listing

M01 002 8 Starter Starter

Bauteilliste

M02 005 6 D*Berieselungspumpe E*Sprinkler pump 11A

M04 014 11 Scheibenwischermotor vorne Windscreen wiper motor, front 7,9A
M05 014 14 Scheibenwischermotor hinten Windscreen wiper motor, rear 7,9A
M06 014 13 Scheibenwaschermotor vorne Windscreen washer motor, front 2,5A
M07 014 15 Scheibenwaschermotor hinten Windscreen washer motor, rear 2,5A
M09 013 1 Kabinenluefter Cabin ventilator MAX.11A
M09 013 3 Kabinenluefter Cabin ventilator MAX.11A

P00 002 11 Betriebsstundenzaehler Operating hour meter

P01 004 18 Tankanzeige Level gauge IN A15
P04 012 15 Geschwindigkeitsanzeige Speedometer
P09 012 5 Frequenz und Geschwindigkeitsanzeige Frequency and Speedometer
P18 013 18 Diagnose Diagnostics

R03 004 19 Geber Tankanzeige Sender, level gauge

R03 004 20 Geber Tankanzeige Sender, level gauge
R09 002 9 Vorwiderstand Dropping resistor 82 OHM
R20 004 18 Widerstand Resistor
R21 004 16 Widerstand Resistor
R22 004 17 Widerstand Resistor
R79 002 6 Kraftstoffvorwärmung fuel preheater 200W
R80 014 17 Heizung Heckscheibe heating rear screen MAX. 13A
R81 002 4 Gluehstiftkerze 1 glow plug 1
R82 002 5 Gluehstiftkerze 2 glow plug 2
R83 002 5 Gluehstiftkerze 3 glow plug 3
R84 002 5 Gluehstiftkerze 4 glow plug 4

S00 002 12 Startschalter Starter switch

S01 003 12 Schalter NOT AUS Switch, emergency off
S02 009 18 Fahrstufenschalter Switch, speed range selector
S03 005 16 Taster Signalhorn Push button, warning horn
S05 005 6 Berieselungsschalter Switch, sprinkler system
S14 007 6 Warnblinkschalter Switch, hazard light
S15 007 17 Beleuchtungsschalter StVZO Switch, lighting StVZO
S20 014 12 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 014 14 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S26 007 2 Schalter Arbeitsbeleuchtung hinten Switch, working head lights, rear
2

S28 013 17 Schalter Kabinenheizung Switch, cabin heating

S30 002 1 Batterietrennschalter Switch, battery disconnect
S31 009 4 Schalter Fahrtrichtung Switch, travel direction
S34 017 7 Schalter Kantenschneidgeraet Switch, edge cutter
S37 007 9 Schalter Blinker Switch, indicator
6

S38 014 5 Schalter Kennleuchte Switch, warning light

S44 013 1 Schalter Kabinenluefter Switch, cabin ventilator
S45 014 7 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 014 20 Schalter Arbeitsbeleuchtung Switch, working lights
538 100 03

S53 015 14 Schalter Arbeitsbeleuchtung Switch, working lights

S111 003 11 Schalter Feststellbremse Switch, parking brake
S158 014 7 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 014 18 Schalter Heckscheibenheizung switch rear screen heating unit
S184 009 10 Schalter Fahrtrichtung switch, travel direction
102

S185 007 13 Schalter Nachtbeleuchtung Modul switch, night illumination module

008 915
V01 04 002 9 Diode BOMAG
Diode MR756, KABEL 571
 Name Bl. Pf. Benennung title TYP

17.3 V02
V09
V10
005
013
013
18
6
10
Diode
Diode
Diode
Diode
Diode
Diode
FE5B, KABEL
Wiring diagram 538 100 03
FE5B
STECKER Y138
V12 007 11 Diode Diode IN A15
V13 007 11 Diode Diode IN A15
V41 003 2 Diode (A1) Diode (A1) DIODENMODUL
V42 003 13 Diode (A2) Diode (A2) Diodenmodul
V45 009 11 Diode (A5) Diode (A5) DIODENMODUL
V46 002 8 Diode (A6) Diode (A6) DIODENMODUL

X1:1 003 12 Wago Zentralelektrik Wago ebox

X1:2 007 17 Wago Zentralelektrik Wago ebox
X1:3 007 17 Wago Zentralelektrik Wago ebox
X1:4 007 17 Wago Zentralelektrik Wago ebox
29.4.08
Nallin
29. 4. 8

X1:5 009 7 Wago Zentralelektrik Wago ebox

X1:6 007 9 Wago Zentralelektrik Wago ebox
X1:7 007 9 Wago Zentralelektrik Wago ebox
X1:8 003 9 Wago Zentralelektrik Wago ebox
X1:9 003 12 Wago Zentralelektrik Wago ebox
X1:10 012 15 Wago Zentralelektrik Wago ebox
X1:11 012 15 Wago Zentralelektrik Wago ebox
X1:12 005 6 Wago Zentralelektrik Wago ebox
X1:13 002 20 Wago Zentralelektrik Wago ebox
X1:14 003 12 Wago Zentralelektrik Wago ebox
X1:15 003 3 Wago Zentralelektrik Wago ebox
X1:16 009 17 Wago Zentralelektrik Wago ebox
X1:17 002 15 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:19 004 17 Wago Zentralelektrik Wago ebox
X1:20 004 16 Wago Zentralelektrik Wago ebox
X1:21 002 17 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:22 004 16 Wago Zentralelektrik Wago ebox
X1:23 002 8 Wago Zentralelektrik Wago ebox
X1:24 004 15 Wago Zentralelektrik Wago ebox
X1:25 004 12 Wago Zentralelektrik Wago ebox
X1:26 004 13 Wago Zentralelektrik Wago ebox
X1:27 009 18 Wago Zentralelektrik Wago ebox
X1:28 002 20 Wago Zentralelektrik Wago ebox
X1:28 016 12 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:31 007 13 Wago Zentralelektrik Wago ebox
X1:32 007 17 Wago Zentralelektrik Wago ebox
X1:33 007 9 Wago Zentralelektrik Wago ebox
X1:34 007 10 Wago Zentralelektrik Wago ebox
X1:41 007 9 Wago Zentralelektrik Wago ebox
component listing

X1:42 004 19 Wago Zentralelektrik Wago ebox

X1:43 005 16 Wago Zentralelektrik Wago ebox
Bauteilliste

X1:44 003 17 Wago Zentralelektrik Wago ebox

X1:45 004 10 Wago Zentralelektrik Wago ebox
X1:46 003 18 Wago Zentralelektrik Wago ebox
X1:47 003 7 Wago Zentralelektrik Wago ebox
X1:48 003 6 Wago Zentralelektrik Wago ebox
X1:49 003 2 Wago Zentralelektrik Wago ebox
X1:49 003 13 Wago Zentralelektrik Wago ebox
X1:49 003 14 Wago Zentralelektrik Wago ebox
X1:49 003 18 Wago Zentralelektrik Wago ebox
X1:49 004 18 Wago Zentralelektrik Wago ebox
X1:49 005 10 Wago Zentralelektrik Wago ebox
X1:49 007 4 Wago Zentralelektrik Wago ebox
X1:49 007 5 Wago Zentralelektrik Wago ebox
X1:49 009 11 Wago Zentralelektrik Wago ebox
X1:50 007 10 Wago Zentralelektrik Wago ebox
X1:51 004 18 Wago Zentralelektrik Wago ebox
X1:52 005 16 Wago Zentralelektrik Wago ebox
X1:53 009 17 Wago Zentralelektrik Wago ebox
X1:54 007 7 Wago Zentralelektrik Wago ebox
X1:55 007 7 Wago Zentralelektrik Wago ebox
X1:61 012 8 Wago Zentralelektrik Wago ebox
X1:71 012 12 Wago Zentralelektrik Wago ebox
X1:72 012 10 Wago Zentralelektrik Wago ebox
X1:73 012 10 Wago Zentralelektrik Wago ebox
X1:81 009 7 Wago Zentralelektrik Wago ebox
X1:82 009 4 Wago Zentralelektrik Wago ebox
X1:83 009 4 Wago Zentralelektrik Wago ebox
X1:91 004 6 Wago Zentralelektrik Wago ebox
X1:92 009 10 Wago Zentralelektrik Wago ebox
X1:93 007 2 Wago Zentralelektrik Wago ebox
X1:94 007 19 Wago Zentralelektrik Wago ebox
X1:95 009 4 Wago Zentralelektrik Wago ebox
X1:96 009 5 Wago Zentralelektrik Wago ebox
X1:97 003 12 Wago Zentralelektrik Wago ebox
X1:98 003 3 Wago Zentralelektrik Wago ebox
X1:99 009 17 Wago Zentralelektrik Wago ebox
X1:102 004 17 Wago Zentralelektrik Wago ebox
3

X1:103 004 16 Wago Zentralelektrik Wago ebox

X1:105 004 16 Wago Zentralelektrik Wago ebox
X1:106 002 8 Wago Zentralelektrik Wago ebox
X1:107 004 15 Wago Zentralelektrik Wago ebox
X1:108 004 12 Wago Zentralelektrik Wago ebox
6

X1:109 004 13 Wago Zentralelektrik Wago ebox

X1:110 009 18 Wago Zentralelektrik Wago ebox
X1:111 005 7 Wago Zentralelektrik Wago ebox
X1:111 007 4 Wago Zentralelektrik Wago ebox
538 100 03

X1:111 009 12 Wago Zentralelektrik Wago ebox

X1:111 009 17 Wago Zentralelektrik Wago ebox
X1:111 012 16 Wago Zentralelektrik Wago ebox
X1:121 007 14 Wago Zentralelektrik Wago ebox
X1:122 007 15 Wago Zentralelektrik Wago ebox
103

X1:123 007 8 Wago Zentralelektrik Wago ebox

X1:124 007 9 Wago Zentralelektrik Wago ebox
572 X1:125 002 18 Wago Zentralelektrik BOMAG
Wago ebox 008 915 04
 Name Bl. Pf. Benennung title TYP
X1:125

X1:125
004
Wiring diagram 538 100 03
X1:125 005
007
9
16
8
Wago Zentralelektrik
Wago Zentralelektrik
Wago Zentralelektrik
Wago ebox
Wago ebox
Wago ebox
17.3
X1:126 004 19 Wago Zentralelektrik Wago ebox
X1:127 005 16 Wago Zentralelektrik Wago ebox
X1:128 004 9 Wago Zentralelektrik Wago ebox
X1:129 002 18 Wago Zentralelektrik Wago ebox
X1:130 007 17 Wago Zentralelektrik Wago ebox
X1:131 007 18 Wago Zentralelektrik Wago ebox
X1:132 005 6 Wago Zentralelektrik Wago ebox
X1:133 005 6 Wago Zentralelektrik Wago ebox
X1:133 009 7 Wago Zentralelektrik Wago ebox
X1:142 004 6 Wago Zentralelektrik Wago ebox
X1:143 009 7 Wago Zentralelektrik Wago ebox
29.4.08
Nallin
29. 4. 8

X1:144 003 12 Wago Zentralelektrik Wago ebox

X1:145 003 3 Wago Zentralelektrik Wago ebox
X1:146 007 2 Wago Zentralelektrik Wago ebox
X1:147 007 2 Wago Zentralelektrik Wago ebox
X1:148 009 9 Wago Zentralelektrik Wago ebox
X1:149 009 10 Wago Zentralelektrik Wago ebox
X1:151 004 3 Wago Zentralelektrik Wago ebox
X1:153 004 16 Wago Zentralelektrik Wago ebox
X1:154 004 16 Wago Zentralelektrik Wago ebox
X1:155 004 8 Wago Zentralelektrik Wago ebox
X1:156 004 9 Wago Zentralelektrik Wago ebox
X1:157 004 8 Wago Zentralelektrik Wago ebox
X1:158 004 8 Wago Zentralelektrik Wago ebox
X1:159 004 19 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:163 002 6 Wago Zentralelektrik Wago ebox
X1:164 002 6 Wago Zentralelektrik Wago ebox
X1:165 002 15 Wago Zentralelektrik Wago ebox
X1:166 002 14 Wago Zentralelektrik Wago ebox
X1:167 002 15 Wago Zentralelektrik Wago ebox
X1:168 002 14 Wago Zentralelektrik Wago ebox
X1:168 002 15 Wago Zentralelektrik Wago ebox
X1:181 017 7 Wago Zentralelektrik Wago ebox
X1:182 017 6 Wago Zentralelektrik Wago ebox
X1:183 017 8 Wago Zentralelektrik Wago ebox
X1:184 017 6 Wago Zentralelektrik Wago ebox
X1:185 017 6 Wago Zentralelektrik Wago ebox
X1:186 017 8 Wago Zentralelektrik Wago ebox
X2:11 002 4 Wago Zentralelektrik Wago ebox
X2:12 002 2 Wago Zentralelektrik Wago ebox
component listing

X2:21 002 2 Wago Zentralelektrik Wago ebox

X2:22 002 12 Wago Zentralelektrik Wago ebox
Bauteilliste

X2:31 002 2 Wago Zentralelektrik Wago ebox

X2:32 002 20 Wago Zentralelektrik Wago ebox
X2:41 002 2 Wago Zentralelektrik Wago ebox
X2:42 005 2 Wago Zentralelektrik Wago ebox
X2:51 002 2 Wago Zentralelektrik Wago ebox
X2:52 007 6 Wago Zentralelektrik Wago ebox
X2:61 002 12 Wago Zentralelektrik Wago ebox
X2:62 002 12 Wago Zentralelektrik Wago ebox
X2:71 003 2 Wago Zentralelektrik Wago ebox
X2:72 003 3 Wago Zentralelektrik Wago ebox
X2:81 004 1 Wago Zentralelektrik Wago ebox
X2:82 004 1 Wago Zentralelektrik Wago ebox
X2:91 004 19 Wago Zentralelektrik Wago ebox
X2:92 004 18 Wago Zentralelektrik Wago ebox
X2:111 007 2 Wago Zentralelektrik Wago ebox
X2:112 007 2 Wago Zentralelektrik Wago ebox
X2:121 005 16 Wago Zentralelektrik Wago ebox
X2:122 005 16 Wago Zentralelektrik Wago ebox
X2:131 003 10 Wago Zentralelektrik Wago ebox
X2:132 003 9 Wago Zentralelektrik Wago ebox
X2:141 009 17 Wago Zentralelektrik Wago ebox
X2:142 009 17 Wago Zentralelektrik Wago ebox
X2:151 007 8 Wago Zentralelektrik Wago ebox
X2:152 007 9 Wago Zentralelektrik Wago ebox
X2:161 009 7 Wago Zentralelektrik Wago ebox
X2:162 009 7 Wago Zentralelektrik Wago ebox
X2:171 007 19 Wago Zentralelektrik Wago ebox
X2:172 007 19 Wago Zentralelektrik Wago ebox
X2:181 007 13 Wago Zentralelektrik Wago ebox
X2:182 007 13 Wago Zentralelektrik Wago ebox
X2:191 007 16 Wago Zentralelektrik Wago ebox
X2:192 007 16 Wago Zentralelektrik Wago ebox
X2:201 007 17 Wago Zentralelektrik Wago ebox
X2:202 007 17 Wago Zentralelektrik Wago ebox
X2:211 007 18 Wago Zentralelektrik Wago ebox
X2:212 007 18 Wago Zentralelektrik Wago ebox
X2:221 005 5 Wago Zentralelektrik Wago ebox
4

X2:222 005 5 Wago Zentralelektrik Wago ebox

X2:231 007 17 Wago Zentralelektrik Wago ebox
X2:232 007 17 Wago Zentralelektrik Wago ebox
X2:241 002 6 Wago Zentralelektrik Wago ebox
X2:242 002 6 Wago Zentralelektrik Wago ebox
6

X2:251 017 7 Wago Zentralelektrik Wago ebox

X2:252 017 7 Wago Zentralelektrik Wago ebox
X2:261 002 15 Wago Zentralelektrik Wago ebox
X2:262 002 15 Wago Zentralelektrik Wago ebox
538 100 03

X3:1 009 2 WARNSUMMER H14 Warning buzer H14

X3:2 009 2 WARNSUMMER H14 Warning buzer H14
X6:1 004 19 ARMATURENPULT Instrument board
X6:3 002 17 ARMATURENPULT Instrument board
X6:7 007 6 ARMATURENPULT Instrument board
104

X6:8 004 13 ARMATURENPULT Instrument board

X6:8 007 11 ARMATURENPULT Instrument board
008 915
X6:11 04 003 7 ARMATURENPULT BOMAG
Instrument board 573
 Name Bl. Pf. Benennung title TYP

17.3 X6:11
X6:12
X6:14
004
003
002
12
6
10
ARMATURENPULT
ARMATURENPULT
ARMATURENPULT
Instrument board
Instrument board
Instrument board
Wiring diagram 538 100 03
X6:15 004 10 ARMATURENPULT Instrument board
X6:16 004 15 ARMATURENPULT Instrument board
X6:17 004 16 ARMATURENPULT Instrument board
X6:18 004 6 ARMATURENPULT Instrument board
X6:18 007 11 ARMATURENPULT Instrument board
X6:19 004 9 ARMATURENPULT Instrument board
X6:19 007 11 ARMATURENPULT Instrument board
X6:20 004 8 ARMATURENPULT Instrument board
X6:21 004 16 ARMATURENPULT Instrument board
X6:22 004 17 ARMATURENPULT Instrument board
X6:23 003 18 ARMATURENPULT Instrument board
29.4.08
Nallin
29. 4. 8

X6:24 003 17 ARMATURENPULT Instrument board

X6:25 004 18 ARMATURENPULT Instrument board
X6:26 004 18 ARMATURENPULT Instrument board
XS 002 20 Steckdose Socket
XS 014 6 Steckdose Socket 15A
X10:1 004 20 KRAFTSTOFFTANK Fuel tank
X10:2 004 19 KRAFTSTOFFTANK Fuel tank
X10:3 004 19 KRAFTSTOFFTANK Fuel tank
X11:1 009 6 FAHRTRICHTUNGSSCHALTE switch, travel direction
X11:2 009 4 FAHRTRICHTUNGSSCHALTE switch, travel direction
X11:3 009 4 FAHRTRICHTUNGSSCHALTE switch, travel direction
X11:4 009 5 FAHRTRICHTUNGSSCHALTE switch, travel direction
X12:1 009 8 FAHRTRICHTUNGSSCHALTE switch, travel direction
X12:2 009 10 FAHRTRICHTUNGSCHALTER switch, travel direction
X12:3 009 9 FAHRTRICHTUNGSSCHALTE switch, travel direction
X12:4 009 8 FAHRTRICHTUNGSSCHALTE switch, travel direction
X13:A 002 12 FAHRERSTAND Operators platform
X13:B 002 12 FAHRERSTAND Operators platform
X13:C 002 13 FAHRERSTAND Operators platform
X14:A 002 13 FAHRERSTAND Operators platform
X14:B 002 13 FAHRERSTAND Operators platform
X17:1 005 6 BERIESELUNGSPUMPE Sprinkler pump
X17:2 005 6 BERIESELUNGSPUMPE Sprinkler pump
X19:1 016 5 KEYBOARD Keyboard
X19:2 016 5 KEYBOARD Keyboard
X19:3 016 5 KEYBOARD Keyboard
X19:4 016 5 KEYBOARD Keyboard
X19:5 016 5 KEYBOARD Keyboard
X19:7 016 5 KEYBOARD Keyboard
component listing

X19:8 016 12 KEYBOARD Keyboard

X19:9 016 5 KEYBOARD Keyboard
Bauteilliste

X19:10 016 5 KEYBOARD Keyboard

X19:11 016 5 KEYBOARD Keyboard
X19:12 016 5 KEYBOARD Keyboard
X21:1 013 7 KLIMAKOMPRESSOR Air conditioning compr.
X22:1 016 13 KEYBOARD Keyboard
X22:2 016 13 KEYBOARD Keyboard
X24:1 012 10 B15 B15
X24:2 012 10 B15 B15
X24:3 012 10 B15 B15
X24:4 012 9 B15 B15
X27:1 004 9 WASSERTANK Water tank
X27:2 004 9 WASSERTANK Water tank
X30:1 003 18 H82 H82
X30:2 003 18 H82 H82
X40:1 013 1 Kabine cabin
X40:2 013 2 Kabine cabin
X40:3 013 3 Kabine cabin
X40:4 013 3 Kabine cabin
X42:1 013 2 Kabine cabin
X42:2 013 2 Kabine cabin
X42:3 013 2 Kabine cabin
X42:4 013 1 Kabine cabin
X43:1 013 7 FAHRERSTAND Operators platform
X43:2 013 7 FAHRERSTAND Operators platform
X43:3 013 7 FAHRERSTAND Operators platform
X43:4 013 7 FAHRERSTAND Operators platform
X44:31 014 12 Kabine cabin
X44:53 014 11 Kabine cabin
X44:31b 014 12 Kabine cabin
X44:53a 014 12 Kabine cabin
X45:1 013 3 Kabine cabin
X45:2 013 4 Kabine cabin
X45:3 013 3 Kabine cabin
X45:4 013 3 Kabine cabin
X46:31 014 14 Kabine cabin
X46:53 014 14 Kabine cabin
X46:31b 014 14 Kabine cabin
5

X46:53a 014 14 Kabine cabin

X49:1 013 9 FAHRERSTAND Operators platform
X49:2 013 9 FAHRERSTAND Operators platform
X50:1 013 7 FAHRERSTAND Operators platform
X51:A 014 7 FAHRERSTAND Operators platform
6

X51:B 014 7 FAHRERSTAND Operators platform

X51:C 002 2 FAHRERSTAND Operators platform
X52:1 013 7 FAHRERSTAND Operators platform
X52:2 013 7 FAHRERSTAND Operators platform
538 100 03

X53:3 013 18 Kabine cabin

X53:5 013 19 Kabine cabin
X53:6 013 18 Kabine cabin
X54:1 013 13 Kraftstoffpumpe fuel pump heating unit
X54:2 013 13 Kraftstoffpumpe fuel pump heating unit
105

X55:1 013 7 FAHRERSTAND Operators platform

X55:2 013 6 FAHRERSTAND Operators platform
574 X61:A 014 15 Kabine BOMAG
cabin 008 915 04
 Name Bl. Pf. Benennung title TYP
X61:B

X62:1
014
Wiring diagram 538 100 03
X61:C 014
014
15
13
14
Kabine
Kabine
Kabine
cabin
cabin
cabin
17.3
X62:2 014 14 Kabine cabin
X63:1 014 13 Kabine cabin
X63:2 014 15 Kabine cabin
X63:3 002 2 KABINE Cabin
X63:4 013 9 Kabine cabin
X63:5 014 20 Kabine cabin
X63:6 013 11 Kabine cabin
X63:7 013 7 Kabine cabin
X63:8 014 7 Kabine cabin
X64:1 014 7 Kabine cabin
X64:2 014 20 Kabine cabin
29.4.08
Nallin
29. 4. 8

X64:3 014 12 Kabine cabin

X64:4 014 5 Kabine cabin
X64:5 014 11 Kabine cabin
X64:6 014 12 Kabine cabin
X64:7 014 6 Kabine cabin
X64:8 014 14 Kabine cabin
X65:2 013 1 Kabine cabin
X65:3 013 2 Kabine cabin
X65:4 013 2 Kabine cabin
X66:1 014 4 Kabine cabin
X67:A 014 8 Kabine cabin
X67:A 014 9 Kabine cabin
X67:A 014 9 Kabine cabin
X67:B 014 8 Kabine cabin
X67:B 014 8 Kabine cabin
X67:B 014 9 Kabine cabin
X67:C 014 9 Kabine cabin
X67:C 014 9 Kabine cabin
X67:C 014 9 Kabine cabin
X89:A 002 1 FAHRERSTAND Operators platform
X89:B 002 2 FAHRERSTAND Operators platform
X91:A 014 2 MOTORRAUM Engine room
X91:B 002 3 MOTORRAUM Engine room
X95:11 007 8 Blende vorn Srceen front
X95:12 007 14 Blende vorn Srceen front
X95:12 007 17 Blende vorn Srceen front
X95:14 007 8 Blende vorn Srceen front
X95:15 007 14 Blende vorn Srceen front
X95:16 007 17 Blende vorn Srceen front
component listing

X95:21 007 9 Blende vorn Srceen front

X95:22 007 15 Blende vorn Srceen front
Bauteilliste

X95:23 007 18 Blende vorn Srceen front

X95:24 007 9 Blende vorn Srceen front
X95:25 007 15 Blende vorn Srceen front
X95:26 007 18 Blende vorn Srceen front
X96:11 007 9 Blende vorn Srceen front
X96:12 007 13 Blende hinten Screen rear
X96:13 007 1 Blende hinten Screen rear
X96:14 007 9 Blende hinten Screen rear
X96:15 007 13 Blende hinten Screen rear
X96:16 007 1 Blende hinten Screen rear
X96:17 007 19 Blende hinten Screen rear
X96:21 007 10 Blende hinten Screen rear
X96:23 007 2 Blende hinten Screen rear
X96:24 007 10 Blende hinten Screen rear
X96:25 007 17 Blende hinten Screen rear
X96:26 007 2 Blende hinten Screen rear
X96:27 007 17 Blende hinten Screen rear
X96:77 007 20 Blende hinten Screen rear
X97:1 007 13 ZA, Umrissleuchte Option, Contour illumination
X97:1 007 16 ZA, Umrissleuchte Option, Contour illumination
X97:2 007 13 ZA, Umrissleuchte Option, Contour illumination
X97:2 007 16 ZA, Umrissleuchte Option, Contour illumination
X98:1 004 10 DEUTSCH 2POL. Deutsch 2pol.
X98:2 004 10 DEUTSCH 2POL. Deutsch 2pol.

Y01 002 11 Magnetventil Startmehrmenge Solenoid valve, start boost fuel 3,5A
Y03 009 17 Magnetventil Fahrstufenumschaltung Solenoid valve, speed range selector KABEL+STECKER
Y04 003 12 Magnetventil Bremse Solenoid valve, brake 2,41A HYTOS
Y13 003 3 Hubmagnet Motor Shut off solenoid, engine 4A
Y14 013 13 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit 2A
Y15 013 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 49W 4A
Y16 009 5 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 26,2W
Y17 009 4 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 26,2W
Y20 017 8 Magnetventil Kantenschneidgeraet Solenoid valve, edge cutter 30W
Y21 017 6 Magnetventil Kantenschneidgeraet Solenoid valve, edge cutter 30W
Y130 009 19 Magnetventil Fahrstufenumschaltung Solenoid valve, speed range selector KABEL+STECKER
Y138 013 9 Magnetveentil Heizung Solenoid valve, heating unit 3,5A
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Y163 009 9 Magnetventil Fahrtrichtung solenoid valve, travel direction

Y164 009 10 Magnetventil Fahrtrichtung solenoid valve, travel direction
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