Service Manuel BW211D-40

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

BW 211 / 212 / 213 PD-40
S/N 101 582 42 . . . . S/N 101 582 43 . . . . S/N 101 582 44 . . . .
S/N 101 583 02 . . . . S/N 101 583 03 . . . . S/N 101 582 55 . . . .
S/N 101 582 47 . . . . S/N 101 582 48 . . . . S/N 101 582 49 . . . .
Single drum roller

Catalogue number.
008 911 63
02/2007
Table of Contents
General
7
1.1 Introduction
1.2 Safety regulations
1.3 General repair instructions
14
1.4 Tightening torques
24
Technical data
29
2.1 Technische Daten
30
2.2 Maintenance chart
38
2.3 Table of fuels and lubricants
40
2.4 Fuels and lubricants
40
Connection overview
43
3.1 Connection overview
Tests and adjustments
47
4.1 Special tools, tests and adjustments
48
4.2 Checking the rotation speeds
52
4.3 Checking / adjusting the neutral positions of the travel pump
54
4.4 Pressure tests in the travel circuit
56
4.5 Checking / adjusting the vibrator shaft speeds
58
4.6 Pressure measurements in the vibration circuit
59
4.7 Check the leakage rate of the vibration motor
60
4.8 Pressure test in steering circuit
61
Flushing and bleeding
63
5.1 Special tools for flushing
64
5.2 Flushing - general
69
5.3 Flushing schematic travel circuit (distribution travel pump)
71
5.4 Flushing the travel circuit (travel pump distribution)
73
5.5 Flushing schematic travel circuit (distribution axle motor)
79
5.6 Flushing the travel circuit (axle motor distribution)
84
5.7 Flushing schematic for vibration drive
89
5.8 Flushing the vibration circuit
90
5.9 Bleeding the travel circuit
94
5.10 Bleeding the vibration circuit
96
Fundamental electrics
008 911 63
44
99
6.1 Understanding circuit diagrams
100
6.2 Terminal designations
104
6.3 Current and voltage
108
6.4 Resistance
112
6.5 Series / parallel connection
114
6.6 Ohm's law
116
6.7 Electrical energy
116
6.8 Formula diagram
117
6.9 Metrology
118
6.10 Diodes, relays, fuses
120
6.11 Batteries
123
6.12 Three-phase generator
126
6.13 Electric starter
133
BOMAG
Table of Contents
6.14 Telemecanique switch
136
6.15 Inductive proximity switches
139
6.16 Angle sensor with current output
140
6.17 Plug connectors
141
6.18 Deutsch plug, series DT and DTM
142
6.19 Plugs and terminals in spring clamping technology
148
Special tools, electrics
153
7.1 Special tools, electrics
Electronic modules
8.1 Vibration module
165
Speedometer Module
169
9.1 Speedometer module
Service Training
171
173
10.1 Electrics BEM (BOMAG Evib-meter)
175
10.2 Service Training
233
Engine
154
163
297
11.1 Diesel engine, general
299
11.2 Service side
300
11.3 Starter side
301
11.4 Lubrication oil circuit
302
11.5 Oil pressure switch and low oil pressure circuitry
304
11.6 Check the engine oil level
305
11.7 Changing engine oil and oil filter cartridges
306
11.8 Coolant circuit
308
11.9 Coolant temperature switch
310
11.10 Disassembling and assembling the coolant temperature switch
311
11.11 Replacing the thermostat
312
11.12 Checking the thermostat in disassembled state
313
11.13 Check the coolant level
314
11.14 Change the coolant
314
11.15 Clean the cooling fins on engine and hydraulic oil cooler
315
316
11.17 Fuel supply
318
11.18 Injection system
321
11.19 Injection pump replacement during service
322
11.20 Injection valve replacement during service
331
11.21 Checking / repairing injection valves
334
11.22 Fuel filter
339
11.23 Check, clean the water separator
341
11.24 Change the fuel pre-filter cartridge
341
11.25 Change the fuel filter cartridge
342
11.26 Checking the compression
343
11.27 Check, adjust the valve clearance
344
11.28 Boost fuel solenoid valve
346
11.29 Engine shut-down solenoid
347
11.30 Air filter
348
11.31 Cleaning, changing the dry air filter cartridge
349
BOMAG
008 911 63
Table of Contents
11.32 Heating flange on engine
11.33 Checking the heating flange control
354
11.34 Electric throttle control
355
11.35 Engine monitoring
357
11.36 Engine
359
11.37 Special tools, Deutz engine (BFM 2012)

Air conditioning system
361
373
12.1 Physical basics
375
12.2 Refrigerant R134a
378
12.3 Compressor oil / refrigeration oil
379
12.4 Working principle of the air conditioning system
380
12.5 Monitoring devices
380
12.6 Description of components
381
12.7 Checking the compressor oil level
387
12.8 Checking the magnetic clutch
388
12.9 Inspection and maintenance work
389
12.10 Checking, replacing the refrigerant compressor V-belt
389
12.11 Service the air conditioning
390
12.12 Drying and evacuation
393
12.13 Emptying in case of repair
393
12.14 Leak test
394
12.15 Filling instructions
395
12.16 Trouble shooting in refrigerant circuit, basic principles
398
12.17 Trouble shooting, refrigerant circuit diagram
402
12.18 Trouble shooting procedure
403
12.19 Steam table for R134a
413
12.20 Heating control / air conditioning control
419
Replacing the cab window panes
425
13.1 Assembly of window panes
426
13.2 Special tools
427
13.3 Auxiliary materials
428
13.4 Removing and installing the window pane
430
Drum
435
14.1 Special tools, drum, single drum rollers
436
14.2 Repair overview for drum
438
14.3 Removing and installing the drum
446
14.4 Repairing the drum
451
14.5 Disassembling and assembling the change-over weight
484
14.6 Changing the rubber buffers and adjusting the pretension
487
Oscillating articulated joint
491
15.1 Special tools
492
15.2 Repair overview oscillating articulated joint
494
15.3 Removing and installing the oscillating articulated joint
497
15.4 Dismantling the oscillating articulated joint
499
15.5 Assembling the oscillating articulated joint
504
Suppliers documentation
515
16.1 Travel pump series 90R
008 911 63
351
BOMAG
517
Table of Contents
16.2 Travel drive series 51
607
16.3 Vibration pump 42R 041
689
16.4 Vibration motor A10FM
727
16.5 MS/MSE 02 ..... 18
751
16.6 Axle DANA 192
801
Circuit diagrams
925
17.1 Wiring diagram
927
17.2 Hydraulic diagram
963
967
BOMAG
008 911 63
1 General
008 911 63
BOMAG
1.1
1.1
Introduction
Introduction
* The applicable documents valid at the date of printing are part of this manual.
This manual is intended to support expert mechanics

in efficient repair and maintenance work. Whoever
wants to do repair work himself should have been sufficiently trained and posses profound expert knowledge, he should limit his work only to those parts and
components which will not affect the safety of the vehicle or the passengers. It is highly recommended to
have repairs to critical systems, such as steering,
brakes and travel drive, sole carried out by a BOMAG
workshop. Untrained persons should NEVER UNTERTAKE SUCH REPAIR WORK.
The repair instructions describe the removal or dismantling and assembly of components and assembly
groups. The repair of disassembled assembly groups
is described as far as this makes sense with respect
to available tools and spare parts supply and as far as
it can be understood by a skilled mechanic.
Documentation
For the BOMAG machines described in this training
manual the following documentation is additionally
available:
1
Operating and maintenance instructions
Spare parts catalogue
Wiring diagram*
Hydraulic diagram*
Service Information
You should only use genuine BOMAG spare parts.

Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
This manual is not subject of any updating service; we
would therefore like to draw your
attention to the additionally published "technical service information".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notification.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.
Danger
Please observe strictly the safety regulations in
this manual, in the operating instructions as well
as the applicable accident prevention regulations.
!
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
BOMAG
008 911 63
1.2
Safety regulations
Important notes
1.2
Safety regulations
These safety regulations must be read and applied by every person involved in the repair 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.
Any suggestions, safety precautions and warnings in this section are intended as a mnemonic
aid for well trained and experienced expert mechanics. This manual should not be considered a
bible on workshop safety.
Workshop equipment and facilities as well as the
use and waste disposal of solvent, fluids, gases
and chemicals are subject to legal regulations,
which are intended to provide a minimum on safety. It is obviously your own responsibility to know
and adhere to these regulations.
This manual contain headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to avoid dangers for health and
for the environment.
Danger
Paragraphs marked like this highlight possible
dangers for persons.
!
Caution
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
!
Note
Paragraphs marked like this contain technical information for the optimal economical use of the machine.
Environment
Paragraphs marked like this point out practices
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Observe the regulations for the protection of the
environment.
Mark a machine that is defective or being repaired

by attaching a clearly visible warning tag to the
steering wheel.
On machines with articulated joint keep the articulated joint locked during work.
Use protective clothes like hard hat, safety boots

and gloves.
Keep unauthorized persons away from the machine

during repair work.
Tools, lifting gear, lifting tackle, supports and other

auxiliary equipment must be fully functional and in
safe condition.
Use only safe and approved lifting gear of sifficient

load bearing capacity to remove and install parts or
components from and to the machine.
Be careful with cleansing agents. Do not use easily

inflammable or harmful substances, such as gasoline or paint thinners for cleaning.
Cleaning or repair work on the fuel tank is very dangerous. Do not smoke or allow any ignitable sparks
or open fire in the vicinity when cleaning or repairing
a tank. .
When performing welding work strictly comply with

the respective welding instructions.
Precautions and codes of conduct for

welding work
Welding work should only be performed by specially
instructed expert 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 coatings, 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).
Ensure good conductivity between earth cable and

work piece.
Start the extraction fan before starting work and

guide with the progressing work as required.
Always isolate the burner when laying it down (remove possible electrode residues).
Protect cables from being damaged, use cables

with insulated couplings.
Ensure sufficient fire protection, keep a fire extinguisher at hand.
General
l
Before starting repair work stand the machine on

level and solid ground.
Always secure the machine against unintended rolling.
Secure the engine reliably against unintentional

starting.
008 911 63
BOMAG
1.2
Safety regulations
In case of welding work in fire or explosion endangered environments, you should always ask for a
welding permission.
Remove combustible parts from the vicinity or cover

such parts.
Avoid prolonged and repetitive contact with oil, especially with old oil. In case of open incisions and injuries seek medical advice immediately.
Name a fire watch during and after welding work.
Do not clamp the welding rod holder and the inert

gas welding gun under your arm and lay these parts
only on an insulated top.
Apply protective cream before starting work, so that

oil can be easier removed from the skin.
Wash with soap and water to ensure that all oil has
been removed (a skin cleaning agent and a nail
brush will help). Lanolin containing agents will replace natural skin oils that were lost.
Do not use gasoline, kerosene, diesel, thinner or

solvents to wash the skin.
Do not put oil soaked cloths into your pockets.
Avoid clothes, especially underpants, getting soiled

by oil.
Overalls must be washed at regular intervals.

Clothes that cannot be washed, must be disposed
of.
If possible degrease components before handling.
Place the inert gas bottles in a safe place and secure them against falling over.
Use a protective screen or an arcing shield with

welding glass, wear welding gloves and clothes,
this applies also for assisting persons.
full face visor; a facility suitable for rinsing the eyes

should also be available.
Switch the welding unit off before connecting welding cables.
Behaviour in case of faults

l
Check electrode holders and electric cables at regular intervals.
In case of deficiencies switch off the welding unit

and inform supervising persons.
In case of an extractor fan failure or any other fault

inform the supervising persons.
Maintenance; waste disposal

l
Replace damaged insulating jaws and welding rod

holders immediately.
Replace the welding wire reels only in deenergized

state.
Environment
It is strictly prohibited to drain off oil into the soil,
the sewer system or into natural waters. Entrust
special companies with the waste disposal of old
oil. If in doubt you should consult your local authorities.
Hydraulics
l
Hydraulic oil escaping under pressure can penetrate the skin and cause severe injury. You should
therefore relieve the pressure in the system before
disconnecting any lines.
Before applying pressure to the system make sure

that all line connections and ports have been properly tightened and are in perfect condition.
Hydraulic oil leaking out of a small opening can

hardly be noticed, therefore please use a piece of
cardboard or wood when checking for leaks. When
being injured by hydraulic oil consult a physician immediately, as otherwise this may cause severe infections.
Do not step in front of or behind the drums/wheels/

crawler tracks when performing adjustment work in
the hydraulic system while the engine is running.
Block drums and/or wheels / crawler tracks with
wedges.
What to do in case of accidents; First Aid

l
Keep calm.
Call first air helpers.
Report the accident.
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 emergency doctor.
Old oils
Prolonged and repetitive contact with mineral oils will
remove the natural greases from the skin and causes
dryness, irritation and dermatitis. Moreover, used engine oils contain potentially hazardous contaminants,
which could cause skin cancer. Appropriate skin protection agents and washing facilities must therefore
be provided.
l
Wear protective clothes and safety gloves, if possible.
If there is a risk of eye contact you should protect

your eyes appropriately, e.g. chemistry goggles or
10
BOMAG
008 911 63
1.2
Safety regulations
Reattach all guards and safety installations after
all work has been completed.
plastic material, a so-called fluoroelastomer. Under

normal operating conditions this material is safe and
does not impose any danger to health.
Environment
It is strictly prohibited to drain off hydraulic oil
into the soil, the sewer system or into natural waters. Entrust special companies with the waste
disposal of old oil. If in doubt you should consult
your local authorities.
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.
Fuels
If the material is in such a state it must only be

touched with special protective gloves. These
gloves must be disposed of directly after use.
If the material has contacted the skin despite these

measures, take off the soiled clothes and seek
medical advice immediately. In the meantime wash
the affected parts of the skin for 15 to 60 minutes
with cold water or lime water.
Danger
Repair work on fuel systems must only be performed by appropriately trained personnel.
!
The following notes refer to general safety precautions for danger free handling of fuel. These notes are
only general instructions; in case of uncertainties you
should consult the person responsible for fire protection.
Fuel vapours not only are easily inflammable, but also
highly explosive inside closed rooms and toxic; dilution 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 easily become distributed by draft. Even the smallest portion of spilled fuel is therefore potentially dangerous.
l
Fire extinguishers charged with FOAM, SCHAUM,

CO2 GAS or POWDER must be available wherever
fuel is stored, filled in, drained off, or where work on
fuel systems is performed.
The vehicle battery must always be disconnected,
BEFORE work in the fuel system is started. While
working on the fuel system you should not disconnect the battery, because this could generate
sparks, which would ignite explosive fuel vapours.
Poisonous substances
Some of the fluids and substances used are toxic and
must under no circumstances be consumed.
Skin contact, especially with open wounds, should be
strictly avoided.
These fluids and substances are, amongst others,
anti-freeze agents, hydraulic oils, washing additives,
lubricants and various bonding agents.

Caution
Lines in the air conditioning system must only be
loosened by trained and explicitly instructed experts.
!
Wear safety goggles! Put on your safety goggles.

This will protect your eyes against coming into contact with refrigerant, which could cause severe
damage by freezing.
Wear safety gloves and an apron! Refrigerant are

excellent solvents for greases and oils. In contact
with skin they will remove the protective grease film.
However, degreased skin is very sensitive against
cold temperatures and germs.
Do not allow liquid refrigerants to come into contact

with skin! Refrigerant takes the heat required for
evaporation from the environment. Very low temperatures may be reached. The results may be local
frost injuries (boiling point of R134a -26.5C at ambient pressure).
Do not inhale higher concentrations of refrigerant

vapours! Escaping refrigerant vapours will mix with
the ambient air and displace the oxygen required for
breathing.
Smoking is strictly prohibited! Refrigerants may be

decomposed by a glowing cigarette. The resulting
substances are highly toxic and must not be inhaled.
Wherever fuel is stored, filled, drained off or where

work on fuel systems is carried out, all potential ignition sources must be extinguished or removed.
Search lights must be fire proof and well protected
against possible contact with running out fuel.
Hot fuels
Before draining fuel off the tank for repair work, you
must strictly apply the following measures:
l
Allow the fuel to cool down, to prevent any contact

with a hot fluid.
Vent the system, by removing the filler cap in a well
ventilated area. Screw the filler cap back on, until
the tank is finally emptied.
Synthetic rubber
Many O-rings, hoses and similar parts, which are apparently made of natural rubber, are actually made of
008 911 63
BOMAG
11
1.2
l
Safety regulations
Welding and soldering on refrigeration equipment!

Before starting welding or soldering work on vehicles, (in the vicinity
of air conditioning components) all refrigerant must
be drawn out and the rests removed by blowing out
the system with nitrogen. The decomposition products created from the refrigerant under the influence
of heat not only are highly toxic, but also have a
strong corrosive effect, so that pipes and system
components may be attacked. The substance is
mainly fluorohydrogen.
Pungent smell! In case of a pungent smell the afore
mentioned decomposition products have already
been created. Extreme care must be exercised not
to inhale these substances, as otherwise the respiratory system, the lungs and other organs may be
harmed.
When blowing out components with compressed air
and nitrogen the gas mixture escaping from the
components must be extracted via suitable exhaust
facilities (workshop exhaust systems).
Handling pressure vessels

l
Since the fluid container is pressurized, the manufacture and testing of these pressure vessels is governed by the pressure vessel directive. (New edition
from April 1989). Paragraph 10 of the pressure vessel directive demands that these pressure containers must be periodically inspected and tested by a
specialist, according to paragraph 32. In this case
periodically recurring inspections consist of external
examinations, normally on containers in operation.
The refrigerant container must be visually inspected
two times per year, within the frame work of major
inspections. Special attention must thereby be paid
to signs of corrosion and mechanical damage. If the
container is in no good condition, it should be replaced for safety reasons, in order to protect the operator or third parties against the dangers when
handling or operating pressure vessels.
Secure pressure vessels against tipping over or rolling away.
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 applies also when snapping off valves on bottles. Bottles must therefore only be transported with the
safety caps properly installed.
Refrigerant bottles must never be placed near heating radiators. Higher temperatures will cause higher
pressures, whereby the permissible pressure of the
vessel may be exceeded. The pressure vessel directive therefore specifies that a pressure vessel
should not be warmed up to temperatures above 50
C.
12
Do not heat up refrigerant bottles with an open

flame. Excessive temperatures can damage the
material and cause the decomposition of refrigerant.
Do not overfill refrigerant bottles, since any temperature increase will cause enormous pressures.
Environment
In operation, during maintenance and repair work
and when taking refrigeration systems our of
service it is not permitted to let refrigerant escape
into the atmosphere, which would contradict the
current status of technology.
Battery
l
Wear goggles and face protection (acid).
Wear suitable clothes to protect face, hands and

body (acid).
Work and store accumulators only well ventilated

rooms. (Development of oxyhydrogen gas).
Do not lean over the battery while it is under load,

being charged or tested. (Danger of explosion).
Burning cigarettes, flames or sparks can cause explosion of the accumulator
Keep ignition sources away from the battery.
Always shield eyes and face towards the battery.
Do not use battery chargers or jump leads without

following the operating instructions.
Keep the cell plugs closed.
After an accident with acid flush the skin with water

and seek medical advice.
Do not allow children access to batteries.
When mixing battery fluid always pour acid into water, never vice-versa.
Special safety regulations

l
Use only genuine BOMAG spare parts for repair

purposes. Original parts and accessories have
been specially designed for this machine.
We wish to make explicitly clear that we have not

tested or approved any parts or accessories not
supplied by us. The installation and/or use of such
products may therefore have an adverse effect on
the specific characteristics of the machine and
thereby impair the active and/or passive driving
safety. The manufacturer explicitly excludes any liability for damage caused by the use of non-original
parts or accessories.
Unauthorized changes to the machine are prohibited for safety reasons.
If tests on the articulated joint need to be performed

with the engine running, do not stand in the articulation area of the machine, danger of injury!
BOMAG
008 911 63
1.2
Safety regulations
l
Do not perform cleaning work while the engine is

running.
If tests must be performed with the engine running

do not touch rotating parts of the engine, danger of
injury.
Exhaust gases are highly dangerous. Always ensure an adequate supply of fresh air when starting
the engine in closed rooms.
Refuel only with the engine shut down. Ensure strict

cleanliness and do not spill any fuel.
Keep used filters in a separate waste container and

dispose of environmentally.
Dispose of oils and fuel environmentally when performing repair or maintenance work.
Do not refuel in closed rooms.
Do not heat up oil higher than 160 C because it

may ignite.
Wipe off spilled oil and fuel.
Do not smoke when refuelling or when checking the

acid level in the battery.
Do not check the acid level of the battery with a naked flame, danger of explosion!
Old batteries contain lead and must be properly disposed of.
There is a danger of scalding when draining off engine or hydraulic oil at operating temperature.
on machines with rubber tires a tire may busr if incorrectly assembled. This can cause severe injury.
Do not exceed the specified highest permissible tire

pressure.
008 911 63
BOMAG
13
1.3
General repair instructions
General
1.3
Electrics
Before removing or disassembling and parts, hoses

or components mark these parts for easier assembly.
Before assembly oil or grease all parts, as far as this
is necessary.
General
The electric and electronic systems in construction
equipment are becoming more and more extensive.
Electronic elements are increasingly gaining importance in hydraulic and mechanical vehicle systems.
Diagnostics according to plan
A structured approach in trouble shooting saves time
and helps to avoid mistakes and expenses, especially
in the fields of electrics and electronics. Understanding electronic controls requires the knowledge of
some basic terms concerning their general performance. In many cases error logs are just simply read
out and control units are replaced without any further
trouble shooting. This is in most cases unnecessary
and, even more important, very expensive.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
l
In approx. 10 % of the examined cases the problems were caused by control units.
In approx. 15 % sensors and actuators were the

cause of the problems.
By far the highest proportion of all faults could be

traced back to wiring and connections (plugs, etc.).
General:
14
Before changing any expensive components, such

as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Electric signals must be checked at
the locations to which they are applied, i.e. on control unit or sensor technology. So, if the system had
been diagnosed without unplugging the control unit
and checking the wiring, one should be alerted.
Check for good cable and ground contacts, therefore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
Perform trouble shooting in a systematic way. Do

not become confused by the high number and variety of electric cables, current can only flow in a
closed circuit. You should first become acquainted
with the function of the corresponding electric circuit
by following the correct wiring diagram. Detected
faults should be rectified immediately. If the system
still does not work correctly after this measure, trouble shooting must be continued. Several faults very
rarely occur at the same time, but it is not impossible.
Do not disconnect or connect battery or generator

while the engine is running.
Do not operate the main battery switch under load.
BOMAG
008 911 63
1.3

l
Do not use jump leads after the battery has been removed.
Sensors and electric actuators on control units must

never be connected individually or between external power sources for the purpose of testing, but
only in connection with the control unit in question,
as otherwise there may be a risk of destruction
(damage)!
Disconnecting the control unit plug connectors with
the control unit switched on, i.e. with the power supply (terminal 15 "On"), is not permitted. Switch the
voltage supply "off" first - then pull out the plug.
Even with an existing polarity reversal protection incorrect polarity must be strictly avoided. Incorrect
polarity can cause damage to control units!
Plug-in connectors on control units are only dust

and water tight if the mating connector is plugged
on! Control units must be protected against spray
water, until the mating connector is finally plugged
on!
Unauthorized opening of the control electronics (micro controller MC) as well as changes or repairs on
the wiring can lead to dangerous malfunctions.
Do not use any radio equipment or mobile phones

inside the driver's cab without an appropriate outside antenna or in the vicinity of the control electronics!
Battery
Rules for the handling of batteries
Even though it may be conveniently installed in the
engine compartment, it should never be used as a rest
for tools. When connecting the poles, e.g. by means
of a spanner, the battery will become an "electric
welder".
As a measure to avoid short circuits you should first
disconnect the negative pole during disassembly and
reconnect the negative pole last during assembly.
Terminal clamps should be assembled with as little
force as possible.
Poles and terminal clamps should always be kept
clean to avoid transition resistances during starting
and the related development of heat.
You should obviously also pay attention to secure fastening of the battery in the vehicle.
Electrical system and welding work

l
Surge voltages in the electric system must be strictly avoided:
When performing welding work always fasten the

earth clamp of the welding unit in the immediate vicinity of the welding location.
Caution
Switch off the main battery switch, doisconnect
the generator and pull the plug out on the control
unit before starting welding work.
!
008 911 63
BOMAG
15
1.3
Hydraulic system
Caution
Do not open any hydraulic components if you
have not been properly trained and without exact
knowledge.
After changing a component perform a high and

charge pressure test, if necessary check the speed
of the exciter shaft.
The operating pressure of the exciter shaft to a

great extent depends on the base under the vibrating drum. If the soil is too hard place the drums on
old rubber tires. Do not activate the vibration on a
hard, concreted base, danger of bearing damage.
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 system depressurized.
Please note
Cleanliness is of utmost importance. Make sure that
no dirt or other contaminating substances can enter
into the system.
l
Clean fittings, filler covers and the area around such

parts before disassembly to avoid entering of dirt.
Before disconnecting hoses, pipes or similar relieve

the system pressure with the engine shut down.
During repair work keep all openings closed with

clean plastic plugs and caps.
Do not run pumps and motors without oil.
When cleaning hydraulic components take care not

to damage any fine machine surfaces.
Chemical and rubber soluble cleansing agents may

only be used to clean metal parts. Do not let such
substances come in contact with sealing material.
Rinse of cleaned parts thoroughly, dry them with

compressed air and apply anti-corrosion oil immediately. Do not install parts that show traces of corrosion.
Avoid the formation of rust on fine machined caused

by hand sweat.
Before commissioning
l
After changing a component clean the hydraulic oil

tank thoroughly.
Fill the housings of hydraulic pumps and motors

with hydraulic oil.
Use only hydraulic oils according to the specification in the maintenance instructions.
After changing a component clean the hydraulic

system as described in the flushing instructions in
order to prevent all other components from being
damaged by abrasion and metal chips remaining in
the system.
Change the hydraulic oil filter.
Commissioning
l
Bleed the hydraulic circuits.
Start up the system without load.

Check the hydraulic oil level in the tank, fill up oil if
necessary.
Grease must not used as a sliding agent for assembly work. Use hydraulic oil.
Do not start the engine after the hydraulic oil has

been drained off.
After commissioning
Use only the specified pressure gauges. Risk of

damaging the pressure gauges under too high pressure.
Clean ports and fittings before removal so that no

dirt can enter into the hydraulic system.
Check the hydraulic oil level before and after the

work.
Use only clean oil according to specification.
Check the hydraulic system for leaks, find and rectify the cause.
Fill new hydraulic units with hydraulic oil before

starting operation.
After changing a component thoroughly flush and

bleed the entire hydraulic system.
Perform measurements at operating temperature of

the hydraulic oil (approx. 40 C).
16
Check system pressures and speeds.
Check fittings and flanges for leaks.
After each repair check all adjustment data, rotational speeds and nominal values in the hydraulic
system, adjust if necessary.
Do not adjust pressure relief valves and control

valves to values above their specified values.
BOMAG
008 911 63
1.3

damp air is drawn into the component by the difference in temperatures.
CFC - halon prohibition
Damaged or leaking parts of the air conditioning

must not be repaired by welding or soldering, but
must generally be replaced.
Do not fill up refrigerant, but extract existing refrigerant and refill the system.
Different types of refrigerant must not be mixed.

Only the refrigerant specified for the corresponding
air conditioning system must be used.
Refrigerant circuits with refrigerant type R134a

must only be operated with the compressor oil / refrigeration oil approved for the compressor.
Used compressor oil / refrigeration oil must be disposed of as hazardous waste.
Due to its chemical properties compressor oil / refrigeration oil must never be disposed of together
with engine or transmission oil.
Compressor oil / refrigeration oil is highly hydroscopic. 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.
All O-rings as well as pipe and hose fittings must be

oiled with compressor/refrigeration oil beforeiassembly.
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.
A too high compressor oil / refrigeration oil level adversely affects the cooling performance and a too
low oil level has a negative effect on the lifetime of
the compressor.
If a air conditioning unit needs to be opened, the

dryer must be replaced in any case.
Always use new O-rings when reassembling the

unit.
Always use two spanners when connecting pipes or

hoses, to prevent the pipe end from being damaged
.
Tighten screw fittings with the specified torque.
Check the connections of pipes, fittings or components thoroughly; do not use if damaged.
Do not leave the refrigerant circuit unnecessarily

open to the atmosphere. Do not attempt to repair
bent or burst pipes.
Compressor valves must only be opened after the

system has been properly sealed.
The use of leak detection colouring matter is not

permitted, because its chemical composition is unknown and its effect on compressor oil and rubber
elements is not predictable. The use of leak detec-
The CFC - halon prohibition from May 06, 1991 regulates the withdrawal from the use of CFC and the handling of these refrigerants.
Contents:
Since 1995 CFC (R12) is no longer permitted for use
in new systems.
In operation, during maintenance and repair work and
when taking refrigeration systems our of service it is
not permitted to let refrigerant escape into the atmosphere, which would contradict the current status of
technology.
Work on refrigeration systems must only be carried
out by persons with well founded knowledge about
such systems and who have the necessary technical
equipment available.
The use of refrigerant must be documented.
Old systems should be converted to refrigerants
harmless to ozone (refrigerant substitutes).
For this reason the Federal Environmental Agency at
the end of 1995 published suitable replacement refrigerants for R 12. As a consequence old systems must
no longer be filled with R12. As soon as such a system
is opened for service, the system must be converted
to a suitable replacement or service refrigerant. Old
systems may still be used, as long as they are leak
tight. R 134a was nominated as replacement for R 12.
Inside the European Union the "EU-Directive 2037/
2000 on substances causing decomposition of the
ozone layer" regulates the production, use and availability of CFC and H-CFC.
l
In case of a repair on the refrigeration system you

should first evacuate the air conditioning system for
at least 45 minutes to remove any moisture from the
system, before you start to refill. Moisture bonded in
the compressor oil / refrigeration oil (PAG oil) can
only be removed from the system by changing the
oil.
During repair work on refrigerant lines and components, these must be kept closed as far as possible,
in order to prevent the invasion of air, moisture and
dirt, because the operational reliability of the system
can only be assured if all components in the refrigerant circuit are clean and dry from inside.
Make sure that no dirt or foreign parts can enter into
the compressor or the air conditioning system. The
area around the refrigerant hoses should be
cleaned with a gasoline free solvent.
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.
Before opening all components should have
warmed up to ambient temperature, to avoid that
008 911 63
BOMAG
17
1.3
tion colouring matter makes any warranty claims

null and void.
l
Tools used on refrigeration circuits must be of excellent condition, thus to avoid the damage of any
connections.
The dryer is to be installed last, after all connections

in the refrigerant circuit have been tightened.
After completion of repair work screw locking caps

(with seals) on all connections with valves and on
the service connections. Start up of the air conditioning system. Observe the filling capacity.
Before start up of the air conditioning system after a

new filling: - Turn the compressor approx. 10 revolutions by hand using the clutch or V-belt pulley of
the magnetic clutch. - Start the engine with the compressor/control valve switched off. - Once the idle
speed of the engine has stabilized switch on the
compressor and run it for at least 10 minutes at idle
speed and maximum cooling power.
Never operate the compressor over longer periods

of time with high engine speeds without a sufficient
amount of refrigerant in the system. This could
probably cause overheating and internal damage.
18
Fuel hoses
Fig. 1
Caution
All fuel hoses have two layers of material, a reinforced rubber coating outside and an internal Viton 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.
!
BOMAG
008 911 63
1.3

Gaskets and mating surfaces
Leaking or failing seals and gaskets can in most cases
be tracked down to careless assembly, causing damage not only to the seal or gasket, but also to the mating surfaces. Careful assembly work is mandatory if
good results are to be achieved.
l
Before assembling replacement seals make sure

that the running surface is free of pitting, flutes, corrosion or other damage.
Inappropriately stored or handled seals (e.g. hanging from hooks or nails) must under no circumstances be used.
Sealing compound should only be used if specially

requested in the instructions. In all other cases
these joints should be assembled in dry condition.
Sealing compound must be applied thin and evenly

on the corresponding surfaces; take care that the
compound does not enter into oil galleries or blind
threaded bores.
threads or splines. If no assembly sleeve is available, you should use a plastic tube or adhesive tape to
prevent the sealing lip from being damaged.
Fig. 3
Before assembly remove any residues of old sealing compound. Do not use any tools that could damage the sealing surfaces.
Examine the contact faces for scratches and burrs,

remove these with a fine file or an oilstone; take
care that no grinding dust and dirt enters into
tapped bores or enclosed components.
Blow lines, ducts and gaps out with compressed air,

replace any O-rings and seals that have been dislodged by the compressed air.
Assembly of radial seals
Lubricate the outer rim 1 (Fig. 3) of the seal and

press it flat on the housing seat.
Note
If possible, use a "bell" 1 (Fig. 3), to make sure that

the seal will not skew. In some cases it may be advisable to assemble the seal into the housing first, before sliding it over the shaft. Under no circumstances
should the full weight of the shaft rest on the seal.
If you have no proper service tools at hand, use a suitable drift punch with a diameter which is about 0.4mm
smaller than the outer diameter of the seal. Use VERY
LIGHT blows with the hammer if no press is available.
l
Press or knock the seal into the housing, until it is

flush with the housing surface.
Fig. 2
l
Lubricate sealing lips 1 (Fig. 2) with clean grease; in

case of double seals fill the space between the sealing lips with a generous amount of grease.
Slide the seal over the shaft, with the lip facing towards the fluid to be sealed.
Note
If possible, use an assembly sleeve 1 (Fig. 2), to protect the lip from being damaged by sharp edges,
008 911 63
BOMAG
19
1.3
Feather keys and keyways
Ball and roller bearings
Caution
Feather keys must only be reused if they show no
differences to new feather keys, any notches must
be considered as initial signs of wear.
Caution
Ball and roller bearings must only be reinstalled
after it has been assured that they are in perfect
condition.
Fig. 4
l
Clean and thoroughly examine the feather key.
Debur and thoroughly clean the edges of the keyway with a fine file before reassembling.
Fig. 5
20
Remove any lubricant residues from the bearing to

be examined by washing it with gasoline or any other appropriate degreasing agent. Cleanliness is of
utmost importance for all related work.
Check balls or rollers, running surfaces, outer faces

of outer races and inner faces of inner races for visible damage. If necessary replace the bearing with
a new one, since these symptoms are first signs of
wear.
Hold the bearing with you thumb and the index finger by the inner race, rotate the outer race and
make sure that it runs without friction. Hold the
bearing by the outer race and repeat this test with
the inner race.
Move the outer race gently to and fro while holding

it by the inner race; check for resistance while rotating and replace the bearing if it does not work correctly.
Lubricate the bearing with an appropriate lubricant

before reinstalling.
BOMAG
008 911 63
1.3

Check shaft and bearing housing for discolouration
or other signs of movement between bearing and
seats.
Make sure that shaft and housing are free of burrs

before assembling the bearing.
If a bearing of a pair of bearings shows any defects,

we highly recommend the replacement of both
bearings.
On greased bearings (e.g. wheel bearings) fill the

space between bearing and outer seal with the recommended type of grease before assembling the
seal.
Always mark the individual parts of separable 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 bearing instead.
Fig. 6
Caution
When assembling the bearing to the shaft load
must only be applied to the inner race 1 (Fig. 6).
!
Screws and nuts

Tightening torque
Caution
Always tighten nuts or screws to the specified
tightening torque. Tightening torques deviating
from the ones in the table are specially mentioned
in the repair instructions.
!
Damaged screws must under no circumstances

be used any longer. Recutting threads with thread
cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or corroded thread pitches can cause incorrect torque
value readings.
Self-locking nuts must be generally renewed.
The use of screws with too high strength can
cause damage!
l
Nut of a higher strength can generally be used instead of nuts of a lower strength classification.
When checking or retightening screw joints to the

specified tightening torque you should first relieve
by a quarter turn and then tighten to the correct
torque.
Before tightening you should lightly oil the thread, in

order to ensure low friction movement. The same
applies for self-locking nuts.
Make sure that no oil or grease will enter into tapped

bores. The hydraulic power generated when turning
in the screw could cause breakage of the effected
part.
When fitting the bearing into the housing load

must only be applied to the outer race (2).
008 911 63
BOMAG
21
1.3
Strength classes of metric screws
Strength classes of metric nuts
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.
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).
Fig. 7 Identification of screws
Example: A screw is identified with 12.9.

The first number corresponds with 1/100 of the nominal tensile strength (minimum tensile strength) in N/
mm2.
The nominal tensile strength is 12 X 100N/mm2 =
1200 N/mm2.
The second number specifies 10-times the ration between lower yield point and nominal tensile strength
(yield point ratio).
Note
When exceeding the lower yield point, the material will

return to its original shape when being relieved (plastic deformation).
When exceeding the upper yield point the material will
not restore its original shape after being relieved.
The lower tensile strength is 9/10 X 1200 N/mm2 =
1080 N/mm2.
Strength class of
nut
4
5
Strength class of associated

screw
3.6, 4.6, 4.8
3.6, 4.6, 4.8
6
8
9
10
12
5.6, 5.8
6.8
8.8
9.8
10.8
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 dimensions, but which can only be classified by their
hardness.
Nut height below 0,5 d (d = nominal dimension).
Note
However, these values are by no means identical with

the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.
22
BOMAG
008 911 63
1.3

Identification in clock system
Fig. 9 Identification of nuts in clock system
For small nuts (Fig. 9) the clock system can be used

for identification.
l
The 12 o'clock position is identified by a dot or the

manufacturer's symbol.
The strength class is identified by a dash (b).
008 911 63
BOMAG
23
1.4
Tightening torques
The values specified in the table apply for screws:

1.4
Tightening torques
black oiled
with surface protection A4C
with surface protection DACROMET
Note
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with metric unified thread1

Screw dimension
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
Tightening torques Nm
8.8
3
6
10
25
50
88
137
211
290
412
560
711
1050
1420
10.9
5
9
15
35
75
123
196
300
412
578
785
1000
1480
2010
12.9
5
10
18
45
83
147
235
358
490
696
942
1200
1774
2400
Coefficient of friction tot. = 0,14
Tightening torques for screws with metric unified fine thread1

Screw dimension
M8 x 1
M10 x 1.25
M12 x 1,25
M12 x 1.5
M14 x 1.5
M16 x 1.5
M18 x 1.5
M20 x 1.5
M22 x 1.5
M24 x 2
M27 x2
M30 x 2
1
24
8.8
26
52
98
93
152
225
324
461
618
780
1147
1568
10.9
37
76
137
127
216
318
466
628
863
1098
1578
2254
12.9
48
88
126
152
255
383
554
775
1058
1294
1920
2695
BOMAG
008 911 63
1.4
Tightening torques
Tightening torques for screws treated with anti-seizure paste OKS 2401 (copper paste)
Screw dimension
M16
M16 x 1.5
M18
M18 x 1.5
M20
M20 x 1.5
M22
M22 x 1.5
M24
M24 x 2
M27
M27 X 2
M30
M30 x 2
3/4 - 10 UNC
3/4 - 16 UNC
1
8.8
169
180
232
260
330
369
448
495
569
624
840
918
1136
1255
276
308
10.9
240
255
330
373
463
502
628
691
800
879
1184
1263
1608
1804
388
432
12.9
287
307
392
444
557
620
754
847
960
1036
1520
1536
1920
2156
464
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) 1 2

Thread diameter
10.9
100
150
300 - 350
400 - 500
500 - 600
M12x1.5
M14x1.5
M18x1.5
M20x1.5
M22x1.5
1
2

These values result in a 90% utilization of the yield point
008 911 63
BOMAG
25
1.4
Tightening torques
The values specified in the table apply for screws:

l
black oiled
with surface protection A4C
with surface protection DACROMET
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. DACROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with UNC thread, 1 UNC Unified Coarse Thread Series, American Unified
Coarse Thread
Screw dimension
1/4 - 20
5/16 - 18
3/8 - 16
7/16 - 14
1/2 - 13
9/16 - 12
5/8 - 11
3/4 - 10
7/8 - 9
1 - 8
1 1/8 - 7
1 1/4 - 7
1 3/8 - 6
1 1/2 - 6
8.8
11
23
39
62
96
140
195
345
560
850
1200
1700
2200
3000
10.9
15
32
55
87
135
200
275
485
770
1200
1700
2400
3100
4200
12.9
19
39
66
105
160
235
330
580
940
1450
2000
2900
3700
5100
Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread
Screw dimension
1/4 - 28
5/16 - 24
3/8 - 24
7/16 - 20
1/2 - 20
9/16 - 18
5/8 - 18
3/4 - 16
7/8 -14
26
8.8
13
25
45
70
110
155
220
385
620
10.9
18
35
63
100
155
220
310
540
870
BOMAG
12.9
22
42
76
120
185
260
370
650
1050
008 911 63
1.4
Tightening torques
Tightening torques for screws with UNF thread, 1 UNF Unified National Fine Thread Series, American
Unified Fine Thread
Screw dimension
1 - 12
1 1/8 - 12
1 1/4 - 12
1 3/8 - 12
1 1/2 - 12
1
8.8
930
1350
1900
2600
3300
10.9
1300
1900
2700
3700
4600
12.9
1600
2300
3200
4400
5600
008 911 63
BOMAG
27
1.4
28
Tightening torques
BOMAG
008 911 63
2 Technical data
008 911 63
BOMAG
29
2.1
Technische Daten
BOMAG Central Service
Seite 1 von 2
BOMAG Central Service - Technical data and adjustment values

Status: 2007-01-29
Product type:
BW 211/212/213 D/PD-40
Type No.:
Serial numbers from:
582 42/43/44/47/48/49
101 582 42/43/44/47/48/49 1001
Engine:
Type:
Combustion principle:
Cooling:
Number of cylinders:
Power acc. to ISO 9249:
Power data at nominal speed of:
Low idle speed:
High idle speed:
Spec. fuel consumption:
Valve clearance, inlet:
Valve clearance, outlet:
Opening pressure, injection valves:
Starter voltage:
Starter power:
BF4M2012C
4-stroke-Diesel
Water
4
98 kW
2300 1/min
900+/-200 1/min
2430+/-50 1/min
243 g/kWh
0,3 mm
0,5 mm
220 bar
12 V
3,1 kW
Travel pump:
Type:
System:
Max. displacement:
Max. flow ratio:
High pressure limitation:
Charge pressure, high idle:
90R 075
Axial piston-swash plate
75 cm3/U
172,9 l/min
400 +26 bar
26 bar
Travel motor, rear:

Type:
System:
Max. displacement (stage 1):
Min. displacement (stage 2):
Perm. leak oil quantity:
Rinsing oil quantity:
Rinsing oil pressure limitation:
51D110
Axial piston-bent axle
110 cm3/U
69 cm3/U
2 l/min
16 l/min
16 bar
Drum drive:
Type:
System:
Displacement stage 1:
Perm. leak oil quantity:
MSE 18 1C
Radial piston
2800 cm3/U
2 l/min
Vibration pump:
http://bsa.bomag.com/bsa/tk_components/english/search_components_result.asp?Typ... 29.01.2007
30
BOMAG
008 911 63
2.1
Technische Daten
BOMAG Central Service
Type:
System:
Max. displacement:
Seite 2 von 2
42R 041
41 cm3/U
Starting pressure:
345+26 bar
Operating pressure, soil dependent: ca.100 bar
Vibration motor:
Type:
System:
Displacement:
Frequency:
Amplitude:
Rinsing oil quantity:
Rinsing oil pressure limitation:
A10FM 45
45 cm3/U
30/35 Hz
2 / 1 mm
6 l/min
13 bar
Steering and charge pump:

Type:
System:
Displacement:
Max. steering pressure:
HY/ZFS11/16
Gear pump
16 cm3/U
175+26 bar
Steering valve:
Type:
System:
OSPC 500 ON
Rotary valve
Rear axle:
Type:
Differential:
Degree of locking:
Reduction ratio:
CHC 192/51HD
No-Spin
100 %
43,72
Filling capacities:
Engine coolant:
16 l (50% Water, 50% Anti-freeze agent on

Ethane-diol-basis)
Engine oil:
10 l (SAE 15W-40, API CG-4 (for details see
maintenance manual))
Hydraulic oil:
60 l (HVLP 46 VI 150)
Vibration bearing housing:
2x 0,8 l (SAE 15W-40, API SJ/CF)
Rear axle:
11 l (SAE 90 EP, API GL 5)
Rear axle wheel hubs:
2,9 l (SAE 90 EP, API GL 5)
AC refrigerant:
1300 g (R 134a)
Compressor oil (filling the system): 100 ml (PAG l)
http://bsa.bomag.com/bsa/tk_components/english/search_components_result.asp?Typ... 29.01.2007
008 911 63
BOMAG
31
2.1
Technische Daten
Fig. 10
Dimensions in
mm
H2
O1
O2
BW 211 D-40
2960
2250
1500
2268
2972
490
5840
60
60
25
2130
BW 211 PD-40
2960
2250
1480
2268
2972
490
5840
60
60
25
2130
Weights
Operating weight (CECE)
with ROPS and cabin
Axle load, drum (CECE)
Rear axle load (CECE)
Static linear load
Travel characteristics
Travel speed (1)
Travel speed (2)
Max. gradability (depending on soil)
Engine
Engine manufacturer
Type
Cooling
Number of cylinders
Rated power DIN ISO
3046
Rated speed
Fuel
Electrical equipment
Drive system
Driven axles
BW 211 D-40
BW 211 PD-40
kg
9500
10500
kg
kg
kg/cm
5750
3750
27
6750
3750
-
km/h
km/h
%
0 ... 6
0 ... 10
45
0 ... 6
0 ... 10
49
kW
Deutz
BF4M 2012C
Water
4
98
Deutz
BF4M 2012C
Water
4
98
2300
Diesel
12
hydrostatic
2
2300
Diesel
12
hydrostatic
2
hydrostatic
hydr.-mech.
hydrostatic
hydr.-mech.
1 rpm
V
Brakes
Service brake
Parking brake
32
BOMAG
008 911 63
2.1
Technische Daten
1
BW 211 D-40
BW 211 PD-40
Steering
Type of steering
Steering operation
articulated
hydrostatic
articulated
hydrostatic
Vibration
Vibrating drum
Drive system
Frequency
Amplitude
Hz
mm
1
hydrostatic
30/36
1,8/0,9
1
hydrostatic
30/36
1,64/0,82
Tires
Tire size
Air pressure
bar
23.1-26/12 PR TL C7
1,4
23.1-26/12TL R1
1,4
Litres
Litres
Litres
Litres
10
250
60
16
10
250
60
16
Filling capacities
Engine
Fuel
Hydraulic oil
Coolant
1
The right for technical modifications remains reserved
008 911 63
BOMAG
33
2.1
Technische Daten
Fig. 11
Dimensions in
mm
H2
O1
O2
BW 212 D-40
2960
2250
1500
2268
2972
490
5840
60
60
25
2130
BW 212 PD-40
2960
2250
1480
2268
2972
490
5840
60
60
25
2130
Weights
with ROPS and cabin
Static linear load
Travel speed (1)
Travel speed (2)
Engine
Engine manufacturer
Type
Cooling
Number of cylinders
Rated power DIN ISO
3046
Rated speed
Fuel
Drive system
Driven axles
BW 212 D-40
BW 212 PD-40
kg
10900
11350
kg
kg
kg/cm
7150
3750
33,6
7600
3750
-
km/h
km/h
%
0 ... 6
0 ... 10
45
0 ... 6
0 ... 10
49
kW
Deutz
BF4M 2012C
Water
4
98
Deutz
BF4M 2012C
Water
4
98
2300
Diesel
12
hydrostatic
2
2300
Diesel
12
hydrostatic
2
hydrostatic
hydrostatic
1 rpm
V
Brakes
Service brake
34
BOMAG
008 911 63
2.1
Technische Daten
1
BW 212 D-40
hydr.-mech.
BW 212 PD-40
hydr.-mech.
Steering
Type of steering
Steering operation
articulated
hydrostatic
articulated
hydrostatic
Vibration
Vibrating drum
Drive system
Frequency
Amplitude
Hz
mm
1
hydrostatic
30/36
1,8/0,9
1
hydrostatic
30/36
1,64/0,82
Tires
Tire size
Air pressure
bar
23.1-26/12 PR TL C7
1,4
23.1-26/12TL R1
1,4
Litres
Litres
Litres
Litres
10
250
60
16
10
250
60
16
Parking brake
Filling capacities
Engine
Fuel
Hydraulic oil
Coolant
1
008 911 63
BOMAG
35
2.1
Technische Daten
Fig. 12
Dimensions in
mm
H2
O1
O2
BW 213 D-40
2960
2250
1500
2268
2972
490
5840
60
60
35
2130
BW 213 PD-40
2960
2250
1480
2268
2972
490
5840
60
60
25
2130
Weights
with ROPS and cabin
Static linear load
Travel speed (1)
Travel speed (2)
Engine
Engine manufacturer
Type
Cooling
Number of cylinders
Rated power DIN ISO
3046
Rated speed
Fuel
Drive system
Driven axles
BW 213 D-40
BW 213 PD-40
kg
12420
12870
kg
kg
kg/cm
7820
4600
36,7
8270
4600
-
km/h
km/h
%
0 ... 6
0 ... 10
45
0 ... 6
0 ... 10
49
kW
Deutz
BF4M 2012C
Water
4
98
Deutz
BF4M 2012C
Water
4
98
2300
Diesel
12
hydrostatic
2
2300
Diesel
12
hydrostatic
2
hydrostatic
hydrostatic
1 rpm
V
Brakes
Service brake
36
BOMAG
008 911 63
2.1
Technische Daten
1
BW 213 D-40
hydr.-mech.
BW 213 PD-40
hydr.-mech.
Steering
Type of steering
Steering operation
articulated
hydrostatic
articulated
hydrostatic
Vibration
Vibrating drum
Drive system
Frequency
Amplitude
Hz
mm
1
hydrostatic
30/36
1,8/0,9
1
hydrostatic
30/36
1,64/0,82
Tires
Tire size
Air pressure
bar
Parking brake
Filling capacities
Engine
Fuel
Hydraulic oil
Coolant
1
23.1-26/12 PR TL C7 23.1-26/12TL R1
1,4
1,4
10
250
60
16
10
250
60
16
Litres
Litres
Litres
Litres
008 911 63
BOMAG
37
2.2
Dipstick mark
5.7
Check the water separator
5.8
Check the fuel level
5.9
Check the hydraulic oil level
5.10 Check the coolant level
Inspection glass
Inspection glass
5.11 Check the dust separator
5.12 Check the tire pressure
5.13 Clean the cooling fins on engine and hydraulic oil cooler
5.14 Check the oil level in the drive axle
5.15 Check the oil level in the wheel hubs
5.16 Check the oil level in the vibration bearings
5.17 Change engine oil and oil filter cartridge1
min. 1x per year
5.18 Drain the sludge from the fuel tank

5.19 Service the battery
X
X
Pole grease
5.20 Check, replace the refrigerant compressor V-belt
5.21 Service the air conditioning
5.22 Check, adjust the valve clearance
as required
Check the engine oil level
every 3000 operating hours
5.6
Remark
Maintenance work
No.
every 10 operating hours, daily
Maintenance chart
Running-in instructions
after 250 operating hours
2.2
Maintenance chart
Intake = 0,3 mm
Exhaust = 0,5 mm
5.23 Check, replace the ribbed V-belt
5.24 Change the fuel filter cartridge
5.25 Change the fuel pre-filter cartridge
5.26 Check the engine mounts
5.27 Oil change in drive axle
min. 1x per year
5.28 Oil change in wheel hubs
min. 1x per year
5.29 Oil change vibration bearings2
see foot note, min. X

1 x per year
5.30 Retighten the fastening of the axle on

the frame
38
BOMAG
008 911 63
5.31 Tighten the wheel nuts
5.32 Check the ROPS
X
X
5.33 Clean the oil bath air filter
min. 1x per year
5.34 Change hydraulic oil and breather filter at least every 2

years
5.35 Change the hydraulic oil filter***
at least every 2
years
5.36 Change the coolant
at least every 2
years
5.37 Check the injection valves

5.38 Service the combustion air filter
Remark
every 10 operating hours, daily
Maintenance work
Running-in instructions
after 250 operating hours
No.
as required
2.2
Maintenance chart
X
min. 1x per year,
safety cartridge at
least every 2 years
5.39 Adjusting the scrapers
5.40 Adjust the parking brake
5.41 Change the tires
5.42 Change the fresh air filter in the cabin
5.43 Tightening torques
5.44 Engine conservation
1
2
3
Oil change intervals depend on quality of oil and fuel (sulphur content)
Oil change intervals after 250 h, after 500 h, after 1000 h, and then every 1000 h.
Also in case of repair in the hydraulic system.
008 911 63
BOMAG
39
2.3
2.3
Table of fuels and lubricants
Table of fuels and lubricants
Assembly
Fuel or lubricant
Summer
Quantity approx.
Winter
Attention
Observe the level marks
Engine
Engine oil ACEA: E3-96/E5-02 or
approx. 8,5 litres without

oil filter
API: CG-4/CH-4
SAE 10W/40
(-20 C to +40 C)
SAE 15W/40
(-15 C to +40 C)
Fuel
Diesel
Hydraulic system
Winter diesel fuel
Hydraulic oil (ISO), HV46, kinem. viscosity
approx. 150 litres

approx. 60 litres
46 mm2/s at 40 C
Vibration bearings
Engine oil SAE 15W/40
approx. 0,8 litres
Drive axle
Gear oil SAE 90, API GL5
approx. 9,5 litres
Wheel hubs
Gear oil SAE 90, API GL5
approx. 1,9 per side

Tires (only BW 213)
Engine cooling system
Refrigerant R134A
approx. 1400 g
Water
approx. 295 litres
Calcium chloride (CaCl2) or magnesium chloride

(MgCl2)
approx. 100 kg
Cooling system protection agent
approx. 16 litres
2.4
Fuels and lubricants
Engine oil
Quality
Lubrication oils are classified according to their performance and quality class. Oils according to other
comparable specifications may be used.
Approved engine oils
Deutz
DQC II
ACAE
E3/96/E5-02
API
CH-4/CG-4
DHD
DHD-1
DQC III
E4-99
-
The exact assignment of the approved oil qualities

and oil change intervals can be taken from the following section "Lubrication oil change intervals".
Consult your local service station if in doubt.
40
BOMAG
008 911 63
2.4

Oil viscosity
API2
Multi-purpose oils should be generally used.
CG-4/CH-4
Since lubrication oil changes its viscosity with the temperature, the ambient temperature at the operating location of the engine is of utmost importance when
choosing the viscosity class (SAE-class) .
Optimal operating conditions can be achieved by using the opposite oil viscosity chart (Fig. 13) as a reference.
Occasionally falling short of the temperature limits will
impair the cold starting ability, but will not cause any
engine damage. In order to keep the occurring wear
as low as possible, occassional exceeding of the limits
should not happen over a longer period of time.
= 500 operating hours
Caution
These intervals apply only when using a diesel
fuel with maximum 0.5 % sulphur by weight and
for ambient temperatures higher than -10 C.
!
When using fuels with a sulphur content of more

than 0.5% to 1% or under ambient temperatures
below -10 C the oil change intervals specified in
the table must be halved. For fuels with a sulphur
content of more than 1% you should consult the
responsible service agency.
Fuels
Quality
You should only use commercially available brand
diesel fuel with a sulphur content below 0.5% and ensure strict cleanliness when filling in. A higher sulphur
content has a negative effect on the oil change intervals. Use only winter-grade diesel fuel under low ambient temperatures. The fuel level should always be
topped up in due time so that the fuel tank is never run
dry, as otherwise filter and injection lines need to be
bled.
When using fuels with a Cetan number < 49 poor
starting and white smoke can be expected, in particular in connection with low ambient temperatures.
The following fuel specifications are permitted: DIN/
EN 590; DIN 51 601; Nato Codes: F-54, F-75; BS
2869: A1 and A2; ASTM D 975-78: 1-D and 2-D.
l
DIN/EN 590
BS 2869
ASTM D 975-78: 1-D and 2-D.
Nato Codes: F-54, F-34, F44 und XF63
Winter fuel
Fig. 13
Diesel fuels must never be mixed with gasoline.
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.
ACEA1
E3-96/E5-02
E4-99
For winter operation use only winter diesel fuel, to

avoid clogging because of paraffin separation. At very
low temperatures disturbing paraffin separation can
also be expected when using winter diesel fuel.
In most cases a sufficient cold resistance can also be
achieved by adding flow enhancing fuel additives.
Consult the engine manufacturer.
= 500 operating hours
European Engine Oil Sequences
008 911 63
Danger
Fire hazard!
!
With their better temperature and oxidation stability

synthetic lubrication oils offer quite a few benefits.
BOMAG
American Petroleum Institute
41
2.4
Operation with rape seed oil methyl ester (RME

Bio Diesel)
cording to ISO 6743/3. The viscosity index (VI) should

be at least 150 (observe information of manufacturer).
Due to the extreme quality differences of RMEW-fuels

available on the market, which are caused by the nonexistence of a standardization, BOMAG does generally not approve any RME-fuels. If this is neglected the
warranty will become null and void!
Bio-degradable hydraulic oil
However, if you still intend to operate the machine

with RME-fuels you should observe the following information:
l
Reduced engine power (approx. 7%), higher fuel

consumption.
The quality of RME-fuel should be in compliance

with DIN draft 51606.
Avoid longer periods of standstill (formation of resin,
corrosion in injection system)
RME-fuel can damage the paint finish of the machine.
Fuel dilution of engine oil, therefore shortening of oil

change intervals to half.
Rubber parts, such as leak fuel return lines, seats

will be damaged in the long run and need to be replaced on a regular basis or should be replaced by
parts made of fluorinated rubber. However, fluorinated rubber is not resistant against normal diesel
fuel.
If the fuel filter is clogged the filter change intervals
must be shortened accordingly.
On request the hydraulic system can also be filled with

ester based biodegradable hydraulic oil (Panolin HLP
Synth. 46). The biologically quickly degradable hydraulic oil 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 manufacturer for details.
Check the filter more frequently after this change.
Caution
Oil change bio-degradable hydraulic oil:
!
Perform regular oil analyses for content of water

and mineral oil.
Replace the hydraulic oil filter element every 500
operating hours.
Oil for drive axle

For the drive axle use only multi-purpose transmission
oil of API-class GL5 with viscosity class SAE 90.
The additives in this oil ensure low wear lubrication
under all operating conditions.
Coolant, anti-freeze agent
Lubrication grease
Use only soft tap water (drinking water) to prepare the

coolant mix.
For lubrication use only EP-high pressure grease, lithium saponified (penetration 2).
As a protection against frost, corrosion and boiling

point anti-freeze agents must be used under any climatic conditions.
The proportion of cooling system protection agent
must be between min. 35% and max. 45% to the water.
Caution
Do not mix different coolants and additives of any
other kind.
!
Environment
Cooling system protection agents must be disposed of environmentally.
Hydraulic oil
The hydraulic system is operated with hydraulic oil HV
46 (ISO) with a kinematic viscosity of
46 mm2/s at 40C. 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 ac42
BOMAG
008 911 63
3 Connection overview
008 911 63
BOMAG
43
3.1
Connection overview
Fig. 1 Travel pump
44
BOMAG
008 911 63
3.1
Connection overview
1
Control solenoid, high frequency
21 Connection D, charge pressure to filter
Control solenoid, low frequency
Multi-function valve 400 bar (boost check and

pressure relief valve), travel system
22 Multi function valve 345 bar (boost check and

pressure relief valve), vibration drive high frequency
Connection, charge pressure to brake solenoid

valve, travel speed range selection and charge oil
supply for vibration pump
23 Connection S, suction line charge pump from hydraulic oil tank

24 Multi function valve 345 bar (boost check and
pressure relief valve), vibration drive low frequency
Multi-function valve 400 bar (boost check and

pressure relief valve), travel system
Setscrew, mechanical neutral position
Connection L, leak oil connection to vibration

pump
Lever, travel control
27 Connection L1, leak oil connection to travel pump
Pilot pressure test port
28 Pressure test port MB, high pressure reverse
25 Charge pressure relief valve, vibration pump

(blocked)
26 Connection E, charge oil from travel pump
10 High pressure port B, high pressure reverse
29 Charge oil from filter
11 Charge pressure relief valve, 26 bar
30 Pressure test port MA, high pressure forward
12 Adjustment screw, low frequency
31 High pressure port A, high pressure forward
13 Connection L2, leak oil to tank
32 Setscrew, mechanical neutral position, vibration
14 Pressure test port MB, high frequency
33 Leak oil connection D, leak oil from axle drive motor
15 High pressure test port MA, low frequency

16 High pressure port A, low frequency
17 High pressure port B, high frequency
18 Charge pump, internal
19 Connection L2, to drum drive motor (flushing)
20 Adjustment screw, high frequency
008 911 63
34 Leak oil connection A, leak oil from travel pump

35 Leak oil connection G, leak oil from drum drive
motor
36 Leak oil connection F, leak oil from vibration motor
37 Radiator inlet
BOMAG
45
3.1
46
Connection overview
BOMAG
008 911 63
4 Tests and adjustments
008 911 63
BOMAG
47
4.1
Special tools, tests and adjustments

4.1 Special tools, tests and adjustments
1. Vibration reed frequency meter
1000 - 4000 rpm
17 - 67 Hz
BOMAG part-no.: 300 120 80
Fig. 1
2. Sirometer (frequency meter)

800 - 50.000 rpm
14 - 750 Hz
Fig. 2
3. Anti-freeze tester, quick and accurate measuring,

sturdy plastic housing, automatic temperature
correction, no after-dripping, instructions for use
on unit, reading down to -40 C. Material: Plastic,
Temperature range: down to -40 C
Fig. 3
4. Digital rpm-meter for petrol engines

Fig. 4
48
BOMAG
008 911 63
4.1

5. Digital rpm-meter for petrol engines
Fig. 5
6. Digital rpm-meter, optical/mechanical, universal

use
Fig. 6
7. Infrared manual thermometer, -18 to 275C

Fig. 7
8. Hydraulic test case, large

i Note
4 X 600 bar pressure gauges
4 X 60 bar pressure gauges
8 pressure test hoses
Fig. 8
008 911 63
BOMAG
49
4.1

9. Hydraulic test case, small
i Note
1X 25 bar pressure gauge
1X 150 bar pressure gauge
2X 400 bar pressure gauges
4 pressure test hoses
Fig. 9
10. Pressure test hoses

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

60 bar BOMAG part-no.: 059 721 07
600 bar BOMAG part-no.: 059 721 04
Fig. 11
12. Adapter for pressure test hose

Fig. 12
50
BOMAG
008 911 63
4.1

13. Gear pump testing device
Fig. 13
14. Vacuum pump for hydraulic oil tank

BOMAG part-no.: 007 610 04 (12 Volt)
BOMAG part-no.: 007 610 24 (24 Volt)
Fig. 14
008 911 63
BOMAG
51
4.2
Checking the rotation speeds

4.2 Checking the rotation speeds
Special tools
Vibration reed frequency meter, RPM-meter for
diesel engines.
Caution
Perform measurements at operating temperature of the hydraulic oil (50 C).
!
1. Drive the machine with both drums on an elastic

base (rubber buffers) (Fig. 1).
2. Block the wheels with suitable chocks.
Fig. 1
Check the engine speed
i Note
If necessary, the engine speed may also be
checked with the vibration Reed frequency meter.
1. Connect the RPM-meter to the injection line (Fig.
2).
2. Run the engine with maximum speed.
3. Apply the brake.
4. Measure the rotation speeds.
Nominal value idle speed:
Low idle speed, see technical data.
High idle speed, see technical data.
5. Switch the vibration on .
Nominal value nominal speed:
Fig. 2
See technical data.

Evaluation of test
If the nominal value is not reached, perform trouble shooting for the engine.
52
BOMAG
008 911 63
4.2
Checking the rotation speeds
Checking the exciter shaft speed

1. Switch the vibration on at max. engine speed.
2. Apply the brake.
3. Measure the speed of the vibrator shaft, rest the
tester on your thumb (Fig. 3).
Nominal value:
See technical data.
Evaluation of test
If the nominal value is not reached, perform trouble shooting in the vibration circuit.
Fig. 3
008 911 63
BOMAG
53
4.3
Checking / adjusting the neutral positions of the travel pump

4.3 Checking / adjusting the neutral positions of the travel pump
Special tools
Hydraulic test case
Caution
!
1. Block drums and wheels with suitable chocks

(Fig. 1).
Fig. 1
2. Unhook the travel cable (Fig. 2) from the pump.
Fig. 2
3. Pull the plug (Fig. 3) off the brake solenoid valve

to close the brake.
Fig. 3
54
BOMAG
008 911 63
Checking / adjusting the neutral positions of the travel pump
4.3
4. Connect 600 bar pressure gauges to high pressure test ports MA and MB (Fig. 4).
Fig. 4
5. Connect the control chamber ports X3 and X4

(Fig. 5) with a hose
Fig. 5
6. Start the engine and run it with maximum speed.

Nominal value
Both pressure gauges (Fig. 6) must show equal
pressure (charge pressure).
Note
If necessary repeat the pressure test with 60 bar
pressure gauges, for more accurate readings.
Fig. 6
Evaluation of test
If pressure builds up on one side, adjust the mechanical neutral position (Fig. 7), until the pressures on both pressure gauges are identical.
Fig. 7
008 911 63
BOMAG
55
4.4
Pressure tests in the travel circuit

4.4 Pressure tests in the travel circuit
Special tools
Hydraulic test case
Caution
!
1. Block drums and wheels with suitable chocks

(Fig. 1).
Fig. 1
2. Pull the plug (Fig. 3) off the brake solenoid valve

to close the brake.
Fig. 2
3. Connect 600 bar pressure gauges to the high

pressure test ports for "forward travel" and "reverse travel" and a 60 bar pressure gauge to the
charge pressure test port (Fig. 2).
5. Read charge and high pressure gauges.
Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = charge pressure at high
idle
Fig. 3
Evaluation of test
If the nominal value is not reached, check the
steering/charge pump.
56
BOMAG
008 911 63
4.4
Pressure tests in the travel circuit
Measurement with quickly operated travel lever

6. Move the travel lever (Fig. 4) quickly forward,
read the pressure gauge.
Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = pressure override
Evaluation of test
If the specified high pressure is not reached,
check the travel pump.
Fig. 4
If the charge pressure drops considerably during

the high pressure test, check the components individually.
008 911 63
BOMAG
57
4.5
Checking / adjusting the vibrator shaft speeds

4.5 Checking / adjusting the vibrator shaft
speeds
Special tools
Vibration reed frequency meter
Caution
!
1. Drive the machine on an elastic base (rubber

buffers) (Fig. 1).
2. Apply the parking brake and block the wheels additionally with suitable chocks.
4. Switch on vibration high frequency / low amplitude or low frequency / high amplitude.
Fig. 1
5. Measure the speed (Fig. 2), rest the tester on

your thumb.
Nominal value
high amplitude/
low frequency = see technical data
low amplitude/
high frequency = see technical data
Evaluation of test
In case of deviations exceeding 10% determine
the cause, perform trouble shooting for engine /
vibration circuit and check vibration motor.
Fig. 2
6. Adjust the speed on the corresponding adjustment screw (Fig. 2).
i Note
Turning the adjustment screw in reduces the
speed, turning the screw out increases the
speed.
Fig. 3
58
BOMAG
008 911 63
4.6
Pressure measurements in the vibration circuit
4.6 Pressure measurements in the vibration circuit

Special tools
Hydraulic test case
Caution
!
1. Drive the machine with both drums on an elastic

base (rubber buffers) (Fig. 1).
2. Block the wheels with suitable chocks.
3. Apply the brake.
Fig. 1
4. Connect a 60 bar pressure gauge (Fig. 2) to the

charge pressure test port.
5. Connect a 600 bar pressure gauge each to the
high pressure test ports for "high amplitude" and
"low amplitude".
7. Switch on vibration with high or low frequency.
Nominal value
Charge pressure = charge pressure at high idle
(see technical data of travel pump).
Start-up pressure = vibration pump start-up pressure (see technical data of vibration pump).
Fig. 2
Operating pressure = vibration pump operating

pressure (see technical data of vibration pump).
Evaluation of test
If the charge pressure drops, check the components individually.
If the starting pressure is not reached, check the
vibration pump.
If the starting pressure is only reached for one frequency, check the high pressure relief valves.
008 911 63
BOMAG
59
4.7
Check the leakage rate of the vibration motor

4.7 Check the leakage rate of the vibration
motor
Caution
!
1. Drive the drum of the machine on an elastic base

(rubber buffers) (Fig. 1) and block the wheels additionally with suitable chocks.
2. Apply the brake.
Fig. 1
3. Block the flushing valve (Fig. 2) with washers.
Fig. 2
4. Disconnect the leak oil hose (Fig. 3), connect a

measuring hose and hold it into a measuring
beaker.
6. Switch the vibration on and measure the running
out leak oil during one timed minute.
Nominal value
max. 1.5 litre/min
Evaluation of test
If the permissible leak oil rate is exceeded, replace the vibration motor.
Fig. 3
60
BOMAG
008 911 63
4.8
Pressure test in steering circuit

4.8 Pressure test in steering circuit
Special tools
Hydraulic test case, gear pump testing equipment

Caution
Perform measurements at operating temperature of the hydraulic oil (approx. 50 C).
!
Measurement 1
1. Connect a 600 bar pressure gauge to the steering
pressure test port (Fig. 1).
2. Start the engine and run it at idle speed.
Danger
Danger of crushing, do not access the articulation area of the machine!
!
3. Turn the steering against an end stop.

4. Read the pressure gauge.
Nominal value
see technical data, max. steering pressure of
Fig. 1
Evaluation of test 1
If the nominal value is reached, check the steering cylinder.
Measurement 2
5. Disconnect the hydraulic hoses from ports L and
R (Fig. 2) (machines with one steering cylinder)
on the steering cylinder and close them with
plugs.
Fig. 2
6. Disconnect the hydraulic hoses from ports L and

R (Fig. 3) (machines with two steering cylinder)
on the steering cylinders and close them with
plugs.
7. Start the engine and run it at idle speed.
8. Turn the steering wheel.
9. Read the pressure gauge.
Nominal value
see technical data for steering/charge pump.
Fig. 3
008 911 63
BOMAG
61
4.8
Pressure test in steering circuit

If the nominal value is reached, replace the steering cylinder.
If the nominal value is not reached, check the
10. Reconnect the hydraulic hoses to the steering
cylinders.
Measurement 3
11. Actuate the emergency stop switch.
Fig. 4
12. Close the pump outlet port (Fig. 5) with the gear
pump test equipment.
13. Crank the engine with the starter
Nominal value
see technical data for steering/charge pump.
If the nominal value is reached, replace the steering valve.
If the nominal value is not reached, replace the
Fig. 5
62
BOMAG
008 911 63
5 Flushing and bleeding
008 911 63
BOMAG
63
5.1
Special tools for flushing

5.1 Special tools for flushing
1. Filling and filtering unit with oil bag
2. Filter element
Fig. 1
3. Flushing filter (S connection)

4. Filter element 1
5. Flushing hose 20S - 25S (2 pieces)
6. Screw socket R1 - 25S (2 pieces)
Fig. 2
7. Flushing filter (L connection)

8. Filter element
9. Flushing hose 15L (2 pieces)
10. Screw socket R3/4 -- 15L (2 pieces)
Fig. 3
11. SAE-flange 1 - 20S

12. O-ring
BOMAG part-no. 062 203 30
Fig. 4
64
BOMAG
008 911 63
5.1

13. Flanged plate 1 - 25S
14. O-ring
BOMAG part-no. 062 202 22
Fig. 5
15. Reducing fitting 18L - 15L

Fig. 6
16. Reducing fitting 25S - 20S

Fig. 7
17. Reducing fitting 20S - 16S

Fig. 8
008 911 63
BOMAG
65
5.1

18. Connecting socket 15L
Fig. 9
19. Connecting socket 18L

Fig. 10
20. Connecting socket 16S

Fig. 11
21. Connecting fitting 20S

Fig. 12
66
BOMAG
008 911 63
5.1

22. Connecting fitting 25S
Fig. 13
23. Angular fitting 18L

Fig. 14
24. Elbow fitting 16L

Fig. 15
25. Elbow 20S

Fig. 16
008 911 63
BOMAG
67
5.1

26. Elbow 25S
Fig. 17
27. Pipe connection 16S - 16S

Fig. 18
28. Connecting hose 15L

Fig. 19
68
BOMAG
008 911 63
5.2
Flushing - general
5.2 Flushing - general
Clean the hydraulic tank
Caution
Solid particles in the circuit will very quickly
cause damage to machine components.
!
Environment
Environmental damage
Catch running out hydraulic oil and dispose
of environmentally.
Changing a component
Fig. 2
Caution
Always flush the complete oil circuit after
you have replaced a component.
!
Caution
Change the oil in case of excessive contamination, oil discoloration or if the oil change
interval is almost due.
!
Chips (abrasion) in the oil

l
Open and clean all components in the oil

circuit, replace if necessary.
Filter the tank content with the filling and filtering unit and pump it into the oil bag.
Clean all high pressure hoses in the oil circuit, replace if necessary.
Mark all hoses and disconnect them from

the hydraulic oil tank.
If abrasion is found in the travel circuit you

should also flush the vibration circuit.
Clean the oil tank thoroughly from inside, if

necessary remove the complete tank cover.
If abrasion is found in the vibration circuit

you should also flush the travel circuit.
Reconnect all hoses.
Fill the hydraulic oil tank again with the filling and filtering unit.
Before flushing
Bleeding
Change the filter element
Fig. 3
Fig. 1
l
Change the hydraulic oil filter element (1).
008 911 63
BOMAG
Always bleed closed hydraulic circuits if

lines had been removed or connected.
69
5.2
Flushing - general
Servicing the flushing filter kit
Fig. 4
70
Replace the filter element of the flushing filter when the red control pin of the contamination indicator is pressed out during the
filtering process.
Clean hoses and connections and store the

flushing kit in a clean and protected environment.
BOMAG
008 911 63
Flushing schematic travel circuit (distribution travel pump)
008 911 63
BOMAG
5.3
71
5.3
Flushing schematic travel circuit (distribution travel pump)
Elbow union (tool)
Connecting union (tool)
Drum drive motor
Axle motor
Screw socket R1 - 25S (tool)
Flushing hose 25S - 20S (tool)
Flushing filter with filter element 1 (tool)
Elbow union (tool)
13 High pressure hose (A, drum drive motor forward)

14 High pressure hose (B, axle motor reverse)
15 High pressure hose (A, axle motor forward)
17 High pressure port (B, drum drive motor reverse)
18 Flushing hose 25S - 20S (tool)
10 Reducing fitting (tool)

11 Travel pump
12 High pressure hose (B, drum drive motor reverse)
72
BOMAG
008 911 63
Flushing the travel circuit (travel pump distribution)
5.4
5.4 Flushing the travel circuit (travel

pump distribution)
Flushing the drum drive
Replacing the hydraulic oil filter element
Cleaning the hydraulic oil tank
i Note
Observe the chapter "Flushing - General"
Installing the flushing filter
Caution
Before the installation of the filters check hoses and connections for cleanliness.
!
The flushing filter must be installed in the low

pressure side in the return flow to the pump,
so that only cleaned oil will enter the travel
pump in forward travel.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
Fig. 1
1. Disconnect the high pressure hose 12 (see chapter "Flushing schematic - travel circuit") from the
travel pump (high pressure port 17) and connect
it with the flushing hose (7) (flushing filter inlet
"IN").
2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port 17) on the travel
pump.
Disconnect the drum drive motor
3. Take the drum drive motor out of the hydraulic circuit by joining the high pressure hoses (12 and
13) on the drum drive motor together.
Fig. 2
008 911 63
BOMAG
73
5.4

Bleeding the travel circuit
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 3
Flushing the hoses

4. Block drums and wheels with suitable chocks.
Fig. 4
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 5
Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
!
5. Start the engine and shift the travel lever to travel

direction forward.
6. Perform the flushing process at various engine
speeds for approx. 10 minutes.
7. Shut down the engine.
8. Reconnect the hydraulic hoses (12 and 13) to the
drum drive motor.
Fig. 6
74
BOMAG
008 911 63
5.4
Flushing the drum drive motor

Danger
Danger of accident!
!
The drum must rotate freely.

9. Jack up the front of the machine, so that the drum
can rotate freely.
10. Secure the rear wheels with chocks.
11. Pre-select the slow speed range.
Fig. 7
Note
flushing process.
Fig. 8
Caution
!
12. Start the engine, run it with maximum speed and

shift the travel lever to travel direction forward.
13. Run the flushing procedure for approx. 10 minutes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve forward travel.
Fig. 9
008 911 63
15. Remove the flushing filter and reconnect the high

pressure lines.
BOMAG
75
5.4

Flushing the axle drive
"IN").
17. Connect the flushing hose (19) (flushing filter outlet "OUT") to the (high pressure port 16) on the
travel pump.
Fig. 10
Disconnecting the axle motor

18. Take the axle drive motor out of the hydraulic circuit by joining the high pressure hoses (14 and
15) on the axle drive motor together.
Fig. 11
Note
Fig. 12
76
BOMAG
008 911 63
5.4
Flushing the hoses

Fig. 13
Note
flushing process.
Fig. 14
Caution
!
direction forward.
axle drive motor.
Fig. 15
Flushing the axle motor

Danger
Danger of accident!
!
Both wheels must be off the ground. The

wheels must be able to rotate freely.
24. Jack up the rear of the machine, so that the
wheels can rotate freely.
25. Secure the drum with wheel chocks.
Fig. 16
008 911 63
BOMAG
77
5.4
i Note
flushing process.
Fig. 17
Caution
!

Fig. 18

pressure lines.
31. Bleed the travel circuit (see corresponding chapter).
Keep circulating the tank content.
32. After completing the bleeding process circulate
the tank content with the filtering unit for another
15 minutes.
Function test
33. Check the hydraulic oil level in the tank, fill up if
necessary.
34. Check all connections for leaks with the engine
running (visual inspection).
35. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting
on a gradient.
36. Check all ports and connections for leak tightness
(visual inspection).
Fig. 19
78
BOMAG
008 911 63
Flushing schematic travel circuit (distribution axle motor)
008 911 63
BOMAG
5.5
79
5.5
80
BOMAG
008 911 63
008 911 63
BOMAG
5.5
81
5.5
82
BOMAG
008 911 63
5.5
Elbow union (tool)
13 High pressure hose (drum drive motor forward)
Drum drive motor
15 High pressure hose (A, axle motor forward)
Axle motor
17 not used
not used
not used
not used
10 Reducing fitting (tool)

11 Travel pump
12 High pressure hose (drum drive motor reverse)
008 911 63
BOMAG
83
5.6
Flushing the travel circuit (axle motor distribution)

5.6 Flushing the travel circuit (axle motor
distribution)
Flushing the drum drive
i Note
Caution
!

so that only cleaned oil will enter the travel
pump in forward travel.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
Fig. 1
"IN").
2. Connect the flushing hose (18) (flushing filter outlet "OUT") to the (high pressure port 16) on the
travel pump.
Disconnect the drum drive motor
3. Take the drum drive motor out of the hydraulic circuit by joining the high pressure hoses (12 and
13) on the drum drive motor together.
Fig. 2
84
BOMAG
008 911 63
5.6
i Note
Fig. 3
Flushing the hoses
i Note
flushing process.
Fig. 4
Fig. 5
Caution
!

direction forward.
drum drive motor.
Fig. 6
008 911 63
BOMAG
85
5.6

Flushing the drum drive motor
Danger
Danger of accident!
!
The drum must rotate freely.

9. Jack up the front of the machine, so that the drum
can rotate freely.
10. Secure the rear wheels with chocks.
Fig. 7
Note
flushing process.
Fig. 8
Caution
!

Fig. 9
86
BOMAG
008 911 63
5.6
Flushing the axle motor

Danger
Danger of accident!
!
Both wheels must be off the ground. The

wheels must be able to rotate freely.
15. Jack up the rear of the machine, so that the
wheels can rotate freely.
16. Secure the drum with wheel chocks.
Fig. 10
i Note
flushing process.
Fig. 11
!
Caution

Fig. 12

pressure lines.
22. Bleed the travel circuit (see corresponding chapter).
15 minutes.
008 911 63
BOMAG
87
5.6

Function test
necessary.
25. Check all connections for leaks with the engine
running (visual inspection).
26. Perform a test drive, load the travel system in forward and reverse, e.g. by driving uphill or starting
on a gradient.
Fig. 13
88
BOMAG
008 911 63
5.7
Flushing schematic for vibration drive
Elbow union (tool)
Vibration motor
SAE flange (tool)
Vibration pump
10 High pressure hose (B, high frequency)
11 High pressure hose (A, low frequency)
008 911 63
BOMAG
89
5.8
Flushing the vibration circuit

5.8

Note

Caution
!

so that only cleaned oil will enter the vibration
pump in high frequency.
For the connection schematic shown here the
vibration must always be filtered with "high
frequency / low amplitude".
Fig. 1
1. Disconnect the high pressure hose 10 (see chapter "Flushing schematic - vibration circuit") from
the vibration pump (4) and connect it with the
flushing hose (7) (flushing filter inlet "IN").
2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port A) on the vibration pump.
Disconnect the vibration motor
3. Take the vibration motor out of the hydraulic circuit by joining the high pressure hoses (10 and
11) on the vibration motor together.
Fig. 2
90
BOMAG
008 911 63
5.8

Bleeding the vibration circuit
i Note
Bleeding the vibration circuit, see chapter "Bleeding the vibration circuit".
Fig. 3
Flushing the hoses

Fig. 4
i Note
flushing process.
Fig. 5
Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
!
5. Switch on vibration with high frequency.

7. Flush the circuit for approx. 10 minutes, thereby
switch the vibration on and off at intervals of approx. 30 seconds.
Fig. 6
008 911 63

vibration motor.
BOMAG
91
5.8

Flushing the vibration motor
10. Unscrew the fastening screws for the vibration
motor and pull the motor out of the coupling.
Fig. 7
Note
flushing process.
Fig. 8
Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
!

12. Run the flushing procedure for approx. 10 minutes. Switch the vibration on and off at intervals of
approx. 30 seconds.
14. Remove the flushing filter and reinstall the vibration motor.
Fig. 9

15. Bleed the vibration circuit (see corresponding
chapter).
15 minutes.
92
BOMAG
008 911 63
5.8

Function test

necessary.
18. Test drive.
Fig. 10
008 911 63
BOMAG
93
5.9

5.9 Bleeding the travel circuit
Environment
Catch hydraulic oil and dispose of environmentally.
1. Install a pressure test hose to the charge pressure test port.
2. Install a pressure test hose each to the high pressure test ports.
Danger
The engine should not start.
!
Fig. 1
4. Hold the open ends of the pressure test hoses

(Fig. 2) into a container.
5. Operate the starter motor for approx. 30 seconds.
Wait one minute and repeat this procedure, until
oil starts to run out from the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 2
7. Unlock the emergency stop switch
Fig. 3
94
BOMAG
008 911 63
5.9
8. Connect a 60 bar pressure gauge to the charge

pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Pause for approx. 30 seconds and keep repeating this procedure, until the gauge shows a constant charge pressure reading.
Fig. 4
Caution
With the flushing filter installed shift the travel
lever only to travel direction forward, as otherwise the flushing filter will be subjected to
oil flow from the wrong direction.
!
Danger
Run the engine with idle speed.
!
10. Start the engine.

11. Shift the travel lever (Fig. 5) approx. 1/3 to forward direction.
Fig. 5
12. After approx. 1 to 2 minutes shut down the engine

for a minute.
i Note
This waiting time is necessary to allow air bubbles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep repeating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
008 911 63
BOMAG
95
5.10

5.10 Bleeding the vibration circuit
Environment
Catch hydraulic oil and dispose of environmentally.
1. Install a pressure test hose to the charge pressure test port.
2. Install a pressure test hose each to the high pressure test ports.
Fig. 1
4. Hold the open ends of the pressure test hoses

(Fig. 2) into a container.
5. Crank the engine approx. 10 seconds with the
starter motor. Wait one minute and keep repeating this procedure, until oil starts to run out from
the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 2
7. Unlock the emergency stop switch
Fig. 3
96
BOMAG
008 911 63
5.10
8. Connect a 60 bar pressure gauge to the charge

pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Wait for approx. 30 seconds and repeat the procedure, until the pressure gauge shows a constant charge pressure.
Fig. 4
Caution
With the flushing filter installed use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direction.
!
10. For bleeding switch on vibration with high frequency (Fig. 5).
11. Start the engine.
12. After running the engine 1 to 2 minutes pause for
approx. one minute.
Note
This waiting time is necessary to allow air bubbles to escape through the leak oil return line.
Fig. 5
13. After a waiting time of approx. 1 minute keep repeating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
008 911 63
BOMAG
97
5.10
98
BOMAG
008 911 63
6 Fundamental electrics
008 911 63
BOMAG
99
6.1
6.1
Understanding circuit diagrams
Wiring diagrams are graphical representations of circuitry conditions, related to the electrical system. They
do not contain any information about the actual type of
wiring, they only serve the purpose of visualizing the
circuitry logics.
The wiring diagram is indispensable for effective and
systematic trouble shooting in the vehicle wiring system. This plan provides the following information:
l
Number and type of individual elements in the examined electric circuit, such as plug connectors,
fuses, switches, consumers, relays, ...
The sequence in which current flows through the individual elements in the electric circuit.
Connections between the examined, faulty electric

circuit and other circuits in the vehicle wiring system.
Pin assignment of plug-and-socket connections.
Structure:
l
Table of contents
Function groups
List of components
Table of contents
The table of contents lists all function groups.
Fig. 6 Table of contents
Example:
Function group "Warning systems, drawing number
XXX XX can be found on page no. 8.
100
BOMAG
008 911 63
6.1

Function groups
On the individual pages the electric circuits are combined to function groups.
From top (plus potential) to bottom (minus potential).
From left to right.
From function group to function group.
Via cross references for potentials and relays.
Arrangement of current paths

The individual current paths must be read as follows:
Fig. 7 Function groups
Relay cross reference
Potential cross references
Relay cross references serve the tracking of signals,

which need to be tracked for components with outgoing contacts.
Potential cross references serve the purpose of tracking signals, which are transmitted from one function
group to another.
Example:
Potential "15" on page no. 6 is continued to the left on
page no. 4 in current path "10" and to the right on page
no. 8 in current path "1.
A mimic diagram with information about the contact

types of a relay and their positions in the wiring diagram is additionally attached to the bottom of each
contactor coil.
Example:
The coil of relay (K99) is located on page no. 8 in current path "6".
The mimic diagram under the relay informs that a
change-over switch with contact types 30, 87 and 87a
is triggered.
The changeover contact can be found on page no. 8
in current path "3".
008 911 63
BOMAG
101
6.1
Current paths
The pages of a circuit diagram are sub-divided into
current paths (Fig. 8) (0 ..... 20).
Fig. 8 Current paths
List of components
Here you find all components used in alphabetical order, related to the name of the component (A01,
A02....).
Fig. 9 List of components
Component cross references

Example:
The warning horn "B 11" is located on page no. 8 in
current path 3.
102
BOMAG
008 911 63
6.1

Graphic symbol
Graphic symbols are standardized representations for
electrical appliances. They serve the purpose of a
simplified representation of complete systems, from
which, however, the function can be clearly identified.
This standardization is in compliance with the globally
valid regulations of the IEC (International Electrical
Commission). For Germany these symbols were included in the DIN-Standard. The standardization
serves the purpose of global understanding and fault

free connection of appliances, especially in automobile repairs.
Since the wiring diagram is intended to show only the
most essential aspects, the graphic symbol only
shows as much of the function, as is needed for easy
recognition and for the avoidance of mistakes.
Fig. 10 Graphic symbol
Current source
Conductor
Switch
Ground
Filament lamp
Filament lamp with two luminous elements
Voltmeter
Amperemeter
Resistance
10 Backup
11 Line connection (fixed)
12 Line connection (separable)
Fig. 11 Graphic symbol
Diode
Transistor
NPN-Transistor
changeable resistance
Condenser
Working current relay
008 911 63
BOMAG
103
6.2
6.2
Terminal designations
For easier connection work almost every connection

on a consumer or switch used in a motor vehicle has
a terminal designation. In Germany the designation of
the individual connection terminals is determined by

the standard DIN 72552. The following table represents a section with the most important terminals from
this standard.
Terminal designation
1
1a
1b
Meaning
Short circuit terminal (magneto ignition)
4
4a
4b
Ignition coil, ignition distributor high voltage

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

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

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

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

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

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

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

Battery changeover relay, output for starter control
Starter control, parallel operation of 2 starters with sequence control
104
Ignition coil, ignition distributor low voltage

Ignition distributor with 2 separate electric circuits, to ignition timer 1
Ignition distributor with 2 separate electric circuits, to ignition timer 2
BOMAG
008 911 63
6.2
50c
Meaning
Start relay for sequence control of engagement current in parallel operation of 2
starters, input in starter relay for starter 1
50d
50f
50g
50h
Start relay for sequence control of engagement current in parallel operation of 2

starters, input in starter relay for starter 2
Start locking relay, input
Start locking relay, output
Start repetition relay, input
Start repetition relay, output
51
51a
A.C.-generator, direct voltage on rectifier

A.C.-generator, direct voltage on rectifier with reactance coil for day travel
52
Trailer signals: further signals from trailer to towing vehicle
53
53a
53b
53c
53e
53i
Wiper motor input (+)

Wiper motor (+) end limit shut down
Wiper shunt winding
Electric windscreen washer pump
Wiper, braking effect
Wiper motor with permanent magnet and 3rd brush for higher speed
54
54g
Trailer signals, trailer plug device and lamp combination, brake light
Trailer signals, compressed air valve for permanent brake in trailer, electromagnetically operated
55
Fog light
56
56a
56b
56d
Head light
Head light, travel light and travel light control
Head lights, dimmed head light
Head lights, flash light
57
57a
57L
57R
Parking light for motor cycles (abroad also for cars and trucks)
Parking light
Parking light left
Parking light right
58
58b
58c
58d
58L
58R
Side lights, tail light, number plate light, dashboard light

Tail light changeover for single axle trailers
Trailer plug for single core wired and trailer fused tail light
Adjustable dashboard light, tail light and side light
Side light, left
Side light, right
59
59a
59b
59c
A.C.-generator (magneto generator), alternating voltage output or rectifier input

A.C.-generator, charging armature output
A.C.-generator, tail light armature output
A.C.-generator, brake light armature output
61
Generator control
71
71a
71b
Intermittent tone control unit, input

Intermittent tone control unit, output to horn 1 + 2 (low)
Intermittent tone control unit, output to horn 3 + 4 (high)
72
Alarm switch (flashing beacon)
008 911 63
BOMAG
105
6.2
75
Meaning
76
Loudspeaker
77
Door valve control
81
81a
81b
Switch (breaker and two-way contact), input

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

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

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

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

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

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

Relay contact on maker and two-way contact, (maker side) output 1
Relay contact on maker, input 1
B+
BD+
DDF
DF1
Battery Plus
Battery Minus
Dynamo Plus
Dynamo Minus
Dynamo field (generator excitation current)
Dynamo field 1 (generator excitation current)
106
Radio, cigarette lighter
BOMAG
008 911 63
6.2
DF2
Meaning
U
V
W
Three-phase generator, three-phase terminal

C
C0
C2
C3
L
R
Travel direction indicator (flasher relay) control light 1

Main connection for control light separated from flasher relay
Travel direction indicator (flasher relay) control light 2
Travel direction indicator (flasher relay) control light 3 (e.g. for 2 trailer operation)
Indicator left
Indicator right
008 911 63
Dynamo field 2 (generator excitation current)
BOMAG
107
6.3
6.3
Current and voltage
Current and voltage
The following statements concerning electric voltage can be made
General
If one wants to describe electric current, this can most
simply be accomplished by means of a comparison:
One simply compares electric current with water.
electric voltage is the pressure or force applied to

free electrons.
the electric voltage is the cause of electric current
electric voltage is a result of the equalization attempt of electric charges.
Voltage is measured with a Voltmeter.
Voltage
Unit, Volt
The electric voltage (U) is measured in Volt (V).
Fig. 1
(Fig. 1) Charge
Voltage
Current
The equalization attempt between different electric

charges is referred to as electric voltage.
Voltage sources have two poles of different charge.
On the one side we have the plus pole with a lack of
electrons, on the opposite side the minus pole with a
surplus of electrons. This electric "pressure" is known
as electric voltage.
Fig. 2
If there is a connection between these two poles a discharge will take place, resulting in the flow of an electric current.
Plus pole= lack of electrons
Minus pole = excess of electrons
108
BOMAG
008 911 63
6.3
Current and voltage

Current
Types of current
Electric current generally describes the directed

movement of charge carriers.
Direct current (D.C.)
The charge carriers may either be electrons or ions.
Electric current can only flow if there is a sufficient

amount of free moving charge carriers.
The higher the number of electrons flowing through

a conductor per second, the higher the amperage.
Current is measured with an ammeter.

Unit, Ampere
Fig. 1 Direct current (D.C.)
The electric amperage (I) is measured in Ampere

(A).
Direct current flows with steady voltage and amperage from the plus to the minus pole.
The technical flow direction is specified from

PLUS to MINUS.
Note
Current actually flows from minus to plus, because the

current flow is made up of negatively charged electrons.
But since this was only discovered after the poles of a
current source had already been designated, the assumption that current flows from plus to minus was
maintained for historic reasons.
Pure D.C.-voltages are only delivered by accumulators or batteries.

The voltage in the vehicle wiring system is no pure
D.C.-voltage. Even without the generator running, but
the consumers switched on, the voltage is not constant, but drops gradually according to the battery
charge condition.
The internal resistance of the battery also causes permanent changes in the vehicle voltage, as soon as
consumers are switched on or off.
Alternating current (A.C.)
Circuit
Fig. 2 Alternating current (A.C.)

Fig. 3 Circuit
A simple circuit consists of a current source 1 (Fig. 3),

a consumer (3) and the connecting wiring.
Alternating current not only changes its direction, but

also its amperage.
Pulsating direct current
When the circuit is closed, current can flow.

The circuit can be interrupted or closed with a switch
(2).
The system is protected by a fuse (4).
Fig. 3 Pulsating direct current
Converting alternating current into a direct current signal by means of a rectifier results in an pulsating direct
current.
008 911 63
BOMAG
109
6.3
Current and voltage
Pulse width modulation (PWM)
Fig. 4 PWM
The PWM signal is in most cases generated by a control and can be used to trigger proportional valves.
The signal (square wave signal) is changed in its
pulse control factor, the period, however, remains unchanged.
The following applies:
l
The signal voltage cannot be measured.
The current can be measured.
Caution
Solenoid valves must not be interference suppressed with suppressor diodes.
!
110
BOMAG
008 911 63
6.3
Current and voltage

Controller Area Network (CAN)
created by Bosch at the end of the eighties for automobile applications.
Development objectives:
Real-time critical, robust and low price communication

of control units, such as transmission and engine control, but also less time critical applications in the field
of convenience electronics, such as air conditioning.
Fig. 5 CAN
Characteristics of CAN
Why CAN?
It is a kind of serial data transmission. The individual

bits are transmitted one after the other, only 2 lines are
required.
Networking of control units for the realization of

complex functions.
Reduction of the extend of wiring and plug connections.
Better diagnostic possibilities (central diagnostics

socket).
CAN lines are twisted together 30 to 40 times per metre. Electromagnetic interferences therefore always
occur simultaneously in both lines, the software is
thus able to filter out interfering signals more easily.
Wire (+) = cable colour blue
Wire (-) = cable colour yellow
008 911 63
BOMAG
111
6.4
6.4
Resistance
Resistance
Resistance and voltage drop

While current flows through a conductor the current
flow is more or less inhibited by the conductor, this inhibitation is referred to as Resistance.
The cleaner the contacts, the better the current.
The quality of the ground cable is of the same importance as the supply line.
Unnecessary resistances
Unnecessary resistances are frequently caused by
mechanical connections, even clean ones, but mainly
soiled and oxidizes terminals, too thin cables, material
with poor conductivity or bent open cable lugs.
Bad
Fig. 1 Various size resistors
Each conductor has its specific resistance, which is

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

Better
Fig. 2 Spring clamps
Connecting clamps for flexible conductors

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

Symbol, R
Unit, Ohm
The electric resistance (R) is measured in Ohm .
Rule of thumb:
l
The thicker the cable cross-section, the lower the

voltage loss.
The shorter the cable, the better the current.
112
BOMAG
008 911 63
6.4
Resistance
Sometimes the flanks of flat plugs bend open. If these

are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely
break sooner or later. It is better to place a small nail
under the bottom of the cable lug before bending.
Fig. 3
In many cases it is better to replace the contact. Soiled

or oxidized contacts should be cleaned with Ballistol
(Fig. 4) and subsequently wetted with copper paste.
Copper paste is a heat resistant grease, which has
been mixed with copper powder. The paste protects
electric contacts against oxidation. Copper paste
keeps water away.
Fig. 5
Hint for practice:

A tool you cannot buy. The pliers were converted, the
nail is permanently present.
Fig. 4 Balistol oil
008 911 63
BOMAG
113
6.5
6.5
Series / parallel connection
In series connection the plus pole of the first battery

must be connected with the minus pole of the second battery.
The sum of all individual voltages is applied to the

free poles.
The total capacity (Ah) is identical with the capacity

of the individual battery.
Series connection
In a series circuit the resistors (consumers) are lined
up one after the other and the same current (I) passes
through each of the consumers However, series connection of consumers is not suitable in practice, as
each resistance causes a voltage drop. In the vehicle
wiring system all consumers are designed for the
same vehicle voltage (e.g. 12 Volt).
Fig. 1 Series connection
Current
In series connection the current is identical at every
point.
Itotal = I1 = I2 = I3
Voltage
The sum of all partial voltages is identical with the total
voltage.
Utotal = U1 + U2 + U3
Resistance
The sum of all partial resistances is identical with the
total resistance.
Rtotal = R1 + R2 + R3
Series connection of batteries
Fig. 2
In order to achieve a vehicle voltage of 24 V two batteries of the same type and capacity must be connected in series mode.
114
BOMAG
008 911 63
6.5

Parallel connection
All resistances (consumers) are supplied with the

same voltage.
In parallel connection the plus pole of the first battery is connected with the plus pole of the second
battery and the minus pole of the first battery with
the minus pole of the second battery.
Each of the resistances (consumers) draws as

much current as required.
Plus and minus poles have the voltage of the single

battery applied.
The total capacity (Ah) is identical with the sum of

all battery capacities.
In parallel connection all resistances (consumers) are

connected between feed and return line.
l
The disadvantage of a parallel connection becomes

apparent, by equalizing currents flowing between parallel batteries, if the batteries have different states of
charging.
Fig. 3 Parallel connection
Current
The total current is the sum of all currents.
Itotal = I1 + I2 + I3
Voltage
The voltage values are identical at every resistance
(consumer).
Utotal = U1 = U2 = U3
Resistance
The total resistance is less than the lowest individual
resistance.
Parallel connection of batteries
Fig. 4
By connecting 2 batteries of same type and capacity

in parallel mode the capacity can be doubled, because the individual capacities add up to the total capacity.
008 911 63
BOMAG
115
6.6
6.6
Ohm's law
Ohm's law
6.7
Electrical energy
In a closed electric circuit voltage, current and resistance must always be considered in close relation.
This relation is represented by Ohm's Law.
Fig. 1
In a closed electric circuit current and voltage generate energy.

Fig. 1
According to this law a voltage of 1V is required to let

1A (ampere) flow through a conductor with a resistance of 1 (Ohm ).
Advice
By means of this triangle the formula can be easily rearranged, the value you are looking form must just be
blanked off with a finger.
Voltage U = I multiplied with R
Resistance R = U divided by I
If a current of 1 Ampere flows at a voltage of 1 Volt,

energy of 1 Watt is produced.
Advice
By means of this triangle the formula can be easily rearranged, the value you are looking form must just be
blanked off with a finger.
Energy P = I multiplied with U
Amperage I = P divided by U
Voltage U = P divided by I
U = Voltage in Volt
Amperage I = U divided by R
U = Voltage in Volt
I = Current in Ampere
P = Power in Watt
I = Current in Ampere
R = Resistance in OHM
116
BOMAG
008 911 63
6.8
Formula diagram
6.8
Formula diagram
Example:
P = 150 Watt
Description:
U = 24 Volt
Select the desired value from the inner circle.
Determine the formula variables in the quarter circle
Calculate
Sought for = Current in Ampere

I = P : U = 150 W : 24 Volt = 6.25 Ampere
Fig. 1 Formula diagram
Resistance, R Ohm
Voltage, U Volt
Current, I Ampere
Power, P Watt
008 911 63
BOMAG
117
6.9
6.9
Metrology
Metrology
Multimeter
This tester is a multimeter and can be used to measure e.g. current, voltage and resistance. Depending
on the design it may also be suitable for transistor and
frequency.
Test lamps
Test lamp
Fig. 1 Multimeter
In order to avoid damage:

Fig. 1 Test lamp
Caution
This type of tester must not be used for testing on
electronic components. The high power consumption of the test lamp may destroy electronic
components in the control units.
!
Diode test lamp

This instrument is used for simple voltage measurements. The test lamp consists of two test points. The
negative measuring cable is connected to ground and
the positive measuring cable to the corresponding
measuring location.
the range selector switch must be correctly set for

the corresponding measurement.
the test cable must be plugged into the correct

socket.
the voltage type (AC/DC) must be set.
In case of direct voltage the correct polarity must be

assured.
the measuring range should be chosen higher at

the beginning of the test.
In order to avoid any influence on the circuitry to be

measured, the internal resistance of the voltage
tester should be as high as possible.
Resistance and continuity measurement with multimeter

The continuity tester of the multimeter can be used to
measure whether there is a connection between 2
measuring points. The following information should be
observed when measuring resistance and continuity:
l
The component to be measured must not be connected to the power supply during the measurement.
At least one side of the component to be measured

must be disconnected from the circuitry, as otherwise the measuring result may be influenced by
parallel components.
Polarity is of no significance.
Fig. 2 Diode test lamp
If voltage is present, the corresponding light emitting

diode will light up.
118
BOMAG
008 911 63
6.9
Metrology
Voltage and voltage drop measurement with multimeter
Clip-on measuring instrument

The clip-on measuring instrument can be used to
measure current, voltage and resistance.
Fig. 2 Voltage measurement

l
The meter is always connected parallel to consumer, component or power source.
Measurement at the voltage source measures the

currently available Voltage.
A measurement at the consumer measures the voltage drop at this component.
Current measurement with the multimeter

Fig. 1 Clip-on measuring instrument
l
For measuring current the individual conductor

must be fully enclosed by the measuring tongs, the
actual measurement takes place without contact.
Fig. 3 Current measurement

l
During the measurement the current must be able

to flow through the meter, i.e. the electric circuit
must be opened. The meter is connected in series
with the consumer.
Advice
If the electric circuit is difficult to access and the internal resistance of the consumer is known, the voltage
may also be measured at the consumer.
The current value can then be calculated with the help
of Ohm's law.
008 911 63
BOMAG
119
6.10
Diodes, relays, fuses
6.10 Diodes, relays, fuses
Magnet tester
Diodes
Fig. 1
Fig. 1 Magnet tester
The magnet tester is used to test solenoid valves and

magnetic coils.
A diode consists of two different semi-conductors,

which are connected by a separating layer. The max.
conducting state current must not be exceeded.
The test lamp responds to the magnetic fields of A.Cvoltage, D.C.-voltage and permanent magnets.
Plus-voltage on diode:
The component to be tested does not need to be removed.
The magnetic coil can also be tested under a protective cap.
At 0.6 0.7 Volt (silicium diode) the diode becomes

conductive.
Negative voltage on diode:

l
The diode does not allow current to pass through.
Fig. 2 Marking of the cathode
Diodes are used:
120
For rectifying A.C. voltage.
For absorbing voltage peaks (free-wheeling diode).
For construction of logical circuits.
BOMAG
008 911 63
6.10

Diode logics and free-wheeling diode
Light emitting diodes
Fig. 4 LED
The light emitting diode, also referred to as LED, is a

semi-conductor diode, which generates (emits) light
during operation in forward direction. A semi-conductor crystal thereby emits a light signal, which is converged or scattered by the lenticular shape of the
head. Light emitting diodes are available in various
colours, sizes and shapes. They are for this reason
used as signal lamps. This component is constructed
of different semi-conductor crystals, depending on its
colour. It works like any other semi-conductor diode.
Fig. 3 Diode circuitry

l
The solenoid valve Y48 (Fig. 3) is supplied with

electric current when switch S34 is switched to position "1" or "2".
Solenoid valve Y20 is supplied, if the switch is in position "1".
Solenoid valve Y21 is supplied, if the switch is in position "2".
The three diodes V02 serve as free-wheeling diodes

with the function of of eliminating voltage peaks.
008 911 63
BOMAG
121
6.10
Relays
85 = Ground supply for coil

30 = Supply voltage
87 = Normally open contact
87a= Normally closed contact
Fuses
Fig. 1 Relays
Relays are commonly used to realize switching processes.

A free-wheeling diode prevents induction voltage from
flowing back from the coil into the vehicle wiring system, which would cause interference with electronic
components (control units).
With the possibility of using breaker - maker contacts
the effect of an information can be reversed.
Fig. 1
Fuses are used to protect lines and equipment against

overloads and short circuit. If the fuse is overloaded
the fusible wire heats up with increasing current, until
it finally melts.
Caution
Fuses must not be repaired or bridged.
!
The melting time at 23 C is:

l
approx. 1 hour with 1.5 times the rated current
approx. 1 minute with 2.5 times the rated current.
A 5 Amp fuse loaded with 1.5 times the rated current

(7.5 Amp) will finally melt after approx. 1.5 hours.
Yellow = 5 A
Brown = 7.5 A
White = 8 A
Red = 16 A
Blue = 25 A
Fig. 2 Relay circuitry
The windscreen wiper and washer motors can only be

operated via switches S20 and S21, when relay K32
is supplied with electric current (Fig. 2).
86 = Positive supply for coil
122
BOMAG
008 911 63
6.11
Batteries
6.11 Batteries
Battery maintenance
Battery accumulator
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 final discharging voltage of 10.5 Volt, as otherwise
there is a risk of sulphation, i.e. the generated lead
sulphate forms increasingly coarser crystals, which
will finally not react at all or only very sluggishly during
a subsequent charging process.
Fig. 1
In vehicles batteries are used to start the engine. The

ability to start the engine depends on the charge condition of the batteries.
Lead collectors or accumulators are secondary elements, i.e they can be recharged after discharging
electric current.
The basic element of a lead accumulator is the cell. It
contains the plate blocks consisting of positive and
negative plates. These plates are separated from
each other by separators.
All positive plates are arranged parallel to the plus
pole, the negative plates parallel to the minus pole of
the cells.
In the worst case the accumulator can only be disposed of after such an exhaustive discharge.
The following therefore applies for longer downtimes:
l
Remove the battery and store it in a cool, dry and

frost protected room.
Check the open circuit voltage on the battery at regular intervals (at least once every month).
Recharge immediately if the open circuit voltage

has dropped to 12.25 Volt (no rapid charging).
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?
Check for e.g. incorrect fastening, foreign bodies on

the battery mounting surface and similar.
Testing batteries with screw plugs

Checking the acid density:
l
The cells are filled with diluted sulphuric acid as

electrolyte (approx. 25 Vol% sulphuric acid in distilled water), also referred to as accumulator acid,
which has a density of 1.285 kg/dm3 at a temperature of +27 Celsius. 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 27C it will only be 1.18 kg/dm3.
With a lead cell the acid density is therefore a measure for the charge condition. This characteristic is
used to determine the charge condition of a lead
Fig. 2
All cells are filled with a conductive fluid, the electrolyte. For a 12 Volt battery 6 cells are connected in series.
Capacity
is a synonym for the amount of current taken up and
discharged by a battery over a specified period of
time.
008 911 63
BOMAG
123
6.11
Batteries
battery. The so-called acid tester (hydrometer) is

used for this purpose. In a battery of good condition
the acid density should be the same in all cells.
Acid density at 27 C in kg/dm3
l
1.25 -1.28, open-circuit voltage approx. 12.7 Volt.

Battery is charged.
1.20 -1.24, open circuit voltage approx.12.4 to 12.5

Volt, is 50% discharged. Charging is necessary.
1.19 and less, open circuit voltage less than 12.3

Volt. Battery is insufficiently charged. Battery needs
to be recharged immediately.
Fig. 4 Battery and generator tester
Note
If the current consumption during charging is not 1/20

of the nominal capacity (example 100 Ah battery:
100Ah x 1/20 = 5 A) or full charging of the battery results in a final acid density of only 1.24 kg/dm3 or less,
the battery shows normal wear by aging. The battery
was insufficient charging or exhaustive discharge.
The battery and generator tester comes with an 8-line

LC display with background illumination and is able to
print out test results via an (optional) integrated thermal printer.
Note
Before testing clean the poles and ensure good connection between clamps and poles.
The test program calculates the text messages "good"
or "replace" on the basis of the charge condition (derived from the battery voltage) and the currently available starting power of the battery. A battery with 45%
starting power may thus be rated good and another
one with 75% starting power as poor ("replace").
The starting power represents the ratio of detected
cold testing current to the entered cold testing current
of the battery.
The starting power can exceed 100%.
Fig. 3 Reading the acid level
l
Maximum permissible tolerance between highest

and lowest measuring value of the 6 cells: 0.03 kg/
dm3.
Testing batteries without screw plugs

On closed batteries the acid density cannot be measured, we therefore recommend testing with the following mobile tester:
124
BOMAG
008 911 63
6.11
Batteries
Charge condition with hydrometer
Fig. 5 Charge condition
Green = Charge condition >65%

Dark = Charge condition <65%
Light = Electrolyte level too low
! Danger
Danger of explosion!!! If the electrolyte level is too
low, the battery must no longer be charged.
008 911 63
BOMAG
125
6.12
Three-phase generator

General
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the vehicle with electric current at a steady voltage already
at idling speed.
Note
Three-phase generators must only be operated in

combination with regulator and battery.
Batteries must not be connected with reversed polarity.
Plus and minus cables must be disconnected during
rapid charging of the battery or electric welding on the
vehicle.
Caution
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 electronic equipment.
!
Fig. 6 Rotor with claw poles
The three stator windings (Fig. 7) are electrically offset

to each other by 120. The excitation of the magnetic
field requires direct current, which is fed to the rotor
via two carbon brushes and slip rings.
When disassembling the battery cable, the B+-nut

underneath 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 circuit and damage to the rectifier elements - the generator will be out of function.
The generator can only be operated with the battery connected. Under special conditions emergency operation 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. After cleaning the generator should
be operated for about 1 - 2 minutes to remove any
deposits of water from the generator.
In the generator the armature windings are located inside the stationary stator, whereas the exciter winding
is arranged on the internally revolving rotor (Fig. 6).
126
BOMAG
008 911 63
6.12
of the wave is allowed to pass, resulting in a pulsating

D.C. voltage.
Reverse current protection
The rectifier diodes also prevent discharging of the
battery via the stator windings. The current can only
flow from the generator to the battery.
Why does three-phase current need to be rectified
and how does this work?
There are a few components for which can either be
operated with alternating current or direct current, because they work independently from the current flow
direction.
This includes :
l
Incandescent lamps
Fluorescent lamps
Glow lamps
Electric heating elements.
There are also a few components that could be operated either with alternating current, direct current or
three-phase current, if the components were designed
accordingly.
Fig. 7 Stator with 3 windings
This includes :
l
Electric motors
Relays
Finally, a variety of important components solely require direct current. These will under no circumstances work with alternating or three-phase current.
This includes :
l
Accumulators
Control units
All electronics
Communication equipment.
Fig. 8 3-phase current
The generator first of all produces three-phase voltage / three-phase current.

The wiring diagram (Fig. 8) shows the 3 windings in Yconnection and the 6 associated rectifier diodes.
The diodes D1, D2, D3 are also referred to as minus
diodes, because they have B- as common connection
(minus plate).
The other diodes are the plus diodes.
The rectifier diodes have the effect that the negative
half-wave is suppressed and only the positive section
008 911 63
BOMAG
127
6.12
Charge control light
Voltage regulator
It has by no means the function to show whether the

ignition is switched on or off. It has the function of indicating that the generator works correctly. Under normal operating conditions the generator should work
and the charge control light should be off. The charge
control lamp receives (+) from the battery at one pole.
The other pole is connected to (D+), i.e. the (+) carbon
of the generator. If the generator is working correctly,
(+) is attached to both connections on the charge control lamp. Since there is no difference in voltage, no
current can flow, the lamp does not light up. If the generator does not work, current flows via the (+) carbon
through the armature winding, via the (-) carbon to
ground and from there back to the battery. The electric
circuit is closed, battery voltage is applied to the
charge control lamp and the lamp lights up. Since the
generator does not work when the engine is not running, the charge control lamp is not connected directly
to the battery, but via the ignition switch. When the ignition is off, the charge control lamp is dead.
A generator without regulator would just work light a

bicycle dynamo. The power output would increase
with rising speed. The voltage output would fluctuate
with the load. (In case of a bicycle dynamo the tail light
bulb is overloaded when the head light does not consume any power). The function of the regulator is the
provision of a uniform vehicle voltage, almost completely independent from speed and load of the generator.
Fig. 9 Regulator with diode plate and rectifier diodes
In most cases voltage regulators (Fig. 9) with carbon

brushes form a compact component. The voltage regulator is maintenance free and the wear of carbon
brushes is only so little, that they hardly ever need to
be replaced during the lifetime of a machine.
The regulator has the following function:
128
To maintain the vehicle voltage under any operating

conditions below 14.4 V.
To match the regulator voltage to the temperature.
Smooth rising of generator current when switching

loads (convenience function to avoid jerking of the
engine).
BOMAG
008 911 63
6.12
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 regulator, the wiring or the V-belt.
When the engine is at rest, the charge control light

must light up. If not, the lamp may probably be defective. Defects on generator or wiring are obviously
also possible.
The following points allow to contain faults in the voltage supply within certain limits.
l
Cable connections on the generator OK?
Fig. 10 Rotor
V-belt OK?
Remove the regulator with carbon brush.
Generator ground (engine ground) OK?
Contact the rotor slip ring with the tester points.
Pre-excitation from vehicle electronics OK?
The resistance should be between 3 and 6 OHM .
The rotor coils should not have continuity to ground.
Only if all criteria mentioned above are OK, the fault

must be in the generator itself. In this case it must be
replaced or the following trouble shooting procedure
must be performed.
Checking the stator
Measuring the charge current

l
All plug-and-socket connectors must be free of corrosion and intermittent contact.
The generator ground connection must be OK.
During the measurement switch on as many consumers as possible.
Attach the clip-on ammeter around the B+ line.
Gradually increase the engine speed.
The generator current must be at least as high as

the total current of all consumers.
Checking the rotor
Note
The rotor coils can only be measured in disassembled

state.
Fig. 11 Stator
Note
The stator coils can only be measured in disassembled state.
008 911 63
Measure the resistance of all three coils.
The coils should not have contact among each other.
BOMAG
129
6.12
Checking the regulator voltage with the generator

tester
Perform the measurement at raised engine speed.
The voltage (B+) should adjust itself at 13 to 14 Volt.
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. 12
The generator test assesses the regulator voltage and

the ripple factor of the generator voltage.
l
The battery should be in good condition the idle

speed voltage of the battery should be at least 12.6
Volt.
If possible switch off all consumers.
Perform the measurement at raised engine speed.
Checking the regulator voltage with the multimeter
Fig. 13
l
The battery should be in good condition the idle

speed voltage of the battery should be at least 12.6
Volt.
If possible switch off all consumers.
130
BOMAG
008 911 63
6.12
Checking the regulator in disassembled state
On a Bosch generator unscrew two fastening screws
for the regulator and lift the regulator off. For this work
the generator does not need to be removed.
The Delco-Remy generator needs to be removed
and partly dismantled, if the regulator needs to be disassembled. Unscrew the housing screws to do so.
Pull rotor with drive bearing and V-belt pulley out of
the stator. Unscrew the ends of the stator winding
from the diode carrier and separate the stator from the
collector ring bearing. Disassemble exciter diodes and
brush holders and remove also the regulator.
Fig. 15
E.g minus controlled regulator
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 diodes, terminal D+. This leaves one further terminal,
this is DF.
D+ (vehicle wiring system)
One connects the regulator (Fig. 15) with D+ and D- to

the power source, as shown in the illustration, and the
lamp to both carbon brushes, instead of the exciter
winding. When slowly increasing the voltage the lamp
will first become brighter, because the regulator allows all lamp current (= exciter current) to flow at voltage values up to 14.4V. Once the regulator voltage is
reached, the regulator switches the lamp current off.
When returning the voltage back below the control
voltage, the regulator will switch the lamp back on.
With this test the major difficulty is the problem to remove the regulator an identify terminals D+, DF and
D-.
D- (ground contact, mostly located on one of the fastening screws)

DF (Dynamo Field)
Fig. 16
Fig. 17
Fig. 14
l
If the carbon brush is connected to ground the regulator 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 illustrations (Fig. 16) and (Fig. 17) show two different regulator types.
The basic function of a disassembled regulator can be

easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).
008 911 63
BOMAG
131
6.12
Replacing the 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 brushes, insert these and fasten the regulator again. For
this work the generator does not need to be removed.
For replacing the carbon brushes in the DelcoRemy generator the generator needs to be disassembled and partly dismantled. The carbon brush
holder is located inside the collector ring bearing.
132
BOMAG
008 911 63
6.13
Electric starter
6.13 Electric starter

The starter converts the electric energy stored in the
battery into mechanical energy. The starter can only
generate its power when a battery with appropriate
capacity is available.
Duties of the starter:
to accelerate the combustion engine to start speed
with lowest possible current consumption.
Pinion
Roller free-wheeling
Steep thread
Guide ring
Spring winding
Armature
Pole shoe
Carbon brushes
Armature brake
to maintain this connection.
to switch on the starter current.
After starting the engine:

l
to return the starter pinion to initial position.
to switch off the starter current.
The contacts on starter terminals 30, 45, 50 must

be protected against unintended shorting (jump
protection).
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.
11 Magnetic switch
12 Engagement lever
Caution
So-called jump starting (using an additional external battery) without the battery connected is dangerous. When disconnecting the cables from the
poles high inductivities (arcs, voltage peaks) may
occur and destroy the electrical installation.
008 911 63
Starter motors must not be cleaned with high

pressure steam cleaning equipment.
10 Collector
establish the gear connection between starter and

combustion engine.
For purposes like e.g. purging the fuel systems,

starters may be operated for maximum 1 minute
without interruption. Then you should wait for at
least 30 minutes (cooling down) until trying again.
During the 1 minute starting period this process
should not be interrupted.
Fig. 1 Electric starter
Always disconnect the battery before starting assembly work in the starter area of the engine or on
the starter itself.
BOMAG
133
6.13
Electric starter
Function of pre-engaged-drive starting motor

This type of starter uses a solenoid to engage the pinion with the ring gear. The engaging solenoid contains
switching contacts for the starting current. When closing the starter switch, the relay holding winding is active and current flows also through the series
connection of pick-up winding and electric motor. The
engaging solenoid picks up and moves the freewheeling with the pinion forward via the engaging lever and the engaging spring. In case of a favourable
position of the pinion to the ring gear a tooth of the pinion will directly engage in a tooth gap. In this case the
pinion will engage over the entire length of the screw
path, until the contact bridge in the engaging relay
touches the relay contacts. The starter motor is no
switched on. However, if the pinion does not directly
find a tooth gap, the ring gear will block any further engaging movement. The engaging lever in this case
compresses the engaging spring and the main contact
closes, even though the pinion and the ring gear are
not engaged. The electric motor keeps rotating the
pinion in front of the ring gear face, until a pinion tooth
gap matches a tooth on the ring gear and the preloaded engaging spring moves pinion and free-wheeling
forward. When switching the relay winding off, the return spring forces the relay armature and the pinion
with free-wheeling back to rest position. This disengagement is supported by the steep thread.
Fig. 2 Switching position during engagement
Magnetic switch
The magnetic switch is normally arranged directly
above the starter.
Fig. 3 Switching position during starting
With the starter switch switched on, both the pickup

winding and the holding winding are energized and
shift the iron core in axial direction. With a lever this
iron core pulls the starter pinion towards the engine
flywheel.
Ground
Battery
Starter switch
Pull-in winding
Once the gears are engaged the starter current is applied to the back through a large cross-section. At the
same time the pickup winding is shorted via the starter
current and thus switched off as a measure to reduce
the load on the energy household.
Holding winding
Exciter winding
Restoring spring
Driver
Pinion
10 Flywheel
134
BOMAG
008 911 63
6.13
Electric starter
Trouble shooting "Starter"
Testing and measuring the electric starter
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 extremely high voltage losses in the overall starter system 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
worn off / soiled (scrape off carefully with a file and
clean)- the starter motor is defective / soiled (remove
armature and clean), cover cleaned, moveable parts
with grease.
The highest current flows when the starter is blocked!

(Short circuit current in starter). This is the case when
the pinion is engaged and the starter has the duty to
accelerate the flywheel to starting speed.
Function test with starter installed
l
Initiate the starting process and measure the voltage on the pickup solenoid switch (50a). At least
10.8 Volt should be applied.
When operating the starter switch the magnetic

switch must engage in the flywheel ring gear (noticeable clicking sound) and release the starting
current to the starter. On most magnetic switches
the voltage can be measured with the multimeter. If
this does not happen even though voltage is applied, replace the magnetic switch.
Frequently a jammed return mechanism is the reason

for a starter failure.
Occasionally worn contacts are found on the magnetic
return switch
Defects on the actual starter motor including pinion
and carbon brushes are very rare.
With a trouble shooting chart the faults in the starter
system can be narrowed down. The starter system
can only work when many conditions are fulfilled at
the same time.
Note
Function tests with disassembled starter

Caution
Before removing the starter you must disconnect
the ground cable from the minus pole of the battery while the ignition is switched off.
!
Check the wear on the carbon brushes and their

contact pressure.
Check the collector, it must not have electrical contact with the rotor shaft.
Emergency stop not actuated?
Check the drive pinion for excessive wear.
Battery sufficiently charged?
Battery poles OK?
Main battery fuse OK?
The return mechanism should not be tight, if necessary grease amply with silicon grease (Bosch PZ 2
V3) or a comparable grease.
l
l
Main battery switch closed?
Main starter cable (terminal 30) OK?
Measure the resistance of the magnetic switch main

contact in disengaged condition. Maximum value
0.2 OHM .
Starter control cable (terminal 50) OK, voltage

drop?
Ground cable OK?
Switching of magnetic switches OK?
Immobilizer deactivated?
Ignition switch OK?
Travel lever in correct position?
The sequence of these tests is generally of no significance. It mainly depends on:

l
the experience of the specialist
the failure probability of the component to be tested

and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault

must be in the starter itself. In this case it can be repaired or replaced.
008 911 63
BOMAG
135
6.14
Telemecanique switch
6.14 Telemecanique switch

Example of terminal designations
Fig. 1 Terminal designations

l
Normally open contact 23 located on block 2
Normally closed contact 12 located on block 1
Normally closed contact 11 located on block 1
Note
If e.g. block 5 is not needed to design a switch, the

numbering for blocks 1,2,3,4 and 6 remains unchanged.
136
BOMAG
008 911 63
6.14
Disassembly
Fig. 2 Disassembly
l
Lift up the interlock (5).
Fig. 4 Pulling out the front element

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

l
Fold down the switch block (4).
Loosen screw (1).
008 911 63
BOMAG
137
6.14
Assembly
Fig. 5 Assembly
Insert the front element (3) into the bore in the control panel.
Fig. 7 Assemble the switch block
Clip on the switch block (4).
Fig. 6 Observe the marks.
Clip the fastening adapter (6) onto the front element

(3).
Note
Hook in the switch block at the bottom first (Fig. 7).
Note
Watch the marls on front element (Fig. 6) and fastening flange.

l
Tighten the screw (1) with a tightening torque of 0.6

Nm.
138
BOMAG
008 911 63
6.15
Inductive proximity switches
6.15 Inductive proximity switches
NPN circuitry
General
In all automated sequences the use of sensors as a
source of information for the electronic control is indispensable. The sensors deliver the necessary signals
about positions, end positions, filling levels or serve as
pulse transducers for counting tasks or speed detection. In industrial applications inductive and capacitive
proximity switches are today indispensable. Compared with mechanical switches, they offer almost ideal prerequisites: non-contact, wear free operation,
high switching frequencies and switching accuracies,
as well as high protection against vibration, dust and
moisture. Inductive sensors detect all metals without
contact, capacitive sensors detect almost all solid and
liquid media, such as metal, glass, wood, plastic, water, oil, etc.
Fig. 10 NPN circuitry
On sensors with NPN-circuitry the output stage contains a NPN-transistor, which switches the load
against the negative operating voltage. The load is
connected between the output and the positive operating voltage.
Breaking and making contacts
Working principle
Fig. 8
The working principle is based on the principle of the

dampened LC-oscillator. The coil of the oscillation circuit forms a high-frequency magnetic stray field.
This stray field leaks out from the active area of the
proximity switch. If metal or non-ferrous metal enters
into the response range energy is absorbed. The oscillator is thus dampened and the resulting change in
current consumption is evaluated.
PNP circuitry
Fig. 11
Proximity switches are used as breaking or making

contacts. Depending on the design the switching distances are 2 or 4 mm. The maximum amperage is 300
mA.
The LED (Fig. 11) lights up, when the initiator has detected metal in its stray field.
Fig. 9 PNP circuitry
On sensors with PNP-circuitry the output stage contains a PNP-transistor, which switches the load
against the positive operating voltage. The load is
connected between the output and the negative operating voltage. The switch is designed with a normally
open contact, i.e. the contact closes when the initiator
comes in "contact" with metal.
008 911 63
BOMAG
139
6.16
Angle sensor with current output
6.16 Angle sensor with current output
Fig. 1 Sensor
Fig. 12 Circuit diagram, making contact
The circuit diagram (Fig. 12) shows a proximity switch

with normally open contact.
Brown = voltage supply
Blue = ground supply
Black = switching output
The initiator switches the relay (K05)
140
The the function of the angle sensor (Fig. 1) is based

on the so-called "Hall-Effect". Named after the American physicist E.H. Hall. Due to the fact that moving
electrons are deflected in a magnetic field, a voltage
transverse to the flow direction of the primary current
can be expected on a current conducting conductor in
the magnetic field. Since the electrons are deflected in
transverse direction by the magnetic field, they must
enrich on the one side and reduce on the opposite
side. If a very thin circuit board is now subjected to a
current that is uniformly distributed across its cross
section, no voltage will be measured between two
points A and B, which have an identical distance to the
current supply lines and are connected by a highly
sensitive galvanometer. When generating a magnetic
field vertical to the circuit board, voltage will be
present between A and B and a current will flow
through the galvanometer connected to these points.
This is referred to as "Hall-Effect". The cause for this
effect is the warping of the originally parallel electron
orbits in the board by the magnetic field.
BOMAG
008 911 63
6.17
Plug connectors
6.17 Plug connectors

Duties and requirements
Electric plug connectors must provide a reliable connection between different system components and
thus ensure the safe function of the systems under
any operating condition. There design ensures that
they will withstand the applied loads throughout the
lifetime of the machine.
Examples for these loads are:
Fig. 2 Connection diagram
Vibration acceleration
Temperature fluctuations, high and low temperatures
Dampness
Micro movements of the contact with resulting friction corrosion.
The angle sensor has 3 electric connections (Fig. 2).

Ub, supply voltage (+ 8.5 Volt)
Gnd, ground
Out, output current 4-20 mA.
These loads may increase the transition resistances

of the contacts, up to total interruption. Even the insulation resistances may drop and thus cause short circuits in neighbouring lines. Electric plug connectors
must therefore have the following properties:
at -35 = 4 mA output current
at 0 = 12 mA output current
Low transition resistances of the conductive parts.
at +35 = 20 mA output current.
High insulation strength between conductive parts

with different voltage potentials.
Excellent leak tightness against water and moisture.
008 911 63
BOMAG
141
6.18
Deutsch plug, series DT and DTM
6.18 Deutsch plug, series DT and

DTM
DT Series
General
Plug connectors DT and DTM have a wedge to hold
the pins and sockets in their position. This wedge can
be removed and replaced, without having to cut any
leads.
Fig. 1 DT plug connection
Fig. 3 Crimp connections

Fig. 2 DT Series
Caution
Do not crimp more than one lead per pin or per
socket.
!
Sockets and pins must not be soldered to leads,

they may only be crimped (see special tools for
electrics).
When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).
Fig. 3 Sectional drawing
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
l
Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force
of 45 N without any difficulties.
142
BOMAG
008 911 63
6.18

Installing DT contacts
Fig. 4
l
Insert the contacts through the rubber grommet until

they click into place.
Insert the orange wedge in direction of arrow.
Caution
Perform a pull test on each lead, each of the terminals and connections must withstand a pulling
force of 45 N without any difficulties.
!
Note
Use the same method when assembling the socket.
008 911 63
BOMAG
143
6.18
Disassembling DT contacts
Fig. 5
l
Pull the orange wedge out with long nose pliers.
Slightly pull the lead and unlock the interlocking

hook with a screw driver.
Pull the contact out of the socket.
Note

In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
144
BOMAG
008 911 63
6.18

DTM Series
Fig. 1 DTM plug connection
Fig. 2 DTM Series
Fig. 3 Sectional drawing
008 911 63
BOMAG
145
6.18
Installing DTM contacts
Fig. 4
l
Insert the contacts through the rubber grommet until

they click into place.
Insert the orange wedge, until it clicks into place.
Caution
Perform a pull test on each lead, each of the terminals and connections must withstand a pulling
force of 45 N without any difficulties.
!
Note
146
BOMAG
008 911 63
6.18

Disassembling DTM contacts
Fig. 5
l
Pull the orange wedge (interlock) out with long nose

pliers.
Slightly pull the lead and unlock the interlocking

hook with a screw driver.
Pull the contact out of the socket.
Note

In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
008 911 63
BOMAG
147
6.19
Plugs and terminals in spring clamping technology
6.19 Plugs and terminals in spring

clamping technology
General
Fig. 1
Spring clamp technology (Fig. 1) for quick, vibration

resistant and maintenance-free connection of all conventional copper conductors (single, multiple or fine
stranded) with or without wire and ferrule.
!
Caution
The spring clamp technology is not suitable for
extra fine conductors. Extra fine conductors can
be easily pulled out of the spring clamp!
148
BOMAG
008 911 63

Connecting terminal for quick repairs
6.19
Fig. 1 That's how it works
The connecting clamp clamps up to 3 or 5 stripped

fine conductors of 0.08 qmm bis 4 mm, single or multiple strand up to 2.5 mm. And this even without tools
(Fig. 2).
That's how it works
l
Strip 9-10 mm of the lead.
Open the actuating lever and insert the strand.
Return the actuating lever to initial position.
!
Caution
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without any difficulties.
Fig. 2 Connecting clamp
008 911 63
BOMAG
149
6.19
Series clamp
That's how it works

l
Insert a screw driver into the actuating opening until

it bottoms.
Strip 9-10 mm of the lead and insert it into the

clamp.
Pull out the screw driver.
Caution
!
Measuring signals
On these terminal blocks the bridge slot is most suitable for tapping off and measuring signals. Here you
may directly insert a 4 mm test adapter (see special
tools for electrics) for connecting a measuring lead.
This test adapter is standard in the central electrics of
heavy equipment machines.
Fig. 2 Test adapter
150
BOMAG
008 911 63

X-COM System
The X-COM-SYSTEM, a synthesis of plug connector
and series clamp, has grown up to a construction kit
6.19
for universal system wiring, ever since it was introduced in 1997. All the familiar series clamping functions have thus become pluggable.
X-COM plug clamp
That's how it works

l
Insert a screw driver into the actuating opening until

it bottoms.
Strip 9-10 mm of the lead and insert it into the plug.
Pull out the screw driver.
Caution
!
Measuring signals
Fig. 3 X-COM plug plugged onto the series clamp
Fig. 2 X-COM plug with measuring cable

l
The most reliable measurements on the plug can be

made when using the measuring and connecting
cable with 2mm plug (see special tools for
electrics).
008 911 63
BOMAG
151
6.19
152
BOMAG
008 911 63
7 Special tools, electrics
008 911 63
BOMAG
153
7.1

7.1 Special tools, electrics
Measuring equipment
14. Electric test case
Fig. 4
15. Multimeter
Fig. 5
16. Test prod black, with flexible insulated shaft and

button operated gripper with 4 mm bushing,
length 157 mm.
17. Test prod red, with flexible insulated shaft and
button operated gripper with 4 mm bushing,
length 157 mm.
Fig. 6
18. Test prod black, with elastic insulated shaft 4 mm

bushing, length 97.5 mm.
19. Test prod red, with elastic insulated shaft 4 mm
bushing, length 97.5 mm.
Fig. 7
154
BOMAG
008 911 63
7.1
20. Measuring and connecting lines with 4mm plug,

high flexible design, black, length 0.5 m.
high flexible design, black, length 1 m.
high flexible design, black, length 2 m.
Fig. 8

high flexible design, red, length 0.5 m.
high flexible design, red, length 1 m.
high flexible design, red, length 2 m.
26. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible design, black, length 300 mm.
and gold plated lamella plugs, high flexible design, black, length 600 mm.
and gold plated lamella plugs, high flexible design, red, length 300 mm.
Fig. 9

and gold plated lamella plugs, high flexible design, red, length 600 mm.
30. Transition plug connector, with 4 mm plug on one
side and 2 mm socket on the other, insulated design
Fig. 10
008 911 63
BOMAG
155
7.1

31. Magnetic coil tester
Fig. 11
32. Clip-on measuring instrument

Fig. 12
33. Battery - generator tester

Fig. 13
Spring clamps (Wago or Weidmller)

34. Cranked screwdriver (Fig. 14) to open spring
clamps (Fig. 15).
Fig. 14
156
BOMAG
008 911 63
7.1
35. Testing adapter to measure the signals from the

series spring clamps (Wago).
Fig. 15
Deutsch contacts
36. Tool to disassemble the interlocking on Deutsch
plugs (series DT and DTM).
Fig. 16
37. Crimping pliers for Deutsch contacts of series DT

and DTM, size AWG 20,16 and 12.
AWG 20 = 0.5 mm2 cable cross-section
AWG 16 = 1,5 mm2 cable cross-section
Fig. 17
38. Crimping pliers for Deutsch contacts of series

HDT, size AWG 6 and 8.
Fig. 18
008 911 63
BOMAG
157
7.1

39. Disassembly tool for Deutsch contacts of series
HDP.
AWG 20, BOMAG part-no.: 079 900 78
Fig. 19
ITT contacts
40. Installation tool for ITT crimp contacts of series
CA-COM, contact size 15S/16S/15/16.
Fig. 20
41. Disassembly tool for ITT male contacts of series

CA-COM, contact size 15S/16S/15/16.
Fig. 21
42. Disassembly tool for ITT female contacts of series CA-COM, contact size 15S/16S/15/16.
Fig. 22
158
BOMAG
008 911 63
7.1

Schaltbau contacts
43. Disassembly tool for Schaltbau contacts of series

M1, M2.
Fig. 23
44. Crimping pliers for Schaltbau contacts of series

M1, M2 with connecting cross-section 0.14 - 6.0
mm2.
Fig. 24
FCI Burndy contacts

45. Disassembly tool for FCI Burndy contacts of series TRIM TRIO
Fig. 25
AMP contacts
46. Crimping pliers for AMP-contacts of series FASTIN-FASTON with a connecting cross-section of
1.0 - 2.5 mm2 (18 -14 AWG).
Fig. 26
008 911 63
BOMAG
159
7.1

47. Crimping pliers for AMP-contacts of series SUPER-SEAL with connecting cross-section 0.75 1.25 mm2.
Fig. 27
48. Crimping pliers for AMP-contacts of series .070SERIES with a connecting cross-section of AWG
20 - 18 (0.5 - 0.9 mm2) and AWG 16 (1.25 - 1.5
mm2).
Fig. 28
49. Crimping pliers for AMP-contacts of series FASTON with connecting cross-section AWG 14 - 10.
Fig. 29
50. Crimping pliers for AMP-contacts of series FASTON with connecting cross-section AWG 16 - 14
and AWG 18.
Fig. 30
160
BOMAG
008 911 63
7.1
51. Disassembly tool for AMP-contacts of series CIRCULAR-CONNECTOR.

1.5 mm2, BOMAG part-no.: 079 900 74
2,5 mm2, BOMAG part-no.: 079 900 75
Spare sleeve 1.5 mm2, BOMAG part-no.: 079
900 76
Spare sleeve 2,5 mm2, BOMAG part-no.: 079
900 77
Fig. 31
Universal tools
52. Universal pressing pliers with toggle lever transmission and adjustable end pressure for Crimping roller connector 0.14 - 1.0 mm2.
Fig. 32
53. Precision pressing pliers for non-insulated flat

male and female connectors0.5 - 6,0 mm2.
Fig. 33
Measuring adapter
54. Current measurement adapter for Hirschmann
plugs.
Fig. 34
008 911 63
BOMAG
161
7.1

55. Voltage measurement adapter for Deutsch plugs,
8-piece (2 to 12 pole).
Fig. 35
56. Current measurement adapter for Deutsch and

AMP plugs, 2 pole.
Fig. 36
162
BOMAG
008 911 63
8 Electronic modules
008 911 63
BOMAG
163
164
BOMAG
008 911 63
8.1
008 911 63
Vibration module
BOMAG
165
8.1
166
Vibration module
BOMAG
008 911 63
8.1
Vibration module
008 911 63
BOMAG
167
8.1
168
Vibration module
BOMAG
008 911 63
9 Speedometer Module
008 911 63
BOMAG
169
170
BOMAG
008 911 63
9.1
Speedometer module
9.1
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 special 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 display range in both directions. The display self-test
takes approx. 15 seconds.
After this the module changes to measuring mode.

The frequency of the travel pulses of the roller is detected and converted to a proportional output voltage that triggers the display.
The output signal for the display is a PWM-signal.
Manual testing of the speedometer

When the module is in learning mode a manual display test can be performed via the input "Test". For
this purpose the input "IN" must be energized with 12
Volt, whereupon the speedometer is constantly triggered with 3 Volt.
008 911 63
BOMAG
171
9.1
Speedometer module
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 (-).
Connect the sensor signal (speed sensor) to frequency input (IN).
Install a cable bridge from terminal "15/54" to the

connection "Teach".
Connect potential "Ignition / 15" to connection "15/

54".
Switch on the ignition, start the engine and travel a

distance of exactly 10 m.
Caution
BW24RH, BW27RH, C550H and C560H = travel 18
meters.
!
All other machines = travel 15 meters.
Note
If the module is in teach mode the LED on output

"OUT +" will flash with the frequency of the path pulses arriving at input (IN).
l
Disconnect the cable bridge from "Teach" to "15/

54.
Switch the ignition off and on again (Reset).
The module has now learned the pulses of the

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

and "OUT .
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10 Service Training
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BOMAG
173
174
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10.1 Electrics BEM (BOMAG Evib-meter)
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175
10.1
Electrics BEM (BOMAG Evib-meter)
BOMAG Evib-meter (BEM)
Hinweis
The documentation "Service Training Electrics MESX" contains also the documentation BEM (BOMAG Evib-meter).
The BOP (BOMAG Operation Panel) is only installed in connection with BVC machines, BEM-machines are
equipped wit display module. The display module is used for the output of fault codes and display values, as
well as for the input of code numbers.
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Service Training
Electrics
MESX
Version 3.01
Status:
Author:
01.04.2005
T.Lw / TE
Dateiname:
p:\schulung\wz-4\elektrik\bvc\englisch\mesx_v3.01_gb.doc
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10.1
Service Training MESX
Table of contents
1
2
3
4
5
Document alteration list.....................................................................................................................3

Proof of software change MESX .......................................................................................................4
Proof of software change BOP..........................................................................................................5
Known faults ......................................................................................................................................6
How to proceed when replacing components? .................................................................................7
5.1 How to proceed when replacing an ESX control? .......................................................................7
5.2 How to proceed when replacing a rear axle sensor? ..................................................................7
5.3 Which components can be replaced without a subsequent adjustment procedure? ..................7
5.4 List of machine types ...................................................................................................................8
6 Possible adjustments on machines without BOP ..............................................................................9
6.1 Description of the Display Module ...............................................................................................9
6.2 Input of code numbers.................................................................................................................9
6.3 Changing the machine type (only via display module)...............................................................10
6.4 Inverting the direction signal (only via display module)..............................................................11
6.5 Changing the bit rate (only with display module) .......................................................................12
7 Adjustment/display possibilities on machines with BOP .................................................................13
7.1 Adjusting the machine type (BOP).............................................................................................13
7.2 Inverting the direction signal via the BOP control terminal ........................................................15
7.3 Accessing the diagnostics menu ...............................................................................................17
7.3.1
Extended diagnostics on machines with circular exciter (BTMplus, BTMprof)................ 19
7.3.2
Extended diagnose BVC machines.......................................................................................... 20
7.4 Changing the printout language.................................................................................................21
7.5 Setting the machine serial number ............................................................................................23
7.6 Teaching distance pulses ..........................................................................................................25
7.7 Activating the amplitude limitation (only BVC machines)...........................................................27
7.8 Changing the display mode (metric/imperial) ............................................................................29
8 Possible settings on the BCM05mobile...........................................................................................31
8.1 Reading the software version ....................................................................................................31
8.2 Changing the language..............................................................................................................31
8.3 Changing the unit system (metric/imperial) ...............................................................................31
9 Block diagram BEM.........................................................................................................................33
10
Block diagram BTMplus / VARIOCONTROL.............................................................................34
11
Block diagram BTMplus / VARIOCONTROL and BCM05mobile ..............................................35
12
Description of the Signals on the ESX-Control..........................................................................36
13
Fault codes of the ESX control ..................................................................................................41
13.1
Overview ...............................................................................................................................41
13.2
Description of fault reactions .................................................................................................42
13.3
Detailed description of fault codes and their possible causes..............................................43
14
Input codes for ESX control (only via display module on BEM).................................................47
14.1
Travel system ........................................................................................................................47
14.2
Vibration ................................................................................................................................48
14.3
Light.......................................................................................................................................48
14.4
Acceleration transducer.........................................................................................................49
14.5
Diesel engine.........................................................................................................................49
14.6
Setting the machine type.......................................................................................................50
14.7
Parameter change.................................................................................................................51
15
Terminology in connection with ESX .........................................................................................52
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10.1
1 Document alteration list

Version Date
Description of changes
0.00
27.04.2004 Creation of version 1
1.00
05.05.2004 Block diagrams added
Description of display module extended
"Proof of software change" added
1.01
23.07.2004 Description of BOP display pages added.
2.00
31.08.04
Input code 4602 replaced by code 4606
Machine type BW219D added
3.00
15.10.2004 Item "How to proceed when replacing components?" added
Description for ESX Pin 0:35 added
Description fault code 4601 and 4606 corrected
Description Software Version 3.00 added
3.01
16.11.2004 Description Code 7534 from version 3.00 added
Description Software change V3.01 added
Description Code 7573 from version 3.01 added
Description of menus "Amplitude limitation" and "Imperial
display" added
Description Software Version up to 3.03 added
Terminal designation MESX canged from X0 to X44
Description of codes 7502, 7511, 7512, 7532, 7541, 7542,
7550, 7551, 7552, 7562, 7571, 7572, 7576 from version 3.03
added
Proof of "Software change" changed to "Software MESX"
Item "Proof of software change BOP" added
Item "Adjustment possibilities on BCM05mobile" added
Block diagram BTMplus / VARIOCONTROL and
BCM05mobile added
Serial numbers added to list of machine types
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10.1
2 Proof of software change MESX

Version
1.00
1.01
1.02
1.03
1.04
1.05
2.00
3.00
3.01
3.02
3.03
Date
25.03.2004 Creation of version 1.00
05.04.2004 Printout modified
Amplitude limitation for Automatic changed to 0.3 mm
Default setting in Automatic changed to "MAX"
13.04.2004 BW213 BVC implemented
Printer control modified (Xon, Xoff protocol)
Software version and revision documented in printout
Finished criterion extended (weak spots of 2 m are tested)
Bmfsa code input for DH machines modified
05.05.2004 Learning mode for travel distance modified (value range
check)
Finished criterion for polygonal drum deactivated
2-stage jump information implemented
Self-latching of control during shut-down implemented
Saving of current adjustment values during shut-down
implemented.
Bmfsa code input for DH machines modified
BW211 D, BW213 D and BW213 DH implemented
Query for software version of BOP implemented
16.04.2004 BW226 BVC Polygon implemented
Max. adjustment angle limited to 80
Max. valve current for BW177 limited to 1000mA
26.07.2004 BW219DH and BW213 BVC Polygon implemented
Termination criteria for while loops incorporated into Evib
calculation
31.08.2004 Number of machine variants extended to 25 (BW219D)
Problem with sporadic SW crash eliminated
15.10.2004 Distance pulse changed to 10m for BW226
Amplitude limitation realized in automatic mode
Simulation mode realized
Changeover metric/imperial realized
minimum required BOP version changed to 3.00 (always the
same version as MESX)
16.11.2004 The ESC-key does not abort the printout, it only resets the
measurement
Machine variant BW226BVC added
01.12.2004 Machine type BW216D activated
Completion report for BW226BVC with smooth drum
activated
Designation on printout modified (RC; DI)
Default setting for amplitude limitation set to "inactive".
Machine types 177PDH, 179DH, 179PDH, 213PDH,
214DH, 214PDH 216D, 216DH,216PDH, 219PDH, 226DH,
226PDH, 226BVC RC" enabled.
Controller settings for BW213BVC and BW226BVC
optimized with respect to pressure peaks
Minimum speed for swivelling of of exciter changed to 0.18
km/h => Build-up of the machine with vibration at standstill
is thereby avoided
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10.1
3 Proof of software change BOP

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

Simulation mode implemented on BOP
New Part-No. 582 701 92
Lw
3.01
24.1.2005
3.02
Part-No. changed to 58 701 93

Designation "ESX" replaced by "MESX" and "BOP" by
"BOP"
Amplitude bar graph in imperial display mode corrected
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10.1
4 Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
Behaviour of machine
Possible cause
During initial commissioning the display shows the Bit rate on bmfsa not set to 125 kBit
reading "ct0"
=> see "Setting the bit rate"
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5 How to proceed when replacing components?

Each machine is adjusted individually during initial commissioning. This is mainly accomplished by
setting the correct machine type (see "5.4 List of machine types", or "7.1 Adjusting the machine type
BOP").
The following chapter describes the necessary adjustments to the control when replacing individual
components in the measuring system.
5.1 How to proceed when replacing an ESX control?

Attention:
A machine must not be operated with a wrong type adjustment,

because in such a case the correct function of the control cannot
be assured!
Therefore set the machine type in the first step! see "5.4 List of
machine types", or "7.1 Adjusting the machine type"
After setting the machine type check the following items:
Check the direction signal, invert the signal if necessary, see 6.4, or 7.2.
Set the machine serial number (only on machines with BOP), see: 7.5
Set the printer language (only machines with printer), see: 7.4
5.2 How to proceed when replacing a rear axle sensor?

Check the direction signal, invert the signal if necessary, see 6.4, or 6.4.
5.3 Which components can be replaced without a subsequent

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

recommended.
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10.1
5.4 List of machine types

Since the same control is used for all single drum rollers with the new measuring technology, it is
necessary to adjust the machine type after installing a new control.
This is necessary during first time commissioning as well as in case of a spare parts installation. This
type adjustment is necessary, because the machines have e.g. different axle loads or different drum
widths, which requires the calculation of measuring values to be adapted. The adjustment procedure is
described under items "6.3 Changing the machine type (only via display module" or "7.1 Adjusting the
machine type (BOP)".
The following machine types can be adjusted:
Machine type
First serial number
Last serial number
Code
177 D
177 DH
177 PDH
177 BVC
101 582 20 1001

101 582 21 1001
101 582 22 1001
101 582 23 1001
XXX XXX XX XXXX

XXX XXX XX XXXX
XXX XXX XX XXXX
XXX XXX XX XXXX
7500
7501
7502
7503
Available from
version
1.00
1.00
3.03
1.00
179 DH
179 PDH
101 582 24 1001

101 582 25 1001
7511
7512
3.03
3.03
211 D
101 582 40 1001

101 582 41 1001
XXX XXX XX XXXX

XXX XXX XX XXXX
XXX XXX XX XXXX
XXX XXX XX XXXX
7520
1.03
213 D
213 DH
213 PDH
213 BVC
213 BVC Platten
213 BVC DI
101 582 50 1001

101 582 51 1001
101 582 52 1001
101 582 53 1001
101 582 54 1001
101 582 53 1001
XXX XXX XX XXXX

XXX XXX XX XXXX
XXX XXX XX XXXX
XXX XXX XX XXXX
XXX XXX XX XXXX
XXX XXX XX XXXX
7530
7531
7532
7533
7534
7535
1.03
1.03
3.03
1.02
3.00
1.05
214 DH
214 PDH
101 582 58 1001

101 582 59 1001
XXX XXX XX XXXX

XXX XXX XX XXXX
7541
7542
3.03
3.03
216 D
216 DH
216 PDH
101 582 62 1001

101 582 60 1001
101 582 61 1001
XXX XXX XX XXXX

XXX XXX XX XXXX
XXX XXX XX XXXX
7550
7551
7552
3.03
3.03
3.03
219 D
219 DH
219 PDH
101 582 72 1001

101 582 70 1001
101 582 71 1001
XXX XXX XX XXXX

XXX XXX XX XXXX
XXX XXX XX XXXX
7560
7561
7562
2.00
1.05
3.03
226 DH
101 582 80 1001

101 582 83 1001
101 582 81 1001
101 582 84 1001
101 582 82 1001
101 582 85 1001
101 582 82 1001
101 582 85 1001
101 582 82 1001
101 582 85 1001
XXX XXX XX XXXX
7571
3.03
XXX XXX XX XXXX
7572
3.03
XXX XXX XX XXXX
7573
3.01
XXX XXX XX XXXX
7575
1.04
XXX XXX XX XXXX
7576
3.03
226 PDH
226 BVC
226 BVC DI
226 BVC RC
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10.1
6 Possible adjustments on machines without BOP

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

For the diagnostics of control inputs and outputs various code numbers can be entered via the display
module of the control. The input of a code number is performed as follows:
1. Press both keys (F1 and F2) on the instrument cluster for 2 seconds.
) The value 0 0 0 0 will be displayed, whereby the 1st digit is flashing.
2. The value of the flashing digit can be increased by pressing the left hand key (F1). When the figure
9 is displayed and the left hand key (F1) is pressed again, the display will return to the value 0 .
3. When pressing the right hand key (F2) the flashing digit will move one digit to the right. When the
4th digit is flashing, the right hand key (F2) is pressed once again to confirm the input. The desired
function is then executed or the desired value is displayed respectively.
In order to terminate a display function you must either enter code number 0 0 0 0 or switch the
ignition off.
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10.1
6.3 Changing the machine type (only via display module)

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

Depending on the installation position, the axle sensor used delivers a 12V output signal in forward and
reverse.
This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the travel direction correspond with the actual travel direction.
Note: Parameter adjustments can only be performed when the engine is not running.
Enter code number 7 6 0 0 . This code number activates the function "Invert direction signal.
The display module now permanently shows the code 7 6 0 0 .

Enter code number 7 6 0 1 . This code number inverts the direction signal.
The display module now permanently shows the code 0 0 0 1
(signal not inverted).
In succession the code number 1 0 0 1
interpreted (see item 14 "14").
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(signal inverted), or the code 0 0 0 0
can be used to check whether the direction signal is correctly
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10.1
6.5 Changing the bit rate (only with display module)

The multi-function display can be operated with different CAN transmission speeds. For operation in
our machines the bit rate must be set to 125 kBit/s. The bit rate is changed as follows:
Hold both keys (F1 and F2) of the multi-function display depressed and switch on the ignition.
) The currently set bit rate is displayed, e.g. 0 1 0 0 .
The bit rate can now be changed in fixed steps by pressing the right hand key (F2). Hold the key
depressed until the display reads 0 1 2 5 .
By pressing the left hand key (F1) the bit rate is accepted and the display changes back to the
normal display mode.
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10.1
7 Adjustment/display possibilities on machines with BOP

7.1 Adjusting the machine type (BOP)
Adjusting the machine type requires the following sequence:
Note:
Parameter adjustments can only be performed when the engine is not running.
Press key "?" to open the screen page "MENU". The following screen is displayed:
Press key "F2" to open the screen page "Adjust machine type". The following screen is displayed:
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10.1
The desired machine type can be selected by pressing the keys "F11" and "F12". (see "List of
machine types" under item 5.4 ".
After selecting the desired machine type press key "F14", until the symbol (F14) lights green for
confirmation (approx. 4s).
When releasing the key the start screen will automatically be displayed and the control will initiate a
restart.
Switch the ignition off and on again.
BOP and MESX are now adjusted to the new machine type.
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10.1
7.2 Inverting the direction signal via the BOP control terminal
Depending on the installation position, the axle sensor used delivers a 12V output signal in forward and
reverse.
This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the travel direction correspond with the actual travel direction.
Note: Parameter adjustments can only be performed when the engine is not running.
Press key "F1" to open the screen page "Invert direction signal". The following screen is displayed:
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10.1
The direction signal can now be inverted or not inverted by pressing key "F5" ("Invert = 1" or "Invert
= 0").
After the desired change press key "F14" to save the adjustment. The symbol lights green for a
moment as a sign of confirmation.
Press "ESC" to leave the page.
Check on the printout or in the diagnostics menu whether the travel direction has been correctly
detected.
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10.1
7.3 Accessing the diagnostics menu
Press key "F5" to open the screen page "Diagnose1". The following screen is displayed:
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10.1
If an actual error is present the corresponding error code will be displayed in the field "Actual Errors".
By pressing key "A" you can change into a machine specific, more detailed diagnostics menu (see
below).
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10.1
7.3.1 Extended diagnostics on machines with circular exciter (BTMplus,

BTMprof)
4.23 V Ubv:
actual voltage front acceleration transducer
4.24 V Ubh:
actual voltage rear acceleration transducer
98% Small Ampl:
Triggering of solenoid valve for low amplitude in percent
0% Big Ampl:
Triggering of solenoid valve for high amplitude in percent
Direction:
Status MESX input travel direction (LED on = 12V)
Ligths:
Status MESX input light detection (LED on = 12V)
MD+
Status MESX input MD+ (detection engine running) (LED on = 12V)
Vibration:
Status of vibration detection in the MESX (LED on = Vibration ON)
+01234
Distance pulses detected by the MESX (10cm steps). The actually detected
travel direction can be recognized by the roller symbol above.
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10.1

7.3.2 Extended diagnose BVC machines
4.25 V Uexciter:
actual voltage of exciter position potentiometer
4.23 V Ubv:
actual voltage front acceleration transducer
4.24 V Ubh:
actual voltage rear acceleration transducer
98% Ampl:
Triggering of solenoid valve for vibration valve in percent
Direction:
Status MESX input travel direction (LED on = 12V)
Ligths:
Status MESX input light detection (LED on = 12V)
MD+
Status MESX input MD+ (detection engine running) (LED on = 12V)
Vibration:
Status of vibration detection in the MESX (LED on = Vibration ON)
+01234
Distance pulses detected by the MESX (10cm steps). The actually detected
travel direction can be recognized by the roller symbol above.
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10.1
7.4 Changing the printout language
Press key "F6" to open the screen page "Printout language". The following screen is displayed:
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10.1
The desired printout language can be selected by pressing the keys "F11" and "F12".
After selecting the desired language press key "F14" to save the adjustment. The symbol (F14)
lights green for a moment as a sign of confirmation.
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10.1
7.5 Setting the machine serial number
Press key "F7" to open the screen page "Serial number". The following screen is displayed:
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10.1
The desired printout language can be selected by pressing the keys "F11" and "F12".
After the adjustment press key"F14" to save the adjustment. The symbol (F14) lights green for a
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10.1
7.6 Teaching distance pulses

The distance pulses for the different machine types are already set by default after adjusting the
correct machine type. However, due to slippage on the rear axle the recorded distance measurement
may deviate from the actually travelled distance. In this case the distances pulses can be adjusted
accordingly.
Note: An adaptation of the distance pulses is only possible within a range of +/- 10% of the
preset value.
Press key "F8" to open the screen page "Distance pulses". The following screen is displayed:
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7.7 Activating the amplitude limitation (only BVC machines)
Press key "F3" to open the screen page "Amplitude limitation". The following screen is displayed:
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10.1
The limitation can now be activated or deactivated by pressing key "F5" ("Limit = 1" or "Limit = 0").
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7.8 Changing the display mode (metric/imperial)
Press key "F4" to open the screen page "Display mode". The following screen is displayed:
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10.1
The imperial display (mph, F, etc.) can now be activated or deactivated by pressing key "F5"
("Imperial = 1" or "Imperial = 0").
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10.1
8 Possible settings on the BCM05mobile

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

Select "Configuration" at the right hand edge of the window.
The software currently installed in the BCM05mobile is displayed at the top left unter the name
BOMAG.
8.2 Changing the language

Open the service window: press the top switch of the three switches at the right hand edge of the
touchscreen "Configuration" for about 5 seconds, until a roller symbol appears under the software
version number at the left hand side of the display. Release the "Configuration" switch and press the
symbol within 3 seconds. The touchscreen now shows 4 switches near the right hand edge and select
the bottom switch "Service".
Note: After this setting the service window must be closed to avoid unauthorized access.
Press "Close window" at the bottom right in the service window.
Press the field "Language". A list with the available languages pops up. Choose the desired language
and confirm with "Select".
8.3 Changing the unit system (metric/imperial)

Open the service window: press the top switch of the three switches at the right hand edge of the
touchscreen "Configuration" for about 5 seconds, until a roller symbol appears under the software
version number at the left hand side of the display. Release the "Configuration" switch and press the
symbol within 3 seconds. The touchscreen now shows 4 switches near the right hand edge and select
the bottom switch "Service".
Note: After this setting the service window must be closed to avoid unauthorized access.
Press "Close window" at the bottom right in the service window.
Shift the switch in the "Unit" field to the desired position.
Status:
Author:
008 911 63
01.04.2005
T.Lw / TE
BOMAG
Page 31 of 55
207
10.1
208
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008 911 63
008 911 63
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01.04.2005
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9 Block diagram BEM
Block diagram
Block diagram
Page 33 of 55
10.1
BOMAG
209
210
Status:
Author:
01.04.2005
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10 Block diagram BTMplus / VARIOCONTROL
Block diagram
Block diagram
Page 34 of 55
10.1
BOMAG
008 911 63
008 911 63
Block diagram
Status:
Author:
01.04.2005
T. Lw / TE
Block diagram
11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile
Page 35 of 55
10.1
BOMAG
211
212
Description of signals
BOMAG
Status:
Author:
X44:9
X44:8
X44:7
X44:6
X44:5
X44:4
01.04.2005
T. Lw / TE
Input exciter position front

Analogue input / voltage input 0..8.5 V
Input acceleration transducer VH20g/HR15g
Interface RS 232 TxD, used for printer control.
4,2..4,3 V
Position of front exciter (measured against AGND)

Bottom stop
)
approx. 2.2 V
Neutral position
)
approx. 4.25 V
Top stop
)
approx. 6.6 V
Open circuit voltage (vibration off):
Acceleration signal (measured against AGND)
Measurement not possible!
approx. 0..6 V
PWM signal (100Hz): )
X44:3
Output Evib Display

PWM (max. 2.5 A)
Interface RS 232 RxD, used for printer control.
Nominal values (voltage / current)

approx. 0 V measured against ground (terminal 31)
ESX terminal Signal description

X44:1
AGND = Analogue ground: Ground potential for sensors (steering
joystick, speed range switch etc.)
X44:2
Notes:
1. Wherever the value of 12 V is mentioned in the following text it refers to the current battery
voltage under due consideration of voltage drops in the lines.
12 Description of the Signals on the ESX-Control
Page 36 of 55
10.1
008 911 63
008 911 63
BOMAG
Status:
Author:
X44:24
X44:23
X44:22
X44:21
X44:20
X44:19
X44:18
X44:17
X44:16
X44:15
X44:14
X44:13
X44:12
X44:11
01.04.2005
T. Lw / TE
)
>6V
)approx.0 V
)
12 V
)
2V
)
12 V
)
2V
)
12 V
)
2V
)
12 V
)
2V
Nominal voltage = 8,5 V

Permissible range: approx. 7,65..9,35 V
This voltage must be measured against AGND.
Vibration on:
Vibration off:
Push button pressed
Push button not pressed
Push button pressed
Push button pressed
Push button pressed
Output voltage supply for sensors

This output supplies steering joystick, travel speed range switch, etc.
Without this voltage the control cannot work correctly and will switch to
override condition (emergency operation).
Input vibration 1 On
Digital input active high
Input button "START" (option)
Input button "STOP" (option)
Input button "PRINT" (option)
Input button "CLEAR" (option)

X44:10
Page 37 of 55
10.1
213
214
BOMAG
X44:31
Status:
Author:
01.04.2005
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4,2..4,3 V
4,2..4,3 V
4,2..4,3 V
Page 38 of 55
Transducer delivers square-wave pulses Frequency depends on machine

type.
Input distance transducer
X44:35
Interface CAN-Bus2 Wire -, is used to communicate with the BCM05.
X44:33
X44:34
X44:32

Input acceleration transducer VV20g/HR15g
X44:30

Input acceleration transducer VH/VR15g
X44:29
Control switched on
Control switched off
)
12 V
)approx.2 V
Input potential terminal 15

This signal must be present, so that the control can work.
Input acceleration transducer VV/VL15g
X44:28
Interface CAN-Bus Wire -, is used to communicate with the BOP

operating unit.
Interface CAN-Bus Wire +, is used to communicate with the BOP
operating unit.
X44:26
X44:27

X44:25
10.1
008 911 63
008 911 63
BOMAG
Status:
Author:
X44:52
X44:51
X44:50
X44:49
X44:48
X44:47
X44:46
X44:45
X44:44
X44:43
X44:42
X44:41
X44:40
X44:39
X44:38
X44:37
01.04.2005
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Output valve 1 front

PWM digital output (max. 4 A)
Output valve 2 front
PWM digital output (max. 4 A)
Input D+ generator
Input vibration 2 On

X44:36
)
12 V
)
0V
)
>6V
)approx.0 V
permissible current range: approx. 0..1,5 A
permissible current range: approx. 0..1,5 A
Engine running / engine is started

Engine not running
Vibration on:
Vibration off:
Page 39 of 55
10.1
215
216
Voltage supply for outputs
X44:56
X44:57
X44:58
X44:59
X44:60
BOMAG
Mouse port Baby Boards
X44:67
X44:68
01.04.2005
T. Lw / TE
X44:66
Status:
Author:
X44:65
X44:64
X44:63
X44:62
X44:61
approx. 12 V measured against ground
Ground connection electronics
X44:55
approx. 0 V
approx. 0 V
approx. 0 V
approx. 0 V

Emergency stop not actuated
)
Emergency stop actuated
)
0 V measured against ground

X44:53
Interface CAN-Bus2 Wire +, is used to communicate with the BCM05.
X44:54
Voltage supply for electronics
12 V
0V
Page 40 of 55
10.1
008 911 63
10.1
Service Training
Fault codes of the ESX control
13 Fault codes of the ESX control

13.1 Overview
Fault code
4501 50
41
0 46
40
60
20 8
8250
Status:
Author:
008 911 63
Fault description
Position controller (exciter potentiometer, valves)
Acceleration transducer
Internal software errors
01.04.2005
T.Lw / TE
Fault codes of the ESX control
BOMAG
Page 41 of 55
217
218
BOMAG
Status:
Author:
Note:
Description of fault reaction

Warning.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
Function affected, the faulty function is replaced by an emergency function.
Partial function faulty, the partial function cannot be overridden by an emergency function.
After the occurrence of the fault the machine is stopped, after returning the travel lever to neutral the machine can move
again.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is no longer able to drive, e.g. because parts of the travel system are defective
) the diesel engine is shut down.
Fatal fault. The function of the control can no longer be guaranteed.
Control is switched off.
Error code is displayed.
Signal light in BOP (option) lights permanently.
Description of fault codes on the ESX control
01.04.2005
T. Lw / TE
Errors with error reaction 1 are only warning messages and are NOT stored in the error log.
Fault reaction
1
13.2 Description of fault reactions
Page 42 of 55
10.1
008 911 63
008 911 63
Input exciter potentiometer front

The voltage applied to the input is above the
specified range (see signal description).
450
2
01.04.2005
T. Lw / TE
Input exciter potentiometer front

The voltage applied to the input is below the
450
1
Status:
Author:
Fault description
Fault
code
Terminal
on ESX
-{}-) Wire breakage in current path

X44:09
) Current path has short circuit to ground
) No voltage supply to potentiometer
) Fuse FM ? has tripped or wire breakage in voltage supply current
path
) Potentiometer defective
) Current path connected to +12 V / +8,5 V
X44:09
) Potentiometer not connected to ground
) Potentiometer defective
Possible cause
13.3 Detailed description of fault codes and their possible causes
Page 43 of 55
Input
Fault
code for reaction
diagnose
5
10.1
BOMAG
219
220
BOMAG
Output proportional solenoid front

Valve for exciter up
Output current too high.

Fault when calibrating the valve

Valve for exciter down
Output current too low.

Output current too high.

Fault when calibrating the valve
452
2
452
3
452
6
452
7
452
8
01.04.2005
T. Lw / TE

Output current too low.
452
1
Status:
Author:
Fault description
Fault
code
) Current path is interrupted

) Current path has unpermitted connection to another current path
/ ground
) Current path has short circuit to voltage supply

) Current path has non-permitted connection to another current
path
path

) Current path has unpermitted connection to another current path
/ ground
X44:46
) Current path has short circuit to voltage supply

path
path
X44:47
X44:47
X44:47
X44:46
X44:46
Terminal
on ESX
Possible cause
Page 44 of 55
Fault
Input
code for reaction
diagnose
2
10.1
008 911 63
008 911 63
BOMAG
Position controller negative limit reached

The exciter does not move to the desired
direction or does not move at all.
Input acceleration transducer 1




453
2
460
1
460
2
460
6
460
7
01.04.2005
T. Lw / TE
Position controller positive limit reached

The exciter does not move to the desired
direction or does not move at all.
453
1
Status:
Author:
Fault description
Fault
code
X44:09
X44:37
X44:09
X44:37
X44:29,
or
X44:31
X44:29,
or
X44:31
X44:30,
or
X44:07
X44:30,
or
X44:07
) Supply and ground terminal on exciter potentiometer mixed up

) Valves for "Exciter up" and "Exciter down" mixed up
) MD+ input has 12 V potential, even though the engine is not
running
) Supply and ground terminal on exciter potentiometer mixed up
) Valves for "Exciter up" and "Exciter down" mixed up
) MD+ input has 12 V potential, even though the engine is not
running
) Current path has no connection to +12 V / +8,5 V
) Current path connected to ground
) Transducer defective
) Current path not connected to ground
) Current path has no connection to +12 V / +8,5 V
) Current path connected to ground
) Current path not connected to ground
Terminal
on ESX
Possible cause
4606
4606
4601
4601
5000
Page 45 of 55
Fault
Input
code for reaction
diagnose
5000
2
10.1
221
222
BOMAG
Status:
Author:
Ct0
800
1 899
9
900
0 999
8
01.04.2005
T. Lw / TE
Display module has no connection to ESXcontrol.
) Wire breakage in CAN bus lines

) Short circuit between CAN bus lines
) One or both CAN bus line(s) has (have) connection to 12V or
ground
) Incorrect bit rate in display module (nominal value: 125 kBit)
) Wire breakage in CAN bus lines

) Short circuit between CAN bus lines
) One or both CAN bus line(s) has (have) connection to 12V or
ground
Error message "Communication via CAN bus

disturbed"
The modules controlled via the CAN bus cannot
be addressed by the main control (ESX). The
respective machine functions are not available
Error message "Incorrect BOP Software version"

The software version of the BOP is too old, i.e.
various functions cannot be displayed.
This fault cannot be rectified on the machine. The
BOP needs to be replaced.
Fault message severe software fault in control
This fault cannot be rectified on the machine. The
control must be immediately replaced.
800
0
Possible cause
Fault description
Fault
code
X44:26
X44:27
X44:26
X44:27-
Terminal
on ESX
Page 46 of 55
Fault
Input
code for reaction
diagnose
2
10.1
008 911 63
008 911 63
Description of input codes for the control
BOMAG
Status:
Author:
1011
1010
1003
1002
01.04.2005
T. Lw / TE
Depending on the selected machine type, e.g. 5896 for

BW177 BVC
0000 )
Direction signal is not inverted
000I )
Direction signal is inverted
Display value = max. speed in km/h
Display value = travel distance in 10 cm
Forward travel detected

Neutral position
Reverse travel detected
Transducer for distance pulses

The distances pulses summarized since starting the machine are
displayed. If the machine has travel a longer distance in reverse than
in forward, the value will be negative
Travel speed
Shows the actual speed.
Parameter "Show distance pulses per 10m"
Eeprom Parameter is displayed
Parameter "Invert travel direction"
Eeprom Parameter is displayed
1000 )
Travel direction
Displays the travel direction derived by the control from the "transducer 0 0 0 0 )
for travel direction".
000I )
1001
Display values
0000 )
0V
0001 )
12 V
Description of display function

Transducer for travel direction
Show status of transducer.
Input code
1000
14.1 Travel system
14 Input codes for ESX control (only via display module on BEM)
Page 47 of 55
10.1
223
224
BOMAG
Status:
Author:
Display values
0000 )
Light OFF
0001 )
Light ON

Input light switch
The status of the lighting is displayed.
Display values
0000 )
Vibration OFF
0001 )
Vibration ON
0000 )
Vibration OFF
0001 )
Vibration ON
0000 )
Vibration OFF
0001 )
Vibration ON

Vibration status general
The status of vibration is displayed.
Vibrations status low amplitude
The vibration status for low amplitude is displayed.
Vibrations status high amplitude
The vibration status for high amplitude is displayed.
01.04.2005
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Input code
3010
14.3 Light
3002
3001
Input code
3000
14.2 Vibration
Page 48 of 55
10.1
008 911 63
008 911 63

Acceleration transducer 1
Shows the voltage of transducer 1.
Acceleration transducer 2
Shows the voltage of transducer 2.
Status:
Author:

Input MD+
Show status of diesel engine.
01.04.2005
T. Lw / TE
Input code
5000
14.5 Diesel engine
4606
Input code
4601
14.4 Acceleration transducer
Display values
0000 )
Engine OFF
0001 )
Engine ON
Display value = voltage in V
Display values
Display value = voltage in V
Page 49 of 55
10.1
BOMAG
225
226
Preselect machine type
7500..75
99
Page 50 of 55
Display values
see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
definiert.)!
definiert.)!
definiert.)!
Confirms entered machine type
7011
01.04.2005
T. Lw / TE
Switches on function Set machine type
7010
Status:
Author:

Shows the adjusted machine type
Input code
7000
14.6 Setting the machine type
10.1
BOMAG
008 911 63
008 911 63
Status:
Author:
Page 51 of 55
Display values
Display value 7 6 0 0
definiert.)!

Switch on function "Invert travel direction"
Inverts the actually adjusted travel direction
01.04.2005
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Input code
7600
7601
14.7 Parameter change
10.1
BOMAG
227
10.1
15 Terminology in connection with ESX

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

loosened, slipped off
broken off,
corroded,
socket / plug faulty
Status:
Author:
228
01.04.2005
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General terminology
BOMAG
Page 52 of 55
008 911 63
10.1

Short circuit to ground
Line, terminal has direct connection to vehicle ground, often in connection with wire breakage
Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)
Analogue
In contrast to Digital many conditions are permitted within a certain range. For instance room
temperature 0 to 40; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 to 300 ;
valve 0% to 100% opened (proportional valve)
Status:
Author:
008 911 63
01.04.2005
T.Lw / TE
General terminology
BOMAG
Page 53 of 55
229
10.1

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

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

closed
(closed loop control circuit)
Measurement and
Value to be adjusted is
comparison of value to measured and compared.
be adjusted:
Reaction to faults
Counteracts to all faults
(generally):
targeting the system to be
controlled.
Technical expense:
Low expense:
Measurement of the value to
be controlled, comparison of
nominal and actual value,
power amplification
Performance in
For unstable systems closed
unstable systems
loop controls must be used.
Status:
Author:
230
01.04.2005
T.Lw / TE
Control
open
(control chain)
Values to be controlled
are not measured and
compared.
Does not respond to
unknown faults
High expense if many
faults have to be
considered, low expense
if not faults occur.
In unstable systems
controls cannot be used.
General terminology
BOMAG
Page 54 of 55
008 911 63
10.1

Current and voltage measurement
Ohms law:
U = Voltage
R = Resistance
I = Current
U =RI
U
I=
R
U
R=
I
Plausibility check
The control (ESX) runs a plausibility check on all inputs. This means the control checks
permanently whether certain state combinations are permitted; e.g. travel lever position
forward and reverse will cause an fault message, because this condition is normally not
possible.
Override / emergency operation
In the event of a major fault the control will switch off and the override function will take over.
This has the effect that the machine can still be moved and steered with reduced speed.
Steering and dozer blade movements are only possible with a constant speed.
(see also: page 34, "")
GND - AGND
Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional
analogue ground, which is only to be used for sensors. (see description of the signals on the
ESX-control)
PWM digital output
Certain outputs on the ESX are designed as so-called PWM digital outputs. This means
that these outputs are special current outputs. Here it is possible to measure a current, but
no voltage. These outputs are used to trigger proportional valves.
Status:
Author:
008 911 63
01.04.2005
T.Lw / TE
General terminology
BOMAG
Page 55 of 55
231
10.1
232
BOMAG
008 911 63
10.2 Service Training
008 911 63
BOMAG
233
10.2
234
Service Training
BOMAG
008 911 63
10.2
Service Training
Service Training
Single Drum Rollers

BW 211 / 212 / 213 D- 40
11/2005
008 911 63
BOMAG
235
10.2
Service Training
Service Training
Table of contents
Travel system
E1
Travel pump
E3
Control
E6
Charge pressure relief valve
E 11
High pressure relief valve
E 12
Pressure override
E 14
Axle drive motor
E 16
Drum drive motor
E 20
Test and adjustment points, travel system
E 25
Trouble shooting in travel system
E 29
BW 211 / 212 / 213 D-40
236
BOMAG
008 911 63
10.2
Service Training
Service Training
Vibration
F1
Vibration pump
F3
High pressure relief valves
F6
Control
F7
Charge pump
F8
Vibration motor
F9
Drum
F 12
Test and adjustment points, vibration system
F 14
Trouble shooting in vibration system
F 16
Steering
G1
Steering pump(s)
G2
Steering valve
G4
Articulated joint
G6
Measuring and adjustment points
G8
Trouble shooting steering system
G9
BW 211 / 212 / 213 D-40
008 911 63
BOMAG
237
238
BW 211 / 212 / 213 D-40
BOMAG
25 bar
Charge pressure from hydraulic oil filter
Charge pressure to vibration pump
Travel pump Sauer 90 R 075
Servo control
M2
T3
M4
M3
from brake valve
Axle drive motor Sauer 51 D 110
Rear axle
Multi function valve
Fig. 1: Hydraulic diagram travel system BW 211 / 212 / 213 D-40
0.81
0.8
M4 M5
Travel circuit
0.6
0.6
Drum drive motor Poclain MSE 18 1C
Flushing valve
Speed range valve
from speed
range valve
10.2
Service Training
Service Training
-E1-
008 911 63
10.2
Service Training
Service Training
The travel system of the single drum rollers is a closed hydraulic circuit and consists mainly of:
travel pump with control and safety elements,
Drum drive motor without brake,
axle drive motor,
rear axle with brake,
charge pump (also for vibration circuit),
hydraulic oil filter (in charge circuit),
hydraulic oil cooler with thermostat
hydraulic lines.
Travel pump and vibration pump are connected to a tandem pump unit. The charge pump is an integral
part of the vibration pump.
The travel pump is the first pump section, flanged directly to the flywheel side of the diesel engine.
The pump delivers the hydraulic oil to the travel motors for drum and axle drives. The multi-function
valves in the pump limit the pressure in the closed circuit to (p = 400 bar between low and high
pressure sides).
A flushing valve in the axle drive motor (and in the Sauer drum drive motor 51 C 110) flushes a certain
oil quantity out of the closed circuit when the machine is driving (p between the two sides of the closed
circuit).
Leakage in the individual components of the circuit are replaced by the charge circuit through the boost
check valves in the travel pump.
The charge pumps draw hydraulic oil out of the tank and deliver it through the hydraulic oil filter and the
charge pressure relief valve to the boost check valves in travel and vibration pumps. The machine is
fitted with two charge pumps. One pump is integrated in the vibration pump and the other pump is driven
by the auxiliary output of the engine and serves primarily as steering pump.
The charge circuit provides the oil for the charge system and the control functions in the closed circuits
for travel and vibration drive, as well as to release the parking brakes and to change the travel speed
ranges.
The travel motor in the axle is desired with variable displacement. The operator can choose from two
different travel speed ranges.
BW 211 / 212 / 213 D-40
008 911 63
-E2-
BOMAG
239
10.2
Service Training
Service Training
Travel pump
The travel pump is a swash plate operated axial piston pump with variable displacement, most suitable
for applications in hydrostatic drives with closed circuit.
M4
M5
25 bar
from/to
Travel motor
from/to
Travel motor
B
Charge pressure to vibration pump
Charge pressure from hydraulic oil filter
Fig. 2: Hydraulic diagram of travel pump

1
Pump drive
Servo control
Multi-function valves
BW 211 / 212 / 213 D-40
240
-E3-
BOMAG
008 911 63
10.2
Service Training
Service Training
The travel pump delivers the hydraulic oil to the motors on rear axle and drum. The pump flow is
proportional to the pump speed (output speed of diesel engine) and the actual displacement (swashing
angle of swash plate) of the pump.
2
3
Fig. 3: Travel pump

1
Control lever
Cylinder block
Drive shaft
Valve plate
Swash plate bearing
Control piston
Pistons with slipper pads
With the servo control the swashing angle can be infinitely adjusted from neutral position (0) to both
maximum displacement positions.
When altering the swash plate position through the neutral position, the oil flow will be reversed and the
machine will drive to the opposite direction.
All valves as well as the safety and control elements needed for operation in a closed circuit, are
integrated in the pump.
Note:
These machines are equipped with two charge pumps.
BW 211 / 212 / 213 D-40
008 911 63
-E4-
BOMAG
241
10.2
Service Training
Service Training
Cross-sectional view of travel pump
2
4
5
3
6
7
10
11
Fig. 4: Cross-sectional view of travel pump
1
Retainer for swash plate
Swash plate bearing
Sliding block
Swash plate guide
Control piston
Swash plate
Servo arm
10
Swashing lever
Servo valve
11
Charge pump (only in vibration pump)
Feedback device
BW 211 / 212 / 213 D-40
242
-E5-
BOMAG
008 911 63
10.2
Service Training
Service Training
View of the rotating group
1
2
Fig. 5: Travel pump, view of the rotating group

1
Working pistons
Slipper pad
Pre-tensioning spring
Cylinder block
Drive shaft
BW 211 / 212 / 213 D-40
008 911 63
-E6-
BOMAG
243
10.2
Service Training
Service Training
Description of function
Fig. 6: Function of travel pump

1
Drive shaft
Cylinder block
Drive shaft bearing
Swash plate
Charge pump (only in vibration pump)
Pistons with slipper pads
Valve plate
The drive shaft (1) is directly driven by the diesel engine via an elastic coupling. the shaft turns the tightly
connected cylinder block (5).
With the rotation of the drive shaft (1) the cylinder block (5) moves the working pistons (4). The slipper
pads of the working pistons abut against the swash plate (3).
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When moving the swash plate out of neutral position, the working pistons will perform a stroke
movement with every rotation of the cylinder block.
The slipper pads are hydrostatically balanced and are retained on the sliding face of the swashing cradle
by a retaining device.
During a full rotation of the cylinder block each working piston will move through the bottom and top dead
centre back to the initial position. During this movement each piston performs a complete stroke.
During the piston stroke each piston draws in a certain quantity of oil from the low pressure side of the
hydraulic circuit and presses it out into the high pressure side.
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Tandem pump
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Tandem pump, connections and adjustment points
32
Thermostat
housing
Fig. 7: Connections and adjustment points
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1
Control solenoid, high frequency (vibration pump)
Control solenoid, low frequency (vibration pump)
Multi-function valve 400 bar (charging and pressure limitation), travel system
Charge pressure to solenoid valve for brakes and speed range selector, charging vibration
Multi-function valve 400 bar (charging and pressure limitation), travel system
6
7
Port L, leak oil to vibration pump
Travel lever
Pressure test port, pilot pressure
10
High pressure port B, high pressure reverse
11
Charge pressure relief valve, 26 bar
12
Adjustment screw, low frequency
13
Port L2, leak oil to tank
14
Pressure test port MB, high frequency
15
Pressure test port MA, low frequency
16
High pressure port A, low frequency
17
High pressure port B, high frequency
18
End plate with integrated charge pump (only in vibration pump)
19
Port L2
20
Adjustment screw, high frequency
21
Port D, charge pressure to filter
22
Multi-function valve 345 bar (charging and pressure limitation), vibration high frequency
23
Port S, suction line between hydraulic oil tank and charge pump
24
Multi-function valve 345 bar (charging and pressure limitation), vibration low frequency
25
Charge pressure relief valve, vibration pump (blocked)
26
Port E, charge oil from travel pump
27
Port L1, leak oil port to travel pump
28
Pressure test port MB, high pressure reverse
29
Charge oil from filter
30
Pressure test port MA, high pressure forward
31
High pressure port A, high pressure forward
32
Adjustment screw for mechanical neutral position, vibration
Thermostat housing: 33, 34, 35, 36 Leak oil port

37
cooler inlet
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servo control
The servo control (mechanical hydraulic displacement control) converts the mechanical input signal
of the pump control lever into a position controlling output signal. This position controlling signal
determines the swashing angle of the swash plate (the displacement of the pump), as well as the
swashing direction (flow direction of the pressure fluid).
The flow quantity delivered by the variable displacement pump is proportional to the value of the
mechanical input signal. A mechanical feedback device ensures the fixed correlation between the
mechanical input signal and the swashing angle of the swash plate (displacement of pump).
Servo cylinder
Control piston
Sliding block
Servo arm
Fig. 8: Control piston

A mechanical safety device (spring) makes sure that a too fast lever movement will not cause any
damage to the servo control.
The pump displacement can be adjusted by actuating the pump control lever via travel lever and travel
control cable. This requires only very little manual forces and only a slight movement of the lever.
Since the control is spring centred, the swash plate will automatically return to neutral position under the
following conditions, thereby interrupting the oil flow and braking the machine:
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when shutting the engine down,
if the external control cable comes loose,
if the pressure in the charge circuit drops below a certain value.
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High pressure limitation
Pumps of series 90 are equipped with so-called multi-function valves, which activate a pressure override
and a pressure relief valve, one after the other.
7
3
A
B
4
7
2
Fig. 9: Multi-function valves
1
to the control
Drive shaft
Multi-function valve
to the control piston
Charge pump
to the control piston
Port A
Pilot pressure relief valve
Port B
If the adjusted pressure is reached, the pressure override will move the swash plate quickly back
towards neutral position, thereby limiting the system pressure. The average response time is less than
90 ms.
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In case of a very quick increase in pressure (pressure peaks) the system utilizes the function of the
pressure relief valves as a protection for the hydraulic systems. In such a case the pressure override
works as a pre-control unit for the control piston of the pressure relief valve. The pressure level of the
high pressure relief valve is higher than the pressure level of the pressure override. The high pressure
relief valves will only respond if the pressure override is not able to swash the pump back quick enough
in case of sudden pressure peaks.
6
9
7
8
10
11
Fig. 10: Multi-function valve, details

1
Reducing fitting
Check valve
Hydraulic by-pass piston
Pressure limitation
Spring plate
Spring
Spring
10
By-pass housing
High pressure relief valve
10
By-pass sleeve
Valve seat
Pressure override and high pressure relief valve are both parts of the multi-function valve, which is
screwed into the pump.
With its possibility to swash the swash plate inside the pump back within a period of 90 ms, the pressure
override makes sure that the high pressure relief valves will only respond in exceptional cases. This
protects the hydraulic circuit against overheating and reduces the load on the diesel engine.
Note:
The multi function valves must be tightened with a torque of 89 Nm!
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The machines are equipped with two charge pumps, one driven by the auxiliary output of the engine
(steering and charge pump) and the other pump is integrated in the vibration pump.
The pressures of both pumps are limited by a charge pressure relief valve.
The charge pressure relief valve is a direct acting valve with fixed adjustment and is part of the safety
elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted
value (26 bar).
The charge circuit compensates leaks and flushing quantities in the closed travel and vibration circuits
and provides the necessary pressure to control the travel and vibration pumps and to operate the multidisc brakes in the travel drives.
Since feeding of cool and filtered oil is only possible in the low pressure side of the closed circuit, the
pressure in the low pressure side is almost identical with the pressure in the charge circuit.
When parking the machine on level ground with the engine running, the pressures in both sides of the
closed circuit are identical (charge pressure).
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Flushing valve
2
1
Fig. 11Cross-section of flushing valve
1 Flushing spool
2 Flushing pressure relief valve
The flushing valve is integrated in the axle drive motor. In case of a pressure increase in one of the two
sides of the closed circuit the flushing valves have the function to flush a certain quantity of oil out of the
low pressure side.
The valve is operated by the pressure difference between the two sides of the closed circuit (A and B).
If the pressure in one side is higher than in the other, this pressure will move the valve out of neutral
position against the neutral setting spring. Oil can now flow out of the low pressure side. This oil flows
through a thermostat valve back to the tank. The oil quantity flushed out of the closed circuit is
immediately replaced by oil entering from the charge circuit through the corresponding boost check
valve (part of the multi-function valve).
In this way the closed travel circuit is permanently supplied with cool and filtered oil and the temperature
household of the hydraulic system is maintained at a permissible level.
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Axle drive motor,
The axle drive motor is a swash plate controlled axial piston motor of series 51 D 110 with variable
displacement.
6
9
11
4
10
3
Fig. 12: Axle drive motor,
1
Control piston
Cylinder block
Flushing valve
Universal joint
Control
Output shaft
Spindle with ball
10
Output shaft bearing
Qmin-screw
11
Working piston
Valve plate
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The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle
between cylinder block and output shaft.
With a large angle position the motor works with maximum displacement, slow speed and high torque.
When changing the swash plate position to minimal angle the motor works with minimum displacement,
high speed and low torque.
The displacement is changed by a control piston, which is tightly connected with the valve segment.
Changing of the displacement is accomplished by pressurizing the corresponding control piston side
with pressure oil from the charge circuit via a 4/2-way solenoid valve.
Function
The motor is connected with the travel pump via the high pressure ports A and B. The hydraulic oil flows
under high pressure through the corresponding port to the back of the working pistons. Since the
working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a
stroke movement, thereby causing a rotation of the output shaft.
Once the respective piston has passed its dead centre (max. extended position), it will change to the
low pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is
thereby displaced out of the cylinder chamber through the low pressure side back to the pump.
The synchronizing shaft with roller surfaces ensures uniform rotation of output shaft and cylinder block.
The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the
connection between output shaft and pistons no other parts are required. The output shaft runs in two
tapered roller bearings.
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Rear axle
Releasing the axle drive brake manually (on both axle drive designs)
For manual releasing of the brakes on the rear axle you should proceed as follows:
Fig. 13: Manual releasing of rear axle brakes

Slacken the counter nut (Fig. 14, Pos. 1) and back it off by approx. 8 mm.
Turn the brake releasing screw (2) in against the stop.
To release the brake tighten the screw for max. 1 complete turn.
Attention!
Turn the screws on both sides in uniformly (alternately by 1/4 of a turn)
Repeat this procedure on the opposite side of the axle.
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Front drum drive motor: Radial piston motor MSE 18 2 CX
On single drum rollers of series D-40 the drum is driven by a hydraulic radial piston motor.
These drum drive motors consist of three housing parts, the flat distributor, the cylinder block with the
working pistons and the output shaft.
3
4
43090070
Fig. 14: Drum drive motor

1
Drive shaft with output flange
Piston with roller
Oil distributor
Cylinder block
Cam ring
Bearing plate
The housing consists of:
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bearing section (drive shaft bearings),
torque section (cam race) and
oil distributor.
Pressure oil flows through the flat distributor to the working pistons in the cylinder block. This pressure
oil presses the working pistons with the rollers against the cam race of the torque section and forces the
rollers to roll along the cam race.
This transforms the axial movement of the pistons to a radial movement of the cylinder block. The
cylinder block transfers this rotation via a splined connection to the output shaft.
The output shaft runs in two tapered roller bearings. It transfers the rotary movement via the drive disc
and the rubber elements to the drum.
The function of the radial piston motor is described hereunder. The piston positions described in this
explanation can be seen in the related illustration.
The movement of a piston along the cam race must be examined in several phases during a full rotation:
5
1
4
2
3
Fig. 15: Function of the radial piston motor
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Piston position 1:
The oil enters into the oil distributor under pressure, flows through the distributor and presses against
the piston. The rotation starts at this point. The pressure applied to the back of the piston moves the
roller along the cam and causes a rotation of the cylinder block.
Piston position 2:
At this point the opening cross-section for the oil flow to the piston has reached its maximum size. The
piston continues his travel along the cam race towards the valley between two cams. As the movement
continues the opening cross-section for the oil supply decreases.
Piston position 3:
Once the piston has reached the bottom of the valley, the oil flow to the piston is interrupted. The piston
is no longer driven. It has reached its dead centre. Now another piston must be driven to move the first
piston out of the dead centre.
Piston position 4:
Other driven pistons now move the first piston out of the dead centre. The oil behind the piston is now
connected with the low pressure side and the reverse movement of the piston presses the oil back to
the pump.
Piston position 5:
The pumping movement of the motor back to the pump comes to an end, the connecting bore between
cylinder chamber and low pressure side closes again. The piston will now reach its second dead centre
position. This point is the start of a new working cycle.
Reversing the oil flow reverses also the rotation of the motor.
The output shaft runs in two tapered roller bearings. It transmits the rotary movement via the drive disc
and the rubber elements to the drum.
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Travel circuit:
Drum drive with radial piston motor
2
3
7
5
High pressure
Tr
e
av
i
ld
tio
c
e
r
Low pressure
Charge pressure
n
1
2
3
4
5
6
7
8
Travel pump
Vibration pump
Travel lever
Hydraulic oil filter
Rear axle
Axle drive motor
Drum drive motor
Hydraulic oil tank
Leak oil (case pressure)
Fig. 16: Single drum rollers D-40, travel circuit, hose installation
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Brake control:
Travel motor in axle
Brake valve
Charge pressure
Brake releasing pressure
Leak oil
Fig. 17: Brake circuit
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Travel drive, components and test points
Travel pump:
2
2
Pos.
Designation
1
2
3
Test port, forward

High pressure port, forward
Charge pressure port
1
Pos. in wiring diagram
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Pos. in hydraulic
diagram
Measuring values
10, MD
10, A
7, MA
max. 426 bar

26 bar
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Travel pump: right hand side
3
2
1
Pos.
Designation
1
2
3
Test port, reverse

High pressure port, reverse
Travel control (travel control cable)
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Pos. in hydraulic
diagram
Measuring values
10, MC
10, B
max. 426 bar
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Front travel motor, without brake (radial piston motor)
2
2
1
45
3
4
6
3
Pos.
Designation
1
2
3
4
High pressure port, forward

High pressure port, reverse
Cross-flushing of travel pump T1
Leak oil port
Measuring values
12, L
12, R
12
12, 1
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Pos. in hydraulic
diagram
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Rear travel motor: Axle motor
1
4
2
Pos.
Designation
Pos. in hydraulic
diagram
Measuring values
Solenoid for speed range selector

valve
Y31
14
Motor Qmax--depressurized,
Motor Qmin--26 bar
2
3
Flushing valve
High pressure port, drum drive
motor forward
High pressure port, drum drive
motor reverse
High pressure from travel pump
forward
High pressure from travel pump
reverse
Qmin- setscrew
4
5
6
7
14
14, A
14, B
14, A
14, B
14
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Brake valve
11
Pos.
Designation
Pos. in hydraulic
diagram
Measuring values
Brake valve
Y 04
08,
open, 12V closed,

de-energized
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Travel lever console
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Travel lever
Pos.
Designation
Initiator for backup alarm
B14
Initiator for brake
B13
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008 911 63
Pos. in hydraulic
diagram
Measuring values
0 / 12V, normally
closed
Normally closed,
opened in braking
position
0/12V
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Trouble shooting
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
SYMPTOMS
TROUBLE SHOOTING TRAVEL

SYSTEM
BW 211 / 212 / 213 D-40
Machine does not drive (forw. and reverse)

Machine drives to one direction only
Machine travels with travel lever in 'Neutral'
Max. travel speed not reached
Hydraulic oil overheating
The numerical values specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
POSSIBLE CAUSES
Brake valve (electric/mechanical/hydraulic)
Brake in axle-drive motor (mechanical/hydraulic)
Travel speed range switch position /defective/wiring
Charge pump / charge pressure relief valve(s)
dirty/defective
Pump control (servo control)
Pressure override/ travel pump high pressure limitation
dirty/out of adjustment/defective
Adjustment of travel cable
Travel pump mechanical neutral
Travel pump(s) defective
Axle drive motor control valve (electric / mechanical / hydraulic)
Flushing valve axle drive motor seized
Travel motor(s) defective
Hydraulic oil cooler soiled (internally/externally)
Thermostat (hydraulics) soiled/jammed/defective
Clutch- Dieselmotor-Pumpe
Dieselmotor
1
2
2 3
1
2
2 1 2 3
3 2
3 3
1 2
3 3
3 2
1 2
3
3
3
3
1
2
2
1
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Vibration system
The vibration system of the single drum rollers of generation D-40 works with two frequencies and two
amplitudes. This enables perfect adaptation of the machine to various types of soil and different
applications.
The vibration drive is a closed hydraulic circuit. The circuit consists of:
the vibration pump,
the vibration motor and
the pressure resistant connecting hoses
to release the brake
from charge pump via

Travel pump
D
L2
M3
Charge oil
Vibration pump
Block
A
M1
M2
S
B
M4
M5
Fig. 1: Vibration circuit

1
2
Vibration pump
Vibration motor
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Vibration pump and travel pump are joined together to a tandem pump unit. This tandem unit is directly
driven by the diesel engine.
When operating a 4/3-way solenoid valve on the pump control the pump is actuated out of neutral
position to one of the two possible displacement positions, pilot oil from the charge circuit is guided to
one of the two control piston sides. The swash plate inside the pump will swash to the corresponding
side and the pump will deliver oil to the vibration motor. The vibration motor starts and rotates the
vibrator shaft inside the drum.
When altering the position of the swash plate through the neutral position to the opposite side, the oil
flow will change its direction and the vibration motor will change its sense of rotation.
Since the end stops for the swash plate are set to different swashing angles to both directions, the angle
for the piston stroke is also different to both sides. This angle influences the length of the piston stroke
and thereby the actual displacement of the pump.
Large angle = high displacement = high vibrator shaft speed (frequency)
Small angle = low displacement = slow vibrator shaft speed (frequency)
The eccentric weights on the vibrator shaft are fitted with additional change-over weights. Depending
on the sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic
weights.
This results in the following constellations:
Basic weight + change-over weight = high amplitude
Basic weight - change-over weight = low amplitude
In order to achieve effective compaction results the vibration system is designed in such a way, that high
amplitude is coupled with low frequency and low amplitude with high frequency.
Fig. 2:
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Vibration pump
Similar to the travel pump the vibration pump is also a swash plate operated axial piston pump with
variable displacement for operation in a closed circuit.
The displacement of the pump is proportional to the engine speed and the chosen displacement.
When actuating the swash plate out of neutral position the flow quantity to the chosen direction will
increase from 0 to the maximum value. When altering the position of the swash plate through the
neutral position to the opposite side, the oil flow will change its direction and the vibration motor will
change its sense of rotation. All valves and safety elements for operation in a closed circuit are
integrated in the pump.
Releasing the brake
from charge pump via

Travel pump
Charge oil
Vibration pump
D
L2
M3
1 Vibration pump
2 Charge pump
3 High pressure limitation
Block
4 4/3-way solenoid valve

A
M1
M2
M4
M5
Fig. 3: Hydraulic diagram vibration pump
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Function
Fig. 4Cross-section of vibration pump

1
Servo piston
Working pistons
Charge pump
Valve plate
Roller bearing
Swash plate
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1
2
5
Fig. 5 Cross-section of vibration pump

1
Control
Servo piston
Friction free swash plate bearing
Attachment plate
Spool valve
The engine drives the drive shaft with the cylinder block. The cylinder block carries the working pistons.
The slipper pads rest against the sliding surface of the swash plate and are at the same time held on
the sliding surface by a retaining device.
During each rotation the piston pass through their upper and lower dead centre back to their initial
position. Between both dead centres each piston performs a full working stroke. During this stroke
movement oil is drawn in from the low pressure side of the closed circuit and pressed out through the
slots in the valve plate into the high pressure side. The oil quantity depends on the piston area and the
length of the working stroke.
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During the suction stroke the oil is drawn into the piston chamber, i.e. the charge pressure forces it into
the piston chamber. On the opposite side the piston presses the oil out into the high pressure side of he
closed circuit.
Control
The electro-hydraulic displacement control (remote control) converts the electric input signal to a load
controlling output signal. Since the pump is not equipped with a proportional control, but a 12 Volt
solenoid valve, the pump is always actuated to one of the two end stop positions.
Charge pumps
These machines are equipped with two charge pumps.
One of the pumps is an external gear pump, which is directly driven by the auxiliary output of the engine
and serves also as steering pump.
The second pump is an internal gear pump and is located in the end cover of the vibration pump.
The oil flow generated by the charge pumps is joined together with the return flow from the steering
valve before the hydraulic oil filter and flows through the filter to the charge ports on travel pump and
vibration pump.
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High pressure relief valves
As a measure to protect the closed vibration circuit against to high pressures the vibration pump is fitted
with pressure relief valves.
1
2
Fig. 6Pressure relief valve

1
From the charge pump
Closed circuit
High pressure relief valve with

integrated boost check valve
Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the
vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this
phase. The high pressure relief valve reduces these pressure peaks to a value of max. 371 bar
(pressure difference between high and low pressure side = 345 bar + charge pressure = 26 bar).
The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the
closed vibration circuit. The function of these valves has already been described in the chapter "travel
system".
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Vibration motor
The vibration motor is a Bosch-Rexroth (Hydromatik) axial piston motor of series A10FM 45 with fixed
displacement in bent axle design. Since the motor can be subjected to pressure from both sides, it is
most suitable for the use in closed hydraulic circuits.
The output speed of the motor depends on the oil quantity supplied by the vibration pump.
10
Fig. 7Cross-section of vibration motor

1
2
Flushing valve block

Flushing valve
Working pistons with slipper pads
Roller bearing for output shaft
Radial seal
Output shaft
swash plate
Retaining plate
Pre-tensioning spring
10
Flushing pressure relief valve
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The output torque raises with increasing pressure difference between low and high pressure side in the
closed circuit.
Changing the flow direction of the oil will also change the sense of rotation of the vibration motor.
When switching the vibration on the motor must first start to move the resting vibration shaft. This
resistance causes a hydraulic starting pressure, which is limited to 345 bar by the corresponding high
pressure relief valve. Once the vibrator shaft has reached its final speed, the pressure will drop to a
value between 100 and 150 bar (operating pressure). The value of the operating pressure mainly
depends on the condition of the ground (degree of compaction, material etc.).
Hard ground = High operating pressure
Loose ground = Low operating pressure
MA
A
2
MB
Fig. 8Circuit diagram of vibration motor

1
Vibration motor
Flushing valve
Flushing pressure relief valve
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The vibration motor is equipped with an integrated flushing valve. When switching the vibration on a
pressure difference will appear between the two sides of the closed circuit. The higher pressure moves
the valve spool of the flushing valve against the neutral setting spring, so that oil can flow out of the low
pressure side.
Fig. 9 Flushing valve

1
2
Flushing spool
Flushing pressure limitation valve
The flushing valve is fitted with a downstream 13 bar pressure relief valve. This valve ensures that only
a certain quantity of hydraulic oil is flushed out of the low pressure side.
This oil flows via a thermostat valve back to the hydraulic tank. The flushed out oil is immediately
replaced with fresh and filtered oil through the corresponding boost check valve.
BW 211 / 212 / 213 D-40
280
- F 10 -
BOMAG
008 911 63
10.2
Service Training
Service Training
Drum
14
13
7
10
11
12
1
Fig. 10Cross-section of drum
1
Drum shell
Change-over weight
Vibration bearing
Coupling vibr.-motor vibrator shaft
Basic weight
10
Travel bearing
Vibrator housing
11
Travel bearing housing
Cooling fan
12
Rubber buffer
Vibrator shaft
13
Vibration motor
Elastic coupling between shafts
14
Flanged bearing housing
BW 211 / 212 / 213 D-40
008 911 63
- F 11 -
BOMAG
281
10.2
Service Training
Service Training
Vibration system: Components and test ports
Vibration pump
11
3
2
5
3
6
5 4
4
Pos.
Designation
1
2
Pressure test port, charge pressure

Hydraulic oil filter (charge circuit)
with visual pressure differential
indicator
High pressure port,
low
amplitude
High pressure port,
high
amplitude
Solenoid valve, low amplitude
Solenoid valve, high amplitude
3
4
5
6
Measuring values
MA
07
26 bar
MF
ME
Y08
Y07
BW 211 / 212 / 213 D-40
282
Pos. in hydraulic
diagram
12V / 3,33A
12V / 3,33A
- F 12 -
BOMAG
008 911 63
10.2
Service Training
Service Training
Vibration pump
Pos.
Designation
Pressure test port, vibration

pressure low amplitude
Pressure test port, vibration
pressure high amplitude
low amplitude
Measuring values
MF
max. 371 bar
ME
max. 371 bar
high amplitude
BW 211 / 212 / 213 D-40
008 911 63
Pos. in hydraulic
diagram
- F 13 -
BOMAG
283
10.2
Service Training
Service Training
Vibration motor
1
2
3
4
Pos.
Designation
1
2
3
High pressure port, high amplitude

High pressure port, low amplitude
Leak oil and flushing oil port
16
16
16
4
5
Flushing spool
Flushing valve
16
16
BW 211 / 212 / 213 D-40
284
Pos. in hydraulic
diagram
Measuring values
approx. 7 l/min,
incl. flushing
quantity
13 bar
- F 14 -
BOMAG
008 911 63
10.2
Service Training
Service Training
Trouble shooting
Procedure:
SYMPTOMS
TROUBLE SHOOTING
VIBRATION
BW 211 / 212 / 213 D-40
No vibration (charge pressure OK)

Vibration only with one amplitude
Exciter shaft speed too low
POSSIBLE CAUSES
Vibration switch (amplitude pre-selection)
Vibration push button (on/off)
Electrics defective / wiring
Pump control (electrical / hydraulic)
Pressure override / high pressure relief valves in vibration pump
soiled/out of adjustment/ defective
Charge pump / charge pressure relief valve
soiled/ defective
Vibration pump frequency adjustment
Vibration pump defective
Coupling between diesel engine and travel pump defective
Exciter shaft bearings defective
Vibration motor coupling defective
Vibration motor defective
Diesel engine
1 1
1
2 2
1 1
2
2
2
2
2
3
2
2
1
1
BW 211 / 212 / 213 D-40
008 911 63
BOMAG
285
10.2
Service Training
Service Training
Steering
Single drum rollers of series BW 211 / 212 / 213 D-40 are equipped with a hydrostatically operated
articulated steering system.
The steering system mainly consists of steering pump, steering valve, steering cylinders and pressure
resistant connecting hoses.
to charge
system
1
7
6
5
3
2
4
from steering pump
Fig. 1Steering hydraulics

1
Rating pump
Distributor valve
Steering pressure relief valve (p =175 bar)
Check valve (pre-loaded to 0.5 bar)
Anti-cavitation valve
Shock valves (240 bar)
Steering cylinders
The steering pump draws the hydraulic oil out of the hydraulic oil tank and delivers it to the steering valve
and the connected steering unit under the operator's platform of the machine. If the steering is not
operated, the complete oil supply will flow through the fine filter to the charge system for the closed travel
circuits.
When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side
of the steering cylinder. A rating pump inside the steering unit measures the exact oil quantity
corresponding with the turning angle of the steering wheel and delivers the oil to the steering cylinders.
The steering cylinders retract or extend and steer the machine.
The steering unit is equipped with a pressure relief valve. This valve limits the steering pressure to 175
bar. The charge pressure must, however, be added to this value, because the oil leaving the steering
system enters the charge circuit. The actual steering pressure is therefore approx. 200 bar.
BW 211 / 212 / 213 D-40
286
-G1-
BOMAG
008 911 63
10.2
Service Training
Service Training
Steering pump
The steering pump is a gear pump with fixed displacement. It is driven by the auxiliary drive of the diesel
engine, draws the hydraulic oil out of the hydraulic oil tank and pumps it through the steering valve to
the steering cylinders or to the boost check valves for travel and vibration circuits.
3
8
2
Fig. 2Steering pump

1
Housing
Flange
Shaft
Bearing plate
Bearing plate
Cover
Gear (driving)
Gear (driven)
Seals
BW 211 / 212 / 213 D-40
008 911 63
-G2-
BOMAG
287
10.2
Service Training
Service Training
Working principle of the gear pumps
The drive gear of the steering pump is connected with the auxiliary drive of the diesel engine via a
coupling. Drive gear and driven gear are positioned by a bearing plate in such a way, that the teeth of
both gears mesh with minimum clearance when rotating.
The displacement chambers are created between the tooth flanks, the inside wall of the housing and
the faces of the bearing plates.
When the pump is running the chambers transport hydraulic oil from the suction side to the pressure
side. This causes a vacuum in the suction line by which the hydraulic oil is drawn out of the tank. The
tooth chambers transport the fluid to the outlet of the pump from where it is pressed to the consumers.
To ensure a safe function of the pump the tooth chambers must be so tightly sealed that the hydraulic
fluid can be transported from the suction side to the pressure side without any losses.
For this purpose external gear pumps are fitted with gap seals. This causes pressure dependent fluid
losses from the pressure side to the suction side. As a measure to ensure that these losses are reduced
to a minimum, the bearing plate on the cover side is pressed against the faces of the gears by an axial
pressure field.
This pressure field is always under the actual system pressure.
BW 211 / 212 / 213 D-40
288
-G3-
BOMAG
008 911 63
10.2
Service Training
Service Training
Steering valve
The steering valve block consists mainly of distributor valve, measuring pump, pressure relief valve and
shock valves.
1
9
3
4
5
8
6
7
Fig. 3Cross-sectional view of steering valve

1
Neutral setting springs
Housing
Inner spool
Outer spool
Universal shaft
Ring gear
Gear
Check valve
Pressure relief valve
When turning the steering wheel the distributor valve guides the oil flow from the pump to the rating
pump.
The rating pump guides the oil flow through the distributor valve to the corresponding
sides of the steering cylinders. The rating pump measures the exact oil quantity in accordance with the
rotation angle of the steering wheel.
This oil flow to the steering cylinders articulates the machine and causes a steering movement.
BW 211 / 212 / 213 D-40
008 911 63
-G4-
BOMAG
289
10.2
Service Training
Service Training
240 bar
p = 175 bar
240 bar
0,5 bar
Fig. 4Steering valve, hydraulic diagram

The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar.
The charge pressure value must be added to this pressure, because the oil leaving the steering system
is fed into the charge circuit for the closed travel circuits.
The steering unit is fitted with so-called shock valves in each supply line to the steering cylinder. These
valves are adjusted to an opening pressure of 240 bar. The valves compensate extreme pressure peaks
which may occur, e.g. when driving over obstructions, and protect the system against overloads.
Each of these shock valves is fitted with an additional anti-cavitation valve. If the shock valves respond
these anti-cavitation valves protect the system against cavitation damage.
A check valve at the inlet of the steering unit makes sure that no oil will flow back to the pump in case
of pressure peaks caused by sudden steering movements. In such a case the steering cylinders would
act as pumps and press the oil back to the pump.
BW 211 / 212 / 213 D-40
290
-G5-
BOMAG
008 911 63
10.2
Service Training
Service Training
Articulated joint
Front and rear frames of the single drum rollers are connected by an oscillating articulated joint. This
ensures that drum and wheels are at all times in contact with the ground, even when driving extreme
curves.
Fig. 5Articulated joint
BW 211 / 212 / 213 D-40
008 911 63
-G6-
BOMAG
291
10.2
Service Training
Service Training
The rear console is tightly bolted to the rear frame.
The front console is fastened with screws to the rear cross-member of the front frame. The use of rocker
bearings between front and rear frame ensures that both frames can oscillate to each other for +/- 12.
This gives drum and wheels excellent ground contact, even under extremely severe conditions.
The front console is connected with the rear console by two vertical bolts. The vertical bolts are mounted
in friction bearings.
The steering cylinder anchor point is welded to the front console.
When turning the steering wheel the steering cylinder will extend or retract. The piston rod swivels the
front console around the vertical bolts. This articulates the machine and results in a steering movement.
All bearings on the articulated joint are maintenance free and do not require any lubrication.
Notes on assembly:
When assembling or repairing the articulated joint the correct pretension of the centre pin is of highest
importance.
Please follow the instructions in the repair manual for the articulated joint.
BW 211 / 212 / 213 D-40
292
-G7-
BOMAG
008 911 63
10.2
Service Training
Service Training
Steering: Components and test ports
Steering pump
Pos.
Designation
1
2
Steering pump (and charge pump)

Steering pressure test port
09
MB
BW 211 / 212 / 213 D-40
008 911 63
Pos. in hydraulic
diagram
Measuring values
max. 175+26 bar
-G8-
BOMAG
293
10.2
Service Training
Service Training
Vibration and noise damper
The damper is located in the steering/charge circuit directly after the steering and charge pump.
It is subjected to hydraulic oil flow and has the function of eliminating any vibrations and noises.
The damper is mounted to the front plate of the rear frame, between both steering cylinders.
BW 211 / 212 / 213 D-40
294
-G9-
BOMAG
008 911 63
10.2
Service Training
Service Training
Steering valve
The steering valve is located under the operator's stand
BW 211 / 212 / 213 D-40
008 911 63
- G 10 -
BOMAG
295
10.2
Service Training
Service Training
Trouble shooting
Procedure:
No steering function
End stops are not reached
Steering hard to move
SYMPTOMS
TROUBLE SHOOTING STEERING

SYSTEM
BW 211 / 212 / 213 D-40
POSSIBLE CAUSES
Steering orbitrol valve
Steering/charge pump
Steering cylinder
Articulated joint
2
1
3
3
2
1
3
3
1
2
3
2
BW 211 / 212 / 213 D-40
296
BOMAG
008 911 63
11 Engine
008 911 63
BOMAG
297
298
BOMAG
008 911 63
11.1
Diesel engine, general
11.1 Diesel engine, general
Fig. 1 Engine compartment
Single drum rollers of series BW211/213 D/PD-4 are

powered by Deutz diesel engines type BF4M 2012 C
with intercooling. The intercooler reduces the thermal
load on the engine, the exhaust temperature and the
fuel consumption and thus enables a higher power
output.
The engines are characterized by the following positive features:
l
short and compact design
low noise level
almost vibration free operation
low fuel consumption
low exhaust emissions (EPA II)
high power reserves and
excellent access to all service locations.
The pistons are made of aluminium alloy. The side

walls of the slightly externally arranged combustion
trough are inclined towards the inside by 10. All pistons are fitted with three piston rings and a cast iron
ring carrier for the first ring. The pistons are oil mist lubricated.
The forged crankshaft is designed with integrated
counter weights.
The block-type cylinder head is made of cast steel.
Each of the cylinders has an inlet and an outlet valve.
The valve guides are shrunk into the cylinders. The
valve seat rings are made of high quality steel and
also shrunk fit.
Crankcase and cylinders on this engine are made of

alloyed cast iron. This provides rigidness and high
wear resistance.
The forged steel conrods are designed with balancing
weights in the area of the conrod bearing seats. These
weights compensate manufacturing tolerances with
respect to weight and position of the centre of gravity.
008 911 63
BOMAG
299
11.2
Service side
11.2 Service side
Fig. 1 Service side
Oil filler neck
Lubrication oil cooler
Engine solenoid
Oil pressure switch (B06)
Radiator fan
Fuel pump
V-belt pulley
Main fuel filter
Lubrication oil filter
10 Oil sump
11 Oil dipstick
12 Compressor (only BW24/27 RH
13 Plug-in injection pumps
14 Generator
15 Heating flange (R19, option)
16 Hydraulic pump
17 Tensioning roller with torsion spring
18 Crankcase ventilation valve
300
BOMAG
008 911 63
11.3
Starter side
11.3 Starter side
Fig. 1 Starter side
Exhaust manifold
Exhaust turbo charger
Oil filling (optional)
Engine mounts
Oil return line from turbo charger
Relay (starter)
Ribbed V-belt
Coolant inlet
Coolant outlet
10 Coolant pump
11 Connection of compensation line
008 911 63
BOMAG
301
11.4
Lubrication oil circuit
11.4 Lubrication oil circuit
Fig. 1 Lubrication oil circuit
18 Leak oil return line
Oil sump
19 Oil filter
Return flow from turbo charger to crankcase
20 Suction line
Turbo charger
21 Crankshaft bearings
Oil line to turbo charger
22 Conrod bearings
Line to mass balancing gear (2 x)
Oil pressure sensor
Valve with pulse lubrication
Push rod, oil supply to rocker arms
Line to spray nozzles
10 Rocker arm
11 Return flow to oil sump
12 Nozzle for piston cooling
13 Camshaft bearings
14 Main oil channel
15 Lubrication oil cooler
16 Oil pump
17 Pressure relief valve
302
BOMAG
008 911 63
11.4
Lubrication oil circuit

General
The oil inside the combustion engine has the function
of lubricating and cooling all drive components, removing impurities and neutralizing chemically effective combustion products, transferring forces and
damping vibrations.. The oil is only able to fulfil this
function, if sufficient quantities are transported to the
critical points in the engine and if its properties are
adapted to the prevailing requirements by corresponding manufacturing processes and refining (additives).
Figure (1) shows pressure circulation lubrication in
combination with splash and oil mist lubrication. Here
oil is transported under pressure to all bearing locations by the oil pump (16), while sliding surfaces are
splash or oil mist lubricated. After flowing through the
bearing locations and along sliding surfaces the oil is
collected in the oil sump (1) under the drive, where the
oil is cooled, defoamed by calming and stored.
The oil filter (19) removes solid foreign particles from
the engine oil (combustion residues, metal abrasion,
dust) and thus maintains the function of the lubrication
oil during the maintenance intervals.
008 911 63
BOMAG
303
11.5
Oil pressure switch and low oil pressure circuitry
11.5 Oil pressure switch and low oil

pressure circuitry
Fig. 1
Oil pressure switch
Pos.
1
304
Designation in
circuit diagram
B06
Designation
Technical data
Oil pressure switch
Below 0.8 bar the contact switches to

engine ground, closed without pressure. Tightening torque 20 +/-2 Nm
with copper ring.
BOMAG
008 911 63
11.6
Check the engine oil level
11.6 Check the engine oil level

! Danger
Danger of injury!
Support the engine hood for all maintenance and

repair work.
Note
The machine must be parked horizontally with the engine shut down.
Fig. 2 Oil pressure switch
The oil pressure switch (B06) is mounted to the engine oil filter. After starting it reports when a safe operating pressure has been reached and causes the
warning light in the monitoring board (A15) to light, if
the engine oil pressure drops below approx. 0.8 bar.
In case of too low engine oil pressure with the engine
running, the monitoring board (A15, terminal 9) will
send a time delayed (10 sec.) 12 V signal to relay K22
(terminal 86). The relay interrupts the electric power
supply to the solenoid valve (Y13) and the diesel engine is shut down.
Fig. 3
l
Pull the dipstick (Fig. 3) out, wipe it off with a lintfree, clean cloth and reinsert it until it bottoms.
Pull the dipstick back out again.
If the oil level is below the "MAX" mark fill in oil.
If the oil level is above the Max mark determine the

cause and drain the oil off.
Caution
Before longer work periods you should always top
the oil up to the "MAX"-mark.
!
For quality and quantity of oil refer to the table of

fuels and lubricants.
008 911 63
BOMAG
305
11.7
Changing engine oil and oil filter cartridges
11.7 Changing engine oil and oil filter cartridges

Caution
The oil change at 500 operating hours refers to the
use of oils of oil quality class API CG-4/CH-4 or
ACAE E3-96/E5-02 respectively.
!
Refer also to the chapter 5.2, fuels and lubricants.

Drain the engine oil only when the engine is warm.
Danger
Danger of scalding!
!
Fig. 5
l
Thoroughly clean the outside of both filter cartridges

(Fig. 5).
Unscrew both filter cartridges using an appropriate

filter wrench.
When draining off hot oil.

By hot oil when unscrewing the engine oil filter.
Environment
Catch running out oil and dispose of environmentally together with the engine oil filter cartridge.
Note
The filter cartridges are fitted with a valve that prevents engine oil from running out during removal and
installation.
l
Clean the sealing face on the filter carrier from any

dirt.
Slightly oil the rubber seal on the new filter cartridges.
Fig. 4
l
Unscrew the drain plug (Fig. 4) and catch running

out oil.
Turn the drain plug tightly back in.
Fig. 6
306
Turn the new filter cartridges (Fig. 6) on by hand,

until the seal contacts.
Tighten the filter cartridges for another half turn.
BOMAG
008 911 63
Changing engine oil and oil filter cartridges
11.7
Fig. 7
l
Fill in new engine oil (Fig. 7).
For quality and quantity of oil refer to the table of

fuels and lubricants.
l
Tighten the oil filler cap properly.
!
Caution
Before starting crank the engine with the starter
motor until the oil pressure warning light goes
out.
l
After a short test run check the oil level on the dipstick, if necessary top up to the top dipstick mark.
Check filter cartridge and drain plug for leaks after a

short test run.
Shut the engine down and wait for about 15 minutes, so that all oil can flow back into the oil sump.
Check the oil level again, if necessary fill up to the

Max.-mark.
008 911 63
BOMAG
307
11.8
Coolant circuit
11.8 Coolant circuit
Fig. 1 Coolant circuit
Radiator
To radiator
From radiator
Coolant pump
Cylinder cooling
Cylinder head cooling
Ventilation connection from cylinder head to heat

exchanger
Fan
308
BOMAG
008 911 63
11.8
Coolant circuit
General
In order to avoid thermal overloads, burning of lubrication oil on piston sliding surfaces and uncontrolled
burns caused by high component temperatures, the
components surrounding the combustion chamber,
like cylinders, cylinder head, valves and possibly also
the pistons, must be cooled intensively.
Brief description
The coolant pump ("water pump") draws coolant
through the hose lines directly out of the radiator and
forces it first of all through the lubrication oil cooler,
which is integrated in the engine. The coolant then enters into the engine, flows up along the cylinders into
the cylinder head and to the thermostat at the coolant
outlet. Form their the coolant is returned through the
corresponding lines to the radiator inlet. When the engine is cold the coolant is pumped in a short circuit
through the engine, until the response temperature of
the thermostat (start of opening) is reached. The water pump draws cold coolant out of the radiator, as required to replenish the hot out flowing coolant.
Fig. 2 Direct heating
Thermostat
Coolant pump
Heat exchanger
The coolant is a mixture of water and anti-freeze

agent. The anti-freeze agent increases the boiling
temperature of the mixture and thus enables temperatures of up to 120 C at an overpressure of up to 1.4
bar.
The coolant compensation tank enables reliable gas
separation, thus avoiding cavitation in the cooling system, which mainly occurs in the suction side of the
pump. The air volume inside the compensation must
be so high, that quick build-up of pressure in case of
heating and expansion of coolant is assured and any
escape of coolant during after-boiling is avoided.
The radiator (1) dissipates the waste heat generated
in the engine into the into the environment.
Part of the combustion heat is transferred to the lubrication oil. The lubrication oil cooler (5) serves the
function of cooling the lubrication oil.
Heating
Water-cooled DEUTZ diesel engines utilize the coolant to heat the driver's cab. For this purpose the engine coolant is guided directly to the heat exchanger
and the heat is directly dissipated into the environment (direct heating).
008 911 63
BOMAG
309
11.9
Coolant temperature switch
11.9 Coolant temperature switch
Fig. 1 Coolant temperature switch
Pos.
310
Designation in
circuit diagram
B152
Designation
Technical data
Contact switches at approx. 110 C

to engine ground
BOMAG
008 911 63
Disassembling and assembling the coolant temperature switch
11.10Disassembling and assembling the coolant temperature

switch
Removal
l
Turn the battery disconnecting switch to position

"OFF".
Installation
l
Clean thread and seat for switch.
Install the temperature switch with Loctite 577 and

a new seal, tightening torque 20 Nm.
Push the plug back on (plug interlock clicks into

place).
Check the plug interlock by lightly pulling on the wiring loom.
Fill in coolant up to the MAX mark .
Open the lid on the coolant reservoir.
! Danger
Danger of scalding!
11.10
For quality of coolant refer to the chapter 5.2, fuels

and lubricants.
Do not remove the cap from the compensation

tank when the engine is still hot.
Run the engine up to operating temperature.
Note
Check the area around the coolant temperature sensor for leaks.
l
Let the engine cool down and check the coolant level again, top up if necessary.
Fig. 2 Temperature switch

l
Press in the locking wire and disconnect the plug

(Fig. 2).
Lay a cloth around the temperature switch and

catch running out coolant.
Environment
Dispose of escaping coolant environmentally
l
Unscrew the temperature switch.

l
Remove and dispose of the seal (Fig. 3).
008 911 63
BOMAG
311
11.11
Replacing the thermostat
11.11Replacing the thermostat

Open the lid on the coolant reservoir.
Danger
Danger of scalding!
!
Do not remove the cap from the compensation

tank when the engine is still hot.
Drain the coolant from the engine and catch it.
Environment
Catch running out coolant and dispose of environmentally.
Fig. 6
l
Assemble the outlet socket (Fig. 6).
Tightening torque: 30 Nm
Install the coolant hose again.
Fill in coolant up to the MAX mark .

and lubricants.
Run the engine up to operating temperature.
Note
Check for leaks around the thermostat.

l
Fig. 4
l
Disconnect the coolant hose.
Remove the outlet socket (Fig. 4).
Remove the thermostat.
Fig. 5
l
Fit a new seal to the thermostat.
Insert the new thermostat with the seal ring (Fig. 5).
Note
Mind the installation position. The arrow (ventilation

groove) points up.
312
BOMAG
008 911 63
11.12
Checking the thermostat in disassembled state
11.12Checking the thermostat in

disassembled state
The temperature increase should not exceed 1C/

min, as otherwise the start of opening will be delayed
accordingly.
The thermostat serves the optimal temperature control of the coolant, in order to promote efficient combustion and to bring the engine quickly to operating
temperature after starting. At temperatures below approx. 83C the thermostat is closed. Once the coolant
temperature has reached about 83C, the thermostat
will start to open, at about 95 C it is fully open. In this
condition the full coolant flow is guided through the radiator.
Fig. 3
l
Measure and write down the measurement "b" on

the thermostat . (Fig. 3).
Calculate the stroke.
Stroke = b - a
i
Fig. 1
Measure and write down the measurement "a" on

the thermostat (Fig. 4).
Note
The stroke at the given temperature (T2) should be

min. 8 mm.
Note
"a" = beginning of stroke at approx. 83 2C (T1)

"b" = end of stroke at approx. 95 C (T2)
Fig. 2
Warm up the thermostat in a water bath (Fig. 2).
Note
In order to determine the exact start of opening the

temperature should be measured as close to the thermostat as possible, but without touching it.
The water must thereby be stirred continuously, to ensure even temperature distribution.
008 911 63
BOMAG
313
11.13
Check the coolant level
11.13Check the coolant level
11.14Change the coolant
! Danger
Danger of scalding!
! Danger
Danger of scalding!
Fill up coolant only when the engine is cold.
Change the coolant only when the engine is cold.

Environment
Catch running out coolant and dispose of environmentally.
Fig. 4
Check the coolant level (Fig. 4).
Caution
If, during the daily inspection the coolant level is
found to have dropped, check all lines, hoses and
engine for leaks.
!
Fig. 5
l
Set the cock valve for the cabin heater to position

"warm".
To top up unscrew the filler cap and fill in coolant up

to the MAX-mark.

and lubricants.
Fig. 6
314
Unscrew the plug, let the coolant run out and catch
it.
Screw the plug back in once all coolant has run out.
BOMAG
008 911 63
Clean the cooling fins on engine and hydraulic oil cooler
11.15
11.15Clean the cooling fins on engine and hydraulic oil cooler

Danger
Danger of injury!
!
Perform cleaning work only after the engine has

cooled down and with the engine stopped.
Caution
Do not damage any cooling fins on the cooler core
when cleaning.
!
Fig. 7
l
Unscrew the cap and fill in coolant up to the MAXmark.

and lubricants.
l
Start the diesel engine and run it warm to operating

temperature.
Note
Dirt on fan blades and oil cooler reduce the cooling effect. Dirt deposits in these areas are substantially supported by oil and fuel on these surfaces. For this
reason you should always seal any oil or fuel leaks in
the vicinity of the cooling fan or the oil cooler and clean
the cooling surfaces after.
Cleaning with compressed air
Fig. 8
Note
Start to blow out from the exhaust side.

Blow the cooler (Fig. 8) out with compressed air.
Cleaning with cold cleansing agent

Caution
Protect electrical equipment such as generator,
regulator and starter against the direct water jet.
!
008 911 63
Spray the engine with a suitable cleansing agent,

e.g. cold cleanser, let it soak in for a while and spray
it off with a strong water jet.
Run the engine warm for a while to avoid corrosion.
BOMAG
315
11.16
11.16Three-phase generator
Fig. 1
Generator (G02)
Pos.
B+
D+
W
316
Designation in
circuit diagram
B+
D+
W
Designation
Technical data
Battery Plus
Dynamo Plus
Rotational speed signal
14.4 Volt, 90 Amp.

14.4 Volt, maximum load 0.2 Amp.
pulsing D.C. voltage to determine the
engine speed
BOMAG
008 911 63
11.16
General
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the vehicle with electric current at a steady voltage already
at idling speed.
Note
The generator is maintenance free. Function tests and

repair work must only be performed in authorized
workshops.
!
Caution
Before removing the generator you must 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 electronic equipment.
When disassembling the battery cable, the B+-nut

underneath on the generator side may also be
loosened. This nut must in this case be 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 circuit and damage to the rectifier elements - the generator will be out of function.
The generator can only be operated with the battery connected. Under special conditions emergency operation 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. After cleaning the generator should
be operated for about 1 - 2 minutes to remove any
deposits of water from the generator.
008 911 63
BOMAG
317
11.17
Fuel supply
11.17Fuel supply
Fig. 1 Fuel supply
11 Pressure retaining valve - 5 bar
Water separator sensor connection
12 Return flow to tank
Flow to fuel lift pump
13 Fuel tank
Fuel lift pump
14 Manual fuel pump
Connecting line between fuel lift pump and main

filter (fuel pre-pressure up to 10 bar)
15 Fuel pre-filter
Main fuel filter (pressure proof)
17 Fuel pre-heating connection (option)
Connecting line between main filter and flow to injection pumps
18 Fuel pre-heating (R79) 200 Watt (option)
Single-cylinder injection pump
High pressure line
Injection nozzle
16 Water separator
19 Water separator sensor (B124)
10 Leak oil line
318
BOMAG
008 911 63
11.17
Fuel supply
Work in the low pressure system
Service and repair work in the low pressure system,
including main fuel filter changes, are only permitted
under absolutely clean environmental conditions, because even smallest dirt particles entering into the
high pressure fuel system will cause considerable
damage. Air pollution, like dirt, dust, moisture etc.
must be strictly avoided. Before starting work in the
fuel system (including filter changes) the engine must
be thoroughly cleaned and dried (steam cleaning
equipment). Engine compartments in which dirt deposits may come loose, must be covered with new
and clean foil. When working in the open you may
need to apply protective measures against dust entering because of wind.
Danger
For diesel fuel the ignition temperature, i.e. the
temperature at which fuel will ignite when coming
into contact with air, is approx. 220C, but may deviate strongly because of impurities.
!
Fuel conducting components and lines therefore

are a source of danger inside the engine compartment, because leaks may lead to fire resulting in
considerably damage to material and persons.
008 911 63
BOMAG
319
11.17
Fuel supply
Check valve
Fig. 1
l
According to our experience, it is not always assured that only clean fuel will be used. Fuel tanks
are frequently filled without suitable precautions
against contamination or fuel filters are inappropriately serviced. Many damage analyses on injection
pumps and injection valves have revealed that most
of these components had failed due to premature
wear. Wear on injection pump plunger and injection
valve needle seat is caused by contaminated fuel.
Modern exhaust optimized diesel engines with high
pressure injection systems strictly require clean fuel
to be able to work reliably over their entire lifetime.
If the throttle resistances of pre-cleaner/main filter
caused by contaminated fuel are so high that the
fuel pump is no longer able to ensure a sufficient
fuel supply, the injection pumps will draw the required fuel through the leak fuiel return line from the
tank without filtration. The engine is no longer able
to provide its full power, operation of construction
equipment or other machines, however, may still be
possible to a limited extent. After short time operation under such conditions the injection system
components may already be pre-damaged.
320
Fig. 2 Observe the direction of flow
Note
From August 2006 the check valve (Fig. 2) is used by

BOMAG in series machines.
Caution
This valve must strictly be installed into the fuel
return line by our customers.
!
BOMAG
008 911 63
11.18
Injection system
11.18Injection system
The injection system serves the fuel supply for the diesel engine.
The low pressure side of an injection system includes
fuel tank, fuel filter and fuel lines.
In the high pressure side the injection pump generates
the pressure required for injection. The fuel is pumped
through the pressure line to the injection pump, from
where it is injected into the combustion chamber.
Load and speed of the diesel engine are adjusted via
the fuel quantity without throttling the intake air. With
a sufficient injection quantity the speed of an unloaded
diesel engine may therefore rise up to the point of self
destruction. A governor for engine speed limitation is
therefore required.
Single cylinder plug-in injection pumps

Deutz diesel engines series 2012/1013 are equipped
with Bosch cylinder plug-in injection pumps series PF
33.
The concept of plug-in injection pumps enables the realization of high injection pressures, combined with
short injection lines, which is necessary to ensure a
high hydraulic stiffness of the injection system. This, in
turn, creates the prerequisite for maintaining low exhaust emission values (soot) in combination with low
fuel consumption values.
The start of injection is influenced by:
l
the fuel consumption

the power
the exhaust emission
Fig. 3 Single cylinder plug-in injection pump
The drive cams 2 (Fig. 3) for the single PF-injection

pumps are located on the camshaft (1) for engine
valve control.
Permissible manufacturing tolerances for the components:
l
Cylinder crankcase
Camshaft
Roller-type plunger
Plug-in injection pump
are determined and eliminated by the adjustment of

the start of injection.
of the engine.
The term "start of injection" refers to the start of the injection pump delivering fuel.
However, in cases of interest for BOMAG field engineers engines are not completely overhauled, but individual injection pumps are replaced. Crankcase,
camshaft and roller-type plunger remain unchanged.
This results in a certain installation measurement for
the drive, which is specified on the engine type plate.
It is stamped as "CODE" in the column "EP" for each
cylinder.
008 911 63
BOMAG
321
11.19
Injection pump replacement during service
11.19Injection pump replacement

during service
Injection valves
Injection valves have the following functions:
l
Preparation of fuel
Forming of the injection sequence
Sealing against the combustion chamber
Disassembly
The peak injection pressure of the diesel fuel is up to

1000 bar. Under these conditions the fuel no longer
behaves like a rigid fluid, but it is compressible. During
the short injection period (1ms) the injection system is
"blown up" and, depending on the nozzle size, more
or less fuel will enter into the combustion chamber.
Caution
Ensure strict cleanliness when working on the injection system.
Fig. 4 Design of injection valve
Fig. 1
Tensioning nut
Nozzle
Intermediate piece
Pressure bolt
Pressure spring
Shim
Disassemble pressure control valve and cylinder

head cover (Fig. 1).
Disconnect the cable plugs from shut-down solenoid, governor and temperature sensor.
Swing the holding plate to the side.
Note
A thicker shim 6 (Fig. 4) increases the opening pressure.

Caution
When replacing an injection pump and/or an injection valve, you must also replace the high pressure line between pump and valve.
!
Fig. 2
l
322
Remove the engine shut-down assy (Fig. 2).
BOMAG
008 911 63
11.19
Fig. 3
Fig. 5
Use the shut-down lever to push the governor rod to

stop position (Fig. 3).
Insert and fasten the pressing device 100 830.
Set the cylinder of the injection pump to be disassembled to top dead centre (TDC) for ignition
(valves overlapping) (Fig. 5).
Turn the crankshaft for approx. 120 against the

sense of rotation.
Note
Illustration shows view on flywheel.
Fig. 4
Use the knurled fastening screw to force the governor rod to stop position (Fig. 4).
Note
Tighten the knurled fastening screw by hand.
Fig. 6
Remove the injection line (Fig. 6).
Note
Close the connections with protection caps.
008 911 63
BOMAG
323
11.19
Fig. 7
l
Carefully remove the shim with a rod-type magneto

(Fig. 7).
324
BOMAG
008 911 63
11.19

Determining the start of injection
Fig. 8 Injection pump code BFM 2012
Note
Old injection pump and shim are not required for this
purpose.
Example:
The injection pump for cylinder 3 is to be replaced on
an engine BF6M 2012.
Procedure:
Read the EP-code for cylinder 3 in the column "EP"
on the type plate (table) (Fig. 8), e.g. 295.
Note
Sequence of reading: Line 1 = cyl.1, line 2 = cyl.2, etc.

l
Take the corrected injection pump installation

measurement (EK) matching the EP-code from the
table (Fig. 11), e.g. 120.875 mm.
Fig. 10 Injection pump length "A" and Lo
Note
Measurement "A" (Fig. 3) determines by how many 1/

100 of a mm the distance between cylinder crankcase
contact surface and plunger foot is longer than the basic measurement Lo.
Basic measurement of injection pump (Lo) = 117.5
mm.
l
Determine the theoretical thickness of the shim

(TS).
TS = EK - (Lo + A/100)
TS = 120.875 mm - (117.5 mm + 42/100 mm)
TS = 2.955 mm
Fig. 9 Length of injection pump (A)
l
Choose the shim thickness (SS) from the table.
Read the coefficient for the injection pump length

(A) (Fig. 9) on the new injection pump, e.g. 42.
008 911 63
BOMAG
325
11.19
TS 2.955 mm = SS 3.0 mm
Theor. thickness "TS"
(mm)
0.95 - 1.049
1.05 - 1.149
1.15 - 1.249
1.25 - 1.349
1.35 - 1.449
1.45 - 1.549
Shim thickness "SS"

(mm)
1.0
1.1
1.2
1.3
1.4
1.5
1.55 - 1.649
1.65 - 1.749
1.75 - 1.849
1.85 - 1.949
1.95 - 2.049
2.05 - 2.149
2.15 - 2.249
2.25 - 2.349
2.35 - 2.449
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
326
Theor. thickness "TS"

(mm)
2.45 - 2.549
2.55 - 2.649
2.65 - 2.749
2.75 - 2.849
2.85 - 2.949
2.95 - 3.049
3.05 - 3.149
3.15 - 3.249
3.25 - 3.349
3.35 - 3.449
3.45 - 3.549
3.55 - 3.649
3.65 - 3.749
3.75 - 3.849
BOMAG
Shim thickness "SS"

(mm)
2.5
2.6
2.7
2.8
2.9
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
008 911 63
11.19
Fig. 11 Table of injection pump codes BFM 2012
008 911 63
BOMAG
327
11.19
Assembly
Fig. 15
l
Slightly oil the receiving bore in the crankcase and

the O-rings on the injection pump.
Carefully insert the injection pump control lever into

the governor rod. (Fig. 15).
Fig. 12
Caution
The roller plunger for the corresponding injection
pump must be positioned on the base circle of
camshaft.
!
Fig. 13
l
Lay the newly determined shim on roller plungers

(Fig. 12) and (Fig. 13).
Fig. 16
l
Attach the flange (Fig. 16).
!
Caution
The chamfer must face towards the injection
pump body.
Fig. 14
l
Turn the injection pump control lever approx. to

middle position (Fig. 14).
328
BOMAG
008 911 63
11.19
Fig. 20
Fig. 17
Turn the screws in again for 60, then tighten in

steps to a torque of 7 Nm, 10 Nm and 30 Nm. (Fig.
20).
l
l
Slightly oil the screws and tighten with a torque of 5

Nm (Fig. 17).
Note
Always start with the outer screw furthest away from

the flywheel.
Fig. 18
l
Loosen the screws again for 60 (Fig. 18).
Fig. 21
l
Turn the knurled fastening screw back (Fig. 21).
Remove the pressing device.
Caution
Check whether the governor rod is light moving
between stop and start position.
!
Operate the shut-down lever to do so.

Fig. 19
l
Carefully turn the injection pump with an open end

spanner anti-clockwise against the noticeable end
stop (Fig. 19).
008 911 63
BOMAG
329
11.19
Fig. 22
Fig. 24
Assemble a new O-ring (Fig. 22).
Caution
Take care that the sealing cones match exactly
when assembling the injection line. Subsequent
bending is not permitted. The injection line must
never be used twice.
!
Note
Cover the O-ring slightly with oil.
Install the new injection line with the sealing rubber

(Fig. 24).
Pre-tension the injection line cap nuts on injection

pump and injection valve with a torque of approx. 5
Nm (use claw spanner 8018).
Tighten the cap nut with 25 3.5 Nm.
Fig. 23
l
Use the shut-down lever to push the governor rod to

stop position and hold it (Fig. 23).
Assemble the engine shut-down assy.
Tighten the screws with 21 Nm.
Plug the cable plug onto the shut-down magneto.
Fig. 25
l
330
Install the gasket (Fig. 25).
BOMAG
008 911 63
11.20
Injection valve replacement during service
11.20Injection valve replacement

during service
Note
Injection valves may wear mechanically over the

course of time. Spray pattern and injection pressure
should be tested on an injection valve test bench ("hydrostesting"). The nozzles must be disassembled for
this purpose. In case of excessive deposits on the
nozzles these may be cleaned in an ultrasonic bath
with gasoline. The injection pressure can be corrected
by means of shims.
Fig. 26
l
Assemble cylinder head cover and holding plate

(Fig. 26).
Caution
Ensure strict cleanliness when working on the injection system. Use only clean testing oil acc. to
ISO 4113 or clean diesel fuel to test the injection
valves.
!
Note
Removal
Ensure the sealing rubber is fitted correctly.

l
If necessary assemble the pressure control valve

with a new seal.
Tighten the screws with 8.5 Nm.
Fig. 1
008 911 63
Disassemble pressure control valve and cylinder

head cover (Fig. 4).
Disconnect the cable plugs from shut-down solenoid, governor and temperature sensor.
Swing the holding plate to the side.
BOMAG
331
11.20

Installation
Fig. 2
Disassemble the injection lines (Fig. 2).
Fig. 1
Slide the new seal rings with some grease over the
injection valves and insert the injection valves (Fig.
1).
Note
Close connections on injection valves and injection

pumps with protective caps.
Caution
The chamfer on the injection valves must point
away from the claws.
!
Fig. 3
Disassemble the claws and take out the injection

valves (Fig. 3).
Fig. 2
Note
In case of tight fit use the extracting device 150 800

with puller 110 030.
Attach the claws and turn the screws in loosely (Fig.

2).
Pull out the seal ring with the extracting device 120
680.
332
BOMAG
008 911 63
11.20
Fig. 3
Fig. 5
Caution
Take care that the sealing cones match exactly
when assembling the injection line. Subsequent
bending is not permitted. The injection line must
never be used twice.
Pre-tension the injection line cap nuts on injection

pumps and injection valves with a torque of approx.
5 Nm (Fig. 5).
Tighten the cap nuts with 25 + 3.5 Nm.
Install the new injection lines with the sealing rubbers (Fig. 3).
Note
Use a claw spanner 8018.
Tighten the cap nuts finger tight.
Fig. 6
l
Fig. 4
l
Install the gasket (Fig. 25).
Tighten the screws for the claws with 16 + 5 Nm

(Fig. 4).
008 911 63
BOMAG
333
11.21
Checking / repairing injection valves
11.21Checking / repairing injection

valves
Special tools:
Nozzle tester 8008
Holder for Injection valve 110 110
Long socket 8012
Caution
Ensure strict cleanliness when working on the injection system. Use only clean testing oil acc. to
ISO 4113 or clean diesel fuel to test the injection
valves.
!
Fig. 7
l
Assemble cylinder head cover and holding plate

(Fig. 26).
Check the injection valves
Note
Ensure the sealing rubber is fitted correctly.

l
If necessary assemble the pressure control valve

with a new seal.
Tighten the screws with 8.5 Nm.
Note
The injection valves are leak fuel free. Fuel cannot

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

tighten it again (Fig. 1).
Tightening instructions: 30 - 40 Nm
Note
Use injection valve holder 110 110.
334
BOMAG
008 911 63
11.21
Adjusting tze opening pressure on the injection valve
Note
If the opening pressure needs toi be corrected: Detach the injection valve from the nozzle tester 8008.
Unscrew the clamping nut and remove all parts. Use
injection valve holder 110 110.
Fig. 2
Mount the injection valve to the nozzle tester (Fig.

2).
! Danger
Keep your hands away from the nozzle spray jet.
Fuel will penetrate deeply into the flesh and may
cause blood poisoning.
Fig. 4
l
Unscrew the clamping nut and remove all parts

(Fig. 4).
Fig. 3
Slowly press the lever of the nozzle tester 8008

down with the pressure gauge connected (Fig. 3).
Opening pressure: 220 bar
Fig. 5
Sequence of disassembly (Fig. 5):
Note
Tensioning nut
Injection nozzle
The opening pressure is reached, when the pointer

stops or suddenly drops.
Intermediate piece
Pressure bolt
The pressure inside the spring chamber will have

build up again after approx. 3 - 4 strokes. In order to
repeat the test the clamping nut needs to be slackened and retightened again, as specified.
Pressure spring
Shim
Once identical values are measured during 3 tests,

the values can be considered valid.
008 911 63
Clean all parts with clean diesel fuel and blow off
with compressed air.
BOMAG
335
11.21
Fig. 6
Fig. 8
Assemble the shim (Fig. 8).
Caution
Nozzle needle and nozzle body have been fitted
by lapping and must never be mixed up by mistake or replaced individually. Do not touch the
nozzle needle with your fingers. With the nozzle
body in vertical position, the nozzle needle must
smoothly slide on its seat just by its own weight
(Fig. 6).
!
Note
Adjust the opening pressure by choosing the required

shim. A thicker shim increases the opening pressure.
Note
If the needle slides down jerkily, wash out the nozzle

body with diesel fuel again, replace if necessary.
Clean the new injection nozzle also in clean diesel fuel.
Fig. 9
l
Assemble the pressure spring.
Fig. 7
l
Check the seat areas of the intermediate piece for

signs of wear. Make sure that the centring pins are
present (Fig. 7).
Fig. 10
l
336
Install the pressure bolt with the centring collar towards the pressure spring (Fig. 10).
BOMAG
008 911 63
11.21
Fig. 11
Fig. 13
Insert the centring pins of the intermediate piece

into the bores of the nozzle holder (Fig. 11).
Screw on the clamping nut.
Note
The chamfer points towards the pressure bolt.
Fig. 14
Tighten the clamping nut.
i
Fig. 12
Attach the centring bores of the injection nozzle to

the centring pins of the intermediate piece (Fig. 12).
Note
Use the injection valve holder 110 110 and a long

socket 8012.
Tightening torque: 30 to 40 Nm
Note
The nozzle needle must not drop out of the nozzle

body.
008 911 63
BOMAG
337
11.21
Leak test
Rattle and spray pattern test
Fig. 1
Fig. 1
Dry nozzle and nozzle holder - blow dry with compressed air.
Press the hand klever of the tester slowly down, to

a point about 20 bar before the previously indicated
opening pressure (Fig. 1).
Switch off the pressure gauge on the tester.
Note
The rattle test enables audible testing of the nozzle

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

cleaning, it nees to be replaced by a new one!
Fig. 2
Note
The nozzle is leak tight, if no drop drips off within a period of 10 seconds.
Caution
If a drop drips off (Fig. 2), the injection valve must
be dismantled and the leak must be eliminated by
thorough cleaning. If this does not lead to a success, replace the injection nozzle.
!
Rework is not permitted!
338
BOMAG
008 911 63
11.22
Fuel filter
11.22Fuel filter
Fig. 1 Fuel pre-filter
Hand pump
Bleeding valve
Filter element
Water and dirt collecting bowl
Drain valve
Water separator sensor connection (B124)
Fuel pre-heating connection (R79) 200 Watt (option)
008 911 63
BOMAG
339
11.22
Fuel filter
General
The quality of the fuel filter and the compliance with
the specified service intervals are decisive for the lifetime of the fuel injection system. The heart of the fuel
filter is made of hydrophobic special paper, which is
spirally wound in form of a bag in order to offer the
largest possible filtering area under the prevailing spatial conditions and thus to achieve a high lifetime in
combination with a high dirt retaining capacity.
The fuel pre-filter / water separator mainly consists of:
l
the dirt / water collecting bowl
and the filter element
Function
The fuel lift pump draws the fuel through this filter.
Any water contained in the fuel deposits on the dirt
side of the filter paper and separates from the fuel in
form of large drops on the clean side of the filter (coalescence effect).
Open the drain valve and drain off approx. 0.5 l of

fuel. The fuel above the filter element presses
through the filter element and frees the underside
from dirt.
Close the drain valve again.
Perform
A power drop or poor starting of the engine is mainly
caused by leaks in the fuel system. If you suspect a filter problem, you should check whether bleeding
screw and drain valve are tightly closed and the filter
element is flush with the sight glass. Check the filter
connections for leaks and the lines for clogging or porous points.
Main fuel filter
Water is heavier than diesel fuel, it settles as a different colour fluid on the bottom.
Once the water level reaches the height of the warning connections (sensor B124), the warning lamp
(H70) in the monitoring board (A15) will come on.
Fuel pre-heating (option)

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

be destroyed and disintegrate by this high pressure This will cause severe damage in the injection system!
Draining off water or fuel

Should the filter element be clogged prematurely (noticeable e.g. by a drop in power), operation of the machine can be continued with the following procedure:
l
Open the bleeding screw (this applies atmospheric

pressure to the filter element and loosens larger dirt
particles from the underside of the filter, which will
then drop down).
340
BOMAG
008 911 63
11.23
Check, clean the water separator
11.23Check, clean the water separator
11.24Change the fuel pre-filter cartridge
Danger
Danger of injury!
Danger
Fire hazard!
Support the engine hood for all maintenance and

repair work.
When working on the fuel system do not use open

fire, do not smoke and do not spill any fuel.
Catch running out fuel, do not let it seep into the

ground.
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 therefore check the water separator every day for signs of water.
Do not inhale any fuel fumes.
If a to high quantity is drained off, the filter must be refilled with fuel. See chapter "maintenance as required", bleeding the fuel system.
Environment
Catch running out fuel and dispose of environmentally.
Fig. 4
l
Unscrew the fuel filter cartridge (Fig. 4) using an appropriate filter wrench.

dirt.
Fig. 3
l
Slacken the drain plug (Fig. 3) for a few turns and

catch running out fuel / water.
Tighten the drain plug again and check for leaks, if

necessary replace the seal ring.
Fig. 5
l
008 911 63
Unscrew the water separator from the filter cartridge (Fig. 5).
BOMAG
341
11.25
Change the fuel filter cartridge
11.25Change the fuel filter cartridge

! Danger
Fire hazard!
When working on the fuel system do not use open

fire, do not smoke and do not spill any fuel.
Catch running out fuel, do not let it seep into the
ground.
Do not inhale any fuel fumes.
Fig. 6
l
Apply a thin coat of oil to the rubber seal of the water

separator 1 (Fig. 6).
Screw the water separator on by hand (2), until the

seal contacts.
Tighten the water separator for another half turn (3).
Fill the filter cartridge with clean diesel fuel (4).
Apply some oil to the rubber seal of the filter element (5) and screw it on by hand, until the seal contacts.
Tighten the filter element for another half turn (6).
Fig. 8
Check the filter cartridge for leaks after a short test

run.
Loosen and unscrew the fuel filter cartridge (Fig. 8)

using an appropriate filter wrench.

dirt.
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 prefilter.
Fig. 9
l
Slightly oil the rubber seal (Fig. 9) on the new filter

cartridge.
Fill the filter cartridge with clean diesel fuel.
Turn the new filter cartridge on by hand, until the

seal contacts.
Tighten the filter element for another half turn.
Check the filter cartridge for leaks after a short test

run.
Fig. 7
l
Slacken the bleeding screw (Fig. 7) on the fuel prefilter for 2 to 3 turns.
Operate the hand pump manually, until fuel flows

out of the slackened bleeding screw (Fig. 7) without
air bubbles.
Then tighten the bleeding screw while pumping.
342
BOMAG
008 911 63
11.26
Checking the compression
11.26Checking the compression

l
Adjust the valves.
Disassemble the injection valves.
Fig. 4
l
Connect the compression tester 8005 (Fig. 4).
Crank the engine with the starter.
Fig. 1
l
Insert the connecting piece 100 110 with seal ring

(Fig. 4).
Note
Check the compression on each of the cylinders.

Compression: 30 - 38 bar
The measured compression depends on the starter
speed during the measuring process and the altitude
of the engine location. Limit values can therefore not
be specified exactly. It is recommended to use the
compression measurement to compare the cylinders
of an engine among each other. Should a deviation of
more than 15% be measured, the affected cylinders
should be dismantled to examine the cause.
l
Remove the compression tester 8005 and the connecting piece 100 110.
Install the injection valves.
Fig. 2
l
Attach the claws (Fig. 2).
Tighten the screw.
Fig. 3
l
Screw on the adapter for connecting piece 100 110

(Fig. 3).
008 911 63
BOMAG
343
11.27
Check, adjust the valve clearance
11.27Check, adjust the valve clearance

Caution
Before checking the valve clearance let the engine
cool down for at least 30 minutes. The engine oil
temperature must be less than 80 C.
!
After a short test run check the engine for leaks.
Valve adjustment schematic

Fig. 7
Crankshaft position 2 (Fig. 7) (4 cylinder engine)

l
Turn the crankshaft one revolution (360) further.
Perform the adjustment of the valve by following the

adjustment diagram "crankshaft position 2", black
mark.
Checking the valve clearance

l
Loosen the crankcase ventilation valve and swing it

to the side.
Fig. 5
Valve 1 (Fig. 5) white = not adjustable

Valve (2) black = adjustable
Fig. 8
l
Remove the valve cover (Fig. 8).
Crankshaft position as per "valve adjustment schematic".
Fig. 6
Crankshaft position 1 (Fig. 6) (4 cylinder engine)

l
Crank the engine with the starter or a spanner by

the V-belt pulley until both valves on cylinder 1 are
overlapping.
Overlapping means: Exhaust valve not yet closed, intake valve starts to open.
l
Perform the adjustment of the valve by following the

adjustment diagram "crankshaft position 1", black
mark.
For control purposes mark the respective rocker

arm with while chalk once the corresponding valve
is adjusted.
344
BOMAG
008 911 63
11.27
Check, adjust the valve clearance
Fig. 9
l
Check valve clearance 2 (Fig. 9) between rocker

arm (1) and valve (3) with a feeler gauge.
Intake valve
= 0,3 mm
Exhaust valve = 0,5 mm

The feeler gauge must fit with little resistance.
l
If the gap is too narrow or too wide for the feeler

gauge, the valve must be adjusted.
Adjusting the valve clearance
Fig. 10
l
Slightly slacken the counter nut. Adjust setscrew 7

(Fig. 10) with a screwdriver, until the feeler gauge
(6) can be inserted and pulled out with little resistance after retightening the counter nut.
Perform tests and adjustments on all other adjustable valves.
Check the gasket of the valve cover, replace it if

necessary.
Reassemble the cylinder head cover.
Swivel the ventilation valve back to correct position

and fasten it.
Fasten the air filter again and ensure correct fit of

combustion air hoses and clamps.
008 911 63
BOMAG
345
11.28
Boost fuel solenoid valve
11.28Boost fuel solenoid valve
Fig. 1
Pos.
1
Designation in
circuit diagram
Y01
Designation
Technical data
12 Volt, approx. 3,5 Amp.
General
During the starting process the solenoid valve is supplied with 12 Volt.
This injection adaptation serves the purpose of compensating for condensation and leakage losses and
for rising the engine torque during the acceleration
phase after starting. For this compensation and to assure starting of the cold engine additional fuel needs
to be injected at the time of starting and accelerating.
346
BOMAG
008 911 63
11.29
Engine shut-down solenoid
11.29Engine shut-down solenoid
Fig. 1
Engine shut-down solenoid
Pos.
1
Designation in
circuit diagram
Y13
Designation
Technical data
Engine solenoid
12 Volt, approx. 4 Amp.
General
When switching the ignition on, the engine solenoid is
supplied with 12 Volt.
Interrupting this power supply shuts down the engine.
The engine shut-down can be triggered through the
ignition switch (S00), the emergency stop button
(S01) or the monitoring board in case of too low oil
pressure (terminal 9).
008 911 63
BOMAG
347
11.30
Air filter
11.30Air filter
Fig. 1
Pos.
Designation in
circuit diagram
Designation
Technical data
Visual differential pressure indicator

Caution
Combustion air lines between filter and engine
("clean air lines") must be absolutely leak tight
and withstand mechanical loads caused by engine vibrations and pressure pulsation.
!
Crankcase ventilation
General
The air filter retains the dust contained in the intake air
and keeps it away from the engine in order to avoid
engine wear.
On paved roads the dust content in the air is 1 mg/m3
on average, on sealed roads or construction sites the
dust content can rise up to 40 mg/m3.
Dry air filters with integrated dust separator are characterized by a good filtering effect (irrespective of engine speed and inclination) and thus enable long
lasting and low wear engine operation.
348
The air filter has the additional function of damping the

air intake noise. This damping is achieved by the design of the air filter in from of a reflection silencer
based on the principle of a Helmholz resonator, damping the intake noise by its resonance frequency.
During the combustion process in a diesel engine certain waste gas quantities escape through the ring
gaps on pistons and piston rings into the crankcase.
The crankcase ventilation serves the discharge of
these waste gases.
The engines are by standard and currently only
equipped with open crankcase ventilation. A crankcase ventilation valve with oil separator separates
most of the oil from the waste gas and returns it into
the engine. The waste gas itself escapes into the atmosphere.
BOMAG
008 911 63
11.31
Cleaning, changing the dry air filter cartridge
11.31Cleaning, changing the dry air

filter cartridge
Caution
Perform cleaning, maintenance and repair work
only with the engine shut down. Do not start the
engine after removing the filter element.
!
Fig. 4
Pull the main filter element (Fig. 4) with light turning

movements.
Cleaning the main filter element

Caution
If necessary, the main filter element may be
cleaned up to five times. It must be renewed at the
latest after a maximum utilization period of two
years.
!
Fig. 2
Servicing of the dry air filter is necessary when the yellow piston (Fig. 2) has reached the inscription "Service" in front of a red background, but at the latest after
2 years.
After completion of the filter service reset the indicator
back to "Zero" by pressing the button.
Removing the main filter element

l
The number of cleaning intervals of the main filter

element can be marked on the safety element with
a ball pen or a felt pen.
Cleaning does not make sense if the main filter element is covered with a sooty deposit. Use a new
filter cartridge.
Incorrectly handled inserts may be ineffective because of damage (e.g. cracks) and cause damage
to the engine.
Fully open the engine hood.
Replace the safety cartridge if the main filter element is defective!

Additional cleaning intervals between two filter
services signalized by the fault monitoring board
are not necessary.
Fig. 3
l
Unclip three clamps on the housing cover and take

off the cover (Fig. 3).
008 911 63
BOMAG
349
11.31
Cleaning, changing the dry air filter cartridge

Caution
When assembling the inner part make sure that
the notch in the cover engages in the opening of
the inner part.
!
Installing the main filter element

Slide the main filter element carefully into the housing.
When closing the housing cover the main filter element is automatically forced in the correct position.
Reinstall the service covers.
Fig. 5
Changing the safety filter element
Note
For cleaning purposes fit a tube to the compressed air

gun (Fig. 5), the end of which should be bent for approx. 90.
The length should reach down to the bottom of the
cartridge.
Blow the cartridge out with compressed air (max. 5
bar) from inside to outside by moving the tube up
and down inside the cartridge, until it if free of dust.
Examine the filter cartridge with a torch for cracks

and holes in the paper bellows.
Caution
The safety filter element must not be cleaned and
should not be used again after it has been removed.
!
Break the seal only to replace the safety filter element.

The safety filter element must be replaced:
if the main filter element is defective,
after five service intervals of the filter cartridge,
at the latest after 2 years,
Caution
Do not continue to run the machine with a damaged main filter element. If in doubt use a new
main filter element.
!
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.
Cleaning the dust bowl
Fig. 7
l
Perforate the seal of the safety filter element from

inside to outside using a suitable tool (Fig. 7) and
pull both latches up.
Grip the safety element by both latches and pull it

out with slight turning movements.
Push in a new safety filter element.
Reassemble main filter element and cover.
Fig. 6
l
Pull the internal part (Fig. 6) out and remove the

dust from the cover.
Reinsert the inner part.
350
BOMAG
008 911 63
11.32
Heating flange on engine

Caution
Make sure that the cover locks engage correctly.
!
11.32Heating flange on engine
Fig. 1 Heating flange
The heating flange is a component with an electrically

operated heating wire and high energy density used to
heat up the intake air in case of very low ambient temperatures.
The heating power is approx. 2000 Watt.
The heating power improves the cold starting characteristics and the exhaust emissions (white smoke) of
the diesel engine.
A differentiation is made between preheating, to assure the cold start ability of the engine, and subsequent heating.
Note
Pre-heating is triggered by switching on the ignition

(12 Volt on control unit A13, terminals 15(7) and S(2)).
With a coolant temperature of -30C the preheating
time will be max. 52 seconds, with +5C the minimum
time will be 38 seconds. During the preheating period
the control light in the monitoring board is permanently
on. In case of a fault the lamp will flash.
After-heating is triggered by the starting process (12
Volt on control unit A13, terminal 50(5)). With a coolant temperature of -30C the subsequent heating time
will be max. 180 seconds, with +25C the minimum
time will be 35 seconds. This after-heating time is not
indicated by the control light.
Caution
Multiple activation of the heater control in short
term operation (low generator running time) discharges the starter battery.
!
If the engine does not start properly in case of automatic starting of the heating flange because the
starter does not get energized due to a fault and
does not crank the engine, the starting process
must be completely aborted (ignition key to OFF,
voltage supply to heating flange interrupted). In
order to avoid damage to heating flange or charge
air hoses caused by overheating, another start of
008 911 63
BOMAG
351
11.32
the engine must be avoided and trouble shooting

should be performed instead.
Several successive starting attempts can cause
overheating of the heating flange .
Fig. 3
Heating control unit (A13)
Heating relay (K14)
Fig. 2 Heating flange (R19) with hose socket BF4M 2012 C
Fig. 4 Coolant temperature sensor
352
Temperature sensor (B113) for heating flange

control (A13)
Coolant temperature switch (B30)
BOMAG
008 911 63
11.32
Pos.
Designation in
circuit diagram
R19
Designation
Technical data
Heating flange
With a coolant temperature of -30C

the preheating time will be max. 52
seconds, with +5C the minimum
time will be 38 seconds.
(Fig. 2)
With a coolant temperature of -30C

the after-heating time will be max.
180 seconds, with +25C the minimum time will be 35 seconds.
12 Volt
approx. 2000 Watt
approx. 167 A
approx. 0.07 Ohm
2 (Fig. 3))
3 (Fig. 3)
A13
K14
Heating control unit

Heating relay
12 Volt
12 Volt
1 (Fig. 4)
B113
approx. 2 Ohm at 20C
2 (Fig. 4)
B30
Temperature sensor for heating

flange control (A13)
Contact switches at approx. 110 C

to ground
Fig. 5 Heating flange function diagram
Heating start
Signal lamp
Start
Switching relay
Condition
Terminal 15/S
Terminal L
Terminal 50
Terminal R
10 Start process
11 Ready for starting: 0 sec.
008 911 63
BOMAG
353
11.33
Checking the heating flange control
11.33Checking the heating flange

control
After the engine has started the after heating time

must continue for 35 to 180 seconds. This after-heating time is not indicated by the control light (K) .
Fig. 1 Monitoring board (A15)
Note
During the preheating period the control light K (Fig. 1)

is permanently on. In case of a fault the lamp (K) will
flash.
The lamp flashes with a frequency of 1 Hz during
the pre-heating phase.
Sensor failure: Either short circuit or cable breakage at the input to the control unit (A13), terminal
T(4)
The lamp flashes with a frequency of 2.5 Hz over
the entire heating phase.
Heating flange failure: Either short circuit or cable

breakage at the output of the control unit (A13),
terminal R(6)
Note
The heating flange only becomes active at a coolant

temperature below 25C. When the plug of the temperature sensor is pulled off (simulated sensor failure), a coolant temperature of 0 C is assumed.
Start the heating process.
Depending on the coolant temperature the control

light (K)(Fig. 1) will light between 30s and 50s, the
heating flange relay is energized.
Place a tong-test ammeter over the heating flange
connecting line.
Rated current: 165 Amp +- 10 Amp.
Note
The relay must remain energized for another approx.

15 seconds, after the control light has gone out.
354
BOMAG
008 911 63
11.34
Electric throttle control
11.34Electric throttle control
Fig. 1 Engine solenoid
Throttle control switch
Fig. 2 Throttle control switch
The throttle control switch (S120) is used to change

from "MIN" to "MAX" idle speed and vice versa.
008 911 63
BOMAG
355
11.34
Electric throttle control
Throttle control solenoid Y120
Note
When switching on, the solenoid plunger is pulled

against the stop. The limit switch then switches the
pick-up and holding winding in series. The current flow
is reduced from approx. 70 A to approx. 3.5 A.
Fig. 3 Electric circuit of solenoid
The throttle control solenoid 5 (Fig. 3)) is equipped

with a pick-up winding (4) and a holding winding (3),
both switched in series. The holding winding has a
much higher resistance than the pick-up winding. The
"aux"-connection is connected between the two windings. The engine solenoid is equipped with a limit
switch (2), which is mechanically connected with the
governor rod (1) on the diesel engine. This switch
bridges the holding winding until the end position of
the governor rod is reached (high engine speed)
This bridging has the effect, that the "aux"-terminal
has the same potential as the "+"-terminal. If the
bridge is open, the "aux"-terminal has almost the
same potential as the "-" terminal, because of the low
resistance of the pick-up winding and the high resistance of the holding winding.
Fig. 5
l
Measure the gap between stop screw 1 (Fig. 5) and

throttle lever (2).
!
Caution
The gap should be min. 0.1 mm and max. 0.5 mm.
If the gap is too small, the limit switch in the solenoid may not be able to operate.
In case of a too wide gap the engine will not reach
its maximum speed.
Adjusting the solenoid
Fig. 4
l
Switch on the ignition.
Turn the rotary switch (Fig. 4) to position "MAX".
356
BOMAG
008 911 63
11.35
Engine monitoring
11.35Engine monitoring
Fig. 1
Monitoring board (A15)
Pos.
Designation
Control light
Control light, overheating of engine

Engine oil pressure control light
Control light for engine air filter
Charge control light
Control light, water in diesel filter
Control light, coolant provision
flashes
b
c
d
i
j
008 911 63
flashes
not used
lights
lights
Warning buzz- Shut-down

time (engine)
er
10 sec.
X
X
Shut-down
time (engine) 2
min.
X
not used
BOMAG
357
11.35
Engine monitoring
Water separator
Push the plug back on, the plug interlock clicks into
place.
Engine overheating
Fig. 2 Sensor water separator

l
Press the plug interlock and disconnect the plug

(Deutsch plug).
Bridge both contacts on the plug of the wiring loom.

Note
Control light i (Fig. 1) lights up. An audible warning will

sound and the engine is shut down after 2 minutes.
Press on the locking wire (Fig. 4) and pull off the

plug.
Bridge both contacts on the plug of the wiring loom.
Push the plug back together, the plug interlock

clicks into place.
Engine oil pressure
Note
The control light a (Fig. 1) flashes. An audible warning

will sound and the engine is shut down after 2 minutes.
l
Push the plug back on, the plug interlock clicks into
place.
Emergency stop switch
Fig. 3 Oil pressure switch

l
Press on the locking wire and pull off the plug 1 (Fig.
3).
Apply the contact to engine ground.

Fig. 5 Emergency stop switch
Note
The control light b (Fig. 1) flashes. An audible warning

will sound and the engine is shut down after 10 seconds.
358
Press the emergency stop switch (Fig. 5). The engine should stop immediately.
BOMAG
008 911 63
11.36
Engine
11.36Engine
Faults
Possible cause
Remedy
The engine
does not start
Starter defective or pinion not engaging
Have examined by a specialist
Fuel tank empty
Fill and bleed the tank
Temperature below starting limit
Use winter fuel and engine oil acc. to the

ambient temperature.
Fuel filter clogged, in winter due to paraffin separation.
Change the filter. use winter fuel
Fuel lines leaking
Check all line connections for leakages

and tighten the fittings.
Battery discharged or not connected
Tighten the pole clamps, check the cable

connections
Injection valves or injection pump defective
Battery power too low, battery clamps

loose or oxidized, causing the starter to
turn too slowly
Have the battery checked, clean the terminal clamps, tighten them and cover
them with acid free grease
Especially during winter: the use of too

viscous engine oil
Use engine oil suitable for the ambient

temperature
Fuel supply restricted, in winter fuel system clogged due to paraffin separation
Change the fuel filter. Check the line connections for leaks and tighten the fittings.
Use winter fuel in the cold season.
Incorrect valve clearance
Adjust the valve clearance
Injection valve defective
Injection lines leaking
Check the lines for leakages
Turbo charger defective
Dry air filter dirty
clean, replace if necessary
Excessive play in the throttle cable
Adjust the throttle cable, change it if necessary
Engine oil level too high
Drain the oil to the upper dipstick mark
clean, replace if necessary
Exhaust gas turbo-charger defective
Poor compression due to burned or broken compression rings or incorrect valve

clearance
Have compression rings and pistons examined by a specialist, adjust the valve
clearance
The engine
starts poorly and
works irregularly
with poor power
Excessive exhaust smoke
008 911 63
BOMAG
359
11.36
Engine
Faults
Possible cause
Remedy
Engine overheats, shut

down immediately!
Cooling fins on radiator extremely soiled

(the warning light "engine oil temperature"
lights)
Clean the cooling fins
Engine oil level too low
Top up engine oil to the upper dipstick

mark
Filling capacity of the injection pump not

correctly adjusted
Have adjusted by a specialist
Cooling air flow restricted
Clean the cooling air duct
V-belt loos or broken
Tension or replace the V-belt
Engine oil level too high
Drain the engine oil down to the upper dipstick mark
clean, change if necessary
Exhaust gas turbo-charger defective
Charge air hose leaking
Check fastening and connections
Engine oil level too low (control light "engine oil pressure" lights, the warning
buzzer sounds)
Top up oil
Leakages in the lubrication system
Shut the engine down immediately, check

fittings on oil lines, lubrication oil filter and
oil cooler for leaks, if necessary tighten
the fittings.
Generator speed too low
Check the V-belt tension, replace the Vbelt if necessary
The generator does not charge the battery, because generator or regulator is defective
Have examined by a specialis
Poor engine
power
Engine oil pressure too low
The charge control light lights

during operation, the warning
buzzer sounds
360
BOMAG
008 911 63
11.37
Special tools, Deutz engine (BFM 2012)
11.37Special tools, Deutz engine

(BFM 2012)
Deutsch English Franais Espaol
No.
Druckpumpe fr Khlmitteldichtheitsprfung
8002
Pressure pump for coolant leakage test.

Pompe refoulante pour contrle de ltanchit du
liquide refroidisseur
Bomba de presin para pruebas de estanqueidad
sistema de lquido refrigerante
35409
Kompressionsdruckprfer
8005
Compression tester
Compressiomtre
Compresmetro
35410
Dsenprfgert
8008
Nozzle tester
Pompe dessai dinjecteurs
Comprobador para inyectores
35411
Stecknuss SW 15, lange Ausfhrung fr Einspritzventil. (berwurfmutter)
8012
Socket a/flats 15, long version for injector

(cap nut)
Douille de 15, version longue pour injecteur
(crou-raccord).
Llave de vaso de 15, versin larga, para inyector
(tuerca de unin)
35412
008 911 63
BOMAG
361
11.37
362
BOMAG
008 911 63
11.37
008 911 63
BOMAG
363
11.37
No.
Anschlustck fr Kompressionsdruckprfer
100 110
Connector for compression tester

Raccord pour compressiomtre
Pieza de empalme para el compresmetro
35421
Durchdrehvorrichtung
100 320
Turning gear
Dispositif vireur
Dispositivo de viraje
35422
Durchdrehvorrichtung
100 330
Turning gear
Dispositif vireur
Dispositivo de viraje
35423
Messuhr M2T mit Feststellring.
100 400
Dial gauge M2T with locking ring

Comparateur M2T avec bague
dimmobilisation
Comparador M2T con anillo exterior
de bloqueo
35424
364
BOMAG
008 911 63
11.37
No.
100 750
Messbalken mit Abstandsblttchen zum Messen

des OT und des Kolbenberstandes.
Measuring bar with spacers for gauging
TDC and piston projection
Barre de mesure avec plaquettes dcartement
pour mesurer le PMH et la cote de dpassement du
piston
Barra de medicin con plaquitas distanciadoras
para la medicin del PMS y saliente de pistn
35425
100 800
Messgert zum Messen und Blockieren der

Regelstange.
Measuring device for measuring and
locking control rod
Appareil de mesure et de blocage de la
crmaillre.
Equipo de medicin y de bloqueo de la cremallera
35426
100 810
Einstellbolzen fr MAG-Wellen.
Adjusting pin for mass balancing shafts
Pige de calage pour arbres masses dquilibrage
(MAG)
Pernos de ajuste para ejes equilibradores
de masa MAG".
35427
100 830
Andrckvorrichtung fr Regelstange
Press-on device for control rod
Dispositif de montage de cremaillre
Dispositivo de presin para la cremallera
35428
008 911 63
BOMAG
365
11.37
No.
Messvorrichtung fr Grundkreismessung
Einspritzpumpe und Frderbeginn.
100 890
Measuring device for base circle measurement

Dispositif de mesure du cercle de base
Dispositivo de medicin del crculo base
bomba de inyeccin y comienzo de alimentacin
35429
Gradscheibe 360 mit Befestigung an der

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

to flywheel for TDC and COD setting
Disque gradu 360 avec fixation sur volant moteur
pour rglage du PMH et point de calage du dbut
dinjection
Disco graduado 360 con fijacin en el volante,
para ajuste del PMS y comienzo de alimentacin
Adapter fr Gradscheibe.
35430
101 030
Adapter for graduated disc

Adaptateur pour disque gradu
Adaptador para el disco graduado
35431
Zeiger fr Gradscheibe.
101 300
Pointer for graduated disc

Index pour disque gradu
Indicador para el disco graduado
35432
366
BOMAG
008 911 63
11.37
008 911 63
BOMAG
367
11.37
No.
Spezialschlssel fr Einspritzleitung
110 500
Special wrench for injection line

Cl spciale pour conduite dinjection
Llave especial para tubera de inyeccin
35436
Ausziehvorrichtung fr den Dichtring unter

dem Einspritzventil.
120 680
Extractor for sealing ring beneath injector

Outil dextraction pour le joint de linjecteur
Dispositivo de extraccin para el anillo de
junta del inyector
35437
Aufspannbock fr Zylinderkopf.
120 900
Clamping stand for cylinder head

Chevalet dablocage pour culasse
Caballete de sujecin para culata
35438
Aufspannplatte fr 120 900.
120 910
Clamping plate for 120 900

Plaque dablocage pour 120 900
Placa de sujecin para 120 900
35439
368
BOMAG
008 911 63
11.37
No.
121 410
Montagewerkzeug fr Ventilschaftabdichtung
Sleeve for fitting valve stem seal
Outil de montage pour joint de tige de soupape
Util de montaje para juntas de vstago de vlvula
35440
130 300
Kolbenring-Auflegezange
Piston ring pliers
Pince monter les segments de piston
Alicates para colocar aros de pistn
35441
130 440
Trapeznut-Verschleilehre
Trapezoidal groove wear gauge
Jauge dusure pour gorge trapzodale
Calibre de desgaste para ranura trapezoidal
35442
130 660
Kolbenringspannband 98 mm
Piston ring compressor
Collier segments de piston de 98 mm
Compresor de aros de pistn, 98 mm
35443
008 911 63
BOMAG
369
11.37
No.
Kolbenringspannband 101 mm
130 670
Piston ring compressor

Collier segments de piston de 101 mm
Compresor de aros de pistn, 101 mm
35443
Montagewerkzeug fr Kurbelwellendichtring vorn.
142 670
Assembly tool for front crankshaft seal

Outil de montage de bague dtanchit de
vilebrequin AV
Herramienta de montaje para el retn delantero del
cigeal
35445
Montagewerkzeug fr Kurbelwellendichtring hinten.
142 830
Assembly tool for rear crankshaft seal

Outil de montage de bague dtanchit de
vilebrequin AR
Herramienta de montaje para el retn trasero del
cigeal
35446
Montagewerkzeug fr MAG-Buchsen.
143 780
Assembly tool for engine balancer bushes

Outil de montage de douilles darbres masses
dquilibrage
Herramienta de montaje para casquillos de ejes
equilibradores
35447
370
BOMAG
008 911 63
11.37
008 911 63
BOMAG
371
11.37
No.
Maul-Steckaufsatz fr Drehmomentschlssel
(mit groem Vierkant 14 x 18 mm) fr Lfter (Ein- /
Ausbau) - Zentralmutter
160 340
Open jawed wrench socket for torque wrench

(large square wrench 14 x 18 mm) for fan
(assembly and removal) center nut
Embout mchoire pour cl dynamomtrique
( grand quatre-pans 14 x 18 mm) pour ventilateur
(dmontage/remontage) crou central
Boca enchufable para llave dinamomtrica
(con macho cuadrado grande 14 x 18 mm) para
(montaje/desmontaje) tuerca central del ventilador
Gegenhalter fr Zahnrad Luftpresser
35455
170 630
Dolly for air compressor gear

Dispositif de maintien pour pignon de compresseur
dair
Dispositivo de retencin para rueda dentada
compresor de aire
35450
Motormontagebock fr doppelseitige Aufspannung
6066
Engine assembly stand for double-sided

chucking
Chevalet de montage moteur avec double
ablocage
Caballete de montaje para sujecin bilateral
del motor
35451
1 Satz Aufspannwinkel fr doppelseitige Auf

spannung.
6066/158
1 Set of angled clamping plates for

double-sided chucking
1 jeu dquerre de fixation pour double ablocage
1 juego de angulares para sujecin bilateral
35452
372
BOMAG
008 911 63
12 Air conditioning system
008 911 63
BOMAG
373
374
BOMAG
008 911 63
12.1
Physical basics
12.1 Physical basics
A - heat absorption
In order to understand the working principle of an air

conditioning system one must first become familiar
with the physical basics of such a system.
B- Heat dissipation
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 matter. Any matter consists of a mass of moving molecules. The rapidly moving molecules or a warmer
matter dissipate part of their energy to the slower
moving molecules with less heat. The movement of
the molecules in the warmer matter becomes slower
and the molecules in the cooler matter are accelerated. This process continued, until all molecules in the
two matters move with identical speed. The 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 reversible. When withdrawing the heat contained in gaseous water, the gas will turn into steam, then into
water and finally into ice.
008 911 63
BOMAG
375
12.1
Physical basics
Pressure and boiling point

The boiling point is the temperature at which fluid
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
the pressure applied to water, the lower the boiling
point.
When looking at water, the following values do apply:
l
Atmospheric pressure, boiling point 100C
Overpressure 0.4 bar, boiling point 126C
Vacuum -0.6 bar, boiling point 71C
4. If a fluid evaporates it requires a lot of heat, i.e. the

fluid thereby cools down the surrounding environment
(e.g. alcohol on skin)
Note
At absolute pressure 0 bar correspond with an absolute vacuum. The normal ambient pressure (overpressure) corresponds with 1 bar absolute pressure. On
the scales of most pressure gauges 0 bar corresponds with an absolute pressure of 1 bar (indicated
by the statement -1 bar below the 0).
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 refrigerant the drawn in closed curve shows the cycle of the
refrigerant. This cycle permanently continues in direction 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

the operation principle of an air conditioning system.
C- relaxation
D- evaporation.
A- liquid
B- gaseous
The diagram shows the evaporation curve of R134a.
The diagram for example shows, that R134a is liquid
at 0C and a pressure of 5 bar, but becomes gaseous
at 40C 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.
376
BOMAG
008 911 63
12.1
Physical basics
Excerpt from the wet steam table 1 R134a
1
This table is used for the determination of evaporation and condensation temperature.
Saturation temperature
-20
-10
0
10
20
008 911 63
Overpressure (pressure gauge

reading Pe in bar)
0,33
1,01
1,93
3,15
4,72
BOMAG
Absolute pressure (pamb = 1 bar

P in bar)
1,33
2,01
2,93
4,15
5,72
377
12.2
Refrigerant R134a
12.2 Refrigerant R134a
Characteristics of the refrigerant R134a:
General
The evaporation and condensation process is the
method commonly used in mobile air conditioning systems. 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 -26.5C 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
Refrigerant R134a is currently available under the following trade marks.

H-FKW 134a
SUVA 134a
KLEA 134a
Colour:
Refrigerant in form of vapour or liquid is colourless as
water. The gas is invisible. Only the bordering layer
between gas and liquid is visible. (Fluid level in rising
pipe of filling cylinder or bubbles in inspection glass).
In the inspection glass the liquid refrigerant R134a
may appear coloured (milky). This turbidity results
from partially dissolved refrigeration oil and is no indicator for a fault.
Steam pressure:
Chemical formula:
In an incompletely filled, closed container, vaporous

refrigerant will volatilize from the surface in the same
quantity that will turn liquid in combination with steam
particles. This state of equilibrium occurs under pressure and is frequently referred to as steam pressure.
The steam pressure is independent from the temperature.
CH2F-CF3 or CF3-CH2F
Chemical designation:
Tetrafluoroethane
Boiling point at 1 bar:

- 26.5 C
Physical properties of R134a:
Solidification point:
The steam pressure curves of R134a and other refrigerants are partly very similar, making a clear differentiation solely by pressure impossible. With R 134a the
compressor is lubricated by special synthetic refrigeration oils, e.g. PAG-oils (polyalkylene glycol oils).
-101.6 C
Critical temperature:
Behaviour with metals:
100,6 C
In pure condition refrigerant R134a is chemically stable and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
compounds, leads to aggressiveness against certain
metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.
Critical pressure:
40.56 bar (absolute)
Critical point:
Critical point (critical temperature and critical pressure) means that above this point there is no separating interface between liquid and gas. Above its critical
point any substance is gaseous. At temperatures below 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 depends on the ambient temperature.
Critical temperature / critical pressure:

Up to a gas pressure of 39.5 bar overpressure (this
corresponds with a temperature of 101 C) the refrigerant R134a remains chemically stable, above this
temperature the refrigerant decomposes (see combustibility).
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
378
BOMAG
008 911 63
12.3
Compressor oil / refrigeration oil

liquid container has absorbed approx. 8 gr. of water,
the refrigerant circuit transports possibly existing water in form of droplets. This water flows to the nozzle
of the expansion valve and turns to ice. The air conditioning system stops cooling. Water destroys the air
conditioning system, because under high pressures
and temperatures and in connection with other contaminants it forms acids.
Inflammability:
Refrigerant is not inflammable. On the contrary, it has
fire inhibiting or fire extinguishing properties. Refrigerant is decomposed by flames or glowing surfaces. Ultraviolet light also cracks refrigerant (caused by
electric welding). This results in toxic fission products,
these must not be inhaled. However, irritation of the
mucous 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 temperature. The steam filled space becomes smaller.
From a certain time on the container will be filled with
just liquid. After this only a minor temperature increase is enough to generate very high pressures in
the 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 directive clearly specifies how many kilograms of refrigerant may be filled into the container per litre volume.
Multiplied with the internal volume this "filling factor"
determines the permissible filling capacity For refrigerants used in motor vehicles it is 1.15 kg/l.
Environmental aspects
The contribution of R134a to the greenhouse effect is
by factor 10 smaller than the contribution of R12.
12.3 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 drying up.
Part of the compressor oil dissolves in the refrigerant
until saturation is reached, so that a gas mixture of refrigerant, water steam, compressor oil and contrast
agent circulates through the system.
Compressor oil (the oil quantity should be 10 % of the
refrigerant weight) mixes with the refrigerant and circulates permanently through the system.
In connection with R134a- air conditioning systems
special synthetic compressor oils, e.g. polyalkylene
glycol (PAG) oils, are used. This is necessary, because e.g. mineral oil does not mix with R134a. Apart
from this, the materials in the R134a air conditioning
system may be attacked when the mixture is flowing
through the refrigerant circuit under high pressure and
at high temperatures or if the lubrication film in the
compressor tears off. The use of non-permitted oils
can cause damage to the air conditioning system, you
should therefore only used the approved oils.
Properties of compressor oil / refrigeration oil:

The most important properties are high solvency in
connection with refrigerants, good lubrication characteristics, that they are free of acids and their low water
content. For this purpose only certain oils can be
used. PAG-oils suitable for use with refrigerant R134a
are highly hygroscopic and will not mix with other oil.
As a protection against the invasion of moisture drums
must immediately be closed again after they had been
opened. Compressor oil ages under the effect of
moisture and acids, becomes dark, viscous and aggressive against metals.
Since approx. 1992 the air conditioning systems for

newly produced construction equipment were successively converted to refrigerant R134a. This refrigerant
does not contain any chlorine and is thus harmless for
the ozone layer. Until approx. 1992 air conditioning
systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decomposition potential and also a potential to amplify the
greenhouse effect. Conversion programs for existing
old systems with the ozone damaging R12 are in effect. For reasons of protecting the environment refrigerant must not be discharged into the atmosphere.
008 911 63
BOMAG
379
12.4
Working principle of the air conditioning system
12.4 Working principle of the air

conditioning system
12.5 Monitoring devices
All air conditioning systems are based on the same

principle. They extract heat from the surrounding environment. Everybody knows the effect: if a sweating
body is exposed to wind it will cool down, because
heat is extracted. For this purpose a refrigerant circulates in a closed circuit inside the vehicle. This refrigerant thereby 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 refrigerant 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 condenser (2). This condenser is arranged directly in front
of the vehicle radiator, so that a sufficient air flow is assured. In the condenser (2) the gas is cooled down
and consequently liquefied.
In the dryer / liquid container (3) the refrigerant is then
collected and freed of moisture and contaminants.
The expansion valve (4) regulates the flow rate from
the dryer / liquid container (3) back to the evaporator
(5) and the circuit starts again.
Pressure switch
The pressure switch (8) is used as monitoring feature
for too high and too low pressures. The switching contacts (4 and 5) effect the magnetic clutch of the compressor via a relay (6).
If the system pressure increases excessively, e.g. because of a excessively soiled condenser, a failed fan
or a defective expansion valve, the high pressure contact (5) will cut off the electric power supply to the
magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off
pressure by the set differential pressure, the magnetic
clutch of the compressor is switched on again.
The low pressure contact (4) interrupts the electric
power supply to the magnetic clutch when the set
pressure is fallen short of (possible causes: lack of refrigerant, defective expansion valve, too low heat
load, defective evaporator fan, ...). Since the refrigerant R134a has an evaporation temperature of 0 C at
an overpressure of 2 bar, the low pressure contact (4)
is set to approx. 1.5 bar to avoid icing. The switch on
pressure is 0.5 to 2 bar higher than the shut-off pressure (depending on system, see description of components.)
Thermostat
A frost protection thermostat (3) protects the evaporator against icing. Similar to the pressure switch, the
thermostat activates or deactivates the magnetic
clutch for the compressor. Depending on the design,
the feeler of the temperature control is mounted between the fins of the evaporator or attached to the
evaporator outlet (suction side). With fixed temperature controls the control switches the compressor off
at about 1 C and back on again at about 2.5C to 5.5
C (depending on system, see description of components.)
With adjustable temperature regulators the switching
point can be changed so that the compressor is already shut down at higher temperatures. This enables
regulation of the air temperature.
380
BOMAG
008 911 63
12.6
Description of components
Monitoring chain
12.6 Description of components

Compressor
Fig. 2 Monitoring chain consisting of:

l
1 Switch
2 Fuse
3 Thermostat
4 Low pressure switch contact
Fig. 1
5 High pressure switch contact
6 Relay
7 Connection for magnetic clutch
8 Pressure switch
The compressor is mounted to the engine and has the

duty to build up the refrigerant pressure required for
the function of the system. Coupling and decoupling is
accomplished by an electromagnetically controlled
mechanical clutch, which is integrated in the V-belt
pulley of the compressor.
Compressor data
Displacement: 155 cm
Weight: 6,9 kg
max. rpm: 6000
Sense of rotation: cw
Refrigerant: R134a
Oil quantity (scope of delivery): 207 gr
Oil: PAG SP-20 (H14-003-404)
Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only refrigeration oil
PAG SP-20 (H14-003-404).
!

or condenser, any compressor oil / refrigeration
oil lost by exchanging the components, must be
replaced with fresh oil.
The actual quantity depends on the amount of oil
that may have been lost in connection with the
possible replacement of other components.
Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
The following table shows how much compressor oil /
refrigeration oil will be lost in connection with various
types of work on the air conditioning system.
008 911 63
BOMAG
381
12.6
Condenser
Reason of oil loss

Amount of oil lost
Loss when emptying
approx. 15 gr
Defective A/C hose
approx. 30 gr
Hose change
approx. 15 gr
Replacement of condens- approx. 30 gr
er
Replacement of evapora- approx. 30 gr
tor
Replacement of liquid con- approx. 30 gr
tainer
Replacement of expan- approx. 15 gr
sion valve
Caution
Please bear in mind, that the new compressor is
delivered with a filling of 207 gr. compressor oil.
To avoid excessive oil in the A/C-system and thus
a poor cooling effect, the oil level in the A/C-system must be adjusted accordingly.
!
The quantity depends on the amount of oil that

may have been lost in connection with the possible replacement of other components.
The compressor oil quantity must be 10% of the
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system requires a compressor oil / refrigerant oil filling of
100 gr.
Procedure:
Drain and measure the compressor oil from the
old compressor.
Fig. 1
The condenser is located in front of the the radiator for

the machine. It emits heat energy from the system into
the surrounding air and liquefies the gaseous refrigerant.
Note
The fins must be free of dirt and damage.

Caution
or condenser, any compressor oil lost by exchanging the components, must be replaced with
fresh oil.
!
Drain the compressor oil from the new compressor and only fill in the exact quantity that had been
drained out of the old compressor. The compressor oil from the new compressor can be used for
this purpose.
Note
Topping up compressor oil / refrigeration oil is possible 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 during the evacuation process.
382
BOMAG
008 911 63
12.6
Dryer / filter / fluid container / inspection
glass
Safety valve
Fig. 2
The fluid container is equipped with a safety valve.
Fig. 1
Response pressure 32 +/- 4 bar
Dryer / filter
The fluid container collects the fluid drops and passes
these then as a constant flow to the expansion valve.
Moisture that has entered during assembly of the refrigerant circuit is absorbed by a dryer in the fluid container.
Tightening torque 10 - 15 Nm
Inspection glass
At evaporation temperatures below zero the refrigerant will deposit previously absorbed moisture on the
expansion valve, where this water turns into ice and
thus adversely affects the controllability of the expansion valve. Moreover, moisture in the refrigerant circuit causes corrosion, forms acids and enters into
chemical compositions.
Inside the refrigerant container the heavy liquid refrigerant collects in the lower part of the container, flows
through a rising pipe to the outlet marked "A" and thus
ensures bubble free operation of the expansion valve.
Fig. 3
Note
Since the absorbing capacity of this filter/dryer is limited, it must be changed within certain service intervals. We recommend to replace it 1 x per years,
before the start of the season.
Caution
The filter/dryer must generally be replaced whenever opening the refrigerant circuit, because
moisture will enter in such a case.
!
This requires emptying the air conditioning system!

Installation position:
The arrow marks on the filter/dryer must point in
flow direction, i.e. towards the expansion valve.
Filter/dryer cannot be treated for further use!
008 911 63
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 refrigerant level in the system. Apart from this, the refrigerant may not sufficiently condense as a result of a
soiled evaporator or a defective condenser fan and
the fluid level in the refrigerant container may drop
down to a level, at which gaseous refrigerant could
flow through the rising tube to the inspection glass.
This results in abnormally high temperatures in and on
the fluid lines (between refrigerant container and expansion valve), as well as very high pressures in the
pressure side.
However, incorrect evacuation or filling may also be
the reason for 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 evacuated and refilled.
BOMAG
383
12.6
i
Expansion valve
Note
Air in the system is characterized by high pressures

and temperatures.
On R134a refrigeration systems from KONVEKTA the
inspection glasses are equipped with moisture indicators. In addition to the float, the dryer/collector/inspection glass combination has an indicator pearl
integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection
glass and should only be checked after approx. 5 minutes continuous operation, because the refrigerant
must first evenly distribute all over the system.
! Danger
In case of mechanical damage or corrosion on
this pressure container this collector unit must be
replaced, to avoid bursting and further damage.
Fig. 1
The expansion valve is mounted inside the HKL-module in the cabin. The expansion valve always allows a
small amount of the high pressure liquefied refrigerant
to flow into the evaporator, which has a much lower
pressure. This lower pressure causes these liquid refrigerant to expand and to evaporate to gaseous state.
The heat required for this evaporation process is taken from the ambient air through the lamellas and supplied to the refrigerant. This is the so-called cooling
effect.
The thermostatic expansion valve operates with an
external pressure compensation. This type of expansion 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 order 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.
Note
In case of dirt in the refrigerant system you should also

check or clean the screen at the expansion valve inlet.+
384
BOMAG
008 911 63
12.6
Evaporator
Defroster thermostat
Fig. 1
Fig. 1
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.
The feeler of a defroster thermostat to switch off the

magnetic clutch in case of icing up or to switch the
clutch back on after defrosting, is mounted on the
evaporator. The correct adjustment of the defroster
thermostat as well as the correct feeler assembly
should be checked during maintenance.
As with the condenser, correct operation of all fans

and cleanliness of the fins must be assured.
Air conditioning systems have a circulation air filter
mounted in the air flow in front of the evaporator,
which should be cleaned or changed by the operator
after each third trip, depending on the amount of dirt.
A condensation water filter is mounted in the air flow
after the evaporator. This filter has the function to collect the water that has condensed from the air in the
evaporator block and to discharge this water into the
water pan With a defective condensation water filter
condensation water may flow into the inside of the vehicle.
Switching point on: + 1C ( 1C)

Switching point off: + 5,5C ( 1C)
Note
It is very important that the feeler is mounted downstream of the evaporator, but before the pressure sensor, in countercurrent direction, with full length and
insulated against the outside temperature.
Caution
or condenser, any compressor oil lost by exchanging the components, must be replaced with
fresh oil.
!
008 911 63
BOMAG
385
12.6
Pressure switch
Pipes and hoses

Pipes and hoses in air conditioning systems must
meet very high requirements with respect to resistance against heat and pressure. The requirements
concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through
the hose material, are very high. Pipes and hoses to
be used must therefore be specially made for air conditioning purposes. For this reason the hoses have an
inside lining of butyl rubber and an outside coating of
EDPM rubber. Hose sections exposed to heat are provided with a special heat insulation.
Fig. 1
After a minimum pressure is reached in the low pressure side or a maximum pressure in the high pressure
side, the pressure switch will switch of the magnetic
clutch of the compressor, thus to avoid destruction of
system components by excessive pressure or drawing in external gases and foreign matter as a result of
too low pressure.
Working pressure:
Low pressure off: 1,5 0,5 bar
O-rings are made of a special type of chloroprene rubber (neoprene). Before assembly of the air conditioning system these O-rings must be lubricated with
compressor oil / refrigeration oil. The O-rings must always be replaced when assembling A/C-components.
Recommended tightening torques for O-ring
sealed fittings
Thread
5/8
3/4
7/8
1 1/16
M30X2
Low pressure on: 3.5 bar

Overpressure off: 25,0 1,5 bar
Overpressure on: 18,0 1,5 bar
M36X2
Bending radii for air conditioning hoses

Hose type
GH 134
GH 134
GH 134
GH 134
GH 494
GH 494
GH 494
386
Spanner width Torque

17 or 19
13,6 - 20,3 Nm
32,5 - 39,3 Nm
27
35,3 - 42,0 Nm
32
40,7 - 47,5 Nm
36
105,0 - 115,0
Nm
41
165,0 - 175,0
Nm
BOMAG
Nominal width
NW8
NW10
NW12
NW16
NW20
NW25
NW32
Bending radius
min. 50 mm
min. 65 mm
min. 75 mm
min. 100 mm
min. 160 mm
min. 194 mm
min. 225 mm
008 911 63
12.7
Checking the compressor oil level
12.7 Checking the compressor oil

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

speed.
In order to avoid any compressor oil losses you

should slowly drain all refrigerant from the air conditioning system.
Fig. 2
Turn the nut that hold the armature clockwise with a

socket wrench, until the counterweight is correctly
positioned.
Note
2 o'clock position with inclination to the right (Fig. 2).

10 o'clock position with inclination to the left
l
Insert the oil dipstick.
Pull out the dipstick and count the notches covered

by oil.
Drain off oil or fill up as specified in the table.
Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
Fig. 1
l
Measure the fastening angle (Fig. 1) of the compressor (oil plug at top)
Remove the oil filler plug.
Fastening angle (degree)

0
10
20
30
40
50
60
90
l
Oil dipstick in increments

5-7
6-8
7-9
8-10
9-11
10-12
11-13
16-18
Screw the oil filler plug back in.
!
Caution
The contact area must be clean and should be free
of damage.
Use a new O-ring.

Tightening torque 15 to 25 Nm
l
008 911 63
Refill the air conditioning system.
BOMAG
387
12.8
Checking the magnetic clutch
12.8 Checking the magnetic clutch
Take off the drive V-belt and rotate the V-belt pulley
by hand while the magnetic clutch is disengaged.
Note
The gap should be 0.4 to 0.8 mm.
Measure the voltage.
Note
Nominal value = vehicle voltage

l
Check the magnetic coil locking ring for secure fit.
Check the current consumption.
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. 1
Note
Nominal value approx. 3.5 Amp.

Overcurrent indicates a short circuit inside the magnetic coil.
No current indicates an interrupted electric circuit.
Fig. 3 Cross-section of magnetic clutch
Fig. 2 Measuring the air gap

l
Measure the air gap on the magnetic clutch between V-belt pulley (2) and thrust plate (1).
388
BOMAG
008 911 63
12.9
Inspection and maintenance work
12.9 Inspection and maintenance

work
12.10Checking, replacing the refrigerant compressor V-belt1
Visual inspection of the complete system for damage.
Check the compressor mounting bracket on the vehicle engine for tight fit and damage.
Check the condition, alignment and tightness of the

V-belt.
Check the routing of refrigerant hoses and cables in

the area of the vehicle engine and transmission, as
well as on the chassis for chafing and rectify any detected faults. Ensure sufficient clearance to hot
parts, such as the exhaust; install a protective
shield, if necessary.
Check the routing of hoses and hoses on the attachment box or in the cabin.
Check all hose and screw fittings for leaks.
Check the fastening of the condenser unit.
Clean the condenser fins, replace the condenser

block if damaged fins are found.
Check the fastening of the evaporator unit.
Check the function of evaporator and condenser

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

the engine shut down.
Wear safety goggles.
Check the V-belt
Fig. 4
Check the electric control panel. If discolorations on

conductors are found, these should be replaced
and possibly also the corresponding relays.
Inspect the entire circumference of the V-belt (Fig.

4) visually for damage and cracks. Replace damaged or cracked V-belts.
Switch on the cooling system and check the refrigerant level.
Filter/dryer and filter/dryer/fluid container combinations must always be replaced after opening the refrigerant circuit. If these are in service for more than
1 year, there is a risk that they may be clogged by
excessive absorption of moisture! The filter/dryer
should be replaced in regular intervals.
Check with thumb pressure whether the V-belt can

be depressed more than 10 to 15 mm (0.4 0.6
inches) between the V-belt pulleys, retighten if necessary.
Measure the temperature on the evaporator: Measure the intake air temperature - Measure the blow
out air temperature - The temperature difference
should be at least 8-10 K.
Measuring the pressure in the refrigerant circuit
Tighten the V-belt.
Fig. 5
l
Slightly slacken fastening screws 1, 2 and 3 (Fig.

5).
008 911 63
BOMAG
Optional equipment
389
12.11
Service the air conditioning
Press the compressor in direction of arrow, until the

correct V-belt tension is reached.
Retighten all fastening screws.
12.11Service the air conditioning1

Cleaning the condenser
Changing the V-belt

l
Slightly slacken the fastening screws 1, 2 and 3.
Press the compressor against the direction of arrow

completely against the engine.
Take the old V-belt off.
Fit the new V-belt to the V-belt pulleys.
Tension the V-belt as previously described.
Caution
Check the V-belt tension after a running time of 30
minutes.
!
!
Caution
A soiled condenser results in a considerable reduction of air conditioning power.
Under extremely dusty conditions it may be necessary to clean the condenser several times per
day.
If, during operation of the air conditioning system,
the warning buzzer sounds switch the air conditioning off and clean the condenser.
In case of formation of foam have the air conditioning system inspected by the service department.
Danger
Danger of accident!
!
Do not clean with a hot water jet. Heat will cause

extreme overpressure, which could cause damage or explosion of the system.
Use access steps and grips to mount and dismount the machine.
Fig. 6
l
Unscrew the condenser fastening screws (Fig. 6)

and fold the condenser forward.
Clean the condenser fins on front and back with

compressed air or cold water .
Checking the refrigerant level
390
Start the engine.
Optional equipment
BOMAG
008 911 63
12.11
Fig. 7
Fig. 9
Switch the air conditioning (Fig. 7) on.
Check whether the white float (Fig. 9) inside the inspection glass of the drier/collector unit floats right
at the top.
Note
The refrigerant level is correct.
Fig. 8
l
Choose a cooling temperature with the rotary switch

for cabin heater (Fig. 8) in the blue section.
Open the air outlet nozzles.
Check, whether the outflowing air is noticeably cooler.
Fig. 10
If the white float (Fig. 10) inside the inspection glass

of the drier/collector unit floats at the bottom, inform
the service department.
Note
The adjusted temperature must be below the actual

temperature inside the cabin, so that the compressor
will be switched on.
l
Open the hood.
The refrigerant level is not correct.

l
008 911 63
Note
Refrigerant must be filled up, if necessary check the
air conditioning system for leaks.
BOMAG
391
12.11
Checking the moisture level of the drying

agent
Fig. 12
l
Check the drier/collector unit (Fig. 12) for mechanical damage or rust.
Fig. 11
Check the moisture indication pearl (Fig. 11) inside

the inspection glass of the drier/collector unit.
orange
= drying agent o.k.
colorless = moisture level of drying agent too high.

Inform the service department. Replace drier/collector unit, check air conditioning system.
Caution
Have the drier/collector unit replaced by the service department every year before the operating
season.
!
Checking the condition of the drier/collector unit

Caution
According to the regulation for pressure reservoirs all pressure reservoirs must be repeatedly
inspected by a specialist. In this sense repeated
inspections are external examinations, normally
on pressure reservoirs in operation. In connection
with this inspection the drier/collector unit must
be visually examined twice every year. During
these inspections special attention must be paid
to corrosion and mechanical damage. If the reservoir is not in proper condition it must be replaced
for safety reasons, as a precaution to protect operators and third parties against any danger arising from the handling and operation of pressure
reservoirs.
!
! 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.
392
BOMAG
008 911 63
12.12
Drying and evacuation
12.12Drying and evacuation
12.13Emptying in case of repair
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.
For repair work the air conditioning systems must very

often be emptied of all refrigerant.
Any water residues in the refrigerant circuit will combine with the refrigerant, which will lead to the previously described consequential damage.
Vacuum pumps with a capacity of more than 100 l/min
and a final pressure of less than 30 micron, i.e. 0.039
mbar should be used to evacuate the refrigeration
system.
The refrigerant compressor is not suitable for the purpose 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 lubrication when running empty during evacuation.
It is common practice to evacuate the refrigeration
system to a final vacuum of 1 Torr, i.e. 1.33 mbar.
An exact time for evacuation and drying cannot be
predicted. It can only be determined by means of a
vacuum meter. However, if there is no vacuum meter
at hand it is generally better to evacuate 1 hour longer
than 1 hour too less.
Function drying:
Under normal ambient pressure (1.013 mbar) evaporates absolute at 100 C. If the pressure is reduced,
water will already evaporate, e.g. under a pressure of
10 mbar, at an ambient temperature of almost 7C,
but the water will not evaporate all at once. Since it is
very difficult to separate the steam from the vacuum in
the system, the evacuation process is supported by
the co-called vacuum breaking (filling the circuit with
dried nitrogen). With vacuum breaking the filled in
dried nitrogen absorbs the moisture in the refrigerant
circuit, which can then be easily discharged together
with the nitrogen.
008 911 63
Especially with expensive refrigerants and larger

amounts of oil it may be necessary to keep the refrigerant for later use.
For later use these refrigerants must be drawn out
with suitable equipment and intermediately stored in
collecting containers.
Environment
Contaminated refrigerant must be disposed of environmentally
Releasing refrigerant into the atmosphere is prohibited (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 appropriate pressure bottles, which must be specially marked and should comply with the pressure
gas directive.
!
When transferring refrigerant you must make sure

that the bottle does not contain more than the permitted amount of refrigerant in litres and has sufficient 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.
BOMAG
393
12.14
Leak test
12.14Leak 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 rubber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Before starting the evacuation process, the refrigerant

circuit is filled with nitrogen through a pressure reducer valve (approx. 22 bar). After this all connections in
the air conditioning system are checked with the help
of a suitable leak detection spray. A leak is thereby indicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air conditioning system with refrigerant.
Leak test with electronic leak tester
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 system. For example, leak detectors for refrigerant R12
are not suitable for R134a, because the refrigerant
R134a is free of chlorine atoms, meaning that this leak
detector will not respond.
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 detection limit for R 134a is 250 g/year.
394
BOMAG
008 911 63
12.15
Filling instructions
12.15Filling instructions
Filling of refrigerant into the dried, vented and oil filed

machines takes place under various conditions.
In most large series production facilities highly complicated equipment is available for this purpose, whereas individual machines at the place of installation must
be filled directly from the refrigerant container.
Liquid refrigerant is only used to pre-fill the pressure
side of the evacuated refrigeration system (protective
filling).
After switching the refrigeration system on and watching the inspection glass, gaseous refrigerant can be
filled into the system while the engine is running, if the
refrigerant level is found to be too low (gas bubbles in
the inspection glass).
!
Caution
Liquid refrigerant in the suction side of the compressor 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 refrigerant container should be about 1/3 filled with liquid 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.
Note
White frost on the suction line is no measure for assessing the filling.
008 911 63
BOMAG
395
12.15
Fig. 1
10 Filter dryer
High pressure - gaseous
11 Fluid container
High pressure - liquid
12 Condenser
Low pressure - gaseous
13 Manual shut-off valve (not used)
Compressor
Compressor pressure switch (not used)
14 Pressure switch with high and low pressure contacts
not used
15 Defroster thermostat
Evaporator
16 Vacuum meter
Expansion valve
17 Low pressure gauge
Inspection glass
18 High pressure gauge
396
BOMAG
008 911 63
12.15
19 Pressure reducing valve
16 Switch off the vacuum pump, watch the pressure

gauges to see whether the vacuum is maintained.
20 Vacuum pump
17 Open the valve on the refrigerant bottle and open

the black and red hand wheels on the pressure
gauge bar. Fill refrigerant into the system, until a
pressure equilibrium between suction and pressure side is reached (reading of pressure gauges).
18 Close the red hand wheel.
21 Nitrogen bottle
22 Refrigerant bottle
23 Pressure gauge bar
Connect the service adapter with the blue hand

wheel in the suction side.
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)
Connect the blue suction hose below the blue

hand wheel on the pressure gauge bar to the blue
service adapter.
Connect the red pressure hose below the red

hand wheel on the pressure gauge bar to the red
service adapter.
Connect the yellow hose below the yellow hand

wheel on the manometer bar to the 2-stage vacuum pump.
Connect the last hose below the black hand wheel

on the nitrogen bottle via the pressure reducing
valve.
Check on the pressure gauge bar that all hand

wheels are closed.
Turn the hand wheels on both service adapter

clockwise. This opens the valves (right hand
stop).
Open the valve on the nitrogen bottle (only via

pressure reducer); pressure approx. 20 bar.
10 Open the black and red hand wheels on the pressure gauge bar and fill nitrogen into the system,
until a pressure of approx. 3.5 to 5.0 bar is indicated on the suction side.
11 Then open the blue hand wheel and raise the
pressure in the suction side (max. 10 bar). Check
for leaks with a leak detection fluid or soapsuds.
19 Perform a leak test with the electronic leak detector.

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

from the system. For this purpose disconnect the
hose from the nitrogen bottle and open the red,
blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand
wheels on the pressure gauge bar. In case of a
leak no or only an insufficient vacuum will be
reached. In this case proceed as described under
point 9-12. Once the leak is sealed continue with
point 14.
15 Once a sufficient vacuum is reached, both pressure gauges show -1, close all hand wheels on the
pressure gauge bar.
008 911 63
BOMAG
397
12.16
Trouble shooting in refrigerant circuit, basic principles
12.16Trouble shooting in refrigerant circuit, basic principles

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

intervals. Calibration can only be made by an approved testing authority.
Pressure gauge
Most pressure gauges used in practice are (for cost
reasons) excess pressure gauges. These pressure
gauges measure the excess pressure in relation to the
ambient pressure (air pressure). In order to achieve
the absolute (actual) pressure the ambient pressure
must be added to the pressure gauge reading. The
absolute pressure is needed for the calculation and
determination of material data.
Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = excess pressure (pressure gauge reading)
398
BOMAG
008 911 63

Pressure gauge with saturation temperature scale
12.16
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 piston and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in
the cylinder causes a direct energy transfer from piston to cylinder cover during compression. The valve
plate may then be damaged by so-called fluid strokes.
Apart from protecting the compressor against fluid,
overheating has further advantages. Since the fluid
proportions in the drawn in steam reduces the flow
rate of the compressor, it may be increased by a overheating. Overheating also improves the oil recirculation.
Common overheating values
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 temperature is assigned to the measured pressure.
If the refrigerant is fluid, the temperature is below the
saturation temperature.
The optimal overheating value is approx. 5 - 8 Kelvin.

With this overheating the maximum system power is
reached. However, the thermostatic expansion valve
is unable to regulate this value exactly. Depending on
design and operating conditions overheating fluctuates within a range between 4 and 12 Kelvin. The influence of the ambient air on the suction line causes
an additional overheating effect.
Overheating is calculated as follows:
to2h = to2h - to
to2h, overheating at evaporator outlet in K
If the refrigerant is gaseous, the temperature is above

the saturation temperature.
to2h, temperature at evaporator outlet in C
Pressure gauges must indicate 0 bar when not connected to the system.
h represents "overheated"
Low pressure gauges have a blue, high pressure

gauges a red border.
Supercooling
Thermometer
Normally digital thermometers with surface or contact
feelers are used. Especially for high temperature differences excellent heat insulation of the measuring location is of utmost importance. The sparing use of a
heat conducting paste is highly recommended. If the
measuring location is soiled, it needs to be cleaned
and probably treated with a fine emery cloth. Only the
temperature of the feeler is measured. Due to missing
heat insulation and insulating oxide layers on the line,
temperature differences of a few degrees Kelvin between the measured and the actual values may arise.
Overheating
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are
not compressible and must therefore not enter into the
compression chamber of the compressor.
008 911 63
to, evaporation temperature in C
It is the function of the expansion valve to reduce the

refrigerant to a lower pressure level (evaporation
pressure) after it has been liquefied. For an optimal
function of the valve pure fluid must be applied to its
inlet port.
The refrigerant must "squeeze" (literally speaking)
through a throttle gap inside the expansion valve.
When comparing a certain mass of refrigerant in fluid
and in vaporous state (with constant pressure), the
vaporous refrigerant requires a much higher volume.
That's why the vaporous refrigerant needs a much
longer time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
If the refrigeration system is operated with the "expansion valve inlet" condition directly on the boiling curve,
slightest fluctuations in operating condition may cause
BOMAG
399
12.16
a formation of bubbles in front of the expansion element.

For this reason one shifts the condition "Expansion
Valve Inlet" away from the boiling curve into the fluid
area and refers to this condition as Supercooling. This
supercooling ensures a fluid supply in front of the expansion valve.
Common supercooling values
In systems with fluid container the supercooling at the
fluid container outlet is approx. Zero "0" Kelvin (assumed that the system is filled with the correct refrigerant quantity). In this case the fluid container
provides the required fluid supply.
Supercooling is calculated as follows:
tc2u = tc - tc2u
tc2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in C
tc, evaporation temperature in C
u represents "supercooled"
400
BOMAG
008 911 63
12.16
Fig. 1 Refrigerant circuit with t, h- diagram
Hot gas line (overheated steam)
Deheating (overheated steam)
Condenser / liquefier
Condensation (wet steam)
Fluid line (supercooled fluid)
Expansion valve
Injection line (wet steam)
Evaporation (wet steam)
Evaporator
10 Overheating (overheated steam)

11 Suction steam line (overheated steam)
12 Compressor
13 Supercooling (fluid)
14 Compression
15 Expansion
008 911 63
BOMAG
401
12.17
Trouble shooting, refrigerant circuit diagram
12.17Trouble shooting, refrigerant

circuit diagram
Fig. 1 Refrigerant circuit diagram
13 Compressor
Cold air
14 Condenser
Evaporator
15 Cooling air
Thermostat
16 Pressure gauge, low pressure
Warm air
Fan
Inspection glass
Expansion valve
Pressure gauge, high pressure
Pressure switch with high and low pressure contacts
10 Dryer
11 Fluid container
12 Hot air
402
BOMAG
008 911 63
12.18
Trouble shooting procedure
12.18Trouble shooting procedure

Procedure
Evaporator and heating (with highest fresh air fan

speed) do not draw leak air.
The fresh air fan runs when the engine is running

and the air conditioning system is set to max. cooling power.
Ambient temperature above 15 C.
The thermostat is correctly installed and the switching temperatures are correct.
Knowledge
Trouble shooting is not possible with exact knowledge
about the system design, the installed components
and their function in the system trouble shooting is not
possible:
Visual inspection
With the appropriate experience some faults can be
visually detected or felt. Frequently occurring condenser soiling or formation of steam bubbles in the inspection glass can be quickly detected.
In case of unusual formation of hoarfrost on the evaporator the hoarfrost pattern provides useful information. Hoarfrost only 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 indicates load problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the
naked eye. At the end of the evaporator there should
be an area which is dry or at least drier at evaporator
temperatures above -2 C.
The fluid line in the refrigeration system is warm. If a
local cooling can be felt or if condensation develops,
this is a clear indicator for an extreme pressure drop
in the line. Similar phenomena can be noticed in case
of blocked filters.
Unusually cold pressure lines indicate "wet" intake of
the compressor.
The oil level in the compressor sight glass provides information about the oil quantity and the oil recirculation 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.
Note
The dangerous part of common rules is that they apply in most, but not in all cases. The refrigerant states
in the individual piping sections or components must
therefore be exactly determined by means of pressure
and temperature measurements.
Test prerequisites
l
Cooler and condenser are clean, clean if necessary.
The ribbed belt for compressor and generator is

correctly tightened.
All air ducts, covers and seals are OK and correctly

fitted. Flaps reach their end positions.
The engine has operating temperature.
008 911 63
BOMAG
403
12.18

Measuring points and measurements
to assess the filling quantity. In systems with fluid container the inspection glass is most suitable to check
the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
Fig. 2 Flow diagram with measuring points

l
C, condenser measuring points
E, expansion valve measuring points
O, evaporator measuring points
V, compressor measuring points
The flow diagram contains "Minimum Requirements"

which must be fulfilled to be able to check the system
or perform trouble shooting.
Temperature and pressure at the evaporator outlet
can be used to derive the overheating of the evaporator. Overheating is a clear indicator for the evaporator
filling level. In case of excessive overheating the refrigerant quantity fed into the evaporator is too low, in
case of insufficient overheating it is too high. In individual cases one must then check if this situation is
caused by the expansion element or by insufficient filling. 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
404
The hot gas temperature can be used to check whether the compressor runs in the permissible operating
range.
Example: Measurement of overheating
l
a) Which measuring equipment is required ?
b) Where to measure with which size ?
c) A pressure gauge connected to the evaporator

indicates "Peo2 = 1.7 bar". How high is the evaporator pressure "Po" ?
d) How high is the evaporator temperature "to" ?
e) A thermal sensor attached to the evaporator outlet measures the temperature "to2h = +3 C". How
high is the overheating to2h ?
f) Evaluation of the measured overheating.
BOMAG
008 911 63
12.18
be a defect in the expansion valve or problems in the

oil recirculation.
Solution:
l
a) Pressure gauge, thermometer, steam table
b) Evaporation pressure "Peo2" and temperature

"to2h" are measured at the same point on the evaporator outlet.
The following list contains pressure values in a system, that can be expected at various ambient temperatures (measured at medium speeds).
c) Po = Peo2 + Pamb, "Evaporation pressure =

pressure on evaporator + atmospheric pressure" =
1.7 bar + 1 bar = 2.7 bar.
Suction pressure (low pressure gauge)
d) "Pc" = 2,7 bar can then be used to derive an condensing temperature "to" of -2,2 C from the steam
table for R134a.
e) to2h = to2h - to, Overheating at evaporator outlet = evaporator outlet temperature - evaporation
temperature" = 3 C - (-2.2 C) = 5.2 Kelvin.
f) The determined overheating is within the usual
range of 4 - 12 Kelvin.
Ambient temperature in C
25
30
35
Excess pressure in bar

approx. 2,0
approx. 2,5
approx. 3
High pressure (high pressure gauge)

Ambient temperature in C
25
35
40
45
Excess pressure in bar

approx. 8,0
approx. 13
approx. 16
approx. 18
Example: Measuring supercooling

l
a) Which measuring equipment is required ?
b) Where to measure with which size ?
c) A pressure gauge connected to the condenser indicates "Pec2 = 15 bar". How high is the condensing
pressure "Pc" ?
d) How high is the condensing temperature "tc" ?
e) A thermal sensor attached to the condenser outlet measures the temperature "tc2u = 58 C". How
high is the supercooling "tc2u" ?
f) Evaluation of the measured supercooling.
Solution:
l
a) Pressure gauge, thermometer, steam table
b) Condensing pressure "Pec2" and temperature

"tc2u" are measured at the same point on the condenser.
c) Pc = Pec2 + Pamb, "Evaporation pressure =

pressure on evaporator + atmospheric pressure" =
15 bar + 1 bar = 16 bar.
d) "Pcc = 16 bar can then be used to derive an condensing temperature "tc" of 57.9 C from the steam
table for R134a.
e) tc2u = tc - tc2u, "Supercooling at condenser outlet = condensing temperature - condenser outlet

temperature" = 57.9C - 58 C) = -0.1 Kelvin.
f) The determined overheating is within the usual
range of approx. "0" Zero Kelvin.
Typical faults and possible causes

Most faults in the refrigerant side of the system can be
clearly assigned with the help a checklist.
r Occurring faults frequently have a similar appearance, but
different causes.
An evaporator showing hoarfrost
may be quite normal.
However, there may also
008 911 63
BOMAG
405
12.18
Values effecting the operating pressures
tions, it is mandatory to know these dependencies.

The following table contains some of these dependencies.
Since the pressures occurring in a refrigeration system are highly dependent on environmental condiMeasuring value
Suction pressure
increases
drops
increases
Compressor speed
X
drops
X
Vehicle interior temperature
increases
Ambient temperature
increases
drops
increases
X
X
X
X
X
X
X
X
drops
406
X
X
drops
Humidity
High pressure
increases
drops
X
BOMAG
008 911 63
12.18
Suction pressure too low (1), high pressure too

low to normal (2)
Fig. 3
Cause
Lack of refrigerant
Possible effect
Remedy
no supercooling, bubbles in inspec- Check for leaks, refill
tion glass, high overheating, hoarfrost 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 thermostat switching too frequently
008 911 63
BOMAG
407
12.18

Suction pressure normal (1), high pressure too
high (2)
Fig. 4
Cause
Condenser dirty
Possible effect
Remedy
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
408
BOMAG
008 911 63
12.18
Suction pressure too high (1), high pressure too

low to normal (2)
Fig. 5
Cause
Compressor defective
008 911 63
Possible effect
Cooling power too low
BOMAG
Remedy
Replace the compressor
409
12.18

Suction pressure too high (1), high pressure too
high (2)
Fig. 6
Cause
Expansion valve defective
410
Possible effect
Remedy
overheating too low, wet operation Replace the valve
of compressor
BOMAG
008 911 63
12.18

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 bewear
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,
check cause for switching
er safety feature has trigand rectify
gered, electrical fault,
cylinder filled with liquid refrigerant
Compressor switches con- Switching difference too
Cycling of compressor, in- Check the control units,
small, triggering of a
tinuously
creased wear, too low cool- check cause for switching
switching element (over- ing power
and rectify
pressure switch, low pressure switch), lack of
refrigerant, fan defective,
overfilled
Excessive overheating
Expansion valve deadjust- low cooling power, hot gas Replace the expansion
valve, clean the screen, fill
ed or screen blocked, lack temperatures too high
in refrigerant, leak test
of refrigerant
Hoarfrost on inlet side of incorrectly working expan- too low infeed of refrigerant Check the expansion
evaporator
valve, check the refrigerant
sion valve, lack of refriger- into the evaporator
filling
ant
Evaporator fully covered Load problem, too low air low cooling power of sys- Clean the evaporator,
with hoarfrost
flow volume
check the evaporator fan
tem
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, resure lines
pressor due to insufficient sive wear of compressor place if necessary, replace
overheating of evaporator
the expansion valve if necessary
Noise in system
Faults
V-belt loose or excessively worn
Magnetic clutch loud
Refrigerant compressor is loud
Possible cause
Remedy
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, reparts worn, low oil level in compres- place the compressor, renew the resor
frigeration oil
Replace the fan motor
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
System overfilled
pressure line, knocking noise in
compressor, ball in inspection glass
floating at the top
Expansion valve loud
excessive moisture in system
Hissing noise in evaporator housing, refrigerant level in system too low
on expansion valve, turbidity in inspection glass or ball does not float
008 911 63
BOMAG
Replace the bearing, check V-belt

pulley for wear
Draw out refrigerant
Replace the dryer

Perform a leak test, fill up the system
411
12.18
Inspection glass
Faults
Steam bubbles in inspection glass
Discolouration of inspection glass

(black from inside)
Moisture indicator changes to pink
Ball floats at bottom
Possible cause
No supercooling before expansion
valve, lack of refrigerant in system,
pressure loss in system, supercooling caused by excessively soiled filter dryer
Lubricant destroyed by excessive
operating temperatures
Moisture level of drying agent too
high
lack of refrigerant
Remedy
Fill up the system, replace the filter
dryer, perform a leak test
Replace the refrigeration oil, examine the temperature increase

Replace the filter dryer
Fill the system
Monitoring devices
Faults
The high pressure contact has
switched off the magnetic clutch
Possible cause
Remedy
System pressure exceeded, conClean the condenser, replace the
denser excessively soiled, condens- expansion valve, check the coner fan defective, expansion valve
denser fan
defective
The low pressure contact has
System pressure fallen short of, re- Clean the evaporator, replace the
switched off the magnetic clutch
expansion valve, check the evaporafrigerant level too low, expansion
valve defective, evaporator fan de- tor fan
fective, heat load too low, ambient
temperature below 1.5 C
The thermostat has switched off the Ambient temperature below 1C, Check the thermostat switching
magnetic clutch
expansion valve defective, thermo- point, replace the expansion valve,
stat defective, air flow volume too clean the evaporator, check the
evaporator fan
low
412
BOMAG
008 911 63
12.19
Steam table for R134a
Tempera- Presture
sure
Density
of the fluid
008 911 63
of the
steam
spec. volume
spec. enthalpy
of the fluid of the

steam
of the fluid of the

steam
BOMAG
Evaporation heat
413
12.19
414
BOMAG
008 911 63
12.19
008 911 63
BOMAG
415
12.19
416
BOMAG
008 911 63
12.19
008 911 63
BOMAG
417
12.19
418
BOMAG
008 911 63
12.20Heating control / air conditioning control
008 911 63
BOMAG
419
12.20
420
Heating control / air conditioning control
BOMAG
008 911 63
008 911 63
BOMAG
12.20
421
12.20
422
BOMAG
008 911 63
008 911 63
BOMAG
12.20
423
12.20
424
BOMAG
008 911 63
13 Replacing the cab window panes
008 911 63
BOMAG
425
13.1
Assembly of window panes
Fig. 1
Glass panes
Fastening element
Fixing washer and spacer
Washer
Hexagon nut, self locking
Protective cap
426
BOMAG
008 911 63
13.2
Special tools
13.2 Special tools
1. Locking handle for fastening element
Fig. 1
2. Suction lifter
commercial
Fig. 2
008 911 63
BOMAG
427
13.3
Auxiliary materials
13.3 Auxiliary materials
Safety gloves
3. Cutter
Commercial
Fig. 1
4. Window glass bonding agent

Fig. 2
5. Activator
Fig. 3
428
BOMAG
008 911 63
13.3
Auxiliary materials
6. Silicone sealant
Fig. 4
008 911 63
BOMAG
429
13.4
Removing and installing the window pane

13.4 Removing and installing the window
pane
Environment
Dispose of glass splinters fro0m machine and
cabin or inside cabin in an environmentally
friendly way.
! Danger
Danger of cutting
Wear safety gloves.

1. Pull large glass rests off the bonding strip (Fig. 1).
Fig. 1
2. Clean the sealing surfaces from any adhesive

material (Fig. 2).
3. Use a cutter to remove adhesive residues with
glass rests.
4. Cover places without adhesive residues with an
activator.
Fig. 2
5. Insert the fastening element with washer into the

bore in the glass pane (Fig. 3).
Fig. 3
430
BOMAG
008 911 63
13.4
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, approx. 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 elements 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 hexagon nut.

12. Fasten the window pane to the fastening bar using a locking handle and a ring spanner (Fig. 7).
i Note
Only use the locking handle to counter.
13. Press the protective cap onto the hexagon nut.
Fig. 7
008 911 63
BOMAG
431
13.4

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
432
BOMAG
008 911 63
13.4
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.
Note
Once the silicone sealing agent has cured it can
only be removed mechanically.
Fig. 14
008 911 63
BOMAG
433
13.4
434
BOMAG
008 911 63
14 Drum
008 911 63
BOMAG
435
14.1
Special tools, drum, single drum rollers

14.1 Special tools, drum, single drum rollers
1. Disassembly device for side plate
Fig. 1
2. Assembly device for side plate

Fig. 2
3. Assembly device for coupling hub and flanged

hub
Fig. 3
436
BOMAG
008 911 63
14.1
Special tools, drum, single drum rollers
4. Pressing plate for cylinder roller bearing
Fig. 4
5. Pressing plate for travel bearing
Fig. 5
6. Pressing bushing for radial seal
Fig. 6
7. Lifting device for exciter unit

Fig. 7
008 911 63
BOMAG
437
14.2
438
Repair overview for drum
BOMAG
008 911 63
14.2

1
Drum
13 Flanged hub
Cylinder roller bearing
14 Vibrator shaft
Coupling
15 Coupling
Vibration motor
16 Vibrator shaft
Rear shell
17 Change-over weight
Grooved ball bearing
18 Cylinder roller bearing
Spacer block
19 Basic weight
Rectangular rubber buffer
20 Flanged housing
Side plate
21 Flange
10 Spacer ring
22 Cylinder roller bearing
11 Grooved ball bearing
23 Rear shell
12 Mechanical seal
008 911 63
BOMAG
439
14.2
440
BOMAG
008 911 63
14.2
008 911 63
BOMAG
441
14.2
442
BOMAG
008 911 63
14.2
008 911 63
BOMAG
443
14.2
444
BOMAG
008 911 63
14.2
008 911 63
BOMAG
445
14.3
Removing and installing the drum

14.3 Removing and installing the drum
i Note
After disassembling the side plate (vibration motor side) the drum can be lifted sideways out of
the frame (Fig. 1).
Fig. 1
i Note
However, the drum can also be removed without
having to disassemble the side plate, if it is lifted
up and out of the frame (Fig. 2).
Fig. 2
Removing the drum
i Note
The following section describes the procedure for
lifting the frame sideways out of the drum.
Environment
Catch running out hydraulic oil and dispose
of environmentally.
1. Mark the hydraulic hoses (Fig. 3)on the travel motor and disconnect them from the ports.
2. Close all hydraulic hoses and motor ports with
suitable plugs.
Fig. 3
446
BOMAG
008 911 63
14.3
3. Mark the hydraulic hoses on the vibration motor

(Fig. 4) and disconnect them from the ports.
4. Close all hydraulic hoses and motor ports with
suitable plugs.
Fig. 4
5. Unscrew screws 1 (Fig. 5) from holding plate (2)

for hydraulic hoses from both sides.
Fig. 5
6. Unscrew screws (Fig. 6) from the spacer piece on

vibration and travel motors.
Fig. 6
7. Fasten the lifting gear to the side plate on the vibration side.
8. Support the front cross-member safely with suitable trestles or wooden blocks (Fig. 7).
9. Unscrew plugs (1) and screws (2).
Fig. 7
008 911 63
BOMAG
447
14.3

10. Support the rear cross-member safely with suitable trestles or wooden blocks (Fig. 8).
11. Unscrew plugs (1) and screws (2).
! Danger
Danger of squashing! Do not stand or step
under loads being loaded.
12. Take off the side plate.
Fig. 8
13. Fasten the lifting tackle to the drum and lift the
drum carefully sideways out of the front frame
(Fig. 9).
! Danger
under loads being loaded.
Fig. 9
14. Check all rubber buffers (Fig. 10), replace if necessary (see corresponding chapter).
Fig. 10
15. Check rectangular rubber buffers (Fig. 11), replace if necessary.
Fig. 11
448
BOMAG
008 911 63
14.3

Installing the drum
Danger
Danger of squashing!
!
Do not stand or step under loads being loaded.

1. Place the drum into the frame and align it parallel
to the frame (Fig. 12).
Fig. 12
2. Attach the side plate, insert screws 2 (Fig. 13) into

the rear cross-member, slide on washers, turn on
and tighten the nuts.
i Note
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
3. Close the screw holes with plugs (1).
Fig. 13
4. Attach the side plate, insert screws 2 (Fig. 14) into

the rear cross-member, slide on washers, turn on
and tighten the nuts.
i Note
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
5. Close the screw holes with plugs (1).
Fig. 14
6. Fasten the spacer pieces with screws (Fig. 15)

and nuts to the side plate.
Fig. 15
008 911 63
BOMAG
449
14.3

Adjust the pretension of the rubber buffers.
7.
Measure distance X between spacer piece 1

(Fig. 16) and side plate.
8. Calculate the thickness of the compensation

plates.
Nominal value:
Distance "X" + 2 mm
9. Turn one screw (3) into the welded nut (2) at top
and bottom and open a sufficient gap to insert the
compensation plates.
Fig. 16
10. Insert the compensation plates (Fig. 17). Insert

screws (1), slide on washers (3), turn on and
tighten nuts (2).
11. Unscrew the screws from the welded nuts.
Fig. 17
12. Connect hydraulic hoses to the connections on

travel motor and vibration motor according to the
marking.
Fig. 18
13. Fasten holding plate 2 (Fig. 19) for hydraulic hoses with screws (1).
Caution
After connecting the hydraulic components
and before starting operation bleed the hydraulic system, check the function and inspect the system for leaks.
!
Fig. 19
450
BOMAG
008 911 63
14.4
Repairing the drum

14.4 Repairing the drum
Removing the travel motor
Danger
!
Do not stand or step under suspended loads.

1. Attach the lifting tackle to the travel motor.
2. Unscrew all nuts (Fig. 3) from the rubber buffers.
3. Take the drive disc with the travel motor off the
rubber buffers.
Fig. 1
4. Unscrew the nuts, pull out the screws and remove the support legs (Fig. 4).
Fig. 2
5. Attach the lifting tackle to the travel motor (Fig. 3).

Danger
!
Fig. 3
008 911 63
BOMAG
451
14.4
Repairing the drum

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

motor side)
1. Unscrew both socket head cap screws from the
flange (Fig. 5).
Fig. 5
2. Mount bracket 1 (Fig. 8) for the lifting device to

the flange.
3. Unscrew screws (2) from the flange.
i Note
Do not unscrew the thin drawn screws.
Fig. 6
452
BOMAG
008 911 63
14.4
Repairing the drum
4. Slide the lifting device over the bracket.

5. Force the exciter unit off with two forcing screws
(Fig. 7).
Fig. 7
Danger
!

6. Pull the exciter unit out of the drum (Fig. 8).
7. Take the coupling element off the coupling half.
Fig. 8
Disassembling the exciter unit (travel

motor side)
1. Unscrew fastening screws 1 (Fig. 9) for the fan.
2. Loosen clamping screw (2).
3. Pull the coupling hub off the shaft.
Fig. 9
008 911 63
BOMAG
453
14.4
Repairing the drum

4. Unscrew all other fastening screws 1 (Fig. 10)
from the flange.
5. Press the flange off the flanged housing with forcing screws (2).
Fig. 10
Environment
Environmental damage!
Catch running out oil and dispose of environmentally.
6. Lift the flange off the flanged housing (Fig. 11).
7. Take the O-ring out of the groove in the flanged
housing.
Fig. 11
8. Unclip the circlip from the groove in the flange

(Fig. 12).
Fig. 12
9. Press the cylinder roller bearing with forcing

screws out of the flange (Fig. 13).
Fig. 13
454
BOMAG
008 911 63
14.4
Repairing the drum
10. Take the exciter unit (Fig. 14) out of the flanged
housing.
Fig. 14
11. Knock the radial seal (Fig. 15) out of the flanged
housing.
Fig. 15
12. Unclip the circlip from the groove in the flanged

housing (Fig. 16).
Fig. 16

screws out of the flanged housing (Fig. 17).
Fig. 17
008 911 63
BOMAG
455
14.4
Repairing the drum

14.
Extract inner ring 1 (Fig. 18) for the radial seal

and inner bearing races (2).
Danger
Danger of burning!
!
Wear safety gloves.
Note
If the rings are very tight, heat them up with a
torch.
Fig. 18
15. Unclip the circlip from the basic weight (Fig. 19).
Fig. 19
16. To change shaft 1 (Fig. 20) knock out dowel pins

(2 and 3) and press the shaft out of the basic
weight.
Note
If necessary disassemble, assemble the changeover weight (see corresponding chapter).
Fig. 20
456
BOMAG
008 911 63
14.4
Repairing the drum
Disassembling the exciter unit (vibration motor side)

1. Unscrew fastening screw 1 (Fig. 21).
2. Take rectangular rubber buffer (2) with spacer
block (3) off the side plate.
i Note
Remove both rectangular rubber buffers.
Fig. 21
3. Unscrew fastening screws 1 (Fig. 22).

4. Force cover (2) together with the attached vibration motor off the side plate with forcing screws.
Fig. 22
5. To change the vibration motor loosen clamping

screw 1 (Fig. 23) and pull off coupling half (2).
Fig. 23
008 911 63
BOMAG
457
14.4
Repairing the drum

6. Unscrew nut 1 (Fig. 24), take off conical socket
(2) and conical disc (3).
7. Take the vibration motor off the cover.
Fig. 24
8. Remove the coupling element (Fig. 25).
Fig. 25
9. Fasten the lifting device.

Caution
The four short fastening screws (2) must remain screwed in (the two others are not visible).
!
Fig. 26
11. Press the exciter unit out of the drum with forcing
screws (Fig. 27).
i Note
The second forcing screw is covered by the side
plate.
Fig. 27
458
BOMAG
008 911 63
14.4
Repairing the drum

!
Caution

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

1. Take off V-ring 1 (Fig. 29).
2. Unclip circlip (2).
Fig. 29
3. Attach the disassembly device to the side plate

(Fig. 30) and force off the side plate.
Fig. 30
4. Lift the side plate of the flanged hub (Fig. 31).
Fig. 31
008 911 63
BOMAG
459
14.4
Repairing the drum

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

(Fig. 34).
Fig. 34
460
BOMAG
008 911 63
14.4
Repairing the drum
Dismantling the exciter unit (vibration

motor side)
1. Unscrew the fastening from the coupling hub.
2. Pull coupling hub (2) off the shaft using a pulling
device (Fig. 35).
Fig. 35
3. Loosen hose clamp 1 (Fig. 36).

4. Pull coupling hub (2) off the shaft.
Fig. 36
5. Unscrew all other fastening screws 1 (Fig. 37)

and press the flanged hub off the flanged housing
with forcing screws (2).
6. Take off the flanged hub.
7. Take the O-ring out of the groove in the flanged
housing.
Fig. 37
008 911 63
BOMAG
461
14.4
Repairing the drum

hub (Fig. 38).
Fig. 38
9. Knock the cylinder roller bearing out of the flanged hub (Fig. 39).
Fig. 39
Environment
Environmental damage!
10. Lift the exciter unit out of the flanged housing (Fig.
40).
Fig. 40
11. Knock the radial seal (Fig. 41) out of the flanged
housing.
Fig. 41
462
BOMAG
008 911 63
14.4
Repairing the drum

housing (Fig. 42).
Fig. 42

screws out of the flanged housing (Fig. 43).
Fig. 43
14. Extract inner rings 1 (Fig. 44) for the radial seals
and inner bearing races (2) from the shaft.
Danger
Danger of burning!
!
Wear protective gloves.
i Note
If the rings are very tight, heat them up with a
torch.
Fig. 44
15. Unclip the circlip from the basic weight and remove the cover (Fig. 45).
i Note
The shafts cannot be pressed out. If damaged
they must be replaced with basic weight and cover.
If necessary disassemble, assemble the changeover weight (see corresponding chapter).
Fig. 45
008 911 63
BOMAG
463
14.4
Repairing the drum

Assembling the exciter unit (vibration
motor side)
!
Caution
Ensure strict cleanliness.
Note
If the shafts are damaged they must be inserted
into the basic weight or the cover as follows.
Danger
When working with liquid nitrogen protect
your face and wear gloves.
!
Do not place any unintended parts into liquid

nitrogen.
Fig. 46
Observe the safety instructions for the handling of liquid nitrogen.

Caution
Close the bores on the short shaft with a
screw.
!
1. Cool the shaft down in liquid nitrogen.

2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
46).
3. Secure shaft 1 (Fig. 47) with dowel pins (2 and 3).
Caution
Assemble the dowel pins with the grooves
offset by 180 to each other, but in line with
the axis of the shaft.
!
Note
Unscrew the screw from the shaft.
Fig. 47
Caution
Close the bores on the short shaft with a
screw.
!

48).
Fig. 48
464
BOMAG
008 911 63
14.4
Repairing the drum

Caution
!
i Note
Unscrew the screw from the shaft.
Fig. 49
7. Insert the fitting key into the keyway in the respective shaft (Fig. 50).
Fig. 50
8.
Insert the circlip into the groove in the basic

weight and on the cover (Fig. 51).
Fig. 51
Danger
Danger of burning!
!
Wear safety gloves.

9. Heat the inner bearing race up to approx. 100 C
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 52).
Fig. 52
008 911 63
BOMAG
465
14.4
Repairing the drum

! Danger
Danger of burning!
Wear safety gloves.

10. Heat the inner ring up to approx. 50 C and slide
it onto the short shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 53).
Fig. 53
Danger
Danger of burning!
!
Wear safety gloves.

and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 54).
Fig. 54
Danger
Danger of burning!
!
Wear safety gloves.

it onto the longer shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 55).
Fig. 55
13. Press cylinder roller bearing 1 (Fig. 56) with

pressing plate (2) into the flanged housing until it
bottoms.
Fig. 56
466
BOMAG
008 911 63
14.4
Repairing the drum
14. Insert the circlip into the groove in the flanged

housing (Fig. 57).
Fig. 57
15. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 58).
16. Fill approx. 1.2 l oil SAE-15W/40 into the flanged
housing.
Fig. 58
Caution
!

17. Insert the exciter unit with the longer shaft forward into the flanged housing (Fig. 59).
Fig. 59

pressing plate (2) into the flanged hub until it bottoms.
Fig. 60
008 911 63
BOMAG
467
14.4
Repairing the drum

19. Insert the circlip into the groove in the flanged hub
(Fig. 61).
Fig. 61
20. Attach the flanged hub to the flanged housing

(Fig. 62).
!
Caution
Fitting and contact surfaces must be absolutely dry and free of grease, paint and conserving agents.
21. Unscrew eye bolts (1) and replace them with

short screws.
22. Turn short screws (2) into the tapped bores in the
flanged housing (four screws) and tighten them.
Fig. 62
23. Apply some grease to the sealing lip of radial seal

1 (Fig. 63).
24. Insert the radial seal into the flanged hub with the
sealing lip facing down and press it down against
the stop with pressing bushing (2).
Danger
Danger of burning!
Fig. 63
Wear protective gloves.

25. Heat the coupling hub up to approx. 80 C and
slide it onto the shaft against the stop (Fig. 64).
Fig. 64
468
BOMAG
008 911 63
14.4
Repairing the drum

1 (Fig. 65).
27. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).
Fig. 65
28. Cover the thread of screw 1 (Fig. 66) with a screw

retention agent (e.g. Loctite CVX strong, blue,
582).
29. Slide on the new U-seal ring (2), turn in and tighten the screws.
! Danger
Danger of burning!
Fig. 66
Wear safety gloves.

30. Heat coupling hub 1 (Fig. 67) with marking letter
L up t approx. 80 C and slide it over the shaft
against the shoulder.
31. Turn in and tighten clamping screw (2).
Fig. 67
008 911 63
BOMAG
469
14.4
Repairing the drum

Assembling and installing the side
plate
1. Fill grooved ball bearing 1 (Fig. 68) on both sides
with grease.
2. Press the grooved ball bearing completely in using pressing plate (2).
Fig. 68
3. Insert the circlip into the groove in the side plate

(Fig. 69).
Fig. 69
4. Apply a thick coat of grease to the spacer ring on

both sides and insert it into the side plate (Fig.
70).
Fig. 70
470
BOMAG
008 911 63
14.4
Repairing the drum
5. Fill grooved ball bearing 1 (Fig. 71) on one sides

with grease.
6. Insert the grooved ball bearing with the grease
side forward and press it completely in with
pressing plate (2).
i Note
Grease the other side after installing the exciter
unit.
Fig. 71
7. Insert the oiled loop-ring into the mechanical seal

(Fig. 72).
8. Clean the sliding surfaces of the mechanical seal
and cover them with oil.
Fig. 72
9. Lay one half of the radial seal on the flanged hub

with the sliding surface pointing up (Fig. 73).
Fig. 73
10. Lay the second half of the mechanical seal down

with the sliding face pointing down (Fig. 74).
Fig. 74
008 911 63
BOMAG
471
14.4
Repairing the drum

11. Bolt the threaded section of the assembly device
to the flanged hub (Fig. 75).
Caution
under suspended loads.
Fig. 75
12. Lay the side plate on the flanged hub (Fig. 76).
Fig. 76
13. Attach bushing 2 (Fig. 77) of the assembly device

and turn on nut (1).
Fig. 77
14. Pull the side plate with the assembly device onto
the flanged hub.
Caution
During assembly make sure that the mechanical seal slides correctly into the side plate
and the loop rings are not damaged (Fig. 78).
!
Fig. 78
472
BOMAG
008 911 63
14.4
Repairing the drum

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

motor side)
Danger
When working with liquid nitrogen protect
your face and wear gloves.
!
Do not place any unintended parts into liquid

nitrogen.
Observe the safety instructions for the handling of liquid nitrogen.
!
Caution
Ensure strict cleanliness.

Fig. 80

80).
!
Caution
Fig. 81
008 911 63
BOMAG
473
14.4
Repairing the drum

4. Insert the circlip into the groove in the basic
weight and on the cover (Fig. 82).
Fig. 82
Danger
Danger of burning!
!
Wear safety gloves.

and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 83).
Fig. 83
Danger
Danger of burning!
!
Wear safety gloves.

it onto the shaft against the shoulder with the wider chamfer facing towards the outside (Fig. 84).
Danger
Danger of burning!
Fig. 84
Wear safety gloves.

and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 85).
Fig. 85
474
BOMAG
008 911 63
14.4
Repairing the drum

pressing plate (2) into the flanged housing until it
bottoms.
Fig. 86
9. Insert the circlip into the groove in the flanged

housing (Fig. 87).
Fig. 87
10. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 88).
11. Fill approx. 1.2 l oil SAE-15W/40 into the flanged
housing.
Caution
Fig. 88
12. Insert the exciter unit into the flanged housing

(Fig. 89).
Fig. 89
008 911 63
BOMAG
475
14.4
Repairing the drum

pressing plate (2) into the flange until it bottoms.
Fig. 90
14. Insert the circlip into the groove in the flange (Fig.
91).
Fig. 91
15. Lift the flange onto the flanged housing and align
it the bores (Fig. 92).
Caution
Fitting and contact surfaces must be absolutely dry and free of grease, paint and conserving agents.
!
Fig. 92
16. Turn the screws into the tapped bores of the

flanged housing and tighten them (Fig. 93).
Fig. 93
476
BOMAG
008 911 63
14.4
Repairing the drum

1 (Fig. 94).
18. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).
Fig. 94
19. Cover the thread of screw 1 (Fig. 95) with a screw

retention agent (e.g. Loctite CVX strong, blue,
582).
20. Slide on the new U-seal ring (2), turn in and tighten the screws.
Fig. 95
21. Insert the fitting key into the keyway of the shaft
(Fig. 96).
Danger
Danger of burning!
Fig. 96
Wear safety gloves.

22. Slide the fan with assembly disc over the shaft.
23. Heat coupling hub 1 (Fig. 97) with marking letter
R up to approx. 80 C and slide it over the shaft
against the shoulder.
24. Turn in and tighten clamping screw (2).
25. Assemble the fan to the coupling hub.
Fig. 97
008 911 63
BOMAG
477
14.4
Repairing the drum

Assembling the exciter unit (travel
motor side)
1. Check coupling elements, replace if necessary.
2. Insert the coupling element into the coupling hub
(Fig. 98).
!
Caution
Fitting and contact surface of the connection
between exciter unit and drum must be absolutely dry and free of grease, oil, paint and
conserving agent.
3. Fasten the lifting device to the exciter unit.

Caution
!
Fig. 98
4. Insert the vibrator unit into the drum (Fig. 99).
Fig. 99
i Note
Insert the exciter unit so that oil filler plug 1 (Fig.
100) is in line with bore (2) in the drum.
Fig. 100
478
BOMAG
008 911 63
14.4
Repairing the drum
5. Turn in and tighten screws 2 (Fig. 101).

6. Remove bracket (1) for the lifting device.
Fig. 101
7. Cover the thread of screws (Fig. 102) with a

screw retention agent (e.g. Loctite green 270).
8. Slide on the new U-seal ring, turn in and tighten
the screws.
Fig. 102
Installing the travel motor

! Danger

1. Fasten the lifting tackle to the travel motor and attach the motor to the drive disc (Fig. 103).
Fig. 103
2. Turn in and tighten the fastening screws (Fig.

104).
Fig. 104
008 911 63
BOMAG
479
14.4
Repairing the drum

3. Mount the support leg to the travel motor, insert
the screws, turn on and tighten the nuts (Fig.
105).
Fig. 105
Danger
!

4. Attach the drive disc with the assembled travel
motor to the rubber buffers. Turn on and tighten
the nuts (Fig. 106).
Fig. 106
Installing the exciter unit (vibration

motor side)
Caution
Fitting and contact surface of the connection
between exciter unit and drum must be absolutely dry and free of grease, oil, paint and
conserving agent.
!
Danger
!
1. Fasten the lifting gear to the exciter unit and insert

it into the drum (Fig. 107).
Fig. 107
480
BOMAG
008 911 63
14.4
Repairing the drum
!
Caution
Ensure correct engagement of coupling and
alignment of shaft (Fig. 108).
If the shafts are not correctly in line determine

the cause, if necessary measure the drum.
Fig. 108
2. Turn in and tighten screws 1 (Fig. 109).

3. Remove the lifting gear.
4. Fit cover (2) to the drum.
Fig. 109
5. Check the end float of the exciter shafts (Fig.

110).
Nominal value: 0.6...1.8 mm
Fig. 110
6. Attach disc 1 (Fig. 111), turn in and tighten the

fastening screws (2).
Fig. 111
008 911 63
BOMAG
481
14.4
Repairing the drum

7. Lay a new V-ring over the journal of the flanged
hub (Fig. 112).
8. Fill the grooved ball bearing with grease.
Fig. 112
9. Check coupling element, replace if necessary.

10. Insert the coupling element into the coupling hub
(Fig. 113).
Fig. 113
11. Fasten the vibration motor to the cover so that

sockets 1 (Fig. 114) and ventilation bore (2) are
opposite each other.
Fig. 114
12. Slide on coupling half 2 (Fig. 115) and secure with

clamping screw (1).
Fig. 115
482
BOMAG
008 911 63
14.4
Repairing the drum
13. Attach the cover with the installed vibration motor, turn in and tighten the screws (Fig. 116).
Fig. 116
14. Install rectangular rubber buffers 2 (Fig. 117) with

attached spacer block (3) and screws (1) to the
side plate.
i Note
Assemble both rectangular rubber buffers.
Fig. 117
008 911 63
BOMAG
483
14.5
Disassembling and assembling the change-over weight

14.5 Disassembling and assembling the
change-over weight
Dismantling the change-over weight
1. Unscrew all screws (Fig. 3).
Fig. 1
2. Force the cover with forcing screws (Fig. 4) off the

basic weight.
Environment
Environmental hazard!
Fig. 2
3. Take the change-over weight out of the basic

weight (Fig. 5).
Fig. 3
484
BOMAG
008 911 63
14.5
4. Take the O-rings 1 and 2 (Fig. 4) out of the

grooves.
Fig. 4
Assembling the change-over weight

1. Insert the new O-rings 1 and 2 (Fig. 5) with
grease.
Fig. 5
2. Place the change-over weight into the basic

weight (Fig. 6).
Fig. 6
3. Fill aprox 2,5 litres of silicone oil 47 V 1000 cst (up

to the upper edge of the change-over weight) into
the basic weight (Fig. 10).
Fig. 7
008 911 63
BOMAG
485
14.5

4. Lay the cover on (Fig. 11), so that the raised areas are in line.
5. Screw the screws in with screw locking agent
(e.g. Loctite green 270) and tighten them with
120 Nm.
6. Check the axial clearance of the shaft.
Note
The shaft must have clearance.
Fig. 8
486
BOMAG
008 911 63
Changing the rubber buffers and adjusting the pretension
14.6
14.6 Changing the rubber buffers and adjusting the pretension

Relieve the rubber buffers
1. Lift the frame up by both sides, until rubber buffers and rectangular buffers are relieved of any
load (Fig. 1).
2. Loosen all fastening screws.
Fig. 1
3. Turn one screw each into the welded nuts (Fig. 2)

on the spacer blocks.
Fig. 2
4.
Remove the compensation shims 1 (Fig. 3).
Fig. 3
008 911 63
BOMAG
487
14.6

5. Unscrew the screws (Fig. 4) from the welded
nuts.
Fig. 4
Changing the rubber buffers

6. Unscrew nut 1 (Fig. 3) and remove the washer.
7. Unscrew screws (2).
8. Take off rubber buffer (3).
9. Attach the new rubber buffer to the drive disc and
align the bores to the tapped bores in the drum.
10. Turn in and tighten the fastening screws.
11. Assemble the washer, turn on and tighten the nut.
Fig. 5
Adjusting the pre-load

12. Measure distance X between spacer piece and
side plate (Fig. 6).
13. Calculate the thickness of the compensation
plates.
Nominal value:
Distance X + 2 mm
Fig. 6
14. Turn in screws into each welded nut and provide

sufficient space to insert the compensation plates
(Fig. 7).
Fig. 7
488
BOMAG
008 911 63
14.6
15. Insert the compensation shims 1 (Fig. 8).
Fig. 8
16. Unscrew the screws (Fig. 9) from the welded

nuts.
Fig. 9
17. Tighten the fastening screws (Fig. 10).

18. Lower the frame again.
Fig. 10
008 911 63
BOMAG
489
14.6
490
BOMAG
008 911 63
15 Oscillating articulated joint
008 911 63
BOMAG
491
15.1
Special tools
15.1 Special tools
1. Pressing mandrel for rocker bearings
Fig. 1
2. Pressing sleeve for outer race of rocker bearing
Fig. 2
3. Pressing sleeve for inner race of rocker bearing
Fig. 3
4. Guide journal
Fig. 4
492
BOMAG
008 911 63
15.1
Special tools
5. Clamping device
Fig. 5
6. Disassembly device
Fig. 6
008 911 63
BOMAG
493
15.2
Repair overview oscillating articulated joint
Housing
12 Rear shell
Seal ring
13 Rear shell
Rear shell
14 Intermediate ring
Self-aligning bearing
15 Self-aligning bearing
Bolt
16 Intermediate ring
Shim/supporting disc
17 Self-aligning bearing
Belleville springs
18 Beam
Self-aligning bearing
19 Friction bearing
Console
20 V-ring
10 Belleville springs
21 Seal ring
11 Shim/supporting disc
494
BOMAG
008 911 63
008 911 63
BOMAG
15.2
495
15.2
496
BOMAG
008 911 63
Removing and installing the oscillating articulated joint
15.3
15.3 Removing and installing the oscillating articulated joint

1. Jack up the frame (Fig. 1) at the back and secure
it with trestles or wooden blocks.
Fig. 1
2. Support the rear frame near the oscillating articulated joint (Fig. 2) on both sides safely with trestles or wooden blocks.
Fig. 2
3. Fasten the lifting tackle to the front frame near the

oscillating articulated joint (Fig. 3).
Fig. 3
008 911 63
BOMAG
497
15.3
Removing and installing the oscillating articulated joint

4. Unscrew fastening screws 1 (Fig. 4) and take off
axle holder (2).
5. Knock out bearing bolt (3).
6. Retract steering cylinder (4).
Fig. 4
Danger
Danger of accident!
!
7. Support the oscillating articulated joint in the middle with a suitable jack or a similar device.
8. Unscrew fastening screws 1 (Fig. 5) and take off
with disc (2).
Fig. 5
9. Unscrew nuts 3 (Fig. 6) and take off the clamping

washers (2).
10. Pull out the fastening screws (1).
11. Slightly raise the front frame and lower the oscillating articulated joint to the ground.
12. Pull out the oscillating articulated joint.
Fig. 6
Note on assembly
13. Insert the bolt for the steering cylinder so that
groove (2) is in line with tapped bores (1).
Fig. 7
498
BOMAG
008 911 63
15.4
Dismantling the oscillating articulated joint
15.4 Dismantling the oscillating articulated

joint
1. Unscrew the nuts from hexagon screw 1 (Fig. 1)
and pull out the hexagon screw.
2. Unscrew the screws (2) for the cover.
Fig. 1
3. Take off the cover with Belleville springs, shim

and backing disc (Fig. 2).
4. Disassemble also the cover from the opposite
side.
i Note
No Belleville springs, shim and backing disc are
under this cover.
Fig. 2
5. Drive the console with a plastic hammer to one

side against the end stop (Fig. 3).
i Note
The outer race of the rocker bearing is thereby
stripped off.
Fig. 3
008 911 63
BOMAG
499
15.4

6. Force inner race 1 (Fig. 4) of the rocker bearing
off the bolt.
7. Take of supporting disc (2).
8. Drive the console to the opposite side and remove the rocker bearing in the same way.
Fig. 4

10. Press bolt (3) out of the console with forcing
screws (2).
Note
Remove the bolt on the opposite side in the same
way.
Fig. 5
11. Lift console 1 (Fig. 6) off housing (2).
Fig. 6
12. Take the seal rings out of the console (Fig. 7).
Fig. 7
500
BOMAG
008 911 63
15.4

13. Remove the cover from the housing.
14. Take off shims 1 (Fig. 8), backing disc (2) and
Belleville springs (3).
Fig. 8
15. Unscrew bolts 1 (Fig. 9) and take off cover (2).
Fig. 9
16. Take the intermediate ring out of the housing

(Fig. 10).
Fig. 10
17. Place the plate 1 (Fig. 11) on the beam.

18. Attach the puller (2) to the housing (3) and separate the carrier from the rocker bearings.
Fig. 11
008 911 63
BOMAG
501
15.4

19. Pull the housing off the beam (Fig. 12).
Fig. 12
20. Drive the outer race of the friction bearing out of

the housing (Fig. 13).
Fig. 13
21. Drive the friction bearing out of the housing (Fig.

14).
Fig. 14
22. Take seal ring 1 (Fig. 15) and V-ring (2) off the
beam.
Fig. 15
502
BOMAG
008 911 63
15.4
23. Check rocker bearings, if necessary press out of

the housing (Fig. 16).
Fig. 16
008 911 63
BOMAG
503
15.5
Assembling the oscillating articulated joint

15.5 Assembling the oscillating articulated
joint
1. If previously disassembled, press the rocker
bearing fully into the housing with a pressing
mandrel (Fig. 1).
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
Caution
Do not use any grease.
!
Fig. 1
2. Slide the new V-ring on the beam against the stop

with the lip facing up (Fig. 2).
Fig. 2
3. Lay the seal ring into the beam (Fig. 3).

4. Fill the space between V-ring and seal ring with
multi-purpose grease.
Fig. 3
504
BOMAG
008 911 63
15.5
5. Press the friction bearing fully into the housing

with the chamfered side pointing towards the outside (Fig. 4).
Fig. 4
6. Slide the housing over the beam (Fig. 5).
i Note
The journal on the housing must be centrally in
the recess of the beam.
Fig. 5
7. Press the seal ring carefully towards the inside,

until it sits in the recess of the housing (Fig. 6).
Fig. 6
8. Spray the sliding surface of the outer rocker bearing race with sliding agent OKS 571.
Caution
!
9. Press the outer rocker bearing race 1 (Fig. 7) in

until it bottoms with the wider outer rim forward
using pressing sleeve (2).
Fig. 7
008 911 63
BOMAG
505
15.5

10. Press inner rocker bearing race 1 (Fig. 8) in until
it bottoms, using pressing sleeve (2).
Fig. 8
11. Insert the intermediate ring (Fig. 9).
Fig. 9
12. Press inner rocker bearing race 1 (Fig. 10) in until

it bottoms, using pressing sleeve (2).
Fig. 10
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
!
Caution
13. Press the outer rocker bearing race 1 (Fig. 11) in

until it bottoms with the wider outer rim pointing
up, using pressing sleeve (2).
Fig. 11
506
BOMAG
008 911 63
15.5
14. Press in intermediate ring 1 (Fig. 12) until it bottoms.

15. Attach cover (2) with the machined edge forward.
16. Turn in screws (3) and tighten crosswise.
Fig. 12
Determining the shim thickness

17. Determine the shim thickness, for this purpose
stand the cross-member on a wooden board with
an 18 mm bore.
Caution
Check the measurement with an axial preload of 40kN. With threaded rod M12-8.8 tightening torque 77Nm. With threaded rod M168.8 tightening torque 90Nm.
!
Fig. 13
18. Slide the rod of the tensioning device in from underneath, attach the plate, screw on the nut and
tighten.
19. Measure the distance from housing edge to intermediate ring (Fig. 13) and write it down, e.g. 4,7
mm.
i Note
From this measured value of 4.7 mm subtract the
fixed value of 4.0 mm to determine the shim thickness.
Calculation example:
4,7 mm - 4,0 mm = 0,7 mm
measured value: 4,7 mm
fixed value: 4,0 mm
Shim thickness: 0,7 mm
20. Remove the tensioning device.
008 911 63
BOMAG
507
15.5

21. Insert shim 2 (Fig. 14) of appropriate thickness
and backing disc (1) into the cover.
Fig. 14
22. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 15).
Fig. 15
23. Assemble cover 2 (Fig. 16) with Belleville springs,

shim and backing disc.
Fig. 16
25. Press the new sealing rings into the respective

groove in the console (Fig. 17).
Fig. 17
508
BOMAG
008 911 63
15.5
26. Lift console 1 (Fig. 18) over the housing (2).
Fig. 18
27. Turn four guide pins into the housing bores (Fig.
19).
Fig. 19
i Note
Perform the following eight work steps on both
sides.
28. Slide the bolt over the guide pins (Fig. 20) and
drive in until it bottoms.
Fig. 20
Caution
When driving in the bolt make sure that the
seal ring is not pressed out through the back
of the console (Fig. 21).
!
Fig. 21
008 911 63
BOMAG
509
15.5

29. Unscrew the guide pins .
30. Turn in the screws and tighten with 75 Nm (Fig.
22).
Fig. 22
31. Slide the backing discs over the bolt (Fig. 23).
Fig. 23
32. Drive the inner rocker bearing race on against the

end stop with the wider outer rim forward (Fig.
24).
Fig. 24
33. Spray the sliding surface of the outer rocker bearing race with sliding agent OKS 571.
Caution
!
34. Attach the outer rocker bearing race with the wider outer rim facing towards the outside (Fig. 25)
and drive it in until it bottoms.
Fig. 25
510
BOMAG
008 911 63
15.5
35. Attach cover 1 (Fig. 26) to the bottom side of the

console.
36. Turn in and tighten screws (2).
Fig. 26
Determining the shim thickness

37. Determine the shim thickness, for this purpose insert rod 1 (Fig. 27) of the tensioning device from
underneath. Attach plate (2), screw on nut (3) and
tighten.
Caution
Check the measurement with an axial preload of 40kN. With threaded rod M12-8.8 tightening torque 77Nm. With threaded rod M168.8 tightening torque 90Nm.
!
Fig. 27
38. Measure the distance from outer rocker bearing

race to console surface (Fig. 28) and write it
down, e.g. 3.4 mm.
Note
From this measured value of 3.4 mm subtract the
fixed value of 2.2 mm to determine the shim thickness.
Calculation example:
3.4 mm - 2.2 mm = 1.2 mm
measured value: 3,4 mm
fixed value: 2,2 mm
Fig. 28
Shim thickness: 1.2 mm

39. Remove the tensioning device.
008 911 63
BOMAG
511
15.5

40. Insert shims 2 (Fig. 29) of appropriate thickness
and backing disc (1) into the cover.
Fig. 29
41. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 30).
Fig. 30
42. Assemble cover 1 (Fig. 31) with Belleville springs,

shims and supporting discs.
Fig. 31
44. Insert hexagon screw 1 (Fig. 32) so that the screw

head rests on the upper side of the console.
Fig. 32
512
BOMAG
008 911 63
15.5
45. Assemble the washer, turn on and tighten the nut

with 120 Nm (Fig. 33).
Fig. 33
008 911 63
BOMAG
513
15.5
514
BOMAG
008 911 63
16 Suppliers documentation
008 911 63
BOMAG
515
516
BOMAG
008 911 63
16.1 Travel pump series 90R
008 911 63
BOMAG
517
16.1
518
Travel pump series 90R
BOMAG
008 911 63
16.1
008 911 63
BOMAG
519
16.1
520
BOMAG
008 911 63
16.1
008 911 63
BOMAG
521
16.1
522
BOMAG
008 911 63
16.1
008 911 63
BOMAG
523
16.1
524
BOMAG
008 911 63
16.1
008 911 63
BOMAG
525
16.1
526
BOMAG
008 911 63
16.1
008 911 63
BOMAG
527
16.1
528
BOMAG
008 911 63
16.1
008 911 63
BOMAG
529
16.1
530
BOMAG
008 911 63
16.1
008 911 63
BOMAG
531
16.1
532
BOMAG
008 911 63
16.1
008 911 63
BOMAG
533
16.1
534
BOMAG
008 911 63
16.1
008 911 63
BOMAG
535
16.1
536
BOMAG
008 911 63
16.1
008 911 63
BOMAG
537
16.1
538
BOMAG
008 911 63
16.1
008 911 63
BOMAG
539
16.1
540
BOMAG
008 911 63
16.1
008 911 63
BOMAG
541
16.1
542
BOMAG
008 911 63
16.1
008 911 63
BOMAG
543
16.1
544
BOMAG
008 911 63
16.1
008 911 63
BOMAG
545
16.1
546
BOMAG
008 911 63
16.1
008 911 63
BOMAG
547
16.1
548
BOMAG
008 911 63
16.1
008 911 63
BOMAG
549
16.1
550
BOMAG
008 911 63
16.1
008 911 63
BOMAG
551
16.1
552
BOMAG
008 911 63
16.1
008 911 63
BOMAG
553
16.1
554
BOMAG
008 911 63
16.1
008 911 63
BOMAG
555
16.1
556
BOMAG
008 911 63
16.1
008 911 63
BOMAG
557
16.1
558
BOMAG
008 911 63
16.1
008 911 63
BOMAG
559
16.1
560
BOMAG
008 911 63
16.1
008 911 63
BOMAG
561
16.1
562
BOMAG
008 911 63
16.1
008 911 63
BOMAG
563
16.1
564
BOMAG
008 911 63
16.1
008 911 63
BOMAG
565
16.1
566
BOMAG
008 911 63
16.1
008 911 63
BOMAG
567
16.1
568
BOMAG
008 911 63
16.1
008 911 63
BOMAG
569
16.1
570
BOMAG
008 911 63
16.1
008 911 63
BOMAG
571
16.1
572
BOMAG
008 911 63
16.1
008 911 63
BOMAG
573
16.1
574
BOMAG
008 911 63
16.1
008 911 63
BOMAG
575
16.1
576
BOMAG
008 911 63
16.1
008 911 63
BOMAG
577
16.1
578
BOMAG
008 911 63
16.1
008 911 63
BOMAG
579
16.1
580
BOMAG
008 911 63
16.1
008 911 63
BOMAG
581
16.1
582
BOMAG
008 911 63
16.1
008 911 63
BOMAG
583
16.1
584
BOMAG
008 911 63
16.1
008 911 63
BOMAG
585
16.1
586
BOMAG
008 911 63
16.1
008 911 63
BOMAG
587
16.1
588
BOMAG
008 911 63
16.1
008 911 63
BOMAG
589
16.1
590
BOMAG
008 911 63
16.1
008 911 63
BOMAG
591
16.1
592
BOMAG
008 911 63
16.1
008 911 63
BOMAG
593
16.1
594
BOMAG
008 911 63
16.1
008 911 63
BOMAG
595
16.1
596
BOMAG
008 911 63
16.1
008 911 63
BOMAG
597
16.1
598
BOMAG
008 911 63
16.1
008 911 63
BOMAG
599
16.1
600
BOMAG
008 911 63
16.1
008 911 63
BOMAG
601
16.1
602
BOMAG
008 911 63
16.1
008 911 63
BOMAG
603
16.1
604
BOMAG
008 911 63
16.1
008 911 63
BOMAG
605
16.1
606
BOMAG
008 911 63
16.2 Travel drive series 51
008 911 63
BOMAG
607
16.2
608
Travel drive series 51
BOMAG
008 911 63
16.2
008 911 63
BOMAG
609
16.2
610
BOMAG
008 911 63
16.2
008 911 63
BOMAG
611
16.2
612
BOMAG
008 911 63
16.2
008 911 63
BOMAG
613
16.2
614
BOMAG
008 911 63
16.2
008 911 63
BOMAG
615
16.2
616
BOMAG
008 911 63
16.2
008 911 63
BOMAG
617
16.2
618
BOMAG
008 911 63
16.2
008 911 63
BOMAG
619
16.2
620
BOMAG
008 911 63
16.2
008 911 63
BOMAG
621
16.2
622
BOMAG
008 911 63
16.2
008 911 63
BOMAG
623
16.2
624
BOMAG
008 911 63
16.2
008 911 63
BOMAG
625
16.2
626
BOMAG
008 911 63
16.2
008 911 63
BOMAG
627
16.2
628
BOMAG
008 911 63
16.2
008 911 63
BOMAG
629
16.2
630
BOMAG
008 911 63
16.2
008 911 63
BOMAG
631
16.2
632
BOMAG
008 911 63
16.2
008 911 63
BOMAG
633
16.2
634
BOMAG
008 911 63
16.2
008 911 63
BOMAG
635
16.2
636
BOMAG
008 911 63
16.2
008 911 63
BOMAG
637
16.2
638
BOMAG
008 911 63
16.2
008 911 63
BOMAG
639
16.2
640
BOMAG
008 911 63
16.2
008 911 63
BOMAG
641
16.2
642
BOMAG
008 911 63
16.2
008 911 63
BOMAG
643
16.2
644
BOMAG
008 911 63
16.2
008 911 63
BOMAG
645
16.2
646
BOMAG
008 911 63
16.2
008 911 63
BOMAG
647
16.2
648
BOMAG
008 911 63
16.2
008 911 63
BOMAG
649
16.2
650
BOMAG
008 911 63
16.2
008 911 63
BOMAG
651
16.2
652
BOMAG
008 911 63
16.2
008 911 63
BOMAG
653
16.2
654
BOMAG
008 911 63
16.2
008 911 63
BOMAG
655
16.2
656
BOMAG
008 911 63
16.2
008 911 63
BOMAG
657
16.2
658
BOMAG
008 911 63
16.2
008 911 63
BOMAG
659
16.2
660
BOMAG
008 911 63
16.2
008 911 63
BOMAG
661
16.2
662
BOMAG
008 911 63
16.2
008 911 63
BOMAG
663
16.2
664
BOMAG
008 911 63
16.2
008 911 63
BOMAG
665
16.2
666
BOMAG
008 911 63
16.2
008 911 63
BOMAG
667
16.2
668
BOMAG
008 911 63
16.2
008 911 63
BOMAG
669
16.2
670
BOMAG
008 911 63
16.2
008 911 63
BOMAG
671
16.2
672
BOMAG
008 911 63
16.2
008 911 63
BOMAG
673
16.2
674
BOMAG
008 911 63
16.2
008 911 63
BOMAG
675
16.2
676
BOMAG
008 911 63
16.2
008 911 63
BOMAG
677
16.2
678
BOMAG
008 911 63
16.2
008 911 63
BOMAG
679
16.2
680
BOMAG
008 911 63
16.2
008 911 63
BOMAG
681
16.2
682
BOMAG
008 911 63
16.2
008 911 63
BOMAG
683
16.2
684
BOMAG
008 911 63
16.2
008 911 63
BOMAG
685
16.2
686
BOMAG
008 911 63
16.2
008 911 63
BOMAG
687
16.2
688
BOMAG
008 911 63
16.3 Vibration pump 42R 041
008 911 63
BOMAG
689
16.3
690
Vibration pump 42R 041
BOMAG
008 911 63
16.3
008 911 63
BOMAG
691
16.3
Series 42
Introduction
1. Introduction
1.1
Using This Manual
The Adjustment and Minor Repair procedures detailed herein may be performed by trained personnel
without voiding the unit warranty.
placed. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. All gasket sealing surfaces must be cleaned prior to installing new gaskets.
Cleanliness is a primary means of assuring satisfactory transmission life. Cleaning parts by using a clean
solvent wash and air drying is usually adequate. As
with any precision equipment, all parts must be kept
free of foreign materials and chemicals. When performing service activities, protect all exposed sealing
surfaces and open cavities from damage and foreign
material.
All exploded view drawings depict the 28cc frame

size. For variances in the 41cc frame size, see the
outline drawings in section 3. Differences in wrench
size and torquing for the two frame sizes are noted in
the text. Note that exterior housing screws are mostly
Torx-type T30 or T45.
These symbols are used within drawings:
Apply petroleum jelly.
Whenever removing a service component, it is recommended that any gaskets and O-rings be re-
1.2
Lubricate with clean hydraulic oil.
Safety Precautions
Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury.
The following general precautions should be taken into consideration whenever servicing a hydrostatic system.
Loss of Hydrostatic Braking Ability
Fluid Under High Pressure
WARNING
When Series 42 units are used in vehicular
hydrostatic drive systems, the loss of hydrostatic drive line power in any mode of operation (e.g. acceleration, deceleration or neutral mode) may cause a loss of hydrostatic
braking capacity. A braking system which is
independent of the hydrostatic transmission
must, therefore, be provided which is adequate
to stop and hold the system should the condition develop.
WARNING
Use caution when dealing with hydraulic fluid
under pressure. Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury. This
fluid may also be hot enough to burn. Serious
infection or reactions can develop if proper
medical treatment is not administered immediately.
Flammable Cleaning Solvents
Disable Work Function
WARNING
Some cleaning solvents are flammable. To
avoid possible fire, do not use cleaning solvents in an area where a source of ignition may
be present.
WARNING
Certain service procedures may require the
vehicle/machine to be disabled (wheels raised
off the ground, work function disconnected,
etc.) while performing them in order to prevent
injury to the technician and bystanders.
F000719
692
Copyright 1996-1998, Sauer-Sundstrand GmbH & Co.

All rights reserved. Contents subject to change. Printed in Germany.
BOMAG
008 911 63
16.3
Series 42
Introduction
Contents
1. Introduction ................................................................................................................................ 2
1.1
Using This Manual................................................................................................................................. 2
1.2
Safety Precautions ................................................................................................................................ 2
2. Model Code ................................................................................................................................. 4

3. Component and Port Locations ............................................................................................... 5
3.1
Component Locations ........................................................................................................................... 5
3.2
Ports and Pressure Gauges .................................................................................................................. 6
4. Adjustment and Minor Repair Instructions ............................................................................. 8

4.1
Size and Torque for Plugs and Fittings .................................................................................................. 8
4.2
Pump Neutral Adjustment ................................................................................................................... 9
4.3
Control Neutral Adjustment for MDC/EDC Controls .......................................................................... 10
4.4
MDC Control Module ............................................................................................................................ 11
4.5
EDC Control Module ........................................................................................................................... 12
4.6
MDC/EDC Control Spool, Control Linkage, and Control Neutral Adjustment Screw ........................... 13
4.7
MDC Neutral Start/Backup Alarm Switch ............................................................................................ 14
4.8
MDC Solenoid Override Valve ............................................................................................................. 16
4.9
FNR, NFPE, and NFPH Controls ........................................................................................................ 17
4.10 System Check Relief Valves (High Pressure Relief, Charge Check, & Bypass Valves) ...................... 18
4.11 Charge Relief Valve............................................................................................................................. 19
4.12 Loop Flushing Valve ............................................................................................................................ 21
4.13 Shaft Seal and Shaft Replacement ..................................................................................................... 22
4.14 Auxiliary Mounting Pads ...................................................................................................................... 24
4.15 Charge Pump ...................................................................................................................................... 25
4.16 Filtration .............................................................................................................................................. 28
4.17 Servo Piston Covers ........................................................................................................................... 29
4.18 Displacement Limiter Adjustment ........................................................................................................ 30
5. Exploded View Parts Drawings............................................................................................... 31

5.1
Shaft Options ...................................................................................................................................... 31
5.2
Filtration, Charge Relief, System Relief, and Loop Flushing ............................................................... 32
5.3
Charge Pump, Auxiliary Pads, and Servo Covers ............................................................................... 33
5.4
Control Options ................................................................................................................................... 34
008 911 63
BOMAG
3693
16.3
694
BOMAG
008 911 63
16.3
Series 42
Component and Port Locations
3. Component and Port Locations

3.1 Component Locations
A pump with a manual displacement control (MDC) and no filtration adapter is shown. With non-feedback and
automotive controls, the positions of the case drains vary (shown in gray). With a filtration adapter, the porting in
the "Filtration Options" area varies (see section 4.16).
Control Neutral Adjustment

(MDC/EDC)
Control Module
(MDC Shown)
Pump Neutral Adjustment
Servo Piston
Covers
System Check
Relief Valves
Displacement
Limiters
Charge
Pump
Shaft
Seal
Filtration Options
(No Filtration Adapter Shown Here)
Auxiliary
Mounting Pad
Charge Relief Valve
(Loop Flushing
Valve)
Left Side View (Side "2")
Right Side View (Side "1")

P100101 E
Series 42 28cc Variable Pump

Control Neutral Adjustment
(MDC/EDC)
Control Module
(MDC Shown)
Servo Piston
Covers
Displacement
Limiters
Charge
Pump
Auxiliary
Mounting
Pad
System Check
Relief Valves
Shaft Seal
Charge Relief Valve
(Loop Flushing Valve)

Filtration Options
(No Filtration Adapter
Shown Here)

P100102 E
Series 42 41cc Variable Pump
008 911 63
BOMAG
5695
16.3
Series 42
3.2
Ports and Pressure Gauges
Proper servicing of pumps and motors requires that

pressure be measured and monitored at various
points in the hydraulic circuit. The Series 42 pump
has several locations at which to take these measure-
Gauge
Port Name
Pressure Measured
ments. The following outlines show the locations of

the various gauge ports. The tables show the recommended gauge size and the fitting size for each port.
Refer to this page when installing pressure gauges.
Fitting
Recommended
Gauge Size
028
041
System Pressure for

Ports A and B
600 bar or 10 000 psi
9/16-18 O-Ring Fitting
M3
Charge Pressure
60 bar or 1000 psi
M4 & M5
Servo Pressure
60 bar or 1000 psi
L1 & L2
Case Pressure
35 bar or 500 psi
1-1/16-12 O-Ring Fitting
Charge Pump Inlet

Vacuum
1 bar, absolute
or 30 in Hg Vacuum
M1 & M2
T000 025E
System Pressure
Gauge Port M2
Servo Pressure
Gauge Port M5
Servo Pressure
Gauge Port M4
System
Pressure
Port B
Charge Pressure
Gauge Port M3
(Charge Pressure
Supply For
No Charge Pump
Option)
Case Drain Port L2

(Non-Feedback
Controls)
System
Pressure
Port A
Case Drain
Port L1
Case Drain Port L1
(Non-Feedback
Controls)
Charge Pump
Inlet Port S
Case Drain
Port L2
System Pressure
Gauge Port M1

P100103 E
28cc Base Unit with MDC and No Filtration Adapter
696 6
BOMAG
008 911 63
16.3
Series 42
Servo Pressure
Gauge Port M5
Servo Pressure
Gauge Port M4
System Pressure
Gauge Port M2
System
Pressure
Port B
Charge Pressure
Gauge Port M3
(Charge Pressure
Supply For
No Charge Pump
Option)
Case Drain
Port L2
System
Pressure
Port A
Charge Pump
Inlet Port S
Case Drain
Port L1
System Pressure
Gauge Port M1
P100104 E
41cc Base Unit with MDC and No Filtration Adapter
To Filter, Port D
(Pressure Filtration)
Charge Pressure
Gauge Port M3
(Full Flow Pressure Filtration)
From Filter, Port E

(Pressure Filtration)
Charge Pressure
Gauge Port M3
(Partial Flow Pressure Filtration)
Charge Pressure
Gauge Port M3
(Suction Filtration)
P100105 E
Filtration Adapter (28cc and 41cc Models)
008 911 63
BOMAG
7697
16.3
Series 42
Adjustments and Minor Repairs
4. Adjustment and Minor Repair Instructions

4.1
Size and Torque for Plugs and Fittings
Plug and fitting sizes are given here. Place a fresh O-ring, lightly lubricated with petroleum jelly, whenever a plug
is removed. Each should be torqued as indicated. A 28cc unit with manual displacement control (MDC) is shown.
Servo Gage
Port M4
11/16 in Hex
27-47 Nm
(20-35 ftlbf)
28cc: 9/16 in Int. Hex

95-135 Nm
(70-100 ftlbf)
Case Drain
Port L1
125-250 Nm
(90-190 ftlbf)
Charge Pressure Gage
Port M3 (Position Varies,
Refer to Filtration Options)
Charge Pump Inlet

Port S
Torque: 115 Nm (85 ftlbf)
Case Drain
Port L2
Port N
(Unused)
11/16 in Hex
27-47 Nm
(20-35 ftlbf)
Servo Gage
Port M5
System Gage
Ports M1 and M2
11/16 in Hex
27-47 Nm
(20-35 ftlbf)
95-135 Nm
(70-100 ftlbf)
125-250 Nm
(90-190 ftlbf)
System Ports
A and B
115 Nm (85 ftlbf)
11/16 in Hex
27-47 Nm
(20-35 ftlbf)
E100001 E
698 8
BOMAG
008 911 63
16.3
Series 42
4.2
The pump neutral adjustment sets the position of the

servo piston and pump swashplate relative to the
controlling mechanism.
WARNING
The following procedure requires the vehicle /
machine to be disabled (wheels raised off the
ground, work function disconnected, etc.) while
performing the procedure in order to prevent
1. Disconnect machine function.
2. Connect a hose between gauge ports M4 and M5
to equalize the pressures on both ends of the
pump servo piston.
Pump "Neutral"
Adjustment Screw
Pump "Neutral"
Adjustment Seal
Lock Nut
3. Install pressure gauges in gauge ports M1 and

M2 to measure system pressure.
4. Start the prime mover and operate at normal
speed.
5. Loosen the pump "neutral" adjustment seal lock
nut [28cc 13 mm Hex; 41cc 17 mm Hex]. Turn
the pump "neutral" adjustment screw [28cc 5
mm Hex; 41cc 7 mm Hex] until the system
pressure gauge readings are equal.
E100002 E
Pump Neutral Adjustment Screw

(MDC Control Shown)
6. Turn the adjustment screw clockwise until one of

the gauges registers an increase in system pressure. Note the position of the adjustment screw.
Turn the screw counterclockwise until the other
gauge registers an increase in system pressure.
Note the position of the adjustment screw.
7. Turn the adjustment screw clockwise to a position halfway between the positions noted above.
The system pressure gauges should indicate
equal pressures.
8. While holding the adjustment screw in position,
torque the seal lock nut [28cc 20-26 Nm (15-19
ftlbf); 41cc 28-51 Nm (21-37 ftlbf)] .
9. Stop the prime mover and remove the hose
between gauge ports M4 and M5. Remove the
pressure gauges installed in gauge ports M1 and
M2. Reinstall the plugs in the gauge ports.
10. Reconnect work function.
IMPORTANT
If the pump is equipped with an MDC or EDC,
the CONTROL "neutral" adjustment MUST also
be performed before putting the pump into
service (see next section).
008 911 63
BOMAG
9699
16.3
Series 42
4.3
Control Neutral Adjustment for MDC/EDC Controls
The control neutral adjustment aligns the pump swashplate and the control spool so that a zero angle control
setting provides a zero degree swashplate setting.
This adjustment should be performed whenever any
part of the control or swashplate mechanisms is
adjusted or removed or after the pump neutral setting
(previous section) is adjusted.
MDC / EDC Control

"Neutral" Adjustment Screw
WARNING
The following procedure requires the vehicle /
machine to be disabled (wheels raised off the
ground, work function disconnected, etc.) while
performing the procedure in order to prevent
1. Disconnect the work function. Disconnect the
external control linkage (for MDC) or control
signal input (for EDC) from the pump.
2. Install pressure gauges in gauge ports M4 and
M5 to measure pressure on the pump servo
piston.
3. Start the prime mover and operate at normal
speed.
MDC / EDC Control "Neutral"

Adjustment Seal Lock Nut
E100003 E
Control Neutral Adjustment Screw

(EDC Control Shown)
4. Loosen the CONTROL "neutral" adjustment seal

lock nut (see drawing) [17 mm Hex] . Turn the
control "neutral" adjustment screw [5 mm Int.
Hex] until the servo piston pressure gauge readings are as close to equal as possible.
5. Turn the adjustment screw clockwise until one of
the gauges registers an increase in pressure on
the servo piston. Note the position of the adjustment screw.
Turn the screw counterclockwise until the other
gauge registers an increase in pressure on the
servo piston. Note the position of the adjustment
screw.
6. Turn the adjustment screw clockwise to a position halfway between the positions noted above.
The servo piston pressure gauges should indicate nearly equal pressures.
7. While holding the adjustment screw in position,
torque the seal lock nut [14-24 Nm (10-18 ftlbf)].
8. Stop the prime mover and remove the pressure
gauges installed in gauge ports M4 and M5.
Reinstall the plugs in the gauge ports.
9. Reconnect the external control linkage (for MDC)
or control signal input (for EDC) to the pump.
Reconnect the work function.
700 1 0
BOMAG
008 911 63
16.3
Series 42
4.4
MDC Control Module
The manual displacement control (MDC) module

provides control of the pump servo piston through a
connection to the summing link pin within the pump
housing. The following procedure shows how to
remove and install the control housing. Section 4.6
explains how to remove and install the control spool
and linkage.
1. Clean the external surfaces of the pump. If necessary, remove the MDC handle.
2. Remove the seven (7) control retaining screws
[Torx T30] that secure the control to the pump
housing. Remove the control and control gasket
from the pump.
Plug for
Visual
Inspection
Nut
Lock Washer
MDC Handle
Control
Retaining
Screws
Control
Gasket
Hold summing link
(and control spool)
in position
Note: See section 4.6 for instructions on removing/installing the control spool and linkage.
3. Clean the sealing surfaces of the control and the
pump housing. Place a new gasket in position on
the housing.
CAUTION
The control orifices are part of the control
gasket. Refer to the appropriate Service Parts
List to determine the correct gasket.
4. Hold the summing link pin in position while installing the control. (The spring on the control spool
will tend to push the link to an extreme position.)
The link pin MUST engage the slot in the control
cam. A plug is provided on the MDC housing to
permit visual inspection of linkage pin engagement.
Note: It may be easiest to lay the servo piston
side of the control down first, then watch the link
pin engage from the charge pump side of the
pump.
E100004 E
MDC Control Module Assembly
Summing
link pin
MUST enter
the slot in
the control
cam!
E100005 E
Link Pin Into Cam Slot
5. Install and torque the control screws [15-17 Nm

(11-13 ftlbf)]. Perform Control Neutral Adjustment (Section 4.3).
WARNING
Failure to properly engage the link pin with the
control cam will result in incorrect control
operation, which may lead to loss of control of
the vehicle / machine.
Link Pin Into Cam Slot
008 911 63
BOMAG
F100201
1 1701
16.3
Series 42
4.5
EDC Control Module
The Electric Displacement Control (EDC) provides a

control function through connections to the summing
link pin within the pump housing. The following procedure shows how to remove and install the control
housings. The next section explains how to remove
and install the control spool and linkage.
1. Clean the external surfaces of the pump. If necessary, remove control input signal.
EDC Control
Pressure Gauge
Port X1
2. Remove the seven (7) control retaining screws

[Torx T30] that secure the control to the pump
housing. Note the position of the different length
screws. Remove the control and control gasket
from the pump.
Note: See next section for instructions on removing/installing the control spool and linkage.
EDC Control
Pressure Gauge
Port X2
3. Clean the sealing surfaces of the control and the

pump housing. Place a new gasket in position on
the housing.
EDC Module Showing Port Locations
CAUTION
The control orifices are part of the control
gasket. Refer to the appropriate Service Parts
List to determine the correct gasket.
Control Retaining
Screws (note different sizes)
4. Hold the summing link pin in position while installing the control. (The spring on the control spool
will tend to push the link to an extreme position.)
The link pin MUST engage the hole in the control
piston fork.
Note: It may be easiest to lay the servo piston
side of the control down first, then watch the link
pin engage from the charge pump side of the
pump.
5. Install and torque the control screws [15-17 Nm
(11-13 ftlbf)]. Perform Control Neutral Adjustment (Section 4.3).
Control
Gasket
Hold summing
link (and control
spool) in
position
WARNING
Failure to properly engage the link pin with
control piston fork will result in incorrect control operation, which may lead to loss of control of the vehicle / machine.
702 1 2
P100106 E
Summing
link pin
MUST enter
the hole in
the control
piston fork!
E100006 E
EDC Control Module Assembly
BOMAG
008 911 63
16.3
Series 42
4.6
MDC/EDC Control Spool, Control Linkage, and Control Neutral

Adjustment Screw
The control spool, control linkage, and control neutral

adjustment screw can be removed for cleaning and to
change the O-rings or the seal lock nut.
Summing Link
Linkage Pivot Screw
Removal of Spool, Linkage, and Adjustment

Screw
1. Clean the external surfaces of the pump.
Neutral
Adjustment
Link
2. Remove the MDC or EDC module and the control

gasket from the pump housing (see previous two
sections).
Feedback Link
Control Neutral
Adjust Screw
Opposite
Bore Plug
Seal Lock
Nut
Control
Spool
and Spring
Note
orientation!
3. Remove the summing link.

4. Remove the control spool bore plug [5/16 in Int.
Hex] or screws [Torx T30], cover, and gasket.
Remove the opposite bore plug [5/16 in Int. Hex],
and remove the control spool and spring.
Housing without
Filtration Adapter
5. Remove the linkage pivot screw [4 mm Int. Hex],

feedback link, and neutral adjustment link.
Control Spool
Bore Plug
6. Remove the seal lock nut [17 mm Hex] and the

control neutral adjustment screw [5 mm Int. Hex].
Installation of Spool, Linkage, and Adjustment
Screw
1. Install the control neutral adjustment screw and
seal lock nut. Do not tighten the nut.
Housing with
Filtration Adapter
Gasket
2. Assemble the "neutral" adjustment link and feedback link, and install as shown. Install and torque
the linkage pivot screw [8-15 Nm (6-11 ftlbf)].
Control Spool
Bore Cover
3. Lubricate and install the control spool and spring

assembly noting proper orientation.
WARNING
The control spool and spring assembly MUST
be oriented in the housing as shown for proper
control operation.
4. Install and torque the control spool bore plug [4194 Nm (30-70 ftlbf)]. Or install the control spool
cover (with a new gasket) or plug, and torque the
screws [15-17 Nm (11-13 ftlbf)].
5. Install the summing link. Hold the control spool in
position while engaging the fork on the summing
link with the flats on the spool. If necessary, rotate
the spool to engage the summing link.
E100007 E
MDC/EDC Control Spool and Linkage
Feedback link
must enter slot in
servo piston
Pivot screw
Slot in "neutral" adjust link

must engage groove in
adjusting screw
Fork on summing link

must engage flats on
control spool
E100008 E
Servo Piston Linkage and Control Spool

(Internal Parts Shown with Housing Removed)
6. Install a new control gasket. Hold the summing

link and control spool in position while reinstalling
the MDC or EDC (see section 4.4 or 4.5). Perform
Control Neutral Adjustment (section 4.3).
008 911 63
BOMAG
1 3703
16.3
Series 42
4.7
MDC Neutral Start/Backup Alarm Switch
The Neutral Start Switch (NSS) prevents the engine

and pump from being started when the pump is out of
neutral. The NSS should be wired in series with the
engine starting circuit. The switch contact is closed at
the control handle's neutral position and opens when
the control handle is rotated 1.5 to 2 from neutral.
NSS Cover
NSS Control Nut
NSS Cam
The Backup Alarm Switch (BUA) outputs an electronic signal when the control handle is in a reverse
position. This switch is normally wired in series with
an audio output. The switch contact is open until the
control handle is rotated 2.6 to 3.75 in the reverse
direction.
NSS Cavity
NSS with
Weatherpack
CAUTION
The control handle's neutral position must
agree with the pump's neutral position for the
NSS/BUA to work effectively (see section 4.3).
NSS with Screw

Terminals
E100009 E
The Neutral Start / Backup Alarm Switch assembly

can be configured for three different settings.
i.
NSS Assembly on MDC
A Neutral Start Switch only.
ii. A Neutral Start Switch with Backup Alarm for

units where clockwise (CW) handle rotation results in "reverse" motion.
iii. A Neutral Start Switch with Backup Alarm for
units where counterclockwise (CCW) handle rotation results in "reverse" motion.
The setting must be in accordance with the configuration of the unit. See the model code (section 2) if
uncertain of the type of NSS you have.
Alignment of the NSS requires a special alignment
tool. Dimensions are given at right.
Control
Yolk Cam
NSS only
NSS with BUA

(CW = Reverse)
NSS with BUA

(CCW = Reverse)
P100107 E
Top View of NSS Showing Cam Positions
(continued)
9/16 -18UNF 2A THD

.04 x 45 Chamfer
R.125
.236.030
Knurl
35.0
1.250
.306
.354
2.000
Material: .75 DIA x 3 ETD150
(All Dimensions in inches)
P100108 E
Alignment Tool
704 1 4
BOMAG
008 911 63
16.3
Series 42
Adjustment is performed by setting the cam position

within the NSS assembly.
1. The MDC module must be removed from the
pump housing. Refer to section 4.4.
NSS Cover
NSS
NSS Control Nut
2. Remove NSS [7/8 in Hex].
NSS Cam
3. Remove the NSS cover by inserting a screwdriver into the NSS cavity and popping off the
cover with a hammer. Be careful not to damage
the internal hardware.
P100109 E
Side View of NSS and NSS Cavity
4. Remove the control nut [8 mm Hex].

5. Use a screwdriver to pop off the cam.
6. Set cam in proper orientation according to the
unit's configuration (i, ii, or iii above).
7. Screw special alignment tool in NSS cavity to
hold cam in place.
8. On the underside of the MDC module, clamp a
pair of locking pliers around the spring contacts of
the control cam. The pliers should hold the nub on
the control cam to the pin underneath. This will
hold the control cam in neutral position.
9. Screw control nut on cam [4.1-6.8 Nm (3-5 ftlbf)].
10. Press new cover on top of cam cavity. This
requires either an arbor press or a full-sized
punch (punch depth = 1.06 mm (0.0417 in),
punch width = 23.3 mm (0.916 in)).
F100202
11. Remove the alignment tool and the locking pliers.
Underside of MDC Module Showing Where to Clamp

Locking Pliers
12. Place a new lubricated O-ring on NSS.

13. Reconnect the NSS [25-29 Nm (18-22 ftlbf)] to
the MDC.
14. Reinstall MDC module onto pump housing (refer
to section 4.4).
008 911 63
BOMAG
1 5705
16.3
Series 42
4.8
MDC Solenoid Override Valve
The solenoid override valve is a safety feature that

connects both ends of the servo control piston together when the solenoid is de-energized. Thus the
pump can be put into stroke only when the solenoid
is energized.
Port L4
Port X7
The solenoid override with brake release includes

hydraulic control of a safety brake. When de-energized, a spring-applied, hydraulically-released brake
is drained through port X7. For conditions where case
back-pressure on the spring-applied brake is critical,
an external drain to the reservoir can be connected
through port L4.
The solenoid override valve can be removed to
inspect and remove foreign matter.
Removal
1. Remove retaining nut [9/16 in Hex].
Solenoid Override Valve

Assembly
E100010 E
Solenoid Override Valve Assembly
2. Remove solenoid housing.

3. Remove retaining ring at base of solenoid.
Retaining Nut
4. Remove solenoid. This should be connected to

internal spool.
Solenoid
Housing
Installation
1. Replace O-ring.
Washer
Retaining Ring
2. Place spring and plunger inside of solenoid.
Solenoid
3. Attach spool (male notch) to plunger (female

notch).
4. Insert solenoid/spool assembly in solenoid override bore.
O-Ring
Spring
Plunger
5. Snap retaining ring over base of solenoid.

Spool
6. Place washer at base of solenoid.

7. Install housing and retaining nut [2-4 Nm (1.5-3.5
ftlbf)].
E100011 E
Exploded View of Solenoid Override Assembly
706 1 6
BOMAG
008 911 63
16.3
Series 42
4.9
FNR, NFPE, and NFPH Controls
The 3-position FNR control and the electric and

hydraulic non-feedback proportional (NFPE and
NFPH) controls are non-feedback type controls. The
FNR and NFPE controls consist of modules mounted
on the pump housing. The hydraulic input for NFPH
is received through ports on the top of the pump
[9/1618 SAE O-ring fitting].
NFPH Ports
(Ports X1 and X2)
The non-feedback controls are set at the factory. The

control modules can be removed to clean the ports
and change the O-rings.
The orifice plugs for the FNR and NFPE are located
inside the servo piston covers. The orifice plugs for
the NFPH are located in the NFPH ports. Orifice
plugs may be cleaned or replaced.
E100012 E
Position of NFPH Ports
Note: Future models may contain orifice plate

between module and pump housing.
Control Solenoid
Control Module
Removal and Installation of FNR and NFPE

Modules
1. Clean pump and module housings.
2. Remove four (4) screws retaining module to
housing [4 mm Int. Hex], and remove module
from pump housing.
Control Ports
Locator Pin
3. Remove O-rings from the control ports. Examine

ports for cleanliness.
4. Clean sealing surfaces.
5. Replace locator pin.
6. Install new O-rings.
7. Replace screws [4.7-6.1 Nm (3.5-4.5 ftlbf].
E100013 E
Removal and Installation of FNR and NFPE

Control Orifices
Note: Future models may contain an orifice plate
between module and pump housing. This will
take the place of the orifice plugs beneath the
servo piston cover.
NFPE Assembly (FNR Similar)

Non-Feedback
Control Orifice
1. Remove servo piston cover (see section 4.17).

2. Remove orifice plug [1/8 in Int. Hex].
3. Examine orifice and port for cleanliness.
4. Install orifice plug [2.0-3.4 Nm (1.5-2.5 ftlbf)].
E100014 E
Location of Non-Feedback Control Orifice
008 911 63
BOMAG
1 7707
16.3
Series 42
4.10 System Check Relief Valves (High Pressure Relief, Charge Check,
& Bypass Valves)
The charge check, high pressure relief, and the loop
bypass functions are all contained within the system
check relief (SCR) valve assembly. This assembly
may be removed for cleaning and installation of fresh
O-rings. The model code specifies whether high
pressure relief valves, combination charge check/
high pressure relief valves, and/or loop bypass valves
are present or not.
With
Bypass
Without
Bypass
Valve
Seat
Plug
1. Remove the valve seat plugs [9 mm Int. Hex] or

valve seat/bypass plugs [1 in Hex] from the pump
housing.
Outer
O-Ring
Backup
Ring
2. Remove the check poppet or relief valve assemblies from the pump housing. The smaller end of
each conical spring is crimped to retain it on the
check poppet or relief valve. Do not remove.
Inner
O-Ring
Valve
Seat
Retaining
Ring
Standard
Bypass
Plunger
O-Ring
Valve
Seat
Plug
Outer
O-Ring
Backup
Ring
Inner
O-Ring
3. Inspect the valves and mating seats in the special

plugs for damage or foreign material.
CAUTION
The relief valves are factory set and should not
be tampered with, except for replacing the
entire valve.
4. The O-ring on the standard bypass plunger may
be replaced by removing the retaining ring and
removing the plunger from the special valve seat
plug. Remove the O-ring from the plunger and
install a new O-ring. Reinstall the plunger and
retaining ring.
Check Poppet or
High Pressure
Relief Valve
Conical Spring
5. Install a new outer O-ring, new backup ring, and

new inner O-ring on each valve seat plug.
6. Check that the conical springs are properly retained on the check poppets or relief valves.
Install the check poppet or high pressure relief
valve assemblies into the pump housing .
CAUTION
The conical springs MUST be correctly positioned on the check poppets or relief valves
after installation for proper pump operation.
E100015 E
System Check Relief Valve Components
7. Install the valve seat plugs or valve seat/bypass

plugs into the pump housing and torque [40-95
Nm (30-70 ftlbf)].
708 1 8
BOMAG
008 911 63
16.3
Series 42
4.11 Charge Relief Valve

The charge relief valve may be removed for cleaning
and installation of fresh O-rings. The pressure setting
may be changed. However, note that the setting will
vary for different charge flows which depends on
charge pump size and pump speed. The factory
setting is set relative to case pressure at 1800 rpm.
The actual charge pressure will vary at different
speeds.
Shim Adjustable Style
1. Remove the shim adjustable charge relief valve
plug [1 in Hex] from the pump housing. Remove
the O-ring from the plug.
Shim Adjustable
Charge Relief Valve Plug
O-Ring
Shims
2. Remove the spring and poppet from the housing.
Spring
Poppet
3. Do not alter the shims which may be installed

between the spring and valve plug, or interchange parts with another valve. Inspect the
poppet and mating seat in the housing for damage or foreign material.
4. If desired, the charge relief valve setting can be
changed. An approximate rule of thumb is 4 bar
/ 1.25 mm (58 psi / 0.050 in). The effective setting
will vary.
To confirm the charge relief valve setting, measure charge pressure (port M3) with the pump in
stroke. The charge pressure should level off
when the relief setting is reached.
5. Install a new O-ring on the valve plug. Reinstall
the poppet, spring, and plug (with shims and Oring) into the pump housing [55-135 Nm (40-100
ftlbf)].
E100016 E
Shim Adjustable Charge Relief Valve Components
Approximate Relief Setting vs Shim Thickness

4 bar / 1.25 mm
(58 psi / 0.050 in)

T000 023E
(continued)
008 911 63
BOMAG
1 9709
16.3
Series 42
Screw Adjustable Style
Charge Relief Lock Nut
1. Before removing the screw adjustable relief valve

plug, mark the plug, lock nut, and housing so as
to approximately maintain the original adjustment when assembling, Remove the screw adjustable charge relief valve plug by loosening the
lock nut [1-1/16 in Hex] and unscrewing the plug
[8 mm Int. Hex]. Remove the O-ring from the plug.
O-Ring
Screw Adjustable
Charge Relief Valve Plug
Spring
Poppet

3. Inspect the poppet and mating seat in the housing for damage or foreign material.
the poppet and spring. Reinstall the plug with its
lock nut [47-57 Nm (34-42 ftlbf)], aligning the
marks made at disassembly.
E100017 E
Screw Adjustable Charge Relief Valve Components
5. Check and adjust, if necessary, the charge pressure. For screw adjustable "anti-stall" charge
relief valves, an approximate rule of thumb is 2.8
bar / quarter turn (40 psi / quarter turn).
To confirm the charge relief valve setting, measure charge pressure (port M3) with the pump in
stroke. The charge pressure should level off
when the relief setting is reached.
710 2 0
BOMAG
Approximate Relief Setting vs Screw Revolution

2.8 bar / 14 turn
(40 psi / 14 turn)

T000 024E
008 911 63
16.3
Series 42
4.12 Loop Flushing Valve

The loop flushing function consists of the loop flushing shuttle valve and the loop flushing relief valve. The
assemblies may be removed for cleaning and installation of new O-rings. The relief valve poppet may be
exchanged for one with a different flow rating, but the
relief valve shims should not be changed out unless
specifically instructed so by Sauer-Sundstrand. The
function also can be defeated.
Loop Flushing
Relief Plug
Loop Flushing Relief
Plug (Defeat)
O-Ring
O-Ring
Shims
Spring
Poppet
Loop Flushing Valve

1. Remove the loop flushing valve plug from the
pump housing [11/16 in Hex]. Remove the O-ring
from the plug.
2. Remove the loop flushing valve spool assembly
from the housing.
3. Inspect the parts for damage or foreign material.
The centering spring must be securely retained to
the spool by the washer.
Loop Flushing
Plug (Defeat)
O-Ring
Defeat
Spool
Loop
Flushing
Plug
O-Ring
Loop
Flushing
Spool
Assembly
4. Install the loop flushing valve spool assembly into

its bore. Install a new O-ring on the loop flushing
plug and install [27-47 Nm (20-35 ftlbf)].
Loop Flushing Relief Valve
1. Remove the loop flushing relief valve internal hex
plug [5/8 in Hex] from the pump housing. Remove
the O-ring from the plug.
3. Do not alter the shims which are installed between the spring and valve plug, or interchange
parts with another valve. Inspect the poppet and
mating seat in the housing for damage or foreign
material. Inspect the orifice in the valve poppet.
the poppet, spring, shims, and plug (with O-ring)
into the pump housing [15-34 Nm (15-25 ftlbf)].
E100018 E
Loop Flushing Valve and Loop Flushing Defeat

Components
Defeating Loop Flushing

1. Remove the loop flushing valve from the pump
housing.
2. Install the defeat spool into the spool bore in the
housing. Install the plain plug with O-ring into the
housing [11/16 in Hex], and torque [27-47 Nm
(20-35 ftlbf)].
3. Remove the charge relief valve (these parts are
not necessary).
4. Install the plain hex plug with O-ring into the end
cap [5/8 in Hex], and torque [15-34 Nm (15-25
ftlbf)].
008 911 63
BOMAG
2 1711
16.3
Series 42
4.13 Shaft Seal and Shaft Replacement

A lip type shaft seal is used in Series 42 pumps. This
seal and/or the shaft can be replaced without major
disassembly of the unit. Replacement generally requires removal of the pump from the machine.
Retaining
Ring
Seal Carrier
Assembly
1. Position the pump with the shaft facing up.

NOTE: If the unit is positioned horizontally when
the shaft is removed, the cylinder block could
move out of place, making shaft installation difficult.
2. Remove the retaining ring from the housing.
3. Pull out seal carrier assembly.
4. Remove the O-ring from the seal carrier. To
install a new shaft only, proceed to step 8.
5. Place the seal carrier in an arbor press with the
shaft bearing side down, and press out the old
seal. An appropriately sized pipe spacer or socket
wrench can be used as a press tool. Once removed, the seal is not reusable.
6. Inspect the seal carrier and the new seal for
damage. Inspect the sealing area on the shaft for
rust, wear, or contamination. Polish the sealing
area on the shaft if necessary.
7. Press the new seal into the shaft bearing side of
the seal carrier. The seal lip must face the outside
of the pump. Be careful not to damage the seal.
The outside diameter of the seal may be coated
with a sealant (e.g. Loctite High Performance
Sealant #59231) prior to installation. This aids in
preventing leaks caused by damage to the seal
bore in the seal carrier.
E100019 E
Shaft Seal Components
O-Ring
Seal
Sealant may
be used on
outside diameter
Seal Carrier
Inside Lip
(face down)
(continued)
Press Seal
to bottom of Seal Carrier
E100020 E
Installation of Shaft Seal
712 2 2
BOMAG
008 911 63
16.3
Series 42
If the shaft is not being replaced proceed to step

11.
Retaining Ring
8. Remove the shaft and roller bearing assembly

from the pump or motor. The bearing assembly
can be transferred to the new shaft (steps 9 and
10).
Roller Bearing
9. Remove the retaining ring that secures roller

bearing assembly with a snap ring plier. Remove
the roller bearing assembly.
10. Place roller bearing assembly on new shaft and
secure with the retaining ring.
Key
Shaft
OR
Shaft Assembly
OR
11. Wrap the spline or key end of shaft with thin

plastic to prevent damage to the seal lip during
installation. Lubricate the inside diameter of the
shaft seal with petroleum jelly.
12. Place the O-ring onto the shaft bearing and
lubricate with petroleum jelly.
13. Slide the seal carrier assembly over the shaft and
into the housing bore. Press against O-ring. Hold
inward pressure against the shaft to compress
the cylinder block spring while pressing the seal
carrier into place.
14. Install the retaining ring.
E100021 E
Shaft Components
008 911 63
BOMAG
2 3713
16.3
Series 42
4.14 Auxiliary Mounting Pads

The following procedure can be used to remove and
install a new auxiliary mounting pad or to install a
fresh O-ring for the current auxiliary mounting pad.
Several auxiliary mounting pads are available.
Auxiliary mounting pads are integrated into the charge
pump cover. When nothing is mounted on the pads,
a flange cover is attached to protect the mounting
flange. This cover is removed when mounting a
Charge
pump.
Removal of Auxiliary Mounting Pad
1. Remove the auxiliary pump or remove the two
screws retaining the flange cover ["A" Pad 9/16
in Hex; "B" Pad 3/4 in Hex]. Remove the O-ring.
Pump
Cover
Pad Cover Screws

Aux Mount Pad Cover
Retaining
Screws
O-Ring
2. Orient pump so that charge pump cover (auxiliary

pad) is facing up.
OR
3. Remove the charge pump cover. The auxiliary

pad is integrated into the charge pump cover.
Use a Torx T45 male driver to remove the screws.
Note: If a different auxiliary pad is being installed,
then a new drive coupling must be installed. To do
this follow the instructions in the section on removing and installing the charge pump (next
section).
Note: If the charge pump components come out
with the charge pump cover refer to section 4.15
on how to properly reinstall them.
4. Install a new charge pump cover gasket.
OR
Auxiliary
Mounting
Pad "A"
Gasket
Auxiliary
Mounting
Pad "B"
No Charge
Pump Defeat
Locating
Pin 1
Charge Pump
Components
5. Install the charge pump cover (auxiliary pump

mounting pad is integrated in cover).
NOTE: The threaded screw holes in the auxiliary
pump mounting pad used on very early production pumps with the SAE "A" pad option are drilled
through into the area between the gerotor cover
and charge pump cover. Any of these holes
which are not used to attach the flange cover or
auxiliary pump should be plugged with internal
hex set screws installed hand tight to prevent the
entrance of water or dirt into this area.
Locating
Pin 2
E100022 E
Auxiliary Pad Options and Components
6. Attach the auxiliary pump. If no pump is to be

attached on an auxiliary mounting pad, the pad
should be protected with a flange cover and Oring to prevent leakage.
714 2 4
BOMAG
008 911 63
16.3
Series 42
4.15 Charge Pump
(Screw used with

"No Pad" and
"A Pad" Only)
Cover
Retaining
Screws
1. Remove auxiliary pump, if necessary.
Charge Pump Cover or Auxiliary Pad
Note: For units without integral charge pumps

see the last page of this section for additional
information.
2. Remove the screws retaining the charge pump

cover to the pump housing [Torx T45] (seven (7)
screws are used with the "no pad" or SAE "A"
auxiliary mounting pad charge pump cover, while
six (6) screws are used with the SAE "B" auxiliary
mounting pad charge pump cover). Remove the
charge pump cover, gasket, and the cover locating pins.
3. Remove the gerotor cover assembly from the
charge pump cover or the back of the pump
housing. Remove the gerotor cover O-rings. Two
(2) O-rings are used on the gerotor cover of all
pumps. (An additional O-ring was used on the
gerotor cover of very early production pumps with
the SAE "A" pad option.)
Gasket
O-Rings
Geroter
Cover
4. Remove the gerotor assembly from the gerotor

cover or pump housing.
5. Remove the gerotor drive pin and drive coupling.
Remove the gerotor cover locating pin from the
pump housing.
6. Each part should be inspected separately if they
are to be reused. If either of the gerotor assembly
parts needs to be replaced, they must both be
replaced. Always replace the O-rings and charge
pump cover gasket. Inspect the journal bearing in
the gerotor cover for excessive wear.
Geroter
Assembly
Drive Coupling
Geroter Cover
Locating Pin
Charge Pump
Cover
Locating
Pin
Geroter Drive Pin

Charge Pump
Cover Locating
Pin
Charge Pump Components
The charge pump may be disassembled to inspect

and clean, or to change the auxiliary shaft drive
coupling.
7. Prior to assembly, lubricate the gerotor assembly

with clean hydraulic oil.
8. Install the gerotor drive pin into the hole in the
drive coupling, and retain with grease or petroleum jelly.
9. Install the drive coupling onto the pump shaft with
the smaller outside diameter oriented away from
the pump shaft. Different couplings are used
with the different auxiliary pad options.
E100023 E
Charge Pump Components
10. Install the gerotor assembly onto the coupling.

(continued)
008 911 63
BOMAG
2 5715
16.3
Series 42
11. Install the gerotor cover locating pin into the

pump housing. Install the gerotor cover assembly
over the gerotor. The locating pin must engage
the slot in the gerotor cover.
NOTE: The charge pump rotation is determined
by the location of the gerotor recess and pressure
balance hole in the gerotor cover. Different
gerotor covers are used for clockwise and
counterclockwise rotation pumps.
12. Install new pressure balance O-rings onto the
gerotor cover and retain with petroleum jelly or
grease. (An additional O-ring was used on the
gerotor cover of very early production pumps with
the SAE "A" pad option.)
13. Install the charge pump cover locating pins and a
new charge pump cover gasket.
14. Install the charge pump cover. The cover must
engage the gerotor cover and the locating pins.
Install the charge pump cover screws and torque
evenly [36-43 Nm (26-32 ftlbf)].
15. If necessary, reinstall auxiliary pump.
CW
CCW
P100110 E
Determining Charge Pump Orientation Looking

Inside of Gerotor Pump Cover
For units without an integral charge pump see the

next section.
(continued)
716 2 6
BOMAG
008 911 63
16.3
Series 42
Units without Integral Charge Pump

Variable Pumps without an integral charge pump do
not have a gerotor assembly, gerotor drive pin, or
gerotor cover locating pin installed. The charge pump
inlet port is plugged with an O-ring plug.
Cover
Retaining
Screws
For these units that are equipped with housings

without filtration adapters, the gerotor cavity outlet
is plugged with a special plug installed in a housing
passage. The 3/416 charge inlet fitting should be
torqued to 68 Nm (50 ftlbf).
For these units that are equipped with housings that
include filtration adapters, the gerotor cavity outlet
is plugged with an O-ring plug installed in the "To
Filter" port of a "Full Filter Flow" (charge relief valve
after filter) filter adapter. The 7/814 charge inlet
fitting should be torqued to 95 Nm (70 ftlbf).
Gasket
Charge Pump Cover or Auxiliary Pad
(Screw used with

"No Pad" and
"A Pad" Only)
CAUTION
A "Partial Filter Flow" (charge relief valve before filter) adapter must not be used on variable
pumps without an integral charge pump. If this
design adapter is used, the charge relief valve
will be defeated.
Geroter
Cover
Drive Coupling
Charge Pump
Cover Locating
Pin 2
Geroter
Cavity
Outlet Plug
(Charge
Pump Defeat)
Charge Pump
Cover Locating
Pin 1
"No Charge Pump" Components
O-Rings
Charge
Inlet
Charge Pump
Inlet Plug
Charge Pump Inlet Plug
Charge Inlet
(For Wrench Sizes
and Torquing
See Filtration Section)
E100024 E
No Charge Pump Option Components

(Housing with Filtration Adapter)
008 911 63
No Charge Pump Option Components

(Housing without Filtration Adapter)
BOMAG
2 7717
16.3
Series 42
4.16 Filtration
Filtration of foreign matter from the hydraulic fluid is
of primary importance. Dirt and foreign fluids within
the hydraulic circuit will greatly reduce the life of the
hydraulic equipment.
M3 Gauge
Port Plug
Filtration Plate
Retaining Screws
Filter-Related Pump Hardware

Filtration mechanisms for the Series 42 pump may
be before (suction filtration) or after (charge pressure
filtration) the charge pump. Sauer-Sundstrand provides a filtration adapter to provide for each type of
filtration configuration. If filtration is provided for
elsewhere in the hydraulic circuit, the pump will not
have a filtration adapter.
Partial Flow
Pressure
Filtration
Full Flow
Pressure
Filtration
Suction
Filtration
Pumps equipped with housings without filtration

adapters have an additional construction bore next to
the charge relief valve which is unused and plugged
[5/8 in Hex, 21-33 Nm (15-25 ftlbf)]. When these
pumps are equipped with suction filtration, the external charge inlet is plugged [5/16 in Int. Hex, 41-94 Nm
(30-70 ftlbf)].
Pumps equipped with housings that include filtration
adapters have the appropriate adapter and gasket
fastened to the housing with screws [Torx T30, 16
Nm (12 ftlbf)]. The position of the M3 gauge port [11/
16 in Hex, 11-13 Nm (8-10 ftlbf)] will vary depending
on filtration type.
Housing with
Filtration Adapter
Filter Specifications
The selection of a filter depends on a number of
factors including the contaminant ingression rate,
the generation of contaminants in the system, the
required fluid cleanliness, and the desired maintenance interval. A filter capable of controlling the fluid
cleanliness to ISO 4406 Class 18/13 or better is
recommended and may be located either on the inlet
(suction filtration) or discharge (charge pressure
filtration) side of the charge pump.
Charge Inlet
Plug
Construction
Bore Plug
E100025 E
Housing without
Filtration Adapter (Suction Filtration Only)
Filter capacity depends on desired maintenance

levels. As a rough guide, a capacity in grams equal
to twice the charge flow in gpm or 1/2 charge flow in
l/min has been found to be satisfactory for many
closed circuit systems.
Filtration Type
Closed Circuit Suction Filtration or
Open Circuit Return Line Filtration
Systems Sharing a Reservoir with
Other Gears, Clutches, or Cylinders
Charge Pressure Filtration
Filter efficiency as measured by a "Beta" () ratio*

should be as in the table at right.
See Sauer-Sundstrand publication BLN-9887 or
697581 and ATI-E 9201 for more information on
filtration.
718 2 8
Plug
-ratio
10 2
10 10
10 10
* Filter x-ratio is a measure of filter efficiency defined by ISO

4572. It is defined as the ratio of the number of particles greater
than a given size (x) upstream of the filter to number of particles
greater than the same size downstream of the filter. The x-ratio
applies to a specific particle size, measured in microns.
BOMAG
008 911 63
16.3
Series 42
4.17 Servo Piston Covers

The servo piston cover can be removed to change the
gasket or to inspect/change the control orifices for
NFP or FNR controls (section 4.9).
Pump Neutral Ajustment

Seal Lock Nut
1. On the right side (side 1) of the pump, remove

the pump neutral adjustment seal lock nut [13
mm Hex]. (Not necessary on side "2")
2. Remove the servo piston cover screws [Torx
T30].
Servo Piston
Cover Screw
Servo Piston Cover
Servo Piston Cover

(Non-Feedback and
Automotive controls only)
3. The left side (side "2") servo cover can be removed directly.
Pump "Neutral"
Adjustment Screw
On the right side (side 1) of the pump, the cover

should be pushed away from the pump housing.
It is then necessary to turn the neutral adjustment screw [5 mm Hex] clockwise (inward) far
enough for the servo cover to clear the nearby
drain port. Then pull the cover away from the
housing and turn the cover counterclockwise to
disengage it from the adjustment screw.
Servo Piston Cover Right Side (Side "1")
4. Remove the gasket.

Note: FNR and NFPE control orifice plugs are
located here, see section 4.9 for more information.
5. Install new gasket.
6. On the right side (side "1"), screw the servo piston
cover on the neutral adjustment screw. Then,
while holding the cover, turn the neutral adjustment screw CCW to engage the cover to the
screw threads.
Servo Piston
Cover Screws
Servo Piston
Cover
7. Install servo piston cover screws (15-17 Nm (1113 ftlbf)].

8. On the right side (side "1"), loosely install neutral
adjustment seal lock nut. Perform pump neutral
adjustment (section 4.2).
Servo Piston Cover Left Side (Side "2")

E100026 E
Servo Piston Cover Components
WARNING
After installing the servo piston cover on right
side (side 1) of the pump, the pump neutral
adjustment and control neutral adjustment
MUST be performed before the vehicle / machine is put back into service.
CAUTION
Performance of the above procedure may adjust the position of the displacement limiter
somewhat.
008 911 63
BOMAG
2 9719
16.3
Series 42
4.18 Displacement Limiter Adjustment

Displacement limiters can limit the maximum swashplate position. For Series 42 pumps, displacement
limiters are available on one or both sides of the servo
piston.
Displacement Limiter
Seal Lock Nut
Adjustment of the displacement limiters should be

performed on a test stand.
Servo Piston
Cover
WARNING
Care should be taken in adjusting displacement limiters to avoid undesirable speed conditions. The limiter screw must have full thread
engagement in the servo piston cover, and the
seal lock nut must be retorqued after every
adjustment to prevent unexpected changes in
operating conditions and external leakage during unit operation.
Displacement Limiter Right Side (Side "1")
(Exploded View, No Need to Remove Limiter or Nut)
1. Mount pump on test stand.

2. Loosen displacement limiter seal lock nut [13 mm
Hex]. Do not remove.
Seal Lock Nut
3. Adjust displacement limiter [4 mm Int. Hex].

Tighten the seal lock nut every time the pump
is to be tested [20-26 Nm (15-19 ftlbf)].
One full turn of the displacement limiter adjustment screw will change the displacement of the
pump approximately as follows.
28 cc
3.6 cc/rev
0.22 in3/rev
41 cc
5.0 cc/rev
0.31 in3/rev
Displacement
Limiter
Servo Piston
Cover
T000 026E
4. After reaching proper displacement tighten the

seal lock nut [20-26 Nm (15-19 ftlbf)].
If necessary, repeat procedure for displacement limiter on other side.
720 3 0
BOMAG
Displacement Limiter Left Side (Side "2")

(Exploded View, No Need to Remove Limiter or Nut)
E100027 E
Displacement Limiters
008 911 63
16.3
Series 42
Exploded View Parts Drawings
5. Exploded View Parts Drawings

5.1
Shaft Options
F096
C020
C017
C018
C015
C005
C002
C003
C001
C015
F001
OR
C001
OR
C001
E100028
008 911 63
BOMAG
3 1721
16.3
Series 42
5.2
Filtration, Charge Relief, System Relief, and Loop Flushing
(F086)
(F086A)
(F043)
(F043A)
(F040)
(F042)
(F040)
(F042)
(F043)
(F043A)
OR
F043
F043A
OR
F040
F042
OR
K001
K001
K005
F091
F091A
G040
G040A
G041
G043
G042
K001A
K001B
F030 K001C
F030A
K006
K007
F041
K008
K009
K010
G043
G042
G041
G040A
G040
OR
045A
G045
K002
J005
J002
J003
F062
F061
F063
F060A
F060
(F060A)
(F060)
F051
OR
F0511
F0512
F0513
F0514
F0515
F050A
F050
OR
(F051)
(F050A)
(F050)
H005
H002
H003
(F091A)
F093
(F091)
F093A
F093
F093A
N002A
N002
E100029
722 3 2
BOMAG
008 911 63
16.3
Series 42
5.3
Charge Pump, Auxiliary Pads, and Servo Covers
L010
L010A
F020
F020A
G005
(G075)
G010
G015
G002
G020
(G021)
G022
G065
G075
G030
F009
G023
G001
M001
OR
(M001)
OR
(G001)
M005
M010A
(M005)
(M010A)
G036
M010
OR
(G080)
(M010)
M020
M025
(G001)
(G036)
G085
G090
(G090)
(G036)
(G080)
(G085)
E100030
008 911 63
BOMAG
3 3723
16.3
Series 42
5.4
Control Options
D039
D038
D037
D081
D003
D003A
(D017)
D080
D082
D019
D016
D002
OR
OR
D017
D056
D040
D010
D012
F035
E001
F035A
D070
OR
OR
D011
D013
F036
D004
F035
F034
D081
D081
OR
D060
(F010)
F010
D090
D014
D015
D032A
E100031
D032
724 3 4
BOMAG
008 911 63
16.3
Series 42
Notes
008 911 63
BOMAG
3 5725
16.3
726
BOMAG
008 911 63
16.4 Vibration motor A10FM
008 911 63
BOMAG
727
16.4
728
Vibration motor A10FM
BOMAG
008 911 63
16.4
A10FM
A10FE
RDE 92172-01-R/08.01
ersetzt / replaces 06.99
Reparaturanleitung - A10FM 28 - 60
Repair instructions -
008 911 63
BOMAG
A10FE 28 - 60
A10FM 28 - 60
A10FE 28 - 60
Baureihe 5
Baureihe 5
Series 5
Series 5
729
RDE 92172-01-R/08.01
16.4
Hinweis / Inhalt
Reparaturanleitung A10FM / A10FE
Notice / Contents
Repair Instructions A10FM / A10FE
HINWEIS
Bezeichnungen, Beschreibungen und Darstellungen
entsprechen dem Informationsstand zum Zeitpunkt der
Drucklegung dieser Unterlage.
nderungen knnen den Service am Produkt beeinflussen, Verpflichtungen entstehen uns daraus nicht.
Methoden und Vorrichtungen sind Empfehlungen, fr
deren Resultat wir keine Haftung bernehmen knnen.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Angabe der Fabrik-Nr. bestellt, sind die Basis guter Reparaturen.
Einstell- und Prfarbeiten sind bei Betriebstemperatur auf
dem Teststand vorzunehmen.
Schutz von Personen und Eigentum ist durch Vorkehrungen sicherzustellen.
Sachkenntnis, die Voraussetzung fr jede Service-arbeit,
vermitteln wir in unseren Schulungskursen.
NOTICE
Specifications, descriptions and illustrative material shown
herein were as accurate as known at the time this
publication was approved for printing.
BRUENINGHAUS HYDROMATIK reserves the right to
discontinue models or options at any time or to change
specifications, materials, or design without notice and
without incurring obligation.
Optional equipment and accessories may add cost to the
basic unit, and some options are available only in
combination with certain models or other options.
For the available combinations refer to the relevant data
sheet for the basic unit and the desired option.
Adjustment and tests have to be carried out on the test
bench under operating temperatures.
Protection of personnel and property has to be guaranteed by appropriate measures.
Expert knowledge, the precondition of any service work,
can be obtained in our training courses.
INHALT
CONTENTS
Seite/
Page
A10FM / A10FE
Schnittbild
Allgemeine Reparaturhinweise
Triebwelle abdichten
Motor demontieren
berprfungshinweise
Motor montieren
Splventil demontieren
Abstimmung- Lagerung / Hinweise
Werkzeuge / Hilfswerkzeuge /
Anziehdrehmomente
Brueninghaus Hydromatik
730
A10FM / A10FE
3
4
5-7
8-14
15
16-19
20
21
27
Sectional view
General repair guidelines
Sealing the drive shaft
Disassemble the motor
Inspection hints
Motor assembly
Disassembly of the flushing valve
Bearing adjustment / Note
Tools / auxiliary tools /
tightening torques
BOMAG
008 911 63
RDE 92172-01-R/08.01
16.4
Schnittbild
Reparaturanleitung A10FM / A10 FE
Sectional view
A10FM
A10FE
Optional
Option
Ausfhrung mit Splventil
Unit with flushing valve
fr geschlossenen Kreislauf
for closed circuit application
008 911 63
BOMAG
731
RDE 92172-01-R/08.01
16.4
Allgemeine Reparaturhinweise
General repair guidelines
Achtung!
Nachfolgend Hinweise bei allen Reparaturarbeiten
an Hydraulikaggregaten beachten!
Attention!
Observe the following guidelines when carrying out repairs
on hydraulic units!
Alle ffnungen der Hydraulikaggregate verschlieen.

Close off all openings of the hydraulic unit.
Alle Dichtungen erneuern.

Nur original BRUENINGHAUS HYDROMATIK
Ersatzteile verwenden.
Replace all of the seals.
Use only original BRUENINGHAUS HYDROMATIK
spare parts.
Alle Dicht- und Gleitflchen auf Verschlei prfen.

Achtung: Nacharbeiten an Dichtflchen z.B. durch
Schleifpapier kann die Oberflche beschdigen.
Check all sealing and sliding surfaces for wear.
Attention: Re-work of the sliding surfaces by using, for
example abrasive paper, can damage the surface.
Hydraulikaggregate vor Inbetriebnahme mit

Hydraulikl befllen.
Fill the hydraulic unit with hydraulic oil
before commissioning.
732
BOMAG
008 911 63
RDE 92172-01-R/08.01
16.4
2
1
1
2
1. Sicherungsring, 2. Wellendichtring
1
1. Circlip, 2. Shaft seal
(Pafeder ausbauen bei Ausfhrung Pafeder))

Triebwelle abkleben.
Sicherungsring ausbauen.
(Remove key, version with keyway)
Protect the drive shaft.
Remove the circlip.
008 911 63
BOMAG
733
RDE 92172-01-R/08.01
16.4
Nach der Demontage des gelaufenen Wellendichtringes,

einfetten des neuen WDR.(Kontrolle der Laufflchen, Welle,
Gehuse).
Change the shaft seal and check its sliding surface (drive shaft)
and housing, grease the sealing ring.
Welle mit Schutzhlse oder Klebeband versehen.

Use installation tool or plastic strip for assembling seal.
Mit geeignetem Rohr den WDR nur so tief montieren,

da der Sicherungsring montierbar ist (zu tiefes Montieren
fhrt zum Ausfall: Berhrung mit dem Wellenlager!).
Use a suitable pipe to mount the shaft seal ring, but don't
push it too deap. If the shaft ring touches the bearing ring
you will damage the seal ring.
Sicherungsring einsetzen.
Assemble the snap ring.
Sicherungsring ganz einrasten.

Assemble the snap ring in the correct position.
734
BOMAG
008 911 63
RDE 92172-01-R/08.01
16.4
Hinweis!
Note!
Die hier beschriebene Mglichkeit zum Wechsel der

Antriebswellen - Abdichtung stellt nicht die serienmige Montage dar. Fr sicheres Dichtungsverhalten ist eine
Montage des Dichtringes zusammen mit dem Kegelrollenlager von innen her durch das Montagegehuse
durchzufhren. Soll aus Grnden der Vereinfachung im
Reparaturfall die vorgehend beschriebene Vorgehensweise durchgefhrt werden, so ist beim Ausbau der
Dichtung besonders darauf zu achten, da die Antriebswelle nicht beschdigt wird.
This discription showes how th change the drive shaft

sealing ring but it isn't the way of serial assembly.
The sealing ring is assembled together with the taper
roller bearing from inside the motor housing normally to
get a secure sealing condition. If you decide to repair the
motor in the shown way be very careful while handling
so that the drive shaft wouldn't be damaged during
disassembly of the shaft sealing ring.
008 911 63
BOMAG
735
RDE 92172-01-R/08.01
16.4
Motor demontieren
A10FM
736
BOMAG
008 911 63
RDE 92172-01-R/08.01
16.4
Motor demontieren
A10FE
10
008 911 63
BOMAG
737
RDE 92172-01-R/08.01
16.4
Motor demontieren
11
Demontageposition
Lage der Anschluplatte zum
Gehuse kennzeichnen.
Disassembly position
Mark the location of the connection plate
on the housing.
12
Anschluplattenbefestigung ber Kreuz lsen.

Remove the connection plate fixing bolts crosswise.
13
Anschluplatte abheben.
Verteilerplatte
kann herunterfallen - festhalten.
Verteilerplatte abheben.
Remove the connection plate.
Distributor plate
can drop down - hold tight.
Remove distributor plate.
10
738
BOMAG
008 911 63
RDE 92172-01-R/08.01
16.4
Motor demontieren
14
Verteilerplatte abheben.
Remove control plate.
15
Lagerauenring mit Abziehvorrichtung ausbauen.

Dichtflche Verteilerplatte nicht beschdigen.
Remove bearing outer ring with withdrawal tool.
Do not damage the sealing surface.
16
Abheben des Kegelrollenlagers (anschluplattenseitig).

Entfernen der Abstimmscheibe.
Disassemble the taper roller bearing (near by port plate)
Remove the adjustment shim.
008 911 63
BOMAG
739 11
RDE 92172-01-R/08.01
16.4
Motor demontieren
17
Triebwerk in horizontaler Lage herausziehen.

Remove the rotary group in a horizontal position.
18
Welle nach hinten herausziehen.

Remove the drive shaft to rear side.
19
Hubscheibe mit Sonderwerkzeug ausbauen (siehe Bild 20).

Remove swash plate with special tool (see picture 20).
20
Der Ausbau der Hubscheibe erfolgt mit einer Schleuder,

ein kleiner Haken - aus Rundmaterial Durchmesser 6 mm greift dabei unter die Hubscheibe.
Loosen the swash plate with a slide hammer ( a small
hook - diameter 6 mm - catches the end of the swash
plate at the bottom).
21
Lager mit Presse abziehen.

Press down bearing.
12
740
BOMAG
008 911 63
RDE 92172-01-R/08.01
16.4
Motor demontieren
22
Abziehen des Lagerauenringes im Pumpengehuse.

Zweckmige Unterlage benutzen, zur Vermeidung von
Gehusebeschdigungen (s. a. Hinweis Abb.xx).
The external front bearing ring is pulled out of the pump
housing (tool and surface infos see picture xx, too).
23
Sicherungsring entfernen.
Disassemblecirclip and shaft seal.
24
Wellendichtring und Fixierscheibe entnehmen

Remove shaft seal ring and shim.
008 911 63
BOMAG
741 13
RDE 92172-01-R/08.01
16.4
Motor demontieren
25
Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.
26
Sicherungsring demontieren.
Feder und Druckstifte ausbauen.
Remove circlip.
Remove spring and pressure pins.
27
14
742
BOMAG
008 911 63
RDE 92172-01-R/08.01
16.4
berprfungshinweise
Inspection hints
28
Kontrolle!
Laufflche (1) keine Kratzer, keine Metalleinlagerungen,
kein Axialspiel (2), (Kolben nur satzweise tauschen).
Check!
Check to see that there are no scratches or metal deposits
on the sliding surface (1), and that there is no axial play (2),
(pistons must only be replaced as a set).
29
Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).
Check!
Cylinder bores (1), splines (2).
30
Riefenfrei, keine Einlaufspuren

Free of grooves, no signs of wear.
31
Kontrolle!
Zylindergleitflche riefenfrei, nicht eingelaufen, keine
Einlagerungen, Steuerplatte nicht riefig (nur satzweise
austauschen).
Check!
Cylinder sliding surface free of grooves, no wear, no
embedded foreign particles. That there are no scratches
on the control plate. (Only replace them as a set).
32
Kontrolle!
Auflageflche - Steuerplatte ohne Beschdigung.
Check!
Mounting surface - control plate undamaged
008 911 63
BOMAG
743 15
RDE 92172-01-R/08.01
16.4
Motor montieren
Motor assembly
33
Sicherungsring ins Gehuse montieren.

Fit the circlip into the housing.
34
Wellendichtring und Fixierscheibe gegen

Sicherungsring einsetzen.
Assemble shaft seal ring and shim
against circlip.
35
3
1
Montage des Wellendichtringes 1 gegen den Sicherungsring 2,

anschlieend Fixierscheibe 3 einlegen.
Assembly of the shaft seal 1 against the safety ring 2,
back up the shim 3 down to the seal ring.
2
36
Lagerauenring ins Gehuse pressen.

Welle mit Lager vormontiert ins Gehuse einstecken.
Wellendichtring nicht beschdigen.
Wellenverzahnung mit Klebeband umwickeln.
Press outer bearing ring into housing.

Shaft seal with pre-assembled bearing into housing.
Protect splines of the shaft with plastic strip
against damage of the seal lip.
16
744
BOMAG
008 911 63
RDE 92172-01-R/08.01
16.4
Motor montieren
Motor assembly
37
Hubscheibe montieren.
Assemble swash plate.
38
Mit Vorrichtung Druckstifte montieren.

Fit pressure pins using an assembly aid.
39
Feder mit Vorrichtung vorspannen.

Pre-tension the spring using a suitable device.
40
41
Kolben mit Rckzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einlen.
Assemble piston with retaining plate.
Note:
Oil piston and slipper pad.
008 911 63
BOMAG
745 17
RDE 92172-01-R/08.01
16.4
Motor montieren
Motor assembly
42
Rotationsgruppe montieren!
Montagehilfe:
Mit O-Ring Kolben festhalten.
Fit rotary group!

Assembly aid:
Hold the pistons by using an O-ring.
43
4
Lager (1) in Anschluplatte montieren.

Zylinderstift (2) einsetzen.
O-Ring (3) einsetzen.
Verteilerplatte (4) aufsetzen.
Montagehilfe:
Teile mit Fett fixieren.
1
2
Fit bearing (1) in connection plate.

Fit cyilindrical pin (2).
Fit O-ring (3).
Fit distributor plate (4).
Assembly:
Hold the components in place with grease.
18
746
BOMAG
008 911 63
RDE 92172-01-R/08.01
16.4
Motor montieren
Motor assembly
44
Verteilerplatte montieren.
Montagehilfe: Fett
Fit distributor plate.
Assembly aid: Grease
45
Anschluplatte aufsetzen und mit Schrauben

ber Kreuz anziehen.
Fit the connection plate and fix it with
the screws crosswise.
A10FM
A10FE
46
008 911 63
BOMAG
747 19
RDE 92172-01-R/08.01
16.4
Splventil demontieren
Disassembly of the flushing valve
47
Beidseitig Schrauben 1 lsen und Federn mit Scheiben 2

entnehmen.
Loosen screws 1, take out springs and shims 2.
2
1
48
Splschieber 3 vorsichtig zu einer Seite heausdrcken.

Take out spool carefully.
49
Verschluschraube Speisedruckventil 4 lsen,

Feder und Einsatz entnehmen.
Loosen the screw of the boost valve and take out
the spring and the cartridge.
Montage in umgekehrter Reihenfolge!

Assembling by opposite steps!
20
748
BOMAG
008 911 63
RDE 92172-01-R/08.01
16.4
Abstimmung- Lagerung / Hinweise
Bearing adjustment / Note
Montage - Abstimmung
(Kegelrollenlager) / Taper roller bearing initial tension
AA10FM Baureihe 50
AA10FM Series 50
0 .... 0,05 mm
Pos. 12
Abstimmung der Triebwerkslagerung
Adjustment of stopper min displacement
Die Vorspannung der Triebwerkslagerung mu im

Gugehuse von 0 bis 0,05 mm durch Abschleifen der
Cast iron housing must have initial tension of bearings:

0 ...... 0,05 mm , grind Pos. 12 if necessary.
Abstimmscheibe Pos. 12 hergestellt werden.

Adjustment: Qmin- stopper
Einstellhinweis: Qmin-Anschlag
Bei gegebenem Zusatzstrom wird bei drucklosem
Umlauf der Anschlag Qmin so eingestellt, da die gemessene Drehzahl des Motors einem Schluckvolumen von
12 cm3 entspricht (vgmin).
Eine kontinuierliche Verstellung bis vgmax = 45 cm3 ist
mglich - Volumennderung pro Gewindestiftumdrehung ca. 3,1 cm3 (s. a. Seite 3).
Schluckvolumen vgmin =
Increase of adjustment is possible to vgmax = 45 cm3

Differential volume is appr. 3,1 cm3 (see page 3).
Displacement vgmin =
Q inflow x 1000
Measurement speed
Q Zulauf x 1000
Medrehzahl
Achtung: Falsch eingestellte Qmin Anschlge knnen zu

berhhten Drehzahlen bis hin zum Ausfall der Bauteile
fhren.
008 911 63
With a given inflow and pressureless circulation adjust

the stopper Qmin displacement so that the measured
speed of the motors results in a displacement of 12 cm3
(vgmin).
BOMAG
Attention: Wrong adjustments of stopper Qmin

displacement increases the speed of the motor up to a
possible failure of parts of the unit.
749 21
RDE 92172-01-R/08.01
16.4
Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente
Tools / auxiliary tools / tightening torques
49
Plastikhammer
Soft hammer
50
Schleuder
...
Anziehdrehmomente /
Tightening torques
Festigkeitsklassen
Bolt tensile strength grade:
Ma
10,9; 12,9
M4
M5
M6
M8
M10
M12
M14
M16
M18
M20
M24
M30
8,8
2,3
5,0
8,5
21
41
72
115
176
240
350
600
1220
10,9
3,2
7,2
12
29
58
100
165
250
350
490
840
1670
12,9
4,1
8,5
14,5
35
70
121
195
300
410
590
990
2000
Ma (Nm) = max. Anziehdrehmoments (gelte Schrauben = 0,125)

Ma (Nm) = max. tightening torques (lubricated screws = 0,125)
22
8,8;
750
BOMAG
51
008 911 63
16.5 MS/MSE 02 ..... 18
008 911 63
BOMAG
751
16.5
752
MS/MSE 02 ..... 18
BOMAG
008 911 63
16.5
MS/MSE 02 ..... 18
Hydraulikmotoren
Hydraulic motors
MS
Reparaturen
Repairs
02
05
08
11
18
MS
MSE
Strungsbeseitigung
Trouble Shooting
Wartungsarbeiten
Maintenance
Reparaturen
Repairs
5767
Ersatzteile
Spare Parts
0549
5766
5763
0545
5764
0550
Ref : 800378128J
REPAR MS2-18 D/GB
Rev : A - Avr - 00
008 911 63
POCLAIN HYDRAULICS Industrie

B.P. 106
60411 VERBERIE CEDEX - FRANCE
Tel.: 33 3 44 40 77 77
Fax: 33 3 44 40 77 99
www.poclain-hydraulics.com
BOMAG
5765
0547
POCLAIN HYDRAULICS
Certifi ISO 9001
753
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Dieses Dokument richtet sich an die Hersteller von Maschinen und Systemen, die Produkte von POCLAIN-HYDRAULICS einbauen, deren
Artikelnummer auf der Titelseite genannt sind. Es beschreibt die Installationsangaben und den Inbetriebnahmevorgang, damit ihre optimale
Funktionsweise gewhrleistet wird.
Es wird empfohlen, da smtliche Arbeiten von Monteuren mit einer angemessene Ausbildung durchgefhrt werden. Sie mssen die Informationen in diesem Dokument gelesen und verstanden haben und vom
Hersteller der Maschine bevollmchtigt sein.
Selbstverstndlich mssen die Monteure die Richtlinien zur Sicherheit
und zur Unfallverhtung beachten.
This document is provided to machine manufacturers integrating POCLAIN-HYDRAULICS products.. It suggests processes that manufacturers may utilize to repair products after the warranty period.
Dieses Dokument enthlt wichtige Hinweise zur Sicherheit. Sie werden

auf folgende Weise gekennzeichnet:
This document includes major safety warnings announced in this way:
It is recommended that all operations be performed by technicians

trained accordingly. The technicians should read and understand the
information given in this document and be authorized by the machine
manufacturer.
It is essential that the technicians comply with safety instructions to prevent injury.
Sicherheitshinweis.
Dieses Dokument enthlt weiterhin wesentliche Anweisungen zum Betrieb des Produkts sowie allgemeine Informationen. Sie werden auf folgende Weise gekennzeichnet:
Safety warning.
Additionally, this document includes instructions essential to product

function as well as those providing general information. Both are announced similar to the following examples:
Essential instruction.
Wesentliche Anweisung.
General information.
Allgemeine Information.
POCLAIN HYDRAULICS kann nicht fr Vorflle haftbar gemacht werden, die auf die Anwendung der in diesem Dokument empfohlenen Verfahren zurckgehen.
POCLAIN HYDRAULICS ist nicht verantwortlich fr die Konstruktion
und die Betriebsbedingungen der Maschinen und Systeme, die mit PHProdukten ausgestattet sind. Ebenso ist POCLAIN HYDRAULICS weder fr die Folgen eines falschen Einbaus der Produkte noch fr ein falsches Parametrieren einstellbarer Werte, noch fr ungltige oder unvollstndige Gebrauchs- und Wartungsanweisungen, die den Endverbrauchern von den Maschinenherstellern zur Verfgung gestellt worden sind,
verantwortlich.
Jegliche nderung einstellbarer Parameter der PH Produkte kann eine
Neuzulassung der Maschinen erforderlich machen.
Mit dem Ziel, den besten Service zu bieten, empfiehlt POCLAIN HYDRAULICS seinen Kunden, jede Anwendung von POCLAIN HYDRAULICS prfen und freigeben zu lassen.
Das ffnen der Produkte fhrt zum Garantieverlust. Verwenden Sie nur
Original-Ersatzteile von POCLAIN HYDRAULICS. Die Montage von
Teilen anderen Ursprungs knnte den Betrieb des Bauteils und des Systems sowie die Sicherheit beeintrchtigen.
POCLAIN HYDRAULICS designs products that are integrated by its

customers in the machines they design.
Subsequently POCLAIN HYDRAULICS disclaims liability for consequences of improper integration of its products and of improper set-up
of adjustable devices. In the same way, POCLAIN HYDRAULICS may
not be liable for incomplete or improper operating and maintenance instructions provided to the end user by the machine manufacturer nor for
failures resulting from operations performed by any person using these
suggested procedures.
A re-certification of the machine may be required for every change in
set-up of adjustable devices.
In order to offer the best quality service, POCLAIN HYDRAULICS recommends to its customers to have applications approved by POCLAIN
HYDRAULICS.
Opening of products voids the warranty contract.
Use only POCLAIN HYDRAULICS genuine spare parts. Using parts
from different sources could reduce the performance of the product and
pose a safety hazard..
Stets um die Verbesserung seiner Erzeugnisse bemht, behlt sich

POCLAIN HYDRAULICS das Recht vor, ohne vorherige Ankndigung
alle nderungen vorzunehmen, die als ntzlich fr die in diesem Dokument beschriebenen Produkte bewertet werden.
Dieses Dokument enthlt Abschnitte auf deutsch und kursiv gedruckte Abschnitte, die bersetzung in englischer Sprache darstellen.
Im Zweifelsfall ist die franzsische Version ausschlaggebend.
Die Mae sind in metrischen Einheiten angegeben. Die Entsprechungen
in anderen Mesystemen (vor allem angelschsisch) werden zur Unterrichtung angegeben.
Die Abbildungen haben unverbindlichen Charakter.
In accordance with its policy of continuous improvement, POCLAIN

HYDRAULICS reserves the right to modify the specifications of all
products described herein without prior notice.
POCLAIN HYDRAULICS Industrie 1998.

Die Handelsmarke POCLAIN HYDRAULICS ist das Eigentum von POCLAIN HYDRAULICS SA.
Dieses Dokument ist das Eigentum von POCLAIN HYDRAULICS Industrie. Es ist streng vertraulich. Es darf ohne unseres vorheriges schriftliches Einverstndnis weder gesamt noch teilweise verwendet, vervielfltigt, kopiert oder an Dritte weitergegeben werden.
FACOM ist ein eingetragenes Warenzeichen der FACOM SA.
LOCTITE ist ein eingetragenes Warenzeichen der LOCTITE SA.
AUTO-TOP ist ein eingetragenes Warenzeichen der AGIP SPA.
POCLAIN HYDRAULICS Industrie 1998.

The trademark POCLAIN HYDRAULICS is the property of POCLAIN
HYDRAULICS S.A.
This document is the property of POCLAIN HYDRAULICS Industrie.
It is strictly confidential. It must not be used, duplicated, copied or disclosed to a third party in full or in part without our prior written consent.
FACOM is FACOM SA registered trademark.
LOCTITE is LOCTITE SA registered trademark.
AUTO-TOP is AGIP SPA registered trademark.
This document contains sections written in German and sections

printed in italics composing the English translation of the French sections. The French sections will be the reference in case of dispute.
All measures are expressed in metric units. Converted values to other
systems (notably US and UK) are given for reference only.
The illustrations for information only.
REPAR MS2-18 D/GB
754
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Inhaltsverzeichnis
Contents
INHALTSVERZEICHNIS ............................................. 3
CONTENTS................................................................. 3
SICHERHEIT UND QUALITT ................................... 4
SAFETY AND QUALITY ............................................. 4
VOR DEN W ARTUNGSARBEITEN ....................................... 4

W HREND DER W ARTUNGSARBEITEN............................... 4
NACH DEN W ARTUNGSARBEITEN ..................................... 4
IDENTIFIZIERUNG DES BAUTEILS ....................................... 5
BEFORE SERVICING ........................................................ 4

DURING SERVICING ......................................................... 4
AFTER SERVICING ........................................................... 4
IDENTIFICATION OF THE COMPONENT................................. 5
STRUNGSBESEITIGUNG........................................ 6
TROUBLE SHOOTING ............................................... 7
WARTUNGSARBEITEN.............................................. 8
MAINTENANCE .......................................................... 8
AUSTAUSCHEN DES MOTORS........................................... 8

Ausbau..................................................................... 8
Einbau...................................................................... 8
MECHANISCHE BREMSLSUNG ........................................ 9
KONTROLLE DER STATISCHE HALTEBREMSE. ................... 10
REPLACING THE MOTOR .................................................. 8

Removal................................................................... 8
Installation................................................................ 8
MECHANICAL BRAKE RELEASE .......................................... 9
CHECKING THE PARKING BRAKE EFFICIENCY..................... 10
REPARATUREN. ...................................................... 11
REPAIRS. ................................................................. 11
AUSWECHSELN DER BREMSKOLBENDICHTUNG................. 11

Demontage ............................................................ 11
Wiedereinbau......................................................... 13
AUSWECHSELN DES LAGERTEILES (070)......................... 16
Demontage ............................................................ 16
Wiedereinbau......................................................... 18
AUSWECHSELN DER BREMSBACKEN ............................... 20
Demontage ............................................................ 20
Wiedereinbau......................................................... 23
AUSWECHSELN DES NOCKENRINGS (026)....................... 27
Demontage ............................................................ 27
Wiedereinbau......................................................... 27
AUSWECHSELN DES KOMPLETTEN ZYLINDERBLOCKS (010) 28
Demontage ............................................................ 28
Wiedereinbau......................................................... 28
AUSWECHSELN DES VERTEILERS (047). ......................... 29
Demontage ............................................................ 29
Wiedereinbau......................................................... 29
AUSWECHSELN DER DECKELDICHTUNG (045).................. 32
Demontage ............................................................ 32
Wiedereinbau......................................................... 33
AUSWECHSELN DES DREHZAHLSENSORS (OPTION).......... 34
Demontage ............................................................ 34
Wiedereinbau......................................................... 35
REPLACEMENT OF THE O-RING OF THE BRAKE PISTON....... 11

Disassembly........................................................... 11
Reassembly. .......................................................... 13
REPLACEMENT OF THE BEARING SUPPORT (070).............. 16
Disassembly........................................................... 16
Reassembly ........................................................... 18
REPLACING THE BRAKE SHOES....................................... 20
Disassembly........................................................... 20
Reassembly ........................................................... 23
REPLACEMENT OF THE CAM (026) .................................. 27
Disassembly........................................................... 27
Reassembly ........................................................... 27
REPLACEMENT OF THE CYLINDERS BLOCK ASSEMBLY (010)28
Disassembly........................................................... 28
Reassembly ........................................................... 28
REPLACEMENT OF THE VALVING (047). ........................... 29
Disassembly........................................................... 29
Reassembly ........................................................... 29
REPLACEMENT OF THE O-RING (045) OF THE END COVER . 32
Disassembly........................................................... 32
Reassembly ........................................................... 33
REPLACING THE SENSOR (OPTIONAL) .............................. 34
Disassembly........................................................... 34
Reassembly ........................................................... 35
WERKZEUG-LISTE .................................................. 36
TOOLING INVENTORY............................................. 36
Standard Werkzeug................................................ 36
Spezialwerkzeuge .................................................. 37
ANZIEHDREHMOMENTE NM 10%........................... 38
ERSATZTEILE.......................................................... 39
MOTOREN MIT KONSTANTEM HUBVOLUMEN MS, MSE 0205-08-11-18. .............................................................. 42
MOTOREN MIT UMSCHALTBAREM HUBVOLUMEN MS, MSE
02-05-08-11-18. ......................................................... 44
800378128J
008 911 63
Standard tools ........................................................ 36

Special tools........................................................... 37
TIGHTENING TORQUES IN [LBF.FT] 10% .......... 38
SPARE PARTS LIST ................................................ 39
SINGLE DISPLACEMENT MOTORS MS, MSE 02-05-08-1118. ............................................................................. 42
DUAL DISPLACEMENT MOTORS MS, MSE 02-05-08-11-18.44
REPAR MS2-18 D/GB
BOMAG
755
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Sicherheit und Qualitt
Safety and Quality
Vor den Wartungsarbeiten
Before servicing
Alle notwendigen Sicherheitsvorkehrungen treffen

(Menschen und Material) und die geltenden Sicherheitsvorschriften beachten.
Parkbremse bettigen und Maschine mit Keilen
festsetzen.
Energieerzeugung (Motor) des Hydrauliksystems
abstellen und die Stromversorgung ausschalten.
Gegebenenfalls eine Sicherheitszone einrichten.
Be extremely careful to prevent personal injury and

to avoid damage to material. Comply with all safety
regulations.
Die Auenflchen der Bauteile reinigen, um

Schmutz und Fett restlos zu entfernen.
Warten, bis das Hydrauliksystem vollstndig abgekhlt und druckentlastet ist (die Speicher entlasten).
Wash dirt and grease from exterior of the components.
Das heie oder unter Druck stehende l

kann zu schweren Verbrennungen mit
Entzndung fhren.
Bei einem Unfall einen Arzt hinzuziehen.
Hot or pressurized hydraulic fluid may

cause serious burns & infections to the
human body.
Consult a physician in case of accident.
Apply the parking brake and prevent the machine

from rolling with tire blocks.
Stop the hydraulic system power source (engine)
and disconnect the battery.
If necessary, block off the safety area.
Await the complete cooling down and depressurization of the hydraulic system (accumulators must be
purged).
Whrend der Wartungsarbeiten
During servicing
Bestimmte Bauteile sind sehr schwer. Sie mssen

bei der Abnahme vom Rahmen mit einer angemessen
ausgelegten Hebevorrichtung gehalten werden.
Die Sauberkeit ist wesentlich beim Betrieb der Hydraulikbauteile. Die meisten Teile knnen mit einem
sauberen Lsungsmittel gereinigt werden.
Whrend der Handhabung alle empfindlichen Oberflchen gegen Ste schtzen (Zentrierungen, gleitende
Teile, Auflagen, Dichtungs- und Lagerauflagen usw.).
Some hydraulic components are very heavy. Secure them with a lifting device of adequate capacity
when removing from the machine frame.
Diese Flchen vor dem Wiederzusammenbau reinigen.

Systematisch die demontierten Dichtungen beim
Wiederzusammenbau durch neue ersetzen. Wir empfehlen, vor der Montage alle Dichtungen zu fetten.
Alle gleitenden Flchen durch Aufbringen eines Films

sauberer Hydraulikflssigkeit len, der eine korrekte
Schmierung beim ersten Neustart gewhrleistet.
Lubricate all surfaces which have relative motion

between parts by coating them with a film of clean hydraulic fluid to assure lubrication at first start.
Niemals die Hydraulikflssigkeit, die sich bei hohen

Temperaturen entznden kann, erwrmen. Einige Lsungsmittel sind ebenfalls entzndlich.
Never heat hydraulic fluid, as it may flame at high

temperature. Some solvents are also flammable.
Whrend der Arbeiten nicht rauchen.
Do not smoke during servicing.
Nach den Wartungsarbeiten
After servicing
Die Bauteile wieder einbauen und das Hydrauliksystem

gem den Anweisungen in den folgenden Dokumenten wieder in Betrieb nehmen:
INSTALLATION MS D/GB (ref: 800078173V)
INSTALLATION CIRCUITS D/GB (ref. 677777853U)
Reinstall the components and restart the hydraulic

system according to instructions defined in the following
documents:
INSTALLATION MS F/GB (ref. 677777844K)
!
4
Cleanliness is essential to functioning of the hydraulic components. Most of the parts may be cleaned
with a clean solvent.
During handling, protect all sensitive surfaces from
shocks (piloting and interface surfaces, thrust & bearings surfaces, seal races, etc...)
Clean up these surfaces before reassembling.
Always install new O-rings, seals & gaskets discarding the old ones. We recommend lubricating all
seals prior to assembly.
INSTALLATION CIRCUITS F/GB (ref. 677777831V)
Die Einstellung der Sicherheitsventile

nicht erhhen.
REPAR MS2-18 D/GB
756
BOMAG
Do not overset relief valves.
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Identification of the component
Identifizierung des Bauteils
MS18-2-D11-F19-2A10-K000
B
D
000143896J
C
40712
001
0349
A : Handelsbezeichnung:
Ex : MSE18-2-D11-F19-2A10-K000
A: Commercial description:
E.g : MSE18-2-D11-F19-2A10-K000
B : Code : Artikelnr.:
Ex : 000143896J
B: Code: Part number.

E.g : 000143896J
C : Serie : Herstellungsnummer
Ex : 001
C: Series: Manufacturing batch number.

E.g : 001
D : Num : Chronologische Ordnungsnummer

Ex : 40712
D: Num: Chronological serial number.

E.g : 40712
Bei smtlichen Ersatzteilbestellungen

mssen die Artikelnummer und die chronologische Ordnungsnummer angegeben werden.
800378128J
008 911 63
The part number and the chronological

serial number must be specified to order
spare parts.
REPAR MS2-18 D/GB
BOMAG
757
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Strungsbeseitigung
BECHDIGUNG ABRIEB ERKENNUNG DURCH FILTER VORBEUGUNG
Strung
Ursachen
Ohne
Last
LAUTE
GERUSCHE DES
MOTORS
Unter
Last
MOTOR DREHT SICH

NICHT
DER MOTOR DREHT

SICH NICHT MIT
NORMALER LASTDREHZAHL
DER MOTOR DREHT

SICH UNREGELMSSIG
USSERE LUNDICHTIGKEITEN
Regelmiges
Brummen
Lagerteil verschlissen
Lagerteil ersetzen
Vibrationen
Lockere Befestigungen
und / oder Anschlsse
Mit entsprechendem Drehmoment anziehen
Klappern
Speisedruck zu niedrig
Speise- und Austauschdruckventil kontrollieren.
Kavitation
Interne Lecks zu gro
Zylinderblock und lverteiler

ersetzen
Der Motor wird nicht versorgt
Den Antrieb der Pumpe und ihre Versorgung berprfen
Kein Druckanstieg im
Kreis
Hochdruck-Begrenzungsventile
kontrollieren (Regler)
Zylinderblock und lverteiler

ersetzen
Die Bremse bleibt angezogen
Den Steuerkreis der Bremse

kontrollieren
Der Frdermenge der

Pumpe ist unzureichend
Die Antriebsdrehzahl und den

Zustand der Pumpe kontrollieren
Den Zustand des Zylinderblocks und des lverteilers

berprfen
Der Betriebsdruck ist zu

niedrig
Den Zustand des Sicherheitsventils kontrollieren (Regler)
Die Frdermenge der

Pumpe schwankt
Steuerdruck und Frdermenge

der Pumpe kontrollieren
Den Zustand des Zylinderblocks und des lverteilers

berprfen.
Gehusedruck zu gro
Den Leckagekreis und den Zustand des Filters berprfen
Dichtungen beschdigt
Die Dichtungen ersetzen
Fehlerhafte Montage
Das Anziehmoment der Montageschrauben, der Entlftungsschrauben und der Anschlsse

kontrollieren
REPAR MS2-18 D/GB
758
Abhilfe
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Trouble shooting
DAMAGE IRON PARTICLES DETECTION BY FILTERS PREVENTION
Troubles
Causes
Without
load
Regular rumbling
Worm bearing support
Replace the bearing support
Vibrations
Mountings and/or hydraulic

piping becoming loose
Tighten to torque
Clattering
Boost pressure too low
Check the setting and condition of counter-pressure valve
Cavitation
Excessive internal leaks
Replace the cylindersblock

and distribution valve assembly
No supply to the motor
Check pump drive and pump

inlet
The circuit does not reach

working pressure
Check condition of safety

valve (regulator)
Replace the cylinders block

and distribution valve assembly
The brake stays engaged
Check the brake pilot circuit
Pump flow is too low
Check drive speed and condition of the pump
Check condition of cylindersblock and distribution valve

assembly
Working pressure is too

low
Check safety valve setting

pressure (regulator)
Irregular flow
Check the pump flow
Excessive leaks
Check condition of cylindersblock and distribution valve

assembly
Too high casing pressure
Check the leakage circuit and

filter condition
Seals damaged
Replace seals
Incorrect assembling
Check tightening of mounting

screws, bleed screws and
unions
NOISY MOTOR
Under load
THE MOTOR DOES

NOT REVOLVE
THE MOTOR DOES

NOT REVOLVE AT
ITS NORMAL SPEED
UNDER LOAD
THE MOTOR REVOLVES IRREGULARLY
EXTERNAL OIL
LEAKS
800378128J
008 911 63
Remedies
REPAR MS2-18 D/GB
BOMAG
759
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Wartungsarbeiten
Maintenance
Austauschen des Motors
Replacing the motor
Ausbau
Removal
Druck im Arbeitskreis abbauen.

Leckageleitung am Tank abschrauben, um ein
Leerlaufen zu verhindern.
Die Rohre oder Schluche, die am Motor angeschlossen sind, abklemmen.
Drehzahlsensor abklemmen.
Die Befestigungsschrauben demontieren und den
Motor ausbauen.
Das Motorgehuse entleeren.
Einbau
Die zum Ausbau angegebenen Arbeitsgnge in umgekehrter Reihenfolge ausfhren.
Fr weitere Informationen beziehen Sie sich bitte auf
folgende Dokumente:
INSTALLATION MS D/GB (ref: 800078173V)
INSTALLATION CIRCUITS D/GB (ref: 677777853U)
Release the pressure in the supply circuit.

Disconnect the drain line at the tank level to avoid
its siphoning.
Disconnect and plug the pipes or hoses which are
connected to the motor.
Disconnect the speed sensor.
Disconnect the mounting screws, and remove the
motor.
Drain the casing.
Installation
Execute the removal operations in the reverse order.
Please refer to the following documentation brochures:
INSTALLATION MS F/GB (ref: 677777844K)

INSTALLATION CIRCUITS F/GB (ref: . 677777831V)
REPAR MS2-18 D/GB
760
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Mechanische Bremslsung
Mechanical brake release
Bei bestimmten Reparaturfllen

oder zum Abschleppen der Maschine mu die integrierte Parkbremse
gelst werden.
In certain service situations, it may

be necessary to release the motor
brake.
Stopfen (142) aus der Schutzkappe (141) herausziehen.
Extract and release the plug

(142) from the brake cover (141).
142
6499
Schraube im Kolben festziehen
Tighten the screw in the piston
6556
Mutter so weit anziehen, bis die

Welle frei dreht.
And tighten the nut until the

motor shaft turns freely.
6555
Force [lbf]
F02-F04
18000
[4.000]
42
[30.9]
M12
F05-F07
20000
[4.500]
47
[34.6]
M12
F08
34000
[7.600]
110
[81.1]
M16
F11
45000
[10.000]
140
[103]
M16
F12
45000
[10.000]
140
[103]
M16
F19
45000
[10.000]
140
[103]
M16
Brakes
Entsprechendes
Drehmoment Nm
Kraft N
Bremsen
Nach Bremslsung, einen neuen Stopfen

(142) einbauen.
800378128J
008 911 63
Equivalent torque [lbf.ft]
Mutter Nut
After brake release, mount a new plug

(142).
REPAR MS2-18 D/GB
BOMAG
761
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Checking the parking brake efficiency.
Kontrolle der statische Haltebremse.
Bei fahrbaren Maschinen den Test auf ebenem

Grund durchfhren.
Bremssteuerdruck:
For a rolling machine, make the test on a horizontal ground.
Pilot brake pressure : minimum 12 bar [174 PSI]

Maximum 30 bar [435 PSI]
mini 12 bar
Maxi 30 bar.
Sich vergewissern, da der Bremsversorgungsdruck gleich Null ist,

Die Bremse ber die hchstgelegene Schraube
(112) entlften,
Den Motor mit Maximaldruck beaufschlagen,
Make sure that the brake supply pressure is zero,
Die Motorwelle darf sich nicht drehen, da andernfalls die Bremse ausgetauscht werden mu :
The motor shaft must not turn, otherwise it is necessary to replace the brake :
10
Purge the brake using the screw (112) located at

the highest level,
Supply the motor up to the setting pressure.
Mehrscheibenbremsen nicht einfahren.
REPAR MS2-18 D/GB
762
BOMAG
Do not run multidisc brakes in.
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Repairs.
Reparaturen.
Auswechseln der
kolbendichtung
Brems-
Replacement of the O-ring

of the brake piston.
Demontage
Disassembly
Remove the motor.

Place the motor on the bearing
support.
Den Motor ausbauen.

Motor auf das Lagerteil stellen.
Muttern zum Schutz der

Gewindebolzen wieder
aufsetzen
Schutzkappe (141) abnehmen

und beseitigen.
Protect the studs by

reinstalling the nuts
Remove and discard the brake

cover.(141)
141
6500
O-Ring (143) herausziehen und

beseitigen.
Extract and discard the O-ring

(143).
143
6501
Tellerfeder (108) zusammendrcken:
Compress the washer (108).
Mit Hilfe des Dorns und Abziehers (siehe Werkzeug Seite

36) (fig 6502)
Mit Hilfe des Dorns und einer
Schraube Klasse 12.9 (siehe
Werkzeug Seite 36)
Presse (fig 6503). Die Kraft F
beibehalten (siehe Schaubild
Seite 9)
Using a mandrel and an extractor (see tools page 36)

(fig 6502)
Using a mandrel and a
screw class 12.9 (see tools
page 36)
Using a mandrel and a press
(fig 6503). Respect the force F
(see table page 9)
Einsatzrichtung des Sicherungsrings markieren.
Mark the mounting direction of the snap ring.
6502
6503
800378128J
008 911 63
REPAR MS2-18 D/GB
BOMAG
11
763
16.5
POCLAIN HYDRAULICS
Sicherungsring (109) mit Hilfe
einer Zange fr Innenringe herausnehmen (siehe Werkzeuge Seite
36)
MS/MSE 02 ..... 18
Remove the snap ring (109)
using internal snap ring pliers. (see
tools page 36)
Extractor and pliers (fig 6504
and 6505)
Press and pliers (fig 6506
and 6507)
Abzieher und Zange (fig

6504 und 6505)
Presse und Zange (fig 6506
und 6507)
Bei Verwendung der Presse das Lagerteil nicht auf

den Gewindebolzen absttzen.
Tellerfeder (108) herausziehen.
6504
6505
6506
6507
If you use the press do

not place the bearing
support on the studs.
Extract the washer (108).
108
6508
Bremskolben (107) herausziehen.
Extract the brake piston (107)
6513
O-Ring (106) beseitigen.
Discard the O-ring (106).

106
6511
12
REPAR MS2-18 D/GB
764
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Wiedereinbau.
Vor dem Wiedereinbau ist unbedingt
sicherzustellen, da alle Teile, Nuten
und Dichtungs-Auflageflchen sauber
sind.
Reassembly.
Before reassembling, it is necessary to ensure that all parts, the
surface condition of the piston seal
contact surface and the grooves are
clean.
Es drfen keine Rost-,

Schmutz- oder Wasserspuren vorhanden sein
Mit Korrosionsschutzfett (siehe

Werkzeug Seite 36) einschmieren:
die Nut, die obere Flche des
Bremskolbens, die Tellerfeder, den
Sicherungsring und die Auflageflche
der Kolbendichtung im Bremsgehuse.
All traces of rust, mud,

water must be removed.
Neuen O-Ring (106) auf den

Kolben (107) montieren.
Coat with anti-oxidizing grease (see

tools page 36), the grooves, the top
of the brake piston, the spring
washer, the snap ring and the piston seal contact surface in the
brake body.
Install a new O-ring (106) on
the piston (107).
Der Ring mu fest an

den Kolben gepret und
nicht verdreht werden.
The ring should be tight

on the piston and not
twisted.
106
6512
Bremskolben (107) einsetzen.
Achtung,
wenn
die
Dichtung ber die Nut
des
Sicherungsrings
gefhrt wird.
Install the brake piston (107).
Take care when passing

the seal over the snap
ring groove.
107
6509
Tellerfeder
(108)
einlegen.
Install the spring washer (108).
108
6513
800378128J
008 911 63
REPAR MS2-18 D/GB
BOMAG
13
765
16.5
POCLAIN HYDRAULICS
Tellerfeder (108) zusammendrcken:
MS/MSE 02 ..... 18
Compress
(108).
the spring washer
Mit Hilfe des Dorns und Abziehers (siehe Werkzeug Seite

36) (fig 6502)
Presse (fig 6503). Die Kraft F
einbehalten (siehe Schaubild
Seite 9)
Using a mandrel and an extractor (see tools page 36)

(fig 6502)
Using a mandrel and a press
(fig 6503). Respect the force F
(see table page 9)
Bei Verwendung der

Presse das Lagerteil
nicht auf den Gewindebolzen absttzen.
If you use the press do

not place the bearing
support on the studs.
6502
6503
Sicherungsring (109) mit Hilfe

einer Zange fr Innenringe gem
der bei der Demontage angebrachten Kennzeichnung montieren: (siehe Werkzeuge Seite 36)
Abzieher und Zange (fig
6504 und 6505)
Presse und Zange (fig 6506
und 6507)
Install the snap ring (109) using

internal snap ring pliers in line with
the mark made during disassembly
. (see tools page 36)
6504
6506
Neuen, mit Korrosionsschutzfett

eingeschmierten O-Ring (143) in
die Nut einsetzen (siehe Werkzeuge Seite 36).
6505
Extractor and pliers (fig 6504

and 6505)
Press and pliers (fig 6506
and 6507)
Install a new O-ring (143)

coated with anti-oxidizing grease in
its groove. (see tools page 36)
6507
143
6515
Neue Schutzkappe (141) auf

den Anschnitt legen.
Place the new cover (141) on

the entry chamfer .
141
6516
14
REPAR MS2-18 D/GB
766
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Schutzkappe mit Hilfe des
Dorns einrasten lassen (siehe
Werkzeug Seite 36).
Click the cover into place using

the right mandrel. (see tools page
36).
Sich vergewissern, da
der Auenrand
des
Schutzkappe in die Nut
eingreift ist.
Make sure that the outer

edge of the cover is engaged in the groove.
6517
Neuen Stopfen (142) einsetzen.
Sich vergewissern, da
zwischen Schutzkappe
und Stopfenrille einwandfreier Kontakt besteht.
Install a new plug (142).
Make sure about the contact between the cover

and the plug groove.
142
6518
Motor wieder einsetzen.
800378128J
008 911 63
Install the motor.
REPAR MS2-18 D/GB
BOMAG
15
767
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Auswechseln
teiles (070)
des
Lager-
Replacement of the bearing

support (070)
Demontage
Disassembly
Motor herausnehmen.
Motor auf der Bremse oder Verschlussplatte absttzen (Motor ohne
Bremse).
Remove the motor.

Place the motor on the brake or on
the end cover (motor without
brake).
Position des Lagerteiles

(070) in Bezug auf Nockenring
(026) und Verteilerdeckel (040)
kennzeichnen.
Mark the position of the

bearing support (070) in relation to
the cam (026) and to the valving
cover (040).
070
025
040
Schrauben
nehmen.
(042)
heraus-
6519
Remove the screws (042).
042
6520
Lagerteil (070) herausnehmen.
Remove the bearing support

(070).
070
6521
Nockenring
nehmen.
(026)
heraus-
Remove the cam (026).

026
6524
16
REPAR MS2-18 D/GB
768
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
O-Ring (027) vom Verteilerdeckel (041) entfernen.
Discard the O-ring (027)

from the valving cover (041).
027
041
6525
O-Ring (027) vom Lagerteil

(071) entfernen.

from the bearing support (071)
027
071
6522
800378128J
008 911 63
REPAR MS2-18 D/GB
BOMAG
17
769
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Wiedereinbau
Reassembly
Vor dem Wiedereinbau ist unbedingt sicherzustellen, da die Nut

sauber ist
Before reassembling it is necessary

to ensure that the groove is clean

Schmutz- oder Wasserspuren vorhanden sein.

water must be removed
Neuen,
mit
Korrosionsschutzfett eingeschmierten O-Ring
(027) in die Nut des Lagerteiles
(071) einsetzen (siehe Werkzeuge
Seite 36) .

coated with anti-oxidizing grease
(see tools page 36) in the groove of
the bearing support (071).
027
071
6523
Neuen,
mit
Korrosionsschutzfett eingeschmierten O-Ring
(027) in die Nut des Verteilerdekkels (041) einsetzen (siehe Werkzeuge Seite 36) .

coated with anti-oxidizing grease
(see tools page 36) in the groove of
the valving cover (041)
041
6525
Nockenring (026) gem der

bei der Demontage markierten
Kennzeichnung montieren.
Groe Ansenkungen in
Richtung Lagerteil
Den Nockenring anhand von zwei

einander
gegenberliegenden
Schrauben (042) zentrieren.
18
Install the cam (026) in line

with the marks made during disassembling.
The big chamfers oriented

towards bearing support
Center the cam using two screws

(042) diametrically opposite.
REPAR MS2-18 D/GB
770
026
BOMAG
6526
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Lagerteil montieren
Bei
Wellenmotoren
mssen die Anschlsse
quer zur Einbauachse
des
Motors
liegen.
(Abb. 6521)
Install the bearing support

For shaft motors the
ports must be perpendicular to the mounting
axis of the motor. (Fig
6521)
6521
A
6527
Befestigungsschrauben (042)
einsetzen und mit dem angegebenen Drehmoment anziehen. (siehe
Schaubild Seite 38).
Install and tighten the mounting

screws (042) to the right torque.
(see table page 38).
042
6520
Motor wieder einsetzen.
800378128J
008 911 63
Install the motor.
REPAR MS2-18 D/GB
BOMAG
19
771
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Auswechseln der
backen
Brems-
Vor der Demontage kann man die

Abnutzung der Bremsbelge durch
die Inspektionsffnungen kontrollieren.
Replacing the brake shoes.
Before disassembling it is possible

to make a visual checking of the
brake pads wear via the inspection
ports.
2055
Demontage
Disassembly
Das Auswechseln des

Bremsbacken und das
Schleifen der Trommeln
mu auf allen Motoren
der gleichen Achse vorgenommen werden.
The
same
repairs
should be made on
each motor of the same
axle when replacing
shoes
and
brake
drums.
Befestigungsmuttern der Felge

lsen.
Maschine auf der Hhe der
auszubauenden Felge hochheben.
Rad abnehmen (Reifen).
Mechanische Bremse lsen.
Loosen the wheel rim retaining

nuts.
Raise the machine on the side
of the wheel rim to be removed.
Remove the wheel rim (tyre).
Release the mechanical brake.
Trommel (096) abziehen.
20
Reibflche der Trommel

berprfen, die weder tiefe
Rillen (tiefer als 0,2 mm)
noch abnormale Abnutzungserscheinungen aufweisen darf, sonst mu
sie geschliffen werden.
(Ra 1,6 bis 3,2)
Extract the drum (096).
Check the friction surface condition of the

drum which should show
no
deep
scratches
(deeper than 0,2 mm
[0.0078 in]) nor abnormal
wear. Otherwise, the
brake drum should be
replaced. (Ra 1.6 to 3.2)
REPAR MS2-18 D/GB
772
BOMAG
096
6528
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Rckholfeder (154.a) abbauen.
Remove
(154.a).
the
return
spring
154.a
6529
6530
Halterungsfedern (154.b) abbauen.
Remove the retention springs

(154.b).
154.b
2
6531
Bremsbacken aus der Bettigungsvorrichtung lsen.
Release the brake shoes from

the regulating mechanism.
6532
Rckholfedern (154.c) abbauen.
Remove
(154.c).
the
return
springs
154.c
6533
800378128J
008 911 63
REPAR MS2-18 D/GB
BOMAG
21
773
16.5
POCLAIN HYDRAULICS
Bremsbacke (154.1) abbauen.
MS/MSE 02 ..... 18
Remove the brake shoe (154.1)
154.1
6534
Den mechanischen Bremshebel

vom Bremsseil lsen und Bremsbacke (154.2) entfernen
Releasing the mechanical brake

control lever from its cable, remove
the brake shoe (154.2)
154.2
6535
6536
22
REPAR MS2-18 D/GB
774
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Wiedereinbau
Vorrichtung
entstauben, sich vergewissern,
da der Radzylinder
dicht ist.
Reassembly
Remove all dust from the

whole assembly. Make
sure there are no leaks at
the wheel cylinder.
Reibflche der Trommel berprfen, die weder tiefe Rillen (tiefer als
0,2 mm) noch abnormale Abnutzungserscheinungen
aufweisen
darf, sonst mu sie geschliffen
werden.
Check the friction surface condition

of the drum which should show no
deep scratches (deeper than 0.2
mm) [0.0078in] nor abnormal wear.
Otherwise, the brake drum should
be replaced.
Den Bremshebel am Bremsseil

(098) befestigen und Bremsbacke
(154.2) einbauen
Attaching the control lever on

the brake cable (098), install the
brake shoe (154.2)
6549
098
154.2
6536
6535
800378128J
008 911 63
REPAR MS2-18 D/GB
BOMAG
23
775
16.5
POCLAIN HYDRAULICS
Rckholplatte an die Bremsbacke (154.2) montieren.
MS/MSE 02 ..... 18
Mount the return plate on the
brake shoe (154.2)
6537
6538
Bremsbacke (154.1) einsetzen.
Install the brake shoe (154.1)
6539
Bremsbacken auf der Bettigungseinrichtung positionieren.
Position the brake shoes on the

regulating mechanism.
6532
Rckholfedern (154.c) einsetzen.
Install the return springs (154.c)
154.c
6533
24
REPAR MS2-18 D/GB
776
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Bremsbacken in die Bettigungseinrichtung einbauen.
Install the brake shoes in the

regulating mechanism
6532
Halterungsfedern (154.b) einsetzen.
Install
(154.b).
the
retention
springs
1
154.b
2
Rckholfedern (154.a) einsetzen.
6531
Install the return spring (154.a).
154.a
6530
Reibungsdurchmesser D der
Trommel und der eingesetzten Backen messen.
Measure the brake drum friction

diameter D and that of the brake
shoes, which have been installed.
Durchmesser D diameter
6529
800378128J
008 911 63
REPAR MS2-18 D/GB
BOMAG
25
777
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Backendurchmesser anpassen,
um bei Bremsen mit mechanischer
Einstellvorrichtung mit Hilfe des einen Zahnrads (156.1), oder bei
Bremsen mit automatischer Bremsennachstellung mit Hilfe der zwei
Zahnrder (156.2 und 156.3), das
ntige Spiel zwischen Belag und
Trommel zu erzielen. In diesem
Fall mu die Wirkung auf die Zahnrder symmetrisch (a) sein. Den
Hebel (156.4) muss zu diesem
Zweck freigngig sein.
Bremsen
Brake
250 x 60
Adjust the brake shoes diameter to obtain correct clearance between the brake padding and the
drum using the adjusting wheel
(156.1) for brakes equipped with
mechanical adjustment system or
two adjusting wheels (156.2 and
156.3) for brakes equipped with
automatic clearance adjustment. In
this case, the adjusting wheels
should be adjusted symmetrically
(a). Release the lever slightly
(156.4) to enable this operation to
take place.
Trommeldurchmesser (mm)
Drum diameter [in]
nominal
maximum
250 [9.84]
252 [9.92]
325 x 80
270 [10.63]
325 [12.79]
272 [10.70]
327 [12.87]
350 x 60
350 [13.78]
352 [13.85]
270 x 60
Trommel aufsetzen und berprfen, ob sie frei dreht.
1 5 6 .4
1 5 6 .2
1 5 6 .3
6540
Total Spiel (mm)

Total clearance [in]
0.55 [0.02]
0.80 [0.03]
0.80 [0.03]
0.80 [0.03]
Install the drum, check that it

can turn freely.
6528
Wenn ntig, den Radzylinder

entlften.
Felge montieren.
Siehe Dokument INSTALLATION
MS D/GB (ref: 800078173V)
26
Bleed the wheel cylinder, if

necessary.
Install the wheel rim.
See documentation INSTALLATION
MS F/GB (ref 677777844K )
REPAR MS2-18 D/GB
778
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Auswechseln des Nockenrings (026)
Replacement of the cam

(026)
Demontage
Dazu die im Kapitel Auswechseln
des Lagerteils unter Demontage
beschriebenen Arbeiten ausfhren,
Seite 16
Wiedereinbau
des Lagerteils unter " Wiedereinbau " beschriebenen Arbeiten ausfhren, Seite 18.
Allerdings mu bei Motoren mit 2
Schluckvolumen
mit
einem
Schluckvolumenverhltnis
ber
oder unter 2 die Winkelposition bercksichtigt werden.
Beispiel: Motor MS18, Schluckvolumen 1747-1049-698
3
Kleines Schluckvolumen: 698 cm
Buchstabe P
3
Mittleres Schluckvolumen: 1 049 cm
Buchstabe M
Die Buchstaben P oder M mssen
sich in der Achse befinden und in
Richtung des Schiebers fr das
Wechseln des Schluckvolumens
zeigen, auf der der Nockenring auf
dem Lagerteil befestigt ist.
Disassembly
Do operations described in chapter
"replacement of the bearing support" section "disassembly" page 16
Reassembly
"replacement of the bearing support" section "reassembly" page 18.
The angular position of the cam
must be respected on dual displacement motors with a displacement ratio different from 2.
Example : Motor MS18 with displacement 1747-1049-698.
3
Small displacement : 698 cm
[42.59 cu.in] letter P
3
Medium displacement : 1049 cm
[64.01 cu.in] letter M.
The letter P or M must be located in
the axis and towards the displacement change spool, with the blind
hole towards the fixing of the cam
on the bearing support.
M
M
MS08
MSE08
A
R A
MS18
MSE18
MS11
MSE11
R A
800378128J
008 911 63
2035
REPAR MS2-18 D/GB
BOMAG
27
779
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Auswechseln des kompletten Zylinderblocks (010)
Replacement of the cylinders block assembly (010)
Demontage
Disassembly

des Lagerteils unter Demontage
beschriebenen Arbeiten ausfhren,
Seite 16

"replacement of the bearing support" section "disassembly" page 16
Nach Demontage des Nockenrings den Zylinderblock ausbauen.
After removing the cam, remove the cylinders block.
6541
Wiedereinbau
Reassembly
Neuen O-Ring (027) einsetzen.
Install a new O-ring (027).
6542
Kompletten Zylinderblock (010)

einsetzen.
Install the cylinders block assembly (010).
6541
Dazu
die
im
Kapitel
Auswechseln des Lagerteils unter
"Wiedereinbau" beschriebenen Arbeiten ausfhren, Seite 18
28
Do operations described in
chapter "replacement of the bearing
support" section "reassembly" page
18
REPAR MS2-18 D/GB
780
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Auswechseln des Verteilers

(047).
Replacement of the valving

(047).
Demontage
Disassembly
Dazu
die
im
Kapitel
Auswechseln des kompletten Zylinderblocks
(010)
unter
Demontage beschriebenen Arbeiten ausfhren, Seite 28.
chapter "replacement of the cylinders bloc assembly (010)" section
"disassembly" page 28.
Position des Verteilers

(047) in Bezug auf Verteilerdeckel (041) kennzeichnen. (Motor mit 2
Hubvolumen).
Mark location to the

valving (047) in relation
to the valving cover
(041) (Dual displacement motor).
Den Verteiler (047) durch Anheben an den Ausrichtungszapfen

oder am Flansch vom Verteilerdekkel (041) abmontieren.
Separate the valving (047) from

the cover (041) by levering at the
indexing pins or at the flange.
2031
Den Verteiler vor Staub

schtzen.
Protect the valving from

dusts.
Federn (052) ausbauen.

Dichtungen und Gegendichtungen (048) vom Verteilerdeckel
(041) herausziehen und beseitigen.
Remove the springs (052).

Remove and discard the seals
and back-up rings (048) from the
cover (041).
Wiedereinbau
Reassembly

Schmutz- oder Wasserspuren vorhanden sein.
Neue Dichtungen und Gegendichtungen (048) len und einsetzen; dabei die Gegendichtungen so
wenig wie mglich verformen.

water must be removed.
Lubricate and install new seals

and back-up rings (048), ensuring
the back up rings are twisted as little as possible.
1135
Die Federn (052) in ihr zuvor

mit Fett geflltes Gehuse einsetzen.
Die
Dichtungsauflageflchen
des Verteilers (047) fetten.
Den Verteiler(047) in den Verteilerdeckel (041) drcken
800378128J
008 911 63
Place the springs (052) in their

housings, previously filled with
grease.
Lubricate the faces of the seals
of the valving (047).
Press the valving (047) into the
cover (041).
REPAR MS2-18 D/GB
BOMAG
29
781
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Die Einbaurichtung des

Verteilers (047) in bezug
auf den Verteilerdeckel
(041) beachten).
Den Einsatz des Verteilers (047) in den Verteilerdeckel (041) nicht

forcieren.
Respect the assembly

sense of the valving
(047) in relation to the
cover (041).
Do not force when installing

the
valving
(047) into the cover
(041).
Montage der Verteilerausfhrung 1C (konstanter

Hubvolumen).
Valving assembly type single displacement motor.
Keine besondere Montagerichtung.
No particular assembly sense.
041
047
Montage der Verteilerausfhrung

2C
(umschaltbarer
Hubvolumen).
Valving assembly type Dual

displacement motor.
Den gewhlten Buchstaben, der

die Drehrichtung anzeigt, gegenber dem Steuerkolben (053) anordnen.
Write the chosen letter indicate

the rotation sense in front of the
displacement change spool (053).
POSITIONIERUNG DES VERTEILERS

G/L Links
VALVING POSITIONING
2031
G/L Left
041
R
047
L
053
6758
R
053
3 2 2 7
30
REPAR MS2-18 D/GB
782
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
D/R Right
D/R Rechts
047
R
041
L
6757
R
A
053
3 2 2 8
Falls kein Buchstabe vorhanden

ist, die Ausrichtung anhand der beim
Ausbau festgelegten Markierungen
vornehmen.
If there is no letter, do the indexing according to the marks

made during disassembly.
Dazu
die
im
Kapitel
Auswechseln des kompletten Zylinderblocks
(010)
unter
Wiedereinbau beschriebenen Arbeiten ausfhren, Seite 28.
chapter "replacement of the cylinders block" section "reassembly"
page 28.
Motoren SE02 und S05
Situation of SE02 and S05 motors
SE02 Motor :
SE02 motor :
D/R Rechts
D/R Right
G/L Links
G/L Left
6959
6 9 5 9
S05 Motor :
S05 motor
G/L Links
G/L Left
D/R Rechts
D/R Right
053
6 9 4 8
6948
800378128J
008 911 63
REPAR MS2-18 D/GB
BOMAG
31
783
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Auswechseln der Deckeldichtung (045)
Replacement of the O-ring

(045) of the end cover
Demontage
Disassembly
Motor auf Lagerteil stellen

(Muttern sind zum Schutz der Gewindebolzen aufgesetzt)
Schrauben (066) herausnehmen.
Place the motor on the bearing

support (fitted with nuts for studs
protection)
Remove the screws (066)
066
6543
Verschlussplatte abnehmen.
Remove the end cover
6544
O-Ring (045) entfernen.

045
057
6545
Wenn Motor mit 2 Hubvolumen, O-Ring (057) entfernen
Discard the O-ring (057) if the

motor has 2-displacement
6546
32
REPAR MS2-18 D/GB
784
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Wiedereinbau
Reassembly
Install
Neuen O-Ring (045) einsetzen.
new
O-ring
(045).
6547
Wenn Motor mit 2 Hubvolumen, neuen O-Ring (057) einsetzen, andernfalls zum nchsten
Schritt bergehen
Install a new O-ring (057) if the

motor has 2-displacement. If not go
to the next section
6548
Verschlussplatte montieren.
Install the end cover
6544
Schrauben (066) einsetzen und

mit entsprechendem Drehmoment
anziehen (siehe Schaubild Seite 38)
Install and tighten the screws

(066) to the right torque (see table
page 38)
6543
800378128J
008 911 63
REPAR MS2-18 D/GB
BOMAG
33
785
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Auswechseln des Drehzahlsensors (Option)
Replacing the sensor (optional)
Demontage
Disassembly
Disconnect
(161.3)
Stecker (161.3) abziehen
the
connector
6550
Schraube (165) aufschrauben

und ausbauen
Unscrew and remove the screw

(165)
165
6551
Sensor (161) mit dem Trger

(166) abziehen
Extract the sensor (161) with its

support (166)
166
161
6552
34
REPAR MS2-18 D/GB
786
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Reassembly
Wiedereinbau
Der Dichtung (164) auf

Sauberkeit der Auflageflche dem Verteilerdeckel (041) prfen.
Make sure that the seal

mounting surface (164)
on the valving cover
(041) is clean.
Neuen Haltering (163) und

neue Dichtung (164) auf den Sensor (161) mit seiner Distanzscheibe
(167) schieben.
Install the new brake washer

(163) and the new seal (164) on the
sensor (161) fitted with its adjusting
sticker (167).
Den Sensor in die Halterung

(166) stecken, so da die Dichtung
(164) korrekt in ihrer Aufnahme
sitzt.
Push the sensor assembly into

the support (166) until the seal
(164) is in its housing.
6552
Sensor (041) in die Bohrung

des Verteilerdeckels bis zum Kontakt mit dem Zylinderblock (011)
schieben.
Push the sensor into the valving

cover (041) until it comes in contact
with the cylinders block (011),
2064
Die Kerbe im Steckeranschluss des

Sensors muss radial zur Mitte des
Motors (Richtung Welle) zeigen.
the notch of the sensor should be

oriented towards the center of the
motor.
1 5 m a x i
1 5 m a x i
6558
Schrauben (165) einsetzen und

mit entsprechendem Drehmoment
anziehen (siehe Schaubild Seite
38)
Install and tighten the screw

(165) to the right torque (see table
page 38)
6551
Stecker
schlieen.
(161.3)
wieder
an-
Reconnect
(161.3).
the
connector
6550
800378128J
008 911 63
REPAR MS2-18 D/GB
BOMAG
35
787
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Tooling inventory
Werkzeug-Liste
Standard tools
Standard Werkzeug
Innensechskant-Schlssel
Ring-/Maulschlssel fr
Sechskantschraube
Hollow head
wrench
5 6 8 10 12 14
Hex head wrench
13 17 19 22 24
Drehmoment-Schlssel
FACOM J 250 A
Drehmoment-Schlssel
FACOM S 250 A Torque wrench
50 bis 240 N.m [35 to 175 lbf.ft]
Drehmoment-Schlssel
FACOM K 250 A Torque wrench
160 bis 800 N.m [120 600 lbf.ft]
Korrosionsschutzfett
Auto-top
2000 Anti-oxidizing
grease
origine AGIP
Leuchtend grne Farbe / fluorescent green color
Zange fr Innenringe
Abzieher
FACOM 499.32
FACOM U 20 B
Torque wrench
6 bis 30 N.m [4.4 to 22.1 lbf.ft]
Internal snap ring

pliers
Extractor
6553
Sechskantschlssel fr
Innensechskantschraube
Hex head wrench
13 17 19 22 24
Drehmoment-Schlssel
FACOM J 250 A
Drehmoment-Schlssel
FACOM S 250 A Torque wrench
50 240 N.m [35 to 175 lbf.ft]
Drehmoment-Schlssel
FACOM K 250 A Torque wrench
160 800 N.m [120 600 lbf.ft]
36
Torque wrench
REPAR MS2-18 D/GB
788
BOMAG
6 30 N.m [4.4 to 22.1 lbf.ft]
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Special tools
Spezialwerkzeuge
Mandrel for reassembling the

brake cover or to compress the
spring washer.
Montagewerkzeug
zum
Anheben
der
Schutzkappe oder zum
Komprimieren der Tellerfeder.
D
0759
F02
mm
[inch]
mm
[inch]
110
[4.3]
100
[4.0]
mm [inch]
125
[4.9]
mm
135
[inch]
[inch]
mm
mm
[inch]
mm
[inch]
[5.3]
F03
F04
M12
F05
125
[4.92]
115
[4.52] 151 [5.94]
159
[6.25]
125
[4.92]
115
[4.52] 151 [5.94]
159
[6.25]
50
[1.96]
10
[0.39]
20
[0.78]
50
[1.96]
10
[0.39]
20
[0.78]
50
[1.96]
20
[0.78]
30
[1.18]
F07
F08
F09
F11
F12
M16
F18
190
[7.48]
180
[7.08] 205 [8.07]
215
[8.46]
F19
[0.39]
10
[2.75]
70
Rohr zum Festsetzen

des Motors
Tube to immobilize the motor
2 5
[0 .9 8 " d ia ]
F21
1 6
[0 .6 2 " d ia ]
5 5
[2 .1 6 " ]
7 0 0
[2 7 .5 5 " ]
M 1 2
H
x 1 2 0
M 1 6 x 1 2 0
c l. 1 0 .9
M 1 2
H M 1 6
Z 1 2 N
Werkzeuge zur mechanischen

Bremslsung.
800378128J
008 911 63
Tools for mechanical

brake
release
REPAR MS2-18 D/GB
BOMAG
A = 2 0 0
A = 2 8 0
F 0 2
F 0 3
F 0 4
F 0 5
F 0 7
F 0 8
F 0 9
F 1 1
F 1 2
F 1 8
F 1 9
F 2 1
6 0 x 3 0
1 6 .5
[0 .6 4 ]
5 0 x 5
37
789
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Anziehdrehmomente
Nm 10%
Tightening torques
in [lbf.ft] 10%
(Gem Norm DIN 912)
(According to the standard DIN 912)
Gre Size
8.8
10.9
12.9
8.8
10.9
12.9
M6
M8
M10
M12
M14
M16
M18
M20
10
25
49
86
135
210
290
410
14
35
69
120
190
295
405
580
17
41
83
145
230
355
485
690
7.5
18.4
36
63.4
100
155
214
302
10
26
51
88.4
140
218
299
428
12.5
30
61
107
170
262
358
509
38
REPAR MS2-18 D/GB
790
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Ersatzteile
Spare parts list

Item
Description
010
Cylinders-block assembly
012
Piston Cl 0 assembly
013
Piston Cl 1 assembly
015
Repair kit
Nummer
Bezeichnung
010
Kompletter Zylinderblock
012
Kompletter Kolben Cl. 0
013
Kompletter Kolben Cl. 1
015
Reparatursatz
026
040
041
042
043
044
045
047
048
050
051
052
053
054
055
056
057
059
065
026
Kompletter Nockenring
027 O-Ring
040
Komplettes Verteilerdeckel
Verteilerdeckel
Schraube
Dichtungsring
Schraube
O-Ring
Verteiler
Dichtungssatz
Stopfen
O-Ring
Feder
Umschaltkolben
Scheibe
Sicherungsring
Feder
O-Ring
Stift
041
042
043
044
045
047
048
050
051
052
053
054
055
056
057
059
Kompletter Verschlussplatte
066 Schraube
067 Dichtring
065
Komplettes Lagerteil
Lagerteil
Innerer Lippendichtring
Rollenlager
Rollenlager
Scheibensatz
Sttzring
Sicherungsring
uerer Dichtring
Abweiser
Dichtungstrger
Passfeder
Welle
Radbolzensatz
Bremstrommel
Schraube
Bremsseil
Sicherungsring
Komplette Bremsbacke
Kompletter Radzylinder
Gegenhalter
070
070
071
072
073
074
075
076
077
078
079
081
087
090
091
096
097
098
099
154
155
156
800378128J
008 911 63
Cam assembly
027 O-ring
End cover assembly

066 Screw
067 Sealing ring
071
072
073
074
075
076
077
078
079
081
087
090
091
096
097
098
099
154
155
156
REPAR MS2-18 D/GB
BOMAG
Valving cover assembly

Valving cover part
Screw
Seal washer
Screw
O-ring
Valving
Seal kit
Plug
O-ring
Spring
Valve spool
Washer
Snap ring
Spring
O-ring
Pin
Bearing support assembly

Bearing support part
Radial lip seal
Roller bearing
Roller bearing
Set of shims
Thrust ring
Snap ring
Lip seal
Deflector
Seal support
Key
Shaft
Set of studs
Drum brake
Screw
Brake cable
Snap ring
Brake shoe sub-assembly
Brake cylinder sub-assembly
Brake adjustment
39
791
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Nummer
100
101
102
106
107
108
109
110
111
112
113
135
141
142
143
150
Item
100
Bezeichnung
Komplette Bremse
Bremsgehuse
Schraube
O-Ring
Kolben
Tellerfeder
Sicherungsring
Welle
Dichtsatz Bremswelle
Schraube
Dichtungsring
Satz Bremslamellen
Schutzkappe
Stopfen
O-Ring
101
102
106
107
108
109
110
111
112
113
135
141
142
143
150
Drehzahlsensor-Vorbereitung
152 Scheibe
153 Scheibe
160
161
162
163
164
161
162
163
164
REPAR MS2-18 D/GB
792
Speed sensor assembly

Speed sensor part
Nut
Washer
Seal
Sub-assembly sold assembled
Als Satz lieferbare Baugruppe
40
Speed sensor predisposition

152 Washer
153 Washer
160
Kompletter Sensor
Sensor
Mutter
Scheibe
Dichtung
Description
Brake assembly
Brake body
Screw
O-ring
Brake piston
Spring washer
Snap ring
Brake shaft
Seal
Screw
Seal washer
Brake kit
Cover
Plug
O-ring
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
800378128J
008 911 63
REPAR MS2-18 D/GB
BOMAG
41
793
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Motoren mit konstantem Hubvolumen MS, MSE 02-05-08-11-18.

Single displacement motors MS, MSE 02-05-08-11-18.
0987
42
REPAR MS2-18 D/GB
794
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Dichtungssatz
Seal kit
800378128J
008 911 63
REPAR MS2-18 D/GB
BOMAG
0988
43
795
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Motoren mit umschaltbarem Hubvolumen MS, MSE 02-05-08-11-18.

Dual displacement motors MS, MSE 02-05-08-11-18.
0990
44
REPAR MS2-18 D/GB
796
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
Dichtungssatz
Seal kit
800378128J
008 911 63
REPAR MS2-18 D/GB
BOMAG
0989
45
797
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
46
REPAR MS2-18 D/GB
798
BOMAG
800378128J
008 911 63
16.5
MS/MSE 02 ..... 18
POCLAIN HYDRAULICS
800378128J
008 911 63
REPAR MS2-18 D/GB
BOMAG
47
799
16.5
MS/MSE 02 ..... 18
China
Espaa & Portugal
POCLAIN HYDRAULICS BEIJING rep. office

Unit A0808, Hui Bin Officies
No.8 Beichendong St.
BEIJING 100101
CHINA
Tel.: 86 10 6499 3988
Fax: 86 10 6499 3979
e-mail: info-china@poclain-hydraulics.com
POCLAIN HYDRAULICS SPAIN S.L.

Gran Via Carlos III no84 1o 3a
08028 BARCELONA
ESPAA
Tel.: 349 3 409 54 54
Fax: 349 3 490 21 79
e-mail: info-espana@poclain-hydraulics.com
France
POCLAIN HYDRAULICS SRO
Krova 186
61900 BRNO
Tel.: 420 5 43217830
Fax: 420 5 43217818
e-mail: info-ceskarepublika@poclain-hydraulics.com
POCLAIN HYDRAULICS France SAS

B.P. 106
60411 VERBERIE CEDEX
FRANCE
Tel.: 33 3 44 40 77 77
Fax: 33 3 44 40 77 91
e-mail: info-france@poclain-hydraulics.com
Deutschland
Japan
POCLAIN HYDRAULICS GMBH

Bergstrasse 106
64319 PFUNGSTADT
DEUTSCHLAND
Tel.: 49 6157 9474 0
Fax: 49 6157 9474 74
e-mail: info-deutschland@poclain-hydraulics.com
POCLAIN HYDRAULICS KK
5-4-6 Kugenumashinme
FUJISAWA 251
JAPAN
Tel: 81 466 50 4400
Fax: 81 466 50 4422
e-mail: info-japan@poclain-hydraulics.com
Italia
United Kingdom
POCLAIN HYDRAULICS SRL

Via Svizzera 4/A
41012 CARPI (MODENA)
ITALIA
Tel.: 390 59 64 22 44
Fax: 390 59 64 20 44
e-mail: info-italia@poclain-hydraulics.com
POCLAIN HYDRAULICS LTD

Nene Valley Business Park
Oundle
PETERBOROUGH, Cambs PE8 4HN
ENGLAND
Tel.: 44 1832 273773
Fax: 44 1832 274990
e-mail: info-uk@poclain-hydraulics.com
Nederland
USA
POCLAIN HYDRAULICS BENELUX BV

Penningweg 32C
4879 AM ETTEN-LEUR
NEDERLAND
POCLAIN HYDRAULICS INC.

7900 Durand Avenue
P.O. BOX 801
STURTEVANT, WI 53177
USA
Tel.: 1 262 554 6739
Fax: 1 262 554 4860
e-mail: info-america@poclain-hydraulics.com
Tel.: 31 76 5021152
Fax: 31 76 5012279
e-mail: info-netherlands@poclain-hydraulics.com
POCLAIN HYDRAULICS INDUSTRIE

B.P. 106
60411 VERBERIE CEDEX - France
Tel.: 33 3 44 40 77 77
Fax: 33 3 44 40 77 99
e-mail: info@poclain-hydraulics.com
www.poclain-hydraulics.com
800
S.A.S. au capital de 85 124 000 Francs

Sige social: Route de Saint Sauveur
VERBERIE (OISE)
R.C.S. Senlis B 414 781 823
Siret 414 781 823 00011
BOMAG
008 911 63
16.6 Axle DANA 192
008 911 63
BOMAG
801
16.6
802
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
803
16.6
804
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
805
16.6
806
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
807
16.6
808
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
809
16.6
810
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
811
16.6
812
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
813
16.6
814
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
815
16.6
816
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
817
16.6
818
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
819
16.6
820
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
821
16.6
822
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
823
16.6
824
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
825
16.6
826
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
827
16.6
828
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
829
16.6
830
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
831
16.6
832
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
833
16.6
834
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
835
16.6
836
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
837
16.6
838
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
839
16.6
840
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
841
16.6
842
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
843
16.6
844
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
845
16.6
846
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
847
16.6
848
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
849
16.6
850
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
851
16.6
852
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
853
16.6
854
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
855
16.6
856
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
857
16.6
858
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
859
16.6
860
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
861
16.6
862
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
863
16.6
864
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
865
16.6
866
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
867
16.6
868
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
869
16.6
870
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
871
16.6
872
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
873
16.6
874
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
875
16.6
876
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
877
16.6
878
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
879
16.6
880
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
881
16.6
882
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
883
16.6
884
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
885
16.6
886
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
887
16.6
888
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
889
16.6
890
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
891
16.6
892
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
893
16.6
894
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
895
16.6
896
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
897
16.6
898
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
899
16.6
900
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
901
16.6
902
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
903
16.6
904
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
905
16.6
906
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
907
16.6
908
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
909
16.6
910
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
911
16.6
912
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
913
16.6
914
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
915
16.6
916
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
917
16.6
918
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
919
16.6
920
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
921
16.6
922
Axle DANA 192
BOMAG
008 911 63
16.6
Axle DANA 192
008 911 63
BOMAG
923
16.6
924
Axle DANA 192
BOMAG
008 911 63
17 Circuit diagrams
008 911 63
BOMAG
925
Circuit diagrams
l
The circuit diagrams valid at the date of printing are

part of these repair instructions.
The circuit diagrams valid for the machine serial

number can be found in the spare parts catalogue
for the machine.
926
BOMAG
008 911 63
17.1 Wiring diagram
008 911 63
BOMAG
927
17.1
Wiring diagram
Wiring diagram 582 702 06 from serial number

101 583 091 001
101 583 101 001
101 582 421 001
101 582 471 001
101 582 431 001
101 582 481 001
101 582 461 001
101 582 501 167
101 583 081 001
101 583 131 001
101 582 441 001
101 582 491 001
101 582 721 113
101 582 731 001
928
BW 211 D-4
BW 211 PD-4
BW 211 D-40
BW 211 PD-40
BW 212 D-40
BW 212 PD-40
BW 213 PD-4
BW 213 D-4
BW 213 D-4
BW 213 PD-4
BW 213 D-40
BW 213 PD-40
BW 219 D-4
BW 219 PD-4
BOMAG
008 911 63
008 911 63
001
002
003
004
005
006
007
008
009
010
101
Blatt Nr.:
sheet no.:
582 702 09
582 702 09
582 702 09
582 702 09
582 702 09
582 702 09
582 702 09
582 702 09
582 702 09
582 702 09
582 702 09
16.11.2005
Vogt
16.11.2005
Seis
Stromlaufplan
circuit diagram
Stromlaufplan
Versorgung, Starten, Motordrehzahl
MotorHeizflansch, Signalhorn, GeschwindigkeitAnz.
Bremse, Rckfahrwarneinr., Anzeige
Fahrstufen, Sitzkontaktsch., Vibration
ZA Messtechnik
BOMAG Compaction Management BCM
ZA Beleuchtung und StvZO
ZA Kabine, Beleuchtung, Radio, Tachograph
ZA Kabinenheizung, Klimaanlage, Zusatzheizung
Bauteilliste
Funktionsgruppe
BW 177..219 D4/D40
BW 177..219 D4/D40
Zeichnungsnummer
drawing no.
Inhaltsverzeichnis:
table of contents:
001
001
BOMAG
001
582 702 09
Circuit Diagram
supply, starting unit, enginespeed
engine heatingflange cont., warning horn, speedometer
brake, back up alarm, indicator
speedranges, seatswitch, vibr.
option measurement equipm.
opt. illumination and StvZO
opt. cabin, headlights, radio, tachograph
opt. cabinheater, air conditioning, add. heater
component listing
function unit
Wiring diagram
17.1
929
87(4)
Sicherung Heizflansch
F48
G03 +
S30
heatingflange
G01 +
F00 2
X36:A
Option
option
Trennschalter Batterie
break switch battery
Batterie
Heizflansch
heatingflange
battery
31
R19
3:5
167A
K14
125A
30(3)
125A
X1:10
X36:B
16.05.2005
Vogt
16.05.2005
Seis
Batterie
battery
X1
X1
K36
4:4
K61
6:2
85
86
30A
X37:A
X1:15A
X1
3:2
85
86
M01
B+
2:5
K11:86
X1:4
79
Starter
starter
50
X38:A
K05/87
S120
Startmehrmenge
start boost fuel
12
X1
80
87
2:16
K114
11
X1
30
3:2
87a
K35
2:16
15:54
Y01 2
X1:53
87a
30
50a
X1 X1
7 8
4:3
87
K05
X37:B
19 17
30
54 58
15:54
2:13
30
Versorgung, Starten, Motordrehzahl

supply, starting unit, enginespeed
2:18
15
X1:55
K11
X1:3
Startschalter
starting switch
87a
30
K09
X1:168
10:7
85
86
4:13
2:5
R10
82 OHM
87
K61/85
D+ MESX
X1:66
D+
65
85
86
Generator
generator
2:8
G02
B+
125mA
K61
2:11
V01
B+
S00
nur bei Klimaanlage

only acc.to air conditioning
2:10
85
AW
+ HW
2x2.5qmm
X1 X1
58 59
87
S01
X1
17A
17E
K11
2:10
87
Hubmagnet Drehzahl
sol. engine speed
62 63
X1 X1
70A/1A
Y120
V47
X1:60
K35
30
86
87a
K114
2:14
2:13
X1:56
85
86
81
24
23
X1
20A
F105
X1
4qmm
F13
125mA
X1:9
Hauptsicherung
main fuse
311
Schalter Motordrehzl
switch engine speed
3.9A
9:2
AUX
X1
55
87a
30
54
1
2
12
11
15A
32
31
31
S01:21
F14:2
K32:86
X1:30A
1 F39
X1:30E
3:1
5:9
5:9
9:2
K11/87 3:1
30 6:1
008 911 63
002
582 702 09
X1:152
22
21
27A
27E
87a
30
Kraftstoffabschaltug
fuel shut off
Y13
X1
87
4:9
K22
NOTAUS
Emerg.Stop
X1:151
X1
15A
F14
nur ohne Sitzkontaktschalter

without switch seatcontact
X1:15E
50A / 10A
BOMAG
3.8A
4:5
930
6:5
K30
17.1
Wiring diagram
nur bei BW 219D4 und D40 USA Version, sonst Option

only at BW 219 D4 and D40 USA version, otherwise option
2:20
2:13
31
Modul Heizflanschsteuerung
modul heatingflangecontrol
K05/87
K11:86
X1
52
BOMAG
64
X1
99
4.2A
100
nicht bei D40/BW211D4 ohne SN1

not at D40/BW211D4 ohne SN1
X1:172
speed
dir. X1:173
Sensor Achse
sender axle
X1:174
B60
X1:171
Lern
A05
Test
SPEED TAC
9:6
SPEED MESX 6:2
DIR MESX 6:2
4:10
Modul Geschw.
modul speedometer
F24:2
nur bei ZA Messtechnik, Geschw.Anzeige und Tachograph

only at opt. measurementequ., speedometer and tachograph
Signalhorn
warning horn
X1
B11 1
MotorHeizflansch, Signalhorn, GeschwindigkeitAnz.

engine heatingflange cont., warning horn, speedometer
Signalhorn
warning horn
B11 1
V22
16.11.2005
Vogt
16.11.2005
Seis
24
14
X1
97
98
X1
X1
101 102
X1
23
13
X1:155
28A
28E
X1
Anbau im Motorbereich
assembled in enginearea
K14
S03
X1
10A
F23
X1
V21
57
75
78
X1
X1
Khlmitteltemperatur
collant temperature
A13
X1
GLH
4:19
Taster Signalhorn
push but. warning horn
2:10
B113
15/54
in
Anbau im Motorbereich
assembled in enginearea
K11/87
Relais Heizflansch
relais heatingflange
OUT+
P04
X1
X1
93
92
K11/87 4:1
003
582 702 09
31 4:1
ZA Geschwindigkeitsanzeige
option speedometer
OUT
008 911 63
4.2A
Geschwindigkeitsanz.
speedometer
2:20
Wiring diagram
17.1
931
Nur bei BW 219 D4 und D40 USA Version, sonst Option

only at BW 219 D4 and D40 USA version, otherwise option
geffnet in 0
BR/BN
X12
X1:156
29A
3:20 31
X1:149
4:3
K48
K48
4:2
87a
2:11
85
86
K05
X1:148
X12 3 X12 2
BL/BU SW/BK
B13
Position (Bremse ein)
Initiator Farhebel"0
proximity switch travel lever "0"position
X1
87
85
86
87
X1:147
11
X1:117
X1
4:8
129
K26
X1
H14+
X9
X9
K26/87A
87
30
X1:117
114
K26
4:6
87a
5:9
X1
X1
X1
89
BEL
Bel.
OUT1
OUT2
15/54
X1:82
X10
R03
X10
X1
X1
Resist. buzzer
X1
69
14
5 4 3 2 1
X1
X1
X1:117
B21
87
106
110
13
X1:57
B03
X1
X1
67
71
15
B30
_t
Motorldruck
X1
X1
B06
X1:74
X1:77
17
73
76
16
5:9
Q
B55
B06:1
Sitz
X21:2
X21:1
X1:68
5:9
8:17
8:17
8:16
B124
1 X8
X8
31 5:1
X1
107 108
X1
111 112
A68/6
BLL
BLR
3:5
X1
X1
GLH
BLW
nicht bei D40/BW177 D4

not at D40/BW177 D4
Blinker links
Blinker rechts
Warnbl.
Vorglhen
X1:72
12
18
19
K11/87 5:1
008 911 63
004
582 702 09
Sensor Wasserabschei
Luftfilter
Motorldruck
sens. water separator
air cleaner
engine oil pressure
Khlmittelstand
Hydrauliklfilter
ltemperatur
coolant stock level
hydraulik oil cleaner
oil temperature
nicht bei D40

not at D40
K48:87A
4:3
X1
11
201918 1716151413 121110
9 8 7 6
HOURS
2:6
X1:117
bl
2
or
105
109
FUEL
X5:120
Tankgeber
sender fuel
10
20
SITZWARN.
5:9
8:5
86
F24:2
Sammelanzeige
monitoring module
A15
3:15
Warnsummer Strung
buzzer failure
85
86
90
X1:31A
Bremse, Rckfahrwarneinr., Anzeige

brake, back up alarm, indicator
K22
5:2
2:18
F25:2
Rckfahrwarnsummer
buzzer back up alarm
85
86
X1:153
X13 3 X13 2
6:2
BRAKE MESX
X1:150
12
BR/BN
BL/BU SW/BK
B14
Magnetventil Bremse
solenoid valve brake
Y04
X1:113
5:9
S01
2:18
4:13
30
16.11.2005
Vogt
16.11.2005
Seis
K48/86
K48:87A
K36
2:7
87a
30
X13
Initiator Vorw. und Null

proximity switch forwards and "0"position
GND
10A
5:9
D+
F24
D+
K61/85
Bremse
X1:31E
Hydrauliklfilter
10A
125mA
125mA
Luftfilter
F25
125mA
300mA
Tankanzeige
Zentralstecker Sammelanzeige (Ansicht von hinten)

mainplug monitoring module (view from backside)
ltemperatur
29E
1
2.5A
X1:61
X1
H07
BOMAG
Sensor
K11/87
Khlmittelfllstand
932
Wasserabscheider
3:20
17.1
Wiring diagram
4:20
31
X1:124
V03
1
2
F14:2
K48/86
B06:1
13
D+
Fahren
14
X1
88
S58
X14
A
X11
X14
S13
X1:157
11
X1:158
Sitzschalter/Vibration
A68 Modul
module seatswitch/vibration
12
ldruck
Fahrstufen, Sitzkontaktsch., Vibration

speedranges, seatswitch, vibr.
V05
SITZWARN.
4:10
4:19
A68/6
V09
S01:21
2:20
K26/87A
4:8
2:20
4:3
4:17
16.11.2005
Vogt
16.11.2005
Vogt
X1:124
X1:141
X1:143
Stufenumschaltung hinten
switching axle
X1:124
Stufenumschaltung vorn
switching drum
Stufenumschaltung vorn
switching drum
nur BW216+219D4
only BW216+219D4
X1:138
X1:142
V02
X1:162
1 5 7 3
Y31
X1:137
X1:144
Fahrstufensch.
switch speed ranges
S42
1234
Y30
X1:141
X1:143
14
13
Y31
S42
Standard DMaschinen/D40 USA

Standard Dmaschines/D40 USA
1.23A
Stufenumsch. hinten
switching axle
Schalter Fahrstufen
switch speed ranges
nur D40/BW177D4
only D40/BW177D4
1.23A
F25:2
4:8
1.23A
4:13
X1:149
D+
X11
Taster Vibration
pushbutton vibration
K11/87
Sitzkontaktschalter
switch seatcontact
X1:154
BOMAG
X1:149
2
2
X6
Y07
X1:116
X6
S35
13
14
15
a
X7
Y08
X1:115
X7
X1:160
14
13
9:7 KA
Vibration vorne gro
vibration big ampl.
Vibration vorne klein
vibration small ampl.
Schalter Vibration klein/gro

switch vibration small/big ampl.
X1:161
24
23
X1:159
Nur mit Sitzkontaktschalter

only with switch seatcontact
3.33A
2
X1:118
3.33A
008 911 63
6:2
30
KA MESX 6:2
GA MESX
K04
X1:32A
15A
F03
X1:32E
56b
31
56
X1:149
4:20
K11/87 8:1
Modul Vibration
modul vibration
Nur ohne Sitzkontaktschalter
without switch seatcontact
005
582 702 09
31 6:1
Wiring diagram
17.1
933
9:6 GA
5:17
5:20
8:4
2:6
4:5
3:16
3:16
5:17
F148:2
15A
7:15
X1:35A
BEL MESX
31
BRAKE MESX
D+ MESX
PITCH MESX
KA MESX
SPEED MESX
DIR MESX
X44:57
16.11.2005
Vogt
16.11.2005
Seis
A83
MesstechnikRechner
measurement calc. unit
X44:28
GA MESX
Pot. 15
X2:57
Leistung
10A
X1:34A
10A
F84
X1:34E
X1:146
X44:58
X44:38
X1:33A
X44:59
X44:15
F146
Elektronik
F148
X44:56
S01
2:18
32
31
X44:54
X44:14
X1:35E
X2:54
X48:3
X48:2
X2:56
X44:37
X2:55
X48:4
15g/bl
/gg
B62
X48:1
X2:53
20g/br
Aufn. vorne 20g
Aufn. vorne 15g
+/sw
X44:31
X1:33E
X44:41
X2:49
X2:58
X49:3
X49:2
X2:60
ZA Messtechnik
option measurement equipm.
X2:59
X49:4
15g/bl
/gg
B62
X49:1
X2:57
20g/br
Aufn. hinten 20g
Pot 15
Aufn. hinten 15g
+/sw
X44:7
X1:145
X44:60
X44:35
X44:29
X44:38
GND
X2:52
X44:1
X2:71
X2:63
AGND MESX
X44:55
K11/87
X44:30
GND
nur bei BTM prof

only at BTM prof
X44:65
8:20
GND
RxD
X2:66
TxD
X2:65
X4:B
X2:64
X74:2
X4:A
X2:70
X74:1
P11
X2:66
X44:67
Pot 30
X44:66
X4:C
X74:3
X44:4
X4:E
X4:D
X74:5
P16
nur bei BEM

only at BEM
CAN+
F1
CAN3+
CAN
X2:50
F2
Anzeige BMFSA
Display BMFSA
EVIBMeter
EVIBmeter
X1:82
+
P07 E
VIB
X1:85
X44:5
30
X44:3
2:20
EVIB
nur bei BEM

only at BEM
CAN1+
X44:27
Drucker
printer
X42:2 X42:3
X46:A X46:E
X42:1
X46:B
CAN3+
31 7:1
008 911 63
006
582 702 09
7:15
CAN3 7:15
CAN3
X2:51
X42:5
X42:4
R20
1
2
60OHM
X46:F
X46:D
P33
X2:48 X2:49
X2:47
30 8:1
Display Messtechnik BOP

display measurem. BOP
X44:33
X74:4
X44:68
BOMAG
X44:53
CAN1
Beschleunigungssensoren
acc. sensor rear
nur bei BTM+/BTM prof

only at BTM+/BTM prof
934
X44:26
Beschleunigungssensoren
acc. sensor front
17.1
Wiring diagram
X44:36
X44:32
008 911 63
6:20
31
16.11.2005
Vogt
16.11.2005
Seis

CAN3
F148:2
BOMAG
P15
1 R242
BCM 05
X75:2
R25
1
2
120 OHM
120 OHM
nur bei BCM

only at BCM
A87
USBCAN Schnittst.
USBCAN Interface BCM
X75:7
X4:N
X2:61
CAN3+
6:18 CAN3+
6:18
6:2
X4:M
X2:62
CAN3
X76:2
X76:1
X2:63
X4:F
X4:G
X2:70
007
582 702 09
31 8:1
Wiring diagram
17.1
935
87a
31
E16 1 E17 1
4,6A
Scheinwerfer rechts
head light RH
Scheinwerfer links
head light LH
7:20
87
8:9
S15
13
32
31
8:10
85
X1:301
24
12
connection working head

lights without StvZO
Anschlu Arbeitsschein
werfer ohne StvZO
4:11
X1:23A
X1:24A
15A
F10
F09
15A
X1:24E
X1:23E
BEL
23
11
6:2
BEL MESX
16.11.2005
Vogt
16.11.2005
Seis
K06
86
S53 14
X1:84
012
E13 1 E12 1 E14 1 E15 1
8:2
K16
Schluleuchte rechts
tail light, RH
Schluleuchte links
tail light, LH
Parkleuchte links
parking light, LH
Parkleuchte rechts
parking light, RH
Anschlu Arbeitsschein
werfer ohne StvZO
connection working head
lights without StvZO
K16 30
X58:5 X1:309
X1:315 X58:6
X1:319
X60:3
X1:323 X60:4
X1:310
X1:26A
X1:83
X1:315 X58:6
Schalter StvZO
switch, StvZO
Schalter Arbeitsbeleuchtung
switch, working head lights
86
X1:22E
4
E25 1
2
E23 1
2
Connection head lights

acc.to ROPS/SD
Anschlu Arbeitsscheinwerfer
bei ROPS/SD Aufbau
X3:1
01
01
H06
14
13
X1:19A
24
23
4:19
BLW
4:19
4:19
L0R
24
14
49L
23
13
A02
X1:96
X1:91
31 82
30
L0R
X1:25A
X1:305
15A
F08
X1:25E
E09 1
2
E08 1
2
BLR
BLL
S37
Bel. Warnbinkschalter
illumination, switch hazard light
Warnblinkschalter
switch, hazard light
S14
Anschlu Arbeitsscheinwerfer
D bei Kabine
Connection head lights
with cabin
STV1
9:17
STV2
9:17
E28 1
X3:5
X1:22A
15A
F19
E27 1
X3:4
87a
ZA Beleuchtung und StvZO

opt. illumination and StvZO
85
X1:21A E
15A
F22
X1:21E
87
K06
8:4
30
X1:19E
X1:304
X1:18A
0,42A
15A
0,42A
X59:5
X1:316 X59:6
X1:311
X58:3
X1:312
X59:3
X1:316 X59:6
0,125A
X1:303
0,125A
10A
0,42A
Arbeitsscheinwerfer hinten links

working head lights, rear lh.
4,6A
X1:302
X1:2
4,6A
X1:308
15A
4,6A
Arbeitsscheinwerfer hinten rechts

working head lights, rear rh.
F07
0,42A
Arbeitsscheinwerfer vorne links

working head lights, front lh.
4,6A
X61:3 X1:320
X1:324 X61:4
Arbeitsscheinwerfer vorne rechts

working head lights, front rh.
4,6A
X1:313
X58:2
49R
Schalter Blinker
switch indicator
2
2
008 911 63
008
582 702 09
Blinkleuchte VR
indicator front, RH
Blinkleuchte HR
indicator rear, RH
31
E11 1
9:1
K11/87 6:2
30
E10 1
Blinkleuchte VL
indicator front, LH
Blinkleuchte HL
indicator rear, LH
X58:6
F18
1,75A
X1:315
X1:307
X1:26E
1,75A
X1:306
X60:1 X1:321
X60:2
X1:323
X1:314
X59:2
X59:6
F11
1,75A
X1:316
X61:1 X1:322
BOMAG
X61:2
K11/87
6:19 30
X1:18E
1,75A
936
X1:324
5:20
17.1
Wiring diagram
12V
XS
Steckdose Fahrerst.
9:6
8:20
Nur bei Gelnder/Rops/SD

only at handrail/Rops/sunroof
X3:3
R80
85
86
9:16
87
K141
31
Relais Kabine
relais cabin
K32
socket operator platform
15A
S45
E29
10A
F42
TK
A12
B51 + +
16.11.2005
Vogt
16.11.2005
Seis
Trkontaktschalter
door switch
S86
A01
E71 1
87a
30
Kontrolleuchte
indicator
F143
Schalter Innenleuche
switches interior lights
87a
4
A51
2
7,8,9
Frequenzmodul
module, frequency
3
A5+A6
P09
A2+A3
15A
F43
S21
01W 7
01
F42 10:8
F130
9:14
X55:2
M05
3,8A
Wischer hinten
windscreen wiper, rear
Wascher hinten
washer rear
M07
X55:1
15A
F44
X56:2
M04
9:9
E70
F130
10A
F130
S158
K141
Wascher vorn
washer front
9:2
8:13
8:13
1 E28
E72
E27
F130 10:7
STV1
STV2
XS
12V
10:18
009
582 702 09
Rundumkennleuchte
rotary beacon
31 10:1
KABINE 31
15A
S38
F144
6
10:2
10:13
10A
K32:87
F41:5
F41
ZA
option
E32
1 E25
4,6A
Arbeitsscheinwerfer vorn
working head lights, front
1 E23
4,6A
Arbeitsscheinwerfer hinten
working head lights, rear
Schalterbel.
switch illum.
15
31
S163 5
Schalter Nachtleuchte
switch, night illumination
M06
3,8A
Wischer vorne
windscreen wiper, rear
S20
01W 7
01
ZA Kabine, Beleuchtung, Radio, Tachograph

opt. cabin, headlights, radio, tachograph
Tachograph
tachograph
C3
B4
B3
1
2
A1
Tachographenmodul
module, tachograph
Radio
radio
15
+ + B51
87
X3:17
4
3:16
A16
SPEED TAC
31
30
K32
9:2
X55:3
X3:8
2,9A
2:20
X56:4
30
X56:3
X3:7
4,7A
2:11
X56:1
K32:86
Heizung Heckscheibe
heating rear screen
1,75A
Innenleuchte
inside light, cabin
0,83A
Nachtleuchte
night illumination
10:13
3 min
4,6A
F42:H
4,6A
X3:6
X3:16
GA
X3:15
5:17
KA
5:16
X55:4
X3:1
Abfallverzgert
BOMAG
X3:2
5A
008 911 63
Steckdose Kabine
socket cabin
2:11 K30
Wiring diagram
17.1
937
9:20
31
Schalter Kabinenlfter
switch blower cabin
ge
M09
rt
or
X3:12
ge
Bedienteil Kabinenheizung/Klimaanlage
Vogt
Seis
16.11.2005
Seis
Kabinenlfter
cab ventilator
br
rt
or
V04
1
X18:2
_t
B131
X18:1
X1:167
X3:14
X54:11
1
2
Y138 1
X1:168
X54:12
X54:2
Magnetventil Heizung
solenoid valve, heating unit
V06
X54:3
3
A72
Steuergert
control unit
6
11
12
X54:4
X54:1
2.5qmm
BOX2
15
Anlaufstrom beim Start = 8,3A
Power Stufe = 2,8A
groe Stufe = 1.9A
mittleter Stufe = 1,0A
Kleine Stufe = 0,67A
Regel aus = 0,4A
12 11 13 14 16
10 6
Kraftstoffpumpe
fuel pump heating unit
X77:2
Y14
X77:1
E30
Zusatzheizung
add. heater
20A
F40
9:19 F41:5
F42:H
9:4
ZA Kabinenheizung, Klimaanlage, Zusatzheizung

opt. cabinheater, air conditioning, add. heater
Klimakompressor
air conditioning compr.
HP
87a
30
Y15
X20:2
X1:170
B104 4
P
LP 3
X19:2
X20:1
_t
B103
X19:1
X1:169
87
2:8
K09
X3:13
X54:6
Potential 30 aus Kabine
9:17 F130
F42 Potential 15 aus Kabine
9:9
controlunit cabheater /air conditioning
X1:164
X17:4
M09
M
Kabinenlfter
br
X53:L
X3:9
X17:1 X1:163
0123
X53:C
X53:M
X3:10
X17:2 X1:165
S44
X53:H
X3:11
X17:3 X1:166
X53:B
20A
F31
Thermofhler Klimaanlage
temperature sensor air conditioning
Potential 15 aus Kabine
X20:3
berwachung Khlmitteldruck
monitoring coolant pressure
K32:87
X20:4
1A
BOMAG
3,5A
Thermofhler Heizung
temperature sensor heating unit
938
2.5qmm
9:20
Schaltuhr Heizung
heater timer
1
9:19
B
BOX2
KABINE 31
2 6 8 9 4 12
S28
5 7 11 3 10 1
5A
F15
008 911 63
010
582 702 09
31
17.1
Wiring diagram
17.1
Wiring diagram
Name
Bl. Pf. Benennung

005 4
title
TYP
MAX. 1,67A
16.11.2005
Vogt
16.11.2005
Seis
Bauteilliste
component listing
1
6
101
582 702 09
A02
A05
A12
A13
A15
A16
A51
A68
A72
A83
A87
008
003
009
003
004
009
009
005
010
006
007
17
17
5
3
16
7
6
10
11
6
15
Blinkrelais
Elektronik Geschwindigkeitsanzeige
Radio
Steuergeraet Heizung
Ueberwachungsmodul
Elektronik Tachograph
Platine Frequenzanzeige
Modul Sitzkontakt
Steuergeraet Klimaanlage, Heizung
Elektronik Messtechnik
USBCAN Schnittstelle BCM
indicator relay
Electronic system, speedometer
Radio
Control unit, heating
monitoring module
Electronic system, tachograph
Circuit board,frequenzy meter
Modul seat contact
Control unit,air conditioning,heating
electronic measurementequipment
USBCAN Interface BCM
B03
B06
B11
B11
B13
B14
B21
B30
B51
B51
B55
B60
B61
B62
B62
B103
B104
B113
B124
B131
004
004
003
003
004
004
004
004
009
009
004
003
006
006
006
010
010
003
004
010
15
17
9
11
2
6
14
16
5
6
17
14
12
8
10
7
7
3
19
10
Unterdruckschalter Luftfilter
Druckschalter Motoroel
Signalhorn
Signalhorn
Naeherungsinitiator Fahrhebel links
Naeherungsinitiator Fahrhebel rechts
Differenzdruckschalter Hydr.Oelfilter
Temperaturschalter Motoroel
Lautsprecher Radio
Lautsprecher Radio
Kuehlmittelstand Ausgleichsbehaelter
Aufnehmer Achsgeschwindigkeit
Aufnehmer Verstellzylinder
Beschleunigungsaufnehmer
Beschleunigungsaufnehmer
Temperaturschalter Klimaanlage
Druckschalter Klimaanlage
EMR Temperaturgeber Kuehlmittel
Geber Wasserstandsabscheider Diesel
Temperaturschalter Heizung
Vacuum switch, air cleaner

Pressure switch, engine oil
Warning horn
Warning horn
Proximity switch, travel lever, lh.
Proximity switch, travel lever, rh.
Pressure diff. switch, hydr. oil filter
Temperature switch, engine oil
Speaker radio
Speaker radio
Coolant charge expansion tank
Sensor, axle speed
Sensor, ajustable zylinder
Acceleration sensor
Acceleration sensor
Temperature switch, air conditioning
Pressure switch, air conditioning
EMR Temperature switch, collant
Sender, water separator fuel
Temperature switch, heating
E08
E09
E10
E11
E12
E13
E14
E15
E16
E17
E23
E23
E25
E25
E27
E27
E28
E28
E29
E30
E32
E70
E71
E72
008
008
008
008
008
008
008
008
008
008
008
009
008
009
008
009
008
009
009
010
009
009
009
009
17
18
19
19
7
6
7
8
2
2
11
18
12
19
10
17
11
17
4
13
19
15
3
16
Blinkleuchte vorne links

Blinkleuchte hinten links
Blinkleuchte vorne rechts
Blinkleuchte hinten rechts
Parkleuchte links
Schlussleuchte links
Parkleuchte rechts
Schlussleuchte rechts
Scheinwerfer links
Scheinwerfer rechts
Innenleuchte Kabine
Heizgeraet
Kennleuchte
Nachtleuchte
Kontrolleuchte Schalter Heckscheibenheizung
Beleuchtung Bedienschalter
Indicator, front, lh.

Indicator, rear, lh.
Indicator, front, rh.
Indicator, rear, rh.
Parking light, lh.
Tail light, lh.
Parking light, rh.
Tail light, rh.
Head light, lh.
Head light, rh.
Working head light, front, lh.
Working head light, front, lh.
Working head light, front, rh.
Working head light, front, rh.
Working head light, rear, lh.
Working head light, rear, lh.
Working head light, rear, rh.
Working head light, rear, rh.
Inside light, cabin
Heating unit
Warning light
Night lamp
indicator light switch rear screen
illum. Switches
F00
F03
F07
F08
F09
F10
F11
F13
F14
F15
F18
F19
F22
F23
F24
F25
F31
F39
F40
F41
F42
F43
F44
F48
F84
FM4
F105
F130
F143
F144
F146
F148
002
005
008
008
008
008
008
002
002
010
008
008
008
003
004
004
010
002
010
009
009
009
009
002
006
006
002
009
009
009
006
006
4
18
15
18
6
8
2
10
18
18
5
12
10
9
10
2
3
19
13
19
4
10
13
3
5
11
16
15
2
20
4
2
Hauptsicherung Batterie
Sicherung Vibration
Sicherung Warnblinker
Sicherung Blinker u. Arbeitsscheinw.
Sicherung Park u. Schlussl. links
Sicherung Park u. Schlussl. rechts
Sicherung Scheinwerfer links
Sicherung Startschalter
Sicherung Hubmagnet Motor
Sicherung Heizgeraet
Vorsicherung Arbeitsscheinw. vorne
Sicherung Arbeitsscheinw. vorne li.
Sicherung Arbeitsscheinwerfer hinten
Sicherung Signalhorn
Sicherung Ueberwachungsmodul
Sicherung Magnetv. Fahren u. Bremse
Sicherung Kabinenluefter
Hauptsicherung Kabine
Sicherung Kabinenheizung
Sicherung Rundumkennleuchte
Sicherung Kabineninnenleuchte
Sicherung Wischermotor hinten
Sicherung Wischermotor vorn
Sicherung Gluehanlage
Sicherung Steuerung (Klemme 54)
Platinensicherung
Sicherung Motordrehzahl
Sicherung Nachtleuchte
Sicherung Heckscheibenheizung
Sicherung Kabinensteckdose
Sicherung Steuerung MESX (Potential 30)
Sicherung Steuerung MESX (Potential 15)
Fuse, main, battery

Fuse, vibration
Fuse, hazard light
Fuse, indicators a. work. head light
Fuse, parking and tail light, lh.
Fuse, parking and tail light, rh.
Fuse, head light, lh.
Fuse, starter switch
Fuse, shut off solenoid, engine
Fuse, heating unit
Primary fuse, work. head light, fr.
Fuse, working head light, front, lh.
Fuse, working head lights, rear
Fuse, warning horn
Fuse, monitoring module
Fuse, sol. valve, travel and brake
Fuse, cabin ventilator
Main fuse, cab
Fuse, heating unit cab
Fuse, rotary beacon
Fuse, inside light cab
Fuse, wipermotor rear
Fuse, wipermotor front
Fuse, glow plug system
Fuse, controller (Pin 54)
Multifuse
Fuse, motor speed
Fuse, night lamp
fuse rear screen heating unit
Fuse cabinsocket
Fuse Controller (Pot. 30)
Fuse Controller (Pot. 15)
G01
G02
G03
002 4
002 5
002 3
Batterie
Generator
Batterie
Battery
Generator
Battery
103A
H06
H07
008 15
004 10
Meldeleuchte Warnblinker
Warnsummer Betriebsstoerung
Indicator light, hazard light

Warning buzzer, breakdown
MAX. 0,12A
008 911 63
BOMAG
MODUL
MAX. 0,12A
MAX.5A
MAX.5A
MAX. 1,75A
MAX. 1,75A
MAX. 1,75A
MAX. 1,75A
MAX. 0,42A
MAX. 0,42A
MAX. 0,42A
MAX. 0,42A
MAX. 4,6A
MAX. 4,6A
MAX. 4,6A
4,6A
MAX. 4,6A
4,6A
MAX. 4,6A
4,6A
MAX. 4,6A
4,6A
1,75A
5A
0,83A
1,75A
125A
MAX. 1,23A
15A
15A
10A
10A
15A
30A
15A
BOX2
30A
30A
30A
10A
10A
10A
15A
BOX2
125A
10A
20A
103A
939
17.1
Name
16.11.2005
Vogt
16.11.2005
Seis
Bauteilliste
component listing
2
6
102
582 702 09
940
Wiring diagram
H14
Bl. Pf. Benennung

004 8
Warnsummer Rueckwaertsfahrt
Backup alarm buzzer
title
MAX. 0,12A
K04
K05
K06
K09
K11
K14
K16
K22
K26
K32
K35
K36
K48
K61
K114
K141
005
004
008
002
002
003
008
004
004
009
002
002
004
002
002
009
18
3
4
8
10
5
9
9
6
2
16
7
2
5
14
16
Schrittrelais Vibration
Relais Startstrom
Relais Scheinwerfer hinten
Relais Klimageraet
Relais Klemme 30 auf 15
Relais Vorgluehen
Relais Scheinwerfer vorne
Relais Hubmagnet Motor
Relais Rueckfahrwarneinrichtung
Relais Kabine
Relais Selbsthaltung
Relais Bremskontrolle
Relais Fahrhebel 0Stellung
Relais Ladekontrolle
Relais Motordrehzahl
Relais Heckscheibenheizung
Toggle relay, vibration

Relay, starting current
Relay, head lights, rear
Relay, air conditioning
Relay, terminal 30 to 15
Relay, glow plug system
Relay, head lights, front
Relay, shut off solenoid, engine
Relay, back up alarm
Relay, cabin
Relay, holding contact
Relay, brake control
Relay, travel lever 0position
Relay, charge control
Relay, engine rpm
relay, heating rear screen
MAX. 1,23A
BOSCHW
BOSCHW
BOSCHW
BOSCHW
BOSCHL
BOSCHW
BOSCHW
BOSCHW
BOSCHW
BOSCHW
BOSCHW
BOSCHW
BOSCHW
BOSCHW
BOSCHW
M01
M04
M05
M06
M07
M09
M09
002
009
009
009
009
010
010
11
13
10
14
11
3
4
Starter
Scheibenwischermotor vorne
Scheibenwischermotor hinten
Scheibenwaschermotor vorne
Scheibenwaschermotor hinten
Kabinenluefter
Kabinenluefter
Starter
Windscreen wiper motor, front
Windscreen wiper motor, rear
Windscreen washer motor, front
Windscreen washer motor, rear
Cabin ventilator
Cabin ventilator
2.3 KW
4,7A
2,9A
MAX. 3,8A
MAX. 3,8A
P04
P07
P09
P11
P15
P16
P33
003
006
009
006
007
006
006
19
15
8
14
16
16
18
Geschwindigkeitsanzeige
Omegameter
Frequenz und Geschwindigkeitsanzeige
Drucker
BCM 03 Bildschirm
Diagnose, Variomatic
Opus 21
Speedometer
Omegameter
Frequency and Speedometer
Printer
BCM 03 terminal
Diagnostics, varimatic
Opus 21
R03
R10
R19
R20
R24
R25
R80
004
002
002
006
007
007
009
12
6
2
17
15
15
2
Geber Tankanzeige
Parallelwiderstand
Heizflansch
Widerstand
Widerstand
Widerstand
Heizung Heckscheibe
Sender, level gauge

Parallel resistor
heater flange
Resistor
Resistor
Resistor
heating rear screen
S00
S01
S03
S13
S14
S15
S20
S21
S28
S30
S35
S37
S38
S42
S42
S44
S45
S53
S58
S86
S120
S158
S163
002
002
003
005
008
008
009
009
010
002
005
008
009
005
005
010
009
008
005
009
002
009
009
10
18
9
13
15
4
13
10
17
3
15
18
19
3
7
3
4
4
13
4
14
15
16
Startschalter
Schalter NOT AUS
Taster Signalhorn
Vibrationsschalter Fahrhebel rechts
Warnblinkschalter
Beleuchtungsschalter StVZO
Schalter Scheibenwischer vorne
Schalter Scheibenwischer hinten
Schalter Kabinenheizung
Batterietrennschalter
Vibrationsschalter klein/gross
Schalter Blinker
Schalter Kennleuchte
Stufenumschalter schnelllangsam
Stufenumschalter schnelllangsam
Schalter Kabinenluefter
Schalter Kabineninnenleuchte
Schalter Arbeitsbeleuchtung
Schalter Aetherstartanlage
Schalter Tuer, links
Schalter Motordrehzahl
Schalter Nachtbeleuchtung
Schalter Heckscheibenheizung
Starter switch
Switch, emergency off
Push button, warning horn
Switch, vibration, travel lever, rh.
Switch, hazard light
Switch, lighting StVZO
Switch, windscreen wiper, front
Switch, windscreen wiper, rear
Switch, cabin heating
Switch, battery disconnect
Switch, vibration low/high
Switch, indicator
Switch, warning light
Speed range selector, fastslow
Speed range selector, fastslow
Switch, cabin ventilator
Switch, cabin inside light
Switch, working lights
Push button, ether starting unit
Switch door, lh.
Switch, engine speed
Switch, cabin night lamp
switch rear screen heating unit
V01
V02
V03
V04
V05
V06
V09
V21
V22
V47
002
005
005
010
005
010
005
003
003
002
6
6
7
8
10
9
10
10
11
15
Diode
Diode
Diode
Diode
Diode
Diode
Diode
Diode
Diode
Diode (A7)
Diode
Diode
Diode
Diode
Diode
Diode
Diode
Diode
Diode
Diode (A7)
X1:1
X1:2
X1:3
X1:4
X1:7
X1:8
X1:9
X1:10
X1:52
X1:53
X1:54
X1:55
X1:55
X1:56
X1:57
X1:57
X1:58
X1:59
X1:60
X1:61
X1:62
002
008
002
002
002
002
002
002
003
002
002
002
002
002
003
004
002
002
002
004
002
5
10
9
10
11
11
4
4
2
12
18
10
18
15
3
15
16
16
16
15
16
WAGO,EKasten
WAGO ZENTRALELEKTRIK
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EBOX
WAGO EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
BOMAG
TYP
82 OHM
167A
60OHM
120 OHM
120 OHM
4UF004
MAX. 1,23A
MAX. 1,23A
FE5B
MAX. 0,12A
MAX. 0,12A
FE5B
008 911 63
17.1
Wiring diagram
Name
16.11.2005
Vogt
16.11.2005
Seis
Bauteilliste
component listing
3
6
103
582 702 09
X1:63
X1:64
X1:65
X1:66
X1:67
X1:68
X1:69
X1:71
X1:72
X1:73
X1:74
X1:75
X1:76
X1:77
X1:78
X1:79
X1:80
X1:81
X1:82
X1:82
X1:83
X1:84
X1:85
X1:86
X1:87
X1:88
X1:89
X1:90
X1:91
X1:92
X1:93
X1:96
X1:97
X1:98
X1:99
X1:100
X1:101
X1:102
X1:105
X1:106
X1:107
X1:108
X1:109
X1:110
X1:111
X1:112
X1:113
X1:114
X1:115
X1:116
X1:117
X1:117
X1:117
X1:117
X1:118
X1:124
X1:124
X1:124
X1:129
X1:137
X1:138
X1:141
X1:141
X1:142
X1:143
X1:143
X1:144
X1:145
X1:146
X1:147
X1:148
X1:149
X1:149
X1:149
X1:149
X1:150
X1:151
X1:152
X1:153
X1:154
X1:155
X1:156
X1:157
X1:158
X1:159
X1:15A
X1:15E
X1:160
X1:161
X1:162
X1:163
X1:164
X1:165
X1:166
X1:167
X1:168
X1:168
X1:169
X1:170
008 911 63
Bl.
002
003
002
002
004
004
004
004
004
004
004
003
004
004
003
002
002
002
004
006
008
008
006
004
004
005
004
004
008
003
003
008
003
003
003
003
003
003
004
004
004
004
004
004
004
004
004
004
005
005
004
004
004
004
005
005
005
005
004
005
005
005
005
005
005
005
005
006
006
004
004
004
005
005
005
004
002
002
004
005
003
004
005
005
005
002
002
005
005
005
010
010
010
010
010
002
010
010
010
Pf.
16
3
5
6
15
17
13
15
17
17
16
4
17
16
4
10
14
14
11
15
5
4
15
10
13
11
10
9
17
19
19
17
9
10
10
11
9
10
12
14
19
20
12
14
19
20
5
8
16
14
5
8
12
14
14
3
6
8
6
4
4
3
8
6
3
8
6
5
5
5
2
1
12
13
19
5
18
18
6
13
9
2
13
13
16
10
10
16
14
7
3
5
3
4
10
8
10
7
7
Benennung
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKASTEN
WAGO,EKASTEN
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKASTEN
WAGO,EKASTEN
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKASTEN
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKASTEN
WAGO,EKASTEN
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
title
TYP
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO, Ebox
WAGO, Ebox
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO, Ebox
WAGO, Ebox
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO,EBOX
WAGO, Ebox
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO EBOX
WAGO,EBOX
WAGO,EBOX
WAGO EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO, Ebox
WAGO, Ebox
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO EBOX
WAGO EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO,EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
BOMAG
941
17.1
Name
16.11.2005
Vogt
16.11.2005
Seis
Bauteilliste
component listing
4
6
104
582 702 09
942
X1:171
X1:172
X1:173
X1:174
X1:17A
X1:17E
X1:18A
X1:18E
X1:19A
X1:19E
X1:21A
X1:21E
X1:22A
X1:22E
X1:23A
X1:23E
X1:24A
X1:24E
X1:25A
X1:25E
X1:26A
X1:26E
X1:27A
X1:27E
X1:28A
X1:28E
X1:29A
X1:29E
X1:301
X1:302
X1:303
X1:304
X1:305
X1:306
X1:307
X1:308
X1:309
X1:30A
X1:30E
X1:310
X1:311
X1:312
X1:313
X1:314
X1:315
X1:315
X1:315
X1:316
X1:316
X1:316
X1:319
X1:31A
X1:31E
X1:320
X1:321
X1:322
X1:323
X1:323
X1:324
X1:324
X1:32A
X1:32E
X1:33A
X1:33E
X1:34A
X1:34E
X1:35A
X1:35E
X2:47
X2:48
X2:49
X2:49
X2:50
X2:51
X2:52
X2:53
X2:54
X2:55
X2:56
X2:57
X2:57
X2:58
X2:59
X2:60
X2:61
X2:62
X2:63
X2:63
X2:64
X2:65
X2:66
X2:66
X2:67
X2:68
X2:69
X2:70
X2:70
X2:71
X2:73
Wiring diagram
Bl.
003
003
003
003
002
002
008
008
008
008
008
008
008
008
008
008
008
008
008
008
008
008
002
002
003
003
004
004
008
008
008
008
008
008
008
008
008
002
002
008
008
008
008
008
008
008
008
008
008
008
008
004
004
008
008
008
008
008
008
008
005
005
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
007
007
006
007
006
006
006
006
006
006
006
006
007
006
006
Pf.
14
15
15
14
16
16
2
2
15
15
10
10
12
12
6
6
8
8
18
18
5
5
18
18
9
9
2
2
5
5
9
15
18
18
18
15
2
19
19
2
7
7
17
19
2
7
17
2
7
19
6
10
10
8
18
19
6
18
8
19
18
18
2
2
5
5
4
4
18
19
9
19
17
18
13
8
7
8
7
2
10
9
10
9
15
16
13
18
14
14
14
14
11
12
12
15
18
14
11
Benennung
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGO,EKasten
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
title
TYP
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO,EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO,EBOX
WAGO,EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO,EBOX
WAGO,EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO,EBOX
WAGO,EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
WAGO EBOX
Wagomeasurement equip.
BOMAG
008 911 63
17.1
Wiring diagram
Name
16.11.2005
Vogt
16.11.2005
Seis
Bauteilliste
component listing
5
6
105
582 702 09
X2:74
X2:75
X2:76
X2:77
X2:78
X3:1
X3:1
X3:2
X3:3
X3:4
X3:5
X3:6
X3:7
X3:8
X3:9
X3:10
X3:11
X3:12
X3:13
X3:14
X3:15
X3:16
X3:17
X4:A
X4:B
X4:C
X4:D
X4:E
X4:F
X4:G
X4:M
X4:N
X6:1
X6:2
X7:1
X7:2
X8:1
X8:2
X9:1
X9:2
XS
XS
X10:2
X10:3
X11:1
X11:2
X12:1
X12:2
X12:3
X13:1
X13:2
X13:3
X14:A
X14:B
X17:1
X17:2
X17:3
X17:4
X18:1
X18:2
X19:1
X19:2
X20:1
X20:2
X20:3
X20:4
X21:1
X21:2
X36:A
X36:B
X37:A
X37:B
X38:A
X42:1
X42:2
X42:3
X42:4
X42:5
X44:1
X44:3
X44:4
X44:5
X44:7
X44:9
X44:14
X44:15
X44:23
X44:26
X44:27
X44:28
X44:29
X44:30
X44:31
X44:32
X44:33
X44:35
X44:36
X44:37
X44:38
008 911 63
Bl.
006
006
006
006
006
008
009
009
009
008
008
009
009
009
010
010
010
010
010
010
009
009
009
006
006
006
006
006
007
007
007
007
005
005
005
005
004
004
004
004
009
009
004
004
005
005
004
004
004
004
004
004
005
005
010
010
010
010
010
010
010
010
010
010
010
010
004
004
002
002
002
002
002
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
Pf.
11
10
10
11
11
11
10
10
2
10
12
2
2
2
3
3
4
4
7
10
7
6
6
14
14
14
14
15
18
18
16
15
14
14
16
16
19
20
8
8
1
20
12
12
13
13
2
2
1
6
6
6
13
13
3
3
4
5
10
10
7
7
7
7
7
7
17
17
4
4
10
11
11
18
19
19
18
18
13
15
14
14
10
12
5
5
11
18
17
2
7
9
8
6
18
5
6
7
4
Benennung
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
WAGOMESSTECHNIK
STECKER ROPS/SD
STECKER KABINE/ROPS
STECKER KABINE/ROPS
STECKER KABINE/ROPS
STECKER ROPS/SD
STECKER ROPS/SD
STECKER KABINE/ROPS
STECKER KABINE/ROPS
STECKER KABINE/ROPS
STECKER KABINE/ROPS
STECKER KABINE/ROPS
STECKER KABINE/ROPS
STECKER KABINE/ROPS
STECKER KABINE/ROPS
STECKER KABINE/ROPS
STECKER KABINE/ROPS
STECKER KABINE/ROPS
STECKER KABINE/ROPS
KABINENST. MESST.
KABINENST. MESST.
KABINENST. MESST.
KABINENST. MESST.
KABINENST. MESST.
KABINENST. MESST.
KABINENST. MESST.
KABINENST. MESST.
KABINENST. MESST.
DEUTSCH
DEUTSCH
DEUTSCH
DEUTSCH
DEUTSCH
DEUTSCH
DEUTSCH
DEUTSCH
Steckdose
Steckdose
AMP SUPERSEAL
AMP SUPERSEAL
DEUTSCH
DEUTSCH
DEUTSCH
DEUTSCH
DEUTSCH
DEUTSCH
DEUTSCH
DEUTSCH
DEUTSCH
DEUTSCH
STECKER LFTER HKL
STECKER LFTER HKL
STECKER LFTER HKL
STECKER LFTER HKL
STECKER THERMOFHLER
STECKER THERMOFHLER
STECKER EISSCHUTZ HKL
STECKER EISSCHUTZ HKL
STECKER DRUCKSCH. KLI
STECKER KHLMITTEL
STECKER KHLMITTEL
EINSPEISUNG SCHALTKAS
EINSPEISUNG SCHALTKAS
ST. ZNDSCHLO EKAST
ST. ZNDSCHLOSS EKAS
ST.STARTER EKASTEN
STECKER ADAPTER BOP
STECKER ADAPTER BOP
STECKER ADAPTER BOP
STECKER ADAPTER BOP
STECKER ADAPTER BOP
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
title
TYP
conn. ROPS/SR
conn. cabin/ROPS
conn. cabin/ROPS
conn. cabin/ROPS
conn. ROPS/SR
conn. ROPS/SR
conn. cabin/ROPS
conn. cabin/ROPS
conn. cabin/ROPS
conn. cabin/ROPS
conn. cabin/ROPS
conn. cabin/ROPS
conn. cabin/ROPS
conn. cabin/ROPS
conn. cabin/ROPS
conn. cabin/ROPS
conn. cabin/ROPS
conn. cabin/ROPS
con. measurem.equipm.
DEUTSCH connector
DEUTSCH connector
DEUTSCH connector
DEUTSCH connector
DEUTSCH connector
DEUTSCH connector
DEUTSCH connector
DEUTSCH connector
Socket
Socket
AMP connector
AMP connector
DEUTSCH connector
DEUTSCH connector
DEUTSCH connector
DEUTSCH connector
DEUTSCH connector
DEUTSCH connector
DEUTSCH connector
DEUTSCH connector
DEUTSCH connector
DEUTSCH connector
conn. blower
conn. blower
conn. blower
conn. blower
conn. sender temp.
conn. sender temp.
conn. antiice aircond.
conn. antiice aircond.
conn. pressuresitch aircond.
connector coolant sensor
connector coolant sensor
supply ebox
supply ebox
connector ignition switch
connector ignition switch, ebox
connector starter ebox
conector adapter BOP
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
BOMAG
943
17.1
Name
16.11.2005
Vogt
16.11.2005
Seis
Bauteilliste
component listing
6
6
106
582 702 09
944
Wiring diagram
Benennung
title
X44:38
X44:41
X44:46
X44:47
X44:53
X44:54
X44:55
X44:56
X44:57
X44:58
X44:59
X44:60
X44:65
X44:66
X44:67
X44:68
X46:A
X46:B
X46:D
X46:E
X46:F
X47:A
X47:B
X47:C
X48:1
X48:2
X48:3
X48:4
X49:1
X49:2
X49:3
X49:4
X53:B
X53:C
X53:H
X53:L
X53:M
X54:1
X54:2
X54:3
X54:4
X54:6
X54:11
X54:12
X55:1
X55:2
X55:3
X55:4
X56:1
X56:2
X56:3
X56:4
X58:2
X58:3
X58:5
X58:6
X58:6
X58:6
X59:2
X59:3
X59:5
X59:6
X59:6
X59:6
X60:1
X60:2
X60:3
X60:4
X61:1
X61:2
X61:3
X61:4
X74:1
X74:2
X74:3
X74:4
X74:5
X75:2
X75:7
X76:1
X76:2
X77:1
X77:2
Bl.
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
006
010
010
010
010
010
010
010
010
010
010
010
010
009
009
009
009
009
009
009
009
008
008
008
008
008
008
008
008
008
008
008
008
008
008
008
008
008
008
008
008
006
006
006
006
006
007
007
007
007
010
010
Pf.
7
7
11
10
17
5
13
4
4
4
5
5
13
13
14
14
19
18
18
19
18
11
12
12
8
7
7
8
10
9
9
10
3
4
4
3
3
11
11
10
10
7
10
11
11
10
10
10
14
13
13
13
17
7
2
2
7
17
19
7
2
2
7
19
18
18
6
6
19
19
8
8
14
14
14
15
14
16
15
17
17
13
13
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
MESX STECKER
STECKER BOP
STECKER BOP
STECKER BOP
STECKER BOP
STECKER BOP
STECKER AUFN. PLEIGER
STECKER AUFN. VORNE
STECKER AUFN. VORNE
STECKER AUFN. VORNE
STECKER AUFN. VORNE
STECKER AUFN. HINTEN
STECKER LFTERSCHALTE
STECKER HEIZSTEUERUNG
STECKER WISCHER HINTE
STECKER WISCHER VORNE
STECKER STVZO VL
STECKER STVZO VL
STECKER STVZO VL
STECKER STVZO VL
STECKER STVZO VL
STECKER STVZO VL
STECKER STVZO VR
STECKER STVZO VR
STECKER STVZO VR
STECKER STVZO VR
STECKER STVZO VR
STECKER STVZO VR
STECKER STVZO HL
STECKER STVZO HL
STECKER STVZO HL
STECKER STVZO HL
STECKER STVZO HR
STECKER STVZO HR
STECKER STVZO HR
STECKER STVZO HR
STECKER DRUCKER
STECKER DRUCKER
STECKER DRUCKER
STECKER DRUCKER
STECKER DRUCKER
SUBD STECKER BCM INT
SUBD STECKER BCM INT
STECKER VERS. BCM
STECKER VERS. BCM
STECKER PUMPE STANDHE
STECKER PUMPE STANDHE
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
MESX Stecker
Connector BOP
Connector BOP
Connector BOP
Connector BOP
Connector BOP
conn. sender PLEIGER
conn. sender front
conn. sender front
conn. sender front
conn. sender front
conn. sender rear
conn. sender rear
conn. sender rear
conn. sender rear
conn. blowerswitch
conn. blowerswitch
conn. blowerswitch
conn. blowerswitch
conn. blowerswitch
conn. heating controller
connector wiper rear
conn. wiper front
conn. wiper front
conn. wiper front
conn. wiper front
Con. STVZO FL
Con. STVZO FL
Con. STVZO FL
Con. STVZO FL
Con. STVZO FL
Con. STVZO FL
Con. STVZO FR
Con. STVZO FR
Con. STVZO FR
Con. STVZO FR
Con. STVZO FR
Con. STVZO FR
Con. STVZO BL
Con. STVZO BL
Con. STVZO BL
Con. STVZO BL
Con. STVZO BR
Con. STVZO BR
Con. STVZO BR
Con. STVZO BR
con. printer
con. printer
con. printer
con. printer
con. printer
con. SUBD BCM
con. SUBD BCM
con. Powersup. BCM
con. Powersup. BCM
Conn. pump add. heater
Conn. pump add. heater
Y01
Y04
Y07
Y08
Y13
Y14
Y15
Y30
Y31
Y31
Y120
Y138
Y140
Y141
002
004
005
005
002
010
010
005
005
005
002
010
006
006
12
5
14
16
18
13
7
6
3
8
16
10
10
11
Magnetventil Startmehrmenge
Magnetventil Bremse
Magnetventil Vibration vorne gross
Magnetventil Vibration vorne klein
Hubmagnet Motor
Kraftstoffpumpe Heizgeraet
Magnetkupplung Klimakompressor
Magnetventil Stufenumschaltung vorn
Magnetventil Stufenumschaltung hinten
Magnetventil Stufenumschaltung hinten
Magnetventil Motordrehzahl hoch
Magnetveentil Heizung
Magnetventil Erreger auf
Magnetventil Erreger ab
Solenoid valve, start boost fuel

Solenoid valve, brake
Solenoid valve, vibration, front, high
Solenoid valve, vibration, front, low
Shut off solenoid, engine
Fuel pump, heating unit
Magnetic clutch, air conditioning compr.
Solenoid valve, speed range sel., front
Solenoid valve, speed range sel., rear
Solenoid valve, speed range sel., rear
Solenoid valve, rpm engine high
Solenoid valve, heating unit
solenoid valve exciter up
solenoid valve exciter down
BOMAG
TYP
MAX. 3.9A
MAX. 1,8A
MAX. 2,5A
MAX. 2,5A
MAX. 3.8A
3,5A
MAX. 1,67A
MAX. 1,23A
MAX. 1,23A
3,5A
008 911 63
X36
X37
X38
K11
008 911 63
BOMAG
A68
945
Name: Seis
Gepr.: 19.10.2005
Name: Vogt
Gez.: 19.10.2005
K04
K26
K114
K61
K48
K35
overview e-box BW 177...219 D-4/D-40
bersicht Schaltkasten BW 177...219 D-4/D-40
Nur wenn kein Sitzkontakt angebaut

only acc. if no seatswitch is assembled
Nur wenn Sitzkontakt angebaut

only acc. if seatswitch is assembled
Nur bei Klimaanlage

only acc. to aircond.
K22
K09
K36
K05
K06
R10
K16
A02
Nur bei StvzO

only acc. To StvZO illumination
Replaces:
Ers. f.:
page: 1
Seite: 1
from: 2
von: 2
582 702 09
Sheet No.: 201
Blatt Nr.: 201
Wiring diagram
17.1
F1
F2
946
A83
Messtechnik Steuerung
CAN 1
Nur bei VM8

only acc. To VM8
BOMAG
008 911 63
overview e-box door BW 177...219 D-4/D-40
Gepr.: 19.10.2005
Name: Seis
Name: Vogt
bersicht Schaltkasten-Tr BW 177...219 D-4/D-40
BCM
Replaces:
Ers. f.:
page: 2
Seite: 2
OPUS 21
Gez.: 19.10.2005
CAN 3
CAN 1
from: 2
von: 2
582 702 09
Sheet No.: 201
Blatt Nr.: 201
17.1
Wiring diagram
17.1
Wiring diagram
WAGO smart DESIGNER 4.1

1
05756417
05756421
2 x 05756425 "L" + 793-501
2 x 05756425 "L" + 05756420 + 793-501
05756422
4 x 05756423 "L" + 05756419 + 793-501
12
18 x 05756436 "R" + 05756419 + 793-501
12
Flachsicherung DIN 72581-C30 / 057 510

99
13

98
14

00
15

98
16

98
17

98
19

97
20

97
21

98
22

97
23

98
24

97
25

97
26

98
27

97
28

98
Optional1 :
Projektgruppe :
Walzenzge-4 Klemmenleisten
Optional2 :
Projekt :
Zeichnung :
Obere Ebenen :
Ort :
Tragschiene :
Zeichnungsnummer :
Artikelnummer :
Artikelnummer lang :
gezeichnet: :
geprft: :
Absicherung D-4 Version
Lieferadresse :
Optional3 :
Optional4 :
Optional5 :
ausgewhlte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 :
Artikelnummer :
Gre der Bohrung :
Optional7 :
210-112
5.20 x 25.00 [mm]
Copyright WAGO. Technische nderungen vorbehalten.

17.11.2005 07:47:59
008 911 63
BOMAG
Seite 1
947
17.1
Wiring diagram

30
2 x 05756436 "R" + 793-501
32
05756435
33
05756417
Optional1 :
Projektgruppe :
Optional2 :
Projekt :
Zeichnung :
Obere Ebenen :
Ort :
Tragschiene :
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
Lieferadresse :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Artikelnummer :
Gre der Bohrung :
Optional7 :
210-112
5.20 x 25.00 [mm]

17.11.2005 07:47:59
948
BOMAG
Seite 2
008 911 63
17.1
Wiring diagram
Optional1 :
Projektgruppe :
Optional2 :
Projekt :
Zeichnung :
Obere Ebenen :
Ort :
Tragschiene :
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
Lieferadresse :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Artikelnummer :
Gre der Bohrung :
Optional7 :
210-112
5.20 x 25.00 [mm]

17.11.2005 07:48:52
008 911 63
BOMAG
Seite 3
949
17.1
Wiring diagram
Optional1 :
Projektgruppe :
Optional2 :
Projekt :
Zeichnung :
Obere Ebenen :
Ort :
Tragschiene :
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
Lieferadresse :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Artikelnummer :
Gre der Bohrung :
Optional7 :
210-112
5.20 x 25.00 [mm]

17.11.2005 07:48:52
950
BOMAG
Seite 4
008 911 63
17.1
Wiring diagram

1
05756417
2 x 05756540 "R" + 793-501 + 05756536
2 x 05756540 "R" + 793-501
3 x 05756539 "R" + 793-501
05756537
10
4 x 05756538 "R" + 793-501
14
05756537
15
3 x 05756538 "R" + 793-501
18
05756537
19
3 x 05756540 "R" + 793-501
22
05756535 "R" + 793-501
23
05756537
24
5 x 05756540 "R" + 793-501
29
05756537
30
2 x 05756538 "R" + 793-501
32
2 x 05756539 "R" + 793-501
34
05756537
35
4 x 05756538 "R" + 793-501
39
05756537
40
4 x 05756540 "R" + 793-501
44
2 x 05756539 "R" + 793-501
46
05756537
47
05756540 "R" + 793-501
48
05756535 "R" + 793-501
Optional1 :
Projektgruppe :
Optional2 :
Projekt :
Zeichnung :
Obere Ebenen :
Ort :
Tragschiene :
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
Kabelbume D Version
Lieferadresse :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Artikelnummer :
Gre der Bohrung :
Optional7 :
210-112
5.20 x 25.00 [mm]

17.11.2005 07:51:17
008 911 63
BOMAG
Seite 1
951
17.1
Wiring diagram

49
05756537
50
2 x 05756538 "R" + 793-501
52
05756537
53
4 x 05756540 "R" + 793-501
57
05756539 "R" + 793-501
58
05756537
59
4 x 05756540 "R" + 793-501
63
05756537
64
05756540 "R" + 793-501
65
05756535 "R" + 793-501
66
05756537
67
05756540 "R" + 793-501
68
05756535 "R" + 793-501
69
05756537
70
05756538 "R" + 793-501
71
2 x 05756540 "R" + 793-501
73
05756539 "R" + 793-501
74
05756537
75
05756417
Optional1 :
Projektgruppe :
Optional2 :
Projekt :
Zeichnung :
Obere Ebenen :
Ort :
Tragschiene :
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
Kabelbume D Version
Lieferadresse :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Artikelnummer :
Gre der Bohrung :
Optional7 :
210-112
5.20 x 25.00 [mm]

17.11.2005 07:51:17
952
BOMAG
Seite 2
008 911 63
17.1
Wiring diagram
Optional1 :
Projektgruppe :
Optional2 :
Projekt :
Zeichnung :
Obere Ebenen :
Ort :
Tragschiene :
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
Kabelbume D Version
Lieferadresse :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Artikelnummer :
Gre der Bohrung :
Optional7 :
210-112
5.20 x 25.00 [mm]

17.11.2005 07:51:57
008 911 63
BOMAG
Seite 3
953
17.1
Wiring diagram
Optional1 :
Projektgruppe :
Optional2 :
Projekt :
Zeichnung :
Obere Ebenen :
Ort :
Tragschiene :
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
Kabelbume D Version
Lieferadresse :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Artikelnummer :
Gre der Bohrung :
Optional7 :
210-112
5.20 x 25.00 [mm]

17.11.2005 07:51:57
954
BOMAG
Seite 4
008 911 63
17.1
Wiring diagram
05756417
2 x 05756540 "R" + 793-501
05756539 "R" + 793-501
05756537
05756538 "R" + 793-501
2 x 05756540 "R" + 793-501
05756538 "R" + 793-501
10
05756537
11
2 x 05756540 "R" + 793-501
Optional1 :
Projektgruppe :
Walzenzge -4 Klemmenleisten
Optional2 :
Projekt :
Zeichnung :
Obere Ebenen :
Ort :
Tragschiene :
Messtechnik D
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
Klemmenleiste X2
Lieferadresse :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Artikelnummer :
Gre der Bohrung :
Optional7 :
210-112
5.20 x 25.00 [mm]

16.11.2005 14:51:24
008 911 63
BOMAG
Seite 1
955
17.1
Wiring diagram

13
05756539 "R" + 793-501
14
05756537
15
05756540 "R" + 793-501
16
05756538 "R" + 793-501
17
05756540 "R" + 793-501
18
05756537
19
05756417
Optional1 :
Projektgruppe :
Optional2 :
Projekt :
Zeichnung :
Obere Ebenen :
Ort :
Tragschiene :
Messtechnik D
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
Klemmenleiste X2
Lieferadresse :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Artikelnummer :
Gre der Bohrung :
Optional7 :
210-112
5.20 x 25.00 [mm]

16.11.2005 14:51:24
956
BOMAG
Seite 2
008 911 63
17.1
Wiring diagram
Optional1 :
Projektgruppe :
Optional2 :
Projekt :
Zeichnung :
Obere Ebenen :
Ort :
Tragschiene :
Messtechnik D
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
Klemmenleiste X2
Lieferadresse :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Artikelnummer :
Gre der Bohrung :
Optional7 :
210-112
5.20 x 25.00 [mm]

16.11.2005 14:51:51
008 911 63
BOMAG
Seite 3
957
17.1
Wiring diagram
Optional1 :
Projektgruppe :
Optional2 :
Projekt :
Zeichnung :
Obere Ebenen :
Ort :
Tragschiene :
Messtechnik D
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
Klemmenleiste X2
Lieferadresse :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Artikelnummer :
Gre der Bohrung :
Optional7 :
210-112
5.20 x 25.00 [mm]

16.11.2005 14:51:51
958
BOMAG
Seite 4
008 911 63
17.1
Wiring diagram
05756417
Nur bei ZA E2 StvZO Beleuchtung
4 x 05756540 "R" + 793-501
05756537
2 x 05756540 "R" + 793-501
10
11
12
13
14
13
4 x 05756538 "R" + 793-501
2 x 05756539 "R" + 793-501
15
05756537
15
16
05756417
16
Optional1 :
Projektgruppe :
Optional2 :
Projekt :
Zeichnung :
Obere Ebenen :
Ort :
Tragschiene :
E2 Beleuchtung
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
Option E2 StvZO Beleuchtung
Lieferadresse :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Artikelnummer :
Gre der Bohrung :
Optional7 :
210-112
5.20 x 25.00 [mm]

16.11.2005 14:48:22
008 911 63
BOMAG
Seite 1
959
17.1
Wiring diagram
Optional1 :
Projektgruppe :
Optional2 :
Projekt :
Zeichnung :
Obere Ebenen :
Ort :
Tragschiene :
E2 Beleuchtung
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
Option E2 StvZO Beleuchtung
Lieferadresse :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Artikelnummer :
Gre der Bohrung :
Optional7 :
210-112
5.20 x 25.00 [mm]

16.11.2005 14:48:52
960
BOMAG
Seite 2
008 911 63
008 911 63
BOMAG
X22
X48 X49
X48 X49
X22
X58
X59
X58
X59
X19
X18
X5
X54
X19
X18
X53
X76
X56
X17
X17
X53 X54
X74 X75
X5
X56 X76
X74 X75
X38 X2
X44
X1
X4 X3
961
Name: Seis
Gepr.: 19.10.2005
Name: Vogt
Gez.: 19.10.2005
X38
X37 X44 X2
X36
X14
X20
X20
X77
X55
X77
X4 X3
X37 X1
X36
X14
X42 X11 X12

X46
X13
X46
X42
X11 X12
X13
X55
X8
X10
X8
X10
X6 X7
X61
X60
X6 X7
X60
X9
X61
X9
Connector overview BW 177...219 D-4/D-40
Steckerbersicht BW 177...219 D-4/D-40
X21
X21
Replaces:
Ers. f.:
page: 1
Seite: 1
von: 1
from: 1
582 702 09
Sheet No.: 301
Blatt Nr.: 301
Wiring diagram
17.1
17.1
962
Wiring diagram
BOMAG
008 911 63
008 911 63
BOMAG
963
17.2
Hydraulic diagram
Hydraulic diagram 582 202 10 from serial number

101 582 431 001
101 582 481 001
101 582 441 001
101 582 491 001
964
BW 212 D-40
BW 212 PD-40
BW 213 D-40
BW 213 PD-40
BOMAG
008 911 63
17.2
Hydraulic diagram
008 911 63
BOMAG
965
17.2
966
Hydraulic diagram
BOMAG
008 911 63
008 911 63
BOMAG
967
17.3
Hydraulic diagram
Hydraulic diagram 581 202 11 from serial number

101 582 421 001 BW 211 D-40
101 582 471 001 BW 211 PD-40
968
BOMAG
008 911 63
17.3
Hydraulic diagram
008 911 63
BOMAG
969
17.3
970
Hydraulic diagram
BOMAG
008 911 63

Service Manuel BW211D-40

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Service Manuel BW211D-40

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Service - Manual

BW 211 / 212 / 213 D-40

Single drum roller

1.2 Safety regulations

1.3 General repair instructions

1.4 Tightening torques

2.2 Maintenance chart

2.3 Table of fuels and lubricants

2.4 Fuels and lubricants

Tests and adjustments

4.2 Checking the rotation speeds

4.3 Checking / adjusting the neutral positions of the travel pump

4.4 Pressure tests in the travel circuit

4.5 Checking / adjusting the vibrator shaft speeds

4.6 Pressure measurements in the vibration circuit

4.7 Check the leakage rate of the vibration motor

4.8 Pressure test in steering circuit

Flushing and bleeding

5.2 Flushing - general

5.3 Flushing schematic travel circuit (distribution travel pump)

5.4 Flushing the travel circuit (travel pump distribution)

5.5 Flushing schematic travel circuit (distribution axle motor)

5.6 Flushing the travel circuit (axle motor distribution)

5.7 Flushing schematic for vibration drive

5.8 Flushing the vibration circuit

5.9 Bleeding the travel circuit

5.10 Bleeding the vibration circuit

6.2 Terminal designations

6.3 Current and voltage

6.5 Series / parallel connection

6.6 Ohm's law

6.7 Electrical energy

6.8 Formula diagram

6.10 Diodes, relays, fuses

6.12 Three-phase generator

6.13 Electric starter

6.15 Inductive proximity switches

6.16 Angle sensor with current output

6.17 Plug connectors

6.18 Deutsch plug, series DT and DTM

6.19 Plugs and terminals in spring clamping technology

Special tools, electrics

10.1 Electrics BEM (BOMAG Evib-meter)

10.2 Service Training

11.2 Service side

11.3 Starter side

11.4 Lubrication oil circuit

11.5 Oil pressure switch and low oil pressure circuitry

11.6 Check the engine oil level

11.7 Changing engine oil and oil filter cartridges

11.8 Coolant circuit

11.9 Coolant temperature switch

11.10 Disassembling and assembling the coolant temperature switch

11.11 Replacing the thermostat

11.12 Checking the thermostat in disassembled state

11.13 Check the coolant level

11.14 Change the coolant

11.16 Three-phase generator

11.17 Fuel supply

11.18 Injection system

11.19 Injection pump replacement during service

11.20 Injection valve replacement during service

11.21 Checking / repairing injection valves

11.22 Fuel filter