BW213DH-4 BVC Service Manual E 00891179.l07 PDF

Service - Manual
Catalogue number.
008 911 79 12/2007
BW 213 DH-4 BVC
BW 213 DH-4 BVC with attachment plate
Variocontrol / Variocontrol+
S/N 101 583 16 ....
S/N 101 583 06 ....
S/N 101 582 12 .... S/N 101 582 13 ....
Single drum roller
Table of Contents
BOMAG 3 008 911 79
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 26
Maintenance 31
2.1 General notes on maintenance 32
2.2 Fuels and lubricants 33
2.3 Table of fuels and lubricants 36
2.4 Running-in instructions 37
2.5 Maintenance chart 38
Technical data 41
3.1 Technical data 42
Connection overview 53
4.1 Connection overview 54
Tests and adjustments 57
5.1 Special tools, tests and adjustments 58
5.2 Activate service mode 62
5.3 Driving against the closed brake 64
5.4 Turn the steering against an end stop. 66
5.5 Pressure tests in the travel circuit 68
5.6 Checking / adjusting the neutral positions of the travel pump 70
5.7 Pressure measurements in the vibration circuit 72
5.8 Check the leakage rate of the vibration motor 73
5.9 Pressure test in steering circuit 74
Flushing and bleeding 77
6.1 Special tools for flushing 78
6.2 Flushing - general 83
6.3 Flushing schematic travel circuit (distribution travel pump) 85
6.4 Flushing the travel circuit (travel pump distribution) 87
6.5 Flushing schematic travel circuit (distribution axle motor) 93
6.6 Flushing the travel circuit (axle motor distribution) 98
6.7 Flushing schematic for vibration drive 103
6.8 Flushing the vibration circuit 104
6.9 Bleeding the travel circuit 108
6.10 Bleeding the vibration circuit 110
Fundamental electrics 113
7.1 Understanding circuit diagrams 114
7.2 Terminal designations 118
7.3 Current and voltage 122
7.4 Resistance 126
7.5 Series / parallel connection 128
7.6 Ohm's law 130
7.7 Electrical energy 130
7.8 Formula diagram 131
7.9 Metrology 132
Table of Contents
BOMAG 4 008 911 79
7.10 Diodes, relays, fuses 134
7.11 Batteries 137
7.12 Three-phase generator 140
7.13 Electric starter 148
7.14 Telemecanique switch 151
7.15 Inductive proximity switches 154
7.16 Angle sensor with current output 155
7.17 Plug connectors 156
7.18 Deutsch plug, series DT and DTM 157
7.19 Plugs and terminals in spring clamping technology 163
Special tools, electrics 167
8.1 Special tools, electrics 168
Machine related electrics 177
9.1 Machine related electrics 179
9.2 Electrics MESX 269
Service Training 331
10.1 Service Training Machine 333
10.2 Service Training BVC 411
Engine 467
11.1 Diesel engine 468
11.2 Engine description TCD 2012 469
11.3 Engine description TCD 2013, 4 and 6 cylinder 471
11.4 Lubrication oil circuit TCD 2012 / 2013 475
11.5 Coolant circuit TCD 2012 / 2013 476
11.6 Fuel system TCD 2012 / 2013 477
11.7 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013 481
11.8 Sensors TCD 2012 / 2013 487
11.9 Engine control EDC16 with EMR 3 for TCD 2012 / 2013 502
11.10 Exhaust gas recirculation TCD 2012 / 2013 507
11.11 Fault code monitoring with display TCD 2012 / 2013 508
11.12 Fault code display TCD 2012 / 2013 509
11.13 EMR3 List of fault codes 510
11.14 SerDia Service-Software TCD 2012 / 2013 520
11.15 General trouble shooting chart TCD 2012 / 2013 523
11.16 Valve adjustment TCD 2012 / 2013 525
11.17 Ribbed V-belt - fan drive TCD 2012 / 2013 528
11.18 Special tools, Deutz engine (TCD 2012 2V) 529
11.19 Special tools, Deutz engine (TCD 2013 2V) 544
Air conditioning system 563
12.1 Physical basics 564
12.2 Refrigerant R134a 567
12.3 Compressor oil / refrigeration oil 568
12.4 Working principle of the air conditioning system 569
12.5 Monitoring devices 569
12.6 Description of components 570
12.7 Checking the compressor oil level 576
12.8 Checking the magnetic clutch 577
Table of Contents
BOMAG 5 008 911 79
12.9 Inspection and maintenance work 578
12.10 Checking, replacing the refrigerant compressor V-belt 578
12.11 Service the air conditioning 579
12.12 Drying and evacuation 582
12.13 Emptying in case of repair 582
12.14 Leak test 583
12.15 Filling instructions 584
12.16 Trouble shooting in refrigerant circuit, basic principles 587
12.17 Trouble shooting, refrigerant circuit diagram 591
12.18 Trouble shooting procedure 592
12.19 Steam table for R134a 602
12.20 Heating control / air conditioning control 607
Replacing the cab window panes 613
13.1 Assembly of window panes 614
13.2 Special tools 615
13.3 Auxiliary materials 616
13.4 Removing and installing the window pane 618
Drum 623
14.1 Special tools, drum BW 213/226 DH-4 BVC and Variocontrol 624
14.2 Removing and installing the drum 626
14.3 Changing the rubber buffers and adjusting the pretension 634
Drum 637
15.1 Repair overview for drum 638
15.2 Assembly of tapered roller bearing 644
Articulated joint, electric steering 651
16.2 Repair overview oscillating articulated joint 654
16.3 Removing and installing the oscillating articulated joint 658
16.4 Dismantling the oscillating articulated joint 661
16.5 Assembling the oscillating articulated joint 665
Articulated joint, hydraulic steering 675
17.2 Repair overview oscillating articulated joint 678
17.3 Removing and installing the oscillating articulated joint 681
17.4 Dismantling the oscillating articulated joint 683
17.5 Assembling the oscillating articulated joint 688
Suppliers documentation 699
18.1 Travel pump / vibration pump series 90R 701
18.2 Vibration motor A2FM 791
18.3 Travel drive series 51 821
18.4 Transmission CR 903
18.5 Axle DANA 193 929
18.6 Auxiliary pump for plate, series 1019
Circuit diagrams 1057
19.1 Wiring diagram 1059
Table of Contents
BOMAG 6 008 911 79
19.4 Hydraulic diagram 1187
BOMAG 7 008 911 79
1 General
1.1 Introduction
BOMAG 8 008 911 79
1.1 Introduction
This manual is intended to support expert mechanics
in efficient repair and maintenance work. Whoever
wants to do repair work himself should have been suf-
ficiently trained and posses profound expert knowl-
edge, he should limit his work only to those parts and
components which will not affect the safety of the ve-
hicle or the passengers. It is highly recommended to
have repairs to critical systems, such as steering,
brakes and travel drive, sole carried out by a BOMAG
workshop. Untrained persons should NEVER UN-
TERTAKE SUCH REPAIR WORK.
The repair instructions describe the removal or dis-
mantling and assembly of components and assembly
groups. The repair of disassembled assembly groups
is described as far as this makes sense with respect
to available tools and spare parts supply and as far as
it can be understood by a skilled mechanic.
Documentation
For the BOMAG machines described in this training
manual the following documentation is additionally
available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Wiring diagram*
4 Hydraulic diagram*
5 Service Information
You should only use genuine BOMAG spare parts.
Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
This manual is not subject of any updating service; we
would therefore like to draw your
attention to the additionally published "technical serv-
ice information".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.
! Danger
Please observe strictly the safety regulations in
this manual, in the operating instructions as well
as the applicable accident prevention regulations.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
* The applicable documents valid at the date of print-
ing are part of this manual.
Safety regulations
BOMAG 9 008 911 79
1.2
1.2 Safety regulations
Important notes
These safety regulations must be read and ap-
plied by every person involved in the repair of this
machine. The applicable accident prevention in-
structions and the safety regulations in the oper-
ating and maintenance instructions must be
additionally observed.
Repair work shall only performed by appropriately
trained personnel or by the after sales service of
BOMAG.
Any suggestions, safety precautions and warn-
ings in this section are intended as a mnemonic
aid for well trained and experienced expert me-
chanics. This manual should not be considered a
bible on workshop safety.
Workshop equipment and facilities as well as the
use and waste disposal of solvent, fluids, gases
and chemicals are subject to legal regulations,
which are intended to provide a minimum on safe-
ty. It is obviously your own responsibility to know
and adhere to these regulations.
This manual contain headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to avoid dangers for health and
for the environment.
! Danger
Paragraphs marked like this highlight possible
dangers for persons.
! Caution
Paragraphs marked like this highlight possible
dangers for machines or parts of the machine.
i
Note
Paragraphs marked like this contain technical infor-
mation for the optimal economical use of the machine.
Environment
Paragraphs marked like this point out practices
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Observe the regulations for the protection of the
environment.
General
Before starting repair work stand the machine on

level and solid ground.
Always secure the machine against unintended roll-

ing.
Secure the engine reliably against unintentional

starting.
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 articu-

lated 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 gaso-
line or paint thinners for cleaning.
Cleaning or repair work on the fuel tank is very dan-

gerous. Do not smoke or allow any ignitable sparks
or open fire in the vicinity when cleaning or repairing
a tank. .
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 coat-
ings, plastic coatings, oil containing dirt deposits,
grease or solvent residues, etc.!
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 (re-

move possible electrode residues).
Protect cables from being damaged, use cables

with insulated couplings.
Ensure sufficient fire protection, keep a fire extin-

guisher at hand.
BOMAG 10 008 911 79
In case of welding work in fire or explosion endan-

gered environments, you should always ask for a
welding permission.
Remove combustible parts from the vicinity or cover

such parts.
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.
Place the inert gas bottles in a safe place and se-

cure 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.
Switch the welding unit off before connecting weld-

ing cables.
Behaviour in case of faults
Check electrode holders and electric cables at reg-

ular 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
Replace damaged insulating jaws and welding rod

holders immediately.
Replace the welding wire reels only in deenergized

state.
What to do in case of accidents; First Aid
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 emer-
gency doctor.
Old oils
Prolonged and repetitive contact with mineral oils will
remove the natural greases from the skin and causes
dryness, irritation and dermatitis. Moreover, used en-
gine oils contain potentially hazardous contaminants,
which could cause skin cancer. Appropriate skin pro-
tection agents and washing facilities must therefore
be provided.
Wear protective clothes and safety gloves, if possi-

ble.
If there is a risk of eye contact you should protect

your eyes appropriately, e.g. chemistry goggles or
full face visor; a facility suitable for rinsing the eyes
should also be available.
Avoid prolonged and repetitive contact with oil, es-

pecially with old oil. In case of open incisions and in-
juries seek medical advice immediately.
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 re-
place 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.

Environment
It is strictly prohibited to drain off oil into the soil,
the sewer system or into natural waters. Entrust
special companies with the waste disposal of old
oil. If in doubt you should consult your local au-
thorities.
Hydraulics
Hydraulic oil escaping under pressure can pene-

trate the skin and cause severe injury. You should
therefore relieve the pressure in the system before
disconnecting any lines.
Before applying pressure to the system make sure

that all line connections and ports have been prop-
erly 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 im-
mediately, as otherwise this may cause severe in-
fections.
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.
Safety regulations
BOMAG 11 008 911 79
1.2
Reattach all guards and safety installations after
all work has been completed.
Environment
It is strictly prohibited to drain off hydraulic oil
into the soil, the sewer system or into natural wa-
ters. Entrust special companies with the waste
disposal of old oil. If in doubt you should consult
your local authorities.
Fuels
! Danger
Repair work on fuel systems must only be per-
formed by appropriately trained personnel.
The following notes refer to general safety precau-
tions for danger free handling of fuel. These notes are
only general instructions; in case of uncertainties you
should consult the person responsible for fire protec-
tion.
Fuel vapours not only are easily inflammable, but also
highly explosive inside closed rooms and toxic; dilu-
tion with air creates an easily inflammable mixture.
The vapours are heavier than air and therefore sink
down to the ground. Inside a workshop they may eas-
ily become distributed by draft. Even the smallest por-
tion of spilled fuel is therefore potentially dangerous.
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 discon-
nect the battery, because this could generate
sparks, which would ignite explosive fuel vapours.
Wherever fuel is stored, filled, drained off or where

work on fuel systems is carried out, all potential ig-
nition sources must be extinguished or removed.
Search lights must be fire proof and well protected
against possible contact with running out fuel.
Hot fuels
Before draining fuel off the tank for repair work, you
must strictly apply the following measures:
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 ap-
parently made of natural rubber, are actually made of
plastic material, a so-called fluoroelastomer. Under
normal operating conditions this material is safe and
does not impose any danger to health.
However, if this material becomes damaged by fire or
extreme heat, it may decompose and form highly
caustic hydrofluoric acid, which can cause severe
burns in contact with skin.
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.
Poisonous substances
Some of the fluids and substances used are toxic and
must under no circumstances be consumed.
Skin contact, especially with open wounds, should be
strictly avoided.
These fluids and substances are, amongst others,
anti-freeze agents, hydraulic oils, washing additives,
lubricants and various bonding agents.
Engine
! Danger
Do not work on the fuel system while the engine is
running - danger to life!
After the engine has stopped wait until the pres-
sure has dropped (on Commonm Rail engines ap-
prox. 5 minutes, other engines 1 minute), because
the system is under high pressure - danger to life!
Keep out of the danger zone during the initial test
rung. Danger caused by high pressure in case of
leaks - danger to life!
When performing work on the fuel system make
sure that the motor cannot be started unitention-
ally - danger to life!
Maintenance and cleaning work on the engine must

onyl be performed with the engine stopped and
cooled down. Make sure that the electric system
has been switched off (ignition key pulled out).
Observe the accident prevention regulations for

electric systems (e.g. -VDE-0100/-0101/-0104/-
0105 Electric precautions against dangerous con-
tact voltages).
Cover all electric components properly before wet

cleaning.
BOMAG 12 008 911 79
Air conditioning system
! Caution
Lines in the air conditioning system must only be
loosened by trained and explicitly instructed ex-
perts.
Wear safety goggles! Put on your safety goggles.

This will protect your eyes against coming into con-
tact with refrigerant, which could cause severe
damage by freezing.
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 tem-
peratures may be reached. The results may be local
frost injuries (boiling point of R134a -26.5C at am-
bient 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 in-
haled.
Welding and soldering on refrigeration equipment!

Before starting welding or soldering work on vehi-
cles, (in the vicinity
of air conditioning components) all refrigerant must
be drawn out and the rests removed by blowing out
the system with nitrogen. The decomposition prod-
ucts created from the refrigerant under the influence
of heat not only are highly toxic, but also have a
strong corrosive effect, so that pipes and system
components may be attacked. The substance is
mainly fluorohydrogen.
Pungent smell! In case of a pungent smell the afore

mentioned decomposition products have already
been created. Extreme care must be exercised not
to inhale these substances, as otherwise the respi-
ratory system, the lungs and other organs may be
harmed.
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
Since the fluid container is pressurized, the manu-

facture and testing of these pressure vessels is gov-
erned by the pressure vessel directive. (New edition
from April 1989). Paragraph 10 of the pressure ves-
sel directive demands that these pressure contain-
ers must be periodically inspected and tested by a
specialist, according to paragraph 32. In this case
periodically recurring inspections consist of external
examinations, normally on containers in operation.
The refrigerant container must be visually inspected
two times per year, within the frame work of major
inspections. Special attention must thereby be paid
to signs of corrosion and mechanical damage. If the
container is in no good condition, it should be re-
placed for safety reasons, in order to protect the op-
erator or third parties against the dangers when
handling or operating pressure vessels.
Secure pressure vessels against tipping over or roll-

ing 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 ap-
plies also when snapping off valves on bottles. Bot-
tles must therefore only be transported with the
safety caps properly installed.
Refrigerant bottles must never be placed near heat-

ing radiators. Higher temperatures will cause higher
pressures, whereby the permissible pressure of the
vessel may be exceeded. The pressure vessel di-
rective therefore specifies that a pressure vessel
should not be warmed up to temperatures above 50
C.
Do not heat up refrigerant bottles with an open

flame. Excessive temperatures can damage the
material and cause the decomposition of refriger-
ant.
Do not overfill refrigerant bottles, since any temper-

ature increase will cause enormous pressures.
Environment
In operation, during maintenance and repair work
and when taking refrigeration systems our of
service it is not permitted to let refrigerant escape
into the atmosphere, which would contradict the
current status of technology.
Battery
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 ex-

plosion of the accumulator
Keep ignition sources away from the battery.

Safety regulations
BOMAG 13 008 911 79
1.2
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 wa-

ter, never vice-versa.
Poisonous substances
Some of the fluids and substances used are toxic and
must under no circumstances be consumed.
Skin contact, especially with open wounds, should be
strictly avoided.
These fluids and substances are, amongst others,
anti-freeze agents, hydraulic oils, washing additives,
lubricants and various bonding agents.
Special safety regulations
Use only genuine BOMAG spare parts for repair

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

tested or approved any parts or accessories not
supplied by us. The installation and/or use of such
products may therefore have an adverse effect on
the specific characteristics of the machine and
thereby impair the active and/or passive driving
safety. The manufacturer explicitly excludes any li-
ability for damage caused by the use of non-original
parts or accessories.
Unauthorized changes to the machine are prohibit-

ed for safety reasons.
If tests on the articulated joint need to be performed

with the engine running, do not stand in the articu-
lation area of the machine, danger of injury!
Do not perform cleaning work while the engine is

running.
If tests must be performed with the engine running

do not touch rotating parts of the engine, danger of
injury.
Exhaust gases are highly dangerous. Always en-

sure an adequate supply of fresh air when starting
the engine in closed rooms.
Refuel only with the engine shut down. Ensure strict

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

dispose of environmentally.
Dispose of oils and fuel environmentally when per-

forming repair or maintenance work.
Do not refuel in closed rooms.
Do not heat up oil higher than 160 C because it

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

acid level in the battery.
Do not check the acid level of the battery with a na-

ked flame, danger of explosion!
Old batteries contain lead and must be properly dis-

posed of.
There is a danger of scalding when draining off en-

gine or hydraulic oil at operating temperature.
on machines with rubber tires a tire may busr if in-

correctly assembled. This can cause severe injury.
Do not exceed the specified highest permissible tire

pressure.
1.3 General repair instructions
BOMAG 14 008 911 79
General
Before removing or disassembling and parts, hoses

or components mark these parts for easier assem-
bly.
Before assembly oil or grease all parts, as far as this

is necessary.
Electrics
General
The electric and electronic systems in construction
equipment are becoming more and more extensive.
Electronic elements are increasingly gaining impor-
tance in hydraulic and mechanical vehicle systems.
Diagnostics according to plan
A structured approach in trouble shooting saves time
and helps to avoid mistakes and expenses, especially
in the fields of electrics and electronics. Understand-
ing electronic controls requires the knowledge of
some basic terms concerning their general perform-
ance. In many cases error logs are just simply read
out and control units are replaced without any further
trouble shooting. This is in most cases unnecessary
and, even more important, very expensive.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
In approx. 10 % of the examined cases the prob-

lems were caused by control units.
In approx. 15 % sensors and actuators were the

cause of the problems.
By far the highest proportion of all faults could be
traced back to wiring and connections (plugs, etc.).
General:
Before changing any expensive components, such

as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Electric signals must be checked at
the locations to which they are applied, i.e. on con-
trol unit or sensor technology. So, if the system had
been diagnosed without unplugging the control unit
and checking the wiring, one should be alerted.
Check for good cable and ground contacts, there-

fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
Perform trouble shooting in a systematic way. Do

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

while the engine is running.
Do not operate the main battery switch under load.

General repair instructions
BOMAG 15 008 911 79
1.3
Do not use jump leads after the battery has been re-
moved.
Sensors and electric actuators on control units must

never be connected individually or between exter-
nal power sources for the purpose of testing, but
only in connection with the control unit in question,
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 sup-
ply (terminal 15 "On"), is not permitted. Switch the
voltage supply "off" first - then pull out the plug.
Even with an existing polarity reversal protection in-

correct 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 (mi-

cro controller MC) as well as changes or repairs on
the wiring can lead to dangerous malfunctions.
Do not use any radio equipment or mobile phones

inside the driver's cab without an appropriate out-
side antenna or in the vicinity of the control electron-
ics!
Electrical system and welding work
Surge voltages in the electric system must be strict-

ly avoided:
When performing welding work always fasten the

earth clamp of the welding unit in the immediate vi-
cinity of the welding location.
! Caution
Switch off the main battery switch, doisconnect
the generator and pull the plug out on the control
unit before starting welding work.
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 fas-
tening of the battery in the vehicle.
BOMAG 16 008 911 79
Hydraulic system
! Caution
Do not open any hydraulic components if you
have not been properly trained and without exact
knowledge.
Please note
Cleanliness is of utmost importance. Make sure that
no dirt or other contaminating substances can enter
into the system.
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 immedi-
ately. Do not install parts that show traces of corro-
sion.
Avoid the formation of rust on fine machined caused

by hand sweat.
Grease must not used as a sliding agent for assem-

bly work. Use hydraulic oil.
Do not start the engine after the hydraulic oil has

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

damaging the pressure gauges under too high pres-
sure.
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 rec-

tify the cause.
Fill new hydraulic units with hydraulic oil before

starting operation.
After changing a component thoroughly flush and

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

the hydraulic oil (approx. 40 C).
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 vibrat-
ing drum. If the soil is too hard place the drums on
old rubber tires. Do not activate the vibration on a
hard, concreted base, danger of bearing damage.
After the completion of all tests perform a test run

and then check all connections and fittings for leaks
with the engine still stopped and the hydraulic sys-
tem depressurized.
Before commissioning
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 specifica-

tion 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
Bleed the hydraulic circuits.
Start up the system without load.
Check the hydraulic oil level in the tank, fill up oil if

necessary.
After commissioning
Check system pressures and speeds.
Check fittings and flanges for leaks.
After each repair check all adjustment data, rota-

tional 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 17 008 911 79
1.3
Air conditioning system
CFC - halon prohibition
The CFC - halon prohibition from May 06, 1991 regu-
lates the withdrawal from the use of CFC and the han-
dling of these refrigerants.
Contents:
Since 1995 CFC (R12) is no longer permitted for use
in new systems.
In operation, during maintenance and repair work and
when taking refrigeration systems our of service it is
not permitted to let refrigerant escape into the atmos-
phere, which would contradict the current status of
technology.
Work on refrigeration systems must only be carried
out by persons with well founded knowledge about
such systems and who have the necessary technical
equipment available.
The use of refrigerant must be documented.
Old systems should be converted to refrigerants
harmless to ozone (refrigerant substitutes).
For this reason the Federal Environmental Agency at
the end of 1995 published suitable replacement refrig-
erants for R 12. As a consequence old systems must
no longer be filled with R12. As soon as such a system
is opened for service, the system must be converted
to a suitable replacement or service refrigerant. Old
systems may still be used, as long as they are leak
tight. R 134a was nominated as replacement for R 12.
Inside the European Union the "EU-Directive 2037/
2000 on substances causing decomposition of the
ozone layer" regulates the production, use and avail-
ability of CFC and H-CFC.
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 compo-

nents, these must be kept closed as far as possible,
in order to prevent the invasion of air, moisture and
dirt, because the operational reliability of the system
can only be assured if all components in the refrig-
erant circuit are clean and dry from inside.
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
damp air is drawn into the component by the differ-
ence in temperatures.
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 refrig-

erant 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 / re-
frigeration oil approved for the compressor.
Used compressor oil / refrigeration oil must be dis-

posed of as hazardous waste.
Due to its chemical properties compressor oil / re-

frigeration oil must never be disposed of together
with engine or transmission oil.
Compressor oil / refrigeration oil is highly hydro-

scopic. Oil cans must strictly be kept closed until
use. Oil rests should not be used, if the can had
been opened over a longer period of time.
All O-rings as well as pipe and hose fittings must be

oiled with compressor/refrigeration oil be-
foreiassembly.
When replacing a heat exchanger, e.g. evaporator

or condenser, any compressor oil / refrigeration oil
lost by exchanging the components, must be re-
placed with fresh oil.
A too high compressor oil / refrigeration oil level ad-

versely affects the cooling performance and a too
low oil level has a negative effect on the lifetime of
the compressor.
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 compo-

nents 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 un-
known and its effect on compressor oil and rubber
elements is not predictable. The use of leak detec-
BOMAG 18 008 911 79
tion colouring matter makes any warranty claims
null and void.
Tools used on refrigeration circuits must be of ex-

cellent condition, thus to avoid the damage of any
connections.
The dryer is to be installed last, after all connections

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

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

new filling: - Turn the compressor approx. 10 revo-
lutions by hand using the clutch or V-belt pulley of
the magnetic clutch. - Start the engine with the com-
pressor/control valve switched off. - Once the idle
speed of the engine has stabilized switch on the
compressor and run it for at least 10 minutes at idle
speed and maximum cooling power.
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.
Notes on cleanliness for Common Rail
engines
Special requirements with respect to cleanliness in
the fuel system do apply for commissioning, mainte-
nance and repair work, particularly for TEIRIII engines
with the DEUTZ Common Rail System. Contamina-
tion like dirt, welding residues or similar can lead to the
failure of individual components and adversely affect
engine operation.
Fig. 1
Spare parts should be left in their original packaging

as long as possible and should only be unpacked
just before use.
When parts are unpacked any connections must be

closed with suitable plugs or caps, in order to pre-
vent (Fig. 1) contamination of hose connections. If
e.g. fuel hoses are connected to one side, while the
second side cannot yet be connected, there is a
danger of dirt entering into the system. The free
connection must in this case also be appropriately
closed.
Notes and measures to be applied before starting
work in the fuel system
The fuel system must be closed. Visual examination

for leaks / damage in the fuel system.
Before starting work in the fuel system clean the

complete engine and the engine compartment with
the system still closed.
The engine should be dry before work is started in

the fuel system.
BOMAG 19 008 911 79
1.3
Blow drying with compressed air is only permitted

while the fuel system is still closed.
When using steam cleaning equipment cover con-

trol unit, cable plugs, all other electrical connections
and the generator beforehand and do not expose
these items to the direct steam jet.
Electrical plug connections must be plugged in dur-

ing jet cleaning.
Remove loose parts (e.g. paint scales that may

have come off during assembly work) with an indus-
trial vacuum cleaner or any means of extraction.
Vacuum cleaning equipment must generally be

used for cleaning when the fuel system is open.
Perform work on the fuel system only in a clean en-

vironment (no dust, no grinding or welding work).
Avoid draughts (dust). The workshop floor must be
cleaned at regular intervals. No brake or power test
stand should be present or operated in the same
room.
Air movements, which could swirl up dust, such as

brake repairs or starting of engines, must be strictly
avoided.
For work, such as disassembly and assembly of de-

fective hydraulic components in the Common Rail
System, it is strongly recommended to set up a sep-
arate workshop area, i.e. an area which is spatially
separated from all other areas (general vehicle re-
pairs, brake repairs).
No general machine tools should be operated in this

room.
Periodic cleaning of this workshop area is obligato-

ry, draughts, ventilation system and heating blow-
ers must be minimized.
Engine compartment area where dirt particles could

come loose, should be covered with new, clean foil.
Working means and tools must be cleaned before

being used for work. Use only tools without dam-
aged chromium coating, or tools without chromium
coating.
Notes and measures to be applied during work in
the fuel system
Wear clean working clothes.
Use only lint-free cleaning cloths for work in the fuel

system.

Vacuum cleaning equipment must generally be
used for cleaning when the fuel system is open.

coating.
Do not use any previously used cleaning or testing

fluids for cleaning.
Compressed air should never be used for cleaning

when the fuel system is open.
Work on disassembled components must only be

carried out at a specially furnished work place.
When disassembling or assembling components

you should not use any materials from which parti-
cles or fibres could flake off (cardboard, wood, tow-
els).
Dismantled parts must only be wiped off with clean,

lint-free cloths if required. No dirt particles must be
wiped into the components.
Close openings on components and engine imme-

diately with suitable plugs/caps.
Plugs/caps must only be removed just before the in-

stallation.
Keep plugs/caps in their original packaging, where

they are protected against dust and dirt, dispose of
after one time use.
Take new parts out of their original packaging just

before installation.
Disassembled components must be stored in new,

sealable bags or if available in the packaging
material of the new components.
Always use the original packaging material of the

new part to return the disassembled old component.
Notes and measures concerning the workshop
area
For work, such as disassembly and assembly of de-

fective hydraulic components in the Common Rail
System, it is strongly recommended to set up a sep-
arate workshop area, i.e. an area which is spatially
separated from all other areas (general vehicle re-
pairs, brake repairs).
The workshop floor must be sealed or tiled.
No welding equipment, grinding machines, general

machine tools, brake or power test benches must
be operated in this room.
Periodic cleaning of this workshop area is obligato-

ry, draughts, ventilation system and heating blow-
ers must be minimized.
Notes and measures for work place and tools in
the workshop
A special work place must be set up for work on dis-

assembled components.
Clean disassembly and assembly tools at regular

intervals and keep these in a closed tool cabinet.
BOMAG 20 008 911 79


coating.
Fuel hoses
Fig. 2
! Caution
All fuel hoses have two layers of material, a rein-
forced rubber coating outside and an internal Vi-
ton hose. If a fuel hose has come loose one must
make absolutely sure that the internal Viton layer
has not been separated from the reinforced outer
layer. In case of a separation the hose needs to be
replaced.
BOMAG 21 008 911 79
1.3
Gaskets and mating surfaces
Leaking or failing seals and gaskets can in most cases
be tracked down to careless assembly, causing dam-
age not only to the seal or gasket, but also to the mat-
ing surfaces. Careful assembly work is mandatory if
good results are to be achieved.
Before assembling replacement seals make sure

that the running surface is free of pitting, flutes, cor-
rosion or other damage.
Inappropriately stored or handled seals (e.g. hang-

ing from hooks or nails) must under no circumstanc-
es be used.
Sealing compound should only be used if specially

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

on the corresponding surfaces; take care that the
compound does not enter into oil galleries or blind
threaded bores.
Before assembly remove any residues of old seal-

ing compound. Do not use any tools that could dam-
age 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 dis-
lodged by the compressed air.
Assembly of radial seals
Fig. 3
Lubricate sealing lips 1 (Fig. 3) with clean grease; in

case of double seals fill the space between the seal-
ing lips with a generous amount of grease.
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.
i
Note
If possible, use an assembly sleeve 1 (Fig. 3), to pro-
tect the lip from being damaged by sharp edges,
threads or splines. If no assembly sleeve is availa-
ble, you should use a plastic tube or adhesive tape to
prevent the sealing lip from being damaged.
Fig. 4
Lubricate the outer rim 1 (Fig. 4) of the seal and

press it flat on the housing seat.
i
Note
If possible, use a "bell" 1 (Fig. 4), to make sure that
the seal will not skew. In some cases it may be ad-
visable to assemble the seal into the housing first, be-
fore 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 suit-
able 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.
Press or knock the seal into the housing, until it is

flush with the housing surface.
BOMAG 22 008 911 79
Feather keys and keyways
! 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.
Fig. 5
Clean and thoroughly examine the feather key.
Debur and thoroughly clean the edges of the key-

way with a fine file before reassembling.
Ball and roller bearings
! Caution
Ball and roller bearings must only be reinstalled
after it has been assured that they are in perfect
condition.
Fig. 6
Remove any lubricant residues from the bearing to

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

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

it by the inner race; check for resistance while rotat-
ing and replace the bearing if it does not work cor-
rectly.
Lubricate the bearing with an appropriate lubricant

before reinstalling.
BOMAG 23 008 911 79
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 rec-
ommended type of grease before assembling the
seal.
Always mark the individual parts of separable bear-

ings (e.g. taper roller bearings) to enable correct re-
assembling. Never assemble the rollers to an outer
race that has already been used, replace the com-
plete bearing instead.
Fig. 7
! Caution
When assembling the bearing to the shaft load
must only be applied to the inner race 1 (Fig. 7).
When fitting the bearing into the housing load
must only be applied to the outer race (2).
Screws and nuts
Tightening torque
! Caution
Always tighten nuts or screws to the specified
tightening torque. Tightening torques deviating
from the ones in the table are specially mentioned
in the repair instructions.
Damaged screws must under no circumstances
be used any longer. Recutting threads with thread
cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
roded thread pitches can cause incorrect torque
value readings.
Self-locking nuts must be generally renewed.
The use of screws with too high strength can
cause damage!
Nut of a higher strength can generally be used in-

stead of nuts of a lower strength classification.
When checking or retightening screw joints to the

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

order to ensure low friction movement. The same
applies for self-locking nuts.
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.
BOMAG 24 008 911 79
Strength classes of metric screws
The strength classes (from 3.6 to 12.9) are specified
for all strength classes from a nominal diameter of
5mm. The corresponding identification can be found
where allowed for by the shape of the screw.
Fig. 8 Identification of screws
Example: A screw is identified with 12.9.
The first number corresponds with 1/100 of the nomi-
nal tensile strength (minimum tensile strength) in N/
mm
2
.
The nominal tensile strength is 12 X 100N/mm

2
=
1200 N/mm
2
.
The second number specifies 10-times the ration be-
tween lower yield point and nominal tensile strength
(yield point ratio).
i
Note
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas-
tic deformation).
When exceeding the upper yield point the material will
not restore its original shape after being relieved.
The lower tensile strength is 9/10 X 1200 N/mm

2
=
1080 N/mm
2
.
i
Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.
Strength classes of metric nuts
Nuts are differentiated by three load groups. Each
load group has a special designation system for the
strength class assigned, so that the load group can be
clearly identified.
Nuts for screw joints with full load capability (4, 5,
6, 8, 10, 12)
Fig. 9 Identification of nuts
In a connection with a screw, these nuts 1 (Fig. 9)
must be able to bear the full pre-load at the yield point.
Nut height above 0.8 d (d = nominal dimension).
Nuts for screw joints with limited load factor (04,
05)
The preceding "0" indicates that, due to their low
height, nuts 2 (Fig. 9) in this group are only able to
withstand the force of a screw to a limited extent.
Nut height below 0.8 d (d = nominal dimension).
Nuts for screw joints without specified load factor
(11H, 14H, 17H, 22H)
This standard contains strength classes (hardness
classes) for nuts 3 (Fig. 9), for which no load values
can be specified, e.g. because of their shape and di-
mensions, but which can only be classified by their
hardness.
Nut height below 0,5 d (d = nominal dimension).
Strength class of
nut
Strength class of associated
screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
6 6.8
8 8.8
9 9.8
10 10.8
12 12.8
BOMAG 25 008 911 79
1.3
Identification in clock system
Fig. 10 Identification of nuts in clock system
For small nuts (Fig. 10) the clock system can be used
for identification.
The 12 o'clock position is identified by a dot or the

manufacturer's symbol.
The strength class is identified by a dash (b).

1.4 Tightening torques
BOMAG 26 008 911 79
The values specified in the table apply for screws:
black oiled
with surface protection A4C
with surface protection DACROMET

i
Note
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with metric unified thread
1
1 Coefficient of friction tot. = 0,14
Screw dimension
Tightening torques Nm
8.8 10.9 12.9
M4 3 5 5
M5 6 9 10
M6 10 15 18
M8 25 35 45
M10 50 75 83
M12 88 123 147
M14 137 196 235
M16 211 300 358
M18 290 412 490
M20 412 578 696
M22 560 785 942
M24 711 1000 1200
M27 1050 1480 1774
M30 1420 2010 2400
Tightening torques for screws with metric unified fine thread
1
Screw dimension
8.8 10.9 12.9
M8 x 1 26 37 48
M10 x 1.25 52 76 88
M12 x 1,25 98 137 126
M12 x 1.5 93 127 152
M14 x 1.5 152 216 255
M16 x 1.5 225 318 383
M18 x 1.5 324 466 554
M20 x 1.5 461 628 775
M22 x 1.5 618 863 1058
M24 x 2 780 1098 1294
M27 x2 1147 1578 1920
M30 x 2 1568 2254 2695
Tightening torques
BOMAG 27 008 911 79
1.4

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

2
2 These values result in a 90% utilization of the yield point
Thread diameter
10.9
M12x1.5 100
M14x1.5 150
M18x1.5 300 - 350
M20x1.5 400 - 500
M22x1.5 500 - 600
BOMAG 28 008 911 79
The values specified in the table apply for screws:
black oiled
with surface protection A4C
with surface protection DACROMET

i
Note
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60 flanks,
as the metric ISO-thread, whereas Withworth has a flank of only 55.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with UNC thread,
1
UNC Unified Coarse Thread Series, American Unified
Coarse Thread
Screw dimension
8.8 10.9 12.9
1/4 - 20 11 15 19
5/16 - 18 23 32 39
3/8 - 16 39 55 66
7/16 - 14 62 87 105
1/2 - 13 96 135 160
9/16 - 12 140 200 235
5/8 - 11 195 275 330
3/4 - 10 345 485 580
7/8 - 9 560 770 940
1 - 8 850 1200 1450
1 1/8 - 7 1200 1700 2000
1 1/4 - 7 1700 2400 2900
1 3/8 - 6 2200 3100 3700
1 1/2 - 6 3000 4200 5100
Tightening torques for screws with UNF thread,
1
UNF Unified National Fine Thread Series, American
Unified Fine Thread
Screw dimension
8.8 10.9 12.9
1/4 - 28 13 18 22
5/16 - 24 25 35 42
3/8 - 24 45 63 76
7/16 - 20 70 100 120
1/2 - 20 110 155 185
9/16 - 18 155 220 260
5/8 - 18 220 310 370
3/4 - 16 385 540 650
7/8 -14 620 870 1050
Tightening torques
BOMAG 29 008 911 79
1.4

1 - 12 930 1300 1600
1 1/8 - 12 1350 1900 2300
1 1/4 - 12 1900 2700 3200
1 3/8 - 12 2600 3700 4400
1 1/2 - 12 3300 4600 5600
Tightening torques for screws with UNF thread,
1
UNF Unified National Fine Thread Series, American
Unified Fine Thread
Screw dimension
8.8 10.9 12.9
BOMAG 30 008 911 79
BOMAG 31 008 911 79
2 Maintenance
2.1 General notes on maintenance
BOMAG 32 008 911 79
2.1 General notes on maintenance
When performing maintenance work always comply
with the appropriate safety regulations.
! Danger
Danger of squashing!
Maintenance and service work must only be per-
formed with the attachment plates in floating posi-
tion. For safety reasons the extension plates are
then lowered to the ground and the hydraulic lines
depressurized.
Thorough maintenance of the machine guarantees far
longer safe functioning of the machine and prolongs
the lifetime of important components. The effort need-
ed for this work is only little compared with the prob-
lems that may arise when not observing this rule.
The terms right/left correspond with travel direction
forward.
Always clean machine and engine thoroughly be-

fore starting maintenance work.
For maintenance work stand the machine on level

ground.
Perform maintenance work only with the engine

shut down.
Relieve hydraulic pressures before working on hy-

draulic lines.
Before working on electric parts of the machine dis-

connect the battery and cover it with insulation ma-
terial.
When working in the area of the articulated joint at-

tach the articulation lock (transport lock).
Environment
During maintenance work catch all oils and fuels
and do not let them seep into the ground or into
the sewage system. Dispose of oils, coolant and
fuels environmentally.
Notes on the fuel system
The lifetime of the diesel engine depends to a great
extent on the cleanliness of the fuel.
Keep fuel free of contaminants and water, since this

will damage the injection elements of the engine.
Drums with inside zinc lining are not suitable to

store fuel.
The fuel drum must rest for a longer period of time

before drawing off fuel.
Do not let the hose stir up the slurry at the bottom of

the drum.
Do not draw off fuel from near the bottom of the

drum.
The rest in the drum is not suitable for the engine

and should only be used for cleaning purposes.
Notes on the performance of the engine
On diesel engines both combustion air and fuel injec-
tion quantities are thoroughly adapted to each other
and determine power, temperature level and exhaust
gas quality of the engine.
If your engine has to work permanently in "thin air" (at
higher altitudes) and under full load, you should con-
sult the customer service of BOMAG or the customer
service of the engine manufacturer.
Notes on the hydraulic system
During maintenance work on the hydraulic system
cleanliness is of major importance. Make sure that no
dirt or other contaminating substances can enter into
the system. Small particles can produce flutes in
valves, cause pumps to seize, clog nozzles and pilot
bores, thereby making expensive repairs inevitable.
If, during the daily inspection of the oil level the hy-
draulic oil level is found to have dropped, check all
lines, hoses and components for leaks.
Seal external leaks immediately. If necessary in-

form the responsible customer service.
Do not store drums with hydraulic oil outdoors, or at

least under a cover. Water can be drawn in through
the bunghole when the weather changes.
Always use the filling and filtering unit (BOMAG

part-no. 007 610 01) to fill the hydraulic system.
This unit is fitted with a fine filter to clean the hydrau-
lic oil, thereby prolonging the lifetime of the filter.
Clean fittings, filler covers and the area around such

parts before disassembly to avoid entering of dirt.
Do not leave the tank opening unnecessarily open,

but cover it so that nothing can fall in.
Notes on the cooling system
For water-cooled engines the preparation and inspec-
tion of the coolant is of greatest importance, as other-
wise the engine may be damaged by corrosion,
cavitation and freezing.
The coolant is prepared by mixing a cooling system
protection agent into the coolant.
The cooling system must be permanently monitored.
Besides the inspection of the coolant level this in-
cludes also the inspection of the concentration of cool-
ing system protection agent.
The concentration of cooling system protection agent
can be checked by means of commercial testers (gly-
comat).
Fuels and lubricants
BOMAG 33 008 911 79
2.2
! Danger
Health hazard!
The mixing of nitrite based anti-freeze agents with
amine based agents results in the formation of
health affecting nitrosamines.
Environment
Cooling system protection agents must be dis-
posed of environmentally.
2.2 Fuels and lubricants
Engine oil
Quality
Lubrication oils are classified according to their per-
formance and quality class. Oils according to other
comparable specifications may be used.
The exact assignment of the approved oil qualities
and oil change intervals can be taken from the follow-
ing section "Lubrication oil change intervals".
Consult your local service station if in doubt.
Oil viscosity
Multi-purpose oils should be generally used.
Since lubrication oil changes its viscosity with the tem-
perature, the ambient temperature at the operating lo-
cation of the engine is of utmost importance when
choosing the viscosity class (SAE-class) .
Optimal operating conditions can be achieved by us-
ing the opposite oil viscosity chart (Fig. 11) as a refer-
ence.
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, occasional exceeding of the limits
should not happen over a longer period of time.
Approved engine oils
Deutz DQC II-05 DQC II-05
ACAE E3/96/E5-02/
E7-04
E4-99/E6-04
API CG-4/CH-4/CI-
4
-
DHD DHD-1 -
2.2 Fuels and lubricants
BOMAG 34 008 911 79
Fig. 11
With their better temperature and oxidation stability
synthetic lubrication oils offer quite a few benefits.
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.
ACEA
1
E3-96/E5-02/E7-04/
E4-99/
E6-04 = 500 operating hours
API
2
CG-4/CH-4/
CI-4 = 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 en-
sure strict cleanliness when filling in. A higher sulphur
content has a negative effect on the oil change inter-
vals. Use only winter-grade diesel fuel under low am-
bient temperatures. The fuel level should always be
topped up in due time so that the fuel tank is never run
dry, as otherwise filter and injection lines need to be
bled.
When using fuels with a Cetan number < 49 poor
starting and white smoke can be expected, in particu-
lar 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.
DIN/EN 590
BS 2869
ASTM D 975-78: 1-D and 2-D.
Nato Codes: F-54, F-34, F44 and XF63

Winter fuel
! Danger
Fire hazard!
Diesel fuels must never be mixed with gasoline.
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. At very
low temperatures disturbing paraffin separation can
also be expected when using winter diesel fuel.
In most cases a sufficient cold resistance can also be
achieved by adding flow enhancing fuel additives.
Consult the engine manufacturer.
Operation with rape seed oil methyl ester (RME
Bio Diesel)
Due to the extreme quality differences of RMEW-fuels
available on the market, which are caused by the non-
existence of a standardization, BOMAG does general-
ly not approve any RME-fuels. If this is neglected the
warranty will become null and void!
However, if you still intend to operate the machine
with RME-fuels you should observe the following in-
formation:
Reduced engine power (approx. 7%), higher fuel

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

with DIN draft 51606.
1 Association des Constructeurs European dAutomobiles
2 American Petroleum Institute
Fuels and lubricants
BOMAG 35 008 911 79
2.2
Avoid longer periods of standstill (formation of resin,

corrosion in injection system)
RME-fuel can damage the paint finish of the ma-

chine.
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 re-
placed on a regular basis or should be replaced by
parts made of fluorinated rubber. However, fluori-
nated rubber is not resistant against normal diesel
fuel.
If the fuel filter is clogged the filter change intervals

must be shortened accordingly.
Coolant, anti-freeze agent
The correct quality of water is highly important when
preparing coolant. Clear and clean water within the
boundaries of the following analysis values should
generally be used.
*
1
Proportion of carbonate hardness on the total hard-
ness min. 3 dGH
Information concerning the water quality can be ob-
tained from the waterworks.
A test case for checking the water quality can be or-
dered from the engine manufacturer.
If the values of the analysis deviate, the water must be
treated accordingly.
pH-value too low

Adding of caustic lye of soda or caustic potash so-
lution.
Total hardness too high:

Mixing with dehardenede water.
Total hardness or carbonate hardness too low:

Mixing with harder water.
Chlorides and/or sulphates too high:

Mixing with dehardenede water.
As a protection against frost, corrosion and boiling
point anti-freeze agents must be used under any cli-
matic conditions.
The proportion of cooling system protection agent
must be between min. 35% and max. 45% to the wa-
ter.
! Caution
Do not mix different coolants and additives of any
other kind.
! Danger
Health hazard!
The mixing of nitrite based anti-freeze agents with
amine based agents results in the formation of
health affecting nitrosamines.
Environment
Cooling system protection agents must be dis-
posed of environmentally.
Hydraulic oil
The hydraulic system is operated with hydraulic oil HV
46 (ISO) with a kinematic viscosity of
46 mm
2
/s at 40C. For topping up or for oil changes
use only high-quality hydraulic oil, type HVLP accord-
ing to DIN 51524, part 3, or hydraulic oils type HV ac-
cording to ISO 6743/3. The viscosity index (VI) should
be at least 150 (observe information of manufacturer).
Bio-degradable hydraulic oil
On request the hydraulic system can also be filled with
ester based biodegradable hydraulic oil (Panolin HLP
Synth. 46). The biologically quickly degradable hy-
draulic 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 lu-
brication 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.
Lubrication grease
For lubrication use only EP-high pressure grease, lith-
ium saponified (penetration 2).
Water quality
Analysis values min. max.
pH-value at 20 C 6,5 8,5
Chloride ion content [mg/dm
3
] - 100
Sulphate ion content [mg/dm
3
] - 100
Total hardness*
1
[dGH] ] 3 12
2.3 Table of fuels and lubricants
BOMAG 36 008 911 79
2.3 Table of fuels and lubricants

Assembly Fuel or lubricant Quantity approx.
Summer Winter Attention
Observe the level marks
Engine Engine oil ACEA: E3/96/E5-02/
E7-04 or
approx. 15,5 litres incl. oil
filter
API: CG-4/CH-4/CI-4
SAE 10W/40
(-20 C to +40 C)
SAE 15W/40
(-15 C to +40 C)
Fuel
Diesel Winter diesel fuel approx. 340 litres
Hydraulic system Hydraulic oil (ISO), HV46, kinem. viscosity approx. 60 litres
46 mm
2
/s at 40 C
Vario exciter drum Engine oil SAE 15W/40 approx. 16,5 litres
Exciter housing attach-
ment plates
Engine oil SAE 15W/40 2.7 litres each
Drive axle Gear oil SAE 90, API GL5 approx. 12,5 litres
Wheel hubs Gear oil SAE 90, API GL5 approx. 0,7 per side
Axle reduction gear Gear oil SAE 90, API GL5 approx. 1,9 litres
Drum drive gear Gear oil SAE 90, API GL5 approx. 3,2 litres
Air conditioning system Refrigerant R134A approx. 1400 g
Engine cooling system Cooling system protection agent approx. 16 litres
Tires Water approx. 300 litres
Calcium chloride (CaCl
2
) or magnesium chloride
(MgCl
2
)
approx. 139 kg
Running-in instructions
BOMAG 37 008 911 79
2.4
2.4 Running-in instructions
The following maintenance work must be per-
formed when running in new machines or over-
hauled engines:
! Caution
Up to approx. 250 operating hours check the en-
gine oil level twice every day.
Depending on the load the engine is subjected to,
the oil consumption will drop to the normal level
after approx. 100 to 250 operating hours.
After a running-in time of 30 minutes
Retighten the V-belt

After 250 operating hours
Retighten bolted connections on intake and exhaust

tubes, oil sump and engine mounts.
Retighten the bolted connections on the machine.
Retighten all wheel fastening screws with the spec-

ified tightening torque.
Oil change diesel engine and engine oil filter
1. Oil change in Vario exciter
Oil change in drive axle
Oil change, axle reduction gear
Oil change in wheel hubs
1. Oil change in drum drive gear

After 500 operating hours
2. Oil change in Vario exciter
2. Oil change in drum drive gear

2.5 Maintenance chart
BOMAG 38 008 911 79
No. Maintenance work Remark
R
u
n
n
i
n
g
-
i
n

i
n
s
t
r
u
c
t
i
o
n
s

a
f
t
e
r

2
5
0

o
p
e
r
a
t
i
n
g

h
o
u
r
s
e
v
e
r
y

1
0

o
p
e
r
a
t
i
n
g

h
o
u
r
s
,

d
a
i
l
y
e
v
e
r
y

2
5
0

o
p
e
r
a
t
i
n
g

h
o
u
r
s
e
v
e
r
y

5
0
0

o
p
e
r
a
t
i
n
g

h
o
u
r
s
e
v
e
r
y

1
0
0
0

o
p
e
r
a
t
i
n
g

h
o
u
r
s
e
v
e
r
y

2
0
0
0

o
p
e
r
a
t
i
n
g

h
o
u
r
s
e
v
e
r
y

3
0
0
0

o
p
e
r
a
t
i
n
g

h
o
u
r
s
e
v
e
r
y

6
0
0
0

o
p
e
r
a
t
i
n
g

h
o
u
r
s
a
s

r
e
q
u
i
r
e
d
5.6
Check the engine oil level Dipstick mark X
5.7
Check the water separator X
5.8
Check the fuel level X
5.9
Check the hydraulic oil level Inspection glass X
5.10
Check the coolant level Inspection glass X
5.11
Check the dust separator X
5.12
Check the tire pressure X
5.13
Clean the cooling fins on engine
and hydraulic oil cooler
X
5.14
Check the oil level in the drive axle X
5.15
Check the oil level in the wheel
hubs
X
5.16
Check the oil level in the axle re-
duction gear
X
5.17
Check the oil level in the drum re-
duction gear
X
5.18
Checking the Vario exciter oil level X
5.19
Change engine oil and oil filter car-
tridge
1
min. 1x per year X X
5.20
Change the fuel filter cartridge X X
5.21
Drain the sludge from the fuel tank X
5.22
Battery maintenance Pole grease X
5.23
Change the fuel pre-filter cartridge X
5.24
Check, replace the refrigerant
compressor V-belt
X
5.25
Service the air conditioning X
5.26
Check, adjust the valve clearance Intake = 0,4 mm
Exhaust = 0,6 mm
X
5.27
Adjusting the control piston play X
Maintenance chart
BOMAG 39 008 911 79
2.5
5.28
Checking, replacing the V-belt X
5.29
Check the engine mounts X X
5.30
Oil change in drive axle min. 1x per year X X
5.31
Oil change in wheel hubs min. 1x per year X X
5.32
Oil change, axle reduction gear min. 1x per year X X
5.33
Oil change in drum drive reduction
gear**
5.34
Oil change in Vario exciter
2
see foot note, min.
1 x per year
X X
5.35
Oil change exciter shaft housing at-
tachment plates
5.36
Retighten the fastening of the axle
on the frame
X
5.37
Tighten the wheel nuts X X
5.38
Check the ROPS X
5.39
Clean the oil bath air filter min. 1x per year X
5.40
Change hydraulic oil and breather
filter
3
at least every 2
years
X
5.41
Change the hydraulic oil filter*** at least every 2
years
X
5.42
Change the steering oil filter*** at least every 2
years
X
5.43
Change the attachment plate oil fil-
ter***
at least every 2
years
X
5.44
Change the coolant at least every 2
years
X
5.45
Replace the crankcase ventilation
valve
at least every 2
years
X
5.46
Electronic injector test EMR X
5.47
Cleaning, changing the dry air filter
cartridge
min. 1x per year,
safety cartridge at
least every 2
years
X
R
u
n
n
i
n
g
-
i
n

i
n
s
t
r
u
c
t
i
o
n
s

a
f
t
e
r

2
5
0

o
p
e
r
a
t
i
n
g

h
o
u
r
s
e
v
e
r
y

1
0

o
p
e
r
a
t
i
n
g

h
o
u
r
s
,

d
a
i
l
y
e
v
e
r
y

2
5
0

o
p
e
r
a
t
i
n
g

h
o
u
r
s
e
v
e
r
y

5
0
0

o
p
e
r
a
t
i
n
g

h
o
u
r
s
e
v
e
r
y

1
0
0
0

o
p
e
r
a
t
i
n
g

h
o
u
r
s
e
v
e
r
y

2
0
0
0

o
p
e
r
a
t
i
n
g

h
o
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r
s
e
v
e
r
y

3
0
0
0

o
p
e
r
a
t
i
n
g

h
o
u
r
s
e
v
e
r
y

6
0
0
0

o
p
e
r
a
t
i
n
g

h
o
u
r
s
a
s

r
e
q
u
i
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e
d
BOMAG 40 008 911 79

5.48
Adjusting the scrapers X
5.49
Adjust the parking brake X
5.50
Change the tires X
5.51
Change the fresh air filter in the
cabin
X
5.52
Tightening torques X
5.53
Engine conservation X
1 Oil change intervals depend on quality of oil and fuel (sulphur content)
2 Oil change intervals after 250 h, after 500 h, after 1000 h, and then every 1000 h.
3 Also in case of repair in the hydraulic system.
R
u
n
n
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n
g
-
i
n

i
n
s
t
r
u
c
t
i
o
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s

a
f
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2
5
0

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p
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g

h
o
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s
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v
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y

1
0

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a
t
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g

h
o
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s
,

d
a
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v
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y

2
5
0

o
p
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a
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g

h
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v
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y

5
0
0

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p
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a
t
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g

h
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v
e
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y

1
0
0
0

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p
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t
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g

h
o
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v
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y

2
0
0
0

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p
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a
t
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g

h
o
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e
v
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y

3
0
0
0

o
p
e
r
a
t
i
n
g

h
o
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s
e
v
e
r
y

6
0
0
0

o
p
e
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a
t
i
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h
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a
s

r
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d
BOMAG 41 008 911 79
3 Technical data
3.1 Technical data
BOMAG 42 008 911 79
3.1 Technical data
Fig. 12
Dimensions in
mm
A B D H H2 K L O1 O2 S W
BW 213 DH-4
BVC/P
2960 2250 1500 2268 2972 490 5808 60 60 35 2130
1
BW 213 DH-4 BVC/P
Weights
Operating weight (CECE)
with ROPS and cabin
kg 15785
Axle load, drum (CECE) kg 7598
Axle load, wheels (CECE) kg 8187
Static linear load kg/cm 35,7
Travel characteristics
Speed km/h 0 ... 13
Max. gradability (depend-
ing on soil)
% 50
Engine
Engine manufacturer Deutz
Type TCD 2013 L04 2V
Cooling Water
Number of cylinders 4
Rated power ISO 3046 kW 119
Rated speed rpm 2200
Electrical equipment V 12
Drive system hydrostatic
Driven axles 2
Brakes
Service brake hydrostatic
Parking brake hydr.-mech.
Steering
Type of steering articulated
Steering operation hydrostatic
Technical data
BOMAG 43 008 911 79
3.1

Vibration, drum
Frequency Hz 28
Amplitude mm 0 ... 2,4
Vibration, attachment
plates
Frequency Hz 40 ... 55
Tires
Tire size 23.1/18-26/12PR
Air pressure bar 1,8
Filling capacities
Engine Litres 15
Fuel Litres 340
Hydraulic oil Litres 60
1 The right for technical modifications remains reserved
1
BW 213 DH-4 BVC/P
3.1 Technical data
BOMAG 44 008 911 79
Fig. 13
Dimensions in
mm
BW 213 DH-4
BVC
2960 2250 1500 2268 2972 490 5808 60 60 35 2130
1
BW 213 DH-4 BVC
Weights
with ROPS and cabin
kg 14900
Speed km/h 0 ... 13
ing on soil)
% 53
Engine
Cooling Water
Driven axles 2
Permissible ambient tem-
peratures
C -20 .... +50
Brakes
Technical data
BOMAG 45 008 911 79
3.1

Steering
Vibration
Vibrating drum
Frequency Hz 28
Tires
Tire size 23.1-26/12 TL R3
Filling capacities
Engine Litres 15
Fuel Litres 340
1
BW 213 DH-4 BVC
3.1 Technical data
BOMAG 46 008 911 79
Fig. 14
Dimensions in
mm
Variocontrol
2960 2250 1500 2268 2972 490 5808 60 60 35 2130
1
Variocontrol
Weights
with ROPS and cabin
kg 14900
Speed km/h 0 ... 13
ing on soil)
% 53
Engine
Cooling Water
Driven axles 2
Permissible ambient tem-
peratures
C -20 .... +50
Brakes
Steering
Technical data
BOMAG 47 008 911 79
3.1

Vibration
Vibrating drum
Frequency Hz 28
Tires
Tire size 23.1-26/12 TL R3
Filling capacities
Engine Litres 15
Fuel Litres 340
1
Variocontrol
3.1 Technical data
BOMAG 48 008 911 79
Fig. 15
Dimensions in
mm
Variocontrol +
2960 2250 1500 2268 2972 490 5808 60 60 35 2130
1
Variocontrol +
Weights
with ROPS and cabin
kg 15785
Speed km/h 0 ... 13
ing on soil)
% 50
Engine
Cooling Water
Driven axles 2
Brakes
Steering
Technical data
BOMAG 49 008 911 79
3.1

Vibration, drum
Frequency Hz 28
Vibration, attachment
plates
Frequency Hz 40 ... 55
Tires
Tire size 23.1/18-26/12PR
Filling capacities
Engine Litres 15
Fuel Litres 340
1
Variocontrol +
3.1 Technical data
BOMAG 50 008 911 79
Additional engine data
Combustion principle 4-stroke diesel
Low idle speed rpm 700 - 800
High idle speed rpm 2200 - 2250
Spec. fuel consumption g/kWh 226
Valve clearance intake mm 0,4
Valve clearance exhaust mm 0,6
Injection valves opening pressure bar DRC / 1600
Travel pump
Manufacturer Sauer
Type 90R100 (EP)
System Axial piston/swash plate
Max. displacement cm
3
/rev. 75
Max. flow capacity ccm x n l/min 75
High pressure limitation bar 400
Charge pressure, high idle bar 25 1
Drum reduction gear
Type CR 31
Transmission ratio 45,6
Drum drive motor
Manufacturer Sauer
Type 51C 110 (EP)
System Axial piston bent axle
Displacement (stage 1) cm
3
/rev. 110
Displacement (stage 2) cm
3
/rev. 31,4
Perm. leak oil rate l/min 2 10
Flushing rate l/min 10
Flushing limitation bar 16
Axle drive motor
Manufacturer Sauer
Type 51D 110 (EP)
System Axial piston bent axle
Max. displacement (stage 1) cm
3
/rev. 110
Min. displacement (stage 2) cm
3
/rev. 55,3
Perm. leak oil rate l/min 2 10
Flushing limitation bar 16
Vibration pump
Manufacturer Sauer
Type 90R 075 (EP)
3
/rev. 75
Start up pressure bar 365 65
Operating pressure (soil depend-
ent)
bar approx. 100
Vibration motor
Manufacturer Bosch-Rexroth
Type A2FM 56 HDD
System Axial piston/bent axle
Displacement cm
3
/rev. 56
Technical data
BOMAG 51 008 911 79
3.1

Flushing pressure limitation bar 13
Check steering/
Type HY/ZFFS11/16+8
System Tandem gear pump
Displacement cm
3
/rev. 16 / 8
Max. steering pressure bar 205 15
Steering valve
Manufacturer Danfoss
Type OSPC 500 ON
System Rotary spool valve
Swivel motor
Type STF 1-000-21
System Piston rack
Rear axle
Manufacturer Dana
Type CHC 193/66LD
Differential No-Spin
Degree of locking % 100
Reduction ratio 65,08
Additional pump for plates
Manufacturer Sauer
Type 42R 041
3
/rev. 41
Start up pressure bar 370 10
Charge pressure, high idle bar 20 2
Vibration motor for plates
Manufacturer Bosch-Rexroth
Type A2FM 16
Displacement cm
3
/rev. 16
Frequency Hz 35-65/45-85
3.1 Technical data
BOMAG 52 008 911 79
The following noise and vibration data acc. to
- EC Machine Regulation edition (98/37/EC) and
- Noise Emission Regulation 2000/14/EC
were determined at nominal speed of the drive engine and with vibration running. The machine was
standing on an elastic base.
During operation these values may vary because of the existing operating conditions.
Noise value
The sound level according to enclosure 1, paragraph 1.7.4. f of the EC-machine regulation is
sound pressure level at the work place of the operator (with cabin):
L
pA
= 75 dB(A)
The nose emission value for the machine according to the noise emission regulation 2000/14/EG is
guaranteed sound capacity level of the machine:
L
WA
= 104 dB(A)
These sound values were determined according to ISO 3744 for the sound capacity level (L
wA
) and ISO 11204
for sound pressure level (L
pA
) at the place of the operator.
Vibration value
The vibration values according to enclosure 1, paragraph 3. 6. 3. a of the EC-machine regulation are:
Vibration of the entire body (drivers seat)
The weighted effective acceleration value determined in accordance with ISO 7096 is 0.5 m/sec
2
.
Hand-arm vibration values
The weighted effective acceleration value determined in accordance with EN 500/ISO 5349, is
2.5 m/sec
2
.
BOMAG 53 008 911 79
4 Connection overview
4.1 Connection overview
BOMAG 54 008 911 79
Fig. 1
Connection overview
BOMAG 55 008 911 79
4.1
1 Proportional valve, vibration low frequency
2 Proportional valve, vibration high frequency
3 Proportional valve, travel drive forward
4 Proportional valve, travel drive reverse
5 Multi-function valve 400 bar (boost check and
pressure relief valve), travel system
pressure relief valve), travel system
7 High pressure port B, reverse
8 High pressure port A, forward
9 Charge pressure relief valve, travel pump
10 Charge pressure (connection to travel pump 15)
11 Charge oil to filter
12 Port L2 (connection to vibration pump 24)
13 Pressure test port MA, high pressure forward
14 Pressure test port MB, high pressure reverse
15 Charge pressure to solenoid valve for brake and
speed range selection (charge oil vibration 10)
16 Charge pressure test port
pressure relief valve), vibration high frequency
pressure relief valve), vibration low frequency
19 Pressure test port, vibration low frequency
20 Pressure test port, vibration high frequency
21 High pressure port, high frequency
22 High pressure port, low frequency
23 Charge pressure relief valve vibration pump
24 Port L2 (connection to travel pump 12)
25 Leak oil port (connection to thermostat housing
port A)
26 Port S, suction line between hydraulic oil tank and
charge pump (charge pump in vibration pump)
27 Charge pump (only in vibration pump)
28 Pressure test port X1/X2, travel pump, control
chamber
29 Adjustment screw, mechanical neutral position
4.1 Connection overview
BOMAG 56 008 911 79
BOMAG 57 008 911 79
5 Tests and adjustments
5.1 Special tools, tests and adjustments
BOMAG 58 008 911 79
1. Vibration reed frequency meter
1000 - 4000 rpm
17 - 67 Hz
BOMAG part-no.: 300 120 80
2. Sirometer (frequency meter)
800 - 50.000 rpm
14 - 750 Hz
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
4. Digital rpm-meter for petrol engines
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Special tools, tests and adjustments
BOMAG 59 008 911 79
5.1
5. Digital rpm-meter for petrol engines
6. Digital rpm-meter, optical/mechanical, universal
use
7. Infrared manual thermometer, -18 to 275C
8. Hydraulic test case, large
i Note
4 X 600 bar pressure gauges
4 X 60 bar pressure gauges
8 pressure test hoses
Fig. 5
Fig. 6
Fig. 7
Fig. 8
BOMAG 60 008 911 79
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
10. Pressure test hoses
1000 mm BOMAG part-no.: 079 930 02
2500 mm BOMAG part-no.: 079 930 03
11. Pressure gauge
60 bar BOMAG part-no.: 059 721 07
600 bar BOMAG part-no.: 059 721 04
12. Adapter for pressure test hose
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Special tools, tests and adjustments
BOMAG 61 008 911 79
5.1
13. Gear pump testing device
14. Vacuum pump for hydraulic oil tank
BOMAG part-no.: 007 610 04 (12 Volt)
BOMAG part-no.: 007 610 24 (24 Volt)
Fig. 13
Fig. 14
5.2 Activate service mode
BOMAG 62 008 911 79
5.2 Activate service mode
Activate the input mode
1. Set the travel lever to braking position
i Note
The function can only be activated when the trav-
el lever is engaged in braking position.
2. Switch on the ignition.
3. Press both Info-buttons (Fig. 1) longer than three
seconds to access the input mode.
T
Activate service mode
i Note
The input mode starts with flashing of the left
hand digit (Fig. 2). Here you have the possibility
to change to the service mode using access code
"9999".
The green buttons F2, F4 (Fig. 3) can be used to
increase or reduce the corresponding digit.
With the blue button F5, F3 (Fig. 4) you can jump
to the corresponding next digit.
Once the last digit has been entered the code will
be transmitted to the control by pressing the right
hand blue button (F3) again.
T
4. Enter access code "9999".
Fig. 1
Fig. 2
Fig. 3
BOMAG 63 008 911 79
5.2
i Note
If the access code has been entered correctly,
the "spanner" symbol appears in the display and
the first digit flashes again.
Individual operating states can now be inter-
rogated, activated or deactivated by transmit-
ting further input codes to the control.
Deactivating the service mode
5. Quit the service mode by switching the ignition
off.
Fig. 4
5.3 Driving against the closed brake
BOMAG 64 008 911 79
i Note
On this machine the electric plug connection to
the brake valve must not be pulled off, because
the ESX-control would in this case detect a line
interruption in the current path to the brake.
i Note
T
i Note
The input mode srats with flashing of the left hand
digit (Fig. 2). Here you have the possibility to
change to the service mode using access code
"9999".
T
4. Enter code number "9999".
Fig. 1
Fig. 2
Fig. 3
Driving against the closed brake
BOMAG 65 008 911 79
5.3
i Note
Activating the brake function
5. Enter code number "0500" via the LC display
(Fig. 5).
The brake will not be released when actuating the
travel lever.
The warning buzzer sounds to inform the opera-
tor about this status. The brake control light in the
LC display remains activated.
Deactivating the brake function
6. Enter code number "501" or switch the ignition off
to stop this function.
Fig. 4
Fig. 5
5.4 Turn the steering against an end stop.
BOMAG 66 008 911 79
5.4 Turn the steering against an end stop.
i Note
The steering is actuated against an "electronic"
stop by the ESX-control. To actuate the steering
against the mechanical stop the ESX-control
must be switched to the mode "Teaching the
electronic end stops of the angle transducer
(BVC)".
i Note
T
i Note
The input mode starts with flashing of the left
hand digit (Fig. 2). Here you have the possibility
to change to the service mode using access code
"9999".
T
4. Enter code number "9999".
Fig. 1
Fig. 2
Fig. 3
Turn the steering against an end stop.
BOMAG 67 008 911 79
5.4
i Note
Activating the mode
5. Enter code number "2010" (Fig. 5) to activate the
mode "teaching the steering stops".
The steering can now be actuated against the
mechanical stop.
The display shows the nominated steering posi-
tion (0..1000).
Deactivating the mode
6. Enter code number "501" or switch the ignition off
to stop this function.
Fig. 4
Fig. 5
5.5 Pressure tests in the travel circuit
BOMAG 68 008 911 79
5.5 Pressure tests in the travel circuit
Special tools
Hydraulic test case
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 C).
1. Block drums and wheels with suitable chocks
(Fig. 1).
! Danger
The closed brake mode must be activated!
i Note
Drive against the closed brake, see correspond-
ing chapter.
2. Enter code number "0500" to close the brake
(Fig. 2).
3. Connect 600 bar pressure gauges to the high
pressure test ports for "forward travel" and "re-
verse travel" and a 60 bar pressure gauge to the
charge pressure test port (Fig. 3).
4. Start the engine and run it with maximum speed.
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
Evaluation of test
If the nominal value is not reached, check the
steering/charge pump.
Fig. 1
Fig. 2
Fig. 3
Pressure tests in the travel circuit
BOMAG 69 008 911 79
5.5
6. Move the travel lever (Fig. 4) quickly forward and
backward, 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.
If the charge pressure drops considerably during
the high pressure test, check the components in-
dividually.
Deactivate the closed brake mode
7. Quit this mode by switching the ignition off.
Fig. 4
5.6 Checking / adjusting the neutral positions of the travel pump
BOMAG 70 008 911 79
5.6 Checking / adjusting the neutral posi-
tions of the travel pump
Special tools
Hydraulic test case
! Caution
1. Block drums and wheels with suitable chocks
(Fig. 1).
! Danger
i Note
ing chapter.
2. Enter code number "0500" to close the brake
(Fig. 2).
3. Connect a 600 bar pressure gauge each to the
high pressure test ports for "forward travel" and
"reverse travel" (Fig. 3).
Fig. 1
Fig. 2
Fig. 3
Checking / adjusting the neutral positions of the travel pump
BOMAG 71 008 911 79
5.6
! Danger
i Note
ing chapter.
4. As a measure to avoid signal residues from the
hydraulic neutral position connect both control
chambers X1 and X2 with a hose (Fig. 4).
6. Read the high pressure gauges (Fig. 5).
Nominal value
Both pressure gauges (Fig. 5) must show equal
pressure (charge pressure).
i Note
If necessary repeat the pressure test with 60 bar
pressure gauges, for more accurate readings.
Evaluation of test
If pressure builds up on one side, adjust the me-
chanical neutral position (Fig. 6), until the pres-
sures on both pressure gauges are identical.
Fig. 4
Fig. 5
Fig. 6
5.7 Pressure measurements in the vibration circuit
BOMAG 72 008 911 79
5.7 Pressure measurements in the vibra-
tion circuit
Special tools
Hydraulic test case
! Caution
1. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
2. Block the wheels with suitable chocks.
3. Apply the brake.
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 at high or low frequency and
read the pressure gauge.
Nominal value
Charge pressure = charge pressure at high idle
(see technical data of travel pump).
Start-up pressure = vibration pump start-up pres-
sure (see technical data of vibration pump).
Operating pressure = vibration pump operating
pressure (see technical data of vibration pump).
Evaluation of test
If the charge pressure drops, check the compo-
nents individually.
If the starting pressure is not reached, check the
vibration pump.
If the starting pressure is only reached for one fre-
quency, check the high pressure relief valves.
Fig. 1
Fig. 2
Check the leakage rate of the vibration motor
BOMAG 73 008 911 79
5.8
5.8 Check the leakage rate of the vibration
motor
! Caution
1. Drive the drum of the machine on an elastic base
(rubber buffers) (Fig. 1) and block the wheels ad-
ditionally with suitable chocks.
1. Apply the brake.
2. Block the flushing pressure relief valve (Fig. 2)
with washers.
3. Disconnect the leak oil hose (Fig. 3), connect a
measuring hose and hold it into a measuring
beaker.
5. Switch the vibration on and measure the running
out leak oil during one timed minute.
Nominal value
max. 1.5 litre/min
Evaluation of test
If the permissible leak oil rate is exceeded, re-
place the vibration motor.
Fig. 1
Fig. 2
Fig. 3
5.9 Pressure test in steering circuit
BOMAG 74 008 911 79
Special tools
Hydraulic test case, gear pump testing equipment
! Caution
ture of the hydraulic oil (approx. 50 C).
Measurement 1
1. Connect a 600 bar pressure gauge to the steering
pressure test port (Fig. 1).
i Note
The steering is actuated against an "electronic"
stop by the ESX-control. To actuate the steering
against the mechanical stop the ESX-control
must be switched to the mode "Teaching the end
stops of the angle transducer (BVC)".
Activate teach mode
i Note
Turn the steering against the mechanical stop,
see corresponding chapter.
2. Enter code number "2010" (Fig. 2).
3. Start the engine and run it at idle speed.
! Danger
Danger of crushing, do not access the articu-
lation area of the machine!
4. Turn the steering against an end stop.
5. Set the travel lever to neutral position (no braking
function).
6. Read the pressure gauge.
Nominal value
see technical data, max. steering pressure of
Evaluation of test 1
If the nominal value is reached, check the steer-
ing cylinder.
Deactivate the steering mode
7. Quit the teach mode by switching the ignition off.
Fig. 1
Fig. 2
Pressure test in steering circuit
BOMAG 75 008 911 79
5.9
Measurement 2
8. Disconnect the hydraulic hoses from ports L and
R (Fig. 3) on the steering cylinders and close
them with plugs.
9. Start the engine and run it at idle speed.
10. Turn the steering wheel.
11. Read the pressure gauge.
Nominal value
see technical data for steering/charge pump.
If the nominal value is reached, replace the steer-
ing cylinder.
If the nominal value is not reached, check the
12. Reconnect the hydraulic hoses to the steering
cylinders.
Measurement 3
13. Close the pump outlet port (Fig. 4) with the gear
pump test equipment.
14. Crank the engine with the starter
Nominal value
see technical data for steering/charge pump.
If the nominal value is reached, replace the steer-
ing valve.
If the nominal value is not reached, replace the
Fig. 3
Fig. 4
BOMAG 76 008 911 79
BOMAG 77 008 911 79
6 Flushing and bleeding
6.1 Special tools for flushing
BOMAG 78 008 911 79
1. Filling and filtering unit with oil bag
2. Filter element
3. Flushing filter (S connection)
4. Filter element 1
5. Flushing hose 20S - 25S (2 pieces)
6. Screw socket R1 - 25S (2 pieces)
7. Flushing filter (L connection)
8. Filter element
9. Flushing hose 15L (2 pieces)
10. Screw socket R3/4 -- 15L (2 pieces)
11. SAE-flange 1 - 20S
12. O-ring
BOMAG part-no. 062 203 30
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Special tools for flushing
BOMAG 79 008 911 79
6.1
13. Flanged plate 1 - 25S
14. O-ring
BOMAG part-no. 062 202 22
15. Reducing fitting 18L - 15L
16. Reducing fitting 25S - 20S
17. Reducing fitting 20S - 16S
Fig. 5
Fig. 6
Fig. 7
Fig. 8
BOMAG 80 008 911 79
18. Connecting socket 15L
19. Connecting socket 18L
20. Connecting socket 16S
21. Connecting fitting 20S
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Special tools for flushing
BOMAG 81 008 911 79
6.1
22. Connecting fitting 25S
23. Angular fitting 18L
24. Elbow fitting 16L
25. Elbow 20S
Fig. 13
Fig. 14
Fig. 15
Fig. 16
BOMAG 82 008 911 79
26. Elbow 25S
27. Pipe connection 16S - 16S
28. Connecting hose 15L
Fig. 17
Fig. 18
Fig. 19
Flushing - general
BOMAG 83 008 911 79
6.2
6.2 Flushing - general
! 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
! Caution
Always flush the complete oil circuit after
you have replaced a component.
Chips (abrasion) in the oil
Open and clean all components in the oil
circuit, replace if necessary.
Clean all high pressure hoses in the oil cir-
cuit, replace if necessary.
If abrasion is found in the travel circuit you
should also flush the vibration circuit.
If abrasion is found in the vibration circuit
you should also flush the travel circuit.
Before flushing
Change the filter element
Fig. 1
Change the hydraulic oil filter element (1).
Clean the hydraulic tank
Fig. 2
! Caution
Change the oil in case of excessive contam-
ination, oil discoloration or if the oil change
interval is almost due.
Filter the tank content with the filling and fil-
tering unit and pump it into the oil bag.
Mark all hoses and disconnect them from
the hydraulic oil tank.
Clean the oil tank thoroughly from inside, if
necessary remove the complete tank cover.
Reconnect all hoses.
Fill the hydraulic oil tank again with the fill-
ing and filtering unit.
Bleeding
Fig. 3
Always bleed closed hydraulic circuits if
lines had been removed or connected.
6.2 Flushing - general
BOMAG 84 008 911 79
Servicing the flushing filter kit
Fig. 4
Replace the filter element of the flushing fil-
ter when the red control pin of the contami-
nation indicator is pressed out during the
filtering process.
Clean hoses and connections and store the
flushing kit in a clean and protected envi-
ronment.
Flushing schematic travel circuit (distribution travel pump)
BOMAG 85 008 911 79
6.3
6.3 Flushing schematic travel circuit (distribution travel pump)
BOMAG 86 008 911 79

1 Elbow union (tool)
2 Connecting union (tool)
3 Drum drive motor
4 Axle motor
5 Screw socket R1 - 25S (tool)
6 Flushing hose 25S - 20S (tool)
8 Flushing filter with filter element 1 (tool)
10 Reducing fitting (tool)
11 Travel pump
12 High pressure hose (B, drum drive motor reverse)
13 High pressure hose (A, drum drive motor for-
ward)
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)
Flushing the travel circuit (travel pump distribution)
BOMAG 87 008 911 79
6.4
6.4 Flushing the travel circuit (travel
pump distribution)
Flushing the drum drive
Replacing the hydraulic oil filter element
Cleaning the hydraulic oil tank
i Note
Observe the chapter "Flushing - General"
Installing the flushing filter
! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
The flushing filter must be installed in the low
pressure side in the return flow to the pump,
so that only cleaned oil will enter the travel
pump in forward travel.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
1. Disconnect the high pressure hose 12 (see chap-
ter "Flushing schematic - travel circuit") from the
travel pump (high pressure port 17) and connect
it with the flushing hose (7) (flushing filter inlet
"IN").
2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port 17) on the travel
pump.
Disconnect the drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
cuit by joining the high pressure hoses (12 and
13) on the drum drive motor together.
Fig. 1
Fig. 2
6.4 Flushing the travel circuit (travel pump distribution)
BOMAG 88 008 911 79
Bleeding the travel circuit
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Flushing the hoses
4. Block drums and wheels with suitable chocks.
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
! 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. 3
Fig. 4
Fig. 5
Fig. 6
BOMAG 89 008 911 79
6.4
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.
i Note
flushing process.
! Caution
12. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
13. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve forward travel.
15. Remove the flushing filter and reconnect the high
pressure lines.
Fig. 7
Fig. 8
Fig. 9
BOMAG 90 008 911 79
Flushing the axle drive
"IN").
17. Connect the flushing hose (19) (flushing filter out-
let "OUT") to the (high pressure port 16) on the
travel pump.
Disconnecting the axle motor
18. Take the axle drive motor out of the hydraulic cir-
15) on the axle drive motor together.
i Note
Fig. 10
Fig. 11
Fig. 12
BOMAG 91 008 911 79
6.4
Flushing the hoses
i Note
flushing process.
! Caution
direction forward.
axle drive motor.
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. 13
Fig. 14
Fig. 15
Fig. 16
BOMAG 92 008 911 79
i Note
flushing process.
! Caution
pressure lines.
31. Bleed the travel circuit (see corresponding chap-
ter).
Keep circulating the tank content.
32. After completing the bleeding process circulate
the tank content with the filtering unit for another
15 minutes.
Function test
33. Check the hydraulic oil level in the tank, fill up if
necessary.
34. Check all connections for leaks with the engine
running (visual inspection).
35. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or starting
on a gradient.
36. Check all ports and connections for leak tightness
(visual inspection).
Fig. 17
Fig. 18
Fig. 19
Flushing schematic travel circuit (distribution axle motor)
BOMAG 93 008 911 79
6.5
6.5 Flushing schematic travel circuit (distribution axle motor)
BOMAG 94 008 911 79
BOMAG 95 008 911 79
6.5
6.5 Flushing schematic travel circuit (distribution axle motor)
BOMAG 96 008 911 79
BOMAG 97 008 911 79
6.5

3 Drum drive motor
4 Axle motor
6 not used
7 not used
9 not used
10 Reducing fitting (tool)
11 Travel pump
12 High pressure hose (drum drive motor reverse)
13 High pressure hose (drum drive motor forward)
15 High pressure hose (A, axle motor forward)
17 not used
6.6 Flushing the travel circuit (axle motor distribution)
BOMAG 98 008 911 79
6.6 Flushing the travel circuit (axle motor
distribution)
Flushing the drum drive
i Note
! Caution
so that only cleaned oil will enter the travel
pump in forward travel.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
"IN").
2. Connect the flushing hose (18) (flushing filter out-
let "OUT") to the (high pressure port 16) on the
travel pump.
Disconnect the drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
13) on the drum drive motor together.
Fig. 1
Fig. 2
Flushing the travel circuit (axle motor distribution)
BOMAG 99 008 911 79
6.6
i Note
Flushing the hoses
i Note
flushing process.
! Caution
direction forward.
drum drive motor.
Fig. 3
Fig. 4
Fig. 5
Fig. 6
BOMAG 100 008 911 79
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.
i Note
flushing process.
! Caution
Fig. 7
Fig. 8
Fig. 9
Flushing the travel circuit (axle motor distribution)
BOMAG 101 008 911 79
6.6
Flushing the axle motor
! Danger
Danger of accident!
Both wheels must be off the ground. The
wheels must be able to rotate freely.
15. Jack up the rear of the machine, so that the
wheels can rotate freely.
16. Secure the drum with wheel chocks.
i Note
flushing process.
! Caution
pressure lines.
22. Bleed the travel circuit (see corresponding chap-
ter).
15 minutes.
Fig. 10
Fig. 11
Fig. 12
BOMAG 102 008 911 79
Function test
necessary.
25. Check all connections for leaks with the engine
running (visual inspection).
26. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or starting
on a gradient.
Fig. 13
Flushing schematic for vibration drive
BOMAG 103 008 911 79
6.7

3 Vibration motor
4 Vibration pump
9 SAE flange (tool)
10 High pressure hose (B, high frequency)
11 High pressure hose (A, low frequency)
6.8 Flushing the vibration circuit
BOMAG 104 008 911 79
i Note
! Caution
so that only cleaned oil will enter the vibration
pump in high frequency.
For the connection schematic shown here the
vibration must always be filtered with "high
frequency / low amplitude".
ter "Flushing schematic - vibration circuit") from
the vibration pump (4) and connect it with the
flushing hose (7) (flushing filter inlet "IN").
2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port A) on the vibra-
tion pump.
Disconnect the vibration motor
3. Take the vibration motor out of the hydraulic cir-
11) on the vibration motor together.
Fig. 1
Fig. 2
Flushing the vibration circuit
BOMAG 105 008 911 79
6.8
Bleeding the vibration circuit
i Note
Bleeding the vibration circuit, see chapter "Bleed-
ing the vibration circuit".
Flushing the hoses
i Note
flushing process.
! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
5. Switch on vibration with high frequency.
7. Flush the circuit for approx. 10 minutes, thereby
switch the vibration on and off at intervals of ap-
prox. 30 seconds.
vibration motor.
Fig. 3
Fig. 4
Fig. 5
Fig. 6
BOMAG 106 008 911 79
Flushing the vibration motor
10. Unscrew the fastening screws for the vibration
motor and pull the motor out of the coupling.
i Note
flushing process.
! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
utes. Switch the vibration on and off at intervals of
approx. 30 seconds.
14. Remove the flushing filter and reinstall the vibra-
tion motor.
15. Bleed the vibration circuit (see corresponding
chapter).
15 minutes.
Fig. 7
Fig. 8
Fig. 9
Flushing the vibration circuit
BOMAG 107 008 911 79
6.8
Function test
necessary.
18. Test drive.
Fig. 10
6.9 Bleeding the travel circuit
BOMAG 108 008 911 79
6.9 Bleeding the travel circuit
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
3. Actuate the emergency stop switch.
! Danger
The engine should not start.
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.
7. Unlock the emergency stop switch
Fig. 1
Fig. 2
Fig. 3
BOMAG 109 008 911 79
6.9
8. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Pause for approx. 30 seconds and keep repeat-
ing this procedure, until the gauge shows a con-
stant charge pressure reading.
! Caution
With the flushing filter installed shift the travel
lever only to travel direction forward, as oth-
erwise the flushing filter will be subjected to
oil flow from the wrong direction.
! Danger
Run the engine with idle speed.
10. Start the engine.
11. Shift the travel lever (Fig. 5) approx. 1/3 to for-
ward direction.
12. After approx. 1 to 2 minutes shut down the engine
for a minute.
i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
Fig. 4
Fig. 5
6.10 Bleeding the vibration circuit
BOMAG 110 008 911 79
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
3. Actuate the emergency stop switch.
4. Hold the open ends of the pressure test hoses
(Fig. 2) into a container.
5. Crank the engine approx. 10 seconds with the
starter motor. Wait one minute and keep repeat-
ing this procedure, until oil starts to run out from
the pressure test hoses.
6. Remove the pressure test hoses.
7. Unlock the emergency stop switch
Fig. 1
Fig. 2
Fig. 3
BOMAG 111 008 911 79
6.10
8. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Wait for approx. 30 seconds and repeat the pro-
cedure, until the pressure gauge shows a con-
stant charge pressure.
! Caution
With the flushing filter installed use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-
tion.
10. For bleeding switch on vibration with high fre-
quency (Fig. 5).
11. Start the engine.
12. After running the engine 1 to 2 minutes pause for
approx. one minute.
i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
Fig. 4
Fig. 5
BOMAG 112 008 911 79
BOMAG 113 008 911 79
7 Fundamental electrics
7.1 Understanding circuit diagrams
BOMAG 114 008 911 79
7.1 Understanding circuit dia-
grams
Wiring diagrams are graphical representations of cir-
cuitry 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 sys-
tem. This plan provides the following information:
Number and type of individual elements in the ex-

amined electric circuit, such as plug connectors,
fuses, switches, consumers, relays, ...
The sequence in which current flows through the in-

dividual elements in the electric circuit.
Connections between the examined, faulty electric

circuit and other circuits in the vehicle wiring sys-
tem.
Pin assignment of plug-and-socket connections.

Structure:
Table of contents
Function groups
List of components
Table of contents
The table of contents lists all function groups.
Fig. 6 Table of contents
Example:
Function group "Warning systems, drawing number
XXX XX can be found on page no. 8.
Understanding circuit diagrams
BOMAG 115 008 911 79
7.1
Function groups
On the individual pages the electric circuits are com-
bined to function groups.
Arrangement of current paths
The individual current paths must be read as follows:
From top (plus potential) to bottom (minus poten-

tial).
From left to right.
From function group to function group.
Via cross references for potentials and relays.

Fig. 7 Function groups
Potential cross references
Potential cross references serve the purpose of track-
ing signals, which are transmitted from one function
group to another.
Example:
Potential "15" on page no. 6 is continued to the left on
page no. 4 in current path "10" and to the right on page
no. 8 in current path "1.
Relay cross reference
Relay cross references serve the tracking of signals,
which need to be tracked for components with outgo-
ing contacts.
A mimic diagram with information about the contact
types of a relay and their positions in the wiring dia-
gram is additionally attached to the bottom of each
contactor coil.
Example:
The coil of relay (K99) is located on page no. 8 in cur-
rent 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".
7.1 Understanding circuit diagrams
BOMAG 116 008 911 79
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 or-
der, 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.
Understanding circuit diagrams
BOMAG 117 008 911 79
7.1
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 in-
cluded in the DIN-Standard. The standardization
serves the purpose of global understanding and fault
free connection of appliances, especially in automo-
bile 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
1 Current source
2 Conductor
3 Switch
4 Ground
5 Filament lamp
6 Filament lamp with two luminous elements
7 Voltmeter
8 Amperemeter
9 Resistance
10 Backup
11 Line connection (fixed)
12 Line connection (separable)
Fig. 11 Graphic symbol
1 Diode
2 Transistor
3 NPN-Transistor
4 changeable resistance
5 Condenser
6 Working current relay
7.2 Terminal designations
BOMAG 118 008 911 79
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 repre-
sents a section with the most important terminals from
this standard.
Terminal designa-
tion
Meaning
1 Ignition coil, ignition distributor low voltage
1a Ignition distributor with 2 separate electric circuits, to ignition timer 1
1b Ignition distributor with 2 separate electric circuits, to ignition timer 2
2 Short circuit terminal (magneto ignition)
4 Ignition coil, ignition distributor high voltage
4a Ignition distributor with 2 separate electric circuits, from ignition coil 1, terminal 4
4b Ignition distributor with 2 separate electric circuits, from ignition coil 2, terminal 4
15 Switch plus (after battery) : Output of ignition-travel switch
15a Output from dropping resistor to ignition coil and starter
17 Preheating starter switch, preheating
19 Preheating starter switch, starting
30 Battery plus direct
30a Battery changeover relay 12V / 24V, input from battery 2 plus
31 Battery minus direct or ground
31a Battery changeover relay 12V / 24V return line to battery 2 minus
31b Return line to battery minus or ground via switch or relay (switched minus)
31c Battery changeover relay 12V / 24V return line to battery 1 minus
32 Electric motors, return line
33 Electric motors, main connection
33a Electric motors, limit shut down
33b Electric motors, shunt field
33f Electric motors, for 2nd lower speed range
33g Electric motors, for 3rd lower speed range
33h Electric motors, for 4th lower speed range
33L Electric motors, counter-clockwise rotation
33R Electric motors, clockwise rotation
45 Starter, separate starter relay output; starter: Input (main current)
45a 2-starter parallel operation, start relay for engagement current, output starter 1
45b 2-starter parallel operation, start relay for engagement current, output starter 2
48 Terminal on starter and on start repeat relay, monitoring of starting process
49 Input flasher relay
49a Output flasher relay
49b Flasher relay output 2nd flasher circuit
49c Flasher relay output 3rd flasher circuit
50 Starter, starter control
50a Battery changeover relay, output for starter control
50b Starter control, parallel operation of 2 starters with sequence control
Terminal designations
BOMAG 119 008 911 79
7.2
50c Start relay for sequence control of engagement current in parallel operation of 2
starters, input in starter relay for starter 1
Start relay for sequence control of engagement current in parallel operation of 2
starters, input in starter relay for starter 2
50d Start locking relay, input
50f Start locking relay, output
50g Start repetition relay, input
50h Start repetition relay, output
51 A.C.-generator, direct voltage on rectifier
51a A.C.-generator, direct voltage on rectifier with reactance coil for day travel
52 Trailer signals: further signals from trailer to towing vehicle
53 Wiper motor input (+)
53a Wiper motor (+) end limit shut down
53b Wiper shunt winding
53c Electric windscreen washer pump
53e Wiper, braking effect
53i Wiper motor with permanent magnet and 3rd brush for higher speed
54 Trailer signals, trailer plug device and lamp combination, brake light
54g Trailer signals, compressed air valve for permanent brake in trailer, electromag-
netically operated
55 Fog light
56 Head light
56a Head light, travel light and travel light control
56b Head lights, dimmed head light
56d Head lights, flash light
57 Parking light for motor cycles (abroad also for cars and trucks)
57a Parking light
57L Parking light left
57R Parking light right
58 Side lights, tail light, number plate light, dashboard light
58b Tail light changeover for single axle trailers
58c Trailer plug for single core wired and trailer fused tail light
58d Adjustable dashboard light, tail light and side light
58L Side light, left
58R Side light, right
59 A.C.-generator (magneto generator), alternating voltage output or rectifier input
59a A.C.-generator, charging armature output
59b A.C.-generator, tail light armature output
59c A.C.-generator, brake light armature output
61 Generator control
71 Intermittent tone control unit, input
71a Intermittent tone control unit, output to horn 1 + 2 (low)
71b Intermittent tone control unit, output to horn 3 + 4 (high)
72 Alarm switch (flashing beacon)
Terminal designa-
tion
Meaning
BOMAG 120 008 911 79
75 Radio, cigarette lighter
76 Loudspeaker
77 Door valve control
81 Switch (breaker and two-way contact), input
81a Switch (breaker and two-way contact), output 1
81b Switch (breaker and two-way contact), output 2
82 Switch (maker), input
82a Switch (maker), output 1
82b Switch (maker), output 2
82z Switch (maker), input 1
82y Switch (maker), input 2
83 Switch (multi-position switch), input
83a Switch (multi-position switch), output position 1
83b Switch (multi-position switch), output position 2
83L Switch (multi-position switch), output position left
83R Switch (multi-position switch), output position right
84 Current relay, input drive and relay contact
84a Current relay, output drive
84b Current relay, output relay contact
85 Switching relay, output drive winding end (minus or ground)
86 Switching relay, input drive winding start
86a Switching relay, input drive winding start 1st winding
86b Switching relay, input drive winding start 2nd winding
87 Relay contact on breaker and two-way contact, input
87a Relay contact on breaker and two-way contact, output 1 (breaker side)
87b Relay contact on breaker and two-way contact, output 2
87c Relay contact on breaker and two-way contact, output 3
87z Relay contact on breaker and two-way contact, input 1
87y Relay contact on breaker and two-way contact, input 2
87x Relay contact on breaker and two-way contact, input 3
88 Relay contact for maker
88a Relay contact on maker and two-way contact, (maker side) output 1
88b Relay contact on maker and two-way contact, (maker side) output 2
88c Relay contact on maker and two-way contact, (maker side) output 3
88z Relay contact on maker, input 1
88y Relay contact on maker, input 2
88x Relay contact on maker, input 3
B+ Battery Plus
B- Battery Minus
D+ Dynamo Plus
D- Dynamo Minus
DF Dynamo field (generator excitation current)
DF1 Dynamo field 1 (generator excitation current)
Terminal designa-
tion
Meaning
Terminal designations
BOMAG 121 008 911 79
7.2

DF2 Dynamo field 2 (generator excitation current)
U Three-phase generator, three-phase terminal
V Three-phase generator, three-phase terminal
W Three-phase generator, three-phase terminal
C Travel direction indicator (flasher relay) control light 1
C0 Main connection for control light separated from flasher relay
C2 Travel direction indicator (flasher relay) control light 2
C3 Travel direction indicator (flasher relay) control light 3 (e.g. for 2 trailer operation)
L Indicator left
R Indicator right
Terminal designa-
tion
Meaning
7.3 Current and voltage
BOMAG 122 008 911 79
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.
Voltage
Fig. 1
1 (Fig. 1) Charge
2 Voltage
3 Current
The equalization attempt between different electric
charges is referred to as electric voltage.
Voltage sources have two poles of different charge.
On the one side we have the plus pole with a lack of
electrons, on the opposite side the minus pole with a
surplus of electrons. This electric "pressure" is known
as electric voltage.
Fig. 2
If there is a connection between these two poles a dis-
charge will take place, resulting in the flow of an elec-
tric current.
Plus pole= lack of electrons
Minus pole = excess of electrons
The following statements concerning electric volt-
age can be made
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 at-

tempt of electric charges.
Voltage is measured with a Voltmeter.
Unit, Volt
The electric voltage (U) is measured in Volt (V).
Current and voltage
BOMAG 123 008 911 79
7.3
Current
Electric current generally describes the directed
movement of charge carriers.
The charge carriers may either be electrons or ions.
Electric current can only flow if there is a sufficient

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

a conductor per second, the higher the amperage.
Current is measured with an ammeter.
Unit, Ampere
The electric amperage (I) is measured in Ampere
(A).
The technical flow direction is specified from
PLUS to MINUS.
i
Note
Current actually flows from minus to plus, because the
current flow is made up of negatively charged elec-
trons.
But since this was only discovered after the poles of a
current source had already been designated, the as-
sumption that current flows from plus to minus was
maintained for historic reasons.
Circuit
Fig. 3 Circuit
A simple circuit consists of a current source 1 (Fig. 3),
a consumer (3) and the connecting wiring.
When the circuit is closed, current can flow.
The circuit can be interrupted or closed with a switch
(2).
The system is protected by a fuse (4).
Types of current
Direct current (D.C.)
Fig. 1 Direct current (D.C.)
Direct current flows with steady voltage and amper-
age from the plus to the minus pole.
Pure D.C.-voltages are only delivered by accumula-
tors 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 con-
stant, but drops gradually according to the battery
charge condition.
The internal resistance of the battery also causes per-
manent changes in the vehicle voltage, as soon as
consumers are switched on or off.
Alternating current (A.C.)
Fig. 2 Alternating current (A.C.)
Alternating current not only changes its direction, but
also its amperage.
Pulsating direct current
Fig. 3 Pulsating direct current
Converting alternating current into a direct current sig-
nal by means of a rectifier results in an pulsating direct
current.
BOMAG 124 008 911 79
Pulse width modulation (PWM)
Fig. 4 PWM
The PWM signal is in most cases generated by a con-
trol and can be used to trigger proportional valves.
The signal (square wave signal) is changed in its
pulse control factor, the period, however, remains un-
changed.
The following applies:
The signal voltage cannot be measured.
The current can be measured.

! Caution
Solenoid valves must not be interference sup-
pressed with suppressor diodes.
Current and voltage
BOMAG 125 008 911 79
7.3
Controller Area Network (CAN)
created by Bosch at the end of the eighties for auto-
mobile applications.
Development objectives:
Real-time critical, robust and low price communication
of control units, such as transmission and engine con-
trol, but also less time critical applications in the field
of convenience electronics, such as air conditioning.
Fig. 5 CAN
Why CAN?
Networking of control units for the realization of

complex functions.
Reduction of the extend of wiring and plug connec-

tions.
Better diagnostic possibilities (central diagnostics

socket).
Characteristics of CAN
It is a kind of serial data transmission. The individual
bits are transmitted one after the other, only 2 lines are
required.
CAN lines are twisted together 30 to 40 times per me-
tre. 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
7.4 Resistance
BOMAG 126 008 911 79
7.4 Resistance
Resistance and voltage drop
While current flows through a conductor the current
flow is more or less inhibited by the conductor, this in-
hibitation is referred to as Resistance.
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. 2 Potentiometer, infinitely adjustable resistor
The resistance can only be measured with a Multime-
ter.
Symbol, R
Unit, Ohm
The electric resistance (R) is measured in Ohm .
Rule of thumb:
The thicker the cable cross-section, the lower the

voltage loss.
The shorter the cable, the better the current.
The cleaner the contacts, the better the current.
The quality of the ground cable is of the same im-

portance as the supply line.
Unnecessary resistances
Unnecessary resistances are frequently caused by
mechanical connections, even clean ones, but mainly
soiled and oxidizes terminals, too thin cables, material
with poor conductivity or bent open cable lugs.
Bad
Fig. 1 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
Resistance
BOMAG 127 008 911 79
7.4
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. 4 Balistol oil
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. 5
Hint for practice:
A tool you cannot buy. The pliers were converted, the
nail is permanently present.
7.5 Series / parallel connection
BOMAG 128 008 911 79
7.5 Series / parallel connection
Series connection
In a series circuit the resistors (consumers) are lined
up one after the other and the same current (I) passes
through each of the consumers However, series con-
nection of consumers is not suitable in practice, as
each resistance causes a voltage drop. In the vehicle
wiring system all consumers are designed for the
same vehicle voltage (e.g. 12 Volt).
Fig. 1 Series connection
Current
In series connection the current is identical at every
point.
Itotal = I1 = I2 = I3
Voltage
The sum of all partial voltages is identical with the total
voltage.
Utotal = U1 + U2 + U3
Resistance
The sum of all partial resistances is identical with the
total resistance.
Rtotal = R1 + R2 + R3
Series connection of batteries
Fig. 2
In order to achieve a vehicle voltage of 24 V two bat-
teries of the same type and capacity must be connect-
ed in series mode.
In series connection the plus pole of the first battery

must be connected with the minus pole of the sec-
ond 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 / parallel connection
BOMAG 129 008 911 79
7.5
Parallel connection
In parallel connection all resistances (consumers) are
connected between feed and return line.
All resistances (consumers) are supplied with the

same voltage.
Each of the resistances (consumers) draws as

much current as required.
Fig. 3 Parallel connection
Current
The total current is the sum of all currents.
Itotal = I1 + I2 + I3
Voltage
The voltage values are identical at every resistance
(consumer).
Utotal = U1 = U2 = U3
Resistance
The total resistance is less than the lowest individual
resistance.
Parallel connection of batteries
Fig. 4
By connecting 2 batteries of same type and capacity
in parallel mode the capacity can be doubled, be-
cause the individual capacities add up to the total ca-
pacity.
In parallel connection the plus pole of the first bat-

tery is connected with the plus pole of the second
battery and the minus pole of the first battery with
the minus pole of the second battery.
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.
The disadvantage of a parallel connection becomes
apparent, by equalizing currents flowing between par-
allel batteries, if the batteries have different states of
charging.
7.6 Ohm's law
BOMAG 130 008 911 79
7.6 Ohm's law
In a closed electric circuit voltage, current and resist-
ance must always be considered in close relation.
This relation is represented by Ohm's Law.
Fig. 1
According to this law a voltage of 1V is required to let
1A (ampere) flow through a conductor with a resist-
ance of 1 (Ohm ).
Advice
By means of this triangle the formula can be easily re-
arranged, 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
Amperage I = U divided by R
U = Voltage in Volt
I = Current in Ampere
R = Resistance in OHM
7.7 Electrical energy
Fig. 1
In a closed electric circuit current and voltage gener-
ate energy.
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 re-
arranged, 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
I = Current in Ampere
P = Power in Watt
Formula diagram
BOMAG 131 008 911 79
7.8
7.8 Formula diagram
Description:
Select the desired value from the inner circle.
Determine the formula variables in the quarter circle
Calculate
Example:
P = 150 Watt
U = 24 Volt
Sought for = Current in Ampere
I = P : U = 150 W : 24 Volt = 6.25 Ampere
Fig. 1 Formula diagram
Resistance, R Ohm
Voltage, U Volt
Current, I Ampere
Power, P Watt
7.9 Metrology
BOMAG 132 008 911 79
7.9 Metrology
Test lamps
Test lamp
Fig. 1 Test lamp
! Caution
This type of tester must not be used for testing on
electronic components. The high power con-
sumption of the test lamp may destroy electronic
components in the control units.
Diode test lamp
This instrument is used for simple voltage measure-
ments. The test lamp consists of two test points. The
negative measuring cable is connected to ground and
the positive measuring cable to the corresponding
measuring location.
Fig. 2 Diode test lamp
If voltage is present, the corresponding light emitting
diode will light up.
Multimeter
This tester is a multimeter and can be used to meas-
ure e.g. current, voltage and resistance. Depending
on the design it may also be suitable for transistor and
frequency.
Fig. 1 Multimeter
In order to avoid damage:
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 mul-
timeter
The continuity tester of the multimeter can be used to
measure whether there is a connection between 2
measuring points. The following information should be
observed when measuring resistance and continuity:
The component to be measured must not be con-

nected to the power supply during the measure-
ment.
At least one side of the component to be measured

must be disconnected from the circuitry, as other-
wise the measuring result may be influenced by
parallel components.
Polarity is of no significance.
Metrology
BOMAG 133 008 911 79
7.9
Voltage and voltage drop measurement with mul-
timeter
Fig. 2 Voltage measurement
The meter is always connected parallel to consum-

er, component or power source.
Measurement at the voltage source measures the

currently available Voltage.
A measurement at the consumer measures the volt-

age drop at this component.
Current measurement with the multimeter
Fig. 3 Current measurement
During the measurement the current must be able

to flow through the meter, i.e. the electric circuit
must be opened. The meter is connected in series
with the consumer.
Advice
If the electric circuit is difficult to access and the inter-
nal resistance of the consumer is known, the voltage
may also be measured at the consumer.
The current value can then be calculated with the help
of Ohm's law.
Clip-on measuring instrument
The clip-on measuring instrument can be used to
measure current, voltage and resistance.
Fig. 1 Clip-on measuring instrument
For measuring current the individual conductor

must be fully enclosed by the measuring tongs, the
actual measurement takes place without contact.
7.10 Diodes, relays, fuses
BOMAG 134 008 911 79
Magnet tester
Fig. 1 Magnet tester
The magnet tester is used to test solenoid valves and
magnetic coils.
The test lamp responds to the magnetic fields of A.C-
voltage, D.C.-voltage and permanent magnets.
The component to be tested does not need to be re-

moved.
The magnetic coil can also be tested under a pro-

tective cap.
Diodes
Fig. 1
A diode consists of two different semi-conductors,
which are connected by a separating layer. The max.
conducting state current must not be exceeded.
Plus-voltage on diode:
At 0.6 0.7 Volt (silicium diode) the diode becomes

conductive.
Negative voltage on diode:
The diode does not allow current to pass through.

Fig. 2 Marking of the cathode
Diodes are used:
For rectifying A.C. voltage.
For absorbing voltage peaks (free-wheeling diode).
For construction of logical circuits.

Diodes, relays, fuses
BOMAG 135 008 911 79
7.10
Diode logics and free-wheeling diode
Fig. 3 Diode circuitry
The solenoid valve Y48 (Fig. 3) is supplied with

electric current when switch S34 is switched to po-
sition "1" or "2".
Solenoid valve Y20 is supplied, if the switch is in po-

sition "1".
Solenoid valve Y21 is supplied, if the switch is in po-

sition "2".
The three diodes V02 serve as free-wheeling diodes
with the function of of eliminating voltage peaks.
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-conduc-
tor crystal thereby emits a light signal, which is con-
verged 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.
BOMAG 136 008 911 79
Relays
Fig. 1 Relays
Relays are commonly used to realize switching proc-
esses.
A free-wheeling diode prevents induction voltage from
flowing back from the coil into the vehicle wiring sys-
tem, 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. 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
85 = Ground supply for coil
30 = Supply voltage
87 = Normally open contact
87a= Normally closed contact
Fuses
Fig. 1
Fuses are used to protect lines and equipment against
overloads and short circuit. If the fuse is overloaded
the fusible wire heats up with increasing current, until
it finally melts.
! Caution
Fuses must not be repaired or bridged.
The melting time at 23 C is:
approx. 1 hour with 1.5 times the rated current
approx. 1 minute with 2.5 times the rated current.

A 5 Amp fuse loaded with 1.5 times the rated current
(7.5 Amp) will finally melt after approx. 1.5 hours.
Yellow = 5 A
Brown = 7.5 A
White = 8 A
Red = 16 A
Blue = 25 A
Batteries
BOMAG 137 008 911 79
7.11
7.11 Batteries
Battery accumulator
Fig. 1
In vehicles batteries are used to start the engine. The
ability to start the engine depends on the charge con-
dition of the batteries.
Lead collectors or accumulators are secondary ele-
ments, i.e they can be recharged after discharging
electric current.
The basic element of a lead accumulator is the cell. It
contains the plate blocks consisting of positive and
negative plates. These plates are separated from
each other by separators.
All positive plates are arranged parallel to the plus
pole, the negative plates parallel to the minus pole of
the cells.
Fig. 2
All cells are filled with a conductive fluid, the electro-
lyte. For a 12 Volt battery 6 cells are connected in se-
ries.
Capacity
is a synonym for the amount of current taken up and
discharged by a battery over a specified period of
time.
Battery maintenance
i
Note
Maintenance free batteries are gaining more and
more significance, this freedom from maintenance,
however, is only limited to the fact that no water needs
to be added.
If the battery is not charged and discharged over a
longer period of time, the battery will slowly discharge
by itself.
The accumulator may only be discharged down to a fi-
nal discharging voltage of 10.5 Volt, as otherwise
there is a risk of sulphation, i.e. the generated lead
sulphate forms increasingly coarser crystals, which
will finally not react at all or only very sluggishly during
a subsequent charging process.
In the worst case the accumulator can only be dis-
posed of after such an exhaustive discharge.
The following therefore applies for longer downtimes:
Remove the battery and store it in a cool, dry and

frost protected room.
Check the open circuit voltage on the battery at reg-

ular intervals (at least once every month).
Recharge immediately if the open circuit voltage

has dropped to 12.25 Volt (no rapid charging).
i
Note
The open circuit voltage of batteries occurs approx. 10
h after the last charging or approx. 1 h after the last
discharge.
Battery test in general
Is the battery leaking? Can traces of impact, shock

or compression be found in the leaking area?
Check for e.g. incorrect fastening, foreign bodies on

the battery mounting surface and similar.
Testing batteries with screw plugs
Checking the acid density:
The cells are filled with diluted sulphuric acid as

electrolyte (approx. 25 Vol% sulphuric acid in dis-
tilled water), also referred to as accumulator acid,
which has a density of 1.285 kg/dm
3
at a tempera-
ture 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 increas-
ingly change to water. Since water has a lower spe-
cific 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/dm
3
.
With a lead cell the acid density is therefore a meas-

ure for the charge condition. This characteristic is
used to determine the charge condition of a lead
7.11 Batteries
BOMAG 138 008 911 79
battery. The so-called acid tester (hydrometer) is
used for this purpose. In a battery of good condition
the acid density should be the same in all cells.
Acid density at 27 C in kg/dm
3
1.25 -1.28, open-circuit voltage approx. 12.7 Volt.

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

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

Volt. Battery is insufficiently charged. Battery needs
to be recharged immediately.
i
Note
If the current consumption during charging is not 1/20
of the nominal capacity (example 100 Ah battery:
100Ah x 1/20 = 5 A) or full charging of the battery re-
sults in a final acid density of only 1.24 kg/dm
3
or less,
the battery shows normal wear by aging. The battery
was insufficient charging or exhaustive discharge.
Fig. 3 Reading the acid level
Maximum permissible tolerance between highest

and lowest measuring value of the 6 cells: 0.03 kg/
dm
3
.
Testing batteries without screw plugs
On closed batteries the acid density cannot be meas-
ured, we therefore recommend testing with the follow-
ing mobile tester:
Fig. 4 Battery and generator tester
The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) integrated ther-
mal printer.
i
Note
Before testing clean the poles and ensure good con-
nection between clamps and poles.
The test program calculates the text messages "good"
or "replace" on the basis of the charge condition (de-
rived from the battery voltage) and the currently avail-
able starting power of the battery. A battery with 45%
starting power may thus be rated good and another
one with 75% starting power as poor ("replace").
The starting power represents the ratio of detected
cold testing current to the entered cold testing current
of the battery.
The starting power can exceed 100%.
Batteries
BOMAG 139 008 911 79
7.11
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.
7.12 Three-phase generator
BOMAG 140 008 911 79
General
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve-
hicle with electric current at a steady voltage already
at idling speed.
! Caution
Before removing the generator you must discon-
nect the ground cable from the minus pole of the
battery while the ignition is switched off. Do not
disconnect the generator while the engine is run-
ning, because this may cause extremely high volt-
age peaks in the vehicle wiring system ("Load
Dump"), which could possibly damage control
units, radios or other electronic equipment.
When disassembling the battery cable, the B+-nut
underneath on the generator side may also be
loosened. This nut must in this case be retight-
ened.
When connecting e.g. the battery cable to the ter-
minal of the generator you must make sure that
the polarity is correct (generator B+ to the + pole
of the battery). Mixing up the polarities by mistake
causes short circuit and damage to the rectifier el-
ements - the generator will be out of function.
The generator can only be operated with the bat-
tery connected. Under special conditions emer-
gency operation without battery is permitted, the
lifetime of the generator is in such cases especial-
ly limited.
Plus and minus cables must be disconnected dur-
ing rapid charging of the battery or electric weld-
ing on the vehicle.
When cleaning the generator with a steam or wa-
ter jet make sure not to direct the steam or water
jet directly on or into the generator openings or
ball bearings. After cleaning the generator should
be operated for about 1 - 2 minutes to remove any
deposits of water from the generator.
Design and function
In the generator the armature windings are located in-
side the stationary stator, whereas the exciter winding
is arranged on the internally revolving rotor (Fig. 6).
Fig. 6 Rotor with claw poles
Fig. 7 Stator with 3 windings
The three stator windings (Fig. 7) are electrically offset
to each other by 120. The excitation of the magnetic
field requires direct current, which is fed to the rotor
via two carbon brushes and slip rings.
Three-phase generator
BOMAG 141 008 911 79
7.12
Fig. 8 3-phase current
The generator first of all produces three-phase volt-
age / three-phase current.
The wiring diagram (Fig. 8) shows the 3 windings in Y-
connection and the 6 associated rectifier diodes.
The diodes D1, D2, D3 are also referred to as minus
diodes, because they have B- as common connection
(minus plate).
The other diodes are the plus diodes.
The rectifier diodes have the effect that the negative
half-wave is suppressed and only the positive section
of the wave is allowed to pass, resulting in a pulsating
D.C. voltage.
Reverse current protection
The rectifier diodes also prevent discharging of the
battery via the stator windings. The current can only
flow from the generator to the battery.
Why does three-phase current need to be rectified
and how does this work?
There are a few components for which can either be
operated with alternating current or direct current, be-
cause they work independently from the current flow
direction.
This includes :
Incandescent lamps
Fluorescent lamps
Glow lamps
Electric heating elements.

There are also a few components that could be oper-
ated either with alternating current, direct current or
three-phase current, if the components were designed
accordingly.
This includes :
Electric motors
Relays
Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc-
es work with alternating or three-phase current.
This includes :
Accumulators
Control units
All electronics
Communication equipment.
Charge control light
It has by no means the function to show whether the
ignition is switched on or off. It has the function of in-
dicating that the generator works correctly. Under nor-
mal operating conditions the generator should work
and the charge control light should be off. The charge
control lamp receives (+) from the battery at one pole.
The other pole is connected to (D+), i.e. the (+) carbon
of the generator. If the generator is working correctly,
(+) is attached to both connections on the charge con-
trol lamp. Since there is no difference in voltage, no
current can flow, the lamp does not light up. If the gen-
erator does not work, current flows via the (+) carbon
through the armature winding, via the (-) carbon to
ground and from there back to the battery. The electric
circuit is closed, battery voltage is applied to the
charge control lamp and the lamp lights up. Since the
generator does not work when the engine is not run-
ning, the charge control lamp is not connected directly
to the battery, but via the ignition switch. When the ig-
nition is off, the charge control lamp is dead.
Voltage regulator
A generator without regulator would just work light a
bicycle dynamo. The power output would increase
with rising speed. The voltage output would fluctuate
with the load. (In case of a bicycle dynamo the tail light
bulb is overloaded when the head light does not con-
sume any power). The function of the regulator is the
provision of a uniform vehicle voltage, almost com-
pletely independent from speed and load of the gen-
erator.
BOMAG 142 008 911 79
Fig. 9 Regulator with diode plate and rectifier diodes
In most cases voltage regulators (Fig. 9) with carbon
brushes form a compact component. The voltage reg-
ulator is maintenance free and the wear of carbon
brushes is only so little, that they hardly ever need to
be replaced during the lifetime of a machine.
The regulator has the following function:
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).
Checking the generator
First one must check whether the generator is actually
defective.
This can be easily found out by checking whether

the charge control light in the dashboard lights up. If
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula-
tor, the wiring or the V-belt.
When the engine is at rest, the charge control light

must light up. If not, the lamp may probably be de-
fective. Defects on generator or wiring are obviously
also possible.
The following points allow to contain faults in the volt-
age supply within certain limits.
Cable connections on the generator OK?
V-belt OK?
Generator ground (engine ground) OK?
Pre-excitation from vehicle electronics OK?

Only if all criteria mentioned above are OK, the fault
must be in the generator itself. In this case it must be
replaced or the following trouble shooting procedure
must be performed.
BOMAG 143 008 911 79
7.12
Checking the pre-excitation circuit
The most common reason for a 3-phase alternator not
charging is a too low pre-excitation current. The pre-
excitation current through connection D+ depends on
the connected consumer (resistance), e.g. charge
control light or relay of a MD+ engine control.
The pre-excitation current should be approx. 250 mA
at 12 Volt. This corresponds with a 3 Watt light bulb or
an equivalent combination of light bulb + resistance or
an LED + resistance.
The total resistance of the disconnected dead supply
line D+ max. should not exceed 48 Ohm.
In case of faults like
charge control light stays on
no voltage increase, e.g. from 12 V to 14 V

one should check that the correct resistance is as-
sured.
Fig. 10 Connections on the three-phase alternator (exemplary de-
sign)
If the charge control light or LED stays on when the
engine is running, you should proceed as follows:
Temporarily bridge connections D+ and B+ on the

three-phase alternator (Fig. 10). The bridging must
be made using an insulated cable with a cross-sec-
tion of approx. 1.0 mm, which is stripped for approx.
5 mm on either end. This cable must be fitted with a
consumer (X), e.g. a light bulb of 21 W, 12 V, in
case of a 12 V system.
If this measure does not clear the fault, the alternator
must be defective.
Measuring the charge current
All plug-and-socket connectors must be free of cor-

rosion and intermittent contact.
The generator ground connection must be OK.
During the measurement switch on as many con-

sumers as possible.
1 Attach the clip-on ammeter around the B+ line.
2 Gradually increase the engine speed.
3 The generator current must be at least as high as
the total current of all consumers.
BOMAG 144 008 911 79
Checking the rotor
i
Note
The rotor coils can only be measured in disassembled
state.
Fig. 11 Rotor
Remove the regulator with carbon brush.
Contact the rotor slip ring with the tester points.
The resistance should be between 3 and 6 OHM .
The rotor coils should not have continuity to ground.

Checking the stator
Fig. 12 Stator
i
Note
The stator coils can only be measured in disassem-
bled state.
Measure the resistance of all three coils.
The coils should not have contact among each oth-

er.
BOMAG 145 008 911 79
7.12
Checking the regulator voltage with the generator
tester
The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) thermal printer.
Fig. 13
The generator test assesses the regulator voltage and
the ripple factor of the generator voltage.

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 multime-
ter
Fig. 14

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.
The voltage (B+) should adjust itself at 13 to 14 Volt.

BOMAG 146 008 911 79
Checking the regulator in disassembled state
On a Bosch generator unscrew two fastening screws
for the regulator and lift the regulator off. For this work
the generator does not need to be removed.
The Delco-Remy generator needs to be removed
and partly dismantled, if the regulator needs to be dis-
assembled. Unscrew the housing screws to do so.
Pull rotor with drive bearing and V-belt pulley out of
the stator. Unscrew the ends of the stator winding
from the diode carrier and separate the stator from the
collector ring bearing. Disassemble exciter diodes and
brush holders and remove also the regulator.
i
Note
When testing the regulator one should be aware that
there are 2 different types of regulators:
If the carbon brush is not connected to ground the

regulator is a so-called minus controlled regulator.
The exciter winding is positioned between D+ and
DF, the regulator therefore regulates the exciter
winding on the ground side. The other carbon brush
is connected with the cathodes of the exciter di-
odes, terminal D+. This leaves one further terminal,
this is DF.
D+ (vehicle wiring system)
D- (ground contact, mostly located on one of the fas-
tening screws)
DF (Dynamo Field)
Fig. 15
If the carbon brush is connected to ground the reg-

ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
The basic function of a disassembled regulator can be
easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).
Fig. 16
E.g minus controlled regulator
One connects the regulator (Fig. 16) 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 al-
lows all lamp current (= exciter current) to flow at volt-
age values up to 14.4V. Once the regulator voltage is
reached, the regulator switches the lamp current off.
When returning the voltage back below the control
voltage, the regulator will switch the lamp back on.
With this test the major difficulty is the problem to re-
move the regulator an identify terminals D+, DF and
D-.
Fig. 17
Fig. 18
The illustrations (Fig. 17) and (Fig. 18) show two dif-
ferent regulator types.
BOMAG 147 008 911 79
7.12
Replacing carbon brushes
On a Bosch generator unscrew two fastening

screws for the regulator and lift the regulator off.
Pull out the carbon brushes from underneath. Their
minimum length is 5 mm, shorter carbon brushes
need to be replaced, unsolder both connection litz
wires. Solder the litz wires of the new carbon brush-
es, insert these and fasten the regulator again. For
this work the generator does not need to be re-
moved.
For replacing the carbon brushes in the Delco-

Remy generator the generator needs to be disas-
sembled and partly dismantled. The carbon brush
holder is located inside the collector ring bearing.
7.13 Electric starter
BOMAG 148 008 911 79
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.
establish the gear connection between starter and

combustion engine.
to maintain this connection.
to switch on the starter current.

After starting the engine:
to return the starter pinion to initial position.
to switch off the starter current.

Fig. 1 Electric starter
1 Pinion
2 Roller free-wheeling
3 Steep thread
4 Guide ring
5 Spring winding
6 Armature
7 Pole shoe
8 Carbon brushes
9 Armature brake
10 Collector
11 Magnetic switch
12 Engagement lever
! Caution
So-called jump starting (using an additional exter-
nal battery) without the battery connected is dan-
gerous. When disconnecting the cables from the
poles high inductivities (arcs, voltage peaks) may
occur and destroy the electrical installation.
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.
Starter motors must not be cleaned with high
pressure steam cleaning equipment.
The contacts on starter terminals 30, 45, 50 must
be protected against unintended shorting (jump
protection).
When replacing the starter the ring gear on the en-
gine flywheel must be checked for damage and its
number of teeth - if necessary replace the ring
gear.
Always disconnect the battery before starting as-
sembly work in the starter area of the engine or on
the starter itself.
Electric starter
BOMAG 149 008 911 79
7.13
Function of pre-engaged-drive starting motor
This type of starter uses a solenoid to engage the pin-
ion with the ring gear. The engaging solenoid contains
switching contacts for the starting current. When clos-
ing the starter switch, the relay holding winding is ac-
tive and current flows also through the series
connection of pick-up winding and electric motor. The
engaging solenoid picks up and moves the free-
wheeling with the pinion forward via the engaging le-
ver and the engaging spring. In case of a favourable
position of the pinion to the ring gear a tooth of the pin-
ion will directly engage in a tooth gap. In this case the
pinion will engage over the entire length of the screw
path, until the contact bridge in the engaging relay
touches the relay contacts. The starter motor is no
switched on. However, if the pinion does not directly
find a tooth gap, the ring gear will block any further en-
gaging movement. The engaging lever in this case
compresses the engaging spring and the main contact
closes, even though the pinion and the ring gear are
not engaged. The electric motor keeps rotating the
pinion in front of the ring gear face, until a pinion tooth
gap matches a tooth on the ring gear and the preload-
ed engaging spring moves pinion and free-wheeling
forward. When switching the relay winding off, the re-
turn spring forces the relay armature and the pinion
with free-wheeling back to rest position. This disen-
gagement is supported by the steep thread.
Magnetic switch
The magnetic switch is normally arranged directly
above the starter.
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.
Once the gears are engaged the starter current is ap-
plied 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.
Fig. 2 Switching position during engagement
Fig. 3 Switching position during starting
1 Ground
2 Battery
3 Starter switch
4 Pull-in winding
5 Holding winding
6 Exciter winding
7 Restoring spring
8 Driver
9 Pinion
10 Flywheel
BOMAG 150 008 911 79
Trouble shooting "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 ex-
tremely high voltage losses in the overall starter sys-
tem are the cause of problems.
If the starter only emits a clicking sound,- either
the magnetic switch is defect / soiled (dismantle and
clean))- the main contacts on the magnetic switch are
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.
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.
Immobilizer deactivated?
Ignition switch OK?
Travel lever in correct position?
Emergency stop not actuated?
Battery sufficiently charged?
Battery poles OK?
Main battery fuse OK?
Main battery switch closed?
Main starter cable (terminal 30) OK?
Starter control cable (terminal 50) OK, voltage

drop?
Ground cable OK?
Switching of magnetic switches OK?

The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
the experience of the specialist
the failure probability of the component to be tested

and the testing effort for the respective part.
Only if all criteria mentioned above are OK, the fault
must be in the starter itself. In this case it can be re-
paired or replaced.
Testing and measuring the electric starter
i
Note
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
Initiate the starting process and measure the volt-

age 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 (no-
ticeable 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 ap-
plied, replace the magnetic switch.
Function tests with disassembled starter
! Caution
Before removing the starter you must disconnect
the ground cable from the minus pole of the bat-
tery 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 con-

tact with the rotor shaft.
Check the drive pinion for excessive wear.
The return mechanism should not be tight, if neces-

sary grease amply with silicon grease (Bosch PZ 2
V3) or a comparable grease.
Measure the resistance of the magnetic switch main

contact in disengaged condition. Maximum value
0.2 OHM .
Telemecanique switch
BOMAG 151 008 911 79
7.14
7.14 Telemecanique switch
Example of terminal designations
Fig. 1 Terminal designations
Normally open contact 23 located on block 2
Normally closed contact 12 located on block 1
Normally closed contact 11 located on block 1

i
Note
If e.g. block 5 is not needed to design a switch, the
numbering for blocks 1,2,3,4 and 6 remains un-
changed.
7.14 Telemecanique switch
BOMAG 152 008 911 79
Disassembly
Fig. 2 Disassembly
Lift up the interlock (5).

Fig. 3 Folding down the switch block
Fold down the switch block (4).
Loosen screw (1).

Fig. 4 Pulling out the front element
Lift up the interlock (2) and pull out the front element
(3).
Telemecanique switch
BOMAG 153 008 911 79
7.14
Assembly
Fig. 5 Assembly
Insert the front element (3) into the bore in the con-
trol panel.
Fig. 6 Observe the marks.
Clip the fastening adapter (6) onto the front element

(3).
i
Note
Watch the marls on front element (Fig. 6) and fasten-
ing flange.
Tighten the screw (1) with a tightening torque of 0.6

Nm.
Fig. 7 Assemble the switch block
Clip on the switch block (4).

i
Note
Hook in the switch block at the bottom first (Fig. 7).
7.15 Inductive proximity switches
BOMAG 154 008 911 79
7.15 Inductive proximity switches
General
In all automated sequences the use of sensors as a
source of information for the electronic control is indis-
pensable. The sensors deliver the necessary signals
about positions, end positions, filling levels or serve as
pulse transducers for counting tasks or speed detec-
tion. In industrial applications inductive and capacitive
proximity switches are today indispensable. Com-
pared with mechanical switches, they offer almost ide-
al 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, wa-
ter, oil, etc.
Working principle
Fig. 8
The working principle is based on the principle of the
dampened LC-oscillator. The coil of the oscillation cir-
cuit forms a high-frequency magnetic stray field.
This stray field leaks out from the active area of the
proximity switch. If metal or non-ferrous metal enters
into the response range energy is absorbed. The os-
cillator is thus dampened and the resulting change in
current consumption is evaluated.
PNP circuitry
Fig. 9 PNP circuitry
On sensors with PNP-circuitry the output stage con-
tains a PNP-transistor, which switches the load
against the positive operating voltage. The load is
connected between the output and the negative oper-
ating voltage. The switch is designed with a normally
open contact, i.e. the contact closes when the initiator
comes in "contact" with metal.
NPN circuitry
Fig. 10 NPN circuitry
On sensors with NPN-circuitry the output stage con-
tains a NPN-transistor, which switches the load
against the negative operating voltage. The load is
connected between the output and the positive oper-
ating voltage.
Breaking and making contacts
Fig. 11
Proximity switches are used as breaking or making
contacts. Depending on the design the switching dis-
tances are 2 or 4 mm. The maximum amperage is 300
mA.
The LED (Fig. 11) lights up, when the initiator has de-
tected metal in its stray field.
Angle sensor with current output
BOMAG 155 008 911 79
7.16
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)
7.16 Angle sensor with current out-
put
Fig. 1 Sensor
The the function of the angle sensor (Fig. 1) is based
on the so-called "Hall-Effect". Named after the Ameri-
can physicist E.H. Hall. Due to the fact that moving
electrons are deflected in a magnetic field, a voltage
transverse to the flow direction of the primary current
can be expected on a current conducting conductor in
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.
7.17 Plug connectors
BOMAG 156 008 911 79
Fig. 2 Connection diagram
The angle sensor has 3 electric connections (Fig. 2).
Ub, supply voltage (+ 8.5 Volt)
Gnd, ground
Out, output current 4-20 mA.
at -35 = 4 mA output current
at 0 = 12 mA output current
at +35 = 20 mA output current.

7.17 Plug connectors
Duties and requirements
Electric plug connectors must provide a reliable con-
nection 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:
Vibration acceleration
Temperature fluctuations, high and low tempera-

tures
Dampness
Micro movements of the contact with resulting fric-

tion corrosion.
These loads may increase the transition resistances
of the contacts, up to total interruption. Even the insu-
lation resistances may drop and thus cause short cir-
cuits in neighbouring lines. Electric plug connectors
must therefore have the following properties:
Low transition resistances of the conductive parts.
High insulation strength between conductive parts

with different voltage potentials.
Excellent leak tightness against water and mois-

ture.
Deutsch plug, series DT and DTM
BOMAG 157 008 911 79
7.18
7.18 Deutsch plug, series DT and
DTM
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. 3 Crimp connections
! Caution
Do not crimp more than one lead per pin or per
socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
Perform a pull test on each lead, each of the termi-

nals and connections must withstand a pulling force
of 45 N without any difficulties.
DT Series
Fig. 1 DT plug connection
Fig. 2 DT Series
Fig. 3 Sectional drawing
7.18 Deutsch plug, series DT and DTM
BOMAG 158 008 911 79
Installing DT contacts
Fig. 4
Insert the contacts through the rubber grommet until

they click into place.
Insert the orange wedge in direction of arrow.

! Caution
nals and connections must withstand a pulling
force of 45 N without any difficulties.
i
Note
Use the same method when assembling the socket.
BOMAG 159 008 911 79
7.18
Disassembling DT contacts
Fig. 5
Pull the orange wedge out with long nose pliers.
Slightly pull the lead and unlock the interlocking

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

i
Note
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
BOMAG 160 008 911 79
DTM Series
Fig. 1 DTM plug connection
Fig. 2 DTM Series
Fig. 3 Sectional drawing
BOMAG 161 008 911 79
7.18
Installing DTM contacts
Fig. 4
Insert the contacts through the rubber grommet until

they click into place.
Insert the orange wedge, until it clicks into place.

! Caution
nals and connections must withstand a pulling
force of 45 N without any difficulties.
i
Note
BOMAG 162 008 911 79
Disassembling DTM contacts
Fig. 5
Pull the orange wedge (interlock) out with long nose

pliers.
Slightly pull the lead and unlock the interlocking

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

i
Note
In this case the interlock disassembly tool (see special
tools for electrics) serves as an aid to remove the
wedges.
Plugs and terminals in spring clamping technology
BOMAG 163 008 911 79
7.19
7.19 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 con-
ventional 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!
Connecting terminal for quick repairs
Fig. 2 That's how it works
The connecting clamp clamps up to 3 or 5 stripped
fine conductors of 0.08 mm to 4 mm, single or multi-
ple strand up to 2.5 mm. And this even without tools
(Fig. 3).
That's how it works
Strip 9-10 mm of the lead.
Open the actuating lever and insert the strand.
Return the actuating lever to initial position.

! Caution
nals must withstand a pulling force of 45 N with-
out any difficulties.
Fig. 3 Connecting clamp
7.19 Plugs and terminals in spring clamping technology
BOMAG 164 008 911 79
Series clamp
That's how it works
Insert a screw driver into the actuating opening until

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

clamp.
Pull out the screw driver.

! Caution
Measuring signals
On these terminal blocks the bridge slot is most suita-
ble for tapping off and measuring signals. Here you
may directly insert a 4 mm test adapter (see special
tools for electrics) for connecting a measuring lead.
This test adapter is standard in the central electrics of
heavy equipment machines.
Fig. 5 Test adapter
Plugs and terminals in spring clamping technology
BOMAG 165 008 911 79
7.19
X-COM System
The X-COM-SYSTEM, a synthesis of plug connector
and series clamp, has grown up to a construction kit
for universal system wiring, ever since it was intro-
duced in 1997. All the familiar series clamping func-
tions have thus become pluggable.
X-COM plug clamp
That's how it works
Insert a screw driver into the actuating opening until

it bottoms.
Strip 9-10 mm of the lead and insert it into the plug.
Pull out the screw driver.

! Caution
Fig. 7 X-COM plug with measuring cable
The most reliable measurements on the plug can be

made when using the measuring and connecting
cable with 2mm plug (see special tools for
electrics).
Measuring signals
Fig. 8 X-COM plug plugged onto the series clamp
7.19 Plugs and terminals in spring clamping technology
BOMAG 166 008 911 79
BOMAG 167 008 911 79
8 Special tools, electrics
8.1 Special tools, electrics
BOMAG 168 008 911 79
Measuring equipment
14. Electric test case
15. Multimeter
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.
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. 9
Fig. 10
Fig. 11
Fig. 12
Special tools, electrics
BOMAG 169 008 911 79
8.1
20. Measuring and connecting lines with 4mm plug,
high flexible design, black, length 0.5 m.
high flexible design, black, length 1 m.
high flexible design, black, length 2 m.
high flexible design, red, length 0.5 m.
high flexible design, red, length 1 m.
high flexible design, red, length 2 m.
26. Measuring and connecting lines with 2 mm plug
and gold plated lamella plugs, high flexible de-
sign, black, length 300 mm.
sign, black, length 600 mm.
sign, red, length 300 mm.
sign, red, length 600 mm.
30. Transition plug connector, with 4 mm plug on one
side and 2 mm socket on the other, insulated de-
sign
Fig. 13
Fig. 14
Fig. 15
BOMAG 170 008 911 79
31. Magnetic coil tester
32. Clip-on measuring instrument
33. Battery - generator tester
Spring clamps (Wago or Weidmller)
34. Cranked screwdriver (Fig. 19) to open spring
clamps (Fig. 20).
Fig. 16
Fig. 17
Fig. 18
Fig. 19
BOMAG 171 008 911 79
8.1
35. Testing adapter to measure the signals from the
series spring clamps (Wago).
Deutsch contacts
36. Tool to disassemble the interlocking on Deutsch
plugs (series DT and DTM).
37. Crimping pliers for Deutsch contacts of series DT
and DTM, size AWG 20,16 and 12.
AWG 20 = 0.5 mm
2
cable cross-section
AWG 16 = 1,5 mm
2
cable cross-section
AWG 12 = 4,0 mm
2
cable cross-section
38. Crimping pliers for Deutsch contacts of series
HDT, size AWG 6 and 8.
AWG 8 = 10,0 mm
2
cable cross-section
AWG 6 = 16,0 mm
2
cable cross-section
AWG 6 = 16,0 mm2 cable cross-section
Fig. 20
Fig. 21
Fig. 22
Fig. 23
BOMAG 172 008 911 79
39. Disassembly tool for Deutsch contacts of series
HDP.
AWG 20, BOMAG part-no.: 079 900 78
ITT contacts
40. Installation tool for ITT crimp contacts of series
CA-COM, contact size 15S/16S/15/16.
41. Disassembly tool for ITT male contacts of series
CA-COM, contact size 15S/16S/15/16.
42. Disassembly tool for ITT female contacts of se-
ries CA-COM, contact size 15S/16S/15/16.
Fig. 24
Fig. 25
Fig. 26
Fig. 27
BOMAG 173 008 911 79
8.1
Schaltbau contacts
43. Disassembly tool for Schaltbau contacts of series
M1, M2.
44. Crimping pliers for Schaltbau contacts of series
M1, M2 with connecting cross-section 0.14 - 6.0
mm
2
.
FCI Burndy contacts
45. Disassembly tool for FCI Burndy contacts of se-
ries TRIM TRIO
AMP contacts
46. Crimping pliers for AMP-contacts of series FAS-
TIN-FASTON with a connecting cross-section of
1.0 - 2.5 mm
2
(18 -14 AWG).
Fig. 28
Fig. 29
Fig. 30
Fig. 31
BOMAG 174 008 911 79
47. Crimping pliers for AMP-contacts of series SU-
PER-SEAL with connecting cross-section 0.75 -
1.25 mm
2
.
48. Crimping pliers for AMP-contacts of series .070-
SERIES with a connecting cross-section of AWG
20 - 18 (0.5 - 0.9 mm
2)
and AWG 16 (1.25 - 1.5
mm
2
).
TON with connecting cross-section AWG 14 - 10.
TON with connecting cross-section AWG 16 - 14
and AWG 18.
Fig. 32
Fig. 33
Fig. 34
Fig. 35
BOMAG 175 008 911 79
8.1
51. Disassembly tool for AMP-contacts of series CIR-
CULAR-CONNECTOR.
1.5 mm
2
, BOMAG part-no.: 079 900 74
2,5 mm
2
, BOMAG part-no.: 079 900 75
Spare sleeve 1.5 mm
2
, BOMAG part-no.: 079
900 76
Spare sleeve 2,5 mm
2
, BOMAG part-no.: 079
900 77
Universal tools
52. Universal pressing pliers with toggle lever trans-
mission and adjustable end pressure for Crimp-
ing roller connector 0.14 - 1.0 mm
2
.
53. Precision pressing pliers for non-insulated flat
male and female connectors0.5 - 6,0 mm
2
.
Measuring adapter
54. Current measurement adapter for Hirschmann
plugs.
Fig. 36
Fig. 37
Fig. 38
Fig. 39
BOMAG 176 008 911 79
55. Voltage measurement adapter for Deutsch plugs,
8-piece (2 to 12 pole).
56. Current measurement adapter for Deutsch and
AMP plugs, 2 pole.
Fig. 40
Fig. 41
BOMAG 177 008 911 79
9 Machine related electrics
BOMAG 178 008 911 79
BOMAG 179 008 911 79
9.1 Machine related electrics
BOMAG 180 008 911 79
Machine related electrics
BOMAG 181 008 911 79
9.1
Version/Status: V3.29 / 13.11.07 Page 1 of 84
Author: Seis,MASH,LOEW / TE/TES
Service Training
Electrics
Single Drum Rollers 4
P/N 00809703 Version 3.29
BOMAG 182 008 911 79
Service Training WZ-4 from Version DH
Table of contents
1 Confirmation of changes................................................................................................ 5
1.1 Document..............................................................................................................................5
1.2 Software................................................................................................................................6
2 Displayed monitoring activities with fault reactions ................................................... 7
3 The diagnostics system................................................................................................. 9
3.1 Display functions .................................................................................................................9
3.2 General facts and operation ...............................................................................................9
3.2.1 Calling up service mode.....................................................................................................9
3.2.2 Entering input codes.........................................................................................................10
3.3 Fault log display and delete...........................................................................................12
3.3.1 Showing stored faults.......................................................................................................12
3.3.2 Delete all stored faults......................................................................................................12
3.4 Delete engine control error log ........................................................................................13
3.4.1 Deleting logged engine errors ..........................................................................................13
3.4.2 Deleting active engine faults ............................................................................................13
4 Settings and queries..................................................................................................... 14
4.1 Setting the machine type ..................................................................................................14
4.2 Driving against the closed brake .....................................................................................17
4.3 Teaching the travel direction sensor ...............................................................................17
4.4 Automatic detection of surge currents in travel system...............................................17
4.5 Changing the steering unit on BVC-4 machines ............................................................19
4.6 Teaching the electronic end stops of the steering angle sensor (BVC) ......................20
4.7 Automatic detection of surge currents on steering valves (BVC)................................22
4.7.1 Reading out actual surge current values..........................................................................23
4.8 "Trimming" the speed measurement...............................................................................23
4.8.1 Quick overview.................................................................................................................23
4.8.2 Explanation ......................................................................................................................23
4.9 Calibrating the speed detection (calibration of wheel diameter)..................................24
4.9.1 Quick overview.................................................................................................................24
4.9.2 Explanation ......................................................................................................................24
4.10 Activating/deactivating the vibration control..................................................................25
4.10.1 Quick overview.................................................................................................................25
4.11 Activating/deactivating the attachment plates ...............................................................25
4.11.1 Quick overview.................................................................................................................25
4.12 Setting the vibration motor type.......................................................................................26
4.12.1 Table of vibration motor types ..........................................................................................26
4.12.2 Table of pulse numbers....................................................................................................27
BOMAG 183 008 911 79
9.1
5 Replacement of components....................................................................................... 28
5.1 How to proceed when replacing components?..............................................................28
5.2 Replacement of an ESX-control .......................................................................................28
5.3 Replacement of a travel pump / axle drive motor / drum drive motor..........................28
5.4 Replacement of a steering valve (BVC) ...........................................................................28
5.5 Replacement of a steering angle sensor.........................................................................28
5.6 How to proceed when replacing a front / rear axle sensors?.......................................28
5.7 Component replacement without adjustment procedure..............................................29
6 Description of the signals on the ESX-control........................................................... 30
7 Description of signals on the data collector .............................................................. 35
8 Description of signals on the travel lever................................................................... 37
9 Descriptions of signals on the LC - Display............................................................... 39
10 Description of Signals on DIOS-Module ..................................................................... 40
11 Fault codes of the ESX control .................................................................................... 41
11.1 Overview.............................................................................................................................41
11.2 Description of fault reactions...........................................................................................42
11.3 Note codes..........................................................................................................................43
11.4 Detailed description of fault codes and their possible causes....................................45
11.4.1 General ............................................................................................................................45
11.4.2 Brake................................................................................................................................46
11.4.3 Travel lever ......................................................................................................................46
11.4.4 Travel speed range selector switch..................................................................................48
11.4.5 Travel system...................................................................................................................48
11.4.6 Steering............................................................................................................................52
11.4.7 Driver's seat arm rest sensor............................................................................................54
11.4.8 Vibration...........................................................................................................................55
11.4.9 Attachment plates ............................................................................................................58
11.4.10 Diesel engine ...................................................................................................................59
11.4.11 Diesel engine EMR...........................................................................................................59
11.4.12 Miscellaneous ..................................................................................................................62
11.4.13 Machine type....................................................................................................................64
11.4.14 Optional functions ............................................................................................................64
12 Input Codes for ESX Control........................................................................................ 65
12.1 Fault log ..............................................................................................................................65
12.2 Value displays ....................................................................................................................65
12.2.1 General ............................................................................................................................65
12.2.2 Brake................................................................................................................................65
12.2.3 Travel lever / driving.........................................................................................................66
12.2.4 Travel speed range selector switch..................................................................................66
12.2.5 Travel pump: Travel direction forward..............................................................................67
12.2.6 Travel pump: Travel direction reverse..............................................................................67
12.2.7 Travel motor front (drum) .................................................................................................68
12.2.8 Travel motor rear (wheel axle)..........................................................................................68
BOMAG 184 008 911 79
12.2.9 Shut-down of drives..........................................................................................................68
12.2.10 Adaptation values for speed regulation ............................................................................69
12.2.11 Travel pressure sensor.....................................................................................................69
12.2.12 Inclination sensor .............................................................................................................69
12.2.13 Travel condition values.....................................................................................................69
12.2.14 Calibrating the wheel diameter .........................................................................................70
12.2.15 Speed limitation................................................................................................................70
12.2.16 Arm rest contact ...............................................................................................................70
12.2.17 Adoption values traction control .......................................................................................71
12.2.18 Steering: Steering valve ...................................................................................................71
12.2.19 Steering: Angle sensor in articulated joint ........................................................................71
12.2.20 Steering: Steering wheel ..................................................................................................72
12.2.21 Vibration...........................................................................................................................72
12.2.22 Vibration (up to version 3.24 ) ..........................................................................................72
Vibration control; Vario and low amplitude circular exciter (from version 3.25 ) .................................73
Vibration control; high amplitude circular exciter (from version 3.25 ) ................................................73
12.2.23 Attachment plates, option (only BW213 BVC) ..................................................................74
12.2.24 Engine..............................................................................................................................75
12.2.25 Hydraulics ........................................................................................................................75
12.3 Test settings.......................................................................................................................76
12.3.1 Brake................................................................................................................................76
12.3.2 Disable electric supply to wheel and drum drive motors (switch off).................................76
12.4 Settings / Teach / Emergency functions..........................................................................77
12.4.1 Changing the machine code.............................................................................................77
12.4.2 Automatic detection of surge currents in travel system....................................................77
12.4.3 Speed detection, trimming of measuring values...............................................................77
12.4.4 Speed detection, teaching of distance pulses ..................................................................77
12.4.5 Detection of wheel rotation...............................................................................................78
12.4.6 Steering: Automatic detection of surge currents on steering valve...................................79
12.4.7 Steering: Determining the steering stops .........................................................................79
12.4.8 Steering: Emergency function ..........................................................................................79
12.4.9 Steering: Other functions..................................................................................................79
12.4.10 Setting the vibration motor type........................................................................................79
12.4.11 Vibration: Travel speed dependent vibration lock.............................................................80
12.4.12 Vibration: Enable frequency setting..................................................................................80
12.4.13 Attachment plates (only circular exciter): Activating/deactivating the attachment plates
option 80
12.4.14 Plates: Preventing reversing with plates lowered .............................................................80
13 Terminology in connection with ESX.......................................................................... 81
BOMAG 185 008 911 79
9.1
1 Confirmation of changes
1.1 Document
No. Date Description of changes resp.
2.01 23.04.2004 Creation of version 1.00 Werner
2.02 06.05.2004 Revision, teach functions Fondel
2.03 11.05.2004 Revision, supplements version 1.01 Seis
2.04 24.06.2004 Revision, supplements to version 1.02
2.05 23.01.2005 Revision, supplement to software versions from 2.00 MASH
2.06 29.04.2005 Revision, supplement to software versions from 2.06 MASH
2.07 22.05.2005 Error code description 5121 changed. Lw
3.01 16.03.2006 Supplements with respect to TIER3 engines. Fault treatment. Lw
3.02 11.08.2006 List of "selected fault reactions" corrected
Documentation of error codes revised
List of machine types changed
Lw
3.03 13.11.2006
26.01.2007
21.02.2007
22.02.2007
Fault codes 5127 and 5136 added.
Machine types of new Tier 3 machines supplemented.
Fault description for steering supplemented.
Note for code list added
Lw
Vogt
MASH
MASH
3.23 22.10.2007 Input codes 3070 to 3072 to activate/deactivate the towed plate
option for circular exciter machines added.
MASH
BOMAG 186 008 911 79
1.2 Software
Ver. Date Description of changes resp.
1.03 02.09.2004 Surge currents travel system teach function changed
Known faults
Revision of error codes
Deactivation of electric steering on BVC machines
How to proceed when replacing components?
Schroeder,
Fondel
2.00 16.12.2004 List of error codes extended Schroeder
Fondel
MASH
2.02 08.03.2005 Adaptive adaptation of gradability. Display codes for the fac-
tors "Front top" 1500 and "Tail top" 1501
Input code to shut down the speed dependent Vib-limitation
(3047..3049).
Error message (8440..8443) for invalid BabyBoard equipment
of the ESX-travel control.
Overspeed protection for wheel drives (axle and drum drives)
MASH
2.06 29.04.2005 Input codes (1158/1159) for manual adaptation of axle speed
recording.
Input codes to record the pulse frequency of the drives:
Recording of speeds (1160..1169)
Adapted tank characteristic.
Change of speed limitation for operation with plates.
MASH
2.07 22.05.2005 Tank characteristic values changed. MASH
2.16
3.00
22.02.2006 Explanation concerning error messages steering supple-
mented.
MASH
2.18
3.01
10.03.2006 Supplements with respect to TIER3 engines.
Fault treatment extended.
Description of "known faults" extended.
MASH
Lw
2.19
3.02
20.03.2006 Fault correction travel pressure monitoring. MASH
Lw
3.04 18.05.2006 Fault monitoring steering wheel revised MASH
3.05 10.07.2006 Problem with start-up of new controls eliminated Lw
3.05 26.07.2006 Optimized CANopen functionality
Fault treatment for steering changed
(faults 2200 and 2201)
Rotary speed (vibration frequency) control and
fault monitoring changed
MASH
3.29 04.10.2006 Implementation of circular exciter machines with plate com-
pactors.
MASH
BOMAG 187 008 911 79
9.1
2 Displayed monitoring activities with fault reactions
Symbol in fault mes-
sage display
Warning
Code output
without buzzer
Warning
Code output
with buzzer
Engine stop
Code output
with buzzer
Engine oil pressure
(from EMR)
5100
5112
5101
5112
Coolant temperature
(from EMR)
5100
5116
5101
5116
Coolant level
5024
after 5s
5025
after 10s
Engine air filter
5026
after 5s
5027
after 2min.
ASC
Various error causes and reaction times.
See error codes
Hydraulic oil filter
5502
after 5s
5503
after 2min.
Water separator in
fuel filter
TIER II Engines
5028
after 5s
5029
after 2min.
Water separator in
fuel filter
TIER III Engines
5100
5119
Seat contact
1300
Arm rest
2300
Reaction
Signal
BOMAG 188 008 911 79
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.
Effect: Cause:
Display remains dark, no voltage PIN in display plug X 28 bent
Error code 5100, 5140 and engine does not re-
spond to full speed switch or travel lever
Switch the ignition off and on and restart the ma-
chine immediately.
After switching on the display shows "Error code
8224"
Code 8224 is no error code, but a software fault in
the display software, which has been rectified in
display firmware version 1.36 and higher
The display shows various engine faults (Code
51xx), even though neither code 5100 nor 5101 is
displayed.
Faulty assessment of engine faults in the EMR3
control unit. Remedy: Delete active and passive
engine faults
(see 3.4 Delete engine control error log)
BOMAG 189 008 911 79
9.1
Version/Status: V3.29 / 13.11.07 Functions of ESX Control Page 9 of 84
3 The diagnostics system
The machine is equipped with a diagnostics system consisting of display unit (LCD) and button-type
input unit (in the travel lever) to report machine faults, display measuring values and to set parame-
ters.
3.1 Display functions
The field t in the LC-Display shows the following diagnostic readings:
Type of indication Flashing Flashing "d"
warning tri-
angle
Flashing "d"
Of the fields
next to the
warning tri-
angle
Comment
Fault message
* * *
Warning
* *
Note
* *
Display, measuring
values
Values ranging from
0 0 0 0 ...9 9 9 9 to be called up via
input codes
Parameter setting Values ranging from
0 0 0 0 ...9 9 9 9 to be called up via
input codes
Negative display values are identified by a "Minus sign".
If several faults are detected, the displayed fault codes will change in a 3 second cycle.
3.2 General facts and operation
The following chapter describes the operation of the LC display via travel lever buttons.
3.2.1 Calling up service mode
For this purpose the display must be switched via input mode to service mode. Dies erfolgt ber die
beiden gelben Infotasten INFO 1 und INFO 2 an der Fahrhebelrckseite. Navigation in input and
service mode takes place via the green and blue buttons on the front of the travel lever.
Navigieren
(blau)
Werte ndern
(grn)
Navigieren
(blau)
Werte ndern
(grn)
INFO 1 Taste
(gelb)
INFO 2 Taste
(gelb)
BOMAG 190 008 911 79
The travel lever must be in locked braking position in order to activate input mode!Input mode
is switched on by simultaneously pressing both INFO buttons over a period of approx. 3 seconds.
3.2.2 Entering input codes
Input mode starts with flashing of the left hand digit. Here service code9 9 9 9 provides the possibility
to change to the service mode. The green buttons can be used to increase or reduce the values of the
corresponding digit. By operating one of the blue buttons one can jump to the next (left or right) digit.
Once the last right hand digit has been entered the code will be transferred to the control by pressing
the right hand blue button once again.
If the access code has been entered correctly, the "Spanner" symbol is displayed and the first input
digit flashes again. Individual operating states of the machine can now be interrogated by transferring
the input code to the control (as described above).
When operating both INFO buttons again for approx. 3 seconds, another input code can be entered.
The input of code "0 0 0 0 " or switching of the ignition quits the service mode.
If the travel lever is shifted out of the brake lock while in service mode, all machine functions will be-
come active, with the exception of the LC-display, which remains in service mode and continues to
display the operating values requested last.
BOMAG 191 008 911 79
9.1
Eingabe - Modus:
Umschaltung Displayfunktion
Einstellungen Display
Plattenverstellung inaktiv!
Bettigen INFO 1
+ INFO 2 ca. 3s
Eingabe
Zugangangscode
9999
Bet. INFO 1 +
INFO 2 ca. 3s
oder Fahrhebel
aus Bremsr.
Normalmodus (Fahrhebel in Bremsraste!)
Aufruf optionaler Anzeigen ber INFO - Taste 1
und INFO - Taste 2
CODE - Eingabe 0000" oder
Zndung aus
Service- Modus:
Eingabe Diagnosecodes
Fehlerspeicher abrufen / lschen
Maschinentypen umstellen
Plattenverstellung inaktiv!
Fahrhebel aus Bremsraste:
Diagnosemodus im Vordergrund aktiv!
BOMAG 192 008 911 79
3.3 Fault log display and delete
3.3.1 Showing stored faults
This function is only valid from software version 1.10!
Switch on function "Show stored faults":
Enter code number 0 7 0 0 ( !WITHOUT service code 9999). This code number enables the func-
tion Show stored faults.
The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are
successively displayed in cycles of 3 second. After the last fault has been displayed, the first fault will
appear again. If no faults are stored in the ESX, the display will show "- - - - - "
Switch off function "Show stored faults":
Enter code number 0 7 0 1 ( !WITHOUT service code 9999). This code number disables the func-
tion Show stored faults.
Note: Apart from the stored faults the current faults are also displayed.
Note: This function can only be activated / deactivated when the travel lever is locked
in the brake gate. ( Input mode)
3.3.2 Delete all stored faults
Execute the function Delete all stored faults:
The engine must not be running!
Enter code number 0 7 1 0 ( !WITHOUT service code 9999).
Switch the ignition off and on again.
All stored faults are now deleted.
Note: The stored faults can only be deleted when the engine is not running.
BOMAG 193 008 911 79
9.1
3.4 Delete engine control error log
3.4.1 Deleting logged engine errors
This function is only valid from software version 2.18 or 3.01 respectively!
Execute the function "Delete all logged faults in engine control unit":
Service code 9 9 9 9 .
Enter code number 0 7 6 0 .
All stored engine faults are now deleted.
3.4.2 Deleting active engine faults
This function is only valid from software version 2.18 or 3.01 respectively!
Execute the function "Delete all logged faults in engine control unit":
Service code 9 9 9 9 .
Enter code number 0 7 6 1 .
All active engine faults are now deleted.
BOMAG 194 008 911 79
4 Settings and queries
4.1 Setting the machine type
Since the same control software is used for all single drum rollers of generation DH-4 (with electroni-
cally controlled engines), the control must be matched to the machine in which it is actually installed
(setting the machine type).
This is necessary during first time commissioning as well as in case of a spare parts replacement.
This type setting is necessary, because different machine types/variants can have different parameter
sets, e.g. different wheel or axle drive motors (different numbers of pulses) or electrically different
hydraulic components (valve spools), or may be equipped with attachment plates or other optional
equipment.
For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the
display module when switching the ignition on. It can also be checked by entering code 0720.
The following machine types can be adjusted:
Machine type First serial number Last serial number Code Available from versi-
on
Standard
1
- - 7200 1.00
177 DH 101 582 21 1001 XXX XXX XX XXXX 7201 1.00
177 PDH 101 582 22 1001 XXX XXX XX XXXX 7202 1.00
179 DH 101 582 24 1001 XXX XXX XX XXXX 7203 1.00
213 DH
213 DH
214 DH
214 DH
101 582 51 1001
101 583 14 1001
101 582 58 1001
101 583 19 1001
XXX XXX XX XXXX
XXX XXX XX XXXX
XXX XXX XX XXXX
XXX XXX XX XXXX
7205 1.00
213 PDH
213 PDH
214 PDH
214 PDH
101 582 52 1001
101 583 15 1001
101 582 59 1001
101 583 20 1001
XXX XXX XX XXXX
XXX XXX XX XXXX
XXX XXX XX XXXX
XXX XXX XX XXXX
7206 1.00
216 DH-4
216 DH-4
101 582 60 1001
101 582 64 1001
XXX XXX XX XXXX
XXX XXX XX XXXX
7209 1.00
216 PDH-4
216 PDH-4
101 582 61 1001
101 582 65 1001
XXX XXX XX XXXX
XXX XXX XX XXXX
7210 1.00
219 DH-4
219 DH-4
101 582 70 1001
101 582 77 1001
XXX XXX XX XXXX
XXX XXX XX XXXX
7211 1.00
219 PDH-4
219 PDH-4
101 582 71 1001
101 582 78 1001
XXX XXX XX XXXX
XXX XXX XX XXXX
7212 1.00
226 DH-4 147kW
226 DH-4 150kW
101 582 80 1001
101 582 88 1001
XXX XXX XX XXXX
XXX XXX XX XXXX
7213 1.00
226 PDH-4 147kW
226 PDH-4 150kW
101 582 81 1001
101 582 89 1001
XXX XXX XX XXXX
XXX XXX XX XXXX
7214 1.00
226 DH-4 174kW 101 582 83 1001 XXX XXX XX XXXX 7215 1.00
226 PDH 174kW 101 582 84 1001 XXX XXX XX XXXX 7216 1.00

1
The standard machine type does not represent a real machine, but is the initial point for not yet set controls
during initial commissioning or after replacing a control.
BOMAG 195 008 911 79
9.1
177 BVC 101 582 23 1001 XXX XXX XX XXXX 7250 1.00
213 BVC
up to engineering status
01.12.05
101 582 53 1001 101 582 53 1082 7251 1.00
213 BVC plates
up to engineering status
01.12.05
101 582 54 1001 101 582 54 1038 7252 1.00
226 BVC 147kW
226 BVC 150kW
101 582 82 1001
101 582 86 1001
XXX XXX XX XXXX
XXX XXX XX XXXX
7253 1.00
226 BVC 174kW 101 582 85 1001 XXX XXX XX XXXX 7254 1.00
213 BVC
from engineering status
01.12.05
213 BVC
Variocontrol
101 582 53 1083
101 583 16 1001
101 582 12 1001
XXX XXX XX XXXX
XXX XXX XX XXXX
XXX XXX XX XXXX
7255 3.00
213 BVC plates
from engineering status
01.12.05
213 BVC plates
Variocontrol +
101 582 54 1039
101 583 06 1001
101 582 13 1001
XXX XXX XX XXXX
XXX XXX XX XXXX
XXX XXX XX XXXX
7256 3.00
EXAMPLE: Machine code for BW 219 PDH-4: 7212
Note:
Parameter adjustments can only be performed when the engine is not running.
This function can only be activated / deactivated when the travel lever is locked in the
brake gate. (Input mode)
Procedure for initial commissioning of a control:
The control has been installed into the machine.
Switch the ignition on. Approx. 4 seconds after switching on the word
C O D E will appear for 3 seconds. After this the display changes and shows code 7000.
Use the Arrow Up or Arrow Down keys to select the correct machine code from the list of codes.
Confirm the selection with the Arrow Right key.
After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for
approx. 3 seconds. The new parameters are loaded according to the machine type setting. Do not
switch the ignition off during this time!
After this switch the ignition off and on again to accept the configuration.
After this the normal display will appear again.
The following applies for a correction of the machine type code after it has been set.
Enter code number 9 9 9 9 (activation of service mode)
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 2 0 0 .
Select the machine code from the table above and confirm it with the Arrow Right key. After oper-
ating the Arrow Right key the control switches automatically off and on again.
After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for
approx. 3 seconds. The new parameters are loaded according to the machine type setting. Do not
switch the ignition off during this time!
BOMAG 196 008 911 79
After this switch the ignition off and on again to accept the configuration.
After this the normal display will appear again.
Attention: A machine must not be operated with a wrong type setting, because in such a
case the correct function of the control cannot be assured!
New controls are delivered with the default machine type setting 7 2 0 0 . This
does not enable to drive or steer the machine. It only serves the purpose of
commissioning.
BOMAG 197 008 911 79
9.1
After entering the code number 0 5 0 0 the brake will not be released. If the travel lever is in this con-
dition shifted out of the brake gate and moved to any travel direction, the travel pumps will be trig-
gered according to the chosen travel direction. At the same time a warning (fault code 0 5 0 0 ) ap-
pears on the display and the warning buzzer is triggered, in order to keep the operator informed about
the condition. The brake control light in the LC-display remains activated.
In order to terminate this function and release the brake you must either enter code number 0 5 0 1 or
switch the ignition off. After entering code number 0 5 0 1 the function is aborted and OK is
displayed as confirmation for 5 seconds. After this the code needs to be entered again.
4.3 Teaching the travel direction sensor
Teaching of the travel direction sensor is required for initial commissioning and after the replacement
of a travel motor. Perform the following sequence
Turn the speed range selector switch to "MAX"
Shift the travel lever slowly out of neutral, until a travel speed of approx. 1 km/h is indicated.
If one or both travel direction sensors detected a counteracting direction the error codes 1106
and/or 1116 will appear after approx. one machine length. Otherwise no error code will be dis-
played. The travel direction detection is now automatically set.
However, should one of the two error codes appear, this must be caused by a sensor fault.
4.4 Automatic detection of surge currents in travel system
For a sensitive and exact function of the travel system the surge currents in the travel system must be
determined for both travel directions. The surge currents are automatically determined after entering a
code number, so that no electric meter is required.
The surge currents must only be determined during initial commissioning in the factory, after a service
during which the control on a steering valve or the complete steering valve has been replaced and
after the replacement of the ESX-control.
The measurement is identical for both travel directions: After entering the respective code number the
current is increased by the control solenoid on the travel pump in steps of 5 mA, starting from 250mA..
After each current increase the system waits for 3 seconds. If a considerable drum movement is
measured during the waiting time, the surge current is reached. In order to enhance the measuring
result this measurement is performed three times. The final surge current is the mean value of these
three measurements. This surge current is automatically stored and is valid from the next start of the
machine.
Before the measurement you should strictly make sure that the machine is parked on level ground and
has a sufficient distance for movement to front and back, because the machine will move to the re-
spective direction when performing the measurement.
Attention! First set the machine to input mode (code 9999). It must be strictly assured that the
speed sensor (in front right hand hydraulic motor) is working correctly. For a function test enter code
number 1106 at the display module. This code can be used to display the number path pulses from
the speed sensor. The displayed value must change when the machine is driven.
BOMAG 198 008 911 79
If this value does not change even though the machine is moving, the measurement must not
be performed!
The state of the speed sensor must first be corrected, as otherwise the movement of the drum will not
be detected. (See also: Resetting the surge currents in the travel system)
Attention!
During the measurement the machine will move when the surge current is reached!
Do not leave the machine while the measurement is progressing!
During the measurement keep an eye on your environment!
To stop the machine reset the travel lever to neutral position!
The automatic measurement of the travel system surge currents is performed as follows:
The speed selection switch must be in position ECO.
If necessary enter code number 9 9 9 9 to access the service mode.
Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents
in the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This
code number must be entered to be able to perform the following steps. From this point the ma-
chine can no longer be operated with the travel lever! The travel lever will only be in func-
tion again after the teach function has been completed or the machine has been restarted.
The measurements (forward/reverse) must be started by entering a code number. The code num-
ber required to teach the travel direction is as follows:
Determination of control surge currents 1 0 9 1
After the input of the above code number the display shows " F O R E ". Shifting the travel lever
forward starts the first surge current measurement for forward travel.
During the measurement the actual current is displayed (display value = current in mA).
Once the surge current measurement is finished the display will show the reading O K for a pe-
riod of 5 seconds.
After this wait time the display reading changes to " B A C K ". Now shift the travel lever backward
to start the surge current measurement in reverse.
After completion of the measuring process in reverse the display will show O K again.
The travel lever must now be returned to braking position.
Once both surge currents have been learned correctly and the travel lever is in "braking position",
the display shows the reading "D O N E", the values are saved and the function is completed.
Now the machine can be operated again with the travel lever. The new surge current values for the
travel system are valid from the next start.
The teach function can at any time be aborted by operation of the emergency stop or the ignition
switch.
The following procedure applies for software versions 1.07 and 1.08:
The automatic measurement of the travel system surge currents is performed as follows:
The seat must be adjusted for travel direction forward!
The speed selection switch must be in position ECO.
If necessary enter code number 9 9 9 9 to access the service mode.
Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents
in the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This
code number must be entered to be able to perform the following steps.
BOMAG 199 008 911 79
9.1
From this point the machine can no longer be operated with the travel lever! The travel lever
will only be in function again after the teach function has been completed or the machine
has been restarted.
Both measurements (forward/reverse) must be started by entering a code number. The code num-
bers for both travel directions are:
Determine surge current for control forward 1 0 9 1
Determine surge current for control reverse 1 0 9 2
After entering one of the above code numbers the measurement will only start after moving the
travel lever to the respective travel direction. ATTENTION:The
ASC fault indicator light will come on during the teach process. In this case this is of no relevance.
The warning will disappear when restarting the machine.
Teaching is required for both travel directions.
When returning the travel lever to neutral position after the two measurements, the display will
show O K for 3 seconds and the averaged values will be saved.
Once both surge currents have been measured the machine can be operated again with the travel
lever. The new surge current values for the travel system are valid from the next start.
The teach function can at any time be aborted by operation of the emergency stop or the ignition
switch.
4.5 Changing the steering unit on BVC-4 machines
Availability: From version 1.09
By standard all BVC-4 machines (code 725x) are equipped with electric steering. For machines with
the Hydraulic Steering Option the steering mode (steering unit) in the travel control must be switched
over (electric steering disabled):
Enter code number 9999 (activation of service mode)
Enter code number 2060. This code number activates the function "Adjusting the steering unit.
The following code numbers are available to activate the assembled steering unit.
Hydraulic steering 2062
Electric steering 2061
The display shows O K
Attention: The steering unit can only be changed when the engine is not running!
BOMAG 200 008 911 79
4.6 Teaching the electronic end stops of the steering angle sensor (BVC)
Attention: Does not apply for BVC machines with "hydraulic steering" option!
Note: During the measurement the machine should be parked on level ground.
The drum should be standing on old rubber tires or a metal plate.
Specify the engine speed -> travel lever out of braking position = neutral position
(Not while entering a code).
To prevent the steering from moving all the way to the mechanical stops of the steering cylinder it is
necessary to determine a defined safety distance to these end stops.
Enter code number 9 9 9 9 to access the service mode.
Enter code number 2 0 1 0 to activate the mode "Teach steering stops".
Return the travel lever to neutral position (no braking function, but to relieve the machine of
strain). The display shows the standardized steering position (0..1000 right ... left).
Now turn the electric steering wheel clockwise, until the mechanical stop is reached The displayed
value should be in the range of 100..300. Then shift the travel lever to braking position and enter
code number 2 0 1 2 (press both Info-buttons first to access the input mode). In case of accep-
tance the value 2 2 2 2 will appear for a moment.In case of a fault the value 9 9 9 9 upon accep-
tance (see below).
Return the travel lever to neutral position (no braking function, but to relieve the machine of
strain). The display shows the standardized steering position (0..1000 right ... left).
Now turn the electric steering wheel anti-clockwise, until the mechanical stop is reached The dis-
played value should be in the range of 700..900. Then shift the travel lever to braking position and
enter code number 2 0 1 3 (press both Info-buttons first to access the input mode). In case of ac-
ceptance the value 3 3 3 3 will appear for a moment. In case of a fault the value 9 9 9 9 upon ac-
ceptance (see below).
To leave the mode the machine must be switched off or code 2 0 1 1 must be entered.
Possible error causes (code 9 9 9 9 ) :
- Incorrect connection of hoses -> have checked by engineer -> correct.
- Connecting fault on potentiometer -> have checked by an electrician -> correct.
- Potentiometer faulty -> replace the potentiometer.
BOMAG 201 008 911 79
9.1
Machine on level
d
Tires or metal
plate under drum
Machine on level
d
Enter 9999
Enter 2010
Travel lever in
neutral position
Turn steering wheel
CLOCKWISE, until STOP
is reached
(noise from pressure
relief valve, cylinder fully
Enter 2012
Travel lever in
braking position
Travel lever in
neutral position
Turn steering wheel
ANTI-CLOCKWISE, until
STOP is reached
(noise from pressure
relief valve, cylinder fully
Enter 2013
Display
shows
2222
Display
shows
9999
Display
shows
3333
Display
shows
9999
Travel lever in
braking position
Switch the ignition
off and on again.
OR
Enter 2011
FINISHED
START
BOMAG 202 008 911 79
4.7 Automatic detection of surge currents on steering valves (BVC)
Attention: Does not apply for BVC machines with "hydraulic steering" option!
Note: Perform this function only AFTER
"Teaching the electronic end stops of the steering angle sensor"
.
During the measurement the machine should be parked on level ground.
Before the measurement both drums should be steered to straight ahead position.
The travel motor must be moved out of braking position -> raised idle speed!
To enable a sensitive and exact function of the steering the surge currents of the two control solenoids
and both steering valves must be measured. The surge currents are automatically adjusted after en-
tering a code number, so that no electric meter is required.
The surge currents must only be adjusted during initial commissioning in the factory, after a service
during which the control on a steering valve or the complete steering valve has been replaced and
after the replacement of the ESX-control.
The measurement is identical for both solenoids:
Example BW 177 BVC:
After entering the respective code numbers the current is increased by the control solenoid in steps of
5 mA, starting from 650mA.. After each increasing step the system waits for 2 seconds. If a change in
drum angle is measured after the waiting time, the surge current is reached. In order to enhance the
measuring result this measurement is performed three times. The final surge current is the mean
value of these three measurements. This surge current is automatically stored and is valid from the
next start of the machine.
For all other machine types the same procedure is used, however, currents and times will vary.
Before the measurement you must strictly make sure that the steering system is bled, because an air
cushion in the steering cylinders would have a negative effect on the measurement and therefore on
the steering performance of the machine. Sufficient bleeding is achieved by performing a few quick
steering movements at full engine speed.
The automatic measurement of the steering valve surge currents is performed as follows:
The engine must be operated in ECO-mode!
Enter code number 9 9 9 9 to access the service mode.
Travel lever in neutral position (Brake must be released!)
Enter code number 2 0 0 0 . This code number activates the function "Automatic detection of
steering valve surge currents"; the display now shows the reading 0 0 0 0 with the first digit flash-
ing.
Now code number 2 0 0 1 must be entered.
After entering one of the above mentioned code numbers the measurement of the surge current
will start immediately.
The drum is thereby first steered to the right and then to the left.
During the measurement the actual valve current is displayed (display value in mA).
Attention! During the measurement the drum cannot be steered ! The steering wheel has no
effect.
During the measurement the machine should not be driven !
Once the measurement is completed the display value OK will appear for 3 seconds, after this the
code number 0000 is displayed with the first digit flashing, the next measurement can be started.
The new surge current values are valid from the next start.
BOMAG 203 008 911 79
9.1
4.7.1 Reading out actual surge current values
Surge current values currently saved in the control can be read out with the following
input codes.
The values should not differ more than +/- 50!
Show surge current for left hand valve control 2 1 0 6
Show surge current for right hand valve control 2 1 0 8
In case of excessively differing surge currents you should first of all run a new teach procedure.
See also fault codes 2 2 0 0 and 2 2 0 1 !
4.8 "Trimming" the speed measurement
4.8.1 Quick overview
Enter 9 9 9 9 : Switch on service mode.
Enter 1 1 5 8 : Allow function "Trimming the speed measurement".
Enter 1 1 5 9 : Start function "Trimming the speed measurement".
Display shows: F O R E : Move the travel lever forward (or back).
Green button up = raise indicated speed (measuring value too low)
Green button down = reduce indicated speed (measuring value too high)
Travel lever in braking position: D O N E = FINISHED! Procedure finished.
4.8.2 Explanation
In order to adjust the speed display (LCD) e.g. to the BOMAG measuring system to reference tests
benches, the machine integrated travel speed detection may be "trimmed", i.e. adjusted.
For this purpose the input codes 1 1 5 8 (enable function) and 1 1 5 9 (start function) are used to
activate the function Speed detection, trimming of measuring values (chapter 12.4.3, page 77).
As a result, the travel speed measured by the machine appears in the LCD-Display.
With the green button on the travel lever an internal calibration value can now be changed to such an
extent, that the displayed speed corresponds with the actual travel speed.
ATTENTION! If the speed detection is extremely falsified because of operating errors, this can
lead to uncomfortable travel behaviour and a reduced ASR control quality.
BOMAG 204 008 911 79
4.9 Calibrating the speed detection (calibration of wheel diameter)
see also 12.2.14 Calibrating the wheel diameter
Enter 1 1 6 0 : Allow function "Calibrate the speed detection".
Enter 1 1 6 1 : Start function "Calibration of speed detection" for a 5m distance.
or enter 1 1 6 2 : For a 10m distance
Display shows: F O R E : Move the travel lever forward (or back).
Green button up = raise indicated speed (measuring value too low)
Green button down = reduce indicated speed (measuring value too high)
Travel lever in braking position: D O N E = FINISHED! Procedure finished.
Enter 1 1 6 8 : Load original value.
Enter 1 1 6 9 : Save the values.
4.9.2 Explanation
The function Speed detection, teaching of distance pulses offers the possibility to calibrate the inter-
nal calibration value of the speed detection..
For this purpose the input code 1 1 6 0 (enable function) and 1 1 6 1 - 1 1 6 5 (start the
respective function) can be used to select a distance, which is then travelled with the machine (as
exact as possible).
During travel a numeric value is displayed.
The measurement is subsequently saved by means of the input code 1 1 6 9 and is now a valid crite-
rion for the speed detection.
With the input code 1 1 6 8 it is also possible to adjust the basic value for series machines ->
(1 1 6 0 - > 1 1 6 9 ).
ATTENTION! If the speed detection is extremely falsified because of operating errors, this can
lead to uncomfortable travel behaviour and a reduced ASR control quality.
BOMAG 205 008 911 79
9.1
4.10 Activating/deactivating the vibration control
Availability: From version 3.20 (design status 01.05.2007)
With design status 01.05.2007 machines with circular exciter (DH-4. Not BVC) were equipped with a
switch in the dashboard to adjust the nominal vibration frequency.
Machines with an older design status and without this switch need to be adjusted accordingly when
using the the currently valid travelling software.
see also 12.4.11 Vibration: Enable frequency setting
Enter 3 0 9 1 : Enable function "Switch over frequency setting".
Enter 3 0 9 2 : Activate frequency setting (machine with switch).
or
Enter 3 0 9 3 : Disable frequency setting (machine WITHOUT switch).
Viewing the current setting:
Enter 3 0 9 0 : View the current setting.
4.11 Activating/deactivating the attachment plates
Availability: From version 3.29 (design status 01.09.2007)
With design status 01.09.2007 the "attachment plate" option was released for machines with circular
exciter (DH-4. Not BVC).
ATTENTION: Machines with attachment plates are setup with the same software identification, as the
machines without plates (213 DH-4 = 213DH-4-plates = 7205)!
see also 12.4.13:
Attachment plates (only circular exciter): Activating/deactivating the attachment plates option
Enter 3 0 7 0 : Optional changeover enabled.
Enter 3 0 7 1 : Activate option "attachment plates").
or
Enter 3 0 7 2 : Disable option "attachment plates".
BOMAG 206 008 911 79
4.12 Setting the vibration motor type
Availability: From version 3.20 (design status 01.05.2007) or 3.21 (design status 01.06.2007)
Other vibration motors (type 2) were introduced as standard for machines (Code numbers 7205 to
7210)
from design status 01.05.2007 and for machines (Code numbers 7251, 7252, 7255, 7256) from design
status 01.06.2007.
Standard settings are shaded grey in the table (from design status 01.06.2007).
ATTENTION! If a machine with an older design status is furnished with the up-to-date travelling soft-
ware, the corresponding vibration motor type needs to be set (see 12.4.10).
Example:
BW213DH-4 (7205) with design status before 01.05.2007: -> 9 9 9 9 -> 3 0 3 1 -> 3 0 3 2 .
Check: -> 3 0 3 0 , display: 47 (see 4.12.2).
4.12.1 Table of vibration motor types
Vibration motor types
Machine
type code
Type1
(3032)
Type 2
(3033)
Type 3
(3034)
Type 4
(3035)
Type 5
(3036)
Type 6
(3037)
Type 7
(3038)
Type 8
(3039)
7201 MMF025
7202 MMF025
7203 MMF025
7204 MMF025
7205 A2FM56 90M055
7206 A2FM56 90M055
7207 A2FM56 90M055
7208 A2FM56 90M055
7209 A2FM56 90M055
7210 A2FM56 90M055
7211 A2FM63
7212 A2FM63
7213 A2FM80
7214 A2FM80
7215 A2FM80
7216 A2FM80
7250 MMF025
7251 A2FM56 90M055
7252 A2FM56 90M055
7253 A2FM80
7254 A2FM80
7255 A2FM56 90M055
7256 A2FM56 90M055
BOMAG 207 008 911 79
9.1
4.12.2 Table of pulse numbers
For correct detection of the vibration frequency, the control must be aware of the number of pulses
(number of pulses per revolution) of the vibration motors. The pulse numbers are determined by the
vibration motor type.
The currently set pulse number can be read out with input code 3030.
Pulse numbers
Machine
type code
Type 1
(3032)
Type 2
(3033)
Type 3
(3034)
Type 4
(3035)
Type 5
(3036)
Type 6
(3037)
Type 7
(3038)
Type 8
(3039)
7201 43
7202 43
7203 43
7204 43
7205 47 52
7206 47 52
7207 47 52
7208 47 52
7209 47 52
7210 47 52
7211 47
7212 47
7213 53
7214 53
7215 53
7216 53
7250 43
7251 47 52
7252 47 52
7253 53
7254 53
7255 47 52
7256 47 52
BOMAG 208 008 911 79
5 Replacement of components
5.1 How to proceed when replacing components?
Each machine is adjusted individually during initial commissioning. This adjustment or teaching proc-
ess is necessary to make sure that the travel and steering functions are almost identical on all ma-
chines. Background of these adjustment procedures are the tolerances of the components used, e.g.
hydraulic pump for travel system, proportional valves for steering, steering angle sensors and ESX
control. These tolerances apply for both mechanical as well as electrical functions and are unavoid-
able for manufacturing reasons.
To enable simple and quick adjustment procedures we have decided to do without expensive tools. All
that is needed is this manual and a bit of time. By following the described procedure it is possible to
take a machine back into operation after the replacement of one of the components specified above
and to re-establish the usual functional quality, with almost any previous knowledge. Even an incor-
rectly or incompletely conducted teaching procedure can be repeated without problems as often as
necessary. At the first glance it seems to be at bit awkward to perform this adjustment work on every
machine, but this procedure enables the operation of all machines with the same operating software.
At the end of the day this considerably increases the spare parts availability.
5.2 Replacement of an ESX-control
Since the control stores all teach values of the machine, each teaching procedure must be performed
with the new control after a replacement.
Attention: Before performing one of the following steps, the machine type must first
be set (see chapter 3.3)!
When changing the machine type all previously made adjustments will be
lost!
Now the teach functions must be executed.
From DH
Automatic detection of travel system surge currents (see chapt. 3.6)
On BVC
Automatic detection of steering valve surge currents (see chapt. 3.7)
Teaching the electronic end stops of the steering angle sensor (see chapt. 3.8)
5.3 Replacement of a travel pump / axle drive motor / drum drive motor
Automatic detection of travel system surge currents (see chapt. 3.6)

5.4 Replacement of a steering valve (BVC)
Automatic detection of steering valve surge currents (BVC) (see chapt. 3.7)

5.5 Replacement of a steering angle sensor
Teaching the electric end stops of the steering angle sensor (see chapt. 3.8)
5.6 How to proceed when replacing a front / rear axle sensors?
Teaching the travel direction sensor
BOMAG 209 008 911 79
9.1
5.7 Component replacement without adjustment procedure
Which components can be replaced without a subsequent adjustment procedure?
Display
Data collector
Joystick
Electric steering wheel
Diesel engine
All switches in the dashboard
Vibration motor
Vibration pump
Note: A final function test of the complete machine is highly recom-
mended.
BOMAG 210 008 911 79
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BOMAG 211 008 911 79
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BOMAG 221 008 911 79
9.1
Service Training Fault codes of the ESX control
Version/Status: V3.29 / 13.11.07 Fault Codes on ESX Control Page 41 of 84
11 Fault codes of the ESX control
11.1 Overview
Fault code Fault description
0 0 0 0 -
0 9 9 9
General faults / warnings / machine tests
1 0 0 0 -
1 9 9 9
Fault in travel system
2 0 0 0 -
2 4 9 9
Fault in steering system
2 5 0 0 -
2 9 9 9
Fault in remote control
3 0 0 0 -
4 4 9 9
Faults in work functions (vibration, attachment plates, rotor, chip
spreader)
4 5 0 0 -
4 9 9 9
Fault in measuring systems
5 0 0 0 -
5 4 9 9
Fault diesel engine
5 5 0 0 -
5 9 9 9
Fault hydraulic system
6 0 0 0 -
6 9 9 9
Fault anti-theft warning system, localization system, access sys-
tem, time account, etc.
7 0 0 0 -
7 4 9 9
Input of machine codes
7 5 0 0 -
7 8 9 9
Input of codes for measuring technology
7 9 0 0 -
7 9 9 9
Operating hours, load spectrum, etc.
8 0 0 0 -
8 9 9 9
Severe software error
1
9 0 0 0 -
9 9 9 9
Errors of external IO-nodes (joystick, data collector, Dios module,
LC-display, etc.)
1

1
These faults are not broken down hereunder!
BOMAG 222 008 911 79
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BOMAG 261 008 911 79
9.1
Service Training WZ 4
Version/Status: V3.29 / 13.11.07 Terminology Page 81 of 84
13 Terminology in connection with ESX
Short circuit
A direct, unwanted connection between two different cables or between machine and ca-
bles.
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)
rubbed through
chafed mostly in connection with a short circuit to ground
Terminal, cable lug
loosened, slipped off
broken off,
corroded,
socket / plug faulty
BOMAG 262 008 911 79
Short circuit to ground
Line, terminal has direct connection to vehicle ground, often in connection with wire break-
age
Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)
Analogue
In contrast to Digital, many states are permitted within a certain range. E.g. room tempera-
ture 0 to 40; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 to 300 ; valve
0% to 100% opened (proportional valve)
BOMAG 263 008 911 79
9.1
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 Closed loop control Control
Operating path: closed
(closed loop control circuit)
open
(control chain)
Measurement and
comparison of value to
be adjusted:
Value to be adjusted is meas-
ured and compared.
Values to be controlled
are not measured and
compared.
Reaction to faults (ge-
nerally):
Counteracts to all faults tar-
geting the system to be con-
trolled.
Does not respond to un-
known faults
Technical expense: Low effort:
Measurement of the value to
be controlled, comparison of
nominal and actual value,
power amplification
High expense if many
faults have to be consid-
ered, low expense if not
faults occur.
Performance in
unstable systems
For unstable systems closed
loop controls must be used.
In unstable systems con-
trols cannot be used.
BOMAG 264 008 911 79
Current and voltage measurement
Ohms law:
U = Voltage
R = Resistance
I = Current
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 for-
ward and reverse will cause an fault message, because this condition is normally not possi-
ble.
GND - AGND
Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional ana-
logue 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.
I
U
R
R
U
I
I R U
=
=
=
BOMAG 265 008 911 79
9.1
BOMAG 266 008 911 79
BOMAG 267 008 911 79
9.1

BOMAG 268 008 911 79
BOMAG 269 008 911 79
9.2 Electrics MESX
9.2 Electrics MESX
BOMAG 270 008 911 79
Electrics MESX
BOMAG 271 008 911 79
9.2
Status: 05.06.2007 Page 1 of 59
Author: T.Lw / TE
Dateiname: p:\schulung\elektrik\wz\mesx_bvc\englisch\schulung elektrik mesx_v4.00_gb.doc
Service Training
Electrics
MESX
008 097 05 Version 4.00
9.2 Electrics MESX
BOMAG 272 008 911 79
Service Training MESX
Status:05.06.2007 Page 2 of 59
Author: T.Lw / TE
Table of contents
1 Document alteration list.....................................................................................................................3
2 Proof of software change MESX.......................................................................................................4
3 Proof of software change BOP..........................................................................................................6
4 Known faults......................................................................................................................................7
5 How to proceed when replacing components?.................................................................................8
5.1 How to proceed when replacing an ESX control? .....................................................................8
5.2 How to proceed when replacing a rear axle sensor? ................................................................8
5.3 Which components can be replaced without a subsequent adjustment procedure?................8
5.4 List of machine types .................................................................................................................9
6 Possible adjustments on machines without BOP ...........................................................................12
6.1 Description of the Display Module ...........................................................................................12
6.2 Input of code numbers .............................................................................................................12
6.3 Changing the machine type (only via display module) ............................................................13
6.4 Inverting the direction signal (only via display module) ...........................................................14
6.5 Changing the bit rate (only with display module).....................................................................15
7 Adjustment/display possibilities on machines with BOP.................................................................16
7.1 Adjusting the machine type (BOP)...........................................................................................16
7.2 Inverting the direction signal via the BOP control terminal ......................................................18
7.3 Accessing the diagnostics menu .............................................................................................20
7.3.1 Extended diagnostics on machines with circular exciter (BTMplus, BTMprof) ................. 22
7.3.2 Extended diagnose BVC machines ......................................................................................... 23
7.4 Changing the printout language...............................................................................................24
7.5 Setting the machine serial number ..........................................................................................26
7.6 Teaching distance pulses ........................................................................................................28
7.7 Activating the amplitude limitation (only BVC machines) ........................................................30
7.8 Changing the display mode (metric/imperial) ..........................................................................32
7.9 Switching the GPS Receiver Voltage Supply Mode ................................................................34
8 Possible settings on the BCM05mobile ..........................................................................................36
8.1 Reading the software version ..................................................................................................36
8.2 Changing the language............................................................................................................36
8.3 Changing the unit system (metric/imperial) .............................................................................36
9 Block diagram BEM.........................................................................................................................37
10 Block diagram BTMplus / VARIOCONTROL...............................................................................38
11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile................................................39
12 Description of the signals on the ESX-control .............................................................................40
13 Fault codes of the ESX control ....................................................................................................45
13.1 Overview...............................................................................................................................45
13.2 Description of fault reactions................................................................................................46
13.3 Detailed description of fault codes and their possible causes ............................................47
14 Input codes for ESX control (only via BEM display module) .......................................................51
14.1 Travel system.......................................................................................................................51
14.2 Vibration ...............................................................................................................................52
14.3 Light ......................................................................................................................................52
14.4 Acceleration transducer........................................................................................................53
14.5 Diesel engine........................................................................................................................53
14.6 Setting the machine type......................................................................................................54
14.7 Parameter change................................................................................................................55
15 Terminology in connection with ESX...........................................................................................56
Electrics MESX
BOMAG 273 008 911 79
9.2
Author: T.Lw / TE
1 Document alteration list
Version Date Description of changes resp.
0.00 27.04.2004 Creation of version 1 Lw
1.00 05.05.2004 Block diagrams added
Description of display module extended
"Proof of software change" added
Lw
1.01 23.07.2004 Description of BOP display pages added. Lw
2.00 31.08.04 Input code 4602 replaced by code 4606
Machine type BW219D added
Lw
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
Lw
3.01 14.02.2005 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 changed from X0 to X44
Description of codes 7502, 7511, 7512, 7532, 7541, 7542,
7550, 7551, 7552, 7562, 7571, 7572, 7576 from version 3.03
added
Proof of "Software change" changed to "Software MESX"
Item "Proof of software change BOP" added
Item "Adjustment possibilities on BCM05mobile" added
Block diagram BTMplus / VARIOCONTROL and
BCM05mobile added
Serial numbers added to list of machine types
Lw,
Horch
4.00 01.05.2007 Description of "GPS Mode" menu added
Item "Change language" changed for BCM 05
Description fault code 4531 and 4532 extended
List of machine types extended
Lw
9.2 Electrics MESX
BOMAG 274 008 911 79
Author: T.Lw / TE
2 Proof of software change MESX
1.00 25.03.2004 Creation of version 1.00 Lw
1.01 05.04.2004 Printout modified
Amplitude limitation for Automatic changed to 0.3 mm
Default setting in Automatic changed to "MAX"
Lw
1.02 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
Lw
1.03 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
Lw
1.04 16.04.2004 BW226 BVC Polygon implemented
Max. adjustment angle limited to 80
Max. valve current for BW177 limited to 1000mA
Lw
1.05 26.07.2004 BW219DH and BW213 BVC Polygon implemented
Termination criteria for while loops incorporated into Evib
calculation
Lw
2.00 31.08.2004 Number of machine variants extended to 25 (BW219D)
Problem with sporadic SW crash eliminated
Lw
3.00 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)
Lw
3.01 16.11.2004 The ESC-key does not abort the printout, it only resets the
measurement
Machine variant BW226BVC added
Lw
3.02 01.12.2004 Machine type BW216D activated
Completion report for BW226BVC with smooth drum
activated
Lw
3.03 14.02.2005 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
Lw
3.04 10.05.2005 Vibration detection for BW177DH/PDH and BW179DH/PDH
corrected
Lw
3.05 19.05.2005 Phase response correction acceleration transducer
activated
"Flash Request" activated
Lw
Electrics MESX
BOMAG 275 008 911 79
9.2
Author: T.Lw / TE
4.00 01.05.2005 Languages Slovakian, Slovenian, Czech, Romanian added
Function "vCheckMMISoftwareVersion" corrected
Teach mode for distance via BCM implemented
Triggering of a relay for GPS receiver voltage supply
implemented
GPS mode changed: Off and ON now independent from
engine run, Automatic depending on engine run!
Setting of work number in serial number has been realized
ATTENTION: Signal distribution for CAN message
MMI_CONFIG_DATA_2 0x156 was changed!!!
new machine types:211PD, 213PD, 216PD, 219PD + "low
cost" designs:
177D40,1777DHC,177D_40,177DHC,177PDHC,177PDH_
40,179DHC,179PDHC,211D_40,211PD_40,213D_40,213D
HC,213PDHC,213PD_40,214DHC,214PDHC,216DHC,216
PDHC,212D_40,212PD_40
Pulse numbers changed to 10m for BW219D
VM classes taken from V3.90, VM class is sent to BCM
Lw
9.2 Electrics MESX
BOMAG 276 008 911 79
Author: T.Lw / TE
3 Proof of software change BOP
1.00 25.03.2004 first software version for series production 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 TN 582 701 92
Lw
3.01 24.1.2005 Part-No. changed to 58 701 93
Designation "ESX" replaced by "MESX" and "BOP" by
"BOP"
Lw
3.02 10.02.2005 Amplitude bar graph in imperial display mode corrected Lw
4.00 01.05.2007 Flags for all EU-languages and additionally Japan and
China stored in OPUS
Page for changing over GPS Receiver Mode implemented
Triggering for fault LED in BVC diagnostics page 2
activated
Lw
Electrics MESX
BOMAG 277 008 911 79
9.2
Author: T.Lw / TE
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
reading "ct0"
Bit rate on bmfsa not set to 125 kbit
=> see "Setting the bit rate"
9.2 Electrics MESX
BOMAG 278 008 911 79
Author: T.Lw / TE
5 How to proceed when replacing components?
Each machine is adjusted individually during initial commissioning. This is mainly accomplished by
setting the correct machine type (see "5.4 List of machine types", or "7.1 Adjusting the machine type
(BOP)").
The following chapter describes the necessary adjustments to the control when replacing individual
components in the measuring system.
5.1 How to proceed when replacing an ESX control?
Attention: A machine must not be operated with a wrong type setting,
because in such a case the correct function of the control cannot
be assured!
You should therefore set the machine type first! see "5.4 List of
machine types, or "7.1 Adjusting the machine type (BOP)").
After setting the machine type check the following items:
Check the direction signal, invert the signal if necessary, see 6.4, or 7.2.
Set the machine serial number (only on machines with BOP), see: 7.5
Set the printer language (only machines with printer), see: 7.4
5.2 How to proceed when replacing a rear axle sensor?
Check the direction signal, invert the signal if necessary, see 6.4, or 7.2.
5.3 Which components can be replaced without a subsequent
adjustment procedure?
BOP
Acceleration transducer
Valve block for exciter adjustment
Printer
Bmfsa display module
All switches in the dashboard
Note: A final function test of the complete machine is highly
recommended.
Electrics MESX
BOMAG 279 008 911 79
9.2
Author: T.Lw / TE
5.4 List of machine types
Since the same control is used for all single drum rollers with the new measuring technology, it is
necessary to adjust the machine type after installing a new control.
This is necessary during first time commissioning as well as in case of a spare parts installation. This
type adjustment is necessary, because the machines have e.g. different axle loads or different drum
widths, which requires the calculation of measuring values to be adapted. The adjustment procedure
is described under items "6.3 Changing the machine type (only via display module)" or "7.1 Adjusting
the machine type (BOP)".
The following machine types can be adjusted:
Machine type First serial number Last serial number Code Available from
version
177 D 101 582 20 1001 XXX XXX XX XXXX 7500 1.00
177 DH 101 582 21 1001 XXX XXX XX XXXX 7501 1.00
177 BVC 101 582 23 1001 XXX XXX XX XXXX 7503 1.00
179 DH 101 582 24 1001 XXX XXX XX XXXX 7511 3.03
211 D 101 582 40 1001
101 582 41 1001
101 583 09 1001
XXX XXX XX XXXX 7520 1.03
211 PD 101 582 45 1001
101 583 10 1001
213 D 101 582 50 1001
101 583 08 1001
213 DH 101 582 51 1001
101 583 14 1001
213 PD 101 582 46 1001
101 583 13 1001
213 BVC 101 582 53 1001
101 583 16 1001
213 BVC plates 101 582 54 1001
101 583 06 1001
213 BVC DI 101 582 53 1001
101 583 16 1001
214 DH 101 582 58 1001
101 583 19 1001
214 PDH 101 582 59 1001
101 583 20 1001
216 D 101 582 62 1001
101 583 23 1001
216 DH 101 582 60 1001
101 582 64 1001
216 PD 101 582 63 1001
101 583 24 1001
216 PDH 101 582 61 1001
101 582 65 1001
219 D 101 582 72 1001
101 582 10 1001
219 DH 101 582 70 1001
101 582 77 1001
219 PD 101 582 73 1001
101 582 11 1001
219 PDH 101 582 71 1001
101 582 78 1001
9.2 Electrics MESX
BOMAG 280 008 911 79
Status:05.06.2007 Page 10 of 59
Author: T.Lw / TE
version
226 DH 101 582 80 1001
101 582 83 1001
101 582 88 1001
226 PDH 101 582 81 1001
101 582 84 1001
101 582 89 1001
226 BVC 101 582 82 1001
101 582 85 1001
101 582 86 1001
226 BVC DI 101 582 82 1001
101 582 85 1001
101 582 86 1001
226 BVC RC 101 582 82 1001
101 582 85 1001
101 582 86 1001
version
VARIOCONTROL 101 582 12 1001 XXX XXX XX XXXX 7537 4.00
VARIOCONTROL+ 101 582 13 1001 XXX XXX XX XXXX 7538 4.00
version
177 D-40
177 DH-40
101 582 26 1001
101 582 27 1001
177 DHC-4 101 582 00 1001 XXX XXX XX XXXX 7601 4.00
177 PDHC-4 101 582 01 1001 XXX XXX XX XXXX 7602 4.00
177 PDH-40 101 582 28 1001 XXX XXX XX XXXX 7609 4.00
179 DHC-4 101 582 02 1001 XXX XXX XX XXXX 7611 4.00
211 D-40 101 583 02 1001
101 583 25 1001
211 PD-40 101 583 03 1001
101 583 26 1001
212 D-40 101 582 43 1001 XXX XXX XX XXXX 7680 4.00
212 PD-40 101 583 48 1001 XXX XXX XX XXXX 7689 4.00
213 D-40
213 DH-40
101 582 44 1001
101 582 55 1001
101 583 07 1001
101 582 56 1001
213 DHC-4 101 582 04 1001
101 583 11 1001
213 PDHC-4 101 582 05 1001
101 583 12 1001
213 PD-40
213 PDH-40
101 582 49 1001
101 582 57 1001
214 DHC-4 101 582 06 1001
101 583 17 1001
214 PDHC-4 101 582 07 1001
101 583 18 1001
216 DHC-4 101 582 08 1001
101 583 21 1001
Electrics MESX
BOMAG 281 008 911 79
9.2
Status:05.06.2007 Page 11 of 59
Author: T.Lw / TE
101 583 22 1001
9.2 Electrics MESX
BOMAG 282 008 911 79
Status: 05.06.2007 Functions of the ESX control Page 12 of 59
Author: T.Lw / TE
6 Possible adjustments on machines without BOP
6.1 Description of the Display Module
Note: The display module described next is only used in machines without the Bomag
Operation Panel (BOP). On machines with BOP the settings are made via the BOP!
(See item 7 "Adjustment/display possibilities on machines with BOP")
The display module consists of a 4-digit display and two keys, F1 and F2.
It is used for the output of fault codes and display values as well as for the input of code numbers.
Faults and warnings are displayed by flashing. If several faults are detected, the displayed fault codes
will change in a 3 second cycle.
Display values are permanently displayed, whereby values from 0 0 0 0 9 9 9 9 are possible. Higher
values lead to the display "- - - - ", negative values are indicated by the "minus dot" lighting up (see
illustration).
The following description describes the input of code numbers.
6.2 Input of code numbers
For the diagnostics of control inputs and outputs various code numbers can be entered via the display
module of the control. The input of a code number is performed as follows:
Press both keys (F1 and F2) on the instrument cluster for 2 seconds.
The value 0 0 0 0 will be displayed, whereby the 1st digit is flashing.
1. The value of the flashing digit can be increased by pressing the left hand key (F1). When the figure 9
is displayed and the left hand key (F1) is pressed again, the display will return to the value .
2. When pressing the right hand key (F2) the flashing digit will move one digit to the right. When the
4th digit is flashing, the right hand key (F2) is pressed once again to confirm the input. The desired
function is then executed or the desired value is displayed respectively.
In order to terminate a display function you must either enter code number 0 0 0 0 or switch the
ignition off.
1
5
/
5
4

s
i
g
n

0
5
7

6
6
7
7
2

Electrics MESX
BOMAG 283 008 911 79
9.2
Author: T.Lw / TE
6.3 Changing the machine type (only via display module)
For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the
display module of the central electrics when switching the ignition on. It can also be checked at any
time by entering code 7000.
Setting the machine type requires the following sequence:
Note: Parameter adjustments can only be performed when the engine is not running!
Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type".
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.
After this the newly adjusted machine type will be displayed for approx. 3 seconds.
Attention: A machine must not be operated with a wrong type setting, because in such a
case the correct function of the control cannot be assured!
New controls are delivered with the default machine type setting 7 5 0 0 .
9.2 Electrics MESX
BOMAG 284 008 911 79
Author: T.Lw / TE
6.4 Inverting the direction signal (only via display module)
Depending on the installation position, the axle sensor used delivers a 12 V output signal in forward and
reverse.
This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the the travel direction correspond with the actual travel direction.
Enter code number 7 6 0 0 . This code number activates the function "Invert direction signal.
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 inverted), or the code 0 0 0 0
(signal not inverted).
In succession the code number 1 0 0 1 can be used to check whether the direction signal is correctly
interpreted (see item 14 "Input codes for ESX control").
Electrics MESX
BOMAG 285 008 911 79
9.2
Author: T.Lw / TE
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.
9.2 Electrics MESX
BOMAG 286 008 911 79
Author: T.Lw / TE
7 Adjustment/display possibilities on machines with BOP
7.1 Adjusting the machine type (BOP)
Setting the machine type requires the following sequence:
Press key "?" to open the screen page "MENU". The following screen is displayed:
Press key "F2" to open the screen page "Adjust machine type". The following screen is displayed:
Electrics MESX
BOMAG 287 008 911 79
9.2
Author: T.Lw / TE
The desired machine type can be selected by pressing the keys "F11" and "F12". (see "List of
machine types" under item "Item 5.4 "List of machine types" ).
After selecting the desired machine type press key "F14", until the symbol (F14) lights green for
confirmation (approx. 4s).
When releasing the key the start screen will automatically be displayed and the control will initiate a restart.
BOP and MESX are now adjusted to the new machine type.
9.2 Electrics MESX
BOMAG 288 008 911 79
Author: T.Lw / TE
7.2 Inverting the direction signal via the BOP control terminal
Depending on the installation position, the axle sensor used delivers a 12V output signal in forward
and reverse.
This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the travel direction correspond with the actual travel direction.
Press key "F1" to open the screen page "Invert direction signal". The following screen is
displayed:
Electrics MESX
BOMAG 289 008 911 79
9.2
Author: T.Lw / TE
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.
9.2 Electrics MESX
BOMAG 290 008 911 79
Author: T.Lw / TE
7.3 Accessing the diagnostics menu
Press key "F5" to open the screen page "Diagnose1". The following screen is displayed:
Electrics MESX
BOMAG 291 008 911 79
9.2
Author: T.Lw / TE
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).
9.2 Electrics MESX
BOMAG 292 008 911 79
Author: T.Lw / TE
7.3.1 Extended diagnostics on machines with circular exciter (BTMplus,
BTMprof)
4.23 V Ubv: actual voltage front acceleration transducer
4.24 V Ubh: actual voltage rear acceleration transducer
98 % Small Ampl: Triggering of solenoid valve for low amplitude in percent
0 % Big Ampl: Triggering of solenoid valve for high amplitude in percent
Direction: Status MESX input travel direction (LED on = 12 V)
Lights: Status MESX input light detection (LED on = 12 V)
MD+ Status MESX input MD+ (detection engine running) (LED on = 12 V)
Vibration: Status of vibration detection in the MESX (LED on = Vibration ON)
+01234 Distance pulses detected by the MESX (10 cm steps). The actually detected
travel direction can be recognized by the roller symbol above.
Electrics MESX
BOMAG 293 008 911 79
9.2
Author: T.Lw / TE
7.3.2 Extended diagnose BVC machines
4.25 V Uexciter: actual voltage of exciter position potentiometer
4.23 V Ubv: actual voltage front acceleration transducer
4.24 V Ubh: actual voltage rear acceleration transducer
98 % Ampl: Triggering of solenoid valve for vibration valve in percent
Direction: Status MESX input travel direction (LED on = 12 V)
Lights: Status MESX input light detection (LED on = 12 V)
MD+ Status MESX input MD+ (detection engine running) (LED on = 12 V)
Vibration: Status of vibration detection in the MESX (LED on = Vibration ON)
+01234 Distance pulses detected by the MESX (10 cm steps). The actually detected
travel direction can be recognized by the roller symbol above.
9.2 Electrics MESX
BOMAG 294 008 911 79
Author: T.Lw / TE
7.4 Changing the printout language
Press key "F6" to open the screen page "Printout language". The following screen is displayed:
Electrics MESX
BOMAG 295 008 911 79
9.2
Author: T.Lw / TE
The desired printout language can be selected by pressing the keys "F11" and "F12".
After selecting the desired language press key "F14" to save the setting. The symbol (F14) lights
green for a moment as a sign of confirmation.
9.2 Electrics MESX
BOMAG 296 008 911 79
Author: T.Lw / TE
7.5 Setting the machine serial number
Press key "F7" to open the screen page "Serial number". The following screen is displayed:
Electrics MESX
BOMAG 297 008 911 79
9.2
Author: T.Lw / TE
The desired printout language can be selected by pressing the keys "F11" and "F12".
After the adjustment press key"F14" to save the setting. The symbol (F14) lights green for a
9.2 Electrics MESX
BOMAG 298 008 911 79
Author: T.Lw / TE
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:
Electrics MESX
BOMAG 299 008 911 79
9.2
Author: T.Lw / TE
Pressing the key "F5" starts the teach mode. The following symbol appears:
Drive a distance of 10 m length in forward and press the key "F6" at the end. The following symbol
appears:
After the end of the measuring travel press key "F14" to save the adjustment. The following
symbol appears:
Note: If the following symbol is displayed after the end of the travel distance the
measured distance pulses are not in the range of +/- 10% of the preset value.
Saving is in this case not possible! The measurement must be repeated!
9.2 Electrics MESX
BOMAG 300 008 911 79
Author: T.Lw / TE
7.7 Activating the amplitude limitation (only BVC machines)
Press key "F3" to open the screen page "Amplitude limitation". The following screen is displayed:
Electrics MESX
BOMAG 301 008 911 79
9.2
Author: T.Lw / TE
The limitation can now be activated or deactivated by pressing key "F5" ("Limit = 1" or "Limit = 0").
9.2 Electrics MESX
BOMAG 302 008 911 79
Author: T.Lw / TE
7.8 Changing the display mode (metric/imperial)
Press key "F4" to open the screen page "Display mode". The following screen is displayed:
Electrics MESX
BOMAG 303 008 911 79
9.2
Author: T.Lw / TE
The imperial display (mph, F, etc.) can now be activated or deactivated by pressing key "F5"
("Imperial = 1" or "Imperial = 0").
9.2 Electrics MESX
BOMAG 304 008 911 79
Author: T.Lw / TE
7.9 Switching the GPS Receiver Voltage Supply Mode
Press key "F14" to open the screen page "GPS Mode". The following screen is displayed:
Electrics MESX
BOMAG 305 008 911 79
9.2
Author: T.Lw / TE
This function enables the GPS Receiver Power Supply to be controlled via MESX, so that the receiver
can be switched on and off in a defined way.
The GPS Mode can now be changed over by pressing the "F5"-key:
"0" OFF GPS Receiver always switched off
"1" ON GPS Receiver switched on as soon as the ignition is switched on.
"2" AUTO GPS Receiver switched on as soon as the BCM transmits data to MESX
9.2 Electrics MESX
BOMAG 306 008 911 79
Author: T.Lw / TE
8 Possible settings on the BCM05mobile
Insert the BCM05mobile into the holder and close the clamp. Switch on the ignition and subsequently
the BCM05mobile by holding the yellow switch on the right depressed for approx. 1-2 seconds; wait
and confirm the time dialog.
For functions beyond the following description, please refer to the BCM05 user manual.
8.1 Reading the software version
Select "Configuration" at the right hand edge of the window.
The software currently installed in the BCM05mobile is displayed at the top left under the name BOMAG.
8.2 Changing the language
Note: This function is only available from software version 1.37!
Select "Configuration" at the right hand edge of the window.
Press the field "Language". A list with the available languages pops up. Choose the desired language
and confirm with "Select".
8.3 Changing the unit system (metric/imperial)
Open the service window: press the top switch of the three switches at the right hand edge of the
touch screen "Configuration" for about 5 seconds, until a roller symbol appears under the software
version number at the left hand side of the display. Release the "Configuration" switch and press the
symbol within 3 seconds. The touch screens now shows 4 switches near the right hand edge and
select the bottom switch "Service".
Note: After this setting the service window must be closed to avoid unauthorized
access. Press "Close window" at the bottom right in the service window.
Shift the switch in the "Unit" field to the desired position.
Electrics MESX
BOMAG 307 008 911 79
9.2
S
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BOMAG 314 008 911 79
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Electrics MESX
BOMAG 315 008 911 79
9.2
Service Training Fault codes of the ESX control
Status: 05.06.2007 Fault codes of the ESX control Page 45 of 59
Author: T.Lw / TE
13 Fault codes of the ESX control
13.1 Overview
Fault code Fault description
4 5 0 1 -
4 5 4 0
Position controller (exciter potentiometer, valves)
4 6 0 1 -
4 6 2 0
8 0 0 0 -
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Internal software errors
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BOMAG 316 008 911 79
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Electrics MESX
BOMAG 325 008 911 79
9.2
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9.2 Electrics MESX
BOMAG 326 008 911 79
Status: 05.06.2007 Terminology Page 56 of 59
Author: T.Lw / TE
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
Electrics MESX
BOMAG 327 008 911 79
9.2
Status: 01.04.2005 General terminology Page 57 of 59
Author: T.Lw / TE
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)
9.2 Electrics MESX
BOMAG 328 008 911 79
Status: 05.06.2007 Terminology Page 58 of 59
Author: T.Lw / TE
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.
distance Controll
disturbance
variable (z)
Output (y)
input (w)
a
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.
distance Controll
disturbance
variable (z)
e Output (y)
input (w)
+
-
u
Marking Closed loop control Control
Operating path: closed
(closed loop control circuit)
open
(control chain)
Measurement and
comparison of value to
be adjusted:
Value to be adjusted is
measured and compared.
Values to be controlled
are not measured and
compared.
Reaction to faults
(generally):
Counteracts to all faults
targeting the system to be
controlled.
Does not respond to
unknown faults
Technical expense: Low effort:
Measurement of the value to
be controlled, comparison of
nominal and actual value,
power amplification
High expense if many
faults have to be
considered, low expense
if not faults occur.
Performance in
unstable systems
For unstable systems closed
loop controls must be used.
In unstable systems
controls cannot be used.
Electrics MESX
BOMAG 329 008 911 79
9.2

Status: 01.04.2005 General terminology Page 59 of 59
Author: T.Lw / TE
Current and voltage measurement
Ohms law:
U = Voltage
R = Resistance
I = Current
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.
I
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=
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=
9.2 Electrics MESX
BOMAG 330 008 911 79
BOMAG 331 008 911 79
10 Service Training
BOMAG 332 008 911 79
BOMAG 333 008 911 79
10.1 Service Training Machine
BOMAG 334 008 911 79
Service Training Machine
BOMAG 335 008 911 79
10.1
BOMAG 336 008 911 79
Service Training
BW 213 / 214 DH / PDH -4
Table of contents
Foreword A 1
Documentation A 2
General A 3
New developments A 5
Travel system E 1
Travel pump E 3
Control E 7
Charge pressure relief valve E 8
High pressure relief valve E 9
Pressure override E11
Axle drive motor E14
Drum drive motor E17
Test and adjustment points, travel system E19
Trouble shooting travel system E27
BOMAG 337 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4
Vibration F 1
Vibration pump F 3
High pressure relief valves F 6
Control F 7
Vibration motor F 8
Drum F11
Test and adjustment points, vibration system F13
Trouble shooting vibration F15
Steering G 1
Charge pump G 2
Steering pump G 3
Steering valve G 5
Articulated joint G 7
Measuring and adjustment points G 9
Trouble shooting steering G10
BOMAG 338 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - A 1 -
Foreword and novelties
Reliable construction equipment is of greatest advantage for all parties involved:
for the customer/user it is a basis for an exact calculation of utilization periods and the completion of
projects as scheduled.
in the rental business it means that the equipment can be reliably used and planned without having
to stock a large number of stand-by machines.
for the manufacturer it means that customers are satisfied, provides him with a good image and gives
him a feeling of confidence.
It is BOMAGs philosophy to design and produce the machines with highest possible reliability. This
aspect of simple and easy maintenance was one of the key issues when developing and designing the
machine:
the location of components in the machine eases maintenance work,
the high quality standard of BOMAG is the basis for the considerable extension of the service and
maintenance intervals.
the After Sales Service of BOMAG, including excellent operating and maintenance instruction
manuals, high quality training courses and on-site machine demonstrations helps the customer to
maintain their machines in good condition over a long period of time.
Permanent training of BOMAGs own service personnel as well as the service personnel of BOMAG
Profit Centres and dealers is therefore a general prerequisite for BOMAGs excellent world-wide service.
This program of permanent training is only possible with appropriate and up-to-date training material for
trainers as well as persons attending the training courses.
This training manual has not only been written as a support for the professional work of the trainer, but
also for the trainees attending these training courses.
The different levels of product training demand, that the training performed by BOMAG, its Profit Centres
or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in
Boppard. For this reason we invested a lot of time in the preparation of these materials .
The structure of this training manual enables us to change or up-date individual chapters in case of
alterations to the machine.
BOMAG 339 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - A 2 -
Documentation
For valid BOMAG single drum roller serie -4 :
BW 213 DH-4
with serialnumber of the machine: 58314, 58315
BW 214 DH-4
with serialnumber of the machine: 58319, 58320
For the BOMAG machines described in this training manual the following documentation is additionally
available:
Attention!
The currently valid part numbers for the documents can be taken from the Doclist or the
Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial
number of the machine.
1. Operating and maintenance instructions
2. Spare parts catalogue
3. Wiring diagram *
4. Hydraulic diagram *
5. Repair instructions
6. Service Information
* The document versions valid at the date of printing are part of this training manual.
BOMAG 340 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - A 3 -
General
The new single drum rollers serie -4 from BOMAG are essentially further developments of their
predecessors, the machines of product range serie -3.
These machines have been successfully and reliably used for years on construction sites all over the
world, especially in earth construction and on sanitary landfill sites.
High compaction power and excellent traction are characteristics, which are of utmost importance for
this type of machine.
All components installed in these machines are manufactured in series production and are subjected to
stringent quality tests. This guarantees a high level of reliability and safety.
As with many other BOMAG products, and here especially with the large single drum rollers of the new
generation, we have decided to use the same successful drive concept with diesel engine (water cooled)
and hydrostatic drives also for these machines. The hydrostatic drives transfer the output power of the
engine directly to drum, drive wheels and steering.
The drive wheels are driven by fast rotating hydraulic motors and axle, whereas the drum is driven by
slow running radial piston motors.
On construction machines the work place of the operator is of utmost importance. Under such working
conditions the health and safety of the operator must be the greatest concern.
The cabin is very spacious and clearly arranged. The drivers seat is very comfortable and can be
individually adjusted for every operator, even for his weight.
All control elements and gauges are within the reach and in the sight of the operator.
A monitoring display with light emitting diodes and clear pictograms informs the operator about any
operating faults. The operator is therefore always informed about the present condition of the machine.
The generously glazed cabin with windscreen wiper and washer systems for front and rear windscreens,
as well as a heated rear windscreen, offers clear vision to all sides.
BOMAG 341 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - A 4 -
Important characteristics of the new generation of single drum rollers are
strong ROPS/FOPS according to SAE-standard
wear free service brake by closed hydrostatic travel circuits
disc brakes in axle and drum drive motor serve as parking and emergency brakes
high stability due to low centre of gravity and the use of an articulated joint
operating safety due to the use of monitoring boards for all important system data
automatic engine shut-down at too engine temperature, too low hydraulic oil level (when reaching the
lowest permissible level the engine will be shut down after 20 seconds) and too low engine oil
pressure.
The new single drum roller serie -4 are well designed down to the smallest detail, so that they can meet
the toughest demands on large scale construction sites all over the world.
BOMAG 342 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - A 5 -
Novelties
The multi-function travel lever and the display
BOMAG 343 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - A 6 -
Control, operation, data collector,
BOMAG 344 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - A 7 -
Diesel engine with EMR
BOMAG 345 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - A 8 -
Travel System
BOMAG 346 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 1 -
Travel system
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1
5
BOMAG 347 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 2 -
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 with reduction gear;
axle drive motor,
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 425 bar (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 pump inside the vibration pump draws hydraulic oil out of the tank and delivers it through
the hydraulic oil filter to the boost check valves in travel and vibration pump. The return flow from the
steering system also flows through the hydraulic oil filter and is then available for the closed circuit
charging system. The charge circuit also provides the oil for the control functions in the closed circuits
for travel and vibration drive and to release the parking brakes.
Both travel motors and the travel and vibration pumps are electrically proportionately controlled.
Pos. Designation Pos. in wiring diagram Pos. in hydraulic
diagram
Measuring values
10 Travel pump, electr.- prop. 90R075 10
12 Drum drive motor electr.-prop.
51C110
12
13 Axle drive motor, electr.-prop.
51D110
13
14 Axle 14
15 Reduction gear CR 31
BOMAG 348 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 3 -
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.
diagram
Measuring values
1 Travel pump, electr.- prop. 90R075 10
2 Charge pressure relief valve
3 Control, electr.-prop.
4 Multi-function valve
1 2
3
4
Charging
BOMAG 349 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 4 -
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.
Fig. 1: Travel pump
1 Electric prop. control 5 Cylinder block
2 Drive shaft 6 Valve plate
3 Swash plate bearing 7 Control piston
4 Pistons with slipper pads
With the servo control the swashing angle can be infinitely adjusted from neutral position (0) to both
maximum displacement positions.
When altering the swash plate position through the neutral position, the oil flow will be reversed and the
machine will drive to the opposite direction.
All valves as well as the safety and control elements needed for operation in a closed circuit, are
integrated in the pump.
1
2
3
4
5
6
7
BOMAG 350 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 5 -
Cross-sectional view of travel pump
Fig. 2: Cross-sectional view of travel pump
1 Retainer for swash plate 7 Swash plate bearing
2 Sliding block 8 Swash plate guide
3 Control piston 9 Swash plate
4 Servo arm 10 Swashing lever
5 Servo valve
6 Feedback device
1
2
3
4
5
6
7
8
9
10
11
BOMAG 351 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 6 -
View of the rotating group
Fig. 3: Travel pump, view of the rotating group
1 Working pistons
2 Slipper pad
3 Pre-tensioning spring
4 Cylinder block
5 Drive shaft
1
2
3
4
5
BOMAG 352 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 7 -
Description of function
Fig. 4: Function of travel pump
1 Drive shaft 5 Cylinder block
2 Drive shaft bearing 6 Multi-function valves
3 Swash plate 7 Charge pump (only in vibration pump)
4 Pistons with slipper pads 8 Valve plate
The drive shaft (1) is directly driven by the diesel engine via an elastic coupling. the shaft turns the tightly
connected cylinder block (5).
With the rotation of the drive shaft (1) the cylinder block (5) moves the working pistons (4). The slipper
pads of the working pistons abut against the swash plate (3).
1
2 3 4 5
6
7
8
6
BOMAG 353 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 8 -
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.
BOMAG 354 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 9 -
Tandem pump, connections and adjustment points
Fig. 5: Connections and adjustment points
38
Thermostat
housing
BOMAG 355 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 10 -
1 Rear vibration pump connecting plate, turned by 90 !!!
2 Proportional solenoid (vibration pump)
3 Multi-function valve 400 bar (charging and pressure limitation), travel system
4 Charge pressure to solenoid valve for brakes and speed range selector, charging vibration
5 Multi-function valve 400 bar (charging and pressure limitation), travel system
6 Pump flange
7 Port L, leak oil to vibration pump
8 Electr.-prop. control (travel pump)
9 Pressure test port, pilot pressure
10 High pressure port B, high pressure reverse
11 Charge pressure relief valve, 26 bar
12 not on EP-pumps
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 Charge pump (only in vibration pump)
19 Port L2, (connection to vibration pump)
20 not on EP-pumps
21 Filter block for charge circuit
22 Multi-function valve 400 bar (charging and pressure limitation), vibration high frequency
23 Port S, suction line between hydraulic oil tank and charge pump
24 Multi-function valve 400 bar (charging and pressure limitation), vibration low frequency
25 Charge pressure relief valve, vibration pump (fixed setting 40 bar)
26 Filter block for charge circuit
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
Thermostat housing:
32 Port C, from solenoid valve for brake/speed range selection
33 Leak oil port D, leak oil from axle drive motor
34 Leak oil port A, leak oil from travel pump
35 Leak oil port G, leak oil from drum drive motor
36 Leak oil port F, leak oil from vibration motor
37 Leak oil port B, leak oil to oil cooler
BOMAG 356 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 11 -
servo control
The servo control (mechanical hydraulic displacement control) converts the mechanical input signal
from the proportional valve 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 input
signal from the proportional valve. A mechanical feedback device ensures the fixed correlation between
the proportional valve input signal and the swashing angle of the swash plate (displacement of pump).
Control piston in pump
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:
when shutting the engine down,
if the pressure in the charge circuit drops below a certain value.
Servo cylinder
Control piston
Sliding block
Servo arm
BOMAG 357 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 12 -
Multi-function valves
High pressure limitation
Pumps of series 90 are equipped with a follower valve, which activates a pressure override and a
pressure relief valve, one after the other.
Fig. 6: Multi-function valves
1 to the control 6 Drive shaft
2 Multi-function valve 7 to the control piston
3 Charge pump 8 to the control piston
4 Charge pressure relief valve A Port A
5 Pilot pressure relief valve B Port B
If the adjusted pressure is reached, the pressure override will move the swash plate quickly back
towards neutral position, thereby limiting the system pressure. The average response time is less than
90 ms.
1 2
3
4
2
5 6
7
7
A
B
BOMAG 358 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 13 -
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.
Fig. 7: Multi-function valve, details
1 Reducing fitting 7 Check valve
2 Hydraulic by-pass piston 8 Pressure limitation
3 Spring plate 9 Spring
4 Spring 10 By-pass housing
5 High pressure relief valve 10 By-pass sleeve
6 Valve seat
Pressure override and high pressure relief valve are both parts of the multi-function valve, which is
screwed into the pump.
With its possibility to swash the swash plate inside the pump back within a period of 90 ms, the pressure
override makes sure that the high pressure relief valves will only respond in exceptional cases. This
protects the hydraulic circuit against overheating and reduces the load on the diesel engine.
Note:
The multi function valves must be tightened with a torque of 89 Nm!
1
2
3
4
5
6
7
8
9
10
11
BOMAG 359 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 14 -
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, the speed range
selection and to operate the multi-disc brakes in the travel drives.
Since feeding of cool and filtered oil is only possible in the low pressure side of the closed circuit, the
pressure in the low pressure side is almost identical with the pressure in the charge circuit.
When parking the machine on level ground with the engine running, the pressures in both
sides of the closed circuit are identical (charge pressure).
BOMAG 360 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 15 -
Axle drive motor
The axle drive motor is a swash plate controlled Sauer-Danfoss axial piston motor of series 51 D 110
with an electrical proportional control for variable displacement.
Fig. 1Hydraulic diagram, axle drive motor
1 Motor drive
2 Control piston
3 Proportional control with proportional solenoid
4 Flushing valve with flushing pressure limitation valve
5 Axle with brake
6) Rotary speed sensor (flange sensor)
Charge pressure
Brake valve HD-Pump
HD-Pump
Leak
2
3
4
5
oil
6
BOMAG 361 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 16 -
.
Fig. 2: Axle drive motor,
1 Control piston 7 Cylinder block
2 Flushing valve 8 Universal joint
3 Proportional control 9 Output shaft
4 Spindle with ball 10 Output shaft bearing
5 Q
min
-screw 11 Working piston
6 Valve plate
1
2
3
4
5
6
7
8
9
10
11
BOMAG 362 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 17 -
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.
Control
The motor is electric-proportionally controlled.
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.
The front travel motor (drum drive) also is an axial travel motor 51C110
from Sauer-Danfoss.
BOMAG 363 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 18 -
Flushing valve
Fig. 8Cross-section of flushing valve
1 Flushing spool
2 Flushing pressure relief valve
The flushing valves are integrated in the axle drive motor, or on DH/PDH machines, also in the drum
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 flushed out oil quantity 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.
1
2
BOMAG 364 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 19 -
Manual releasing of brake on axle drive
For manual releasing of the brakes on the rear axle you should proceed as follows:
Fig. 9: 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.
BOMAG 365 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 20 -
Drum drive motor 51C110 with reduction gear CR 31
The drums on the DH-4 and PDH-4 versions are driven by a swash plate operated Sauer axial piston
motor 51C110. This motor is almost identical with the rear axle motor. Another detailed description at
this point is therefore not necessary.
Fig. 10: Reduction gear CR 31
1 Travel motor 6 Sun gear
2 Tapered roller bearing 7 Planet carrier
3 Spur wheel 8 Brake discs
4 Hollow wheel 9 Mechanical seal
5 Planet wheel 10 Brake piston
This motor is a fast rotating hydraulic motor. Since the output speed of this motor is much too high to
drive the drum, a reduction gear reduces the output speed to the actually required drum drive speed.
1
2
3
4
5
6
7
8
9
10
BOMAG 366 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 21 -
Brake control
During operation the closed hydrostatic travel circuit has the function of a service brake. When moving
the travel lever from full forward or reverse position towards neutral, the travel pump will follow towards
zero position relative to the movement of the travel lever. The oil flow is thereby reduced and the
machine is hydraulically braked. When moving the travel lever to neutral position, the pump will also
return to neutral, the supply of oil is interrupted and the hydraulic circuit brakes the machine to standstill.
However, since minor leaks cannot be avoided in any hydraulic circuit and such minor leaks will cause
creeping of the machine when it is parked on a slope with the engine running, the machine is additionally
equipped with multi-disc brakes in drum drive and both wheel drives. When engaging the travel lever in
neutral position the multi-disc brakes will close and the machine can be parked on slopes with the
engine running and without the risk of creeping.
However, these parking brakes can also be operated via a 3/2-way solenoid valve. In de-energized
condition the multi-disc brakes in the travel drives are unloaded. The charge pressure to the brakes is
interrupted and the oil from the brake housings flows as leak oil back into the tank.
If the brake solenoid valve is supplied with current while the engine is running and the brake is open,
the connection of the brake line to the tank is interrupted and oil from the charge circuit is guided to the
brake pistons. The oil pressure works against the spring force of the brake spring and relieves the brake
discs.
BOMAG 367 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 22 -
Manual drum drive brake release (in the reduction gear)
For manual brake release both screws on the drum drive reduction gear (marked with arrow) must be
turned in uniformly, until the drum is able to rotate freely.
Brake releasing device
in operation position
Brake releasing device in
position brake manually
released
BOMAG 368 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 23 -
Travel circuit with drum drive motor 51C110 and CR 31 (position of
components)
Fig. 11: Travel circuit with 51 C 110 and CR 31
High pressure
Low pressure
Charge pressure
Leak oil
1
2
3
4
5
6
7
8
1 Travel pump
2 Vibration pump
3 Hydraulic oil filter
4 Rear axle
5 Axle drive motor
6 Reduction gear
7 Drum drive motor
8 Hydraulic oil tank
9
Travel lever
forward
9 Travel lever
T
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BOMAG 369 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 24 -
Brake control BW 213 (with Sauer motor 51C110 and CR 31)
Brake valve
Charge pressure
Brake releasing pressure
Leak oil
BOMAG 370 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 25 -
Test and adjustment points, travel system
Charge pressure filter and travel pump
diagram
Measuring values
1 charge oil filter 07
2 Charge oil filter pressure differential
switch
B21 p 3,5 bar
3 Pressure test port, charge pressure MA 26+/-3 bar
4 Travel pump - pressure test port
Travel pressure forward
10 / A / MD max. 426 bar
5 Test port travel pump forward A 10 / A
2
3
4
1
5
BOMAG 371 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 26 -
Travel pump
diagram
Measuring values
1 Travel pump - pressure test port
Travel pressure reverse
10 / B / MC max.426 bar
2 Prop. solenoid travel forward Bl.004 / Y17 / X16 12V / 0,4-1,2 A
3 Prop. solenoid travel reverse Bl.004 / Y16 / X15 12V / 0,4-1,2 A
1
2
3
1
3
2
BOMAG 372 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 27 -
Travel and vibration pump
diagram
Measuring values
1 Test port travel pump reverse B 10 / B
2 Pressure test port, charge pressure MA 26+/-3 bar
1
2
BOMAG 373 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 28 -
Travel motor (drum drive)
diagram
Measuring values
1 Pressure travel forward 12 - A
2 Pressure travel reverse 12 - B
3 Port X X1 approx. 26bar
4 Prop. solenoid Y30 12V / 0,4-1,2 A
5 Speed flange sensor PPU B59
1
2
3
4
5
2
3
4
5
1
BOMAG 374 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 29 -
Travel motor (axle drive)
diagram
Measuring values
1 Prop. solenoid Y 31 12V / 0,4-1,2 A
2 Port X X1 approx. 26bar
3 Travel pressure sensor B 112 26 -426 bar
4 High pressure travel pump forward
and further to drum drive motor
13 - B
5 High pressure travel pump reverse
and further to drum drive motor
13 - A
6 Speed sensor (flange sensor) B 60
1
2
3
4
5
6
BOMAG 375 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 30 -
Speed sensor and travel pressure sensor
NEW : Speed flange sensors in both travel motors and a travel
pressure sensor at the front left hand side under the operator's platform!
diagram
Measuring values
1 Speed flange sensor PPU axle
motor
B60
1 Speed flange sensor PPU drum
drive motor
B59
2 Travel pressure sensor in frame,
front left under operator's platform
B112
3
2
1
2
1
1
BOMAG 376 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 31 -
Brake valve
diagram
Measuring values
1 Brake valve Y 04 08 0V closed 12V
open
3
2
1
3
4
5
1
BOMAG 377 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 32 -
Travel lever
Multi-function travel lever
For a detailed description of the travel lever buttons
please refer to the page on " Electrics" (Service Training Electrics)
4
5
BOMAG 378 008 911 79
Service Training
BW 213 / 214 DH / PDH-4
- E 33 -
Trouble shooting
The display shows the fault codes
For a detailed description of how to read out fault codes and the display
All electric faults are mainly shown by the display
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.
BOMAG 379 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH-4
- E 34 -
Procedure:
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
FEHLERSUCHE FAHRANTRIEB
BW 213/214 DH/PDH-4
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MGLICHE URSACHEN
Bremsventil (elektrisch/mechanisch/hydraulisch) 1
Bremse Achse/Bandagenmotor (mechanisch/hydraulisch) 2 2 3
Fahrpropverstellung /defekt/Verkabelung 1
Speisepumpe / Speisedruckbegrenzungsventil(e)
verschmutzt/defekt
2 3
Pumpenansteuerung (Servoverstellung) 2 1 2 3
Druckabschneidung/ Hochdruckbegrenzung Fahrpumpe
verschmutzt/verstellt/defekt
3 2 3 3
Fahrhebel 1 2
Nullage Fahrpumpe 3 3
Fahrpumpe(n) defekt 3 3 2
Stellventil Fahrmotoren (elektrisch / mechanisch / hydraulisch) 1 2
Splventil Fahrmotoren hngt 3
Fahrmotor(en) defekt 3 3
Hydrauliklkhler verschmutzt (intern/extern) 1
Thermostat (Hydraulik) verschmutzt/verklemmt/defekt 2
Kupplung Dieselmotor-Pumpe 2
Dieselmotor 1
Drehzahl-Flanschsensoren im Fahrmotor (Verkabelung) 1 1 2
F E H L E R S U C H E
BOMAG 380 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - F 1 -
Vibration
diagram
Measuring values
1 Vibration pump 75 cm 11
2 Integrated charge pump 17 cm
3 Multi-function valves with high
pressure limitation and boost check
valve function
4 Proportional control
3
4

2
BOMAG 381 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - F 2 -
The vibration system on these single drum rollers works with different frequencies and tow amplitudes.
This enables perfect adaptation of the machine to various types of soil and different applications.
The vibration circuit is also a closed hydraulic circuit, similar to the travel circuit.
The main components of this circuit are
vibration pump,
Vibration motor
and the pressure resistant hydraulic hoses.
Vibration pump and travel pump are joined to a tandem unit, which is driven by the flywheel end of the
diesel engine.
By operation of a proportional valve the pilot oil is guided to one of the control piston sides. This actuates
the pump from neutral position to one of the two possible maximum displacement positions.
When changing the swashing angle through the neutral position to the opposite side, the flow direction
of the oil and the sense of rotation of the vibration motors will change.
Since the engine speed is variable in "Position AUTO", the pump displacement must always be
proportionately adapted in order to maintain the vibration frequency at a constant level.
The vibration motor output shaft is joined with the exciter shaft in the drum via a Bowex coupling. The
rotation of the exciter shaft with the bolted on eccentric weights causes the vibration of the elastically
suspended drums.
The eccentric weights on the vibrator shaft are fitted with additional change-over weights.
5 Vibration motor with flushing valve 15
diagram
Measuring values
BOMAG 382 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - F 3 -
Depending on the sense of rotation of the vibrator shaft these change-over weights add to or subtract
from the basic weights.
Basic weight +change-over weight =high amplitude
Basic weight - change-over weight =low amplitude
The displacement of the pump may be different to both flow directions. This results in different exciter
shaft speeds for the different senses of rotation of the motor.
The vibration system is designed in such a way, that the high exciter shaft speed (frequency) is coupled
with the low amplitude and the low exciter shaft speed (frequency) with the high amplitude.
Sense of rotation of exciter shaft
BOMAG 383 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - F 4 -
Vibration pump
The vibration pump is a swash-plate controlled axial piston pump with variable displacement of type 90
R 075 EP from Sauer-Danfoss. The pump is fitted with all control and safety elements needed for
operation in a closed hydraulic circuit.
diagram
Measuring values
1 Vibration pump 75 cm 11
2 Integrated charge pump 17 cm
3 Multi-function valves with high
pressure limitation and boost check
valve function
4 Prop. solenoids X 6 and X 7
5 servo control
6 Safety valve in charge circuit
2
4
5
3
6
BOMAG 384 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - F 5 -
Function
Cross-section of vibration pump
1 Servo piston
2 Working pistons
3 Charge pump
4 Valve plate
5 Roller bearing
6 Swash plate
1 2
3 4 5
6
BOMAG 385 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - F 6 -
Cross-section of vibration pump
1 Control
2 Servo piston
3 Friction free swash plate bearing
4 Attachment plate
5 Spool valve
1
2
3
4
5
BOMAG 386 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - F 7 -
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.
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 converts the electric proportional input signal into a load
controlling output signal.
The vibration pump has an integrated charge pump, an internal gear pump with a displacement of 17
cm per revolution
The vibration pump is equipped with an integrated charge pressure relief valve, which is set to a
pressure of 40 bar. This valve only has a safety function in the charge circuit.
BOMAG 387 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - F 8 -
Multi-function valve
As a measure to protect the closed vibration circuit against to high pressures the vibration pump is fitted
with pressure relief valves.
1 From the charge pump
2 Closed circuit
3 High pressure relief valve with integrated boost check valve
Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the
vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this
phase. The high pressure relief valve reduces these pressure peaks to a value of max. 426 bar
(pressure difference between high and low pressure side =400 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.
1
2
3
BOMAG 388 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - F 9 -
Vibration motor
The vibration motor is a Bosch-Rexroth axial piston motor of series A2FM 56 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.
BOMAG 389 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - F 10 -
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 426 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
Circuit diagram of vibration motor
1 Vibration motor
2 Flushing valve
1
2
3
A
B
MA
MB
BOMAG 390 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - F 11 -
Flushing valve
The vibration motor is equipped with an integrated flushing valve. This flushing valve is located inside
the bolted on connecting block. 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.
Flushing valve
1 Flushing spool
The flushing valve is fitted with a downstream 16 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.
A
B
1
2
BOMAG 391 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - F 12 -
Speed sensor
The fixed displacement vibration motor A2FM56 is equipped with a Bosch-Rexroth speed sensor
HDD1L16 or HDD2L16 with an installation depth of 16 mm, which uses the Hall-effect.
Connection in wiring diagram, vibration speed sensor B16 on page 006
Fixed displacement motor
A2FM56
BOMAG 392 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - F 13 -
Drum
Fig. 1 Cross-section of drum
1 Drum shell 8 Change-over weight
2 Vibration bearing 9 Coupling vibr.-motor vibrator shaft
3 Basic weight 10 Travel bearing
4 Vibrator housing 11 Travel bearing housing
5 Cooling fan 12 Rubber buffer
6 Vibrator shaft 13 Vibration motor
7 Elastic coupling between shafts 14 Flanged bearing housing
1
2
3
4
5
6
7
8
9
10
11
12
13
14
BOMAG 393 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - F 14 -
Test and adjustment points, vibration system
Vibration pump
diagram
Measuring values
1 Pressure test port, vibration
pressure low amplitude
11 - B - ME Starting pressure
330 -400 bar
2 Pressure test port, vibration
pressure high amplitude
11 - A - MF Starting pressure
330 -400 bar
3 High pressure port low amplitude 11 - B max. 426 bar
4 High pressure port high amplitude 11 - A max. 426 bar
5 Multi-function valve with high
pressure limitation low amplitude
11 - B
6 Multi-function valve with high
pressure limitation high amplitude
11 - A
7 Solenoid valve, low amplitude Y07 / X 8 11 - B 12V / 0,4 - 1,2A
8 Solenoid valve, high amplitude Y07 / X 7 11 - A 12V / 0,4 - 1,2A
1
2
3
4
5
6
7 8
2
1
3
6
7
4
5
1
3
4
5 6
7
8
2
BOMAG 394 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - F 15 -
Vibration motor
diagram
Measuring values
1 High pressure port high amplitude 15 - A
2 High pressure port, low amplitude 15 - B
3 Flushing valve 15
4 Leakage and flushing 15 - L1 approx. 2.5 l..
Flushing quantity
1
2
3
1 2
3
4
5
1
2
4
3
BOMAG 395 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - F 16 -
diagram
Measuring values
1 Speed-sensor B 16 15
1
BOMAG 396 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - F 17 -
Trouble shooting
BOMAG 397 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - F 18 -
Procedure:
FEHLERSUCHE VIBRATION
BW 213/214 DH/PDH-4
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MGLICHE URSACHEN
Vibrationschalter (Amplitudenvorwahl) 1 1
Fahrhebel, Taster Vibration (an/aus), Verkabelung 1
Elektrik defekt / Verkabelung 2 2
Pumpenansteuerung (elektrisch / hydraulisch) 1 1
Druckabschneidung/ Hochdruckbegrenzung Vibrationspumpe
verschmutzt/verstellt/defekt
2
Speisepumpe / Speisedruckbegrenzungsventil
verschmutzt/defekt
2
Frequenzeinstellung Vibrationspumpe 2
Vibrationspumpe defekt 2 2
Kupplung zwischen Dieselmotor und Fahrpumpe defekt
Erregerwellenlager defekt 3
Vibrationsmotorkupplung defekt 2
Vibrationsmotor defekt 2 1
Dieselmotor 1 1 1
Drehzahlsensor (Verkabelung) 1 1 1
Splventil Vibmotor hngt 2
BOMAG 398 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - G 1 -
Steering
Single drum rollers of series BW 213 / 214 DH-4 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.
Fig. 1Steering hydraulics
1 Rating pump
2 Distributor valve
3 Steering pressure relief valve (p =175 bar)
4 Check valve (pre-loaded to 0.5 bar)
5 Anti-cavitation valve
6 Shock valves (240 bar)
7 Steering cylinders
The steering pump draws the hydraulic oil out of the hydraulic oil tank and delivers it to the steering valve
and the connected steering unit under the operator's platform of the machine. If the steering is not
operated, the complete oil supply will flow through the fine filter to the charge system for the closed travel
circuits.
When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side
of the steering cylinder. A rating pump inside the steering unit measures the exact oil quantity
corresponding with the turning angle of the steering wheel and delivers the oil to the steering cylinders.
The steering cylinders retract or extend and steer the machine.
The steering unit is equipped with a pressure relief valve. This valve limits the steering pressure to 175
bar. The charge pressure must, however, be added to this value, because the oil leaving the steering
system enters the charge circuit. The actual steering pressure is therefore approx. 200 bar.
7
6
5
2
1
3
4
to charge
system
from steering pump
BOMAG 399 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - G 2 -
Charge pump
The charge pump for travel circuit and vibration works also as steering pump The pump is an external
gear pump with fixed displacement.
The oil flow generated by the charge pump 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.
BOMAG 400 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - G 3 -
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.
Fig. 2Steering pump
1 Housing
2 Flange
3 Shaft
4 Bearing plate
5 Bearing plate
6 Cover
7 Gear (driving)
8 Gear (driven)
9 Seals
1
2
3
4
5
6
7
8
9
9
9
BOMAG 401 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - G 4 -
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.
BOMAG 402 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - G 5 -
Steering valve
The steering valve block consists mainly of distributor valve, measuring pump, pressure relief valve and
shock valves.
Fig. 3Cross-sectional view of steering valve
1 Neutral setting springs
2 Housing
3 Inner spool
4 Outer spool
5 Universal shaft
6 Ring gear
7 Gear
8 Check valve
9 Pressure relief valve
When turning the steering wheel the distributor valve guides the oil flow from the pump to the rating
pump. The rating pump guides the oil flow through the distributor valve to the corresponding
sides of the steering cylinders. The rating pump measures the exact oil quantity in accordance with the
rotation angle of the steering wheel.
This oil flow to the steering cylinders articulates the machine and causes a steering movement.
1
2
3
4
5
6
7
8
9
BOMAG 403 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - G 6 -
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.
240 bar
240 bar
0,5 bar
p =175 bar
BOMAG 404 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - G 7 -
Articulated joint
Front and rear frames of the single drum rollers BW 177 D-4 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
BOMAG 405 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - G 8 -
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.
BOMAG 406 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - G 9 -
Test and adjustment points steering points
Steering pump
diagram
Measuring values
1 Steering pump (and charge pump) 09
2 Steering pressure test port MB 200 +/-10 bar
2
3
4
5
1
2
BOMAG 407 008 911 79
10.1
Service Training
BW 213 / 214 DH / PDH -4 - G 10 -
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.
BOMAG 408 008 911 79
Service Training
BW 213 / 214 DH / PDH -4 - G 11 -
Trouble shooting
BOMAG 409 008 911 79
10.1

Service Training
BW 213 / 214 DH / PDH -4 - G 12 -
Procedure:
FEHLERSUCHE LENKUNG
BW 213/214 DH/PDH-4
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MGLICHE URSACHEN
Lenkorbitrol 2 2 1
Lenk- Speisepumpe 1 1 2
Lenkzylinder 3 3 3
Knickgelenk 3 3 2
BOMAG 410 008 911 79
BOMAG 411 008 911 79
10.2 Service Training BVC
BOMAG 412 008 911 79
Service Training BVC
BOMAG 413 008 911 79
10.2
Service Training
12/2004 Teile-Nr. 008 099 94
Variocontrol
Single drum roller - 4
BW 177 / 213 / 226 BVC
BOMAG 414 008 911 79
Service Training
Variocontrol Single Drum Rollers Series 4
Table of contents
Foreword A 1
Documentation A 2
General B 1
Peculiarities B 3
Electric steering C 1
Steering circuit C 2
Steering pump C 4
Steering wheel C 5
Steering valve C 6
Steering angle sensor C12
Trouble shooting C15
Compaction measuring system D 1
BEM D 1
BTM plus D 2
BTM prof. D 3
BVC D 4
BVC - System E 1
Exciter system E 4
Gear pump E 5
Valve block E 7
Swashing motor E 9
Acceleration transducer E 10
MESX-control E 11
BOP E 12
Working principle of the system F 1
BOMAG 415 008 911 79
10.2
Service Training
Variocontrol Single Drum Rollers Series 4
Repair and adjustments G 1
Replacement of swashing motor G 2
Replacement of potentiometer G 3
Potentiometer adjustment G 4
Trouble shooting H 1
Electrics I 1
Service Training
MESX - Service Training
Wiring diagram
Hydraulic diagrams
BOMAG 416 008 911 79
Service Training
Variocontrol Single Drum Rollers Series 4 - A 1 -
Foreword
Reliable construction equipment is of greatest advantage for all parties involved:
for the customer/user it is a basis for an exact calculation of utilization periods and the completion of
projects as scheduled.
in the rental business it means that the equipment can be reliably used and planned without having
to stock a large number of stand-by machines.
for the manufacturer it means that customers are satisfied, provides him with a good image and gives
him a feeling of confidence.
It is BOMAGs philosophy to design and produce the machines with highest possible reliability. This
aspect of simple and easy maintenance was one of the key issues when developing and designing the
machine:
the location of components in the machine eases maintenance work,
the high quality standard of BOMAG is the basis for the considerable extension of the service and
maintenance intervals.
the After Sales Service of BOMAG, including excellent operating and maintenance instruction
manuals, high quality training courses and on-site machine demonstrations helps the customer to
maintain their machines in good condition over a long period of time.
Permanent training of BOMAGs own service personnel as well as the service personnel of BOMAG
Profit Centres and dealers is therefore a general prerequisite for BOMAGs excellent world-wide service.
This program of permanent training is only possible with appropriate and up-to-date training material for
trainers as well as persons attending the training courses.
This training manual has not only been written as a support for the professional work of the trainer, but
also for the trainees attending these training courses.
The different levels of product training demand, that the training performed by BOMAG, its Profit Centres
or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in
Boppard. For this reason we invested a lot of time in the preparation of these materials .
The structure of this training manual enables us to change or up-date individual chapters in case of
alterations to the machine.
BOMAG 417 008 911 79
10.2
Service Training
Variocontrol Single Drum Rollers Series 4 - A 2 -
Documentation
These Variocontrol training documents are valid for the following single drum rollers of series 4:
BW 177 DH-4 BVC
BW 213 DH-4 BVC
BW 213 DH-4 BVC + vibratory plates
BW 226 DH-4 BVC
For the BOMAG machines described in this training manual the following documentation is additionally
available:
Attention!
The currently valid part numbers for the documents can be taken from the Doclist or the
Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial
number of the machine.
1. Operating and maintenance instructions
2. Spare parts catalogue
3. Wiring diagram *
4. Hydraulic diagram *
5. Repair instructions
6. Service Information
* The document versions valid at the date of printing are part of this training manual.
BOMAG 418 008 911 79
Service Training
Variocontrol Single Drum Rollers Series 4 - B 1 -
General
BOMAG VARIOCONTROL (BVC)
The increased demands concerning quantity and quality in the application and compaction of soils and
rolled asphalt inevitably requires a permanent further development of vibratory rollers.
From the contractor's point of view a vibratory roller must fulfil three major requirements:
1. efficient operation
2. fulfilment of a task according to specification
3.flexible in use
Due to the inflexible parameterization, standard compaction systems are not able to adapt to the
permanently changing construction conditions in an optimal way.
However, this problem can be solved by the introduction of intelligent compaction systems. The control
values required for an automatic optimization of the compaction parameters are directly gained from the
interaction between drum and material to be compacted.
BOMAG VARIOCONTROL is a compaction system, which improves the quality and reproducibility of
compaction and enhances the efficiency of the roller, independently from the roller operator.
BOMAG VARIOCONTROL offers the user the following advantages:
1.Automatic adaptation of the emitted compaction energy to the actual compaction status
2. Better, reproducible results on all materials
3.No jump operation and therefore no particle destruction or loosening of material
4. The resulting direction of force is automatically adapted to the travel direction. This improves the
surface quality of the material and the gradability of the roller.
5.Low vibration loads for driver and environment
The further development of the VARIOCONTROL system for earthwork was founded on experiences
gained with the VARIOMATIC system used for asphalt compaction . The basic difference between
VARIOCONTROL and VARIOMATIC is the new exciter system.
It meets the demands of many users for an " intelligent" roller with automatic adaptation
of compaction.
BOMAG 419 008 911 79
10.2
Service Training
Part of this new further development is the new display and control element BOP (Bomag
Operation Panel) in connection with the MESX.
Besides the display of the entire operation of the measuring technology the BOP also enables a simple
self diagnose of the overall system.
The operation of the BOP is described in detail in the operating and maintenance instructions.
Error and input codes can be found on the electrics page (MESX Service Training).
BOP ----- Bomag Operation Panel
BOMAG 420 008 911 79
Service Training
Specialities
All BVC single drum rollers of series 4 are equipped with an electric steering
system as standard.
The hydraulic steering is also available as an option.
BOMAG 421 008 911 79
10.2
Service Training
Variocontrol Single Drum Rollers Series 4 - C 1 -
Electric steering
The electric steering consists of an electronically controlled closed control loop and a hydraulic steering
circuit.
Theelectronically controlled circuit consists of a small electric steering wheel (in the left hand seat
armrest), the ESX-control (located in the electric junction box), which converts the signal from the
steering wheel into electric signals for the proportional solenoids of the steering valve and the
steering angle sensor (located on the articulated joint), which feeds the steering angle back to the
control.
The hydraulic steering circuit consists of steering pump, high pressure filter, steering valve and
steering cylinders.
BOMAG 422 008 911 79
Service Training
BOMAG 423 008 911 79
10.2
Service Training
Hydraulic steering circuit
to charging
06
from
hydr.
tank
to emergency steering
and Vario control valve
MG
BOMAG 424 008 911 79
Service Training
Emergency steering:
The emergency steering valve is only an option and can only be operated via a special
input code. The valve is supplied by the additional Variocontrol gear pump.
diagram
Measuring values
05 one steering cylinder on BW 177 05
05 two steering cylinders
on BW 213 and 226
05
06 Steering valve with 2 proportional
solenoids and an integrated
accumulator
Y92 / Y93
Page 006
06
07 High pressure filter 12m 07
09 Steering pump and charge pump 09 / MB 200 +/-10 bar
17 additional gear pump 5.5 cm on
BW 177 BVC
17 / MG 80 bar
17 additional gear pump 8 cm on BW
213 and 226 BVC
17 / MG 120 bar
20 High pressure line filter for
Variocontrol 100 m
20
21 Optional emergency steering valve
with 2 B/W solenoids
Y112 / Y113
Page 006
21
BOMAG 425 008 911 79
10.2
Service Training
Steering pump with filter
Steering pressure
Steering pump
Pressure test port
12 m with
Steering circuit
High pressure filter
Pressure differential switc
3,5 bar
Filter outlet
Filter inlet
BOMAG 426 008 911 79
Service Training
Steering wheel
The small steering wheel is located in the left hand armrest of the driver's seat
diagram
Measuring values
Electric steering wheel A 45
Page 006
VCC 8,5 V
BOMAG 427 008 911 79
10.2
Service Training
Steering valve, electrically proportional
The steering valve, together with the optional emergency steering valve, is located
behind a protection box on the right hand side of the frame under the operator's stand
or the cabin.
to the
Steerin
cylinder
from the
to the charge
system
pump
BOMAG 428 008 911 79
Service Training
Steering valve
diagram
Measuring values
1 Steering valve port P 06
2 Steering valve port T 06
3 Steering valve ports A and B 06
4 Steering valve, pressure relief valve 06 175 +25 bar
5 Steering valve, shock valves 06 230 bar
6 Steering valve, accumulator 06 Accumulator
pressure 50bar
7 Steering valve, prop. solenoid Y 93 Page 006 0,4 - 1,2 A
8 Steering valve, prop. solenoid Y 92 Page 006 0,4 - 1,2 A
9 Emergency steering valve B/W
solenoid
Y 113 Page 006 0/12 V
10 Emergency steering valve B/W
solenoid
Y 112 Page 006 0/12 V
1 2
3
4
5
6
7 8
BOMAG 429 008 911 79
10.2
Service Training
Emergency steering valve (option, can only be operated via input code) !!!
9
10
BOMAG 430 008 911 79
Service Training
BW 177 BVC
diagram
Measuring values
1 Steering valve Y92 / Y93 06
2 Optional emergency steering valve Y112 / Y113 21
3 High pressure line filter 100m in
Vario-circuit
20
1
2
3
BOMAG 431 008 911 79
10.2
Service Training
Piping BW 177
BOMAG 432 008 911 79
Service Training
BW 213 and 226 BVC
diagram
Measuring values
1 Steering valve Y92 / Y93 06
2 Optional emergency steering valve Y112 / Y113 21
3 Pressure retaining valve,
Variocontrol circuit
22 110 / 99 bar
4 Accumulator for Variocontrol circuit 23 Accumulator
pressure 85bar
5 High pressure line filter 100m in
Vario-circuit
20
5
4
2
1
3
BOMAG 433 008 911 79
10.2
Service Training
Piping BW 213 and 226
BOMAG 434 008 911 79
Service Training
Steering angle sensor
The steering angle potentiometer is located on the articulated joint BW 177 and BW 213
The steering angle potentiometer is located inside the articulated joint BW 226
BOMAG 435 008 911 79
10.2
Service Training
BW 177 and 213 BVC
BOMAG 436 008 911 79
Service Training
BW 226 BVC
BOMAG 437 008 911 79
10.2
Service Training
Trouble shooting
The display shows error codes
A detailed description of how to read out the error codes and on the display
can be found in chapter " Electrics" (Service Training " Electrics" )
All electric faults are primarily displayed in the display.
BOMAG 438 008 911 79
Service Training
Procedure:
The following trouble shooting chart mainly lists mechanical and hydraulic faults.
FEHLERSUCHE el ektr.LENKUNG
BVC-4 Maschi nen
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MGLICHE URSACHEN
Lenkventil 2 2 1
Lenk- Speisepumpe 1 1 2
Lenkzylinder 3 3 3
Knickgelenk 3 3 2
BOMAG 439 008 911 79
10.2
Service Training
Variocontrol Single Drum Rollers Series 4 - D 1 -
Compaction measuring system for single drum rollers:
BEM
(Bomag E-vib Meter) for circular exciters
!
MESX
Bedienfunktionen
E vib
0
50
150
200
250
E VIB
MN/mm
BMFSA
Beschleuni gung
VV / VL 15g
Beschleuni gung
VH / VL 15g
Befehle
Neutral
Pos.
D+ Signal
Vibrationspumpe
Stromsignal
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BOMAG 440 008 911 79
Service Training
BTM prof
(Bomag Terrameter) for circular exciters
!
MESX
Bedienfunktionen
R
S
2
3
2
Drucker
BOP
Beschleunigung
VV / VL 15g
Beschleunigung
VH / VL 15g
Drehzahlsensor
hinten
Neutral
Pos.
D+ Signal
Vibrationspumpe
Stromsignal
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BOMAG 441 008 911 79
10.2
Service Training
BTM plus
(Bomag Terrameter) for circular exciters
!
MESX
Bedienfunktionen
BOP
Beschleuni gung
VV / VL 15g
Beschleuni gung
VH / VL 15g
Drehzahlsensor
hinten
Neutral
Pos.
D+ Signal
Vi brationspumpe
Stromsignal
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A
N

B
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BOMAG 442 008 911 79
Service Training
BVC
(Bomag Variocontrol) for Vario exciters
!
MESX
Bedienfunktionen
R
S
2
3
2
Drucker
BOP
Lageregelung
Ventil 1 vorn
Lageregelung
Ventil 2 vorn
Beschleunigung
VV / VL 15g
Beschleunigung
VH / VL 15g
Befehle
Erreger
Position vorn
Drehzahlsensor
hinten
Neutral
Pos.
D+ Signal
Vibrationspumpe
Stromsignal
S
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B
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BOMAG 443 008 911 79
10.2
Service Training
Variocontrol Single Drum Rollers Series 4 - E 1 -
BVC - System
BOMAG VARIOCONTROL is able to control the compaction power, independently from the driver. For
this purpose the size and direction of the effective amplitude is automatically adjusted in dependence
on compaction status and travel direction of the roller. This optimal adaptation of compaction ensures
that the roller emits the max. compaction power to the soil at any time. Apart from this, jumping of the
drum with the related over-compaction of the material is automatically prevented.
The VARIOCONTROL system consists of the following primary
components:
1. Exciter unit
2. Additional gear pump with line filter
3. Valve block with pressure relief valve and shock valves and (accumulator on
BW 213 and BW 226)
4. Variable displacement motor with integrated potentiometer based distance
measuring system
5. 2 acceleration transducers
6. Programmable logic control =MESX
7. Display and control unit =BOP
8. ) Optional printer
BOMAG 444 008 911 79
Service Training
BVC Circuit diagram for BW 177 DH-4
Legend from the hydraulic
diagram:
17) External gear pump
5.5 cm
18) Valve block with 80
bar pressure relief valve
19) Swivel drive, variable
displacement motor
20) High pressure line
filter
20
to filter
to steering system
from
tank
to the
tank
rear front
Y141 Y140
BOMAG 445 008 911 79
10.2
Service Training
BVC Circuit diagram for BW 213 / 226 DH-4
Legend from the hydraulic diagram:
17) External gear pump 8cm
18) Valve block with pressure relief valve (120 bar)
19) Swivel drive, variable displacement motor
20) High pressure line filter
22) Pressure override valve (99-110 bar)
23) Accumulator (1.4l, 85bar)
to filter
from
tank
to
Emergency
steering
to the
tank
Steering valve
Y141 Y140
front rear
BOMAG 446 008 911 79
Service Training
Exciter unit
BVC uses a new type of exciter system with two counter-rotating, concentrically arranged
shafts, generating directed vibrations (see Fig. below).
One common shaft carries three eccentrics, the two smaller weights near the ends and the
larger eccentric weight in the middle of the exciter shaft. The middle eccentric weight rotates in
opposite direction to the outer weights. The resulting centrifugal forces add up to a directed
vibration. The effective direction of this directed vibration can be adjusted by turning the
complete vibrator unit. Any desired angle position between horizontal and vertical oscillating
direction is possible.
The adjustment of the exciter unit is accommodated by a hydraulic swashing motor with
integrated displacement measuring system (potentiometer). The vibrator system is driven by a
hydraulic motor, the eccentrics are synchronized by gears.

General design of the VARIOCONTROL - exciter unit
BOMAG 447 008 911 79
10.2
Service Training
Gear pump with high pressure filter
BW 177 BVC
additional
gear pump
for Variocontrol system
Test port input
Variocontrol system
Filter
Input
High pressure
Line filter
Filter
Output
BOMAG 448 008 911 79
Service Training
BW 213 and 226 BVC
The pressure retaining valve with accumulator is located between Vario pump and valve block.
It helps to keep any losses through the pressure relief valve as low as possible.
diagram
Measuring values
1 P3 Input 22
2 P5 to valve block 22
3 T 22
4 T 22
5 Pressure retaining valve, opens and
closes
22 110 bar / 99 bar
6 P6 to accumulator 23 Preload pressure
85bar
7 High pressure line filter 22
8 T1 22
9 P4 22
1
2
3
4
6
5
8
9
7
BOMAG 449 008 911 79
10.2
Service Training
Valve block
The valve block has the function of triggering the adjusting motor. It consists of an electrical proportional
valve.
On BW 213 and BW 226 the valve is equipped with an upstream pressure retaining valve.
Assignment of valves to adjusting motor with exciter:
Y140 ---- valve outlet B ----- control Direction vertical forward
Y141 ---- valve outlet A ----- control Direction vertical backward
diagram
Measuring values
1 Test port BW 177 18 80 bar
1 Test port BW 213 and 226 18 120 bar
2 P2 18
3 A 18
4 T1 18
5 P1 18
6 B 18
7 T2 18
8 Shock valves 18 120 bar
9 Prop. solenoid Y 141 Page 008 18 0,4 - 1,2 A
10 Prop. solenoid Y 140 Page 008 18 0,4 - 1,2 A
11 Pressure relief valve BW 177 18 80 bar
1
2
3
4
5
6
7
8
9
10
8
11
BOMAG 450 008 911 79
Service Training
Valve block installation front left and protection housing for electric connections
11 Pressure relief valve BW 213 and
226
18 120 bar
diagram
Measuring values
Potentiometer
Pressure relief valve
BOMAG 451 008 911 79
10.2
Service Training
Under the protection
housing there are the
cable connections for
X 22 - speed sensor
X 47 - potentiometer for swa
X 48 - Acceleration
tranducer front
X 49 - Acceleration
transducer rear
BOMAG 452 008 911 79
Service Training
Swashing motor
with integrated potentiometer based distance measuring
system
As with the VARIOMATIC system, the resulting force may occur at any angle position
between horizontal and vertical direction of vibration. The adjusting motor is equipped
with an integrated displacement measuring system. This displacement measuring
system is based on a potentiometer mounted on the motor output shaft. Each position
of the motor has a resistance or voltage value assigned.
Potentiometer voltage:
Vertical forward approx. 2 V, Horizontal approx. 4,25 V, Vertical backward
approx. 6,5 V
Swashing motor, principle cross-sectional view (Pleiger)
BOMAG 453 008 911 79
10.2
Service Training
BOMAG 454 008 911 79
Service Training
The Variocontrol system is equipped with two acceleration transducers arranged one after the other on
the gearbox on the left hand side of the drum. These are mounted under an angle of 45 on either side
of the vertical. These transducer permanently deliver acceleration signals, which form the basis for the
entire control system.
There are two connection assignments
the signal outputs of the transducers:
BW 177 BVC signal brown 20g
BW 213 and 226 BVC signal blue 15g
see wiring diagram, page 008, path 8 and10, B62
BOMAG 455 008 911 79
10.2
Service Training
MESX-control
The MESX-control is located inside the electric junction box, below the ESX-travel control inside the
door of the electrics terminal box. The MESX takes over the function to control the Variocontrol system.
The sticker on the MESX control informs about the installed software version.
A detailed description can be found in the chapter " Electrics" , Service
Training MESX.
MESX
BOMAG 456 008 911 79
Service Training
BOP
Bomag Operation Panel
The operation of the BOP is described in detail in the operating and maintenance instructions!
1 E
VIB
display 11) Rotary switch for mode selection (Automatic/Manual)
2 not used 12) Push button F12 automatic operation
3 Push button F5 START 13) Push button F11 manual operation
4 Push button F6 STOP 14) Rotary switch, manual setting of amplitude direction
5 Push button F7 PRINT 15) Push button F10 vertical effective direction
6 Push button F8 DELETE 16) Push button F9 horizontal effective direction
7 Display of vibration frequency 17) Travel speed display
8 Rotary switch for setpoint adjustment (automatic operation) 18) Amplitude display
9 Push button F14 setpoint increase 19) Optional measuring value printer
10 Push button F13 Setpoint reduction
BOMAG 457 008 911 79
10.2
Service Training
Variocontrol Single Drum Rollers Series 4 - F 1 -
Working principle of system
Die Messung der Bodenkontaktkraft zwischen der Bandage und dem Einbaumaterial
erfolgt durch die beiden Beschleunigungsaufnehmer an der Bandage, die das
dynamische Verhalten kontinuierlich berwachen. Die Beschleunigungssignale, die
aus der dynamischen Wechselwirkung zwischen dem Walzenkrper und der
Unterlage resultieren, werden an die MESX-Steuerung weitergeleitet.
Werden bestimmte Grenzzustnde bzw. Sollzustnde erreicht, wird von der MESX ein
Signal auf die Verstelleinheit gegeben und dadurch die Verdichtungsenergie an den
neuen Einbauzustand angepat.
Signalisieren die Beschleunigungsaufnehmer eine geringe Bodensteifigkeit, schwenkt
das Erregersystem so weit in Richtung der vertikalen Arbeitsrichtung, bis die maximal
mgliche Verdichtungsenergie abgegeben wird. Nimmt die Bodensteifigkeit zu und
werden bestimmte Grenzwerte bzw. Sollwerte erreicht, schwenkt das Erregersystem
in Richtung der horizontalen Arbeitsrichtung, bis die Sollwerte unterschritten werden.
Das Ergebnis dieser Regelung ist, da das VARIOCONTROL-System die maximal
mgliche Verdichtungsenergie automatisch an den jeweiligen Einbauzustand anpat.
Das System mu dabei sehr schnell auf die Steifigkeitsnderungen reagieren. Die
Verstellzeiten von vertikaler zu horizontaler Arbeitsrichtung liegen unter einer Sekunde.
Damit kann das System
1. auf Vernderungen der Bodensteifigkeit unmittelbar reagieren
2. und zerstrende Bewegungen der Bandage verhindern.
BOMAG 458 008 911 79
Service Training
Variocontrol Single Drum Rollers Series 4 - F 2 -
Vibration parameters
Fr den Verdichtungserfolg ist schon die erste dynamische berfahrt von entscheidender
Bedeutung.
Die VARIOCONTROL Walzenzge sind daher auf besonders hohe Zentrifugalkrfte bzw.
Amplituden ausgelegt. Hierdurch wird eine sehr hohe Verdichtung und eine gute
Tiefenwirkung erzeugt.
Durch die groe Amplitude wrde die VARIOCONTROL Walzenzge frher springen als
Standardwalzenzge gleichen Betriebsgewicht. Durch die Automatik wird aber der
Vertikalanteil der Amplitude dann automatisch zurckgenommen und so ein Springen der
Walze verhindert.
Di chte
BW 177 BW 213 BW 219 BW 225
BVC Standard BVC Standard Standard BVC Standard
Schwi ngende Masse kg 2440 1970 4800 4250 5500 6630 6300
Zentrifugalkraft kN 189 126/100 365 275/198 326/250 402 330/182
Ampl itude mm 2,5 1,8 / 1,0 2,4 1,8 / 0,9 2,1 / 1,2 2,3 2,0 / 1,1
Frequenz Hz 28 30 / 36 28 30 / 36 26 / 30 26 26 / 26
0 1 2 3 4 5 6 7
Hochlei stungswalze
groe Amplitude
Standardwalze
bergnge
BOMAG 459 008 911 79
10.2
Service Training
Variocontrol Single Drum Rollers Series 4 - G 1 -
Repair and adjustments
Replacement of swashing motor and potentiometer
Swashing motor
Potentiometer
Fastening
screws
Potentiometer
BOMAG 460 008 911 79
Service Training
Locking screw
horizontal
Locking screw
vertical reverse
BOMAG 461 008 911 79
10.2
Service Training
Replaceing the swashing motor
1. If necessary remove the vibration motor
2. Unscrew the bottom plug (Pos.26, P/N 076 320 16) from the gearbox
3. Disconnect the hydraulic hoses and the electric connections from the potentiometer on the swashing
motor
4. Connect the hand pump to the front port (in travel direction) of the swashing motor (Pos.5) and pump
to the right, until the locking recess in the gear is in line with the bore in the gearbox.
5. Turn the locking screw (P/N 955 822 11) into the gearbox, the exciter is thus blocked in position
vertical reverse.
6. Remove the manual pump
7. Remove the swashing motor
8. Connect the manual pump again zo the front port of the new swashing motor and pump to the right
to the same position as with the removed swashing motor (position vertical forward)
9. Install the swashing motor, grease the splined shaft (with Optimol White P/N 009 960 01) and connect
hydraulically and electrically.
10. Remove the bottom locking screw (P/N 955 822 11) again and turn in the plug (Pos.26, P/N
076 320 16) with seal ring.
11. Tighten all fastening screws with the specified torque.
BOMAG 462 008 911 79
Service Training
BOMAG 463 008 911 79
10.2
Service Training
Adjusting the potentiometer
1. Unscrew the top plug (Pos.16, P/N 076 320 16) from the gearbox
2. Connect the hand pump to the rear port (in travel direction) of the swashing motor (Pos.4) and pump
to the left (middle position of swashing motor), until the locking recess in the upper gear is in line with
the bore in the gearbox.
3. Turn the locking screw (P/N 955 821 69) into the upper bore in the gearbox, the exciter is thus blocked
in position horizontal.
4. Loosen the fastening screws for the potentiometer so that it can be adjusted in the slots.
BOMAG 464 008 911 79
Service Training
5. Switch on the ignition and measure the supply voltage between X2:67 and X2:68 (e.g. U=8,42V).
6. Measure the signal voltage between X2:69 (white cable) and X2:68 (AGND).
The terminal bar X2 for the volatge measurement is located inside the electrics junction box.
7. Nominal value =1/2 supply voltage (e.g. 8,42/2 =4,21V) in case of deviations turn the potentiometer,
until the nominal value is reached.
8. Fasten the potentiometer.
9. Remove the blocking screw and insert the plug with a new seal ring.
10. Check the swashing motor by pumping it to both end positions with the hand pump and measure the
voltage values. Nominal values: left hand stop vertical forward approx. 2V and right hand stop vertical
reverse approx. 6,5V
This process 1 - 10 must also be performed when changing a potentiometer.
Wiring diagram Bl 008, Pf 11, B61
BOMAG 465 008 911 79
10.2
Service Training
Exciter lock in vertical reverse
Exciter lock in horizontal
BOMAG 466 008 911 79
Service Training
Variocontrol Single Drum Rollers Series 4 - H 1 -
Trouble shooting
In case of a fault in the Vario system the red triangular lamp lights up.
Show the fault code by pressing button ? followed by button F5
For detail info on reading out fault codes please refer to the chapter " Electrics, Training MESX" .
Red fault light
Button F5
Button ?
BOMAG 467 008 911 79
11 Engine
11.1 Diesel engine
BOMAG 468 008 911 79
11.1 Diesel engine
Series 4 single drum rollers are powered by 4 or 6 cyl-
inder Deutz diesel engines type TCD 2013 or a 6-cyl-
inder engine TCD 2012.
The engines are water cooled in-line engines with
EMR3 electronics.
The engines are mainly designed in two-valve tech-
nology with turbo charging and intercooler. They are
highly compact and come with a Deutz-Common-Rail
injection system, called DCR in short.
All engines are designed with exhaust gas recircula-
tion and thus reach emission values complying with
EPA/ COM/ Tier/ stage lll
The engines are characterized by the following posi-
tive features:
compact design
low noise level
almost vibration free operation
low fuel consumption
low exhaust emission EPA/COM IIl
high power density
excellent access to all service locations.
high reliability
low running costs,
long lifetime
Fig. 1 Deutz diesel engine TCD 2012 and 2013
Engine description TCD 2012
BOMAG 469 008 911 79
11.2
11.2 Engine description TCD 2012
Fig. 1 Deutz diesel engine TCD 2012, right hand side
1 Lubrication oil filling neck
2 Combustion air inlet
3 Cover
4 Fan
5 Generator
6 Fuel lift pump
7 Idler pulley
8 Lubrication oil cooler
9 Fuel filter
10 Replaceable lubrication oil filter
11 Lubrication oil sump
12 Possible installation of hydraulic pump or com-
pressor (optional)
13 Flywheel or (transmission connection SAE)
14 Crankcase ventilation valve
15 Transport device
16 Charge air line
17 Fuel control unit
11.2 Engine description TCD 2012
BOMAG 470 008 911 79
Fig. 2 Deutz diesel engine TCD 2012, left hand side
1 Exhaust manifold
2 Exhaust turbo charger
3 Lubrication oil filling neck (optional)
4 Engine mounts
5 Lubrication oil return line from exhaust gas turbo
charger
6 Relay (starter)
7 Ribbed V-belt
8 Coolant inlet
9 Coolant outlet
10 Coolant pump
11 Connection cabin heater ort compensation line
Engine description TCD 2013, 4 and 6 cylinder
BOMAG 471 008 911 79
11.3
11.3 Engine description TCD 2013,
4 and 6 cylinder
Fig. 1 Deutz diesel engine TCD 2013 L04 2V, right hand side
1 Combustion air inlet (possibility to install a heating
flange, optionally)
3 Fan
4 Generator
5 Belt pulley on crankshaft
6 V-belt
7 Fuel lift pump drive
8 Fuel filter
11 Possible installation of hydraulic pump or com-
pressor (optional)
12 Lubrication oil return line crankcase ventilation
13 Central plug (for engine control)
14 Fuel control unit
15 High pressure pump
17 Injector
11.3 Engine description TCD 2013, 4 and 6 cylinder
BOMAG 472 008 911 79
Fig. 2 Deutz diesel engine TCD 2013 L04 V2, left hand side
1 Lubrication oil filling neck (optional)
2 Transmission connection (SAE)
3 Engine mounts
4 Lubrication oil drain plug
6 Starter motor
7 Lubrication oil return line from exhaust gas turbo
charger
9 Coolant inlet
10 Charge air connection to intercooler
11 Coolant outlet
12 Exhaust manifold
13 Charge air line
14 Transport device
Engine description TCD 2013, 4 and 6 cylinder
BOMAG 473 008 911 79
11.3
Fig. 3 Deutz diesel engine TCD 2013 L06 2V, right hand side
1 Combustion air inlet
3 Transport device
4 Fan hub
5 Generator
7 Fuel filter
9 Oil dipstick
10 Lubrication oil drain plug
11 Oil return line crankcase ventilation
12 Engine mounts
13 Transmission connection (SAE)
14 Central plug (for engine control)
16 Rail
18 Injector
11.3 Engine description TCD 2013, 4 and 6 cylinder
BOMAG 474 008 911 79
Fig. 4 Deutz diesel engine TCD 2013 L06 2V, left hand side
2 Exhaust manifold
3 Starter motor
4 Lubrication oil flow to exhaust turbo charger
5 Coolant drain plug
6 Coolant inlet
7 Ribbed V-belt
8 Fan hub
9 Idler pulley
11 Ventilation line to compensation tank
12 Coolant line from engine to radiator
Lubrication oil circuit TCD 2012 / 2013
BOMAG 475 008 911 79
11.4
11.4 Lubrication oil circuit TCD
2012 / 2013
Fig. 1 Lubrication oil diagram
2 Lubrication oil suction pipe
3 Lubrication oil pump
4 Pressure relief valve
6 Return flow check valve (only on 2012)
7 By-pass valve
8 By-pass valve lubrication oil filter
9 Pressure control valve
11 Main lubrication oil lines
12 Internally switched exhaust gas recirculation
13 Crankshaft bearings
14 Conrod bearings
15 Camshaft bearings
16 Line to spray nozzle
17 Piston cooling nozzle with pressure maintaining
valve
18 Plunger with rocker arm pulse lubrication
19 Push rod, lubrication oil supply for rocker arm lu-
brication
20 Rocker arm
21 Return line to lubrication oil sump
22 Lubrication oil flow to exhaust turbo charger
24 Return line from compressor / hydraulic pump to
crankcase
25 Compressor or hydraulic pump
26 Lubrication oil line to crankshaft and camshaft,
compressor / hydraulic pump
27 Return flow from exhaust turbo charger
1
1
1
2
3
5
6
7
8
4 9
10
11
13 14
15
16
17
12
123
12
12 18
19
20 21
22
23
24
25
26
27
11.5 Coolant circuit TCD 2012 / 2013
BOMAG 476 008 911 79
11.5 Coolant circuit TCD 2012 /
2013
Fig. 1 Fuel diagram
1 Coolant outlet on radiator
2 Thermostat
3 Coolant - supply to water pump
4 Coolant pump
6 Cylinder cooling
7 Cylinder liner / head cooling
8 Coolant flow to heater
9 Cabin heater (optional)
10 Coolant to thermostat
11 Connection for cabin heater
12 Compensation line
13 Ventilation line to compensation tank
14 Coolant outlet to radiator
15 Compensation tank
16 Compensation line to heat exchanger
Fuel system TCD 2012 / 2013
BOMAG 477 008 911 79
11.6
11.6 Fuel system TCD 2012 / 2013
Fig. 1 Coolant diagram
1 Fuel tank A= minimum distance 500 mm
2 Fuel pre-filter with pre-pressure pumping possibil-
ity to fill the low pressure section (provided by cus-
tomer)
3 Line to fuel lift pump
4 Fuel lift pump
5 Fuel filter
6 Fuel supply line to fuel control unit
7 Rail
9 Fuel supply line to injector
10 Injector
11 FCU (Fuel Control Unit)
12 Fuel return flow on cylinder head
13 Fuel return line to fuel tank
14 Fuel lines from fuel control unit to high pressure
pumps and rail
15 Fuel lift pump 2013
BOMAG 478 008 911 79
Fuel pre-filter
Fig. 2 Fuel pre-filter
1 Fuel supply to pump
2 Fuel return flow from FCU (Fuel Control Unit)
3 Manual fuel pump with bayonet lock to lock and
unlock
4 Thermostat valve with shut-down lever
5 Filter cartridge
6 Possibility to connect an electric water level sen-
sor
7 Drain tap
8 Water collecting bowl
9 Fuel inlet from fuel tank
10 Fuel return flow to fuel tank
A Electric water level sensor
Fuel system TCD 2012 / 2013
BOMAG 479 008 911 79
11.6
TCD 2013 Fuel filter system
Fig. 3 TCD 2013 Fuel system
1 Fuel pre-filter
2 Hand pump
3 Fuel pressure filter min. 3m
4 Input fuel control unit
5 Fuel low pressure sensor
1
1
4
2
2
4
1
2
3
4
5
BOMAG 480 008 911 79
TCD 2012 Fuel filter system
Fig. 4 TCD 2012 Fuel system
1 Fuel pre-filter
2 Hand pump
3 Fuel pressure filter min. 3m
4 Input fuel control unit
5 Fuel low pressure sensor
1
1
4
2
2
4
1
3
4
5
2
Deutz Common Rail (DCR) injection system for TCD 2012 / 2013
BOMAG 481 008 911 79
11.7
11.7 Deutz Common Rail (DCR) in-
jection system for TCD 2012 /
2013
The diesel engines type TCD 2012 and 2013 are
equipped with a "Deutz Common Rail" injection sys-
tem, DCR in short.
The English term "Common Rail" indicates that the
system is based on a common rail. It describes the
use of a common high pressure fuel line with corre-
sponding branches to supply all cylinders with fuel.
The "Common Rail" injection is an injection system for
combustion engines, in which a high pressure pump
pressurizes the fuel to a high pressure level. The pres-
surized fuel fills a piping system, which is permanently
under pressure while the engine is running.
The general idea is the total isolation of the pressure
generation from the actual injection process. An injec-
tion solely controlled by mapping is only possible un-
der this condition. Injection timing and injection
quantity are controlled by the engine electronics. The
electric signals control an electrically operated valve
per cylinder, which is integrated in the injection noz-
zle. The short distances between valve and injection
nozzle result in short pressure rise times, which has a
positive effect on the combustion process and its con-
trol. Various types of injection van be realized, e.g.
pre-injection, main injection and post-injection. These
are freely controllable, in dependence on the control
unit.
The electric control is accomplished by the electronic
control unit (EDC16) with EMR3, in dependence on
the operating parameters. The system is capable of
providing a wide range of limp-home functions, should
any of the sensors fail. This ensures a reliable and
safe completion of travel and work.
Fig. 1 TCD 2012 and 2013
Overview of electronic diesel fuel control
Sensors Control unit (EMR3)
Actuators
Pump
Injector
Rail
11.7 Deutz Common Rail (DCR) injection system for TCD 2012 / 2013
BOMAG 482 008 911 79
Fig. 2 Schematic of the Deutz Common Rail System "DCR"
1 Fuel filter high pressure
2 Fuel low pressure sensor (5-7bar) B145
3 High pressure pumps
4 Fuel lift pump
5 Rail (high pressure pipe up to 1600 bar)
6 PRV (max. rail pressure limitation 1600bar)
7 Rail pressure sensor (B145)
8 Injectors (B148)
9 FCU Fuel Control Unit (Y137)
10 Engine control EDC16 - EMR3
11 Fuel filter with water separator
12 Hand pump
Under normal conditions the rail pressure is be-
tween 300 and 1350 bar
The PRV is set to 1600 bar
If the PRV is defective or always open, the pres-
sure in the rail will only build up to max. 700 bar.
The rail pressure must be at least 1.5 bar to start
the diesel engine
The fuel low pressure sensor is located after the
fuel filter and the pressure is normally between 5
and 7 bar.
The solenoid valve of the Fuel Control Unit (FCU)
is dead, open towards the tank.
The voltage applied to the injectors is normally
approx. 40 V.
4
1
5
6
7
8
9
10
11
12
BOMAG 483 008 911 79
11.7
FCU Fuel Control Unit (Y137)
Fig. 3 Fuel Control Unit FCU
Two high pressure pumps
Fig. 4 High pressure pump
electric connection
High pressure
Low
pressure
High pressu
pumps
BOMAG 484 008 911 79
Injector ( Y148 )
Fig. 5 Injector
Wiring diagram page 4
Fig. 6 Excerpt from the wiring diagram
Armature group
Supply
Return flow
Nozzle
electric connections
Engine control EDC16 - EMR3
FCU FCU
BOMAG 485 008 911 79
11.7
TCD 2013
Fig. 7 TCD 2013
1 Fuel pre-filter
2 Hand pump
3 Fuel filter
5 Rail
6 Fuel low pressure sensor (B145)
7 Connecting plug EMR3
1
3
2
4
6
5
7
BOMAG 486 008 911 79
TCD 2012
Fig. 8 Diesel engine TCD 2012
1 Rail pressure sensor (B93)
2 Rail pressure PRV
3 Fuel filter
5 Rail
6 Fuel low pressure sensor (B145)
7 Connecting plug EMR3
2
4
6
5
1
5
2
3
4
6
7
Sensors TCD 2012 / 2013
BOMAG 487 008 911 79
11.8
11.8 Sensors TCD 2012 / 2013
Fig. 1 Sensors TCD 2013
1 Fuel control unit (FCU)
2 Coolant temperature sensor
3 Sensor for charge air temperature and charge air
pressure
4 Possibility to connect a control unit
5 Engine control unit
6 Rotary speed sensor for crankshaft
7 Rail pressure sensor
8 Optional oil level sensor
9 Oil pressure sensor
10 Fuel pressure sensor
11 Rotary speed sensor for camshaft
12 Central plug for engine control
10
Diagnostics interface
Serdia connection
11.8 Sensors TCD 2012 / 2013
BOMAG 488 008 911 79
Fig. 2 Sensors TCD 2013
Fig. 3 Wiring loom TCD 2013
BOMAG 489 008 911 79
11.8
Camshaft speed sensor, B114
Inductive sensor
Determination of TDC
Limp-home function in case of crankshaft sensor

failure
Crankshaft speed sensor, B130
Inductive sensor
Exact determination of engine speed
Limp-home function in case of camshaft sensor fail-

ure
Charge pressure sensor, B133
Pressure sensor
Avoidance of smoke development
Adaptation of injection pump in case of too low

charge pressure
Determination of air mass for cylinder

Oil pressure sensor, B88
Pressure sensor
Monitors the oil pressure
Engine protection by switching of in case of too low

oil pressure
Charge air temperature sensor, B133
Temperature sensor
Temperature correction of air mass
Optimized injection quantity during cold start

Coolant temperature sensor, B113
Temperature sensor
Engine protection in case of excessive temperature

by reduction of injection quantity
Optimized injection quantity during cold start

Rail pressure sensor, B93
Pressure sensor
Monitoring the injection pressure)

Fuel low pressure sensor
Pressure sensor
Monitoring the inlet pressure approx. 5-7 bar

11.8 Sensors TCD 2012 / 2013
BOMAG 490 008 911 79
TCD 2012 Crankshaft speed sensor (B130)
Fig. 4 Crankshaft speed sensor TCD 2012
Fig. 5 Crankshaft speed sensor
Adjustment measurement or sensor gap meas-
urement
1 Toothed disc on crankshaft
2 Speed sensor
Gap measurement C = 0,6mm +/- 0.5mm
BOMAG 491 008 911 79
11.8
TCD 2013 Crankshaft speed sensor (B130)
Fig. 6 Crankshaft speed sensor TCD 2013
Fig. 7 Crankshaft speed sensor
urement
1 Toothed disc on crankshaft
2 Speed sensor
Gap measurement C = 0,6mm +/- 0,1mm
11.8 Sensors TCD 2012 / 2013
BOMAG 492 008 911 79
Camshaft speed sensor (B114)
Fig. 8 Camshaft speed sensor TCD 2012/2013
Fig. 9 Camshaft speed sensor
urement
1 Camshaft sprocket
2 Speed sensor
Gap measurement C = 1mm +/- 0.5mm
BOMAG 493 008 911 79
11.8
Measuring and testing
Fig. 10 Electric wiring diagram, page 004
Fig. 11 Speed sensor
Sensor test
Resistance measurement between Pin1 and Pin2 is
approx. 3.8 KOhm
If a magnetically conductive material is moved along a
sensor at a certain distance, a positive semi-wave
must be created on Pin 1, 2.
At a rotary speed of approx. 25 rpm there is a signal
voltage amplitude of at least 200mV from peak to
peak.
Camshaft Crankshaft
11.8 Sensors TCD 2012 / 2013
BOMAG 494 008 911 79
Combination sensor for charge air pressure and
charge air temperature (B133)
Fig. 12 TCD 2012
Fig. 13 TCD 2013
BOMAG 495 008 911 79
11.8
Fig. 14 Charge air pressure and temperature sensor
Charge air temperature
Pin 2--- NTC-Temperature
Resistance R=2510 Ohm = 20C
Resistance R=851 Ohm = 50C
Charge air pressure
Pin4
0.5 Volt = 0 bar at 5 V feed voltage
4,5 Volt = 4 bar at 5 V feed voltage
4
3 2 1
Pin
11.8 Sensors TCD 2012 / 2013
BOMAG 496 008 911 79
Oil pressure sensor (B88)
Fig. 16 TCD 2012
Fig. 17 TCD 2013
BOMAG 497 008 911 79
11.8
Fig. 19 Assignment of connections
Measurement
Pin 2 = Signal
11.8 Sensors TCD 2012 / 2013
BOMAG 498 008 911 79
Coolant temperature senor (B113)
Fig. 20 TCD 2013
Measurement
Pin 1 = Signal
Resistance R=2500 Ohm = 20 C
Resistance R=186 Ohm = 100 C
BOMAG 499 008 911 79
11.8
Rail pressure senor (B93)
Fig. 22 TCD 2012
Measurement
Pin 2 = Signal
11.8 Sensors TCD 2012 / 2013
BOMAG 500 008 911 79
Fuel low pressure sensor (B145)
Fig. 24 TCD 2012
Fig. 25 TCD 2013
BOMAG 501 008 911 79
11.8
Fig. 27 Connecting plug
Measurement
Pin 2 = Signal
Pin 2
Signal
Pin 4
Ground
Pin 1 +
11.9 Engine control EDC16 with EMR 3 for TCD 2012 / 2013
BOMAG 502 008 911 79
11.9 Engine control EDC16 with
EMR 3 for TCD 2012 / 2013
Control unit EDC 16 - EMR 3
Operating voltage 12 V DC and 24 V DC
Working range 9-31 V
Engine start possible from 6 V

Fig. 1 EDC 16 - EMR 3 TCD 2012 and 1013
Vehicle side
Engine side
Connection
Connection
Engine control EDC16 with EMR 3 for TCD 2012 / 2013
BOMAG 503 008 911 79
11.9
EMR 3 - interface description
Fig. 2 EMR 3 - connecting plug TCD 2012 and 2013
Fig. 3 Connecting plug EMR3
Engine side
D 2.1
Pin 1-60
in wiring diagram
Page 004
X31:1 to X31:90
Vehicle side
D 2.2
Pin 1-94
in wiring diagram
Page 004
X30:1 to X30:94
16
Engine side
Vehicle side
BOMAG 504 008 911 79
Interface on engine side X31:
Engine control EDC16 with EMR 3 for TCD 2012 / 2013
BOMAG 505 008 911 79
11.9
Interface on vehicle side X30:
BOMAG 506 008 911 79
Engine control EDC16 / EMR3
The EDC16 is located under the operator's stand
Fig. 6 EMR3-position in the machine under the operator's stand
Exhaust gas recirculation TCD 2012 / 2013
BOMAG 507 008 911 79
11.10
11.10Exhaust gas recirculation TCD
2012 / 2013
In order to be able to meet the exhaust gas stand-
ards EC and stage/Tier3, all engines are designed
with exhaust gas recirculation.
On 4-cylinder engines TCD 2012/2013 the exhaust
gas recirculation has been realized internally
through the intake valves, on 6-cylinders through
the exhaust valves. For this purpose the camshaft
has been manufactured with an additional cam for
short-term opening of the intake valve or exhaust
valve respectively.
Fig. 1 Exhaust/intake valve control TCD 2012 / 2013
11.11 Fault code monitoring with display TCD 2012 / 2013
BOMAG 508 008 911 79
11.11Fault code monitoring with
display TCD 2012 / 2013
Fig. 1 Display
LCD display
i
Note
With the ignition switch in position I all gauges and in-
struments are switched on for 3 seconds.
Toggling between the displays is described in the
chapter "Operation".
b = Fuel level gauge
c = Upper display field, shows either the time
or the coolant temperature
e red = flashes if engine oil pressure too low, en-
gine is shut down after 10 seconds.
Check engine oil level, repair the engine
if necessary.
f red = flashes if the engine overheats (oil tem-
perature), the warning buzzer sounds,
the engine is shut down after 2 minutes.
Switch off vibration, run engine with idle
speed or shut down engine if necessary,
clean engine oil cooler and radiator, if
necessary repair engine.
g yellow = lights if combustion air filter cartridge is
soiled, clean or replace if necessary.
h red = flashes when the coolant (filling) level is
too low.
Engine is shut down after 10 seconds.
k yellow = lights when temperatures are low (pre-
heating for starting)
l yellow = Charge control light, lights if the battery is
not being charged.
Check V-belt, if necessary repair the
generator.
m red = Water separator in fuel pre-cleaner.
Lights when the water proportion in the
transparent section of the fuel filter
reaches the contacts.
o = Fault code display
t red = The seat occupation monitoring system
lights when the seat is not occupied. If
the machine is travelling the warning
buzzer will sound, engine is shut down
after 4 seconds.
v red = Central warning light, lights if a fault code
is displayed
x = Engine rpm-meter
Fault code display TCD 2012 / 2013
BOMAG 509 008 911 79
11.12
11.12Fault code display TCD 2012 /
2013
Fig. 1 Display
For a detailed description of how to read out fault
codes and the display please refer to the page on
electrics in the Service Training Manual.
! Caution
All detected faults are displayed
Fault codes 5000 - 5499 are diesel engine related
A detailed reading out of fault code for the diesel
engine is only possible through Deutz-Serdia
11.13 EMR3 List of fault codes
BOMAG 510 008 911 79
11.13EMR3 List of fault codes
EMR3 List of fault codes
BOMAG 511 008 911 79
11.13
BOMAG 512 008 911 79
BOMAG 513 008 911 79
11.13
BOMAG 514 008 911 79
BOMAG 515 008 911 79
11.13
BOMAG 516 008 911 79
BOMAG 517 008 911 79
11.13
BOMAG 518 008 911 79
BOMAG 519 008 911 79
11.13
11.14 SerDia Service-Software TCD 2012 / 2013
BOMAG 520 008 911 79
11.14SerDia Service-Software TCD
2012 / 2013
Fig. 1 Service-Software TCD 2012 / 2013
SerDIA is a software program from Deutz which ena-
bles the use of a laptop computer to run a more de-
tailed fault analysis and to read out the error log in
particular.
This procedure displays information like:
Location of fault (e.g. coolant temperature sensor)
Type of fault (e.g. 'bottom limit value fallen short of',
'sporadic fault')
Environmental data/operating data (speed and oper-
ating hours at the time of the last occurrence of the
fault).
Number of fault locations.
Frequency of fault
Fault status (active - fault present / passive - fault no
longer present).
Fault messages for faults that are no longer active or
have been rectified can be deleted with SERDIA.
Other possible displays:
Function test: Control outputs and governor rod travel
can be activated with the engine stopped.
Assignment of inputs / outputs: Display of the current
assignment of inputs and outputs on the EMR-control
Representation of measuring values: There is a vast
variety of measuring values available for selection
which can even be used if no EMR-fault is present
(start behaviour, engine sawing, lack of power).
Connection
For this purpose the PC or laptop is connected to the
diagnostic interface by means of an interface cable.
Work with SERDIA is described in separate operating
instructions.
EDC16
EMR3
SerDia Service-Software TCD 2012 / 2013
BOMAG 521 008 911 79
11.14
Fig. 2 Serdia connection socket electric cabinet
Replacing the EMR3 control unit
Each control unit is firmly assigned to the engine, ac-
cording to its application. In case of replacement the
control unit must therefore be completed with an en-
gine specific data set. When ordering a new control
unit the engine serial number (sticker on EMR control
unit) must be specified alongside the part number.
Note: The Deutz part number specified on the EMR
control unit is the part number without engine specific
software. The correct part number is to be taken from
the spare parts catalogue.
Replacing the EMR or DCR components
On TCD-engines with Common Rail technology the
system pressure is so high, that in case of leaks or re-
pair all parts need to be replaced. When replacing
sensors or other electric components, the new parts
must be calibrated with the EMR control unit. The cal-
ibration must be made with the help of SERDIA (Level
IIIa). (see also SERDIA manual).
Any other EMR components (sensors etc) must under
no circumstances be repaired, but must be replaced if
they are defective.
SerDia connection
Serdia
connection
socket
11.14 SerDia Service-Software TCD 2012 / 2013
BOMAG 522 008 911 79
SerDia screen shot
Fig. 3 Error log
General trouble shooting chart TCD 2012 / 2013
BOMAG 523 008 911 79
11.15
11.15General trouble shooting
chart TCD 2012 / 2013
Faults Causes Action
Engine does not
start or starts
poorly
Temperature below starting limit Check
Oil level too low Fill up lubrication oil
Lubrication oil level too high Check the lubrication oil level, drain off if nec-
essary
Lubrication oil cooler defective Check
Exhaust gas counter pressure too high Check
V-belt/ribbed V-belt (fuel pump in belt drive) check, whether torn or loose
Engine oil with wrong SAE viscosity class Change the lubrication oil
Fuel quality not as specified in the operating
instructions
Change the fuel
Air in the fuel system Bleed the fuel system
Battery defective or not charged Check the battery
Cable to starter loose or oxidized Check cable connection
Starter defective or pinion does not engage Check starter
Engine does not
start and diag-
nostic lamp flash-
ing
Engine electronics prevent starting Check fault by fault code, repair as necessary
Engine starts, but
runs irregularly or
misfires
Incorrect valve clearance Adjust
Injector defective replaced
Glow plugs defective replace
Air in the fuel system bleed
Fuel pre-filter/fuel pre-cleaner soiled Clean
instructions
Change the fuel
Injection line leaking Check the injection line
Injection valve defective Check / replace the injection valve
Speed changes
are possible and
diagnostic lamp
lights
Engine electronics detected a system fault
and activates a substitute speed
Check fault by fault code, repair as necessary
Engine overheat-
ing. Temperature
warning system
responds
Bleeding line clogged Clean
Engine shut-down lever still in stop position
(shut-down solenoid defective)
Check/replace
Injector defective replace
Coolant heat exchanger soiled Clean
Coolant pump defective (V-belt torn or loose) check, whether torn or loose
Lack of coolant top up
Charge air pipe leaking Check the charge air pipe
Lubrication oil filter on air or lubrication oil
side soiled
replace
Lubrication oil level too low Fill up lubrication oil
Lubrication oil level too high Check the lubrication oil level, drain off if nec-
essary
Air filter clogged / exhaust turbocharger de-
fective
Check/replace
Air filter service switch / indicator defective Check/replace
Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary
Short circuit of heat in cooling system Check the cooling system
Resistance in cooling system too high / flow
quantity too low
check
11.15 General trouble shooting chart TCD 2012 / 2013
BOMAG 524 008 911 79

Insufficient en-
gine power
Engine oil level too high Check the oil level
Engine shut-down lever still in stop position Shut-down solenoid defective
instructions
Change the fuel
fective
Check/replace
Air filter service switch / indicator defective Check/replace
Intercooler soiled Clean
Injection line leaking Check the injection line
Injection valve defective Check the injection valves
Insufficient en-
gine power and
diagnostic lamp
lights
Engine electronics reducing the output power Check fault by fault code, repair as necessary
Engine does not
work with all cyl-
inders
Injection line leaking Check the injection valve / replace if neces-
sary
Injection valve defective Check the injection valve / replace if neces-
sary
Engine has to low
or no oil pressure
Oil level too low Fill up lubrication oil
Extremely slanted position of engine Check engine pillow blocks / reduce the en-
gine inclination
Engine oil of wrong SAE class or quality Change the lubrication oil
Engine has ex-
cessive oil con-
sumption
Engine oil level too high Check oil level, drain off if necessary
gine inclination
Blue engine ex-
haust smoke
Engine oil level too high Check oil level, drain off if necessary
gine inclination
White engine ex-
haust smoke
Temperature below starting limit
instructions
Change the fuel
sary
Black engine ex-
haust smoke
fective
Check / replace if necessary
Air filter service switch / indicator defective Check / replace if necessary
sary
Faults Causes Action
Valve adjustment TCD 2012 / 2013
BOMAG 525 008 911 79
11.16
11.16Valve adjustment TCD 2012 /
2013
Fig. 1 TCD 2012 and 2013
General definition
Cylinder arrangement, engine side and sense of rota-
tion
The cylinders must be successively numbered, start-
ing with 1 at the flywheel .
Sense of rotation
Viewed on drive side (flywheel side)
turning ccw: counter-clockwise (see example)
Engine sides: Viewed on power take-off side.
left = left = exhaust side
right = right = operation side
Fig. 1 TCD 2012 / 2013 Valves
Adjusting the valve clearance (without exhaust
gas recirculation)
Loosen the counter nut (1).
Attach the rotation angle disc (3) and the spanner
socket (4) to the valve clearance adjustment screw
(2).
Fix the magnet (5) of the rotation angle disc (3).
Turn the rotation angle disc (3) clockwise against the
stop (rocker arm no clearance) and set the scale to ze-
ro.
Turn the rotation angle disc (3) clockwise, until the
specified angle is reached:
Engine TCD 2012
IN = intake valve 75
EX = exhaust valve 120
Engine TCD 2013
EX = Exhaust valve 150Hold the rotation angle disc
(3) against turning
Tighten the counter nut (1).
11.16 Valve adjustment TCD 2012 / 2013
BOMAG 526 008 911 79
Then adjust the second valve on the rocker arm as de-
scribed above.
Repeat the adjustment procedure on each cylinder.
Valve adjustment TCD 2012 / 2013
BOMAG 527 008 911 79
11.16
Fig. 2 TCD 2012 / 2013 Valves
Adjusting the valve clearance (with exhaust gas
recirculation)
For the exhaust valves the same adjustment proce-
dure is to be used as for engines with exhaust gas re-
circulation.
Adjusting the intake valves
Loosen the counter nut (6).
Attach the rotation angle disc (3) with the special
spanner (8) to the valve adjustment screw (7) on the
intake valve.
Fix the magnet (5) of the rotation angle disc (3).
Turn the rotation angle disc (3) clockwise against the
stop (rocker arm no clearance) and set the scale to ze-
ro.
Turn the rotation angle disc (3) clockwise, until the
specified angle is reached:
Engine TCD 2012
IN = intake valve 75 Engine
TCD 2013
Hold the rotation angle disc (3) tight to prevent it from
turning.
Tighten the counter nut (6).
Then adjust the second valve on the rocker arm as de-
scribed above.
Repeat the adjustment procedure on each cylinder.
Valve clearance adjustment schematic
Overlapping of valves: Exhaust valve not yet closed,
intake valve starts to open.
! Caution
These engines are equipped with an exhaust gas
recirculation system.
During the exhaust cycle the intake valve opens
for a short moment.
This must not be mistaken as overlapping of
valves!
TCD 2012 / 2013 - 4 cylinder
Overlapping of valves adjustment
1 4
3 2
4 1
2 3
TCD 2012 / 2013 - 6 cylinder
Overlapping of valves adjustment
1 6
5 2
3 4
6 1
2 5
4 3
11.17 Ribbed V-belt - fan drive TCD 2012 / 2013
BOMAG 528 008 911 79
11.17Ribbed V-belt - fan drive TCD
2012 / 2013
Fig. 1 Ribbed V-belt
i
Note
Check the distance between the tongue of the move-
able tensioner arm and the stop on the fixed tensioner
housing.
If the distance "a" is smaller than 3 mm, replace the
belt.
Special tools, Deutz engine (TCD 2012 2V)
BOMAG 529 008 911 79
11.18
11.18Special tools, Deutz engine
(TCD 2012 2V)
Standard tools

TCD 2012 2V
8002
Pressure pump
Checking fuel system for leak-tightness
35409-2
8005
Compression pressure tester
for diesel engines
10 - 40 bar
35410-3
8024
Assembly pliers
Removing valve stem gaskets
37509-2
057 250 66
057 250 67
057 250 68
11.18 Special tools, Deutz engine (TCD 2012 2V)
BOMAG 530 008 911 79
TCD 2012 2V Standard tools
8113
Socket wrench insert
Torx - E 14
43022-0
8114
Torx - E 20
35415-1
8115
V-belt tension meter
150 to 600 N
for checking the V-belt tension
35416-3
057 250 69
057 250 70
079 947 09
BOMAG 531 008 911 79
11.18
Standard tools

TCD 2012 2V
8189
Torx tool set
Case containing:
- Double-ended ring spanner E6/E8
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)
39432-1
8190
Rotation angle disc
with magnet
Setting valve clearance
43528-0
8191
Screwdriver insert
for slotted screw
Valve clearance setting
43060-0
057 250 72
079 947 01
057 250 74
BOMAG 532 008 911 79
8192
Bowl wrench
Fuel pre-filter (type: Racor)
43193-1
8194
Screwdriver insert
with hexagonal socket (size 4 mm),
1/2 inch, long version
(in conjunction with rotation angle disc 8190)
43183-0
8196
Open end wrench adapter
Size 13,
for torque wrench
Tightening of lock nut of the valve clearance setting
screw
43019-0
057 250 73
057 250 75
057 250 71
BOMAG 533 008 911 79
11.18
Standard tools

TCD 2012 2V
8198
Pricker
Removing rotary shaft lip seal
43206-0
8199
Crowfoot wrench
Size 15
3/4 inch
(in connection with rotation angle disc 8190)
44309-0
9017
Assembly lever
Example: Removing and installing the valves
37511-2
057 250 76
057 250 77
057 250 78
BOMAG 534 008 911 79
3/12
Special tools

TCD 2012 2V
100 190
Connection piece
(in conjunction with compression pressure tester 8005)
42524-1
100 320
Turning gear
flywheel side
35422-1
100 330
Turning gear
V-belt pulley
Turning crankshaft on torsional vibration damper
35423-1
057 250 79
057 250 80
079 947 19
BOMAG 535 008 911 79
11.18
TCD 2012 2V Special tools
100 400
Dial gauge with fixing wheel
Measuring range 0 -10mm / 0.01mm
35424-1
100 410
Digital gauge
Measuring range 0 -30 mm / 0.01 mm
43205-0
100 750
Measuring apparatus
Measuring bar with two spacing washers
(in conjunction with 100 400 or 100 410)
Checking valve lag dimension
Checking piston projection
39402-1
057 250 81
057 250 82
057 250 83
BOMAG 536 008 911 79
Special tools

TCD 2012 2V
103 050
Size 15
for valve clearance setting with removed exhaust return
module
(in connection with 8190)
43023-0
103 220
Special pliers
for removing the roller tappet
43010-0
110 500
Special wrench
Size 17
Removing and installing high-pressure lines
35436-1
057 250 84
057 250 85
057 250 86
BOMAG 537 008 911 79
11.18
110 700
long
Assembling/disassembling pressure sensors
(rail pressure, oil pressure, fuel pressure)
43198-2
110 900
Assembly case
Case for O-rings, complete with:
Disassembly tool 110 901 and three assembly sleeves
with guide:
- High pressure pump ( 36), 110 902
- Injector, 2V motor ( 16), 110 903
Disassembling/assembling O-rings
43208-0
120 430
Assembly tool
Removing and installing the heating plugs
43020-0
057 250 87
057 250 88
057 250 89
BOMAG 538 008 911 79
Special tools

TCD 2012 2V
120 900
Support bracket
pivoting
Clamping cylinder head
35438-3
120 910
Base plate for support bracket
(in conjunction with support bracket 120 900 if support
bracket is not screwed tightly)
35439-3
121 410
Assembly tool
Assembling valve stem gaskets
37614-2
057 250 90
057 250 91
057 250 92
BOMAG 539 008 911 79
11.18
121 420
Assembly sleeves
Set of assembly sleeves for valve stem gasket
43210-0
130 300
Universal piston ring pliers
Removing and installing the piston rings
43021-0
130 440
Trapezoidal groove wear gauge
for piston diameter 101 mm
Check piston ring groove
36461-2
057 250 93
057 250 94
057 250 95
BOMAG 540 008 911 79
Special tools

TCD 2012 2V
130 450
for piston diameter 98 mm
Check piston ring groove
36461-2
130 660
Piston ring tensioning band
Piston diameter 98 mm
39408-1
130 670
Piston ring tensioning band
39408-1
057 250 96
057 250 97
057 250 98
BOMAG 541 008 911 79
11.18
142 670
Assembly tool
Assembling crankshaft sealing ring
(opposite side to flywheel)
35445-1
142 830
Assembly tool
for crankshaft (flywheel side)
35446-1
144 800
Counter support
Torsional vibration damper
35453-1
079 947 26
079 947 27
057 250 99
BOMAG 542 008 911 79
Special tools

TCD 2012 2V
170 050
Special wrench
Unscrew the filter cartridges
37629-2
170 160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
43663-0
6066
Assembly block
Engine clamping, double-sided
35451-2
079 947 28
079 947 29
079 947 30
BOMAG 543 008 911 79
11.18
6066/158
Clamping bracket
consisting of:
1 holder 6066/158-1 rear right,
1 holder 6066/158-2 rear left,
1 holder 6066/158-3 front right,
1 holder 6066/158-4 front left
(in connection with assembly block 6066)
Clamping of the engine, double-sided
35452-1
079 947 31
BOMAG 544 008 911 79
11.19Special tools, Deutz engine
(TCD 2013 2V)
Standard tools TCD 2013 2V
8002
Pressure pump
Checking cooling system for leak-tightness
35409-2
8005
Compression pressure tester
for diesel engines
10 - 40 bar
35410-3
8011
Hose clip pliers
e. g. fuel return pipe
39426-1
057 250 66
057 250 67
BOMAG 545 008 911 79
11.19
8024
Assembly pliers
Removing valve stem gaskets
37509-2
8035
reinforced, size 22
removing and installing main bearing
37504-2
8113
Torx - E 14
43022-0
057 250 68
057 250 69
BOMAG 546 008 911 79
8114
Torx - E 20
35415-1
8115
V-belt tension measuring device
150 to 600 N
for checking the V-belt tension
35416-3
8189
Torx tool set
Contents of case:
Socket wrench insert E8 and E10 (1/4 inch)
- Socket wrench insert E10 and E12 (3/8 inch)
- Socket wrench insert E18 (1/2 inch)
39432-1
079 947 09
079 947 01
079 947 09
079 947 01
BOMAG 547 008 911 79
11.19
8190
Rotation angle disc
with magnet
Setting valve clearance
43528-0
8191
Screwdriver insert
for slotted screw
Valve clearance setting
43060-0
8192
Bowl wrench
Fuel pre-filter (type: Racor)
43193-1
057 250 80
057 250 74
057 250 73
BOMAG 548 008 911 79
8193
Screwdriver insert
with pressed in hexagonal pin (5 mm),
43183-0
8194
Screwdriver insert
with hexagon socket (size 4 mm),
43183-0
8195
Multi-toothed screwdriver set
260 mm long
remove and install air compressor
43195-0
057 250 75
BOMAG 549 008 911 79
11.19
8196
Open end wrench adapter
Size 13,
for torque wrench
Tightening of lock nut of the valve clearance setting
screw
43019-0
8198
Pricker
Removing rotary shaft lip seal
43206-0
8199
Crowfoot wrench
Size 15
3/4 inch
(in connection with rotation angle disc 8190)
44309-0
057 250 71
057 250 76
057 250 77
BOMAG 550 008 911 79
9017
Assembly lever
Example: Removing and installing the valves
37511-2
9090
Spring band pliers
320 mm
tighten spring band clamp
35420-3
057 250 78
BOMAG 551 008 911 79
11.19
Special tools TCD 2013 2V
100 190
Connector
(in conjunction with compression pressure tester 8005)
42524-1
100 320
Turning gear
flywheel side
35422-1
100 330
Turning gear
V-belt pulley
Turning crankshaft on torsional vibration damper
35423-1
057 250 79
057 250 80
079 947 19
BOMAG 552 008 911 79
100 400
Dial gauge with fixing wheel
Measuring range 0 - 10 mm / 0.01 mm
35424-1
100 410
Digital gauge
Measuring range 0 - 30 mm / 0.01 mm
43205-0
100 750
Measuring device
Measuring bar with two shims
(in conjunction with 100400 and 100410)
Checking valve lag dimension
Checking piston projection
39402-1
057 250 81
057 250 82
057 250 83
BOMAG 553 008 911 79
11.19
103 050
Size 15
for valve clearance setting with removed exhaust return
module
(in connection with 8190)
43023-0
103 220
Special pliers
for removing the roller tappet
43010-0
110 500
Special wrench
Size 17
Removing and installing high-pressure lines
35436-1
057 250 84
057 250 85
057 250 86
BOMAG 554 008 911 79
110 640
Lever tool
Remove injector
43941-0
110 700
long
Installing and removing pressure sensors
(rail pressure, oil pressure, fuel pressure)
43198-2
110 900
Assembly case
Case for O-rings, complete with:
Disassembly tool 110 901 and three
assembly sleeves with guide:
- High pressure pump ( 36), 110 902
Removing and installing O-rings
43208-0
057 250 87
057 250 88
BOMAG 555 008 911 79
11.19
120 430
Assembly tool
Removing and installing the glow plugs
43020-0
120 680
Puller
(in conjunction with slide hammer 150 800)
Removing fixed injector sealing ring
35437-1
120 900
Support bracket
pivoting
Clamping cylinder head
35438-3
057 250 89
057 250 90
BOMAG 556 008 911 79
120 910
Base plate
(in conjunction with support bracket 120 900 if support
bracket is not screwed tightly)
35439-3
121 330
Assembly lever
Removing and installing the valves
43185-0
121 420
Assembly sleeves
Set of assembly sleeves for valve stem gasket
43210-0
057 250 91
057 250 93
BOMAG 557 008 911 79
11.19
130 300
Universal piston ring pliers
Removing and installing the piston rings
43021-0
130 420
36461-2
130 640
Piston ring compressor
39408-1
057 250 94
BOMAG 558 008 911 79
142 810
Assembly tool
Installing crankshaft sealing ring
(flywheel side)
35446-1
142 820
Assembly tool
Installing crankshaft sealing ring
(opposite side to flywheel)
35445-1
150 170
Puller, universal
Comprising traverse, support and threaded rod
(in conjunction with disc 150 171)
Removing cylinder liner
43207-0
BOMAG 559 008 911 79
11.19
150 171
Plate
(in conjunction with puller 150 170)
for liner diameter: 108 mm
Removing cylinder liner
43204-0
150 180
Liner holder
(Set comprises 7 holders)
Turning crankshaft with cylinder head removed
43181-0
150 190
Assembly lever
Lever with bolts
(in conjunction with disc 150 191)
Installing cylinder liner
43209-2
BOMAG 560 008 911 79
150 191
Washer
(in conjunction with assembly tool 150 190)
for liner diameter: 108 mm
Installing cylinder liner
43203-2
150 800
Slide hammer
(in conjunction with puller 120 680)
Removing injector sealing ring
35449-2
170 050
Special wrench
Unscrewing the filter cartridges
37629-2
079 947 18
079 947 18
079 947 28
BOMAG 561 008 911 79
11.19
170 160
Stoppers/caps
1 set of differently-sized stoppers and caps
Sealing openings on the fuel system
43663-0
6066
Assembly block
Engine clamping, double-sided
35451-2
6066/158
Clamping bracket
consisting of:
1 holder 6066/158-1 rear right,
1 holder 6066/158-2 rear left,
1 holder 6066/158-3 front right,
1 holder 6066/158-4 front left
(in connection with assembly block 6066)
Clamping of the engine, double-sided
35452-1
079 947 29
079 947 30
079 947 31
BOMAG 562 008 911 79
6068
Engine lifting device
Version for commercial vehicles with worm gear, ulti-
mate load (2t), 3-point suspension, spindle clamp,
traverse, chains and hooks
43184-0
6692
Slotted nut wrench
Cable plug
43199-0
BOMAG 563 008 911 79
12 Air conditioning system
12.1 Physical basics
BOMAG 564 008 911 79
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.
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. 1
If the water in a container is heated up (absorption of
heat), the rising steam is visible. If the steam is heated
up further, due to the absorption of heat, the visible
steam will turn into invisible gas. This process is re-
versible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into
water and finally into ice.
A - heat absorption
B- Heat dissipation
Fig. 2
Heat always flows from the warmer to the colder mat-
ter. Any matter consists of a mass of moving mole-
cules. The rapidly moving molecules or a warmer
matter dissipate part of their energy to the slower
moving molecules with less heat. The movement of
the molecules in the warmer matter becomes slower
and the molecules in the cooler matter are accelerat-
ed. This process continued, until all molecules in the
two matters move with identical speed. The matters
have then reached an identical temperature and the
transfer of heat stops.
Physical basics
BOMAG 565 008 911 79
12.1
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:
Atmospheric pressure, boiling point 100C
Overpressure 0.4 bar, boiling point 126C
Vacuum -0.6 bar, boiling point 71C

For an optimal exchange of heat, liquid refrigerants
must have a low boiling point, so that they can absorb
and dissipate heat quickly.
Fig. 3 Steam pressure curve
Steam pressure curve for refrigerant R134a
The steam pressure curve is a means for explaining
the operation principle of an air conditioning system.
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.
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)
i
Note
At absolute pressure 0 bar correspond with an abso-
lute vacuum. The normal ambient pressure (overpres-
sure) corresponds with 1 bar absolute pressure. On
the scales of most pressure gauges 0 bar corre-
sponds with an absolute pressure of 1 bar (indicated
by the statement -1 bar below the 0).
Fig. 4 Pressure - Temperature Diagram
In the pressure - temperature diagram for the refriger-
ant the drawn in closed curve shows the cycle of the
refrigerant. This cycle permanently continues in direc-
tion of the arrow.
The characters A, B, C, D stand for:
A - compression
B- condensation
C- relaxation
D- evaporation.
BOMAG 566 008 911 79
Excerpt from the wet steam table
1
R134a

1 This table is used for the determination of evaporation and con-
densation temperature.
Saturation temperature Overpressure (pressure gauge
reading Pe in bar)
Absolute pressure (pamb = 1 bar
P in bar)
-20 0,33 1,33
-10 1,01 2,01
0 1,93 2,93
10 3,15 4,15
20 4,72 5,72
Refrigerant R134a
BOMAG 567 008 911 79
12.2
12.2 Refrigerant R134a
General
The evaporation and condensation process is the
method commonly used in mobile air conditioning sys-
tems. The system in this case works with a substance
that boils at low temperature, a substance referred to
a refrigerant. The refrigerant used is tetrafluoroethane
R134a, which boils at a temperature of -26.5C 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
Chemical formula:
CH2F-CF3 or CF3-CH2F
Chemical designation:
Tetrafluoroethane
Boiling point at 1 bar:
- 26.5 C
Solidification point:
-101.6 C
Critical temperature:
100,6 C
Critical pressure:
40.56 bar (absolute)
Critical point:
Critical point (critical temperature and critical pres-
sure) means that above this point there is no separat-
ing interface between liquid and gas. Above its critical
point any substance is gaseous. At temperatures be-
low the critical point all refrigerant types in pressure
containers have a liquid and a gaseous phase, i.e. a
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature.
Characteristics of the refrigerant R134a:
Refrigerant R134a is currently available under the fol-
lowing trade marks.
H-FKW 134a
SUVA 134a
KLEA 134a
Colour:
Refrigerant in form of vapour or liquid is colourless as
water. The gas is invisible. Only the bordering layer
between gas and liquid is visible. (Fluid level in rising
pipe of filling cylinder or bubbles in inspection glass).
In the inspection glass the liquid refrigerant R134a
may appear coloured (milky). This turbidity results
from partially dissolved refrigeration oil and is no indi-
cator for a fault.
Steam pressure:
In an incompletely filled, closed container, vaporous
refrigerant will volatilize from the surface in the same
quantity that will turn liquid in combination with steam
particles. This state of equilibrium occurs under pres-
sure and is frequently referred to as steam pressure.
The steam pressure is independent from the temper-
ature.
Physical properties of R134a:
The steam pressure curves of R134a and other refrig-
erants are partly very similar, making a clear differen-
tiation solely by pressure impossible. With R 134a the
compressor is lubricated by special synthetic refriger-
ation oils, e.g. PAG-oils (polyalkylene glycol oils).
Behaviour with metals:
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
compounds, leads to aggressiveness against certain
metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.
Critical temperature / critical pressure:
Up to a gas pressure of 39.5 bar overpressure (this
corresponds with a temperature of 101 C) the refrig-
erant R134a remains chemically stable, above this
temperature the refrigerant decomposes (see com-
bustibility).
Water content:
In liquid refrigerant water can only be dissolved in very
low quantities. In contrast to this refrigerant steam
mixes with water steam at any ratio. If the dryer in the
12.3 Compressor oil / refrigeration oil
BOMAG 568 008 911 79
liquid container has absorbed approx. 8 gr. of water,
the refrigerant circuit transports possibly existing wa-
ter in form of droplets. This water flows to the nozzle
of the expansion valve and turns to ice. The air condi-
tioning system stops cooling. Water destroys the air
conditioning system, because under high pressures
and temperatures and in connection with other con-
taminants it forms acids.
Inflammability:
Refrigerant is not inflammable. On the contrary, it has
fire inhibiting or fire extinguishing properties. Refriger-
ant is decomposed by flames or glowing surfaces. Ul-
traviolet light also cracks refrigerant (caused by
electric welding). This results in toxic fission products,
these must not be inhaled. However, irritation of the
mucous membranes is an early and in-time warning.
Filling factor:
In a container there must be a steam space above the
liquid space. The liquid expands with increasing tem-
perature. The steam filled space becomes smaller.
From a certain time on the container will be filled with
just liquid. After this only a minor temperature in-
crease is enough to generate very high pressures in
the container, because the liquid would like to expand,
but there is no more room. The related forces are high
enough to cause the container to burst. In order to
avoid overfilling of a container the pressure gas direc-
tive clearly specifies how many kilograms of refriger-
ant may be filled into the container per litre volume.
Multiplied with the internal volume this "filling factor"
determines the permissible filling capacity For refrig-
erants used in motor vehicles it is 1.15 kg/l.
Environmental aspects
The contribution of R134a to the greenhouse effect is
by factor 10 smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for
newly produced construction equipment were succes-
sively converted to refrigerant R134a. This refrigerant
does not contain any chlorine and is thus harmless for
the ozone layer. Until approx. 1992 air conditioning
systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decompo-
sition potential and also a potential to amplify the
greenhouse effect. Conversion programs for existing
old systems with the ozone damaging R12 are in ef-
fect. For reasons of protecting the environment refrig-
erant must not be discharged into the atmosphere.
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 dry-
ing up.
Part of the compressor oil dissolves in the refrigerant
until saturation is reached, so that a gas mixture of re-
frigerant, water steam, compressor oil and contrast
agent circulates through the system.
Compressor oil (the oil quantity should be 10 % of the
refrigerant weight) mixes with the refrigerant and cir-
culates permanently through the system.
In connection with R134a- air conditioning systems
special synthetic compressor oils, e.g. polyalkylene
glycol (PAG) oils, are used. This is necessary, be-
cause e.g. mineral oil does not mix with R134a. Apart
from this, the materials in the R134a air conditioning
system may be attacked when the mixture is flowing
through the refrigerant circuit under high pressure and
at high temperatures or if the lubrication film in the
compressor tears off. The use of non-permitted oils
can cause damage to the air conditioning system, you
should therefore only used the approved oils.
Properties of compressor oil / refrigeration oil:
The most important properties are high solvency in
connection with refrigerants, good lubrication charac-
teristics, that they are free of acids and their low water
content. For this purpose only certain oils can be
used. PAG-oils suitable for use with refrigerant R134a
are highly hygroscopic and will not mix with other oil.
As a protection against the invasion of moisture drums
must immediately be closed again after they had been
opened. Compressor oil ages under the effect of
moisture and acids, becomes dark, viscous and ag-
gressive against metals.
Working principle of the air conditioning system
BOMAG 569 008 911 79
12.4
12.4 Working principle of the air
conditioning system
All air conditioning systems are based on the same
principle. They extract heat from the surrounding en-
vironment. Everybody knows the effect: if a sweating
body is exposed to wind it will cool down, because
heat is extracted. For this purpose a refrigerant circu-
lates in a closed circuit inside the vehicle. This refrig-
erant thereby continuously changes its physical state
between liquid and gaseous.
Fig. 1 Principle sketch of an air conditioning system
An engine driven compressor (1) draws in gaseous re-
frigerant from the evaporator (5) and compresses it.
During this process the temperature of the refrigerant
increases tremendously.
The refrigerant vapour is then pumped to the con-
denser (2). This condenser is arranged directly in front
of the vehicle radiator, so that a sufficient air flow is as-
sured. In the condenser (2) the gas is cooled down
and consequently liquefied.
In the dryer / liquid container (3) the refrigerant is then
collected and freed of moisture and contaminants.
The expansion valve (4) regulates the flow rate from
the dryer / liquid container (3) back to the evaporator
(5) and the circuit starts again.
12.5 Monitoring devices
Pressure switch
The pressure switch (8) is used as monitoring feature
for too high and too low pressures. The switching con-
tacts (4 and 5) effect the magnetic clutch of the com-
pressor via a relay (6).
If the system pressure increases excessively, e.g. be-
cause of a excessively soiled condenser, a failed fan
or a defective expansion valve, the high pressure con-
tact (5) will cut off the electric power supply to the
magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off
pressure by the set differential pressure, the magnetic
clutch of the compressor is switched on again.
The low pressure contact (4) interrupts the electric
power supply to the magnetic clutch when the set
pressure is fallen short of (possible causes: lack of re-
frigerant, defective expansion valve, too low heat
load, defective evaporator fan, ...). Since the refriger-
ant R134a has an evaporation temperature of 0 C at
an overpressure of 2 bar, the low pressure contact (4)
is set to approx. 1.5 bar to avoid icing. The switch on
pressure is 0.5 to 2 bar higher than the shut-off pres-
sure (depending on system, see description of com-
ponents.)
Thermostat
A frost protection thermostat (3) protects the evapora-
tor against icing. Similar to the pressure switch, the
thermostat activates or deactivates the magnetic
clutch for the compressor. Depending on the design,
the feeler of the temperature control is mounted be-
tween the fins of the evaporator or attached to the
evaporator outlet (suction side). With fixed tempera-
ture controls the control switches the compressor off
at about 1 C and back on again at about 2.5C to 5.5
C (depending on system, see description of compo-
nents.)
With adjustable temperature regulators the switching
point can be changed so that the compressor is al-
ready shut down at higher temperatures. This enables
regulation of the air temperature.
12.6 Description of components
BOMAG 570 008 911 79
Monitoring chain
Fig. 2 Monitoring chain consisting of:
1 Switch
2 Fuse
3 Thermostat
4 Low pressure switch contact
5 High pressure switch contact
6 Relay
7 Connection for magnetic clutch
8 Pressure switch
Compressor
Fig. 1
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.
Description of components
BOMAG 571 008 911 79
12.6
! 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-sys-
tem must be adjusted accordingly.
The quantity depends on the amount of oil that
may have been lost in connection with the possi-
ble 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 re-
quires a compressor oil / refrigerant oil filling of
100 gr.
Procedure:
Drain and measure the compressor oil from the
old compressor.
Drain the compressor oil from the new compres-
sor and only fill in the exact quantity that had been
drained out of the old compressor. The compres-
sor oil from the new compressor can be used for
this purpose.
i
Note
Topping up compressor oil / refrigeration oil is possi-
ble on a pressureless compressor directly into the oil
pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
into the pressure side of the refrigeration system dur-
ing the evacuation process.
Condenser
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 refriger-
ant.
i
Note
The fins must be free of dirt and damage.
! Caution
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.
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-
er
approx. 30 gr
Replacement of evapora-
tor
approx. 30 gr
Replacement of liquid con-
tainer
approx. 30 gr
Replacement of expan-
sion valve
approx. 15 gr
BOMAG 572 008 911 79
Dryer / filter / fluid container / inspection
glass
Fig. 1
Dryer / filter
The fluid container collects the fluid drops and passes
these then as a constant flow to the expansion valve.
Moisture that has entered during assembly of the re-
frigerant circuit is absorbed by a dryer in the fluid con-
tainer.
At evaporation temperatures below zero the refriger-
ant will deposit previously absorbed moisture on the
expansion valve, where this water turns into ice and
thus adversely affects the controllability of the expan-
sion valve. Moreover, moisture in the refrigerant cir-
cuit causes corrosion, forms acids and enters into
chemical compositions.
Inside the refrigerant container the heavy liquid refrig-
erant collects in the lower part of the container, flows
through a rising pipe to the outlet marked "A" and thus
ensures bubble free operation of the expansion valve.
i
Note
Since the absorbing capacity of this filter/dryer is lim-
ited, it must be changed within certain service inter-
vals. We recommend to replace it 1 x per years,
before the start of the season.
! Caution
The filter/dryer must generally be replaced when-
ever opening the refrigerant circuit, because
moisture will enter in such a case.
This requires emptying the air conditioning sys-
tem!
Installation position:
The arrow marks on the filter/dryer must point in
flow direction, i.e. towards the expansion valve.
Filter/dryer cannot be treated for further use!
Safety valve
Fig. 2
The fluid container is equipped with a safety valve.
Response pressure 32 +/- 4 bar
Tightening torque 10 - 15 Nm
Inspection glass
Fig. 3
During operation the refrigerant must flow through the
inspection glass without air bubbles. In most cases
the presence of air bubbles is a sign for a too low re-
frigerant level in the system. Apart from this, the refrig-
erant may not sufficiently condense as a result of a
soiled evaporator or a defective condenser fan and
the fluid level in the refrigerant container may drop
down to a level, at which gaseous refrigerant could
flow through the rising tube to the inspection glass.
This results in abnormally high temperatures in and on
the fluid lines (between refrigerant container and ex-
pansion valve), as well as very high pressures in the
pressure side.
However, incorrect evacuation or filling may also be
the reason for air entering into the system and since
air cannot be condensed, one will not be able to get
rid of these bubbles by topping up refrigerant. In this
case the air conditioning system needs to be evacuat-
ed and refilled.
BOMAG 573 008 911 79
12.6
i
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 indica-
tors. In addition to the float, the dryer/collector/inspec-
tion glass combination has an indicator pearl
integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection
glass and should only be checked after approx. 5 min-
utes continuous operation, because the refrigerant
must first evenly distribute all over the system.
! Danger
In case of mechanical damage or corrosion on
this pressure container this collector unit must be
replaced, to avoid bursting and further damage.
Expansion valve
Fig. 1
The expansion valve is mounted inside the HKL-mod-
ule in the cabin. The expansion valve always allows a
small amount of the high pressure liquefied refrigerant
to flow into the evaporator, which has a much lower
pressure. This lower pressure causes these liquid re-
frigerant to expand and to evaporate to gaseous state.
The heat required for this evaporation process is tak-
en from the ambient air through the lamellas and sup-
plied to the refrigerant. This is the so-called cooling
effect.
The thermostatic expansion valve operates with an
external pressure compensation. This type of expan-
sion valve works with high accuracy, because it uses
pressure and temperature at the evaporator outlet and
adjusts and overheating of approx. 7 K. The already
installed expansion valves and the ones delivered as
spare parts have this overheating value pre-set. In or-
der to prevent a loss in performance or compressor
damage you should only use original expansion
valves, because adjusting expansion valves takes a
lot of time and care.
i
Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+
BOMAG 574 008 911 79
Evaporator
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.
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 col-
lect the water that has condensed from the air in the
evaporator block and to discharge this water into the
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.
! Caution
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.
Defroster thermostat
Fig. 1
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.
Switching point on: + 1C ( 1C)
Switching point off: + 5,5C ( 1C)
i
Note
It is very important that the feeler is mounted down-
stream of the evaporator, but before the pressure sen-
sor, in countercurrent direction, with full length and
insulated against the outside temperature.
BOMAG 575 008 911 79
12.6
Pressure switch
Fig. 1
After a minimum pressure is reached in the low pres-
sure side or a maximum pressure in the high pressure
side, the pressure switch will switch of the magnetic
clutch of the compressor, thus to avoid destruction of
system components by excessive pressure or draw-
ing in external gases and foreign matter as a result of
too low pressure.
Working pressure:
Low pressure off: 1,5 0,5 bar
Low pressure on: 3.5 bar
Overpressure off: 25,0 1,5 bar
Overpressure on: 18,0 1,5 bar
Pipes and hoses
Pipes and hoses in air conditioning systems must
meet very high requirements with respect to resist-
ance against heat and pressure. The requirements
concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through
the hose material, are very high. Pipes and hoses to
be used must therefore be specially made for air con-
ditioning purposes. For this reason the hoses have an
inside lining of butyl rubber and an outside coating of
EDPM rubber. Hose sections exposed to heat are pro-
vided with a special heat insulation.
O-rings are made of a special type of chloroprene rub-
ber (neoprene). Before assembly of the air condition-
ing system these O-rings must be lubricated with
compressor oil / refrigeration oil. The O-rings must al-
ways be replaced when assembling A/C-components.
Recommended tightening torques for O-ring
sealed fittings
Bending radii for air conditioning hoses

Thread Spanner width Torque
5/8 17 or 19 13,6 - 20,3 Nm
3/4 32,5 - 39,3 Nm
7/8 27 35,3 - 42,0 Nm
1 1/16 32 40,7 - 47,5 Nm
M30X2 36 105,0 - 115,0
Nm
M36X2 41 165,0 - 175,0
Nm
Hose type Nominal width Bending radius
GH 134 NW8 min. 50 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm
12.7 Checking the compressor oil level
BOMAG 576 008 911 79
12.7 Checking the compressor oil
level
Checking the compressor oil level / refrig-
eration oil level
! Caution
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only compressor oil / re-
frigeration oil PAG SP-20 (H14-003-404).
Run the compressor for 10 minutes at engine idle

speed.
In order to avoid any compressor oil losses you

should slowly drain all refrigerant from the air condi-
tioning system.
Fig. 1
Measure the fastening angle (Fig. 1) of the com-

pressor (oil plug at top)
Remove the oil filler plug.

Fig. 2
Turn the nut that hold the armature clockwise with a

socket wrench, until the counterweight is correctly
positioned.
i
Note
2 o'clock position with inclination to the right (Fig. 2).
10 o'clock position with inclination to the left
Insert the oil dipstick.
Pull out the dipstick and count the notches covered

by oil.
Drain off oil or fill up as specified in the table.

Environment
Used compressor oil / refrigeration oil must be
disposed of as hazardous waste.
Screw the oil filler plug back in.

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

Fastening angle (de-
gree)
Oil dipstick in incre-
ments
0 5-7
10 6-8
20 7-9
30 8-10
40 9-11
50 10-12
60 11-13
90 16-18
Checking the magnetic clutch
BOMAG 577 008 911 79
12.8
12.8 Checking the magnetic clutch
Measure the voltage.

i
Note
Nominal value = vehicle voltage
Check the magnetic coil locking ring for secure fit.
Check the current consumption.

Fig. 1
i
Note
Nominal value approx. 3.5 Amp.
Overcurrent indicates a short circuit inside the mag-
netic coil.
No current indicates an interrupted electric circuit.
Fig. 2 Measuring the air gap
Measure the air gap on the magnetic clutch be-

tween V-belt pulley (2) and thrust plate (1).
i
Note
The gap should be 0.4 to 0.8 mm.
Take off the drive V-belt and rotate the V-belt pulley
by hand while the magnetic clutch is disengaged.
i
Note
In case of excessive flatness faults or deviations the
magnetic clutch needs to be replaced.
Cross-section of magnetic clutch
Fig. 3 shows a cross-section of the magnetic clutch. If
the coil (7) is not supplied with operating voltage,
there is no contact between the front plate of the
clutch (1) and the V-belt pulley (2). A spring presses
the front plate away from the belt pulley. The V-belt
pulley rotates with the bearing (3) in idle speed, the
compressor does not work. When the coil is supplied
with operating voltage (12 or 24 V), a magnetic field is
generated and pulls the front plate of the clutch. Both
front plate and compressor shaft (8) are then driven by
the V-belt pulley, the compressor works.
Fig. 3 Cross-section of magnetic clutch
12.9 Inspection and maintenance work
BOMAG 578 008 911 79
12.9 Inspection and maintenance
work
Visual inspection of the complete system for dam-

age.
Check the compressor mounting bracket on the ve-

hicle 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 de-
tected faults. Ensure sufficient clearance to hot
parts, such as the exhaust; install a protective
shield, if necessary.
Check the routing of hoses and hoses on the at-

tachment box or in the cabin.
Check all hose and screw fittings for leaks.
Check the fastening of the condenser unit.
Clean the condenser fins, replace the condenser

block if damaged fins are found.
Check the fastening of the evaporator unit.
Check the function of evaporator and condenser

fans.
Check the electric control panel. If discolorations on

conductors are found, these should be replaced
and possibly also the corresponding relays.
Switch on the cooling system and check the refrig-

erant level.
Filter/dryer and filter/dryer/fluid container combina-

tions must always be replaced after opening the re-
frigerant circuit. If these are in service for more than
1 year, there is a risk that they may be clogged by
excessive absorption of moisture! The filter/dryer
should be replaced in regular intervals.
Measure the temperature on the evaporator: Meas-

ure the intake air temperature - Measure the blow
out air temperature - The temperature difference
should be at least 8-10 K.
Measuring the pressure in the refrigerant circuit

12.10Checking, replacing the refrig-
erant compressor V-belt
1

! 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
Inspect the entire circumference of the V-belt (Fig.

4) visually for damage and cracks. Replace dam-
aged or cracked V-belts.
Check with thumb pressure whether the V-belt can

be depressed more than 10 to 15 mm (0.4 0.6
inches) between the V-belt pulleys, retighten if nec-
essary.
Tighten the V-belt.
Fig. 5
Slightly slacken fastening screws 1, 2 and 3 (Fig.

5).
1 Optional equipment
Service the air conditioning
BOMAG 579 008 911 79
12.11
Press the compressor in direction of arrow, until the

correct V-belt tension is reached.
Retighten all fastening screws.

Changing the V-belt
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.
12.11Service the air conditioning
1
Cleaning the condenser
! Caution
A soiled condenser results in a considerable re-
duction of air conditioning power.
Under extremely dusty conditions it may be nec-
essary to clean the condenser several times per
day.
If, during operation of the air conditioning system,
the warning buzzer sounds switch the air condi-
tioning off and clean the condenser.
In case of formation of foam have the air condi-
tioning system inspected by the service depart-
ment.
! Danger
Danger of accident!
Do not clean with a hot water jet. Heat will cause
extreme overpressure, which could cause dam-
age or explosion of the system.
Use access steps and grips to mount and dis-
mount the machine.
Fig. 6
Unscrew the condenser fastening screws (Fig. 6)

and fold the condenser forward.
Clean the condenser fins on front and back with

compressed air or cold water .
Checking the refrigerant level
Start the engine.

1 Optional equipment
12.11 Service the air conditioning
BOMAG 580 008 911 79
Fig. 7
Switch the air conditioning (Fig. 7) on.

Fig. 8
Choose a cooling temperature with the rotary switch

for cabin heater (Fig. 8) in the blue section.
Open the air outlet nozzles.
Check, whether the outflowing air is noticeably cool-

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

Fig. 9
Check whether the white float (Fig. 9) inside the in-

spection glass of the drier/collector unit floats right
at the top.
i
Note
The refrigerant level is correct.
Fig. 10
If the white float (Fig. 10) inside the inspection glass

of the drier/collector unit floats at the bottom, inform
the service department.
i
Note
The refrigerant level is not correct.
Refrigerant must be filled up, if necessary check the

air conditioning system for leaks.
Service the air conditioning
BOMAG 581 008 911 79
12.11
Checking the moisture level of the drying
agent
Fig. 11
Check the moisture indication pearl (Fig. 11) inside

the inspection glass of the drier/collector unit.
orange = drying agent o.k.
colorless = moisture level of drying agent too high.
Inform the service department. Replace drier/col-

lector unit, check air conditioning system.
! Caution
Have the drier/collector unit replaced by the serv-
ice department every year before the operating
season.
Checking the condition of the drier/col-
lector unit
! Caution
According to the regulation for pressure reser-
voirs all pressure reservoirs must be repeatedly
inspected by a specialist. In this sense repeated
inspections are external examinations, normally
on pressure reservoirs in operation. In connection
with this inspection the drier/collector unit must
be visually examined twice every year. During
these inspections special attention must be paid
to corrosion and mechanical damage. If the reser-
voir is not in proper condition it must be replaced
for safety reasons, as a precaution to protect op-
erators and third parties against any danger aris-
ing from the handling and operation of pressure
reservoirs.
! Danger
Danger of injury!
In case of mechanical damage or corrosion on
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.
Fig. 12
Check the drier/collector unit (Fig. 12) for mechani-

cal damage or rust.
12.12 Drying and evacuation
BOMAG 582 008 911 79
12.12Drying and evacuation
Evacuation of air conditioning systems using R-type
refrigerants not only has the purpose of emptying the
system of all air before filling in refrigerant, but also to
verify the leak tightness over a longer lifetime in the
achieved vacuum. However, the most important factor
in this work step is the drying of the system.
Any water residues in the refrigerant circuit will com-
bine with the refrigerant, which will lead to the previ-
ously described consequential damage.
Vacuum pumps with a capacity of more than 100 l/min
and a final pressure of less than 30 micron, i.e. 0.039
mbar should be used to evacuate the refrigeration
system.
The refrigerant compressor is not suitable for the pur-
pose of evacuation, because it is not able to achieve
a sufficient final vacuum and, apart from this, may be
mechanically damaged because of a lack of lubrica-
tion when running empty during evacuation.
It is common practice to evacuate the refrigeration
system to a final vacuum of 1 Torr, i.e. 1.33 mbar.
An exact time for evacuation and drying cannot be
predicted. It can only be determined by means of a
vacuum meter. However, if there is no vacuum meter
at hand it is generally better to evacuate 1 hour longer
than 1 hour too less.
Function drying:
Under normal ambient pressure (1.013 mbar) evapo-
rates absolute at 100 C. If the pressure is reduced,
water will already evaporate, e.g. under a pressure of
10 mbar, at an ambient temperature of almost 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.
12.13Emptying in case of repair
For repair work the air conditioning systems must very
often be emptied of all refrigerant.
Especially with expensive refrigerants and larger
amounts of oil it may be necessary to keep the refrig-
erant for later use.
For later use these refrigerants must be drawn out
with suitable equipment and intermediately stored in
collecting containers.
Environment
Contaminated refrigerant must be disposed of en-
vironmentally
Releasing refrigerant into the atmosphere is pro-
hibited (see restrictive injunction concerning
CFC, day of enforcement 01. 08. 1991, 8)
! Danger
For draining refrigeration systems you should not
simply use any delivery containers, but only ap-
propriate pressure bottles, which must be special-
ly marked and should comply with the pressure
gas directive.
When transferring refrigerant you must make sure
that the bottle does not contain more than the per-
mitted amount of refrigerant in litres and has suf-
ficient gas space for expansion (filling factor: 0,7).
In order to reduce the evacuation period in case of
short repairs, you may fill the refrigerant circuit with
approx. 0.5 bar nitrogen when opening. This ensures
that nitrogen will flow out of the refrigerant circuit while
it is open and no air or moisture can enter. However,
the necessity for vacuum generation and a dryer
change remains.
Leak test
BOMAG 583 008 911 79
12.14
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 rub-
ber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Before starting the evacuation process, the refrigerant
circuit is filled with nitrogen through a pressure reduc-
er valve (approx. 22 bar). After this all connections in
the air conditioning system are checked with the help
of a suitable leak detection spray. A leak is thereby in-
dicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air con-
ditioning system with refrigerant.
Leak test with electronic leak tester
Fig. 1 Electronic leak tester
Small leaks with only very low amounts of refrigerant
escaping can be detected, e.g. with an electronic leak
tester. Such equipment is able to detect leaks of less
than 5 gr. per year.
The leak tester used must be specially designed for
the refrigerant composition in the air conditioning sys-
tem. For example, leak detectors for refrigerant R12
are not suitable for R134a, because the refrigerant
R134a is free of chlorine atoms, meaning that this leak
detector will not respond.
Leak test with soap bubbles
Fig. 2 Soap bubble test
Points susceptible for leakage are sprayed with a
soapy solution. Bubbles indicate the leak. The detec-
tion limit for R 134a is 250 g/year.
12.15 Filling instructions
BOMAG 584 008 911 79
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 compli-
cated equipment is available for this purpose, where-
as individual machines at the place of installation must
be filled directly from the refrigerant container.
Liquid refrigerant is only used to pre-fill the pressure
side of the evacuated refrigeration system (protective
filling).
After switching the refrigeration system on and watch-
ing the inspection glass, gaseous refrigerant can be
filled into the system while the engine is running, if the
refrigerant level is found to be too low (gas bubbles in
the inspection glass).
! Caution
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from
the refrigerant bottle care must be taken not to overfill
the system. As an additional control and for statistical
purposes, e.g. for refilling, it is important to write down
the weight of the filled in refrigerant.
With correct operation of the air conditioning the re-
frigerant container should be about 1/3 filled with liq-
uid refrigerant, the evaporator should be maximally
filled at the calculated evaporation temperature, i.e.
the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the
pressure gauge.
i
Note
White frost on the suction line is no measure for as-
sessing the filling.
Filling instructions
BOMAG 585 008 911 79
12.15
Fig. 1
1 High pressure - gaseous
2 High pressure - liquid
3 Low pressure - gaseous
4 Compressor
5 Compressor pressure switch (not used)
6 not used
7 Evaporator
8 Expansion valve
9 Inspection glass
10 Filter dryer
11 Fluid container
12 Condenser
13 Manual shut-off valve (not used)
14 Pressure switch with high and low pressure con-
tacts
15 Defroster thermostat
16 Vacuum meter
17 Low pressure gauge
18 High pressure gauge
12.15 Filling instructions
BOMAG 586 008 911 79
19 Pressure reducing valve
20 Vacuum pump
21 Nitrogen bottle
22 Refrigerant bottle
23 Pressure gauge bar
Filling instructions
1 Connect the service adapter with the blue hand
wheel in the suction side.
2 Connect the service adapter with the red hand
wheel in the pressure side (the hand wheels on
the service adapters must be fully backed out - left
hand stop)
3 Connect the blue suction hose below the blue
hand wheel on the pressure gauge bar to the blue
service adapter.
4 Connect the red pressure hose below the red
hand wheel on the pressure gauge bar to the red
service adapter.
5 Connect the yellow hose below the yellow hand
wheel on the manometer bar to the 2-stage vacu-
um pump.
6 Connect the last hose below the black hand wheel
on the nitrogen bottle via the pressure reducing
valve.
7 Check on the pressure gauge bar that all hand
wheels are closed.
8 Turn the hand wheels on both service adapter
clockwise. This opens the valves (right hand
stop).
9 Open the valve on the nitrogen bottle (only via
pressure reducer); pressure approx. 20 bar.
10 Open the black and red hand wheels on the pres-
sure gauge bar and fill nitrogen into the system,
until a pressure of approx. 3.5 to 5.0 bar is indicat-
ed on the suction side.
11 Then open the blue hand wheel and raise the
pressure in the suction side (max. 10 bar). Check
for leaks with a leak detection fluid or soapsuds.
12 If the system is leak tight, release the nitrogen
from the system. For this purpose disconnect the
hose from the nitrogen bottle and open the red,
blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand
wheels on the pressure gauge bar. In case of a
leak no or only an insufficient vacuum will be
reached. In this case proceed as described under
point 9-12. Once the leak is sealed continue with
point 14.
15 Once a sufficient vacuum is reached, both pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.
16 Switch off the vacuum pump, watch the pressure
gauges to see whether the vacuum is maintained.
17 Open the valve on the refrigerant bottle and open
the black and red hand wheels on the pressure
gauge bar. Fill refrigerant into the system, until a
pressure equilibrium between suction and pres-
sure side is reached (reading of pressure gaug-
es).
18 Close the red hand wheel.
19 Perform a leak test with the electronic leak detec-
tor.
20 Start the engine and switch on the system.
21 Open the blue hand wheel and continue filling in
refrigerant until the inspection glass is free or air
bubbles (in fluid container/dryer combinations the
white pearl should float in the upper third of the in-
spection glass). Then close the refrigerant bottle.
22 Close the blue hand wheel on the pressure gauge
bar.
23 Preparing the test run: -Close windows and doors
-Fan on full speed stage -Mount measuring feel-
ers to air discharge and air intake.
24 Run the system for approx. 20 minutes with medi-
um engine speed.
25 The temperature difference between air discharge
and air intake should be (depending on type of air
condition) 8-10C. The ambient temperature
thereby is approx. 20C. (These data are only ref-
erence values, which may be influenced by possi-
ble insolation)
26 Switch off system and engine and check for leaks
again.
27 Turn out (left hand stop) and remove the hand
wheels on both service adapters.
28 Fit all valves with dust caps.
29 Perform a leak test.
30 Mark the system with the corresponding type
plates and information decals, such as type of oil
and refrigerant.
Trouble shooting in refrigerant circuit, basic principles
BOMAG 587 008 911 79
12.16
12.16Trouble shooting in refriger-
ant circuit, basic principles
Basic principles
Requirements
For trouble shooting two requirements must be ful-
filled:
Expert knowledge
technical equipment
Technical equipment
The most important aids for trouble shooting are pres-
sure gauges and thermometer. The refrigerant condi-
tions, like overheating and excessive cooling provide
important Information when searching for faults. Even
your own senses are important aids for trouble shoot-
ing. Bubbles in the sight glass, dirt and white frost can
be visibly perceived. If the compressor draws in wet
steam, this can be noticed by the suction line and it
may also be audibly detectable. An overloaded com-
pressor can even be smelled.
The following tools and auxiliary materials should be
available for trouble shooting:
Service station
Pressure gauge
Thermometer
dry nitrogen
Refrigerant bottle for new refrigerant
Container for old oil
Vacuum pump
Hoses
Scales
Suction station
Leak detector
The measuring equipment must be checked at regular
intervals. Calibration can only be made by an ap-
proved testing authority.
Pressure gauge
Most pressure gauges used in practice are (for cost
reasons) excess pressure gauges. These pressure
gauges measure the excess pressure in relation to the
ambient pressure (air pressure). In order to achieve
the absolute (actual) pressure the ambient pressure
must be added to the pressure gauge reading. The
absolute pressure is needed for the calculation and
determination of material data.
P
abs
= P
amb
+ P
e
P
abs
= absolute pressure
P
amb
= atmospheric air pressure (ambient pressure)
P
e
= excess pressure (pressure gauge reading)
Fig. 2 Pressure gauge
Example:
A totally empty air conditioning system holds an at-
mospheric pressure of approx. P
amp
= 1 bar.
Filling the system with refrigerant causes an excess
pressure of P
e
= 3 bar.
P
abs
= P
amb
+ P
e
= 1 bar + 3 bar = 4 bar
Evacuating the system down to P
e
= -0.6 bar, creates
a "vacuum" (negative excess pressure).
P
abs
= P
amb
+ P
e
= 1 bar +(- 0,6) bar = 0,4 bar
12.16 Trouble shooting in refrigerant circuit, basic principles
BOMAG 588 008 911 79
Pressure gauge with saturation temperature scale
Fig. 3 Absolute pressure gauge
Temperature scales on the pressure gauges always
refer to the absolute pressures Pabs. Please note that
it is not possible to measure a temperature directly
with a pressure gauge. The indicated temperatures
are just reference values. Only the saturation temper-
ature is assigned to the measured pressure.
If the refrigerant is fluid, the temperature is below the
saturation temperature.
If the refrigerant is gaseous, the temperature is above
the saturation temperature.
Pressure gauges must indicate 0 bar when not con-
nected to the system.
Low pressure gauges have a blue, high pressure
gauges a red border.
Thermometer
Normally digital thermometers with surface or contact
feelers are used. Especially for high temperature dif-
ferences excellent heat insulation of the measuring lo-
cation is of utmost importance. The sparing use of a
heat conducting paste is highly recommended. If the
measuring location is soiled, it needs to be cleaned
and probably treated with a fine emery cloth. Only the
temperature of the feeler is measured. Due to missing
heat insulation and insulating oxide layers on the line,
temperature differences of a few degrees Kelvin be-
tween the measured and the actual values may arise.
Overheating
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are
not compressible and must therefore not enter into the
compression chamber of the compressor.
If the suction condition of the compressor is directly on
the dew line, an e.g. incorrect evaporator load can
cause "wet suction". This can lead to two processes,
which are destructive for the compressor. The liquid
refrigerant washes off the lubricating film between pis-
ton and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in
the cylinder causes a direct energy transfer from pis-
ton to cylinder cover during compression. The valve
plate may then be damaged by so-called fluid strokes.
Apart from protecting the compressor against fluid,
overheating has further advantages. Since the fluid
proportions in the drawn in steam reduces the flow
rate of the compressor, it may be increased by a over-
heating. Overheating also improves the oil recircula-
tion.
Common overheating values
The optimal overheating value is approx. 5 - 8 Kelvin.
With this overheating the maximum system power is
reached. However, the thermostatic expansion valve
is unable to regulate this value exactly. Depending on
design and operating conditions overheating fluctu-
ates within a range between 4 and 12 Kelvin. The in-
fluence of the ambient air on the suction line causes
an additional overheating effect.
Overheating is calculated as follows:
t
o2h
= t
o2h
- t
o
t
o2h
, overheating at evaporator outlet in K
t
o2h
, temperature at evaporator outlet in C
t
o
, evaporation temperature in C
h
represents "overheated"
Supercooling
It is the function of the expansion valve to reduce the
refrigerant to a lower pressure level (evaporation
pressure) after it has been liquefied. For an optimal
function of the valve pure fluid must be applied to its
inlet port.
The refrigerant must "squeeze" (literally speaking)
through a throttle gap inside the expansion valve.
When comparing a certain mass of refrigerant in fluid
and in vaporous state (with constant pressure), the
vaporous refrigerant requires a much higher volume.
That's why the vaporous refrigerant needs a much
longer time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
If the refrigeration system is operated with the "expan-
sion valve inlet" condition directly on the boiling curve,
slightest fluctuations in operating condition may cause
Trouble shooting in refrigerant circuit, basic principles
BOMAG 589 008 911 79
12.16
a formation of bubbles in front of the expansion ele-
ment.
For this reason one shifts the condition "Expansion
Valve Inlet" away from the boiling curve into the fluid
area and refers to this condition as Supercooling. This
supercooling ensures a fluid supply in front of the ex-
pansion valve.
Common supercooling values
In systems with fluid container the supercooling at the
fluid container outlet is approx. Zero "0" Kelvin (as-
sumed that the system is filled with the correct refrig-
erant quantity). In this case the fluid container
provides the required fluid supply.
Supercooling is calculated as follows:
t
c2u
= t
c
- t
c2u
t
c2u
, supercooling at evaporator outlet in K
t
c2u
, temperature at evaporator outlet in C
t
c
, evaporation temperature in C
u
represents "supercooled"
12.16 Trouble shooting in refrigerant circuit, basic principles
BOMAG 590 008 911 79
Fig. 1 Refrigerant circuit with t, h- diagram
1 Hot gas line (overheated steam)
2 Deheating (overheated steam)
3 Condenser / liquefier
4 Condensation (wet steam)
5 Fluid line (supercooled fluid)
6 Expansion valve
7 Injection line (wet steam)
8 Evaporation (wet steam)
9 Evaporator
10 Overheating (overheated steam)
11 Suction steam line (overheated steam)
12 Compressor
13 Supercooling (fluid)
14 Compression
15 Expansion
Trouble shooting, refrigerant circuit diagram
BOMAG 591 008 911 79
12.17
12.17Trouble shooting, refrigerant
circuit diagram
Fig. 1 Refrigerant circuit diagram
1 Cold air
2 Evaporator
3 Thermostat
4 Warm air
5 Fan
6 Inspection glass
7 Expansion valve
8 Pressure gauge, high pressure
9 Pressure switch with high and low pressure con-
tacts
10 Dryer
11 Fluid container
12 Hot air
13 Compressor
14 Condenser
15 Cooling air
16 Pressure gauge, low pressure
12.18 Trouble shooting procedure
BOMAG 592 008 911 79
12.18Trouble shooting procedure
Procedure
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 con-
denser soiling or formation of steam bubbles in the in-
spection glass can be quickly detected.
In case of unusual formation of hoarfrost on the evap-
orator the hoarfrost pattern provides useful informa-
tion. Hoarfrost only occurring at the inlet side is a clear
indication of insufficient refrigerant feed, which in turn
indicates an incorrectly working expansion valve or a
lack of refrigerant.. Complete hoarfrost covering indi-
cates load problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the
naked eye. At the end of the evaporator there should
be an area which is dry or at least drier at evaporator
temperatures above -2 C.
The fluid line in the refrigeration system is warm. If a
local cooling can be felt or if condensation develops,
this is a clear indicator for an extreme pressure drop
in the line. Similar phenomena can be noticed in case
of blocked filters.
Unusually cold pressure lines indicate "wet" intake of
the compressor.
The oil level in the compressor sight glass provides in-
formation about the oil quantity and the oil recircula-
tion in the system. However, the oil level may also be
considerably influenced by condensing refrigerant.
Discoloration informs about the state of the oil.
Water in the system can simply be detected through
the inspection glass with moisture indicator.
i
Note
The dangerous part of common rules is that they ap-
ply in most, but not in all cases. The refrigerant states
in the individual piping sections or components must
therefore be exactly determined by means of pressure
and temperature measurements.
Test prerequisites
Cooler and condenser are clean, clean if neces-

sary.
The ribbed belt for compressor and generator is

correctly tightened.
All air ducts, covers and seals are OK and correctly

fitted. Flaps reach their end positions.
The engine has operating temperature.
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. cool-
ing power.
Ambient temperature above 15 C.
The thermostat is correctly installed and the switch-

ing temperatures are correct.
Trouble shooting procedure
BOMAG 593 008 911 79
12.18
Measuring points and measurements
Fig. 2 Flow diagram with measuring points
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 evapora-
tor. Overheating is a clear indicator for the evaporator
filling level. In case of excessive overheating the re-
frigerant quantity fed into the evaporator is too low, in
case of insufficient overheating it is too high. In indi-
vidual cases one must then check if this situation is
caused by the expansion element or by insufficient fill-
ing. A differentiation is only possible if there is a clear
indicator for the refrigerant filling quantity.
Pressure and temperature at the condenser outlet can
be used to derive the supercooling. This can be used
to assess the filling quantity. In systems with fluid con-
tainer the inspection glass is most suitable to check
the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
The hot gas temperature can be used to check wheth-
er the compressor runs in the permissible operating
range.
Example: Measurement of overheating
a) Which measuring equipment is required ?
b) Where to measure with which size ?
c) A pressure gauge connected to the evaporator

indicates "P
eo2
= 1.7 bar". How high is the evapora-
tor pressure "P
o
" ?
d) How high is the evaporator temperature "t

o
" ?
e) A thermal sensor attached to the evaporator out-

let measures the temperature "t
o2h
= +3 C". How
high is the overheating t
o2h
?
f) Evaluation of the measured overheating.

BOMAG 594 008 911 79
Solution:
a) Pressure gauge, thermometer, steam table
b) Evaporation pressure "P

eo2
" and temperature
"t
o2h
" are measured at the same point on the evap-
orator outlet.
c) P
o
= P
eo2
+ P
amb
, "Evaporation pressure =
pressure on evaporator + atmospheric pressure" =
1.7 bar + 1 bar = 2.7 bar.
d) "P
c
" = 2,7 bar can then be used to derive an con-
densing temperature "t
o
" of -2,2 C from the steam
table for R134a.
e) t
o2h
= t
o2h
- t
o
, Overheating at evaporator out-
let = 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.
Example: Measuring supercooling
a) Which measuring equipment is required ?
b) Where to measure with which size ?
c) A pressure gauge connected to the condenser in-

dicates "P
ec2
= 15 bar". How high is the condensing
pressure "P
c
" ?
d) How high is the condensing temperature "t

c
" ?
e) A thermal sensor attached to the condenser out-

let measures the temperature "t
c2u
= 58 C". How
high is the supercooling "t
c2u
" ?
f) Evaluation of the measured supercooling.

Solution:
a) Pressure gauge, thermometer, steam table
b) Condensing pressure "P

ec2
" and temperature
"t
c2u
" are measured at the same point on the con-
denser.
c) P
c
= P
ec2
+ P
amb
, "Evaporation pressure =
pressure on evaporator + atmospheric pressure" =
15 bar + 1 bar = 16 bar.
d) "P
c
c = 16 bar can then be used to derive an con-
densing temperature "t
c
" of 57.9 C from the steam
table for R134a.
e) t
c2u
= t
c
- t
c2u
, "Supercooling at condenser out-
let = 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 Occur-
ring faults frequently have a similar appearance, but
different causes. An evaporator showing hoarfrost
may be quite normal. However, there may also
be a defect in the expansion valve or problems in the
oil recirculation.
The following list contains pressure values in a sys-
tem, that can be expected at various ambient temper-
atures (measured at medium speeds).
Suction pressure (low pressure gauge)
High pressure (high pressure gauge)
Ambient temperature in C Excess pressure in bar
25 approx. 2,0
30 approx. 2,5
35 approx. 3
Ambient temperature in C Excess pressure in bar
25 approx. 8,0
35 approx. 13
40 approx. 16
45 approx. 18
BOMAG 595 008 911 79
12.18
Values effecting the operating pressures
Since the pressures occurring in a refrigeration sys-
tem are highly dependent on environmental condi-
tions, it is mandatory to know these dependencies.
The following table contains some of these dependen-
cies.
Measuring value Suction pressure High pressure
increases drops increases drops
Compressor speed
increases
X X
drops
X X
Vehicle interior tempera-
ture
increases
X X
drops
X X
Ambient temperature
increases
X X
drops
X X
Humidity
increases
X X
drops
X X
BOMAG 596 008 911 79
Suction pressure too low (1), high pressure too
low to normal (2)
Fig. 3
Cause Possible effect Remedy
Lack of refrigerant no supercooling, bubbles in inspec-
tion glass, high overheating, hoar-
frost on evaporator
Check for leaks, refill
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-
uum, because the valve has closed
Replace the valve
Screen or nozzle in expansion valve
clogged
high overheating clean
Filter dryer clogged Bubbles in inspection glass, high
overheating, filter dryer cold
Change filter dryer
Heat power too low Frequent low pressure shut off,
thawing thermostat / rotary thermo-
stat switching too frequently
Check the control
BOMAG 597 008 911 79
12.18
Suction pressure normal (1), high pressure too
high (2)
Fig. 4
Condenser dirty high hot gas temperature, low cool-
ing power
clean
Condenser fan failed high hot gas temperature, high pres-
sure shut down
repair
overfilled high hot gas temperature, low su-
percooling, low cooling power
Correct the filling capacity
Leak gas (air) high hot gas temperature, low
measured supercooling, low cooling
power
renew filling
Restriction between compressor and
condenser
high hot gas temperature, low cool-
ing power
Check lines and valves
BOMAG 598 008 911 79
Suction pressure too high (1), high pressure too
low to normal (2)
Fig. 5
Compressor defective Cooling power too low Replace the compressor
BOMAG 599 008 911 79
12.18
Suction pressure too high (1), high pressure too
high (2)
Fig. 6
Expansion valve defective overheating too low, wet operation
of compressor
Replace the valve
BOMAG 600 008 911 79
Other faults
Noise in system
Symptom Cause Possible effect Remedy
Hot gas temperature too
high, the hot gas line be-
comes so hot that it cannot
be touched long with a
hand
Lack of refrigeration oil increased compressor
wear
Refill refrigeration oil
Compressor does not start Pressure switch or any oth-
er safety feature has trig-
gered, electrical fault,
cylinder filled with liquid re-
frigerant
System stopped Check the control units,
check cause for switching
and rectify
Compressor switches con-
tinuously
Switching difference too
small, triggering of a
switching element (over-
pressure switch, low pres-
sure switch), lack of
refrigerant, fan defective,
overfilled
Cycling of compressor, in-
creased wear, too low cool-
ing power
Check the control units,
check cause for switching
and rectify
Excessive overheating Expansion valve deadjust-
ed or screen blocked, lack
of refrigerant
low cooling power, hot gas
temperatures too high
Replace the expansion
valve, clean the screen, fill
in refrigerant, leak test
Hoarfrost on inlet side of
evaporator
incorrectly working expan-
sion valve, lack of refriger-
ant
too low infeed of refrigerant
into the evaporator
Check the expansion
valve, check the refrigerant
filling
Evaporator fully covered
with hoarfrost
Load problem, too low air
flow volume
low cooling power of sys-
tem
Clean the evaporator,
check the evaporator fan
Fluid line is warm and
shows condensation
Pressure drop in fluid line,
filter dryer clogged
low cooling power Eliminate the pressure
drop, replace the filter dryer
Exceptionally cold pres-
sure lines
"Wet intake" of the com-
pressor due to insufficient
overheating of evaporator
low cooling power, exces-
sive wear of compressor
Clean the compressor, re-
place if necessary, replace
the expansion valve if nec-
essary
Faults Possible cause Remedy
V-belt loose or excessively worn V-belt slips and generates noise Retention or renew the V-belt
Magnetic clutch loud Magnetic clutch runs until high pres-
sure builds up, then the clutch starts
to slip
Repair or replace the magnetic
clutch
Refrigerant compressor is loud Mounting bracket is loose, internal
parts worn, low oil level in compres-
sor
Repair the mounting bracket, re-
place the compressor, renew the re-
frigeration oil
Fan is loud, fan motor excessively
worn
Replace the fan motor
Whistling and rattling noise in opera-
tion, noticeable unevenness when
turning by hand
V-belt pulley and bearing worn Replace the bearing, check V-belt
pulley for wear
Rattling noise or vibration of high
pressure line, knocking noise in
compressor, ball in inspection glass
floating at the top
System overfilled Draw out refrigerant
Expansion valve loud excessive moisture in system Replace the dryer
Hissing noise in evaporator housing,
on expansion valve, turbidity in in-
spection glass or ball does not float
refrigerant level in system too low Perform a leak test, fill up the system
BOMAG 601 008 911 79
12.18
Inspection glass
Monitoring devices

Steam bubbles in inspection glass No supercooling before expansion
valve, lack of refrigerant in system,
pressure loss in system, supercool-
ing caused by excessively soiled fil-
ter dryer
Fill up the system, replace the filter
dryer, perform a leak test
Discolouration of inspection glass
(black from inside)
Lubricant destroyed by excessive
operating temperatures
Replace the refrigeration oil, exam-
ine the temperature increase
Moisture indicator changes to pink Moisture level of drying agent too
high
Replace the filter dryer
Ball floats at bottom lack of refrigerant Fill the system
The high pressure contact has
switched off the magnetic clutch
System pressure exceeded, con-
denser excessively soiled, condens-
er fan defective, expansion valve
defective
Clean the condenser, replace the
expansion valve, check the con-
denser fan
The low pressure contact has
switched off the magnetic clutch
System pressure fallen short of, re-
frigerant level too low, expansion
valve defective, evaporator fan de-
fective, heat load too low, ambient
temperature below 1.5 C
Clean the evaporator, replace the
expansion valve, check the evapora-
tor fan
The thermostat has switched off the
magnetic clutch
Ambient temperature below 1C,
expansion valve defective, thermo-
stat defective, air flow volume too
low
Check the thermostat switching
point, replace the expansion valve,
clean the evaporator, check the
evaporator fan
12.19 Steam table for R134a
BOMAG 602 008 911 79
Tempera-
ture
Pres-
sure
Density spec. volume spec. enthalpy Evapora-
tion heat
of the fluid of the
steam
of the fluid of the
steam
of the fluid of the
steam
Steam table for R134a
BOMAG 603 008 911 79
12.19
BOMAG 604 008 911 79
Steam table for R134a
BOMAG 605 008 911 79
12.19
BOMAG 606 008 911 79
BOMAG 607 008 911 79
12.20Heating control / air conditioning control
12.20 Heating control / air conditioning control
BOMAG 608 008 911 79
Heating control / air conditioning control
BOMAG 609 008 911 79
12.20
BOMAG 610 008 911 79
Heating control / air conditioning control
BOMAG 611 008 911 79
12.20

BOMAG 612 008 911 79
BOMAG 613 008 911 79
13 Replacing the cab window panes
13.1 Assembly of window panes
BOMAG 614 008 911 79
Fig. 1
1 Glass panes
2 Fastening element
3 Fixing washer and spacer
4 Washer
5 Hexagon nut, self locking
6 Protective cap
Special tools
BOMAG 615 008 911 79
13.2
13.2 Special tools
1. Locking handle for fastening element
2. Suction lifter
commercial
Fig. 1
Fig. 2
13.3 Auxiliary materials
BOMAG 616 008 911 79
13.3 Auxiliary materials
Safety gloves
3. Cutter
Commercial
4. Window glass bonding agent
5. Activator
Fig. 1
Fig. 2
Fig. 3
Auxiliary materials
BOMAG 617 008 911 79
13.3
6. Silicone sealant
Fig. 4
13.4 Removing and installing the window pane
BOMAG 618 008 911 79
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).
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.
5. Insert the fastening element with washer into the
bore in the glass pane (Fig. 3).
Fig. 1
Fig. 2
Fig. 3
Removing and installing the window pane
BOMAG 619 008 911 79
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.
7. Lay an approx. 1 cm high triangular bead of glass
pane bonding agent on the inside of the pane, ap-
prox. 1.5 cm away from the edge (Fig. 5).
i Note
Apply window pane bonding agent only to the
sides (sealing areas) which have contact with the
cabin.
8. Attach the suction lifter to the outside of the pane
(Fig. 6).
9. Install the window pane so that the fastening ele-
ments fit into the bores of the fastening bars.
10. Press the glass pane against the sealing surface.
11. Assemble the washer and the self-locking hexa-
gon nut.
12. Fasten the window pane to the fastening bar us-
ing a locking handle and a ring spanner (Fig. 7).
i Note
Only use the locking handle to counter.
13. Press the protective cap onto the hexagon nut.
Fig. 4
Fig. 5
Fig. 6
Fig. 7
BOMAG 620 008 911 79
14. Remove the suction lifter (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.
17. Apply silicone sealant evenly and under pressure
first to the inside joint edge (Fig. 10).
18. Then apply silicone sealant evenly and under
pressure to the outside joint edge (Fig. 11).
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Removing and installing the window pane
BOMAG 621 008 911 79
13.4
19. Then spray the joints from inside and outside with
water containing washing up liquid (Fig. 12).
20. Treat the inside joint (Fig. 13)
21. and the outside joint (Fig. 14) with a scraper or a
spattle.
i Note
Once the silicone sealing agent has cured it can
only be removed mechanically.
Fig. 12
Fig. 13
Fig. 14
BOMAG 622 008 911 79
BOMAG 623 008 911 79
14 Drum
14.1 Special tools, drum BW 213/226 DH-4 BVC and Variocontrol
BOMAG 624 008 911 79
14.1 Special tools, drum BW 213/226 DH-4
BVC and Variocontrol
1. Mechanical fixation, assembly of gearbox cover
with weights pointing downward (vertical ampli-
tude) .
2. Mechanical fixation, adjustment of potentiometer
for horizontal amplitude.
3. Auxiliary assembly rings, side plate.
Fig. 1
Fig. 2
Fig. 3
Special tools, drum BW 213/226 DH-4 BVC and Variocontrol
BOMAG 625 008 911 79
14.1
4. Centring sleeve for side plate 10 (Fig. 4) and
flanged hub (8).
5. Pressing tool, inner races of tapered roller bear-
ings
6. Pressing tool, outer races of tapered roller bear-
ings
Fig. 4
Fig. 5
Fig. 6
14.2 Removing and installing the drum
BOMAG 626 008 911 79
i Note
After disassembling the side plate (vibration mo-
tor side) the drum can be lifted sideways out of
the frame (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).
Removing the drum
i Note
The following section describes the procedure for
lifting the frame sideways out of the drum.
7. Unscrew the fastening screws and remove the
protection hood (Fig. 3).
Fig. 1
Fig. 2
Fig. 3
Removing and installing the drum
BOMAG 627 008 911 79
14.2
1. Open the hose brackets (Fig. 4) on both sides of
the drum.
Environment
Catch running out hydraulic oil and dispose
of environmentally.
2. Mark the hydraulic hoses on the vibration motor
(Fig. 5) and disconnect them from the ports.
3. Close all hydraulic hoses and vibration motor
ports with suitable plugs.
4. Mark the hydraulic hoses on the slewing motor
(Fig. 6) and disconnect them from the ports.
5. Close all hydraulic hoses and slewing motor ports
with suitable plugs.
6. Mark the hydraulic hoses on the control valve
block (Fig. 7) and disconnect them from the ports.
7. Close all hydraulic hoses and control valve ports
8. Pull off both plugs (2) from the solenoid valve.
9. Disassemble the protection hood (1) for the plug
of the wiring loom.
Fig. 4
Fig. 5
Fig. 6
Fig. 7
BOMAG 628 008 911 79
10. Disconnect all plugs (Fig. 8).
11. Mark the hydraulic hoses (Fig. 9) on the travel
motor and disconnect them from the ports.
12. Close all hydraulic hoses and travel motor ports
13. Disassemble the guard plates for speed range
selection solenoid valve (1) and speed sensor
(2).
14. Disconnect the plug from the speed sensor sole-
noid valve (Fig. 10).
15. Close the connections with plugs.
16. Disassemble the front scraper 1 (Fig. 11).
17. Disassemble the rear scraper (2).
Fig. 8
Fig. 9
Fig. 10
Fig. 11
BOMAG 629 008 911 79
14.2
! Danger
Danger of accident!
Do not start or run the engine during repair
work.
18. Support the front cross-member safely (Fig. 12).
19. Properly support the rear cross-member on both
sides (Fig. 13).
20. Attach the lifting tackle to the side plate (Fig. 14).
21. Unscrew the front and rear fastening screws from
the side plate.
22. Unscrew the fastening screws (Fig. 15) from the
spacer block on the vibration motor.
! Danger
Danger of accident! Do not stand or step un-
der loads being loaded.
23. Take off the side plate and lay it down.
Fig. 12
Fig. 13
Fig. 14
Fig. 15
BOMAG 630 008 911 79
24. Unscrew the fastening screws on the travel motor
side (Fig. 16).
25. Fasten the lifting tackle to the drum and lift the
drum carefully sideways out of the front frame
(Fig. 17).
! Danger
Danger of squashing! Do not stand or step
under loads being loaded.
26. Examine all rubber buffers on the travel motor
side (Fig. 18) for wear, replace if necessary.
27. Check the rectangular rubber buffers on the vi-
bration motor side, replace if necessary.
Fig. 16
Fig. 17
Fig. 18
BOMAG 631 008 911 79
14.2
Installing the drum
! Danger
Danger of squashing!
Do not stand or step under loads being load-
ed.
1. Place the drum into the frame and align it parallel
to the frame (Fig. 19).
Assemble the side plate
2. Attach the lifting tackle and assemble the side
plate (Fig. 20).
i Note
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
3. Turn in the front and rear fastening screws and
tighten with 463 Nm.
4. Turn in and tighten the fastening screws on the
travel motor side (Fig. 21).
Adjust the pretension of the rubber buffers.
5. On the vibration motor side measure the distance
X between spacer block 1 (Fig. 22) and side
plate.
6. Calculate the thickness of the compensation
plates.

Nominal value:
Distance X + 2 mm
7. Turn in one screw (3) into each welded nut (2) on
the spacer blocks and provide sufficient space to
insert the compensation plates.
Fig. 19
Fig. 20
Fig. 21
Fig. 22
BOMAG 632 008 911 79
8. Insert the compensation plates (Fig. 23).
9. Turn in the fastening screws.
10. Unscrew the screws from the welded nuts.
11. Tighten the fastening screws.
Connecting the travel motor side
12. Connect hydraulic hoses to the travel motor ports
according to the marks made during disassembly
(Fig. 24).
13. Connect the plugs (Solenoid valve for travel
speed range selection and speed sensor) and re-
assemble the guard plates (1) and (2).
Connecting the vibration motor side
14. Connect the hydraulic hoses to the ports on the
vibration motor according to the marking (Fig.
25).
15. Connect hydraulic hoses to the slewing motor
ports according to the marks made during disas-
sembly (Fig. 26).
Fig. 23
Fig. 24
Fig. 25
Fig. 26
BOMAG 633 008 911 79
14.2
16. Connect all cable plugs and reassemble the pro-
tection hood 1 (Fig. 27).
! Caution
Ensure correct routing of the wiring harness-
es!
17. Connect the hydraulic hoses to the ports on the
control valve block according to the marking.
18. Plug in both plugs (2) on the solenoid valve.
19. Fasten the brackets (Fig. 28) for the hydraulic
hoses on both sides.
Adjusting the scrapers
20. Assemble the front scraper 1 (Fig. 29).
21. Assemble the rear scraper (2).
i Note
Observe the adjustment measurement 30-35
mm.
22. Assemble the protection hood (Fig. 30).
! Caution
Check the hydraulic system for function and
leak tightness before putting the machine
back into service.
Adjust the potentiometer (see Technical Man-
ual VC).
Adjust the slewing motor (see Technical Man-
ual VC).
Fig. 27
Fig. 28
Fig. 29
Fig. 30
14.3 Changing the rubber buffers and adjusting the pretension
BOMAG 634 008 911 79
14.3 Changing the rubber buffers and ad-
justing the pretension
Relieve the rubber buffers
1. Lift the frame up by both sides, until rubber buff-
ers and rectangular buffers are relieved of any
load (Fig. 1).
2. Loosen all fastening screws.
3. Turn one screw each into the welded nuts (Fig. 2)
on the spacer blocks.
4. Remove the compensation shims (Fig. 3).
Fig. 1
Fig. 2
Fig. 3
Changing the rubber buffers and adjusting the pretension
BOMAG 635 008 911 79
14.3
5. Unscrew the screws (Fig. 4) from the welded
nuts.
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.
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
14. Turn in screws into each welded nut and provide
sufficient space to insert the compensation plates
(Fig. 7).
Fig. 4
Fig. 5
Fig. 6
Fig. 7
14.3 Changing the rubber buffers and adjusting the pretension
BOMAG 636 008 911 79
15. Assemble the compensation shims (Fig. 8).
16. Unscrew the screws (Fig. 9) from the welded
nuts.
17. Tighten the fastening screws (Fig. 10).
18. Lower the frame again.
Fig. 8
Fig. 9
Fig. 10
BOMAG 637 008 911 79
15 Drum
15.1 Repair overview for drum
BOMAG 638 008 911 79
Fig. 1 Vario drum
Repair overview for drum
BOMAG 639 008 911 79
15.1
1 Eccentric weight
2 Swivel motor
3 Swashing shaft
4 Vibrator shaft
5 Eccentric weight
6 Rectangular rubber buffer (BW 213, 4 pieces / BW
226, 8 pieces)
7 Vibration motor
8 Flanged hub
9 Mechanical seal
10 Side plate
11 Drum shell
12 Taper roller bearing
13 Intermediate rings
14 Spacer ring
15 Circlip
16 Clamping ring
! Caution
a) The thread must be free of grease, oil, paint and
conserving agents.
b) Fitting and contact surfaces of the connection
between exciter unit and drum must be absolutely
dry and free of grease, oil, paint and conserving
agent.
c) Allow the bearing to cool down before pressing
in.
d) Tighten the screws cross-wise.
BOMAG 640 008 911 79
Fig. 2
1) (Fig. 2) Cover the bearing with grease AUTOL TOP
2000 Temp (00996001), fill the bearing housing with
grease.
2) Protect the splined shaft with Optimol (00970037),
fill the chambers with paste.
3) Coat the gearbox from inside with grease AUTOL
TOP 2000 Temp (00996001).
! Caution
4) Open the gearbox cover only after consulting
BOMAG.
5) Assemble the O-ring with grease.
BOMAG 641 008 911 79
15.1
Fig. 3
1) Assemble the O-ring with grease (Fig. 3).
2) Protect the splined shaft with Optimol White
(00970037), fill the chambers with paste.
3) Secure with LOCTITE Blue No. 243.
4) Sealed with Hylomar SQ32/M.
BOMAG 642 008 911 79
Exciter fixation for vertical amplitude
! Caution
The mechanical fixation for vertical amplitude ad-
justment must only be made by BOMAG.
Fig. 4 Fixation of vertical amplitude
i
Note
View from outside into drum (Fig. 4).
Assembly position for gearbox: Eccentric weight verti-
cal (vertical amplitude).
a) Mark on swashing motor
b) Middle of tooth on swashing motor (= zero position)
i
Note
Mechanical fixation for assembly of gearbox cover
with weights pointing downward (vertical amplitude)
(Fig. 5).
Motor is mounted to gearbox cover in zero position,

this applies also for the gear wheel.
The motor is then swivelled with the gear for 90

(pumping) and assembled in this position.
BOMAG 643 008 911 79
15.1
Exciter fixation for horizontal amplitude
! Caution
The mechanical fixation for horizontal amplitude
potentiometer adjustment must only be made by
BOMAG.
Fig. 7 Fixation of horizontal amplitude
i
Note
View from outside into drum (Fig. 7).
Position: Eccentric weights horizontal, horizontal am-
plitude.
a) Mark on swashing motor
b) Middle of tooth on swashing motor (= zero position)
Fig. 8 Fixation
Fig. 9 Fixation
15.2 Assembly of tapered roller bearing
BOMAG 644 008 911 79
Fig. 1 Cross-sectional drawing of right hand drum side
Assembly of tapered roller bearing
BOMAG 645 008 911 79
15.2
1
2 Swivel motor
3 Swashing shaft
4
5
6 Rectangular rubber buffer (BW 213, 4 pieces / BW
226, 8 pieces)
7 Vibration motor
8 Flanged hub
9 Mechanical seal
10 Side plate
11 Drum shell
12 Taper roller bearing
13 Intermediate rings
14 Spacer ring
15 Circlip
16 Clamping ring
Fig. 2
1. Insert half of mechanical seal 9 (Fig. 2) into flang-

ed hub (8).
Grease the seal ring and fill the space between me-
chanical seal and flanged hub with grease.
Fig. 3
Attach the auxiliary assembly rings to the flanged

hub 8 (Fig. 3).
BOMAG 646 008 911 79
Fig. 4
2. Insert half of mechanical seal 9 (Fig. 4) into side

plate (10).
Grease the sealing ring.

Fig. 5
Use the centring sleeve to slide the side plate 10

(Fig. 5) on the flanged hub (8).
Remove the centring sleeve.

Fig. 6
Brush some grease on the collar of the side plate

(Fig. 6).
Fig. 7
Heat the inner ring of the 1st tapered roller bearing

up to approx. 100C.
! Danger
Danger of burning!
Wear protective gloves.
Insert the inner race into the side plate (Fig. 7).
Press down with a pressing tool.
Fill the space between inner race and side plate col-
lar with grease.
BOMAG 647 008 911 79
15.2
Fig. 8
Cool the outer race of the 1st tapered roller bearing

with liquid nitrogen down to approx. -30C.
! Danger
Persons handling liquid oxygen must learn the
following safety instructions:
Safety instructions, handling low temperature liq-
uid gases
Safety instructions, lack of oxygen.
Safety instructions, oxygen enrichment.
Safety instructions, frost bites and congelation.
Assemble the outer race (Fig. 8).

! Caution
The outer race must firmly rest against the shoul-
der of the side plate.
Fig. 9
Insert the two matching intermediate rings of the ta-

pered roller bearing set 13 (Fig. 9).
! Caution
The bearing set must only be assembled with the
associated intermediate rings. Replacement of in-
dividual bearings without intermediate rings is not
permitted!
Fill the chamber with grease.

Fig. 10
Cool the outer race of the 2nd tapered roller bearing

with liquid nitrogen down to approx. -30C.
BOMAG 648 008 911 79
! Danger
Persons handling liquid oxygen must learn the
following safety instructions:
Safety instructions, handling low temperature liq-
uid gases
Safety instructions, lack of oxygen.
Safety instructions, oxygen enrichment.
Safety instructions, frost bites and congelation.
Assemble the outer race (Fig. 10).

Fig. 11
Insert the spacer ring 14 (Fig. 11).

Fig. 12
Remove the auxiliary assembly ring (Fig. 12).

! Caution
During the assembly process rotate the side plate
only to one direction, so that the tapered rollers in
the bottom bearing rest against the big collar of
the inner ring.
Fig. 13
Heat the inner ring of the 2nd tapered roller bearing

up to approx. 100C.
! Danger
Danger of burning!
Wear protective gloves.
Insert the inner ring (Fig. 13).

Fig. 14
Install circlip 15 (Fig. 14).

BOMAG 649 008 911 79
15.2
Fig. 15
Fasten the clamping ring 16 (Fig. 15) with screws.

! Caution
When turning the side plate while tensioning the
screws an increase in the required force should
be noticed.
Follow the procedure described next to tighten
the screws:
a) Tighten the screws crosswise with 80 Nm, then
rotate the side plate three times.
b) Retighten the screws crosswise with 100 Nm,
c) Retighten the screws crosswise with 120 Nm,
d) Mark the position of the screws to the clamping
ring, then loosen one screw at a time and screw it
back in with Loctite 2701 and tighten it to the
mark.
Inspection:
There must be clearance between clamping ring
and flanged hub, check with a feeler gauge.
BOMAG 650 008 911 79
BOMAG 651 008 911 79
16 Articulated joint, electric steering
16.1 Special tools
BOMAG 652 008 911 79
16.1 Special tools
1. Pressing device for rocker bearings
2. Pressing sleeve for inner and outer rocker bear-
ing races
3. Guide pin
4. Clamping device
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Special tools
BOMAG 653 008 911 79
16.1
16.2 Repair overview oscillating articulated joint
BOMAG 654 008 911 79
Repair overview oscillating articulated joint
BOMAG 655 008 911 79
16.2
BOMAG 656 008 911 79
BOMAG 657 008 911 79
16.2
16.3 Removing and installing the oscillating articulated joint
BOMAG 658 008 911 79
16.3 Removing and installing the oscillat-
ing articulated joint
1. Jack up the frame at the back on both sides and
secure it with trestles or wooden blocks (Fig. 1).
! Danger
Make sure that front and rear frames are prop-
erly secured against rolling and tipping over.
Danger of accident! Do not stand or step un-
der loads being loaded.
Do not work in the articulation area of the roll-
er while the engine is running.
! Caution
Do not start the engine during repair work on
the articulated joint!
2. Support the rear frame near the oscillating articu-
lated joint (Fig. 2) on both sides safely with tres-
tles or wooden blocks.
3. Fasten the lifting tackle to the front frame near the
oscillating articulated joint (Fig. 3).
Fig. 1
Fig. 2
Fig. 3
Removing and installing the oscillating articulated joint
BOMAG 659 008 911 79
16.3
4. Unscrew the fastening screws and lift off the an-
gle sensor (Fig. 5).
i Note
Does not apply for BVC machines with the hy-
draulic steering option.
5. Unscrew fastening screws 1 (Fig. 5) and take off
axle holder (2).
6. Knock out bearing bolt (3).
7. Retract steering cylinder (4).
! Danger
Danger of accident!
8. Support the oscillating articulated joint in the mid-
dle with a suitable jack or a similar device.
with disc (2).
10. Unscrew nuts 3 (Fig. 7) and take off the clamping
washers (2).
11. Pull out the fastening screws (1).
12. Slightly raise the front frame and lower the oscil-
lating articulated joint to the ground.
13. Pull out the oscillating articulated joint.
Fig. 4
Fig. 5
Fig. 6
Fig. 7
BOMAG 660 008 911 79
Notes on assembly
14. Insert the bolt for the steering cylinder so that
groove 2 (Fig. 8) is in line with tapped bores (1).
i Note
15. Align the angle sensor (Fig. 9).
i Note
Observe the marks.
16. Teach the electric end stops for the steering an-
gle sensor.
i Note
Teaching the electric end stops of the steering
angle sensor, see electrics of machine.
Fig. 8
Fig. 9
Dismantling the oscillating articulated joint
BOMAG 661 008 911 79
16.4
16.4 Dismantling the oscillating articulated
joint
1. Unscrew the nut from the long hexagon screw
and pull out the hexagon screw downwards (Fig.
1).
2. Unscrew the screws for the upper cover.
3. Take off the upper cover with Belleville springs,
shim and backing disc.
4. Remove the bottom cover.
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.
6. Force inner race 1 (Fig. 5) of the rocker bearing
off the bolt.
7. Take of supporting disc (2).
8. Drive the console to the opposite side and re-
move the rocker bearing in the same way.
Fig. 1
Fig. 2
Fig. 3
16.4 Dismantling the oscillating articulated joint
BOMAG 662 008 911 79
9. Unscrew fastening screws 1 (Fig. 6).
10. Press bolt (3) out of the console with forcing
screws (2).
i Note
Remove the bolt on the opposite side in the same
way.
11. Lift console 1 (Fig. 7) off housing (2).
12. Take the seal rings out of the console (Fig. 8).
13. Remove the cover from the housing.
14. Take off shims 1 (Fig. 7), backing disc (2) and
Belleville springs (3).
Fig. 4
Fig. 5
Fig. 6
Fig. 7
BOMAG 663 008 911 79
16.4
15. Unscrew bolts 1 (Fig. 8) and take off cover (2).
16. Take the intermediate ring out of the housing
(Fig. 9).
17. Place the plate 1 (Fig. 10) on the beam.
18. Attach the puller (2) to the housing (3) and sepa-
rate the carrier from the rocker bearings.
19. Pull the housing off the beam (Fig. 11).
Fig. 8
Fig. 9
Fig. 10
Fig. 11
BOMAG 664 008 911 79
20. Drive the outer race of the friction bearing out of
the housing (Fig. 12).
21. Drive the friction bearing out of the housing (Fig.
13).
22. Take seal ring 1 (Fig. 14) and V-ring (2) off the
beam.
23. Check rocker bearings, if necessary press out of
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Assembling the oscillating articulated joint
BOMAG 665 008 911 79
16.5
16.5 Assembling the oscillating articulated
joint
1. If previously disassembled, press the rocker
bearing fully into the housing with a pressing
mandrel (Fig. 1).
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
! Caution
Do not use any grease.
2. Slide the new V-ring on the beam against the stop
with the lip facing up (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. 1
Fig. 2
Fig. 3
16.5 Assembling the oscillating articulated joint
BOMAG 666 008 911 79
5. Press the friction bearing fully into the housing
with the chamfered side pointing towards the out-
side (Fig. 5).
6. Slide the housing over the beam (Fig. 6).
i Note
The journal on the housing must be centrally in
the recess of the beam.
7. Press the seal ring carefully towards the inside,
until it sits in the recess of the housing (Fig. 7).
8. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.
! Caution
9. Press the outer rocker bearing race 1 (Fig. 8) in
until it bottoms with the wider outer rim forward
using pressing sleeve (2).
Fig. 4
Fig. 5
Fig. 6
Fig. 7
BOMAG 667 008 911 79
16.5
10. Press inner rocker bearing race 1 (Fig. 7) in until
it bottoms, using pressing sleeve (2).
11. Insert the intermediate ring (Fig. 8).
i Note
to ease assembly
! Caution
until it bottoms with the wider outer rim pointing
up, using pressing sleeve (2).
Fig. 8
Fig. 9
Fig. 10
Fig. 11
BOMAG 668 008 911 79
14. Press in intermediate ring 1 (Fig. 12) until it bot-
toms.
15. Attach cover (2) with the machined edge forward.
16. Turn in screws (3) and tighten crosswise.
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 M16-8.8 tight-
ening torque 90Nm.
18. Slide the rod of the tensioning device in from un-
derneath, attach the plate, screw on the nut and
tighten.
19. Measure the distance from housing edge to inter-
mediate ring (Fig. 13) and write it down, e.g. 4,7
mm.
i Note
From this measured value of 4.7mm subtract the
fixed value of (3.9 mm, BW177) (4.0 mm,
BW213) to determine the shim thickness.
Calculation example BW 177:
4,7 mm - 3,9 mm = 0,8 mm
Shim thickness = 0,8 mm
Calculation example BW 213:
4,7 mm - 4,0 mm = 0,7 mm
Shim thickness = 0.7 mm
20. Remove the tensioning device.
Fig. 12
Fig. 13
BOMAG 669 008 911 79
16.5
21. Insert shim 2 (Fig. 14) of appropriate thickness
and backing disc (1) into the cover.
22. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 15).
23. Assemble cover 2 (Fig. 16) with Belleville springs,
25. Press the new sealing rings into the respective
groove in the console (Fig. 17).
Fig. 14
Fig. 15
Fig. 16
Fig. 17
BOMAG 670 008 911 79
26. Lift console 1 (Fig. 18) over the housing (2).
Remove the bolts from both sides.
27. Turn four guide pins into the housing bores (Fig.
19).
28. Slide the bolt over the guide pins and drive in until
it bottoms (Fig. 20).
i Note
Spray the mating surfaces with sliding lacquer
OKS 571 or cover with grease to ease assembly .
! 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. 18
Fig. 19
Fig. 20
Fig. 21
BOMAG 671 008 911 79
16.5
29. Unscrew the guide pins .
30. Turn in the screws and tighten with 75 Nm (Fig.
22).
i Note
Repeat steps 27 to 30 on the opposite side of the
joint.
31. Cover the rod with LOCTITE blue 243 and insert
it into the upper joint bolt (Fig. 23).
i Note
Assemble the rocker bearings on both sides.
32. Slide the backing discs over the bolt (Fig. 24).
33. Drive the inner rocker bearing race on against the
end stop with the wider outer rim forward (Fig.
25).
Fig. 22
Fig. 23
Fig. 24
Fig. 25
BOMAG 672 008 911 79
! Caution
35. Attach the outer rocker bearing race with the wid-
er outer rim facing towards the outside (Fig. 26)
and drive it in until it bottoms.
i Note
Repeat steps 32 to 35 on the opposite side of the
joint.
36. Attach the lower cover 1 (Fig. 27).
38. Determine the shim thickness, for this purpose in-
sert rod 1 (Fig. 28) 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 M16-8.8 tight-
ening torque 90Nm.
39. Measure the distance from outer rocker bearing
race to console surface (Fig. 29) and write it
down, e.g.
3.2mm.
i Note
From this measured value of 3,2mm subtract the
fixed value of 1,9mm to determine the shim thick-
ness.
Calculation example:
3,2mm - 1,9mm = 1,3mm
Shim thickness = 1,3mm
Fig. 26
Fig. 27
Fig. 28
Fig. 29
BOMAG 673 008 911 79
16.5
41. Insert shims 2 (Fig. 30) of appropriate thickness
and backing disc (1) into the upper cover.
42. Lay the Belleville springs into the upper cover
with the curvature pointing down (Fig. 31).
43. Assemble the upper cover with Belleville springs,
shims and backing disc (Fig. 32).
44. Turn in the cover fastening screws and tighten
crosswise.
45. Push in the long hexagon screw from under-
neath, assemble the washer, screw on the nut
and tighten
with 120 Nm.
Fig. 30
Fig. 31
Fig. 32
BOMAG 674 008 911 79
BOMAG 675 008 911 79
17 Articulated joint, hydraulic steering
17.1 Special tools
BOMAG 676 008 911 79
17.1 Special tools
1. Pressing mandrel for rocker bearings
2. Pressing sleeve for outer race of rocker bearing
3. Pressing sleeve for inner race of rocker bearing
4. Guide journal
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Special tools
BOMAG 677 008 911 79
17.1
5. Clamping device
6. Disassembly device
Fig. 5
Fig. 6
BOMAG 678 008 911 79
Fig. 1
1 Housing
2 Seal ring
3 Cover
4 Self-aligning bearing
5 Bolt
6 Shim/supporting disc
7 Belleville springs
9 Console
10 Belleville springs
11 Shim/supporting disc
12 Cover
13 Cover
14 Intermediate ring
16 Intermediate ring
18 Beam
19 Friction bearing
20 V-ring
21 Seal ring
BOMAG 679 008 911 79
17.2
Fig. 2
BOMAG 680 008 911 79
Fig. 3
Removing and installing the oscillating articulated joint
BOMAG 681 008 911 79
17.3
17.3 Removing and installing the oscillat-
ing articulated joint
1. Jack up the frame (Fig. 1) at the back and secure
it with trestles or wooden blocks.
2. Support the rear frame near the oscillating articu-
lated joint (Fig. 2) on both sides safely with tres-
tles or wooden blocks.
3. Fasten the lifting tackle to the front frame near the
oscillating articulated joint (Fig. 3).
Fig. 1
Fig. 2
Fig. 3
BOMAG 682 008 911 79
axle holder (2).
5. Knock out bearing bolt (3).
6. Retract steering cylinder (4).
! Danger
Danger of accident!
7. Support the oscillating articulated joint in the mid-
dle with a suitable jack or a similar device.
with disc (2).
9. Unscrew nuts 3 (Fig. 6) and take off the clamping
washers (2).
10. Pull out the fastening screws (1).
11. Slightly raise the front frame and lower the oscil-
lating articulated joint to the ground.
12. Pull out the oscillating articulated joint.
Note on assembly
13. Insert the bolt for the steering cylinder so that
groove (2) is in line with tapped bores (1).
Fig. 4
Fig. 5
Fig. 6
Fig. 7
BOMAG 683 008 911 79
17.4
17.4 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.
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.
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. 1
Fig. 2
Fig. 3
BOMAG 684 008 911 79
6. Force inner race 1 (Fig. 4) of the rocker bearing
off the bolt.
7. Take of supporting disc (2).
8. Drive the console to the opposite side and re-
move the rocker bearing in the same way.
9. Unscrew fastening screws 1 (Fig. 5).
10. Press bolt (3) out of the console with forcing
screws (2).
i Note
Remove the bolt on the opposite side in the same
way.
11. Lift console 1 (Fig. 6) off housing (2).
12. Take the seal rings out of the console (Fig. 7).
Fig. 4
Fig. 5
Fig. 6
Fig. 7
BOMAG 685 008 911 79
17.4
13. Remove the cover from the housing.
14. Take off shims 1 (Fig. 8), backing disc (2) and
Belleville springs (3).
15. Unscrew bolts 1 (Fig. 9) and take off cover (2).
16. Take the intermediate ring out of the housing
(Fig. 10).
17. Place the plate 1 (Fig. 11) on the beam.
18. Attach the puller (2) to the housing (3) and sepa-
rate the carrier from the rocker bearings.
Fig. 8
Fig. 9
Fig. 10
Fig. 11
BOMAG 686 008 911 79
19. Pull the housing off the beam (Fig. 12).
20. Drive the outer race of the friction bearing out of
21. Drive the friction bearing out of the housing (Fig.
14).
22. Take seal ring 1 (Fig. 15) and V-ring (2) off the
beam.
Fig. 12
Fig. 13
Fig. 14
Fig. 15
BOMAG 687 008 911 79
17.4
23. Check rocker bearings, if necessary press out of
Fig. 16
BOMAG 688 008 911 79
17.5 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
to ease assembly
! Caution
2. Slide the new V-ring on the beam against the stop
with the lip facing up (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. 1
Fig. 2
Fig. 3
BOMAG 689 008 911 79
17.5
5. Press the friction bearing fully into the housing
with the chamfered side pointing towards the out-
side (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.
7. Press the seal ring carefully towards the inside,
until it sits in the recess of the housing (Fig. 6).
! Caution
until it bottoms with the wider outer rim forward
using pressing sleeve (2).
Fig. 4
Fig. 5
Fig. 6
Fig. 7
BOMAG 690 008 911 79
11. Insert the intermediate ring (Fig. 9).
i Note
to ease assembly
! Caution
until it bottoms with the wider outer rim pointing
up, using pressing sleeve (2).
Fig. 8
Fig. 9
Fig. 10
Fig. 11
BOMAG 691 008 911 79
17.5
14. Press in intermediate ring 1 (Fig. 12) until it bot-
toms.
15. Attach cover (2) with the machined edge forward.
17. Determine the shim thickness, for this purpose
stand the cross-member on a wooden board with
an 18 mm bore.
! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
18. Slide the rod of the tensioning device in from un-
derneath, attach the plate, screw on the nut and
tighten.
19. Measure the distance from housing edge to inter-
mediate ring (Fig. 13) and write it down, e.g. 4,7
mm.
i Note
From this measured value of 4.7 mm subtract the
fixed value of 4.0 mm to determine the shim thick-
ness.
4,7 mm - 4,0 mm = 0,7 mm
measured value: 4,7 mm
fixed value: 4,0 mm
Shim thickness: 0,7 mm
Fig. 12
Fig. 13
BOMAG 692 008 911 79
21. Insert shim 2 (Fig. 14) of appropriate thickness
25. Press the new sealing rings into the respective
groove in the console (Fig. 17).
Fig. 14
Fig. 15
Fig. 16
Fig. 17
BOMAG 693 008 911 79
17.5
26. Lift console 1 (Fig. 18) over the housing (2).
27. Turn four guide pins into the housing bores (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.
! 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. 18
Fig. 19
Fig. 20
Fig. 21
BOMAG 694 008 911 79
29. Unscrew the guide pins .
30. Turn in the screws and tighten with 75 Nm (Fig.
22).
31. Slide the backing discs over the bolt (Fig. 23).
32. Drive the inner rocker bearing race on against the
end stop with the wider outer rim forward (Fig.
24).
! Caution
34. Attach the outer rocker bearing race with the wid-
er outer rim facing towards the outside (Fig. 25)
and drive it in until it bottoms.
Fig. 22
Fig. 23
Fig. 24
Fig. 25
BOMAG 695 008 911 79
17.5
35. Attach cover 1 (Fig. 26) to the bottom side of the
console.
36. Turn in and tighten screws (2).
37. Determine the shim thickness, for this purpose in-
sert rod 1 (Fig. 27) of the tensioning device from
underneath. Attach plate (2), screw on nut (3) and
tighten.
! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
38. Measure the distance from outer rocker bearing
race to console surface (Fig. 28) and write it
down, e.g. 3.4 mm.
i Note
From this measured value of 3.4 mm subtract the
fixed value of 2.2 mm to determine the shim thick-
ness.
3.4 mm - 2.2 mm = 1.2 mm
measured value: 3,4 mm
fixed value: 2,2 mm
Shim thickness: 1.2 mm
Fig. 26
Fig. 27
Fig. 28
BOMAG 696 008 911 79
40. Insert shims 2 (Fig. 29) of appropriate thickness
shims and supporting discs.
44. Insert hexagon screw 1 (Fig. 32) so that the screw
head rests on the upper side of the console.
Fig. 29
Fig. 30
Fig. 31
Fig. 32
BOMAG 697 008 911 79
17.5
45. Assemble the washer, turn on and tighten the nut
with 120 Nm (Fig. 33).
Fig. 33
BOMAG 698 008 911 79
BOMAG 699 008 911 79
18 Suppliers documentation
BOMAG 700 008 911 79
BOMAG 701 008 911 79
18.1 Travel pump / vibration pump series 90R
BOMAG 702 008 911 79
Travel pump / vibration pump series 90R
BOMAG 703 008 911 79
18.1
Axial Piston
Pumps and Motors
Service Manual
Series 90
BOMAG 704 008 911 79
2
Series 90 Introduction
Copyright 1987-1998, SAUER-SUNDSTRAND GmbH & Co.
All rights reserved. Contents subject to change.
Introduction
Use of this Manual
S90MVCTCD
S90PVMFCD
This manual includes information for the normal opera-
tion, maintenance, and servicing of the Series 90 family
of hydrostatic pumps and motors.
The manual also includes the description of the units and
their individual components, troubleshooting informa-
tion, adjustment instructions, and minor repair proce-
dures. Unit warranty obligations should not be affected if
maintenance, adjustment, and minor repairs are per-
formed according to the procedures described in this
manual.
Many service and adjustment activities can be performed
without removing the unit from the vehicle or machine.
However, adequate access to the unit must be available,
and the unit must be thoroughly cleaned before beginning
maintenance, adjustment, or repair activities.
Since dirt and contamination are the greatest enemies of
any type of hydraulic equipment, cleanliness require-
ments must be strictly adhered to. This is especially
important when changing the system filter and during
adjustment and repair activities.
For further information refer to Series 90 Technical
Information. For information about fluid requirements
refer to SAUER-SUNDSTRAND BLN 9887 or SDF (Id No.
697581).
A worldwide network of SAUER-SUNDSTRAND Autho-
rized Service Centers is available should repairs be
needed. Contact any SAUER-SUNDSTRAND Autho-
rized Service Center for details. A list of all Service
Centers can be found in bulletin BLN-2-400527, or in
brochure SAW (Ident. No. 698266).
Fluid under High Pressure
Safety Precautions
Observe the following safety precautions when using and servicing hydrostatic products.
Flammable Cleaning Solvents Disable Work Function
Loss of Hydrostatic Braking Ability
WARNING
The loss of hydrostatic drive line power in any
mode of operation (e.g., forward, reverse, or "neu-
tral" mode) may cause the loss of hydrostatic
braking capacity. A braking system, redundant to
the hydrostatic transmission must, therefore, be
provided which is adequate to stop and hold the
system should the condition develop.
S000 001E
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 treat-
ment is not administered immediately.
S000 003E
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.
S000 004E
WARNING
Certain service procedures may require the ve-
hicle/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.
S000 005E
BOMAG 705 008 911 79
18.1
3
Series 90 Contents
Contents
Introduction......................................................................................................................................................................... 2
Use of this Manual ........................................................................................................................................................................................ 2
Safety Precautions ........................................................................................................................................................................................ 2
Functional Description....................................................................................................................................................... 5
General Description and Cross Sectional Views ......................................................................................................................................... 5
Variable Displacement Pumps................................................................................................................................................................ 5
Fixed Displacement Motor ..................................................................................................................................................................... 5
Variable Displacement Motor .................................................................................................................................................................. 6
The System Circuit ....................................................................................................................................................................................... 7
The Basic Closed Circuit ........................................................................................................................................................................ 7
Case Drain and Heat Exchanger ........................................................................................................................................................... 7
Common Features of Pumps and Motors.................................................................................................................................................... 8
End Caps and Shafts ............................................................................................................................................................................. 8
Speed Sensors ....................................................................................................................................................................................... 8
Pump Features ............................................................................................................................................................................................. 9
Charge Pump .......................................................................................................................................................................................... 9
Charge Relief Valve................................................................................................................................................................................. 9
Multi-Function Valves .............................................................................................................................................................................. 9
Pressure Limiter and High Pressure Relief Valves ....................................................................................................................... 10
System Check Valves .................................................................................................................................................................... 10
Bypass Valves ................................................................................................................................................................................ 10
Displacement Limiters .......................................................................................................................................................................... 11
Auxiliary Mounting Pads ....................................................................................................................................................................... 11
Filtration Options ................................................................................................................................................................................... 11
Pressure Override (POR) - 180 Frame Size Only ............................................................................................................................. 12
Pump Control Options .......................................................................................................................................................................... 13
Manual Displacement Control (MDC) ........................................................................................................................................... 13
Hydraulic Displacement Control (HDC) ........................................................................................................................................ 13
Electric Displacement Control (EDC) ............................................................................................................................................ 14
Automotive Control (FBA II B) ....................................................................................................................................................... 14
3-Position (FNR) Electric Control .................................................................................................................................................. 14
Motor Features ........................................................................................................................................................................................... 15
Motor Loop Flushing Valve and Charge Relief Valve ........................................................................................................................... 15
Variable Motor Displacement Limiters.................................................................................................................................................. 15
Variable Motor Controls ........................................................................................................................................................................ 16
Hydraulic 2-Position Control .......................................................................................................................................................... 16
Electric 2-Position Control .............................................................................................................................................................. 16
Technical Specifications .................................................................................................................................................. 17
General Specifications ................................................................................................................................................................................ 17
Circuit Diagrams ......................................................................................................................................................................................... 17
Hydraulic Parameters ................................................................................................................................................................................. 18
Size Specific Data ....................................................................................................................................................................................... 19
Pressure Measurement ................................................................................................................................................... 20
Required Tools ............................................................................................................................................................................................ 20
Port Locations and Pressure Gauge Installation ....................................................................................................................................... 20
Variable Pump ....................................................................................................................................................................................... 20
Fixed Motor ........................................................................................................................................................................................... 23
Variable Motor ....................................................................................................................................................................................... 24
Initial Start-Up Procedure ................................................................................................................................................ 25
Fluid and Filter Maintenance ........................................................................................................................................... 26
Troubleshooting ................................................................................................................................................................ 27
"NEUTRAL" Difficult or Impossible to Find................................................................................................................................................. 27
System Operating Hot ................................................................................................................................................................................ 27
Transmission Operates Normally in One Direction Only .......................................................................................................................... 28
System Will Not Operate in Either Direction .............................................................................................................................................. 28
Low Motor Output Torque ........................................................................................................................................................................... 29
Improper Motor Output Speed.................................................................................................................................................................... 29
Excessive Noise and/or Vibration .............................................................................................................................................................. 30
System Response is Sluggish.................................................................................................................................................................... 30
BOMAG 706 008 911 79
4
Series 90 Contents
Inspections and Adjustments ......................................................................................................................................... 31
Pump Adjustments ...................................................................................................................................................................................... 31
Charge Pressure Relief Valve Adjustment ........................................................................................................................................... 31
Multi-Function Valve Pressure Adjustment .......................................................................................................................................... 33
Engaging the Bypass Function ............................................................................................................................................................ 35
Pressure Override (POR) Valve Pressure Adjustment (Option for 180 Frame Size) ....................................................................... 36
Displacement Limiter Adjustment ......................................................................................................................................................... 37
Pump Control Adjustments ......................................................................................................................................................................... 38
Standard Manual Displacement Control (MDC) Adjustment .............................................................................................................. 38
Non-Linear Manual Displacement Control (MDC) .............................................................................................................................. 39
MDC Neutral Start Switch (NSS) Adjustments .................................................................................................................................... 40
Hydraulic Displacement Control (HDC) and Electric Displacement Control (EDC) Adjustment ....................................................... 46
Motor Adjustments ...................................................................................................................................................................................... 48
Charge Relief Valve Adjustment ........................................................................................................................................................... 48
Displacement Limiter Adjustment (MV) ................................................................................................................................................ 49
Displacement Control Adjustments ...................................................................................................................................................... 49
Speed Sensor Adjustment .......................................................................................................................................................................... 50
Minor Repair Instructions ................................................................................................................................................ 51
Pump and Motor Minor Repair .................................................................................................................................................................... 53
Pump / Fitting Torques .......................................................................................................................................................................... 53
Shaft Seal and Shaft Replacement ...................................................................................................................................................... 54
Pump Minor Repairs ................................................................................................................................................................................... 56
Multi-Function Valve Cartridges ........................................................................................................................................................... 56
Pressure Override Valve (Option for 180 Frame Size) ....................................................................................................................... 57
Charge Relief Valve............................................................................................................................................................................... 57
Charge Pump - Remove ...................................................................................................................................................................... 58
Installing the Charge Pump .................................................................................................................................................................. 60
Auxiliary Pad Installation ....................................................................................................................................................................... 62
Auxiliary Pad Conversion ..................................................................................................................................................................... 63
Filtration Options ................................................................................................................................................................................... 64
Pump controls ....................................................................................................................................................................................... 65
Cover Plate ..................................................................................................................................................................................... 65
Manual Displacement Control (MDC) ........................................................................................................................................... 66
Solenoid Override Valve for MDC .................................................................................................................................................. 67
Solenoid Override Valve for MDC with Pressure Released Brake .............................................................................................. 67
Hydraulic and Electric Displacement Controls ............................................................................................................................. 68
Pressure Control Pilot (PCP) for Electric Displacement Control .................................................................................................. 68
3-Position (FNR) Electric Control .................................................................................................................................................. 69
Displacement Control Components............................................................................................................................................... 69
Minor Repair - Motor ................................................................................................................................................................................... 71
Loop Flushing and Charge Relief Valves ............................................................................................................................................. 71
Variable Motor Displacement Limiters.................................................................................................................................................. 73
Variable Motor Controls............................................................................................................................................................................... 74
Electrohydraulic 2-Position Control (Types NA, NB, NC, and ND) ..................................................................................................... 74
Hydraulic 2-Position Control (Type PT) ............................................................................................................................................... 74
Control Plugs ........................................................................................................................................................................................ 74
Variable Motor Control Orifices ............................................................................................................................................................ 75
Speed Sensor .............................................................................................................................................................................................. 77
Exploded View Parts Drawings / Parts Lists .................................................................................................................. 78
Variable Pumps ........................................................................................................................................................................................... 78
Minor Repair Parts................................................................................................................................................................................ 78
Parts List ............................................................................................................................................................................................... 79
Variable Pump Controls ........................................................................................................................................................................ 80
Control Parts List .................................................................................................................................................................................. 81
Filter and Options ................................................................................................................................................................................. 82
Parts List Filter and Options ................................................................................................................................................................. 83
Name Plates ......................................................................................................................................................................................... 83
Fixed Motor ................................................................................................................................................................................................. 84
Parts List ............................................................................................................................................................................................... 85
Name Plates ......................................................................................................................................................................................... 85
Variable Motor .............................................................................................................................................................................................. 86
Parts List ............................................................................................................................................................................................... 87
Name Plate............................................................................................................................................................................................ 87
BOMAG 707 008 911 79
18.1
5
Series 90 Functional Description
Functional Description
This section describes the operation of pumps, motors, and their various serviceable features. It is a useful reference for
readers unfamiliar with the functioning of a specific system.
General Description and Cross Sectional Views
P001 413E
Series 90 Variable Displacement Pump (PV)
Series 90 Fixed Displacement Motor (MF)
90000347
F000 539
Series 90 PV Cross Section
Variable Displacement Pumps
The Variable Displacement Pump (PV) is designed to
convert an input torque into hydraulic power. The input
shaft turns the pump cylinder which contains a ring of
pistons. The pistons run against a tilted plate, called the
swashplate. This causes the pistons to compress the
hydraulic fluid which imparts the input energy into the
hydraulic fluid. The high pressure fluid is then ported out
to provide power to a remote function.
The swashplate angle can be varied by the control piston.
Altering the swashplate angle varies the displacement of
fluid in a given revolution of the input shaft.
Fixed Displacement Motor
The Fixed Displacement Motor (MF) is designed to
convert an input of hydraulic power into an output torque.
It operates in the reverse manner of the pump. The high
pressure hydraulic fluid enters through the input port. The
fluid pressure builds behind the pistons causing them to
move down the swashplate (the path of least resistance).
As the piston returns up the swashplate again, the fluid is
allowed to exit through the exit port. The spinning pistons
are housed in a cylinder which is connected to the output
shaft. The output torque can be applied to a mechanical
function.
Slider Block
Servo Piston
Servo Arm
Servo Valve
Cradle Bearing
Cradle Hold Down
Charge Pump
Cradle Leveler
Cradle
Cradle Guide
Feed Back
BOMAG 708 008 911 79
6
90000234E
90000348
Series 90 Variable Displacement Motor (MV)
Series 90 MV Cross Section
90000190E
Series 90 MF Cross Section
In the Fixed Displacement Motor the "swashplate" is
fixed, so any variation in motor speed and torque must be
made by the input mechanism, i.e. the pump.
Variable Displacement Motor
The Variable Displacement Motor (MV) operates in the
same manner as the fixed motor. However, its swashplate
is not fixed; it can be switched between minimum and
maximum angle to amplify torque or speed like the
Variable Displacement Pump.
Piston
Roller Bearing
Output Shaft
Valve Plate
Loop Flushing Valve
Cylinder Block
Fixed Swashplate
End Cap
"A"
"A"
Electric 2-Position Control (optional)
Piston
Roller Bearing
Valve Plate
Cradle Swashplate
Output Shaft
Cylinder Block
Minimum Angle
Control Piston
Partial Section "A-A"
Cradle Swashplate in Full
Displacement Position
Maximum Angle
Control Piston
Cradle Swashplate
End Cap
BOMAG 709 008 911 79
18.1
7
Basic Closed Circuit
90000803E
The Basic Closed Circuit
The main ports of the pump are connected by hydraulic
lines to the main ports of the motor. Fluid flows, in either
direction, from the pump to the motor then back to the
pump in this closed circuit. Either of the hydraulic lines
can be under high pressure. In pumping mode the
position of the pump swashplate determines which line is
high pressure as well as the direction of fluid flow.
Case Drain and Heat Exchanger
The pump and motor require case drain lines to remove
hot fluid from the system. The motor should be drained
from its topmost drain port to ensure the case remains full
of fluid. The motor case drain can then be connected to
the lower drain port on the pump housing and out the top
most port. A heat exchanger, with a bypass valve, is
required to cool the case drain fluid before it returns to the
reservoir.
Circuit Diagram for Series 90 PV and 90 MF
90000800E
The System Circuit
Control Handle Displacement Control Valve
Orificed
Check Valve
Heat Exchanger
Bypass Valve
Heat Exchanger
Reservoir
Vacuum Gauge
Multi-Function Valve
Servo Control
Cylinder
Pump Swashplate
Motor Swashplate
Input
Shaft
Output Shaft
to Pump
Case
Charge Pump
Servo Pres.
Relief Valve
Multi-Function
Valve
Charge Pressure
Relief Valve
Fixed Displacement
Motor
Servo Control
Cylinder
Variable
Displacement
Pump
Case drain fluid
System loop (high pressure)
System loop (low pressure)
Loop Flushing Valve
Purge Relief Valve
Control fluid
Suction line
Pump Fixed Motor
Input
PV
MF
Case Drain Line
Output
Flow (Bi-directional)
Reservoir
BOMAG 710 008 911 79
8
Common Features of Pumps and Motors
End Caps and Shafts
Series 90 pumps and motors can be supplied with a
variety of end caps and shafts to allow for almost any
configuration. For pumps, end caps are available with
system ports on either side ("side ports") or both ports on
one side ("twin ports"). Motors have end caps with ports
on the face of the end cap ("axial ports") or both ports on
one side ("twin ports"). See the Series 90 Technical
Information manuals (BLN-10029 and BLN-10030) or the
Series 90 Price Book (BLN-2-40588) for information on
available options.
Removing the end cap will void the warranty on a
Series 90 pump or motor.
Speed Sensor
90000810
Speed Sensors
An optional speed sensor can be installed on Series 90
pumps and motors to provide unit speed information. The
sensor reads a magnetic ring wrapped about the unit's
cylinder. See the corresponding Section to locate, install
and adjust the sensor.
BOMAG 711 008 911 79
18.1
9
Charge Pump
The charge pump is necessary to supply cool fluid to the
system, to maintain positive pressure in the main system
loop, to provide pressure to operate the control system,
and to make up for internal leakage. Charge pressure
must be at its specified pressure under all conditions of
driving and braking to prevent damage to the transmis-
sion.
The charge pump is a fixed-displacement, gerotor type
pump installed in the variable displacement pump and
driven off the main pump shaft. Charge pressure is limited
by a relief valve.
The standard charge pump will be satisfactory for most
applications. However, if the charge pump sizes available
for the given main pump size are not adequate, a gear
pump may be mounted to the auxiliary mounting pad and
supply the required additional charge flow.
Charge Relief Valve
The charge relief valve on the pump serves to maintain
charge pressure at a designated level. A direct-acting
poppet valve relieves charge pressure whenever it sur-
passes a certain level. This level is nominally set refer-
encing case pressure at 1500 rpm. This nominal setting
assumes the pump is in neutral (zero flow); in forward or
reverse charge pressure will be lower. The charge relief
valve setting is specified on the model code of the pump.
Multi-Function Valves
The multi-function valve incorporates
the system check valve,
the pressure limiter valve,
the high pressure relief valve and
the bypass valve
in a replaceable cartridge.
These functions are described separately. There are two
multi-function valve cartridges in each Series 90 pump to
handle functions in either direction. See corresponding
Sections for adjustments and repairs.
NOTE: Some multi-function valves do not include a
pressure limiter valve.
PV with Charge Pump
90000243
Pump Charge System
90000804E
Pump Features
90000243
Case
Drain
Line
Charge Relief Valve
Charge
Pump
System
Check
Valves
Input
Inlet Filter
Tank
PV PF
BOMAG 712 008 911 79
10
Circuit Diagram showing Pressure
Control Mechanism
90000801E
Cross Section of Multi-Function Valve
90000806E
Pressure Limiter and High Pressure Relief Valves
Series 90 pumps are designed with a sequenced pres-
sure limiting system and high pressure relief valves.
When the preset pressure is reached, the pressure limiter
system acts to rapidly destroke the pump so as to limit the
system pressure. For unusually rapid load application,
the high pressure relief valve acts to immediately limit
system pressure by cross-porting system flow to the low
pressure side of the loop. The pressure limiter valve acts
as the pilot for the high pressure relief valve spool. The
high pressure relief valve is sequenced to operate at
approximately 35 bar (500 psi) above the level that ini-
tiates the pressure limiter valve.
Both the pressure limiter sensing valves and relief valves
are built into the multi-function valves (see above).
NOTE: For some applications, such as dual path ve-
hicles, the pressure limiter function may be de-
feated so that only the high pressure relief valve
function remains.
System Check Valves
The system check valves allow pressurized flow from the
charge pump to enter the low pressure side of the loop
whenever system pressure dips below a certain level.
This is needed as the pump will generally lose system
pressure due to leakage and other factors. Since the
pump can operate in either direction, two system check
valves are used to direct the charge supply into the low
pressure lines. The system check valves are poppet
valves located in the multi-function valve assembly.
Bypass Valves
The bypass valves ("tow") can be operated when it is
desired to move the vehicle or mechanical function when
the pump is not running. The valve is opened by manually
resetting the valve position.
The bypass valves are built into the multi-function valves.
Servo Pres.
Relief Valve
Charge Pressure
Relief Valve
To Control
Servo Piston
Servo Piston
Port "A"
Port "B"
Bypass
Adjustment
High Pressure
Relief / check
Valve Poppet
Pressure Limiter
Valve Poppet
Bypass
Actuator
Pressure Limiter
Adjustment Screw
Pressure Limiter
Lock Nut
Pressure Limiter Housing
Check Valve
Poppet
Bypass
BOMAG 713 008 911 79
18.1
11
Displacement Limiters
All Series 90 pumps are designed for optional mechanical
displacement (stroke) limiters. The maximum displace-
ment of the pump can be limited in either direction.
The setting can be set as low as 0 in either direction.
For instructions on adjustment see corresponding Sec-
tion.
Auxiliary Mounting Pads
Auxiliary mounting pads are available on all Series 90
pumps. SAE A through E mounts are available (availabil-
ity varies by pump size). This pad is used for mounting
auxiliary hydraulic pumps and for mounting additional
Series 90 pumps to make tandem pumps. The pads allow
for full through-torque capability.
Filtration Options
All Series 90 pumps are available with provisions for
either suction or charge pressure filtration (integral or
remote mounted) to filter the fluid entering the charge
circuit.
Suction Filtration
The suction filter is placed in the circuit between the
reservoir and the inlet to the charge pump. When suction
filtration is used, a reducer fitting is placed in the charge
pressure gauge port (M3). Filtration devices of this type
are provided by the user.
Charge Pressure Filtration
The pressure filter may be integrally mounted directly on
the pump or a filter may be remotely mounted for ease of
servicing.
A 125 m screen, located in the reservoir or the charge
inlet line, is recommended when using this filtration
option.
90000244
PV with Displacement Limiters
90000243
PV with Suction Filtration
(No filtration device attached)
90000246
PV with Integral Charge
Pump
90000247
PV with Auxillary Mounting Pad
90000242
PV with Remote Charge
Pump
BOMAG 714 008 911 79
12
Pressure Override (POR) - 180 Frame Size Only
The pressure override valve (POR) modulates the control
pressure to the displacement control to maintain a pump
displacement which will produce a system pressure level
less than or equal to the POR setting. For unusually rapid
load application, the high pressure relief valve function of
the multifunction valves is available to also limit the
pressure level.
The pressure override consists of a three-way normally
open valve which operates in series with the pump
displacement control. Control supply pressure is nor-
mally ported through the pressure override valve to the
displacement control valve for controlling the pump's
displacement. If the system demands a pressure above
the override setting, the POR valve will override the
control by reducing the control pressure supplied to the
displacement control. As the control pressure reduces,
the internal forces tending to rotate the swashplate
overcome the force of the servo pistons and allow the
pump's displacement to decrease.
POR-Valve (180 Frame Size only)
90000802E
Shuttle
Valve
Bypass
Adjustment
Charge Pressure
Relief Valve
Pressure
Override Control Valve
To Control
Port "A"
Port "B"
BOMAG 715 008 911 79
18.1
13
PV with Manual Displacement Control and
Neutral Start Switch
PV with Hydraulic Displacement Control
PV with Manual Displacement Control
90000237
90000239
90000240
Pump Control Options
Non-Linear MDC
The non-linear manual displacement control operates in
the same manner as the regular MDC except that it is
designed so the change in the angular position of the
pump swashplate progressively increases as the control
input shaft is rotated toward its maximum displacement
position.
Solenoid Override Valve for MDC
A solenoid override valve option (not shown here) is
available for MDC. This safety feature will return the
swashplate to zero displacement position when acti-
vated. The valve may be set in either a normally open or
normally closed mode.
Neutral Start Switch (NSS)
The neutral start switch is an optional feature available
with MDC. When connected properly with the vehicles
electrical system, the neutral start switch ensures that the
prime mover can be started only when the control is in a
neutral position.
Hydraulic Displacement Control (HDC)
The hydraulic displacement control uses a hydraulic input
signal to operate a spring-centered four-way servo valve.
This valve ports hydraulic pressure to either side of a
dual-acting servo piston. The servo piston rotates the
cradle swashplate through an angular rotation of 17,
thus varying the pumps displacement from full displace-
ment in one direction to full displacement in the opposite
direction. The HDC is designed so the angular position of
the pump swashplate is proportional to input pressure.
Manual Displacement Control (MDC)
The manual displacement control converts a mechanical input signal to a hydraulic signal using a spring- centered four-
way servo valve. This valve ports hydraulic pressure to either side of a dual-acting servo piston. The servo piston rotates
the cradle swashplate through an angular rotation of 17, thus varying the pumps displacement from full displacement
in one direction to full displacement in the opposite direction.
The MDC is designed so the angular position of the pump swashplate is proportional to the rotation of the control input
shaft.
BOMAG 716 008 911 79
14
PV with 3-Position (FNR) Electric Control
90000354
PV with Electric Displacement Control
Electric Displacement Control (EDC)
The electric displacement control is similar to the hydrau-
lic displacement control with the input signal pressure
controlled by a pressure control pilot (PCP) valve. The
PCP valve converts a DC electrical input signal to a
hydraulic signal which operates a spring- centered four-
way servo valve. This valve ports hydraulic pressure to
either side of a dual-acting servo piston. The servo piston
rotates the cradle swashplate through an angular rotation
of 17, thus varying the pumps displacement from full
displacement in one direction to full displacement in the
opposite direction. The control is designed so the angular
position of the swashplate is proportional to the EDC
input.
Automotive Control (FBA II B)
Automotive Control allows a vehicle to be driven in a
manner similar to an automobile with an automatic trans-
mission.
The Automotive Control includes a three-position electric
control to provide direction control.
3-Position (FNR) Electric Control
This control utilizes a 12 or 24 VDC electrically operated
spool valve to port pressure to either side of the pump
displacement control piston. Energizing one of the sole-
noids will cause the pump to go to its maximum displace-
ment in the corresponding direction.
All functions of the three-position (FNR) electric control
are preset at the factory.
90000241
BOMAG 717 008 911 79
18.1
15
Motor Features
Motor Loop Flushing Valve and Charge Relief
Valve
All Series 90 motors are designed to accommodate a loop
flushing valve. The loop flushing valve is used in instal-
lations which require additional fluid to be removed from
the main hydraulic circuit because of transmission cool-
ing requirements, or unusual circuits requiring additional
loop flushing to remove excessive contamination in the
high pressure circuit.
A shuttle valve and charge relief valve are installed in the
motor end cap to provide the loop flushing function. The
shuttle valve provides a circuit between the low pressure
side of the closed loop and the charge relief valve in the
motor end cap.
The motor charge relief valve regulates the charge pres-
sure level only when there is a pressure differential in the
main loop. The shuttle valve is spring centered to the
closed position so that no high pressure fluid is lost from
the circuit when reversing pressures.
For charge relief valve adjustment see corresponding
Section.
Variable Motor Displacement Limiters
All Series 90 variable motors include mechanical dis-
placement (stroke) limiters. Both the maximum and mini-
mum displacement of the motor can be limited.
The range of the settings is as follows:
V M 5 5 0 V M 5 7 0
m u m i n i M
t n e m e c a l p s i D
m c 0 4 - 9 1
3
n i 4 . 2 - 2 . 1
3
m c 4 5 - 6 2
3
n i 3 . 3 - 6 . 1
3
m u m i x a M
% 0 0 1 - 5 6 % 0 0 1 - 5 6
E 1 5 2 2 0 0 T
Loop Flushing Valve (MF)
90000248
90000238E
Motor Charge Relief Valve and Loop Flushing
Shuttle Valve
MV Maximum Displacement Limiter
(Minimum Displacement Limiters on opposite side)
90000352
Charge Relief Valve
Loop Flushing Shuttle Valve
End Cap
Top of Motor
BOMAG 718 008 911 79
16
MV with Electric 2-Position Control
Hydraulic 2-Position Control
This control utilizes a hydraulically operated three-way
hydraulic valve to port system pressure to either of the
motor displacement control pistons. The motor is nor-
mally held at its maximum displacement. Supplying pilot
hydraulic pressure to the valve will cause the motor to go
to its minimum displacement.
Electric 2-Position Control
This control utilizes an electric solenoid operated three-
way hydraulic valve to port system pressure to either of
the motor displacement control pistons. The motor is
normally held at its maximum displacement. Energizing
the solenoid will cause the motor to go to its minimum
displacement.
Variable Motor Controls
MV with Hydraulic 2-Position Control
90000351
90000350
BOMAG 719 008 911 79
18.1
17
Series 90 Technical Specifications
PV with Charge Pump and Manual
Displacement Control
MF
MV with Electrohydraulic 2-Position
Control
M2
B
L1
M1 A
L2
M3
M1
M2
A
B
M4
M5
L2 S L1
M3
X5
M3
Vg
max
M2 B
L1
M1 A
L2
Technical Specifications
General Specifications
Design
Variable Pumps and Motors: Axial piston pump of vari-
able displacement, cradle swashplate design.
Fixed Motors: Axial piston motor with fixed displacement,
fixed swashplate design.
Type of Mounting (per SAE J744)
SAE flange, Size "B", 2 bolts,
SAE flange, Size "C and E", 4 bolts.
Cartridge flange, 2 bolts (for motor only).
Port Connections
(for details see chapter "Pressure Measurement")
Main pressure ports: SAE flange, Code 62,
Remaining ports: SAE straight thread O-ring boss.
Direction of Rotation
Clockwise or counterclockwise (motors are bi-directional)
Recommended Installation Position
Pump installation recommended with control position on
the top or side. Consult SAUER-SUNDSTRAND for non-
conformance guidelines. The housing must always be
filled with hydraulic fluid.
Circuit Diagrams
90000811
90000812
90000813
BOMAG 720 008 911 79
18
Hydraulic Fluid
Refer to SAUER-SUNDSTRAND BLN 9887 or SDF (Id
No. 697581). Also refer to publication ATI-E 9101 for
information relating to biogradable fluids.
Hydraulic Parameters
Cleanliness
Refer to SAUER-SUNDSTRAND Publications BLN 9887
or SDF (NO. 697581) and ATI-E 9201.
Refer to Series 90 technical information for definitions.
e g n a R e r u s s e r P m e t s y S r a b i s p
e r u s s e r P d e t a R 0 2 4 0 0 0 6
e r u s s e r P m u m i x a M 0 8 4 0 6 9 6
E 2 5 2 2 0 0 T
e g n a R e r u t a r e p m e T
) 1
C ] F [
m u m i n i M 0 4 - ] 0 4 - [ t r a t s d l o c , t n e t t i m r e t n i
d e t a R 4 0 1 ] 0 2 2 [
m u m i x a M 5 1 1 ] 0 4 2 [ t n e t t i m r e t n i
E 6 0 0 2 0 0 T
) 1
e s a c e h t y l l a m r o n , t n i o p t s e t t o h e h t t A
. t r o p n i a r d
y t i s o c s i V
m m
2
s / ] S U S [
m u m i n i M 7 ] 9 4 [ t n e t t i m r e t n i
d e d n e m m o c e R
e g n a r g n i t a r e p o
0 6 - 2 1 ] 8 7 2 - 0 7 [
m u m i x a M 0 0 6 1 ] 0 0 5 7 [
, t n e t t i m r e t n i
t r a t s d l o c
E 0 1 0 2 0 0 T
m u u c a V t e l n I p m u P e g r a h C
) y l n o s p m u p n o (
s b a r a b g H n i
m u u c a V m u m i n i M
) s u o u n i t n o c (
7 . 0 0 1
g n i r u d m u u c a V m u m i n i M
t r a t S d l o C
) t n e t t i m r e t n I (
2 . 0 5 2
E 3 5 2 2 0 0 T
e r u s s e r P e s a C r a b i s p
) s u o u n i t n o C ( m u m i x a M 3 4 4
t r a t S d l o C g n i r u d m u m i x a M
) t n e t t i m r e t n I (
5 3 7
E 4 5 2 2 0 0 T
d n a l e v e L s s e n i l n a e l C
x
o i t a R -
s s e n i l n a e l c d i u l f d e r i u q e R
l e v e l
3 1 / 8 1 s s a l C 6 0 4 4 O S I
x
o i t a r -
n o i t a r t l i f n o i t c u s r o f

5 4 - 5 3
( 5 7 =
0 1
) 2
x
o i t a r -
e r u s s e r p e g r a h c r o f
n o i t a r t l i f
0 2 - 5 1
( 5 7 =
0 1
) 0 1
t e l n i d e d n e m m o c e R
e g r a h c r o f e z i s n e e r c s
n o i t a r t l i f e r u s s e r p
0 0 1 5 2 1 - m m
E 7 0 0 2 0 0 T
BOMAG 721 008 911 79
18.1
19
Fixed and Variable Displacement Motors
Variable Displacement Pumps
Size Specific Data
Refer to Series 90 technical information for definitions.
n o i s n e m i D V P 0 3 0 V P 2 4 0 V P 5 5 0 V P 5 7 0 V P 0 0 1 V P 0 3 1 V P 0 8 1 V P 0 5 2
) m u m i x a m (
m c
3
n i
3
0 3
3 8 . 1
2 4
6 5 . 2
5 5
5 3 . 3
5 7
7 5 . 4
0 0 1
0 1 . 6
0 3 1
3 9 . 7
0 8 1
8 9 . 0 1
0 5 2
5 2 . 5 1
d e e p S m u m i n i M n i m
1 -
) m p r ( 0 0 5 0 0 5 0 0 5 0 0 5 0 0 5 0 0 5 0 0 5 0 0 5
d e e p S d e t a R n i m
1 -
) m p r ( 0 0 2 4 0 0 2 4 0 0 9 3 0 0 6 3 0 0 3 3 0 0 1 3 0 0 6 2 0 0 3 2
d e e p S m u m i x a M n i m
1 -
) m p r ( 0 0 6 4 0 0 6 4 0 5 2 4 0 5 9 3 0 5 6 3 0 0 4 3 0 5 8 2 0 0 5 2
d e e p S e l b a n i a t t a m u m i x a M
t n e m e c a l p s i D . x a m t a
n i m
1 -
) m p r ( 0 0 0 5 0 0 0 5 0 0 7 4 0 0 3 4 0 0 0 4 0 0 7 3 0 5 1 3 0 5 7 2
t a e u q r o T l a c i t e r o e h T
t n e m e c a l p s i D . x a m
r a b / m N
i s p 0 0 0 1 / n i f b l
8 4 . 0
0 9 2
7 6 . 0
0 8 3
8 8 . 0
0 3 5
9 1 . 1
0 3 7
9 5 . 1
0 7 8
7 0 . 2
0 6 2 1
7 8 . 2
0 5 7 1
7 9 . 3
3 3 4 2
t h g i e W
) t i n u e s a b y l n o (
g k
b l
8 2
2 6
4 3
5 7
0 4
8 8
9 4
8 0 1
8 6
0 5 1
8 8
5 9 1
6 3 1
0 0 3
4 5 1
0 4 3
E 7 5 2 2 0 0 T
t i e h n i E F M 0 3 0 F M 2 4 0 F M 5 5 0 F M 5 7 0 F M 0 0 1 F M 0 3 1 V M 5 5 0 V M 5 7 0
) m u m i x a m ( t n e m e c a l p s i D
m c
3
n i
3
0 3
3 8 . 1
2 4
6 5 . 2
5 5
5 3 . 3
5 7
7 5 . 4
0 0 1
0 1 . 6
0 3 1
3 9 . 7
5 5
5 3 . 3
5 7
7 5 . 4
) m u m i n i m ( t n e m e c a l p s i D
m c
3
n i
3
- - - - - - - - - - - - 9 1 6 2
d e t a R
d e e p s
m u m i x a m t a
t n e m e c a l p s i d
n i m
1 -
) m p r ( 0 0 2 4 0 0 2 4 0 0 9 3 0 0 6 3 0 0 3 3 0 0 1 3 0 0 9 3 0 0 6 3
m u m i n i m t a
n i m
1 -
) m p r ( - - - - - - - - - - - - 0 0 6 4 0 5 2 4
m u m i x a M
d e e p s
m u m i x a m t a
n i m
1 -
) m p r ( 0 0 6 4 0 0 6 4 0 5 2 4 0 5 9 3 0 5 6 3 0 0 4 3 0 5 2 4 0 5 9 3
m u m i n i m t a
n i m
1 -
) m p r ( - - - - - - - - - - - - 0 0 1 5 0 0 7 4
t a d e e p s e l b a n i a t t a . x a M
t n e m e c a l p s i d . x a m
n i m
1 -
) m p r ( 0 0 0 5 0 0 0 5 0 0 7 4 0 0 3 4 0 0 0 4 0 0 7 3 0 0 7 4 0 0 3 4
. x a m t a e u q r o t l a c i t e r o e h T
r a b / m N
i s p 0 0 0 1 / n i f b l
8 4 . 0
0 9 2
7 6 . 0
0 8 3
8 8 . 0
0 3 5
9 1 . 1
0 3 7
9 5 . 1
0 7 9
7 0 . 2
0 6 2 1
8 8 . 0
0 3 5
9 1 . 1
0 3 7
. x a m r a w o l f m u m i x a M
n i m / l
n i m / l a g
8 3 1
5 . 6 3
3 9 1
1 5
4 3 2
2 6
6 9 2
8 7
5 6 3
6 9
2 4 4
7 1 1
4 3 2
2 6
6 9 2
8 7
r e w o p r e n r o c . x a M
W k
p h
1 1 1
9 4 1
5 5 1
8 0 2
7 8 1
1 5 2
7 3 2
8 1 3
2 9 2
2 9 3
4 5 3
5 7 4
4 2 2
0 0 3
2 8 2
8 7 3
t h g i e W
e g n a l F - E A S
g k
b l
1 1
4 2
5 1
4 3
2 2
9 4
6 2
7 5
4 3
4 7
5 4
9 9
9 3
6 8
4 4
8 9
t h g i e W
r o t o M e g d i r t r a C
g k
b l
- -
1 2
6 4
6 2
7 5
3 3
2 7
- - - -
0 4
8 8
6 4
1 0 1
E 8 5 2 2 0 0 T
BOMAG 722 008 911 79
20
Series 90 Pressure Measurement
Pressure Measurement
Required Tools
The service procedures described in this manual for
Series 90 pumps and motors can be performed using
common mechanic's tools. Special tools, if required are
shown.
Port Locations and Pressure Gauge Installation
Pressure gauges should be calibrated frequently to en-
sure accuracy. Snubbers are recommended to protect
pressure gauges.
The following sections list the ports for each type of
hydraulic unit. The recommended pressure gauge and
fitting are also specified.
Variable Pump
t r o P n o i t c n u F
e z i S e g u a G
d n a
g n i t t i F
1 M
e r u s s e r P m e t s y S
" A " t r o P
i s p 0 0 0 0 1 r o r a b 0 0 0 1
g n i r - O 8 1 - 6 1 / 9
2 M
" B " t r o P
i s p 0 0 0 0 1 r o r a b 0 0 0 1
g n i t t i f g n i r - O 8 1 - 6 1 / 9
3 M
) 6 M (
e r u s s e r P e g r a h C
i s p 0 0 0 1 r o r a b 0 5
g n i r - O 8 1 - 6 1 / 9
4 M
5 M
e r u s s e r P o v r e S
i s p 0 0 0 1 r o r a b 0 5
g n i r - O 8 1 - 6 1 / 9
E 9 5 2 2 0 0 T
Outline drawings showing port locations follow the tables
below.
e z i S e g u a G
d n a
g n i t t i F
1 L
2 L
e r u s s e r P e s a C
i s p 0 0 1 r o r a b 0 1
0 3 0
2 4 0
g n i r - O 4 1 - 8 / 7
5 5 0
5 7 0
0 0 1
g n i r - O 2 1 - 6 1 / 1 - 1
0 3 1 g n i r - O 2 1 - 6 1 / 5 - 1
0 8 1
0 5 2
g n i r - O 2 1 - 8 / 5 - 1
1 X
2 X
C D E / C D H
e r u s s e r P l o r t n o C
i s p 0 0 0 1 r o r a b 0 5
g n i r - O 0 2 - 6 1 / 7
r o
g n i r - O 8 1 - 6 1 / 9
3 X
l o r t n o C l a n r e t x E
e r u s s e r P
i s p 0 0 0 1 r o r a b 0 5
g n i r - O 8 1 - 6 1 / 9
S t e l n I p m u P e g r a h C
o t n i e e T , e g u a G m u u c a V
e n i L t e l n I
0 3 0
2 4 0
g n i r - O 2 1 - 6 1 / 1 - 1
5 5 0
5 7 0
g n i r - O 2 1 - 6 1 / 5 - 1
0 0 1
0 3 1
0 8 1
g n i r - O 2 1 - 8 / 5 - 1
0 5 2
t i l p S - E A S 2 / 1 - 1
e g n a l F
E 0 6 2 2 0 0 T
BOMAG 723 008 911 79
18.1
21
PV with Side Port End Cap and Manual Displacement Control
90000814E
90000815E
90000816E
Servo / Displacement
Cylinder Pressure
Gauge Port M5
Cylinder Pressure
Gauge Port M4
Case Drain
Port L1
Top View
System Pressure
Port B
System Pressure
Gauge Port M2
System Pressure
Gauge Port M1
System Pressure
Port A
Case Drain Port L2
Left Side View
System Pressure
Port B
Carge Pump
Inlet Port S
Charge Inlet Pressure
External Control Pressure
Supply Port X3
Charge Pressure
Gauge Port M3
Right Side View
Speed Sensor
BOMAG 724 008 911 79
22
PV with Side Port End Cap and Remote Pressure Filtration PV with Side Port End Cap and Integral Pressure Filtration
PV with Twin Port End Cap and Manual Displacement Control
90000817E
90000818E
90000819E
90000820E
System Pressure
Gauge Port M2
System Pressure
Gauge Port M1
Case Drain Port L2
Left Side View
System Pressure
Port B
Charge Pump Inlet
Port S
System Pressure
Port A
Cylinder Pressure
Gauge Port M5
Cylinder Pressure
Gauge Port M4
Case Drain
Port L1
Top View
Charge Pressure
Gauge Port M3
(after the filter)
Port E
(from filter)
Port D
(to filter)
Rear View
Charge Pressure
Gauge Port M3
(after the filter)
Charge Pressure
Gauge Port M6
(before the filter)
Rear View
BOMAG 725 008 911 79
18.1
23
Case Drain Port L1
Case Drain Port L2
System Pressure Port B
Left Side View
Left Side View
Rear View
Rear View
System Pressure Port A
System Pressure
Gauge Port M1
Case Drain Port L1
Case Drain Port L2
Speed Sensor
Speed Sensor
Charge Pressure
Gauge Port M3
System Pressure
Gauge Port M2
System Pressure
Gauge Port M1
Charge Pressure
Gauge Port M3
System Pressure
Gauge Port M2
Fixed Motor
MF with SAE Flange
90000821E
MF with Cartridge Flange
e z i S e g u a G
d n a
g n i t t i F
1 M
" A " t r o P
i s p 0 0 0 0 1 r o r a b 0 0 0 1
g n i r - O 8 1 - 6 1 / 9
2 M
" B " t r o P
i s p 0 0 0 0 1 r o r a b 0 0 0 1
g n i r - O 8 1 - 6 1 / 9
3 M
i s p 0 0 0 1 r o r a b 0 5
g n i r - O 8 1 - 6 1 / 9
E 1 6 2 2 0 0 T
e z i S e g u a G
d n a
g n i t t i F
1 L
2 L
) e r u s s e r P e s a C
i s p 0 0 5 r o r a b 0 1
0 3 0
2 4 0
5 5 0
g n i r - O 4 1 - 8 / 7
5 7 0
0 0 1
0 3 1
g n i r - O 2 1 - 6 1 / 1 - 1
E 2 6 2 2 0 0 T
BOMAG 726 008 911 79
24
Cylinder Pressure
Gauge Port M4
Min. Displacement
Cylinder Pressure
Gauge Port M5
Max. Displacement
(Newer Production)
Cylinder Pressure
Gauge Port M5
Max. Displacement
(Earlier Production -
Not available as gauge
port with servo orifices)
System Pressure
Gauge Port M2
Control Pressure
Port X1
(Hydraulic 2-Position Control)
System Pressure
Gauge Port M1
Case Drain Port L1
Case Drain Port L2
Left Side View
Right Side View
Speed Sensor
charge Pressure
Gauge Port M3
(Same position as in MF)
Variable Motor
MV with Cartridge Flange and Hydraulic 2-Position Control (SAE Flange Version Similar)
90000823E
e z i S e g u a G
d n a
g n i t t i F
4 M
r e d b n i l y C l o r t n o C
m u m i n i M " e r u s s e r P
" t n e m e c a l p s i D
i s p 0 0 0 0 1 r o r a b 0 0 0 1
g n i r - O 0 2 - 6 1 / 7
5 M
r e d b n i l y C l o r t n o C
m u m i x a M " e r u s s e r P
" t n e m e c a l p s i D
i s p 0 0 0 0 1 r o r a b 0 0 0 1
g n i r - O 0 2 - 6 1 / 7
1 L
2 L
e r u s s e r P e s a C
i s p 0 0 5 r o r a b 0 1
g n i r - O 2 1 - 6 1 / 1 - 1
E 4 6 2 2 0 0 T
e z i S e g u a G
d n a
g n i t t i F
1 M
e r u s s e r p m e t s y S
" A " t r o P
i s p 0 0 0 0 1 r o r a b 0 0 0 1
g n i r - O 8 1 - 6 1 / 9
2 M
e r u s s e r p m e t s y S
" B " t r o P
i s p 0 0 0 0 1 r o r a b 0 0 0 1
g n i r - O 8 1 - 6 1 / 9
3 M
i s p 0 0 0 1 r o r a b 0 5
g n i r - O 8 1 - 6 1 / 9
E 3 6 2 2 0 0 T
MV with SAE Flange (Cartridge Flange Version Similar)
BOMAG 727 008 911 79
18.1
25
Series 90 Initial Start-Up Procedure
Initial Start-Up Procedure
The following start-up procedure should always be fol-
lowed when starting-up a new Series 90 installation or
when restarting an installation in which either the pump or
motor had been removed.
connections for EDC) be disconnected at the pump
control until after initial start-up. This will ensure that the
pump remains in its neutral position.
Prior to installing the pump and/or motor, inspect the units
for damage incurred during shipping and handling. Make
certain all system components (reservoir, hoses, valves,
fittings, heat exchanger, etc.) are clean prior to filling with
fluid.
Fill the reservoir with recommended hydraulic fluid. This
fluid should be passed through a 10 micron (nominal, no
bypass) filter prior to entering the reservoir. The use of
contaminated fluid will cause damage to the components,
which may result in unexpected vehicle/machine move-
ment. See the publications BLN-9887 and SDF 697581
for further related information.
The inlet line leading from the reservoir to the pump must
be filled prior to start-up. Check inlet line for properly
tightened fittings and make sure it is free of restrictions
and air leaks.
Be certain to fill the pump and/or motor housing with
clean hydraulic fluid prior to start up.
Fill the housing by pouring filtered oil into the upper case
drain port.
Install a 50 bar (or 1000 psi) pressure gauge in the charge
pressure gauge port to monitor the charge pressure
during start-up.
It is recommended that the external control input signal
(linkage for MDC, hydraulic lines for HDC, or electrical
Jog or slowly rotate prime mover until charge pressure
starts to rise. Start the prime mover and run at the lowest
possible RPM until charge pressure has been estab-
lished. Excess air may be bled from the high pressure
lines through the high pressure system gauge port.
Once charge pressure has been established, increase
speed to normal operating RPM. Charge pressure should
be as indicated in the pump model code. If charge
pressure is inadequate, shut down and determine cause
for improper pressure. Refer to Troubleshooting.
WARNING
The following procedure may require the vehicle/
machine to be disabled (wheels raised off the ground,
work function disconnected, etc.) while performing
the procedure in order to prevent injury to the
technician and bystanders. Take necessary safety
precautions before moving the vehicle/machine.
S000 007E
WARNING
Do not start prime mover unless pump is in neutral
position (0 swashplate angle). Take precautions to
prevent machine movement in case pump is actuated
during initial start up.
S000 008E
Shut down the prime mover and connect the external
control input signal. Also reconnect the machine function
if disconnected earlier. Start the prime mover, checking
to be certain the pump remains in neutral. With the prime
mover at normal operating speed, slowly check for for-
ward and reverse machine operation.
Charge pressure may slightly decrease during forward or
reverse operation. Continue to cycle slowly between
forward and reverse for at least five minutes.
Shut down prime mover, remove gauges, and plug ports.
Check reservoir level and add filtered fluid if needed.
The transmission is now ready for operation.
WARNING
Take necessary precautions that the motor shaft
remains stationary during the adjustment
procedure.
S000 010E
BOMAG 728 008 911 79
26
Series 90 Fluid and Filter Maintenance
Fluid and Filter Maintenance
To ensure optimum service life of Series 90 products,
regular maintenance of the fluid and filter must be per-
formed. Contaminated fluid is the main cause of unit
failure. Care should be taken to maintain fluid cleanliness
while performing any service procedure.
Check the reservoir daily for proper fluid level, the pres-
ence of water (noted by a cloudy to milky appearance, or
free water in bottom of reservoir), and rancid fluid odor
(indicating excessive heat). If either of these conditions
occur, change the fluid and filter immediately.
It is recommended that the fluid and filter be changed
per the vehicle/machine manufacturers recommenda-
tions or at the following intervals:
First change
500 operating hours after start up
second and subsequent changes
every 2000 operating hours or once a year.
This recommendation applies for the most applications.
High temperatures and pressures will result in acceler-
ated fluid aging and an earlier fluid change may be
required. At lower fluid loads longer change intervalls are
possible. Therefore we suggest to check the fluid with the
manufacturer for suitability. This should be done at latest
half way between fluid changes.
It may be necessary to change the fluid more frequently
than the above intervals if the fluid becomes contami-
nated with foreign matter (dirt, water, grease, etc.) or if
the fluid has been subjected to temperature levels greater
than the recommended maximum. Never reuse fluid.
The filter should be changed whenever the fluid is changed
or whenever the filter indicator shows that it is necessary
to change the filter.
P000 797E
P000 798E
Suction Filtration Schematic
Charge Pressure Filtration Schematic
(Partial flow)
Charge pump
Filter
Hydraulic fluid reservoir
Adjustable
Charge pressure relief valve
To pump case
to low
pressure
side and
control
Mano-
Vacuummeter
To pump case
Charge pump
Hydraulic fluid reservoir
Filter
to low
pressure
side and
control
Screen
Adjustable
Charge pressure
relief valve
d n a l e v e L s s e n i l n a e l C
x
o i t a R -
s s e n i l n a e l c d i u l f d e r i u q e R
l e v e l
3 1 / 8 1 s s a l C 6 0 4 4 O S I
x
o i t a r -
n o i t a r t l i f n o i t c u s r o f

5 4 - 5 3
( 5 7 =
0 1
) 2
x
o i t a r -
e r u s s e r p e g r a h c r o f
n o i t a r t l i f
0 2 - 5 1
( 5 7 =
0 1
) 0 1
t e l n i d e d n e m m o c e R
e g r a h c r o f e z i s n e e r c s
n o i t a r t l i f e r u s s e r p
0 0 1 5 2 1 - m m
E 7 0 0 2 0 0 T
BOMAG 729 008 911 79
18.1
27
Series 90 Toubleshooting
Troubleshooting
This section provides general steps to follow if certain undesirable system conditions are observed. Follow the steps in
a section until the problem is solved. Some of the items will be system specific. For areas covered in this manual, a section
is referenced. Always observe the safety precautions listed in the section "Introduction" and related to your
specific equipment.
"NEUTRAL" Difficult or Impossible to Find
Check Description Action
1. Input to pump control.
2. Pump displacement control.
Input to control module is operating
improperly.
Control linkages are not secure, control
orifices are blocked, etc.
Check control input and repair or re-
place as necessary.
Adjust, repair, or replace control mod-
ule as necessary.
System Operating Hot
1. Oil level in reservoir.
2. Heat exchanger.
3. Charge pressure.
4. Charge pump inlet vacuum.
5. System relief pressure settings.
6. For internal leakage in motor.
7. System pressure.
Insufficient hydraulic fluid will not meet
cooling demands of system.
Heat exchanger not sufficiently cooling
the system.
Low charge pressure will overwork sys-
tem.
High inlet vacuum will overwork sys-
tem. A dirty filter will increase the inlet
vacuum. Inadequate line size will re-
strict flow.
If the system relief settings are too low,
the relief valves will be overworked.
Leakage will reduce low side system
pressure and overwork the system.
High system pressure will overheat
system.
Fill reservoir to proper level.
Check air flow and input air tempera-
ture for heat exchanger. Clean, repair
or replace heat exchanger.
Measure charge pressure. Inspect and
adjust or replace charge relief valve. Or
repair leaky charge pump.
Check charge inlet vacuum. If high,
inspect inlet filter and replace as neces-
sary. Check for adequate line size,
length or other restrictions.
Verify settings of pressure limiters and
high pressure relief valves and adjust
or replace multi-function valves as nec-
essary.
Monitor motor case flow without loop
flushing in the circuit (use defeat spool).
If flow is excessive, replace motor.
Measure system pressure. If pressure
is high reduce loads.
If the above actions do not remedy the problem
contact a SAUER-SUNDSTRAND Authorized Service Center.
BOMAG 730 008 911 79
28
Transmission Operates Normally in One Direction Only
3. Interchange system pressure limit-
ers, high pressure relief valves, and
system check valves.
4. Charge pressure.
improperly.
Interchanging the multi-function valves
will show if the problem is related to the
valve functions contained in the multi-
function valves.
If charge pressure decays in one direc-
tion the loop flushing valve may be
sticking in one direction.
place as necessary.
Repair or replace control module as
necessary.
Interchange multi-function valves. If the
problem changes direction, repair or
replace the valve on the side that does
not operate.
Measure charge pressure in forward
and reverse. If pressure decays in one
direction, inspect and repair the motor
loop flushing valve.
System Will Not Operate in Either Direction
4. Ensure bypass valve(s) are closed.
5. Charge pressure with pump in neu-
tral.
6. Charge pressure with pump in
stroke.
7. Pump charge relief valve.
8. Charge pump inlet filter.
9. Charge pump.
Insufficient hydraulic fluid to supply
system loop.
improperly.
If bypass valve(s) is open, the system
loop will be depressurized.
Low charge pressure insufficient to re-
charge system loop.
Low charge pressure with the pump in
stroke indicates a motor charge relief
valve or system pressure relief valve
may be improperly set.
A pump charge relief valve that is leaky
or set too low will depressurize the
system.
A clogged filter will undersupply system
loop.
A malfunctioning charge pump will pro-
vide insufficient charge flow.
place as necessary.
necessary.
Close bypass valves. Replace multi-
function valve if defective.
Measure charge pressure with the pump
in neutral. If pressure is low, go to step
6; otherwise continue with step 5.
Measure charge pressure with pump in
stroke. If pressure is low, adjust or
replace motor charge relief valve, oth-
erwise go to step 9.
Adjust or replace pump charge relief
valve as necessary.
Inspect filter and replace if necessary.
Repair or replace the charge pump. If
OK go to last step.
BOMAG 731 008 911 79
18.1
29
Low Motor Output Torque
1. System pressure at motor.
2. Variable motor stuck at minimum
displacement.
3. For internal leakage.
Low system pressure at the motor will
reduce torque.
Minimum motor displacement yields low
output torque.
Internal leakage will reduce system
pressure.
Measure system pressure at motor. If
pressure limiter setting is low, increase
setting.
Check control supply pressure or re-
pair displacement control. Check mo-
tor control orifices.
Check for leakage in O-rings, gaskets,
and other fittings. Repair unit as re-
quired, or replace leaky unit.
Improper Motor Output Speed
2. Pump output flow.
3. Variable motor displacement con-
trol.
4. For internal leakage.
Insufficient hydraulic fluid will reduce
motor speed.
Incorrect outflow will affect output
speed. Incorrect output flow indicates
the swashplate is out of position.
If variable motor displacement control
is not functioning correctly, variable
motor swashplate may be in wrong
position.
pressure.
Fill oil to proper level.
Measure pump output and check for
proper pump speed and see that the
pump is in full stroke.
See if variable motor displacement con-
trol is responding. If not, repair or re-
place control.
and other fittings. Repair unit as re-
quired, or replace leaky unit.
11. System pressure.
12. System multi-function valves.
Low system pressure will not provide
power necessary to move load.
Defective multi-function valves will
cause system pressure to be low.
necessary.
Measure system pressure. Continue
with next step.
Repair or replace multi-function valve(s).
BOMAG 732 008 911 79
30
System Response is Sluggish
2. Multi-function valves pressure set-
tings.
3. Pump inlet vacuum.
4. Prime mover speed.
5. Charge and control pressures.
6. System internal leakage.
Insufficient hydraulic fluid will reduce
output pressure.
Incorrect pressure settings will affect
system reaction time.
High pump inlet vacuum will reduce
system pressure.
Low engine speed will reduce system
performance.
Incorrect charge or control pressures
will affect system performance.
pressure.
Adjust or replace multi-function valves.
Measure charge inlet vacuum. If high
replace inlet filter.
Adjust engine speed.
Measure charge and control pressures
and correct if necessary.
and other fittings.
Excessive Noise and/or Vibration
1. Oil in reservoir.
2. Air in system.
3. Pump inlet vacuum.
4. Shaft couplings.
5. Shaft alignment.
Insufficient hydraulic fluid will lead to
cavitation.
Air bubbles will lead to cavitation.
High inlet vacuum will create noise. A
dirty filter will increase the inlet vacuum.
A loose shaft coupling will cause exces-
sive noise.
Unaligned shafts will create excessive
frictional noise.
Look for foam in reservoir. Check for
leaks on inlet side of system loop. After-
wards, let reservoir settle until bubbles
are gone. Run system at low speed to
move system fluid to reservoir. Repeat.
Inspect and replace filter as necessary.
Check for proper suction line size.
Replace loose shaft coupling in charge
pump or replace pump or motor.
Align shafts.
BOMAG 733 008 911 79
18.1
31
Series 90 Inspections and Adjustments
Inspections and Adjustments
This section offers instruction on how to perform inspections and adjustments on pump and motor components. Read
through the entire related section before beginning a service activity. Refer to the corresponding section for location of
gauge ports and suggested gauge size.
Pump Adjustments
Charge Pressure Gauge Port (Reducer fitting shown - if
filtration device attached)
90000243
90L055 EA 1 N
6 S 3 C6 C 03
HNN 35 35 24
Model Code on Unit Name Plate (24 bar)
Nominal
Charge Pressure
Charge Pressure Relief Valve Adjustment
The following procedure explains how to check and adjust
the charge pressure relief valve.
* This is the actual charge pressure port gauge reading minus
the case pressure port gauge reading.
Note: These pressures assume a pump speed of
1450 - 1500 rpm. At higher pump input speeds
(with higher charge flows) the charge pressure
will rise over the rated setting.
WARNING
S000 007E
1. To measure pump charge pressure, install a pres-
sure gauge in the pump charge pressure gauge port
(M3). Also install a gauge to measure case pressure
(tee into L1 or L2 or use servo gauge port). Operate
the system with the pump in neutral (zero displace-
ment) when measuring pump charge pressure.
2. The table shows the acceptable pump charge pres-
sure range for some nominal charge relief valve
settings (see sample model code at right). These
pressures assume 1500 pump rpm and a reservoir
temperature of 50C (120F ), and are referenced to
case pressure (see footnote on next page). Smaller
displacement charge pumps will produce charge
pressure readings in the lower portion of the range,
while larger displacement charge pumps will produce
readings in the higher portion of the range.
e d o C l e d o M * e r u s s e r P e g r a h C d e r u s a e M
0 2
r a b 7 . 1 2 s i b 1 . 8 1
) i s p 5 1 3 o t 2 6 2 (
4 2
r a b 9 . 6 2 s i b 0 . 2 2
) i s p 0 9 3 o t 9 1 3 (
8 2
r a b 7 . 0 3 s i b 8 . 5 2
) i s p 5 4 4 o t 4 7 3 (
E 6 6 2 2 0 0 T
e h t s u n i m g n i d a e r e g u a g t r o p e r u s s e r p e g r a h c l a u t c a e h t s i s i h T *
. g n i d a e r e g u a g t r o p e r u s s e r p e s a c
BOMAG 734 008 911 79
32
Shim Adjustable Charge
Pressure Relief Valve
(Pump)
Screw Adjustable Charge
(Pump)
90000262 90000264
3. Earlier production Series 90 pumps are equipped
with a shim adjustable charge pressure relief valve.
Shim kits are available from SAUER-SUNDSTRAND.
Adjustment of charge pressure is accomplished by
removing the plug [1 inch Hex] and changing the shim
thickness behind the spring. The plug for this type of
charge relief valve should be torqued to 68 Nm
(50 lbf ft).
Later production Series 90 pumps are equipped with
an external screw adjustable charge pressure relief
valve. Adjustment of the charge pressure is accom-
plished by loosening the lock nut -
e z i S e m a r F e z i S h c n e r W
0 0 1 - 0 3 0 h c n i 6 1 / 1 - 1
0 5 2 - 0 3 1 h c n i 8 / 5 - 1
E 7 6 2 2 0 0 T
and turning the adjustment plug with a large screw-
driver or a 1/2 inch hex wrench.
Clockwise rotation of the plug increases the setting,
and counterclockwise rotation decreases the setting
(at a rate of approximately 3.9 bar (50 psi) per turn).
The lock nut for this type of charge relief valve should
be torqued to 52 Nm (39 lbf ft).
4. Once the desired charge pressure setting is achieved,
remove the gauges.
BOMAG 735 008 911 79
18.1
33
Multi-Function Valve Pressure Adjustment
Adjustment of the pressure limiter setting and the high
pressure relief valve setting is accomplished simulta-
neously. The latter is automatically set approximately
35 bar (500 psi) above the former.
In order to adjust the pressure limiter setting, the motor
output shaft must be locked so it does not rotate. This
may be accomplished by locking the vehicles brakes or
rigidly fixing the work function so it cannot rotate.
1. Install two 1000 bar (or 10 000 psi) pressure gauges
in the high pressure gauge ports (M1 and M2). Install
a 50 bar (or 1000 psi) pressure gauge in the pump
charge pressure gauge port (M3).
2. Start the prime mover and operate at normal speed.
3. Loosen locking nut.
y l r a e
0 0 1 - 2 4 0
m m 0 1
r e w e n
0 0 1 - 0 3 0
m m 9 1
0 3 1 y l r a e m m 3 1
0 5 2 - 0 3 1 m m 4 2
E 8 6 2 2 0 0 T
4. Insert a internal hex wrench into the pressure adjust-
ing screw.
e z i S e m a r F e z i S h c n e r W x e H l a n r e t n I
y l r a e
0 0 1 - 2 4 0
m m 3
r e w e n
0 0 1 - 0 3 0
m m 5
0 3 1 y l r a e m m 4
0 5 2 - 0 3 1 m m 8
E 9 6 2 2 0 0 T
Note: A plastic dust plug is installed in the adjusting
screw on 030 and late 042 through 250 units.
90000258
Multi-Function Valves on PV
Loosen Pressure Adjusting Screw Lock Nut
90000259
WARNING
Take necessary precautions that the motor shaft
remains stationary during the adjustment procedure.
S000 010E
BOMAG 736 008 911 79
34
Rotate Pressure Adjusting Screw
90000260
Tighten Lock Nut
90000261
90L055 EA 1 N
6 S 3 C6 C 03
HNN 35 35 24
Pressure Limiter Setting
Ports A and B (differential
pressure in 10s of bars,
e.g. 35 = 350 bar)
5. The factory preset pressure limiter setting is shown
on the model code as at right. It is referenced to
charge pressure, so the pressure limiter setting is the
difference between the high and low pressure sides
of the system loop. Activate or move the control input
so that pressure increases in the high pressure side
of the closed circuit to the pressure limiter pressure
setting. The pressure limiter setting is reached when
the pressure stops increasing and remains steady at
a given pressure level (as shown on the gauges).
6. Return the pump to its neutral (zero flow) position
and adjust the pressure limiter setting by rotating the
pressure adjusting screw with the internal hex wrench.
Clockwise rotation of the pressure adjustment screw
will increase the pressure setting, and counterclock-
wise rotation will decrease the pressure setting. Each
complete rotation of the pressure adjusting screw
changes the pressure as shown in the following table.
e z i S e m a r F
e h t f o v e R r e p e g n a h C x o r p p A
w e r c S g n i t s u j d A
y l r a e
0 0 1 - 2 4 0
v e R r e p ) i s p 7 5 1 1 ( r a b 0 8
r e w e n
0 0 1 - 0 3 0
r a b 0 9 v e R r e p ) i s p 0 0 3 1 (
0 5 2 - 0 3 1 r a b 0 8 v e R r e p ) i s p 7 5 1 1 (
E 0 7 2 2 0 0 T
7. To verify the actual pressure setting, actuate or move
the control input so that the pump again develops
pressure in the high pressure circuit to the newly
adjusted pressure limiter pressure setting, and read
the high pressure gauge. Then allow the pump to
return to its neutral position. The pressure in the
high pressure circuit should return to the charge
pressure setting.
8. While holding the pressure adjusting screw station-
ary, tighten the pressure adjusting screw lock.
e z i S e m a r F e u q r o T
y l r a e
0 0 1 - 2 4 0
) n i f b l 6 2 ( m N 3
r e w e n
0 0 1 - 0 3 0
m N 0 2 ) t f f b l 5 1 (
0 5 2 - 0 3 1 0 3 ( m N 0 4 ) t f f b l
E 1 7 2 2 0 0 T
Do not overtorque.
9. Shut down the prime mover, remove the gauges and
install the gauge port plugs. Replace the plastic dust
plugs (if used).
The same procedure is used for setting the pressure limit
of the other multi-function valve, but the control input
signal must be activated or moved in the opposite direc-
tion so that high pressure develops in the opposite side
of the closed circuit.
BOMAG 737 008 911 79
18.1
35
Loosening and Rotating Bypass Hex on Multi-Function
Valve
90000266
Multi-Function Valve with Bypass Function Engaged
90000827E
Engaging the Bypass Function
The bypass function is performed by the multi-function
valve cartridges. The prime mover should be shut down
when opening or closing the bypass valves.
The bypass valves on both of the multi-function valves
must be opened to engaged the bypass function.
1. Using a
r e w e n
0 0 1 - 0 3 0
h c n i 6 1 / 1 - 1
0 5 2 - 0 3 1 h c n i 8 / 3 - 1
E 2 7 2 2 0 0 T
wrench on the middle sized hex of the multi-function
valve cartridge, and a
r e w e n
0 0 1 - 0 3 0
h c n i 4 / 1 - 1
0 5 2 - 0 3 1 h c n i 8 / 5 - 1
E 3 7 2 2 0 0 T
wrench on the large hex to prevent rotation of the
cartridge assembly, rotate the middle hex three
revolutions counterclockwise to open the bypass
valve. Do not rotate more than 3-1/2 revolutions,
as additional rotation will permit external leak-
age.
2. For units with an MDC-type control, prior to moving
the vehicle or otherwise causing the motor shaft to
turn, move the control handle of the manual displace-
ment control on the pump to the maximum full
forward position. Hold the handle in this position
during bypass valve operation.
Caution
"Tow" at extremely low speeds and for short
distances only.
S000 011E
3. To close the bypass valve, rotate the middle hex
clockwise until it is seated. Then torque the middle
hex.
r e w e n
0 0 1 - 0 3 0
) t f f b l 0 3 ( m N 1 4
0 5 2 - 0 3 1 ) t f f b l 5 7 ( m N 0 0 1
E 4 7 2 2 0 0 T
Bypass
Actuator
Opening Bypass Valve
allows flow to circuit
through Multi-Function Valves
BOMAG 738 008 911 79
36
Pressure Override Valve for 180 Frame Size
90000828E
Pressure Override (POR) Valve Pressure
Adjustment (Option for 180 Frame Size)
The Pressure Override Valve is explained in the corre-
sponding section.
1. Install two 1000 bar (or 10 000 psi) pressure gauges
in the high pressure gauge ports (M1 and M2). Install
a 50 bar (or 1000 psi) pressure gauge in the pump
charge pressure gauge port (M3).
2. Start the prime mover and operate at normal speed.
3. With the pump operating at approximately 20% dis-
placement, load the work function and note the
pressure as the POR valve operates (pump displace-
ment reduces to zero).
4. Adjustment of the pressure override setting is made
by loosening the lock nut with a 9/16 inch hex wrench
and turning the adjustment screw with a 3/16 inch
internal hex wrench. The POR setting should be at
least 50 bar (750 psi) below the high pressure relief
valve setting of the multi-function valves for proper
operation.
5. Following the adjustment, torque the lock nut to
43 Nm (32 lbf ft).
6. Shut down the prime mover and remove the gauges
and install the gauge port plugs.
Right Side View
Pressure Override Valve
Lock Nut
Adjusting Screw
BOMAG 739 008 911 79
18.1
37
Loosen Displacement Limiter Lock Nut
90000267
90000268
Rotate Adjusting Screw
Tighten Lock Nut
90000269
Displacement Limiter Adjustment
The maximum displacement can be limited in either
direction.
1. Loosen the seal lock nut retaining the displacement
limiter adjusting screw.
0 0 1 - 0 3 0 m m 3 1
0 3 1 m m 7 1
0 5 2 - 0 8 1 m m 9 1
E 5 7 2 2 0 0 T
2. Rotate the adjusting screw.
e z i S e m a r F e z i S h c n e r W x e H l a n r e t n I
0 0 1 - 0 3 0 m m 4
0 3 1 m m 5
0 5 2 - 0 8 1 m m 6
E 6 7 2 2 0 0 T
Rotating the adjusting screw clockwise will decrease
the maximum displacement of the pump while rotat-
ing the adjusting screw counterclockwise will in-
crease the maximum displacement.
3. After establishing the desired maximum displace-
ment setting, tighten the lock nut on the adjusting
screw as follows.
0 0 1 - 0 3 0 ) t f f b l 8 1 ( m N 4 2
0 3 1 m N 8 4 ) t f f b l 5 3 (
0 5 2 - 0 8 1 ) t f f b l 2 9 ( m N 5 2 1
E 8 7 2 2 0 0 T
4. One turn of the adjusting screw will change the
maximum displacement approximately as follows.
e z i S e m a r F
f o v e R r e p p s i D n i e g n a h C x o r p p A
0 3 0 m c 8 . 2
3
n i 7 1 . 0 ( v e R /
3
) v e R /
2 4 0 m c 5 . 3
3
n i 1 2 . 0 ( v e R /
3
) v e R /
5 5 0 m c 2 . 4
3
n i 6 2 . 0 ( v e R /
3
) v e R /
5 7 0 m c 1 . 5
3
n i 1 3 . 0 ( v e R /
3
) v e R /
0 0 1 m c 2 . 6
3
n i 8 3 . 0 ( v e R /
3
) v e R /
0 3 1 m c 8 . 8
3
n i 3 5 . 0 ( v e R /
3
) v e R /
0 8 1 m c 5 . 2 1
3
n i 6 7 . 0 ( v e R /
3
) v e R /
0 5 2 m c 3 . 7 1
3
n i 6 0 . 1 ( v e R /
3
) v e R /
E 7 7 2 2 0 0 T
Caution
Care should be taken in adjusting displacement
limiters to avoid undesirable flow or speed conditions.
The seal lock nut must be retorqued after every
adjustment to prevent an unexpected change in
operating conditions and to prevent external leakage
during unit operation.
S000 012E
BOMAG 740 008 911 79
38
Variable Displacement Pump with Standard Manual
90000237
Pump Control Adjustments
Standard Manual Displacement Control (MDC)
Adjustment
There are no adjustable elements in the manual dis-
placement control. The control spool is held in its neutral
position by centering springs and washers on each end of
the spool. Since there is no centering spring on the control
input shaft, the shaft will automatically assume the appro-
priate position when the control is installed on the pump.
BOMAG 741 008 911 79
18.1
39
90000357
Rotate Neutral Adjusting
Screw
90000358
Tighten Neutral Adjusting
Screw Lock Nut
Variable Displacement Pump with Non-Linear Manual
90000829
Non-Linear Manual Displacement Control
(MDC)
A centering spring, located on the control input shaft,
locates the control shaft in its neutral position. A bias
spring on the control spool maintains a force on the spool
and the control linkage to eliminate looseness (free-
play) in the linkage.
The neutral adjustment is the only adjustment that can
be made on the nonlinear manual displacement control.
All other functions are preset at the factory.
This adjustment must be made on a test stand or on the
vehicle/machine with the prime mover operating.
1. Install two 50 bar (or 1000 psi) gauges in each of the
displacement control cylinder gauge ports (M4 and
M5). Disconnect the external control linkage from the
control handle and make certain the control shaft is
in its neutral position. Start the prime mover and
operate at normal speed.
2. Loosen the lock nut on the neutral adjusting screw
with a 13 mm hex wrench.
3. Using a 4 mm internal hex wrench, rotate the neutral
adjusting screw clockwise until the pressure increases
on one of the pressure gauges. Note the angular
position of the wrench.
4. Rotate the adjusting screw counterclockwise until the
pressure increases by an equal amount on the other
gauge. Note the angular position of the wrench.
5. Rotate the adjusting screw clockwise half the dis-
tance between the locations noted above. The gauges
should read the same pressure (case pressure),
indicating that the control is in its neutral position.
6. Hold the adjusting screw stationary and tighten the
lock nut to 13.5 Nm (10 lbf ft). Do not overtorque
the nut.
7. Once the neutral position is set, stop the prime
mover, remove the gauges, and install the gauge
port plugs. Reconnect the external control linkage.
WARNING
S000 007E
BOMAG 742 008 911 79
40
Components of the Standard Manual Displacement Control
with Neutral Start Switch
90000830E
MDC Neutral Start Switch (NSS) Adjustments
The neutral start switch (NSS) provides a means to
prevent the system prime mover from starting while the
pump control handle and control input shaft are in a
position which would command the pump to go in-
stroke in either the forward or reverse direction.
When the control input shaft is in its neutral position, the
inner end of the switch pin moves into a slot on the
eccentric cam attached to the control shaft. This allows
the spring loaded NSS to close, completing the electrical
starting circuit for the prime mover.
When the control input shaft is NOT in its neutral
position, the eccentric cam moves the switch pin out of
the slot. This forces the NSS to open, breaking the
electrical starting circuit for the prime mover.
The neutral start switch is threaded into the special lock
nut for the eccentric plug.
Turning the NSS clockwise (CW) into the special nut will
move the NSS closer to the switch cam on the control
shaft, and will narrow the NSS deadband. Turning the
NSS counterclockwise (CCW) out of the special nut will
move the NSS farther from the switch cam on the control
shaft, and will widen the NSS deadband.
The switch pin is located in an eccentric plug which is
turned to move the center of the NSS deadband.
(continued)
View at Section A-A
Control Link Assembly
Control Spool Assembly
Orifice Check Valve Seat
Eccentric Plug
Switch Pin
Special Lock Nut
for Eccentric Plug
Switch Lock Nut
MDC with Neutral Start switch
A A
Control Shaft
Switch Cam
BOMAG 743 008 911 79
18.1
41
Neutral Start Switch Adjustment Requirements
90000831E
The NSS must be adjusted to meet the following three
requirements:
i. The distance the control handle can be turned with-
out opening the NSS is called the NSS Deadband.
The distance the control handle can be moved with-
out moving the control spool enough to port hydraulic
fluid to the pump displacement control cylinders is
called the Control Deadband. These deadbands
must be centered in relation to each other.
Since the position of the control deadband cannot be
adjusted, the position of the NSS deadband must be
adjusted to match it.
ii. The NSS deadband must be wide enough so the NSS
will not open within the loose area of control handle
movement caused by normal operating clearances in
the control linkage (control shaft free-play).
By setting the NSS to open outside this area, the
control spool springs or control shaft centering spring
can always act to return the handle to neutral and
re-close the NSS.
iii. The NSS deadband must be narrow enough so the
NSS will open before the unit builds 7 bar (100 psi)
differential system pressure in either direction.
(continued)
Control Shaft
("Free-Play")
Control Shaft
Total Control
Shaft Rotation
Control Deadband
("Neutral")
NSS Deadband
(Switch closed, "ON")
BOMAG 744 008 911 79
42
Checking Continuity of NSS (System Pressure Gauges
installed on far side)
NSS
Loosening the NSS Lock Nut
90000253
90000870
90000832E
NSS Deadband Adjustment (Conditions ii & iii)
The NSS deadband must be wide enough so the NSS will
not open within the control shaft free-play area, and it
must be narrow enough so the NSS will open before the
unit builds 7 bar (100 psi) differential system pressure in
either direction.
1. Install two 1000 bar (10 000 psi) pressure gauges in
the system pressure gauge ports M1 and M2.
2. Using two 1-1/8 inch wrenches, hold the neutral start
switch from turning and loosen the locknut.
3. Disconnect the external control linkage and make
certain the control shaft is in its neutral position.
4. Attach a continuity checker to the terminals of the
switch. With the control shaft in its neutral position,
turn the switch clockwise (CW) until electrical conti-
nuity is broken, then turn the switch counterclockwise
(CCW) until electrical continuity is obtained. Turn the
switch counterclockwise (CCW) an additional 1/4
turn (90) after continuity has been obtained.
5. Hold the switch in place and tighten the locknut to
27 Nm (20 lbf ft) torque.
6. With the continuity checker attached to the switch,
rotate the control handle (or the control shaft) in each
direction to assure continuity is broken when the
control is not in the neutral position.
7. If continuity is obtained in neutral and satisfactorily
interrupted in each direction, proceed to check the
switch with the prime mover running. The switch
must open before the unit builds 7 bar (100 psi)
differential system pressure in either direction.
If the switch opens after the unit builds system
pressure in either direction, loosen the switch lock
nut and turn the switch clockwise (CW) 1/12 turn
(30). Tighten the switch lock nut and recheck the
switch operation. Repeat this procedure if neces-
sary.
8. If continuity is not interrupted with an equal move-
ment of the control handle in each direction, turn off
prime mover, remove the pressure gauges, and
continue with the next section.
9. If neutral start switch operation is satisfactory, turn
off the prime mover, remove the pressure gauges,
and reconnect the external control linkage.
Switch Pin
1-1/8 in. hex wrench
Torque: 27 Nm (20 lbf ft)
Switch Cam
Switch Lock Nut
Control Shaft
BOMAG 745 008 911 79
18.1
43
NSS with Eccentric Plug
Eccentric Plug Adjustment Tool
NSS Removed Loosen Eccentric Lock Nut
90000257 90000256
90000833E
90000834E
Neutral Start Switch Eccentric Plug Adjustment (Con-
dition i)
The NSS deadband and the control deadband must be
centered in relation to each other.
Since the position of the control deadband cannot be
adjusted, the position of the NSS deadband must be
adjusted to match it. The switch pin is located in an
eccentric plug which is turned to move the center of the
NSS deadband.
The MDC should be installed on the pump and be in its
neutral position when adjusting the neutral start switch
eccentric plug.
The accompanying drawing provides dimensions for an
Eccentric Plug Adjustment Tool.
1. Hold the switch and eccentric plug from turning and
use two 1-1/8 inch wrenches to loosen the locknut.
Remove the neutral start switch.
2. Note the slots on the eccentric plug for the adjust-
ment tool. Hold the eccentric plug in place with the
adjustment tool, and loosen the lock nut with a
1-1/8 inch wrench.
(continued)
WARNING
Do not start the prime mover while the neutral start
switch is removed from the control. Case pressure
will force the pin out of the eccentric plug, causing
oil loss.
S000 032E
Switch
Lock Nut
Eccentric Plug
Switch Pin
Special Lock Nut
for Eccentric Plug
Eccentric Plug
Switch Pin
Special Lock Nut
for Eccentric Plug
Control
Mounting
Surface
View in Direction X
(Switch and lock nut removed)
MDC with Neutral Start Switch
X
12.7
(0.5)
9.14
(0.36)
3.175
(0.125)
1.52
(0.06)
25.4+
(1.0)
BOMAG 746 008 911 79
44
Eccentric Plug Adjustment
90000256
Adjust the Eccentric Plug
90000835E
3. Position the eccentric plug so the switch pin is offset
toward the control mounting surface. This will provide
the best contact between the pin and the cam on the
control shaft.
4. Hold the control shaft in its neutral position (in the
center of the control shaft free-play area). Locate
the switch pin in the slot of the switch cam by turning
the eccentric plug while checking the pin position
(depth) in the plug. When the pin engages the cam
slot, the pin will be at its maximum depth in the plug.
Hand tighten the plug lock nut to hold the eccentric
plug in position.
5. Turn the control shaft an equal amount in either
direction from neutral. The switch pin should move
out of the eccentric plug an equal distance when the
control shaft is turned. Turn the eccentric plug to
center the switch pin with the cam slot. Only a small
amount of adjustment in either direction should be
needed to center the pin.
6. While holding the eccentric plug in place, tighten the
eccentric plug lock nut to 27 Nm (20 lbf ft). Reinstall
and adjust the switch as outlined in the previous
section.
Note: The eccentric plug normally requires between
5-1/2 and 6-1/2 turns to install into the control
housing .
Eccentric Plug
Switch Pin
Eccentric Plug
Adjustment Range
90 90
Control Mounting
Surface
7. Once the switch is correctly adjusted, hold the switch
in place and tighten the locknut to 27 Nm (20 lbf ft)
torque.
(continued)
Caution
Do not turn the eccentric plug into or out of the
housing beyond specifications.
S000 014E
BOMAG 747 008 911 79
18.1
45
90000255
Checking Continuity of NSS
(Gauges installed in Servo Gauge Ports)
Checking Switch Continuity
Recheck switch continuity to determine whether addi-
tional adjustment of the eccentric plug is necessary.
WARNING
S000 007E
displacement control cylinder gauge ports (M4 and
M5). Attach a continuity checker to the terminals of
the neutral start switch.
2. Energize the starter circuit, and start the prime
mover.
3. While operating at normal speed and with the pump
in its neutral (zero flow) position, note the pressure
reading on the gauges. This reading should be noted
as the base pressure.
4. Slowly move the control handle in one direction while
observing the pressure gauges and the continuity
checker. Continuity must be broken before the pres-
sure on either gauge increases more than 1 bar
(12 psi) from the base pressure obtained at neutral.
5. Slowly move the control handle in the opposite
direction. Again, continuity must be broken before
the gauge pressure increases more than 1 bar (12 psi)
from base pressure.
6. Continuity must again be verified when the control is
returned to neutral.
7. If continuity is not broken at base pressure plus 0 to
1 bar (0 to 12 psi) in either direction, stop the prime
mover and readjust the eccentric plug as described
in the previous section. If the pressure difference is
equal in each direction but greater than 1 bar (12 psi),
loosen the switch locknut and turn the switch clock-
wise 1/12 turn (30) to increase the sensitivity. Re-
tighten the locknut and recheck pressure differences
and continuity.
8. After verifying proper control and switch operation,
stop the prime mover. Remove the continuity checker
and pressure gauges. Reinstall the servo pressure
port plugs and reconnect the electrical leads from the
machine starter circuit to the neutral start switch.
Install and adjust, if necessary, the external control
linkage.
BOMAG 748 008 911 79
46
PV with Hydraulic Displacement Control
90000240
PV with Electric Displacement Control
Install Gauges in Displacement Control Cylinder Gauge
Ports
90000249
90000241
Hydraulic Displacement Control (HDC) and
Electric Displacement Control (EDC) Adjust-
ment
The neutral adjustment is the only adjustment that can
be made on hydraulic and electric displacement controls.
All other functions are preset at the factory.
This adjustment must be made on a test stand or on the
vehicle/machine with the prime mover operating.
The neutral adjustment is performed by adjusting a
neutral adjusting shaft (earlier production EDCs) or a
neutral adjusting screw (HDCs and current production
EDCs).
WARNING
S000 007E
two displacement control cylinder gauge ports (M4
and M5). Disconnect the external control input (hy-
draulic or electronic) from the control. Start the prime
mover and operate at normal speed.
2. Loosen the lock nut with a 17 mm hex wrench for the
neutral adjusting shaft or with a 10 mm or 13 mm hex
wrench for the neutral adjusting screw.
BOMAG 749 008 911 79
18.1
47
Shaft
(Early production)
90000250 90000252
Shaft Lock Nut
(Early production)
Screw
(Later production)
Screw Lock Nut
(Later production)
90000251 90000318
Shaft
(Current production HDC)
Shaft Lock Nut
(Current production HDC)
90000355 90000356
3. Using a 5 mm internal hex wrench for the neutral
adjusting shaft or a 3 mm or 4 mm internal hex
wrench for the neutral adjusting screw, rotate clock-
wise until the pressure increases in one of the
pressure gauges. Note the angular position of the
wrench. Then rotate the neutral adjusting shaft or
screw counterclockwise until the pressure increases
by an equal amount on the other gauge. Again note
the angular position of the wrench.
4. Rotate the neutral shaft or adjusting screw clockwise
half the distance between the locations noted above.
The gauges should read the same pressure (case
pressure), indicating that the control is in its neutral
position.
5. Hold the neutral adjusting shaft or screw stationary.
Tighten the neutral shaft lock nut (early production
controls) to 22 Nm (195 lbf in.). Tighten the neutral
adjusting screw lock nut (later production controls) to
7 Nm (62 lbf in.) for the 6 mm screw or 13.5 Nm
(120 lbf in.) for the 8 mm screw. Do not overtorque
the nut.
6. Once the neutral position is set, stop the prime
mover, remove the gauges, and install the gauge
port plugs. Reconnect the external control input.
BOMAG 750 008 911 79
48
Motor Adjustments
(Motor)
(Motor)
Charge Pressure Gauge Port (MF)
90000248
90000263 90000343
Nominal charge
Pressure Setting
90M055 NC 0 N
8 N 0 C6 W 00
NNN 00 00 24
Charge Relief Valve Adjustment
1. To measure motor charge pressure, install a 50 bar
(or 1000 psi) pressure gauge in the motor charge
pressure gauge port (M3). Size 30 and 42 dont have
the M3 gauge port. Install pressure gauge in the
motor system pressure gauge port. For this kind of
measurement add 1 bar (14.5 psi) to the nominal
values shown in the table. Also install a gauge to
measure case pressure. Operate the system with the
pump in stroke (forward or reverse) when measuring
motor charge pressure.
2. The following table shows acceptable motor charge
pressures for some nominal charge relief valve set-
tings (see model code at right). These pressures
assume a reservoir temperature of 50C (120F).
They are referenced to case pressure and assume a
one pump/one motor system.
3. Earlier production Series 90 motors are equipped
with a shim adjustable charge relief valve. Shim kits
are available as service items. Adjustment of the
charge pressure is accomplished by removing the
plug (7/8 inch hex) and changing the shim thickness
behind the spring. The plug for this type charge relief
port should be torqued to 68 Nm (50 lbf ft).
Later production Series 90 motors are equipped with
an external screw adjustable charge relief valve.
Adjustment of charge pressure is accomplished by
loosening the lock nut,
0 3 1 - 0 3 0 h c n i 6 1 / 1 - 1
E 3 9 2 2 0 0 T
and turning the adjustment plug with a large screw-
driver or a 1/2 inch hex wrench. Clockwise rotation of
the plug increases the setting, and counterclockwise
rotation decreases the setting (at a rate of approxi-
mately 5.4 bar [78 psi] per turn). The lock nut for this
type charge relief valve should be torqued to 52 Nm
(38 lbf ft).
4. Once the desired charge pressure setting is achieved,
remove the gauges.
Model Code at the Name Plate (24 bar)
e d o C l e d o M
e r u s s e r P e g r a h C r o t o M
) ] i s p 0 2 [ r a b 4 . 1 (
0 1 ) i s p 7 1 1 ( r a b 1 . 8
8 1 ) i s p 3 3 2 ( r a b 1 . 6 1
0 2 ) i s p 2 6 2 ( r a b 1 . 8 1
4 2 ) i s p 0 2 3 ( r a b 1 . 2 2
8 2 ) i s p 8 7 3 ( r a b 1 . 6 2
0 3 ) i s p 5 3 4 ( r a b 0 . 0 3
E 9 7 2 2 0 0 T
BOMAG 751 008 911 79
18.1
49
90000359
Rotate Adjusting Screw for
Minimum Displacement
Limiter
90000352
Maximum Displacement Limiter
90000360
Tighten Lock Nut for
Limiter
MV Displacement Limiters
90000837E
Displacement Limiter Adjustment (MV)
Both the maximum and minimum displacement may be
limited.
1. Remove the tamper resistant cap from the displace-
ment limiter screw. Loosen the seal lock nut retaining
the displacement limiter adjusting screw with a 19 mm
wrench.
3. After establishing the desired displacement setting,
tighten the lock nut on the adjusting screw to 54 Nm
(40 lbf ft). Install a new tamper resistant cap.
4. One turn of the adjusting screw will change the
maximum or minimum displacement according to the
following chart.
e z i S e m a r F
5 5 0 m c 6 . 5
3
n i 4 3 . 0 ( v e R /
3
) v e R /
5 7 0 m c 1 . 7
3
n i 3 4 . 0 ( v e R /
3
) v e R /
E 0 8 2 2 0 0 T
Displacement Control Adjustments
All variable motor displacement control settings do not
require adjusting.
Caution
The displacement limiters act as travel stops for the
swashplate. Do not turn the limiter screws
counterclockwise beyond the point of contact with
the swashplate for either the maximum or minimum
displacement position.
S000 015E
Caution
limiters to avoid undesirable flow or speed
conditions. See corresponding section for speed
and pressure limits.
The seal lock nut must be retorqued after every
S000 016E
2. All adjustments can only be done when the motor is
running and the pump is in neutral position. Steer the
respective displacement limiter by the control.
Rotate the adjusting screw with a 6 mm internal hex
wrench. Rotating the maximum displacement adjust-
ing screw clockwise will decrease the maximum
displacement of the motor. Rotating the minimum
displacement adjusting screw clockwise will increase
the minimum displacement of the motor.
Limiter Screw
Seal Lock Nut
Tamper-Resistant Cap
Seal Lock Nut
Maximum Displacement
Limiter Screw
SAE Flange Version shown
(Cartridge Version similar)
BOMAG 752 008 911 79
50
Positioning Speed Sensor relative to Pump or Motor Shaft
Cross Section View of Speed Sensor in Variable Pump
Cross Section View of Speed Sensor in fixed Motor
Cross Section View of Speed Sensor in Variable Motor
Speed Sensor Adjustment
90000838E
90000839E
90000840E
90000841E
When installing or adjusting the speed sensor on a pump
or motor, it must be set at a specific distance from the
speed ring on the units cylinder. To locate the position of
the speed sensor on the unit or description see the
corresponding section.
1. Loosen the sensor lock nut with an 1-1/16 inch hex
wrench.
2. Turn the sensor clockwise (CW) by hand until it
contacts the speed ring.
3. Turn the sensor counterclockwise (CCW) 1/2 turn
(180) to establish the nominal gap of 0.71 mm
(0.028 inch).
4. Then turn the sensor clockwise (CW) until the wrench
flats on sensor body are positioned at a 22 angle to
the pump shaft center line.
Note: Many adjustable wrenches have a 22 handle
offset.
5. The final sensor position should be between
1/2 (180) and 1/4 turn (90) counterclockwise (CCW)
from the point where the sensor contacts the speed
ring.
6. Hold sensor in position with a 1/2 inch hex wrench
while tightening the lock nut to 13 Nm (10 lbf ft).
1/2 in. Wrench Flats
22
Speed Sensor with
Packard Connector
22
Speed Sensor with
Turck Connector
1/2 in. Wrench Flats
22
Speed Sensor with
Packard Connector
22
Speed Sensor with
Turck Connector
Shaft Centerline
Shaft Centerline
Magnetic Speed Ring
Speed Sensor
Gap
Magnetic Speed Ring
Speed Sensor
Gap
Magnetic Speed Ring
Speed Sensor
Gap
BOMAG 753 008 911 79
18.1
51
Series 90 Minor Repair Instructions
Minor Repair Instructions
items must be kept free of foreign materials and chemi-
cals.
Protect all exposed sealing surfaces and open cavities
from damage and foreign material.
It is recommended that all gaskets and O-rings be
replaced when servicing. All gasket sealing surfaces
must be cleaned prior to installing new gaskets. Lightly
lubricate all O-rings with clean petroleum jelly prior to
assembly.
Minor repairs may be performed, following the proce-
dures in this section, without voiding the unit warranty.
Although specific models are shown, these procedures
apply to all series and types of units in the Series 90
Family.
Cleanliness is a primary means of ensuring satisfactory
transmission life, on either new or repaired units. Clean-
ing parts by using a solvent wash and air drying is
adequate, providing clean solvent is used. As with any
precision equipment, the internal mechanism and related
BOMAG 754 008 911 79
52
Hydrostatic Unit Outlines for Minor Repair Reference
Cartridge Flange MV
Cartridge Flange MF SAE Flange MF
SAE-Flange PV
SAE Flange MV
90000843E
90000844E
90000845E
Filtration Options
Speed Sensor
Left Side View
Charge Pressure
Relief Valve
Shaft Seal
Control
Control Orifice
Charge Pump
(Auxiliary Pad)
Right Side View
Main Shaft
(Speed Sensor)
Left Side View
Shaft
Seal
Charge Pressure
Relief Valve
Loop Flushing
Valve
Left Side View
Shaft
Seal
Charge Pressure
Relief Valve
Loop Flushing
Valve
(Speed Sensor)
Left Side View
Charge Pressure
Relief Valve
Shaft
Seal
Maximum Angle
Displacement Limiter
Control
Loop Flushing
Valve
Control Orifices
Minimum Angle
Left Side View
Shaft
Seal
Charge Pressure
Relief Valve
Maximum Angle
Loop Flushing
Valve
Control
Control Orifices
Minimum Angle
BOMAG 755 008 911 79
18.1
53
Pump and Motor Minor Repair
Pump / Fitting Torques
If any plugs or fittings are removed from the pump or
motor during servicing, they should be torqued as indi-
cated in the accompanying table.
Always install new O-rings before reinstalling the plugs or
fittings.
n o i t p i r c s e D e u q r o T
g n i r - O 0 2 - 6 1 / 7
h c n e r W x e H h c n i 6 1 / 9
m N 0 2
) t f f b l 5 1 (
g n i r - O 0 2 - 6 1 / 7
h c n e r W x e H l a n r e t n I h c n i 6 1 / 3
m N 2 1
) t f f b l 9 (
g n i r - O 8 1 - 6 1 / 9
h c n e r W x e H h c n i 6 1 / 1 1
m N 7 3
) t f f b l 7 2 (
g n i r - O 8 1 - 6 1 / 9
h c n e r W x e H l a n r e t n I h c n i 4 / 1
m N 3 2
) t f f b l 7 1 (
g n i r - O 6 1 - 4 / 3
h c n e r W x e H h c n i 8 / 7
m N 8 6
) t f f b l 0 5 (
g n i r - O 6 1 - 4 / 3
m N 8 6
) t f f b l 0 5 (
g n i r - O 4 1 - 8 / 7
h c n e r W x e H h c n i 1
m N 5 9
) t f f b l 0 7 (
g n i r - O 4 1 - 8 / 7
m N 8 6
) t f f b l 0 5 (
g n i r - O 2 1 - 6 1 / 1 - 1
h c n e r W x e H h c n i 4 / 1 1
m N 3 6 1
) t f f b l 0 2 1 (
g n i r - O 2 1 - 6 1 / 1 - 1
m N 5 1 1
) t f f b l 5 8 (
g n i r - O 2 1 - 6 1 / 5 - 1
h c n e r W x e H h c n i 2 / 1 - 1
m N 0 9 1
) t f f b l 0 4 1 (
g n i r - O 2 1 - 6 1 / 5 - 1
m N 9 2 1
) t f f b l 5 9 (
g n i r - O 2 1 - 8 / 5 - 1
h c n e r W x e H h c n i 8 / 7 - 1
m N 4 2 2
) t f f b l 5 6 1 (
E 1 8 2 2 0 0 T
Caution
Plugs or fittings installed into aluminum housings
should always be torqued to the lower values
specified for internal hex plugs of the same size.
S000 017E
BOMAG 756 008 911 79
54
Series 90 Shaft Seal Components
Shaft Seal and Shaft Replacement
Remove Seal Carrier Remove Screws Holding
Retainer Plate and Seal
Carrier
90000270 90000271
Press Out Old Seal New Seal Installed in Carrier
90000272 90000273
90000846E
Lip type shaft seals are used on Series 90 pumps and
motors. These seals and/or the shafts can be replaced
without major disassembly of the unit. However, replace-
ment usually requires removal of the pump or motor from
the machine.
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 three or four screws holding the retainer
plate and seal carrier to the housing, using a 10 mm
hex wrench (030 and 042 units), a 5 mm internal hex
wrench (055 through 100 units), or a 6 mm internal
hex wrench (130 through 250 units). Remove the
retainer plate.
Note: Certain earlier production units use a one piece
retainer plate and seal carrier.
3. After removing the screws, the spring force on the
shaft may move the seal carrier out of its bore by
approximately 5 mm (1/4 inch). If the seal carrier
does not move from its bore after removing the
screws, pry it from its bore as shown and/or lightly tap
the end of the shaft with a soft mallet.
4. Remove the O-ring from the seal carrier.
5. Place seal carrier and seal in an arbor press and
press out old seal.
6. Inspect the seal carrier, the new seal and the O-ring
for any damage or nicks.
7. Using the arbor press, press the new seal into seal
carrier. Be careful not to damage the seal.
Note: The outside diameter of the seal may be lightly
coated with a sealant (such as Loctite High
Performance Sealant #59231) prior to installa-
tion. This aids in preventing leaks caused by
damage to the seal bore in the seal carrier.
Screw
Seal
O-ring
Seal
Seal Carrier
(One Piece)
Seal Carrier
Retaining Plate
Screw
BOMAG 757 008 911 79
18.1
55
Install Seal Carrier Torque Retainer Screw
90000274 90000275
8. Inspect the sealing area on the shaft for rust, wear,
or contamination.
If the shaft is not being replaced proceed to step
12.
9. Remove shaft and roller bearing assembly from
pump or motor. The bearing assembly can be trans-
ferred to the new shaft.
10. Remove the retaining ring that secures roller bearing
assembly with a snap ring pliers. Remove the roller
bearing assembly.
11. Place roller bearing assembly on new shaft and
secure with the retaining ring.
12. Wrap spline or key end of shaft with plastic film to
prevent damage to the sealing lip on the seal during
installation.
13. Prior to assembly, lubricate the O-ring on the O.D. of
the seal carrier and the I.D. of the seal with clean
petroleum jelly.
14. Assemble the seal carrier and seal over the shaft and
into the housing bore. Install the retainer plate (if
used).
15. Install the screws and torque like the tables.
Pumps
e z i S e m a r F s p m u P e u q r o T
2 4 0 - 0 3 0 m N 2 1 ) t f f b l 9 (
0 0 1 - 5 5 0 m N 6 1 ) t f f b l 2 1 (
0 5 2 - 0 3 1 ) t f f b l 4 2 ( m N 2 3
E 2 8 2 2 0 0 T
Motors
e z i S e m a r F s r o t o M e u q r o T
0 0 1 - 0 3 0 m N 5 . 9 ) t f f b l 7 (
0 3 1 ) t f f b l 6 . 6 1 ( m N 5 . 2 2
E 3 8 2 2 0 0 T
Note: Torque the screws in a sequenced pattern then
recheck.
Fixed Motor Shaft Configuration
Variable Motor Shaft Configuration
Variable Pump Shaft Configuration
90000866E
90000867E
90000868E
OR
OR
OR
Splined
Shaft
Tapered
Shaft
Straight Key
Shaft
Retaining Ring
Roller Bearing
Roller Bearing
Assembly
OR
OR
OR
Splined
Shaft
Roller Bearing
Assembly
Tapered
Shaft
Straigt Key
Shaft
Rollen Bearing
Retaining Ring
OR
Splined
Shaft
Roller Bearing
Assembly Retaining
Ring
Tapered
Shaft
BOMAG 758 008 911 79
56
Pump Minor Repairs
Remove Multi-Function
Valve Cartridge
Install and Torque Cartridge
Multi-Function Valve Cartridge Components
(Later production)
Multi-Function Valve Cartridge Components
(Earlier production)
90000276 90000277
90000278
90000279
Multi-Function Valve Cartridge Sectional View
90000869E
Multi-Function Valve Cartridges
1. The multi-function valve cartridge is removed with a
hex wrench on the largest hex on the cartridge.
0 0 1 - 0 3 0 h c n i 4 / 1 - 1
0 5 2 - 0 3 1 h c n i 8 / 5 - 1
E 4 8 2 2 0 0 T
2. Inspect cartridge for damage to parts and O-rings.
The multi-function valve cartridge may be disas-
sembled for cleaning. However, if the pressure limiter
housing assembly is disassembled, the pressure
settings must be readjusted. Usually, if there is
contamination problem, it will be in the valve seat
assembly. If it is not necessary to clean the interior of
the cartridge, proceed to step 7.
Note: Multi-function valve components are not sold
separately as service parts (except O-rings).
3. On early versions of the multi-function valves, the
valve seat assembly is held by a retaining ring.
Remove retaining ring with a snap ring pliers.
On late versions, the valve seat section is pressed over
a lip. Place the cartridge in a vise and pry the lower
section off with an appropriate tool. Maintain sufficient
control to prevent the contents from flying loose.
4. Remove pressure limiter lock nut and bypass actuator.
5. Unscrew the pressure limiter adjustment screw from
the bypass actuator. Clean and inspect all disas-
sembled parts.
6. Reassemble with new, lightly lubricated O-rings by
reversing the above procedure. For early versions
assemble with the retaining ring. For late versions,
place the cartridge in a vise and press on lower
assembly.
High Pressure
Relief/Check
Valve Poppet
Spring Seat
Check Valve
Poppet
Valve Seat
Spring
Pressure Limiter
Valve Poppet
Pressure Limiter
Valve Poppet
Pressure Limiter
Valve Spring
Bypass
Actuator
Pressure Limiter
Adjustment Screw
Pressure Limiter
Lock Nut
Pressure Limiter
Housing
Caution
The pressure settings must be readjusted after
disassembling the pressure limiter housing of the
multi-function valve cartridge.
S000 018E
7. Install cartridge in multi-function valve cavity and torque.
0 0 1 - 0 3 0 ) t f f b l 6 6 ( m N 9 8
0 5 2 - 0 3 1 ) t f f b l 5 5 1 ( m N 0 1 2
E 5 8 2 2 0 0 T
Do not overtorque the multi-function valve cartridge.
BOMAG 759 008 911 79
18.1
57
Relief Valve
Remove Charge Relief Valve
(Shim adjustable)
90000262 90000280
Remove Charge Relief Valve
(Screw adjustable)
Relief Valve
90000265 90000264
Pressure Override Valve Components
90000870E
Charge Relief Valve
The pump charge relief valve may be shim adjustable
(early models) or screw adjustable (late models).
1. Remove the shim adjustable charge relief valve plug
with a 1 inch hex wrench.
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 with a
wrench.
0 0 1 - 0 3 0 h c n i 6 1 / 1 - 1
0 5 2 - 0 3 1 h c n i 8 / 5 - 1
E 6 8 2 2 0 0 T
Unscrew the plug with a large screwdriver or 1/2 inch
hex wrench.
2. Remove the spring and relief valve poppet.
3. Inspect the poppet and mating seat in the end cap for
damage or foreign material.
When inspecting shim adjustable valves, do not alter
the shims or interchange parts with another valve.
4. Install the poppet and spring. For shim adjustable
valves, install the plug and torque to 68 Nm (50 lbf ft).
For screw adjustable valves, install the plug with its
lock nut, aligning the marks made at disassembly,
and torque the lock nut to 52 Nm (38 lbf ft).
Check the charge pressure and adjust, if necessary.
Pressure Override
Valve
O-rings
Screws
Pressure Override Valve (Option for 180 Frame
Size)
1. Remove the four screws attaching the pressure
override valve to the pump end cap with a 5 mm
internal hex wrench. Remove the O-rings.
2. Inspect valve for damage to parts.
3. Install new O-rings. Install the valve onto the pump
end cap and torque the screws to 16 Nm (12 lbf ft).
BOMAG 760 008 911 79
58
Remove Retainer Screws Remove Charge Pump Cover
90000284 90000282
Orienting Alignment Pin
90000871E
Charge Pump - Remove
The following procedure shows how to remove and install
a charge pump.
1. For pumps with an auxiliary mounting pad, remove
the four screws holding the pad to the end cap and
remove the pad. Refer to the Auxiliary Mounting Pad
Installation instructions (next section) for details.
Note: At earlier production frame size 75 pumps with
twin ports secure the end cap to the pump
housing with a clamp to avoid gasket damage.
Remove Auxiliary Pad
Adapter Screws
90000281
Remove Auxiliary Pad
Adapter
90000303
Remove Drive Coupling
90000297
Inlet
Discharge
Alignment Pin
Gerotor Assembly
Right Hand Rotation
(Outside looking into pump)
Gerotor
Assembly
Inlet
Discharge
Left Hand Rotation
Alignment Pin
Caution
Do not allow the force of the cylinder block spring
and swashplate leveler springs to separate the end
cap from the pump housing. Gasket damage and
external leakage may result.
S000 019E
2. Remove the six screws holding the charge pump
cover retainer.
0 0 1 - 0 3 0 m m 0 1
0 5 2 - 0 3 1 m m 3 1
E 7 8 2 2 0 0 T
3. Remove the retainer and the charge pump cover. For
pumps with an auxiliary mounting pad, remove the
auxiliary drive coupling. Note the orientation of the
gerotor.
4. Remove the charge pump shaft and charge pump
drive key.
5. Remove the spacer plate(s), if present (intermediate
production pumps only).
Remove the charge pump outer port plate, if present
(early and intermediate production pumps).
Remove the charge pump gerotor assembly.
6. Remove the outer eccentric ring and alignment pin.
7. Remove the inner port plate.
8. Inspect all parts for abnormal wear or damage.
BOMAG 761 008 911 79
18.1
59
Charge Pump Components (Early Production)
90000872E
90000873E
90000874E
90000875E
Journal Bearing
Cover Retainer
Cover
O-ring
Retainer Screw
Shaft
Key
Standard End Cap Screws
Thin Port Plate
Charge Pump Assembly
Alignment Pin
Thick Port Plate
Gerotor Assembly
Eccentric Ring
Charge Pump Components (Intermediate Production)
Charge Pump Components (Late Production)
Cover Retainer
Cover
Journal Bearing
O-ring
Standard End Cap Screw
Retainer Screw
Thin Port Plate
Alignment Pin
Shaft
Key
Thin Port Plate
Spacer Plate(s)
Gerotor Assembly
Eccentric Ring
Journal Bearing
Cover Retainer
Cover
O-ring
Retainer Screw
Shaft
Key
Alignment Pin
Port Plate
Gerotor Assembly
Eccentric Ring
"No Charge Pump" Components
Cover
Journal Bearing
O-ring
Shaft
Spacer
Plug
Cover Retainer
Retainer Screw
Note: If a different displacement charge pump is be-
ing installed, the gerotor assembly, gerotor outer
eccentric ring, and inner port plate (early and
late production pumps) or outer spacer plate(s)
(intermediate production pumps) must be re-
placed together. If different thickness port plates
are used in an early production charge pump
assembly, the thicker plate is the inner port
plate (installed next to the pump end cap).
Each charge pump assembly includes a different quan-
tity / types of port plates and spacer plates.
The charge pump kit "No Charge Pump" includes a
spacer.
BOMAG 762 008 911 79
60
Install Alignment Pin
Install Gerotor Assembly
Outer Ring
Install Inner Port Plate
Install Gerotor Assembly
Install Outer Port Plate
(Early and intermediate
production only)
Install Spacer Plate
(Intermediate production
only)
90000286 90000285
90000288 90000287
90000290 90000289
90000871E
Installing the Charge Pump
Be sure to install the charge pump in the proper orienta-
tion. If unsure of charge pump rotation, refer to the model
code.
Note: The charge pump rotation is determined by the
orientation of the gerotor assembly outer ec-
centric ring and the location of the alignment pin
in the end cap.
Do not mix charge pump piece parts from differ-
ent production periods. Always install as a com-
plete assembly.
1. Install the inner port plate and the gerotor assembly
outer ring.
2. Install the alignment pin to properly orient the port
plates and outer eccentric ring for corresponding
pump rotation.
3. Prior to installation, apply a small quantity of petro-
leum jelly to the I.D., O.D., and side faces of the
gerotor assembly to provide initial lubrication.
4. Install the gerotor assembly.
5. Install the outer port plate (early production and
intermediate production pumps only).
6. Install the spacer plate, if present (intermediate
production pumps).
7. Install the charge pump drive key into the charge
pump shaft and retain with petroleum jelly.
Orienting Alignment Pin
Inlet
Discharge
Alignment Pin
Gerotor Assembly
Right Hand Rotation
Gerotor
Assembly
Inlet
Discharge
Left Hand Rotation
Alignment Pin
BOMAG 763 008 911 79
18.1
61
90000291 90000292
Keyways in Charge Pump
Shaft (Intermediate Produc-
tion 075 and 100)
Install Charge Pump Shaft
Alignment Pin Installed in
Cover
90000293
Install Charge Pump Cover
90000294
90000283 90000295
Torque Retainer Screws Install Cover Retainer
100 cc 75 cc
Note: Intermediate production 75 cc and 100 cc pumps
use the same charge pump drive shaft. Two
keyways are provided in the drive shaft for the
charge pumps used in these units. The rear
keyway (with identifier groove) is used in 75 cc
pumps. The front keyway (closest to the inter-
nally splined end of the shaft) is used in 100 cc
pumps.
8. Install the charge pump shaft. The internally splined
end of the shaft must engage the main pump shaft.
Note: The outside diameter of the internally splined
end of some early production charge pump
shafts was chamfered. Early production end
caps may not be machined to accept a non-
chamfered shaft. Always use a chamfered
charge pump shaft in pumps with the early end
cap.
9. For pumps with an auxiliary mounting pad, install the
auxiliary drive coupling.
10. Install a new O-ring onto the non-auxiliary pad charge
pump cover. (If an auxiliary pad is installed, an O-ring
is not used on the cover.)
11. Carefully remove the alignment pin from the charge
pump parts. Install the pin in its hole in the charge
pump cover (see previous page for correct orienta-
tion) and retain with petroleum jelly. Install the cover
(with alignment pin) into the end cap and aligned
charge pump parts. (Take care not to damage the
cover O-ring, if used.)
Caution
In order to avoid loss of charge pressure in pumps
with an auxiliary mounting pad, always install the
charge pump cover with the pad drain hole located
on the same side of the end cap as the charge inlet
port. Refer to the section Auxiliary Pad Installation
for details.
S000 020E
12. Install the charge pump cover retainer and the six hex
screws and torque the screws.
0 0 1 - 0 3 0 ) t f f b l 0 1 ( m N 5 . 3 1
0 5 2 - 0 3 1 ) t f f b l 4 2 ( m N 2 3
E 8 8 2 2 0 0 T
13. For pumps with auxiliary mounting pads, install the
O-ring and auxiliary mounting pad adaptor onto the
end cap. Refer to the corresponding section for
instructions on auxiliary pad installation.
BOMAG 764 008 911 79
62
Auxiliary Pad Components (Typical)
90000284 90000282
Remove Large End Cap Screws
90000296
90000876E
Auxiliary Pad Installation
1. Remove the six screws holding the charge pump
cover retainer. Remove the retainer.
0 0 1 - 0 3 0 m m 0 1
0 5 2 - 0 3 1 m m 3 1
E 7 8 2 2 0 0 T
2. Remove the charge pump cover and its O-ring.
Note: The original charge pump cover will not be used
when installing the auxiliary pad.
3. Remove the four large screws which fasten the end
cap to the pump housing.
e z i S e m a r F s e z i S h c n e r W
x e H l a n r e t n I x e H l a n r e t x E
- 0 3 0
2 4 0 y l r a e
m m 8
2 4 0 e t a l m m 0 1
5 5 0 m m 9 1
0 0 1 - 5 7 0 m m 4 2
0 3 1 - 0 0 1 m m 4 1
0 5 2 - 0 8 1 m m 7 1
E 9 8 2 2 0 0 T
Note: At earlier production frame size 75 pumps with
twin ports secure the end cap to the pump
housing with a clamp to avoid gasket damage.
Remove Screws and
Retainer
Remove Charge Pump Cover
Pad Cover
Special Washer
Cover Retainer
Retainer Screw
Screw
O-ring
auxiliary Pad
(Typical)
O-ring
Cover
Assembly
Journal Bearing
Auxiliary Pad Kit
End Cap
Screw
Charge Pump Parts
Coupling
(Typical)
Caution
Do not allow the force of the cylinder block spring
and swashplate leveler springs to separate the end
cap from the pump housing. Gasket damage and
external leakage may result.
S000 019E
4. Take care to assure the surfaces are clean and free
of any foreign material or paint prior to installing the
auxiliary pad.
5. Install the auxiliary drive coupling onto the pump
drive shaft spline (auxiliary drive spline must be
toward the rear of the pump).
BOMAG 765 008 911 79
18.1
63
Install Drive Coupling Install Alignment Pin in
Cover (CCW rotation shown)
90000298 90000297
Install Auxiliary Pad Adapter
Screws
Torque Pad Adapter Screws
90000305 90000281
Install O-ring on End Cap
Pilot
Install Auxiliary Pad Adapter
90000303 90000302
Install New Charge Pump
Cover
Install Screws and Cover
Retainer
90000300
90000299
7. Install the charge pump cover retainer and the six hex
screws and torque the screws.
0 0 1 - 0 3 0 ) t f f b l 0 1 ( m N 5 . 3 1
0 5 2 - 0 3 1 ) t f f b l 4 2 ( m N 2 3
E 8 8 2 2 0 0 T
8. Install O-ring on end cap pilot.
9. Install the auxiliary mounting pad adapter on external
pilot on rear of end cap.
10. Install four new large screws and washers through
the mounting pad and end cap into the housing.
Torque per the accompanying table.
- 0 3 0
2 4 0 y l r a e
) t f f b l 3 4 ( m N 8 5
2 4 0 e t a l ) t f f b l 0 9 ( m N 2 2 1
5 5 0 ) t f f b l 0 9 ( m N 2 2 1
0 0 1 - 5 7 0 ) t f f b l 9 8 1 ( m N 6 5 2
0 3 1 - 0 0 1 ) t f f b l 0 2 2 ( m N 8 9 2
0 5 2 - 0 8 1 ) t f f b l 9 2 4 ( m N 0 8 5
E 0 9 2 2 0 0 T
11. Install the O-ring and flange cover or auxiliary pump.
Auxiliary Pad Conversion
To convert an auxiliary mounting pad to a different size
mounting pad, use the above procedure with the following
additions:
After removing the charge pump cover (step 2), remove
the old auxiliary drive coupling.
After removing the four end cap retaining screws, remove
the old auxiliary mounting pad adapter.
Caution
In order to avoid loss of charge pressure in pumps
with an auxiliary mounting pad, always install the
charge pump cover with the pad drain hole lo-
cated on the same side of the end cap as the
charge inlet port. Refer to the section "Auxiliary
Pad Installation" for details.
S000 020E
6. Carefully remove the alignment pin from the charge
pump parts. Install the pin in its hole in the new
charge pump cover (with hole for the auxiliary cou-
pling) and retain with petroleum jelly. Install the new
charge pump cover with alignment pin into the end
cap and the aligned charge pump parts.
BOMAG 766 008 911 79
64
Series 90 Minor Repair
90000243 90000310
Charge Pump Inlet Reducer Fitting and
Gauge Port Plug
90000311 90000314
Integral Pressure Filter Head remote Pressure Filter
Manifold
90000315 90000312
Install Remote Pressure
Filter Manifold
Install Integral Pressure
Filter Head
90000313 90000316
Tighten Integral Pressure
Filter Head Lock Nut
Tighten Remote Pressure
Filter Manifold Lock Nut
Filtration Options
Suction Filtration Installation
1. Install the hydraulic fitting to connect the external
suction filter to the charge pump inlet port.
2. The reducer fitting (placed on the charge pressure
gauge port) is installed as follows.
e z i S e m a r F e z i S h c n e r W e u q r o T
2 4 0 - 0 3 0 h c n i 4 / 1 - 1 ) t f f b l 2 5 ( m N 0 7
0 3 1 - 5 5 0 h c n i 2 / 1 - 1 ) t f f b l 0 9 ( m N 2 2 1
0 5 2 - 0 8 1 h c n i 2 / 1 - 1 ) t f f b l 5 1 1 ( m N 6 5 1
E 1 9 2 2 0 0 T
The gauge port plug takes a 1/4 inch internal hex
wrench and is torqued to 27 Nm (20 lbf ft).
Remote Charge Pressure Filtration or Integral Charge
Pressure Filtration
Install either of these two filtration devices as follows.
1. Remove the reducer fitting, located at charge pres-
sure gauge port, from pump end cap (this part will not
be used).
2. Install the filter manifold or filter head into the port.
The hydraulic tube should enter its mating bore in the
pump end cap with a low force.
3. After rotating the filter manifold or filter head clock-
wise so that the threads engage with the threads in
the end cap, continue to rotate it clockwise between
6 and 7 revolutions. Face manifold or head to the
desired position.
Caution
Failure to install the filter manifold or filter head to a
sufficient depth in the end cap will result in insufficient
engagement of the tube in the end cap bore. This may
allow unfiltered oil to bypass the filter and enter the
charge system.
S000 021E
4. While holding the filter manifold or filter head in the
desired position, tighten the swivel lock nut.
e z i S e m a r F e z i S h c n e r W e u q r o T
2 4 0 - 0 3 0 h c n i 8 / 3 - 1 ) t f f b l 2 5 ( m N 0 7
0 3 1 - 5 5 0 h c n i 8 / 5 - 1 ) t f f b l 0 9 ( m N 2 2 1
0 5 2 - 0 8 1 h c n i 8 / 5 - 1 ) t f f b l 5 1 1 ( m N 6 5 1
E 2 9 2 2 0 0 T
5. After installing the integral pressure filter head as-
sembly, install the filter canister per the instructions
on the filter canister.
BOMAG 767 008 911 79
18.1
65
Pump with Cover Plate
90000361
Pump controls
Cover Plate
1. Thoroughly clean external surfaces prior to removal
of cover plate.
2. Using a 5 mm internal hex wrench, remove the eight
cover plate mounting screws. Remove the cover
plate and gasket from housing.
3. In preparation for installing the cover plate, place a
new gasket on the housing. Place the cover plate into
position and install the screws. Torque the screws to
16 Nm (12 lbf ft).
Caution
Protect exposed surfaces and cavities from damage
and foreign material.
S000 022E
NOTE
A sealing washer must be installed under the head of
any mounting screws that are installed into "thru"
holes in the housing.
S000 023E
BOMAG 768 008 911 79
66
Remove Mounting Screws Remove Control
Inner Face of Control Assemble Control to Linkage
Assemble Control to
Pump
Torque Mounting Screws
90000320 90000319
90000322 90000321
90000324 90000323
Manual Displacement Control (MDC)
of control.
control mounting screws. Remove the control (with
orifice check valve and spring) and control gasket
from housing.
NOTE
any mounting screws that are installed into "thru"
S000 023E
Caution
S000 022E
3. In preparation for installing the control, place a new
gasket on the housing. Inspect to assure that the
control orifice check valve and spring are in their
proper position in the control.
4. While setting the control into position, engage the pin
on the control linkage into the mating hole in the link
attached to the swashplate.
5. With the control in position, move control lever both
directions to check proper engagement of control
linkage pin. Proper engagement will be indicated by
centering torque as the lever is moved from center.
Non-engagement of control linkage pin is indicated
by lack of centering torque as the lever is moved. In
case of non-engagement remove the control and
repeat the above procedure.
6. Align the control gasket and install the screws. Torque
the screws to 16 Nm (12 lbf ft).
7. If the control is equipped with a neutral start switch,
refer to the "MDC Neutral Start Switch Adjustment"
instructions.
WARNING
The neutral start switch "neutral" must be read-
justed after reassembling the MDC module.
S000 024E
BOMAG 769 008 911 79
18.1
67
Components of Solenoid Override for MDC
90000363
90000364
Solenoid Override Valve for MDC
of valve.
2. Using a 5 mm internal hex wrench, remove the two
screws and remove solenoid manifold from housing.
Remove the old gasket.
3. The solenoid may be removed from the valve by
removing the nut with a 3/4 inch hex wrench. The
solenoid valve may be removed from the manifold
with a 7/8 inch hex wrench.
4. When installing the solenoid valve into the manifold,
the valve should be torqued to 24 2.4 Nm (17.7 1.8
lbf ft). When installing the solenoid onto the valve,
torque the nut to 6 Nm (53 12 lbf in).
5. In preparation for installing the solenoid manifold,
place a new gasket on the control housing. Install the
manifold onto the control housing, align the gasket,
and install the screws. Torque the screws to
13.5 Nm (10 lbf ft).
Solenoid Override Valve for MDC with Pressure
Released Brake
of valve.
2. Using a 4 mm internal hex wrench, remove the four
solenoid valve mounting screws. Remove the sole-
noid valve (with O-rings) from the adapter plate.
adapter plate mounting screws. Remove the adapter
plate and O-rings from the control housing.
4. Remove the check valve seat and O-ring from the
control side of the adapter plate. Remove the check
ball and spring.
5. Install a new O-ring on the check valve seat and
reassemble the check valve spring, ball, and seat
into the adapter plate.
6. Install new O-rings on the adapter plate. Place the
adapter plate into position and install the screws.
Torque the screws to 5.4 Nm (48 lbf in).
7. Install new O-rings onto the solenoid valve assembly
and install the solenoid valve onto the adapter plate.
Install the screws and torque to 5.4 Nm (48 lbf in).
Components of Solenoid Override with Brake Pressure
Defeat for MDC
BOMAG 770 008 911 79
68
PCP Components Torque PCP Valve Screws
Install Mounting Screws Torque Mounting Screws
Inner Face of Control Assemble Control to Linkage
Remove Mounting Screws Remove Control
90000326 90000325
90000328 90000327
90000330 90000329
90000334 90000332
Caution
S000 022E
Pressure Control Pilot (PCP) for Electric Displace-
ment Control
1. Thoroughly clean external surfaces of control.
screws and remove the PCP.
3. Check surfaces for nicks or damage. Clean internal
screens.
4. Install new O-rings in PCP Housing. Place PCP
against EDC housing and install the screws. Torque
to 5.4 Nm (48 lbf in).
Note: Do not remove black plastic cover from the
aluminum plate. This is not a serviceable item
and will void the product warranty.
Hydraulic and Electric Displacement Controls
of control.
control mounting screws. Remove the control (with
orifice check valve and spring) and control gasket
from housing.
Caution
A sealing washer must be installed under the
head of any mounting screws that are installed
into "thru" holes in the housing.
S000 023E
3. In preparation for installing the control, place a new
gasket on the housing. Inspect to ensure that the
control orifice check valve and spring are in their
proper position in the control.
4. While setting the control into position, engage the pin
on the control linkage into the mating hole in the link
attached to the swashplate.
5. With the control in position, move control assembly
left and right to check engagement of pin in the link.
Proper engagement will be indicated by an increas-
ing resistance as the control is moved away from
center position. Non-engagement of pin will be indi-
cated by lack of spring force. In case of non-engage-
ment, remove control and repeat the above proce-
dure.
6. Align the control gasket and install the screws. Torque
the screws to 16 Nm (12 lbf ft).
BOMAG 771 008 911 79
18.1
69
3-Position Electric Control Components
90000362
3-Position (FNR) Electric Control
of control.
solenoid valve mounting screws. Remove the sole-
noid valve (with O-rings and orifice) from the adapter
plate.
adapter plate mounting screws. Remove the adapter
plate and gasket from housing.
Underside of an HDC/EDC Module Showing Orifice
Locations
90000849E
P
B
A
TB
TA
Orifice Check Valve
Orifice Plugs
Displacement Control Components
Displacement Control Orifices
1. Remove the control assembly as described in the
instructions for the specific displacement control.
2. Orifice plugs may be located in the control assembly,
at the pump housing face surface. Remove the
orifice plugs with a 4 mm internal hex wrench. Note
the location of each plug, do not interchange plugs.
Torque the orifice plugs to 3 Nm (26 lbf in).
3. Assemble the control onto the pump. Refer to the
instructions for the specific control.
NOTE
any mounting screws that are installed into thru
S000 023E
Caution
S000 022E
4. Inspect the orifice installed between the valve and
adapter plate. This orifice MUST be installed in the
case drain passage for proper pressure limiter op-
eration.
5. In preparation for installing the adapter plate, place a
new gasket on the housing. Place the adapter plate
into position and install the screws. Torque the
screws to 16 Nm (12 lbf ft).
6. Install new O-rings and the orifice onto the solenoid
valve assembly and install the solenoid valve onto
the adapter plate. Install the screws and torque to
5.4 Nm (48 lbf in).
BOMAG 772 008 911 79
70
Displacement Control Adapter Plate (Early production
130cc Pumps only)
Underside of an MDC Module Showing Orifice Locations
90000847
90000848E
Displacement Control Orifice Check Valve
1. Remove the control assembly as described in the
instructions for the specific displacement control.
2. The orifice check valve is located in the control
assembly, at the surface of the pump housing face.
Remove the spring retainer and spring from the
orifice check valve cavity and then remove the orifice
check valve.
3. Install the desired orifice check valve in the cavity and
then install the spring and spring retainer to hold the
orifice check valve in position.
4. Assemble the control onto the pump. Refer to the
instructions for the specific control.
Displacement Control Adapter Plate (Early produc-
tion 130 Pumps only)
The screws fastening the control adapter plate to the
housing have retaining compound on the threads. They
are removed with a 6 mm internal hex wrench.
When installing the adapter plate, ensure the O-rings are
in the proper position and torque the screws to 32 Nm
(24 lbf ft).
Displacement Control Filter Screens
If the pump is equipped with control filter screens in the
pump housing (late production), they should be pressed
into position (with the rounded edge of the filter screens
facing the control until they are flush to 2.0 mm (0.08 inch)
below the surface of the housing.
P
B
A
TB
TA
Orifice check Valve
Orifice Plugs
BOMAG 773 008 911 79
18.1
71
Remove Flushing Shuttle
Spool
Remove Plugs Springs
Install Flushing Shuttle
Spool
Torque Plugs
Remove Screw Charge Relief
Valve
90000339 90000338
90000341 90000340
90000343 90000342
Remove Shim Charge Relief
Valve
Loop Flushing and Charge Relief Valves
Loop Flushing Valve
1. Using an 1-1/16 inch wrench, remove the hex plugs
and O-rings from both sides of the valve. Remove the
springs, shoulder washers, and flushing valve shuttle
spool. Note orientation of the washers. Remove the
flushing valve spool.
2. Inspect parts for damage or foreign material.
Note: Early production motors used a small diameter
shuttle valve spool. Late production motors use
a larger diameter spool.
3. Install flushing valve spool in end cap, then install the
shoulder washers (with shoulders facing out) and
springs on each end of the spool. Install the hex plugs
with O-rings, and torque to 41 Nm (30 lbf ft) on 030
through 100 motors or 68 Nm (50 lbf ft) on 130
motors.
Motor Charge Relief Valve
1. Remove the shim adjustable charge relief valve plug
with a 7/8 inch hex wrench.
plug, mark the plug, lock nut, and housing so as to be
able to maintain the original adjustment when assem-
bling. Remove the screw adjustable charge relief
valve plug by loosening the lock nut with a 1-1/16 inch
hex wrench for 030 through 100 units, or a 1-5/8 inch
hex wrench for 130 units, and unscrewing the plug
with a large screwdriver or 1/2 inch hex wrench.
2. Remove the spring and valve poppet.
3. Inspect the poppet and mating seat in the end cap for
damage or foreign material. When inspecting shim
adjustable valves, do not alter the shims or inter-
change parts with another valve.
Minor Repair - Motor
BOMAG 774 008 911 79
72
Motor charge Relief Valve and Loop Flushing Valve Parts
90000850E
Relief Valve
90000345 90000344
Relief Valve
Spring
Spool
Shoulder Washer
O-ring
Spring
O-ring
Shoulder Washer
Plug
Spool (defeat)
Plug
Lock Nut
Spring
O-ring
Poppet
Plug
Plug with O-ring
(defeat)
Note orientation of washers!
Shoulder OUT (toward spring).
Plug with O-ring
(defeat)
Plug
O-ring
Shims
Spring
Poppet
Plug with O-ring
(defeat)
4. Install the poppet and spring. For shim adjustable
valves, install the plug and torque to 68 Nm (50 lbf ft).
For screw adjustable valves, install the plug with its
and torque the lock nut to 52 Nm (38 lbf ft).
5. Check and adjust the charge pressure.
Defeating the Loop Flushing Valve
1. Remove loop flushing valve components (these parts
will not be used).
2. Install defeating spool into spool bore in end cap.
3. Install hex plugs provided and torque to 41 Nm
(30 lbf ft).
4. Remove charge relief valve components (these parts
are not necessary).
5. Replace with the hex plug provided and torque to
41 Nm (30 lbf ft).
BOMAG 775 008 911 79
18.1
73
MV Displacement Limiters
90000851E
Variable Motor Displacement Limiters
1. Remove the tamper-resistant cap from the displace-
ment limiter. Measure and note the length of the
adjustment screw up to the seal lock nut. Using a
19 mm hex wrench, loosen the seal lock nut and
remove the nut. Remove the limiter screw from the
motor housing with a 6 mm internal hex wrench.
2. Install the limiter screw with the noted length between
adjustment screw and the seal lock nut. Do not install
a new tamper-resistant cap until the limiter has been
adjusted.
3. Final adjustment of the displacement limiters should
be performed on a test stand.
Do not turn the limiter screws counterclockwise
beyond their initial adjustment positions.
One full turn of the displacement limiter adjustment
screw will change the displacement as follows:
e z i S e m a r F
5 5 0 m c 6 . 5
3
n i 4 3 . 0 ( v e R /
3
) v e R /
5 7 0 m c 1 . 7
3
n i 3 4 . 0 ( v e R /
3
) v e R /
E 5 9 2 2 0 0 T
4. Following the final adjustment, install new tamper
resistant caps.
Caution
limiters to avoid undesirable speed conditions. The
seal lock nut must be retorqued after every
S000 026E
Limiter Screw
Seal Lock Nut
Seal Lock Nut
Maximum Displacement
Limiter Screw
SAE Flange Version shown
(cartridge Version similar)
BOMAG 776 008 911 79
74
MV Control components
MV Control Plugs
Variable Motor Controls
90000852E
90000853E
Electrohydraulic 2-Position Control (Types
NA, NB, NC, and ND)
of the control.
2. Disconnect the external electrical signal connection.
3. Remove the hex nut and solenoid from the control
valve.
4. Remove the orifice check valve for the maximum
angle control cylinder, if equipped.
5. Remove the control valve from the motor housing.
6. Remove O-rings from the valve.
7. Install new O-rings on the control valve.
8. Install the valve into the motor housing and torque to
47 Nm (35 lbf ft). Do not overtorque the control
valve. Over-torquing may result in the valve spool
sticking.
9. Install the solenoid onto the valve and torque the hex
nut to 5 Nm (44 lbf in). Do not overtorque the nut.
10. If previously removed, reinstall the orifice check
valve. Reconnect the external signal connection.
Hydraulic 2-Position Control (Type PT)
Follow the steps above, except that in step 2 a hydraulic
signal line will be disconnected, and steps 3 and 9 are not
applicable.
Control Plugs
Remove the control plugs from the housings of earlier
production motors, if necessary. Install new O-rings,
reinstall, and torque.
1/8 in. int. hex wrench
Torque: 5.4 Nm (48 lbf in)
9/16 in. hex wrench
7/8 in. hex wrench
Electric 2-Position
Control Valve
Hydraulic 2-Position
Control Valve
Remove BEFORE removing control.
Install AFTER installing control.
Refer to "Control Orifices" Section
Note:
BOMAG 777 008 911 79
18.1
75
MV Control Supply Orifice
MV Minimum Displacement Orifice
90000855E
90000854E
Minimum Displacement Cylinder Orifice or Orifice
Check Valve
1. Remove the minimum displacement cylinder drain
orifice or the orifice check valve from the motor
housing with an 1-1/16 inch hex wrench.
2. Remove the O-rings and the backup washers. Check
that the orifice is not plugged. Check that the check
valve seat is secure in the body and that the check
ball is free.
3. Install new backup washers and O-rings onto the
orifice body. Install the orifice into the motor housing
and torque to 37 Nm (27 lbf ft).
Caution
Do not interchange the control supply orifice (previous
section) with the minimum displacement orifice.
S000 028E
Caution
Do not interchange the control supply orifice with the
minimum displacement orifice (next section).
S000 027E
Variable Motor Control Orifices
Control Supply Orifice
1. Remove the control supply orifice from the motor
housing with an 1-1/16 inch hex wrench.
2. Remove the O-rings and the backup washers. Check
that the filter screen is secure in the orifice body and
that the screen and the orifice are not plugged.
3. Install new backup washers and O-rings onto the
orifice body. Install the orifice into the motor housing
and torque to 37 Nm (27 lbf ft).
Control Suply Orifice
O-ring
Backup Washer
Backup Washer
O-ring
Screen (pressed in)
Orifice Body
Screen
(pressed in)
Cross-section View of
Control Supply Orifice Assembly
O-ring
O-ring
Backup Washer Backup Washer
Orifice / Check Valve
Assembly
O-ring
O-ring
Backup Washer
Backup Washer
Orifice
Orifice Body
Kugel
Orifice Seat
(Spot welded)
Backup Washer
Backup Washer
Spring Pin
O-ring
O-ring
Orifice Body
Backup Washer
Backup Washer
O-ring
O-ring
Cross-Section View of
Orifice Assembly
Assembly
BOMAG 778 008 911 79
76
MV Maximum Displacement Orifice
90000856E
Maximum Displacement Cylinder Orifice Check Valve
1. Remove the seal lock nut with a 3/4 inch hex wrench.
Remove the maximum displacement cylinder orifice
check valve from the motor housing with a 1/4 inch
end wrench. Remove the O-ring. The check ball in
the valve must be free.
2. Reinstall the check valve and torque to 15 Nm
(11 lbf ft). Install a new O-ring. Install the seal lock
nut with the seal toward the motor housing.
Hold the check valve from turning while torquing
the seal lock nut to 34 Nm (25 lbfft).
3. If no orifice check valve is installed, the housing plug
may be removed with a 9/16 inch hex wrench. Always
install a new O-ring. Reinstall the plug and torque to
20 Nm (15 lbf ft).
Orifice / Check Valve Assembly
Housing Plug
Seal Lock Nut
(seal toward housing)
O-ring
Orifice Body
Check Ball
Spring Pin
O-ring
Seal Lock Nut
(seal toward housing)
Assembly
BOMAG 779 008 911 79
18.1
77
Typical Location of Speed Sensor - PV
Typical Location of Speed Sensor - MF
Typical Location of Speed Sensor - MV
Speed Sensor
90000857E
90000858E
90000859E
1. Remove the speed sensor by disconnecting the
electrical connector, loosening the lock nut, and
unscrewing the speed sensor from the pump or
motor housing.
2. Always install a new O-ring before installing the
sensor.
3. Reinstall the speed sensor (with lock nut and O-ring)
into the housing. Adjust the gap between the sensor
and the magnetic speed ring as instructed in Section
"Speed Sensor Adjustment" and torque the sensor
lock nut.
4. If a speed sensor is not installed, the housing plug
should be torqued as indicated in the accompanying
figure.
After adjustment!
Housing Plug
or
Speed Sensor
After adjustment!
Housing Plug
or
Speed Sensor
or
After adjustment!
Housing Plug
Speed Sensor
BOMAG 780 008 911 79
78
Series 90 Exploded View Parts Drawings / Parts Lists
Exploded View Parts Drawings / Parts Lists
90000860E
Variable Pumps
Minor Repair Parts
G512
G516
P2B_
P06
P13
P2A_
G502
G506
G532
G536
P30
P06
G542
G546
P13
K018
bis
K042
OR
BOTH SIDES
K90
K10
K50
(G502
G506)
B70
G172
G176
K70
K80
(B70)
B80
(B80)
(G63)
(G64)
G64
(CODE 61 OPTION)
G63
(CODE 61 OPTION)
B90
G522
G526
P30
(G502
G506)
B71
(B90) B82
(L70)
L70
L60
L40
L50
(L40)
L35
(Early Production
075 Frame Size)
L30
(G501
G508)
G521
G528
(G63)
(G64)
G63
(CODE 61 OPTION)
G501
G508
G511
G518
G541
G548
G531
G538
(K018
THRU
K042)
(G501
G508) G64
(CODE 61 OPTION)
B83
B83
OR
BOMAG 781 008 911 79
18.1
79
Parts List
B70............... Plug ......................................................... 2
B71............... Plug ......................................................... 1
B80............... Plug ......................................................... 1
B82............... Plug ......................................................... 1
B90............... Filter screen ............................................ 3
G63 .............. Split flange clamp .................................... 4
G64 .............. Plug ......................................................... 4
G172 ............ Plug ......................................................... 1
G176 ............ O-ring ...................................................... 1
G501 ............ Plug ......................................................... 3
G502 ............ Plug ......................................................... 3
G506 ............ O-ring ...................................................... 3
G508 ............ O-ring ...................................................... 3
G511 ............ Plug ......................................................... 1
G512 ............ Plug ......................................................... 1
G516 ............ O-ring ...................................................... 1
G518 ............ O-ring ...................................................... 1
G521 ............ Plug ......................................................... 1
G522 ............ Plug ......................................................... 1
G526 ............ O-ring ...................................................... 1
G528 ............ O-ring ...................................................... 1
G531 ............ Plug ......................................................... 1
Item Description Qty Item Description Qty
G532 ............ Plug ......................................................... 1
G536 ............ O-ring ...................................................... 1
G538 ............ O-ring ...................................................... 1
G541 ............ Plug ......................................................... 1
G542 ............ Plug ......................................................... 1
G546 ............ O-ring ...................................................... 1
G548 ............ O-ring ...................................................... 1
K10............... Plug assembly ......................................... 1
K50............... O-ring ...................................................... 1
K70............... Spring ...................................................... 1
K80............... Poppet ..................................................... 1
K90............... Nut ........................................................... 1
L30 ............... Seal carrier .............................................. 1
L35 ............... Seal carrier .............................................. 1
L40 ............... Lip seal .................................................... 1
L50 ............... O-ring ...................................................... 1
L60 ............... Retainer ................................................... 1
L70 ............... Screw ...................................................... 3
L8 ................. Key .......................................................... 1
L9 ................. Slotted nut ............................................... 1
BOMAG 782 008 911 79
80
Variable Pump Controls
90000861E
M95M
OR
OR
M87E
M95E
M96E
M880
M91E
M1EA
M1EF
M1EP
M0EA
M0EF
M0EP
M98E
M90E
M97E
M9EA
M9EP
M11E
OR
M87C
M0CA
M1CA
M90C
M11C
OR
M0DC
M0DD M90D
M11D
M1DC
M1DD
M87H
M0HA, M0HC
M0HF, M0HG
M0HH, M0HJ
M0HK, M0HL
M0HM, M0HN
M90H
M11H
M880
M1HA, M1HC
M1HF, M1HG
M1HH, M1HJ
M1HK, M1HL
M1HM, M1HN
M880
M830
M840
M87M
M74M
T001
THRU
T009,
T022
T050
M75M
M810
M840
REF
M840
REF
M820
M860
M870
M850
M92M
M98M
S40
M0MA M0ME
M0MB M0MF
M0MC M0MG
M0MD M0M9
M90M
M7MA
M7MB
M7MC
M7MD
M7ME
M7MF
M7MG
M72M
M71M
M78M
M77M
M76M
T301
THRU
T309,
T322
T350
T401
THRU
T409,
T422
T450
M97M
M96M
M9ME
M11M
T201
THRU
T209,
T222
T250
M1MA
M1MB
M1MC
M1MD
M1ME
M1MF
M1MG
(Early Production
130 cc Frame Size)
BOMAG 783 008 911 79
18.1
81
M0CA ........... Cover plate kit ......................................... 1
M1CA ........... Cover plate .............................................. 1
M11C ........... Control gasket ......................................... 1
M11D ........... Control gasket ......................................... 1
M87C ........... Washer, seal (042) ................................. 1
M90C ........... Screw ...................................................... 6
M0DC........... Control kit, 3-position FNR 12V .............. 1
M0DD........... Control kit, 3-position FNR 24V .............. 1
M1DC........... Control, 3-position FNR 12V ................... 1
M1DD........... Control, 3-position FNR 24V ................... 1
M80 .............. Control gasket ......................................... 1
M87D ........... Washer, seal (042) ................................. 1
M90D ........... Screw ...................................................... 6
M0EA ........... Control kit, EDC with
MS connector .......................................... 1
M0EP ........... Control kit, EDC with
Packard connector .................................. 1
M1EA ........... Control, EDC with
MS-connector .......................................... 1
M1EP ........... Control, EDC with
Packard-connector .................................. 1
M9EA ........... PCP type 3 oil filled (MS) ........................ 1
M9EA ........... PCP type 3 oil filled (Packard) ................ 1
M80 .............. Control gasket ......................................... 1
M87E............ Washer, seal (042) ................................. 1
M90E............ Screw ...................................................... 6
M91E............ Plastic cap (MS) ...................................... 1
M95E............ O-ring ...................................................... 2
M96E............ O-ring ...................................................... 1
M97E............ O-ring ...................................................... 1
M98E............ Screw ...................................................... 4
M1MA........... Servovalve kit .......................................... 1
M0HA ........... Control kit, hydraulic, HDC ..................... 1
M0HC........... Control kit, hydraulic, HDC ..................... 1
M1HA ........... Control, hydraulic, HDC .......................... 1
M1HC........... Control, hydraulic, HDC .......................... 1
M11H ........... Control gasket ......................................... 1
M80 .............. Control gasket ......................................... 1
M87H ........... Washer, seal (042) ................................. 1
M90H ........... Screw ...................................................... 6
M0MA........... Control MDC
w/o neutral start switch ........................... 1
M7M............. Control handle ......................................... 1
M71M........... Washer .................................................... 1
M72M........... Nut ........................................................... 1
M80 .............. Control gasket ......................................... 1
M87M........... Washer, seal (042) ................................. 1
M90M........... Screw ...................................................... 6
M0MB........... Control MDC
w/ neutral start switch ............................. 1
M71M........... Washer .................................................... 1
M72M........... Nut ........................................................... 1
M80 .............. Control gasket ......................................... 1
M87M........... Washer, seal (042) ................................. 1
M90M........... Screw ...................................................... 6
S40............... Neutral start switch kit ............................. 1
M0MC .......... Control MDC w/ sol. valve ...................... 1
M71M........... Washer .................................................... 1
M72M........... Nut ........................................................... 1
M74M........... Solenoid valve ......................................... 1
M75M........... Control manifold ...................................... 1
M77M........... Manifold gasket ....................................... 1
M78M........... Screw ...................................................... 2
M80 .............. Control gasket ......................................... 1
M87M........... Washer, seal (042) ................................. 1
M90M........... Screw ...................................................... 6
M0MD .......... Control MDC w/ sol. valve and
neutral start switch .................................. 1
M71M........... Washer .................................................... 1
M72M........... Nut ........................................................... 1
M75M........... Control manifold ...................................... 1
M76M........... Solenoid valve ......................................... 1
M77M........... Manifold gasket ....................................... 1
M78M........... Screw ...................................................... 2
M80 .............. Control gasket ......................................... 1
M87M........... Washer, seal (042) ................................. 1
M90M........... Screw ...................................................... 6
S40............... Neutral start switch ................................. 1
M810 ............ Adapter plate - Control (130 cc) ............. 1
M820 ............ O-ring (130 cc) ........................................ 1
M830 ............ O-ring (130 cc) ........................................ 1
M840 ............ O-ring (130 cc) ........................................ 2
M850 ............ Plug (130 cc) ........................................... 1
M860 ............ Screw (130 cc) ........................................ 6
M870 ............ Plug (130 cc) ........................................... 1
M9ME........... 4/2 Way valve ......................................... 1
M92M........... Screw ...................................................... 4
M95M........... O-ring ...................................................... 1
M96M........... O-ring ...................................................... 1
M97M........... O-ring ...................................................... 1
M98M........... Screw ...................................................... 4
T001-9.......... Control orifice kit ..................................... 1
T201-9.......... Orificed check valve ................................ 1
T301-9.......... Spring ...................................................... 1
T401-9.......... Spring retainer ......................................... 1
Control Parts List
BOMAG 784 008 911 79
82
Filter and Options
OR
H70
J15N
J30
J40N
H30
OR
OR
H40
H50
H60
H50
H50L
J80N
OR
J92_
J10_
J70_
H80
H70
J95_
J90_
J60_
J50_
J15_
J30
J00_
J80_
H90L
(H30)
H05
H30
H40
H50
H60
H05
H40
H50
H60
H05
H80
Or
OR
N25R
N35S
N10S
N40P
N40L
N20R
N15M
N35R
N00M
N15R
N25M
N00R
N10R
N31R
N30R
N20M
N10M
N35M
N35M
REF
N00S
90000863E
90000862E
BOMAG 785 008 911 79
18.1
83
Parts List Filter and Options
H05B-H ........ Kit - Charge pump................................... 1
H50L ............ Spacer (No charge pump) ...................... 1
H30 .............. Port plate ................................................. 2
H40 .............. Pin ........................................................... 1
H50 .............. Charge pump shaft ................................. 1
H60 .............. Key .......................................................... 1
H70 .............. Retaining plate ........................................ 1
H80 .............. Screw ...................................................... 6
H90L ............ Plug ......................................................... 1
J00A ............. Aux. mtg. SAE A flange .......................... 1
J00B ............. Aux. mtg. SAE B flange .......................... 1
J00C............. Aux. mtg. SAE C flange .......................... 1
J00D............. Aux. mtg. SAE D flange .......................... 1
J00T ............. Aux. mtg. SAE A flange (11 T) ............... 1
J00V ............. Aux. mtg. SAE B-B flange....................... 1
J00N............. Aux. mtg. flange - none .......................... 1
J10A-V ......... Coupling .................................................. 1
J15 ............... Charge pump cover assembly ................ 1
J15N............. Charge pump cover assembly ................ 1
J30 ............... Bushing ................................................... 1
J50A-V ......... O-ring ...................................................... 1
J60A/T.......... Flange adaptor SAE A ............................ 1
J60B/V ......... Flange adaptor SAE B ............................ 1
J60C............. Flange adaptor SAE C ............................ 1
J60D............. Flange adaptor SAE D ............................ 1
J70A-V ......... Washer .................................................... 4
J80A-V ......... Screw ...................................................... 4
J80N............. Screw ...................................................... 4
J90A-V ......... O-ring ...................................................... 1
J92A-V ......... Cover plate .............................................. 1
J95A-V ......... Screw ................................................... 2/4
N00M ........... Filtration manifold kit (Int) ....................... 1
N10M ........... Manifold................................................... 1
N15M ........... O-ring ...................................................... 2
N20M ........... Nut ........................................................... 1
N25M ........... Tube ........................................................ 1
N35M ........... Plug ......................................................... 2
N40L ............ Filter ........................................................ 1
N40P ............ Filter ........................................................ 1
N00R............ Filtration manifold kit (Rmt) ..................... 1
N10R............ Manifold................................................... 1
N15R............ O-ring ...................................................... 1
N20R............ Nut ........................................................... 1
N25R............ Tube ........................................................ 1
N30R............ Plastic plug .............................................. 2
N35R............ Plug ......................................................... 1
N00S ............ Filtration kit (Suction Flt) ......................... 1
N10S ............ Reducer fitting (Suction Flt) .................... 1
N35S ............ Plug ......................................................... 1
Name Plates
Place of Manufacture
Name Plate (German Production) Name Plate (U.S.A. Production)
MADE IN U.S.A.
Model Code Typ
90L055 EA 1 N
6 S 3 C6 C 03
Model No. Ident Nr
Serial No. Fabr Nr
Ames, Iowa, U.S.A. Neumnster, Germany
94 2029
Model
Code
Model Number
Serial Number
Model Code Typ
Model No. Ident Nr
Serial No. Fabr Nr
MADE IN GERMANY
90L055 EA 1 N
6 S 3 C6 C 03
687459
Model
Code
Model Number
Serial Number
BOMAG 786 008 911 79
84
90000864E
Fixed Motor
Minor Repair Parts
G64
(CODE 61 OPTION)
(G64)
(G63)
G63
(CODE 61 OPTION)
G50
H20W
H50W
H40W
H30W
H10W
H10N
H50N
G70
(H50W)
(H40W)
(H20W)
(H30W)
(H50N)
(G50)
H60N
H66W
H64W
H62W
H60W
H68W
(B80)
B80
(L70)
L70
L60
L40
L50
(L40)
L35
(Early Production
075 Frame Size)
L30
OR
G63
(CODE 61 OPTION)
G64
(CODE 61 OPTION)
(G64)
(G63)
B83
B83
(B80)
B80
(B83)
(B83)
BOMAG 787 008 911 79
18.1
85
Name Plates
MADE IN U.S.A.
Model Code Typ
90M055 NC 0 N
8 N 0 C6 W 00
NNN 00 00 24
Model No. Ident Nr
Serial No. Fabr Nr
Model Code Typ
Model No. Ident Nr
Serial No. Fabr Nr
MADE IN GERMANY
90M055 NC 0 N
8 N 0 C6 W 00
NNN 00 00 24
312918
N 91 26 67890
94 2029
A 91 26 67890
Model
Code
Model
Code
Name Plate (German Production) Name Plate (U.S.A. Production)
Model Number
Serial Number
Parts List
Item Description Qty
B80............... Plug ......................................................... 2
B83............... Plug ......................................................... 1
B83............... Speed sensor .......................................... 1
G50 .............. Plug ......................................................... 2
G70 .............. Plug ......................................................... 1
G63 .............. Split flange screw .................................... 4
G64 .............. Screw - Shipping Cover .......................... 4
H10N ............ Loop flushing spool - defeat .................... 1
H50N ............ Plug ......................................................... 2
H10W........... Shuttle valve spool .................................. 1
H20W........... Spring guide ............................................ 2
H30W........... Spring ...................................................... 2
H40W........... O-ring ...................................................... 2
H50W........... Plug ......................................................... 2
H60W........... Charge relief valve plug .......................... 1
H62W........... O-ring ...................................................... 1
H64W........... Spring ...................................................... 1
H66W........... Charge relief poppet ............................... 1
H68W........... Lock nut ................................................... 1
L30 ............... Seal carrier .............................................. 1
L35 ............... Seal carrier .............................................. 1
L40 ............... Lip seal .................................................... 1
L50 ............... O-ring ...................................................... 1
L60 ............... Retainer ................................................... 1
L70 ............... Screw ...................................................... 3
L8 ................. Key .......................................................... 1
L9 ................. Slotted nut ............................................... 1
Model Number
Serial Number
BOMAG 788 008 911 79
86
(H30W)
H10W
H20W
H40W
H30W
(H40W)
(H20W)
H50W
H10N
P600
P602
H60W
H68W
H64W
G63
(CODE 61 OPTION)
G64
(CODE 61 OPTION)
(G64)
H62W
H66W
(H50W)
T100
T101
(B74)
T40
T50
(T50)
T60
B76
T30
(P400)
(P401)
(P402)
(P403)
E35
E26
E15
(B80)
(L70)
L70
L60
L40
L50
(L40)
L35
(Early Production
075 Frame Size)
L30
(P400)
(P401)
(P402)
(P403)
E35
E25
E15
P800
H60N
G50
(G50)
(H50N)
H50N G70
B74
P700
P702
B80
P601
P603
M1PT
M1NA, M1NB
M1NC, M1ND
Y70
Y80
Y71
Y72
(B74)
(G63)
B83
B83
(B74)
Y60
Y40
Y50
(Y50)
Y102 Y100
Y101
Variable Motor
Minor Repair Parts
90000865E
BOMAG 789 008 911 79
18.1
87
Parts List
B74............... Plug ......................................................... 4
B76............... Plug ......................................................... 1
B80............... Plug ......................................................... 2
B83............... Plug ......................................................... 1
B83............... Speed sensor .......................................... 1
E15............... Cap .......................................................... 1
E25............... Set screw ................................................ 1
E35............... Nut - Seal Lock ....................................... 1
G50 .............. Plug ......................................................... 2
G63 .............. Split flange clamp .................................... 4
G64 .............. Shipping cover screw.............................. 4
G70 .............. Plug ......................................................... 1
H10N ............ Loop flushing spool - defeat .................... 1
H50N ............ Plug ......................................................... 2
H60N ............ Plug ......................................................... 1
H10W........... Shuttle valve spool .................................. 1
H20W........... Spring guide ............................................ 2
H30W........... Spring ...................................................... 2
H40W........... O-ring ...................................................... 2
H50W........... Plug ......................................................... 2
H60W........... Charge relief valve plug .......................... 1
H62W........... O-ring ...................................................... 1
H64W........... Spring ...................................................... 1
H66W........... Charge relief poppet ............................... 1
H68W........... Lock nut ................................................... 1
L8 ................. Key .......................................................... 1
L9 ................. Slotted nut ............................................... 1
L30 ............... Seal carrier .............................................. 1
L35 ............... Seal carrier .............................................. 1
L40 ............... Lip seal .................................................... 1
L50 ............... O-ring ...................................................... 1
L60 ............... Retainer ................................................... 1
L70 ............... Screw ...................................................... 3
M1N ............. Control valve - electric ............................ 1
M1P.............. Control valve - hydraulic ......................... 1
P400............. Plug ......................................................... 2
P600............. Plug ......................................................... 1
P601............. PCOR-Valve............................................ 1
P700............. Special plug ............................................. 1
P800............. O-ring ...................................................... 1
T30 ............... Filter screen ............................................ 1
T40 ............... O-ring ...................................................... 1
T50 ............... Backup ring ............................................. 2
T60 ............... O-ring ...................................................... 1
T100 ............. Orifice plug .............................................. 1
Y40............... O-ring ...................................................... 1
Y50............... Backup ring ............................................. 2
Y60............... O-ring ...................................................... 1
Y70............... Orifice check valve .................................. 1
Y71............... Nut - Seal Lock ....................................... 1
Y72............... O-ring ...................................................... 1
Y80............... Plug ......................................................... 1
Y100............. Orifice plug .............................................. 1
Y102............. Orifice check valve .................................. 1
Name Plate
Name Plate (U.S.A. Production)
MADE IN U.S.A.
Model Code Typ
90S055 NB 2 0
8 N 4 S1 W 01
NNN 01 00 24
Model No. Ident Nr
Serial No. Fabr Nr
94 4002
A 91 26 67890
Serial Number
Model Number
Model Code
BOMAG 790 008 911 79
F000 686 F000 691 F000 692
F000 690 F000 688
F000 684
F000 693 F000 687 F000 717
F000 685
Hydraulic Power Systems
SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide
Worldwide Service Support
SAUER-SUNDSTRAND provides comprehensive worldwide service for its
produkts through an extensive network of Authorized Service Centers
strategically located in all parts of the world.
Look to SAUER-SUNDSTRAND for the best in WORLDWIDE SERVICE.
Hydrostatc Transmission
Packages
Genuine Service Parts Gear Pumps and Motors
Cartridge Motors/
Compact Wheel Drives
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Pumps and Motors
Microcontrollers and
Electrohydraulic Controls
Open Circuit Axial Piston Pumps
SAUER-SUNDSTRAND GMBH & CO.
Postfach 2460 D-24531 Neumnster
Krokamp 35 D-24539 Neumnster Germany
Phone: (04321) 871-0 Fax: (04321) 871 122
SAUER-SUNDSTRAND is a world leader in the design
and manufacture of Hydraulic Power Systems. Research
and development resources in both North America and
Europe enable SAUER-SUNDSTRAND to offer a wide
range of design solutions utilizing hydraulic power system
technology.
Heavy Duty Bent Axis
Variable Motors
Heavy Duty Axial Piston
Pumps and Motors
http://www.sauer-danfoss.com
Original
Ersatzteile
Genuine Parts
SAUER-SUNDSTRAND specializes in integrating a full
range of system components to provide vehicle designers
with the most advanced total-design system.
SAUER-SUNDSTRAND is Your World Source for Controlled
SAUER-SUNDSTRAND COMPANY
2800 East 13th Street
Ames IA 50010 U.S.A.
Phone: (515) 239-6000 Fax: (515) 239-6618
SM-SPV/SMF/SMV90-E 10/98 300047G
BOMAG 791 008 911 79
18.2 Vibration motor A2FM
BOMAG 792 008 911 79
Vibration motor A2FM
BOMAG 793 008 911 79
18.2
Industrial
Hydraulics
Electric Drives
and Controls
Linear Motion and
Assembly Technologies Pneumatics
Service
Automation
Mobile
Hydraulics
Konstantmotor A2FM/E
Fixed Displacement Motor A2FM/E
Baureihe / Series 61
Reparaturanleitung / Repair Instructions
RDE 91 001-03-R/05.03
ersetzt / replaces 04.00
BOMAG 794 008 911 79
2 Bosch Rexroth AG | Mobile Hydraulics A2F | RDE 91 001-03-R/05.03
Hinweis / Inhalt
Notice / Contents
HINWEIS
Bezeichnungen, Beschreibungen und Darstellungen entsprechen
dem Informationsstand zum Zeitpunkt der Drucklegung dieser
Unterlage.
nderungen knnen den Service am Produkt beeinflussen, Ver-
pflichtungen entstehen uns daraus nicht.
Methoden und Vorrichtungen sind Empfehlungen, fr deren Re-
sultat 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 si-
cherzustellen.
Sachkenntnis, die Voraussetzung fr jede Service-arbeit, vermit-
teln wir in unseren Schulungskursen.
INHALT Seite/
Page
A2F
Schnittbild 3-6
Allgemeine Reparaturhinweise 7
Dichtstze und Baugruppen 8-9
Triebwelle abdichten 10
Anschluplatte abdichten 11-14
Triebwerk ausbauen 15-16
berprfungshinweise 17-18
Triebwerk einbauen 19-21
Anziehdrehmomente 22-24
Sicherheitsbestimmungen 25
NOTICE
Specifications, descriptions and illustrative material shown here
in were as accurate as known at the time this publication was
approved for printing.
BRUENINGHAUS HYDROMATIK reserves the right to dis-
conti nue model s or opti ons at any ti me or to change
specifications, materials, or design without notice and without
incurring obligation.
Optional equipment and accessories may add cost to the basic
unit, and some options are available only in combination with
certain models or other options.
For the available combinations refer to the relevant data sheet for
the basic unit and the desired option.
Adjustment and tests have to be carried out on the test bench
under operating temperatures.
Protection of personnel and property has to be guar-anteed by
appropriate measures.
Expert knowledge, the precondition of any service work, can be
obtained in our training courses.
CONTENTS
A2F
Sectional view
Seal kits and sub-assemblies
Sealing of the drive shaft
Sealing of the cover plate
Removal the rotary group
Inspection guidelines
Installing rotary group
Tightening torques
Safety regulations
BOMAG 795 008 911 79
18.2
RDE 91 001-03-R/05.03 | A2F Mobile Hydraulics | Bosch Rexroth AG 3
Schnittbild
Sectional view
Pos.B
Pos.D
Pos.A
Mepunkte:
Siehe Serviceinfo
Measuring points:
See service information
A2FM
BOMAG 796 008 911 79
Schnittbild
Sectional view
A2FM mit Splventil /
A2FM with flushing valve
BOMAG 797 008 911 79
18.2
Schnittbild
Sectional view
A2FE
BOMAG 798 008 911 79
Schnittbild
Sectional view
A2FE
BOMAG 799 008 911 79
18.2
Achtung!
Nachfolgende Hinweise bei allen Reparatur-
arbeiten an Hydraulikaggregaten beachten!
Attention!
Observe the following notices when carrying out
repair work at hydraulic aggregates!
Alle ffnungen der Hydraulikaggregate
verschlieen.
Close all ports of the hydraulic aggregates.
Alle Dichtungen erneuern.
Nur ORIGINAL BRUENINGHAUS HYDROMATIK
-Ersatzteile verwenden.
Replace all seals.
Use onl y ORI GI NAL BRUENI NGHAUS
HYDROMATIK spare parts.
Alle Dicht- und Gleitflchen auf Verschlei prfen.
Achtung: Nacharbeiten an Dichtflchen z.B. durch
Schleifpapier kann die Oberflche beschdigen.
Check all seal and sliding surfaces for wear.
Attention: Rework of sealing area f. ex. with abrasive
paper can damage surface.
Hydraulikaggregate vor Inbetriebnahme mit
Betriebsmedium befllen bzw. entlften.
Before start-up fill up hydraulic aggregates with
hydraulic oil respectively deaerate.
Allgemeine Reparaturhinweise
BOMAG 800 008 911 79
Dichtstze und Baugruppen
Dichtsatz
Seal kit
Triebwerk, mechanischer Teil;
mu abgestimmt werden Pos. "A".
(siehe Serviceinfo)
Rotary group, mechanical part;
has to be adjusted to item "A".
(see service info)
Lagersatz, komplett abgestimmt.
Pos. B (Sttzscheibe und Sicherungsring
nicht tauschbar)
zustzliche Abstimmung Pos. "A".
(siehe Serviceinfo)
Bearing set, matched
Item B (support disc and circlip are
not exchangeable)
Additional adjustment item "A".
(see service info)
Triebwerk, mechanischer Teil /
Rotary group, mechanical part
BOMAG 801 008 911 79
18.2
Triebwerk, hydraulischer Teil;
Abstimmung hydraulischer Teil Pos. "D".
(siehe Serviceinfo)
Rotary group, hydraulic part;
Adjustment of the hydraulic part Pos. "D".
(see service info)
Triebwerk komplett; - fertig vorabgestimmt -
Abstimmung hydraulischer Teil Pos. "D".
(siehe Serviceinfo)
Complete rotary group, - pre-adjusted -
Adjustment of the hydraulic part Pos. "D".
(see service info)
Dichtstze und Baugruppen
Triebwerk, hydraulischer Teil /
Rotary group, hydraulic part
Splventil
Flushing valve
Ventil
Valve
BOMAG 802 008 911 79
Bei nicht verzahnten Triebwellen: Pafeder abneh-
men. Triebwelle abkleben,
For non-splined shafts: remove key.
Protect the drive shaft (e.g. tape).
Sicherungsring ausbauen, Verschluring abdrcken
Remove circlip, prise off cover.
Sichtkontrolle
Wellendichtring (1), Verschluring (2),
Triebwelle (3), Gehuse (4), O-Ring (5).
Visual check
Shaft seal (1), cover (2), drive shaft (3),
housing (4), O-ring (5).
Triebwelle abdichten
BOMAG 803 008 911 79
18.2
Wellendichtring demontieren.
Remove shaft seal.
Neuen Wellendichtring lagerichtig mit
passender Bchse einpressen.
Press in the new shaft seal,ensuring that
it is correctly orientated, using a suitable bush.
Neuen O-Ring einlegen, auf bndiges Anliegen
achten. O-Ring sowie Dicht- und Staublippe des
Wellendichtringes einfetten. (siehe Serviceinfo)
Fit new O-ring, ensure that it is correctly located.
Grease the O-ring as well as the seal and dust lips
of the shaft seal. (see service information)
Sicherungsring einbauen.
Sitzkontrolle des Sicherungsringes in der Nut.
Fit circlip.
Check to ensure that the circlip is correctly located
within the groove.
Triebwelle abdichten
BOMAG 804 008 911 79
Lage der Anschluplatte zum Gehuse kenn-
zeichnen (Pfeil), Befestigungsschrauben lsen.
Mark the position of the cover plate with regard
to the housing (arrow), loosen the fixing screws.
Anschluplatte um Verdrillstift schwenken (1)
und abheben (2).
Swing the connection plate about the locating
pin (1) and lift off (2).
Anschluplatte abdichten
BOMAG 805 008 911 79
18.2
Auf Montagestellung des Verdrillstiftes achten
(Pfeile).
Take the assembly position of the locating
pin (arrow) into account.
Pumpe, Drehrichtung rechts.
(Blick auf sphrische Flche.)
Pump, clockwise rotation.
(viewed on spherical surface.)
Pumpe, Drehrichtung links.
Pump, anti-clockwise rotation.
(viewed on spherical surface.)
Motor, beide Drehrichtungen.
Motor, bi-directional.
(Viewed on spherical surface.)
Druckseite /
Pressure side
Saugseite /
Suction side
Druckseite /
Pressure side
Saugseite /
Suction side
BOMAG 806 008 911 79
Neuen O-Ring einlegen, zuvor leicht einfetten.
Lightly grease and fit O-ring.
Anschluplatte aufsetzen, auf Kennzeichnung und
Lage des Verdrillstiftes achten.
Place the cover plate onto the housing taking into
account the location mark and position of the
locating pin.
Befestigungsschrauben mit Drehmomenten-
schlssel anziehen.
Tighten fixing screws using a torque wrench.
Sichtkontrolle
O-Ring (1), Einstich (2), Platte (3).
Visual check
O-ring (1), Groove (2), Plate (3).
BOMAG 807 008 911 79
18.2
Demontage der Anschluplatte.
Steuerplatte abheben.
Zylinder am Mittelzapfen mit Schraube befestigen.
Removal of the connection plate.
Lift off the control plate.
Secure the cylinder to the centre pin using a screw.
Gewindestift,Zylinderschraube /
Threaded pin,socket head screw
Triebwerk ausbauen
Lagersatz / Bearing set
NG / Size (mm)
10; 12; 16 M3 x 35
23; 28; 32 M5 x 45
45 M5 x 50
56; 63 M5 x 55
80; 90 M5 x 60
107; 125; 131 M6 x 70
160; 180 M6 x 85
BOMAG 808 008 911 79
Verschluring, O-Ring und Pascheibe ausbauen.
Remove the cover, O-ring and shim.
Triebwerk mit Vorrichtung ausbauen.
Withdraw the rotary group using an extractor.
Befestigungsschraube ausbauen.
Zylinder abheben.
Remove the fixing screw.
Lift off the cylinder.
Rckzugplatte demontieren, Schrauben sind
eingeklebt.
Komplettes Triebwerk bei ca. 120
o
C im lbad
erwrmen. Danach Befestigungsschrauben lsen!
Disassemble the retaining plate, screws are locked
with an adhesive.
Heat up the complete rotary group in an oil bath
to approx 120
o
C, then remove the fixing screws.
Triebwerk ausbauen
BOMAG 809 008 911 79
18.2
Triebwelle
1. kein Passungsrost, nicht ausgeschlagen.
2. keine Einlaufspuren, riefenfrei.
3. Kalotten riefenfrei und keine Pittings.
4. Keine Laufspuren (Lagerdreher)
Drive shaft
1. No wear, or fretting
2. No traces of wear, free of scratches.
3. Cups free of wear and no pitting.
4. No traces of wear, (bearing rotation).
1. Axiales Kolbenspiel
1. Axial play of piston.
Kolben
Riefenfrei, keine Pittings.
Piston
Free of scratches, no pitting.
Mittelzapfen
1. Riefenfrei, ohne Pittings.
2. Riefenfrei.
Center pin
1. Free of scratches, no pittings.
2. Free of scratches.
Rckzugplatte
Riefenfrei, keine Ausbrche.
Retaining plate
Free of scratches, no wear.
berprfungshinweise
1
3
3
4
4
2
1
1
2
Neu / New
Alt / Old
BOMAG 810 008 911 79
Zylinder/Steuerplatte
1. Bohrungen riefenfrei, nicht ausgelaufen.
2. Gleichmiges Tragbild, ri- und riefenfrei.
Cylinder / control plate
1. Bores unscratched, and no traces of wear.
2. Even load distribution, free of cracks and
grooves.
Gehuse
Im Lagerbereich riefenfrei und keine
Einlaufspuren.
Housing
No traces of wear in the bearing area.
Nur kompletten Kolbensatz austauschen.
Only exchange the pistons as a complete set.
Zylinder und Steuerplatte nur gemeinsam
austauschen.
Only replace the cylinder and control plate as a pair.
berprfungshinweise
BOMAG 811 008 911 79
18.2
Triebwerk einbauen
Rckzugplatte mit Kolben und Mittelzapfen
einsetzen.
Schrauben mit Precote-Beschichtung verwenden.
Fit retaining plate complete with pistons and
centre pin.
Uses screws with a Precote coating.
Druckfeder (1) und Abstimmscheibe (2) einbauen.
Fit the compression spring (1) and shim(2).
Zylinder in Neutralposition befestigen.
Fix the cylinder in the neutral position.
Triebwelle mit Lager vormontiert verwenden.
Use a pre-assembled drive shaft with bearings.
1
2
Abstimmung Pos. A / Adjustment item A
A = A* + S
S = Nennma - Sicherungsring /Safety ring
A A*
S
BOMAG 812 008 911 79
Triebwerk max. ausschwenken.
Swivel the rotary group to max.
Neuer Radialwellendichtring montiert?
Is the new shaft seal fitted?
Gehuse auf ca. 80
o
C erwrmen.
Heat the housing to approx. 80
o
C.
Heies Gehuse bis zum Anschlag aufsetzen.
Push on the hot housing until the stop is reached.
Neue Montagestellung.
New assembly position.
Triebwerk einbauen
BOMAG 813 008 911 79
18.2
Pascheibe, O-Ring einlegen. Verschluring
montieren.
O-Ring, Zwischenraum Wellendichtring einfetten
(siehe Serviceinfo).
Fit the shim and O-ring. Then fit the cover.
Grease the O-ring as well as the seal and dust
lipsof the shaft seal.
Triebwerk gegen Verschluring ziehen.
Kontrolle: Verschluring spielfrei.
Pull the rotary group against the cover.
Check: to see that the cover is free of play.
Befestigungsschraube ausbauen.
Steuerplatte lagerichtig aufsetzen.
Fertigmontage
Abstimmung Pos. D - siehe Serviceinfo
Remove fixing screw. Fit the control plate into its
correct location.
Final assembly
For adjustment of Pos. D - see service info
Anschlsse mit Staubschutz abdichten.
Korrosionsschutz (innen/auen). Fertig!
Seal connections to protect against dust.
Corrosion proctection (internal/external).
Assembly complete.
Triebwerk einbauen
Pos. D
Abstimmung Pos. D / Adjustment item D
BOMAG 814 008 911 79
Montageanweisung fr Anziehdrehmomente
Assembly guidelines for tightening torques
1. Schaftschrauben (nach N 08.001)
Die Werte gelten fr Schaftschrauben mit metri-
schem ISO-Gewinde nach DIN 13 Teil 13, sowie
Kopfauflagemaen nach DIN 912 Zylinder-
schrauben, DIN 931 Sechskantschrauben mit
Schaft bzw. DIN 933 Sechskantschrauben mit
Gewinde bis Kopf.
1. Bolts (to N 08.001)
The values stated are valid for bolts with metric
ISO threads to DIN 13 part 13, as well as head
areas to DIN 912 socked head cap screws, DIN
931 hexagon bolt or DIN 933 hexagon bolts with
threads up to the head.
Festigkeitsklassen / Tensile strength class
Gewinde / Thread 8.8 10.9 12.9
Anziehdrehmoment / Tightening torque M
A
in Nm
M3 1,1 1,6 1,9
M4 3,1 4,5 5,3
M5 6,1 8,9 10,4
M6 10,4 15,5 18
M8 25 37 43
M10 51 75 87
M12 87 130 150
M14 140 205 240
M16 215 310 370
M18 300 430 510
M20 430 620 720
M22 580 830 970
M24 740 1060 1240
BOMAG 815 008 911 79
18.2
2. Verschluschrauben mit Innensechskant und
Profildichtring (nach N 02.009).
2. Plugs with internal hexagon and profile seal ring
(to N 02.009).
EOLASTIC-
Dichtung / Seal
G
Gewinde / Anziehdrehmoment / Gewinde / Anziehdrehmoment
Thread Tightening torque Thread Tightening torque
M
A
in Nm M
A
in Nm
M8 x 1 5 G 1/8 A 10
M10 x 1 10 G 1/4 A 30
M12 x 1,5 20 G 3/8 A 35
M14 x 1,5 30 G 1/2 A 60
M16 x 1,5 35 G 3/4 A 90
M18 x 1,5 40 G 1 A 140
M20 x 1,5 50 G 1 1/4 A 240
M22 x 1,5 60 G 1 1/2 A 300
M26 x 1,5 70
M27 x 2 90
M30 x 1,5 100
M33 x 2 140
M42 x 2 240
M48 x 2 300
BOMAG 816 008 911 79
7. Linsenschrauben
mit Innen-TORX, Gewindevorbeschichtung mit

"precote"
7. Oval head screw
with inner TORX, thread precoated with

"precote"
precote 80 - Rot / Red Standard / Standard
precote 86 - Blau / Blue
Variante / Variant
*
* mit Unterkopfbeschichtung - farblos
* with head bottom coating - colorless
2602493 M5 x 16
2602395 M6 x 20
siehe Stckliste / as to parts list
Festigkeitsklassen / Tensile strength class
Gewinde / Thread 10.9
Anziehdrehmoment / Tightening torque M
A
in Nm
M3 2,1
M4 4,7
M5 9,1
M6 15,8
M8 37,7
BOMAG 817 008 911 79
18.2
General advice
Make yourself familiar with the equipment of the
machine.
Only operate the machine if your are completely familiar with
the operating and control elements as well as the functioning
of the machine.
Use your safety equipment like helmet, safety shoes and
hearing protection.
Make yourself familiar with your working field.
Only operate the machine for its intended purpose.
Please observe the guidelines of the Professional
Association and the machine manufacturer.
Sicherheitsbestimmungen
Safety regulations
Allgemein
Machen Sie sich mit der Ausstattung der Maschine
vertraut.
Fahren Sie die Maschine nur, wenn Sie sich vllig mit den
Bedien- und Steuerelementen sowie der Arbeitsweise der
Maschine vertraut gemacht haben.
Benutzen Sie Ihre Schutzausrstung wie Schutzhelm,
Sicherheitsschuhe und Gehrschutz.
Machen Sie sich mit Ihrem Arbeitsgebiet vertraut.
Benutzen Sie die Maschine nur fr den ihr zugedachten
Zweck.
Beachten Sie bitte die Richtlinien der Berufsgenossenschaft
und des Maschinenherstellers
Hydraulikanlage
1. Hydraulikanlage steht unter hohem Druck!
Unter hohem Druck austretende Hochdruck-Flssig-
keiten (Kraftstoff, Hydraulikl) knnen die Haut durch-
dringen und schwere Verletzungen verursachen.
Daher sofort einen Arzt aufsuchen, da anderenfalls
schwere Infektionen entstehen knnen!
2. Bei der Suche nach Leckstellen wegen Verletzungsgefahr
geeignete Hilfsmittel verwenden!
3. Vor Arbeiten an der Hydraulikanlage diese unbedingt
drucklos machen und angebaute Gerte absenken!
4. Bei Arbeiten an der Hydraulikanlage unbedingt Motor
abstellen und Traktor gegen Wegrollen sichern
(Feststellbremse, Unterlegkeil)!
5. Beim Anschlieen von Hydraulikzylindern und -motoren ist
auf vorgeschriebenen Anschlu der Hydraulikschluche
zu achten!
6. Bei Vertauschen der Anschlsse umgekehrte Funktionen
(z.B. Heben/Senken) - Unfallgefahr!
7. Hydraulikschlauchleitungen regelmig kontrollieren und
bei Beschdigung und Alterung austauschen! Die
Austausch schlauchleitungen mssen den technischen
Anforderungen des Gerteherstellers entsprechen!
le, Kraftstoffe und Filter ordnungsgem
entsorgen!
Hydraulic equipment
1. Hydraulic equipment is standing under high pressure.
High pressure fluids (fuel, hydraulic oil) which escape
under high pressure can penetrate the skin and cause
heavy injuries.
Therefore immediately consult a doctor as otherwise
heavy infections can be caused.
2. When searching leakages use appropriate auxiliary devices
because of the danger of accidents.
3. Before working at the hydraulic equipment, lower pressure
to zero and lower working arms of the rnachine.
4. When working at the hydraulic equipment, absolutely stop
motor and secure tractor against rolling away
(parking brake, shim)!
5. When connecting hydraulic cylinders and motor pay
attention to correct connection of hydraulic flexible hoses.
6. In case of exchanging the ports, the tunctions are vice versa
(f. ex. lift-up/lower) - danger of accidents!
7. Check hydraulic flexible hoses regularly and replace them in
case of dammage or wear! The new hose pipes must comply
with the technical requirements of the machine manufacturer!
Orderly disposal or recycling of oil, fuel and
filters!
BOMAG 818 008 911 79
BOMAG 819 008 911 79
18.2
BOMAG 820 008 911 79
Bosch Rexroth AG
Mobile Hydraulics
Produktbereich Axialkolbenmaschinen
Werk / Plant Elchingen
Glockeraustrae 2
89275 Elchingen, Germany
Telefon +49 (0) 73 08 82-0
Telefax +49 (0) 73 08 72 74
info.brm-ak@boschrexroth.de
www.boschrexroth.com/brm
2003 by Bosch Rexroth AG,
Mobile Hydraulics, 89275 Elchingen
Alle Rechte vorbehalten. Kein Teil des
Werkes darf in irgendeiner Form ohne
vorherige schriftliche Zustimmung der
Bosch Rexroth AG reproduziert oder
unter Verwendung elektronischer
Systeme gespeichert, verarbeitet,
vervielfltigt oder verbreitet werden.
Zuwiderhandlungen verpflichten zu
Schadensersatz.
Die angegebenen Daten dienen allein
der Produktbeschreibung. Eine
Aussage ber eine bestimmte
Beschaffenheit oder eine Eignung fr
einen bestimmten Einsatzzweck kann
aus unseren Angaben nicht abgeleitet
werden. Die Angaben entbinden den
Verwender nicht von eigenen
Beurteilungen und Prfungen. Es ist
zu beachten, dass unsere Produkte
einem natrlichen Verschlei- und
Alterungsprozess unterliegen.
Printed in Germany
RDE 91 001-03-R/05.03
2003 by Bosch Rexroth AG,
Mobile Hydraulics, 89275 Elchingen
All rights reserved. No part of this
document may be reproduced or
stored, processed, duplicated or
circulated using electronic systems, in
any form or by any means, without the
prior written authorization of Bosch
Rexroth AG. In the event of
contravention of the above provisions,
the contravening party is obliged to
pay compensation.
The data specified above only serve to
describe the product. No statements
concerning a certain condition or
suitability for a certain application can
be derived from our information. The
given information does not release the
user from the obligation of own
judgement and verification. It must be
remembered that our products are
subject to a natural process of wear
and aging.
BOMAG 821 008 911 79
18.3 Travel drive series 51
BOMAG 822 008 911 79
Travel drive series 51
BOMAG 823 008 911 79
18.3
Series 51
saue
Bent Axis
Variable Motors
Service Manual
BOMAG 824 008 911 79
saue
Bent Axis Variable Displacement Motors Series 51
2
The Series 51 - Advanced Technology Today
The Most Technically Advanced Hydraulic Units in the Industry
SAE Flange and Cartridge Motors
Cartridge Motors designed for Direct Installation in Compact
Planetary Drives
Large Displacement Ratio (5:1)
Complete Family of Control Systems
Proven Reliability and Performance
Optimum Product Configurations
Compact, Lightweight
Motors equipped with controls normally start at maxi-
mum displacement. This provides maximum starting
torque (high acceleration).
The controls may utilize externally or internally sup-
plied servo pressure. They may be overridden by a
pressure compensator which functions when the
motor is operating in motor and pump modes. A
defeat option is available to disable the pressure
compensator override when the motor is running in
pump mode.
The pressure compensator option features a low
pressure rise (short ramp) to provide optimal power
utilization throughout the entire displacement range
of the motor. The pressure compensator is also
available as a stand-alone regulator.
Series 51 Variable Displacement Motors are bent
axis design units, incorporating spherical pistons.
These motors are designed primarily to be combined
with other products in closed circuit systems to trans-
fer and control hydraulic power.
Series 51 Motors have a large maximum / minimum
displacement ratio (5 to 1) and high output speed
capabilities. SAE flange and cartridge motor configu-
rations are available.
A complete family of controls and regulators is avai-
lable to fulfill the requirements of a wide range of
applications.
Front page: Option - hydraulic two-position control
Copyright 1992-1997, Sauer-Sundstrand Company.
All rights reserved. Contents subject to change. Printed in U.S.A. 0992H
General Description
BOMAG 825 008 911 79
18.3
saue
3
Contents
Introduction ......................................................................................................................................................4
Basic Hydraulic Circuits ...................................................................................................................................4
General Description of the Series 51 Variable Displacement Motors ..............................................................5
Functional Description...................................................................................................................................... 6
Technical Specifications and Data - Variable Displacement Motors .............................................................. 20
Safety Precautions .........................................................................................................................................21
Gauge Installation .......................................................................................................................................... 23
Start-Up Procedure and Maintenance............................................................................................................25
Component Inspection and Adjustment .........................................................................................................27
Troubleshooting ............................................................................................................................................. 37
Exploded View of the Series 51 Variable Motor ............................................................................................. 41
Minor Repair and Replacement - Variable Motor ........................................................................................... 51
General .....................................................................................................................................................51
Shaft Seal (SAE Flange Configuration) .................................................................................................... 52
Shaft Seal (Cartridge Configuration) .........................................................................................................53
Loop Flushing Shuttle Valve (Option)........................................................................................................ 54
Charge Pressure Relief Valve ...................................................................................................................55
Minimum Angle Servo Cover .................................................................................................................... 55
Hydraulic 2-Position Control (Type N2) .....................................................................................................56
Electrohydraulic 2-Position Controls (Types E1E2 and F1F2) ............................................................... 57
Electric 2-Position Controls (Type S1) ...................................................................................................... 58
Hydraulic Proportional Control (Type HZ) ................................................................................................. 59
Hydraulic Proportional Control (Type HS) ................................................................................................. 60
Hydraulic Proportional Control with Maximum Angle Over-ride (Types H1H2 or K1K2) ........................61
Two Connection Hydraulic Proportional Control (Type HP) ...................................................................... 62
Two Connection Hydraulic Proportional Control for Dual Path Vehicles (Type HC) ...............................64
Electrohydraulic Proportional Control (Types EP and EQ)........................................................................ 68
Pressure Control Pilot (PCP) Valve for Electrohydraulic Proportional Control (Types EP and EQ) .......... 70
Multi-function Block ...................................................................................................................................71
Pressure Compensator Regulator (Type PC) ........................................................................................... 76
Control Orifices .........................................................................................................................................77
Plug / Fitting Torques ................................................................................................................................77
0 - 1
BOMAG 826 008 911 79
saue
4
Introduction
Dirt or contamination is the greatest enemy of any
type of hydraulic equipment. The greatest possible
cleanliness is necessary when starting up the sys-
tem, changing filters, or performing any other service
procedure.
For Technical Information on Series 51 motors, refer
to publication BLN-10042 or 368753.
For Fluid Quality Requirements, refer to publication
BLN-9987 or 697581.
Sauer-Sundstrand provides a complete repair serv-
ice for its products. Contact any Sauer-Sundstrand
Authorized Service Center for details. Sauer-Sund-
strand Authorized Service Center locations are listed
in publication BLN-2-40527 or 698266.
The purpose of this manual is to provide information
necessary for the normal servicing of the Series 51
family of variable displacement hydrostatic motors.
This manual includes unit and component descrip-
tion, troubleshooting, adjustments, and minor repair
procedures. By following the procedures in this
manual, inspections and minor repairs may be per-
formed without affecting the unit warranty.
A Series 51 motor does occasionally require servic-
ing, and these units are designed to meet this require-
ment.
Many repairs or adjustments can be completed with-
out removing the unit from the vehicle or machine,
provided the unit is accessible and can be thoroughly
cleaned before beginning any procedures.
INPUT
PV
MV
CASE
DRAIN
LINE
OUTPUT
FLOW (BI-DIRECTIONAL)
RESERVOIR
51000001
Fig. 0-1 - Basic Closed Circuit
Closed Circuit
The main ports of the pump are connected by hydrau-
lic lines to the main ports of the motor. Fluid flows in
either direction from the pump to the motor then back
to the pump in this closed circuit. Either of the hydrau-
lic lines can be under high pressure. The direction
and speed of fluid flow (and the motor output shaft
rotation) depends on the position of the pump swash-
plate. The system pressure is determined by the
machine load.
Open Circuit
The outlet port of the pump is connected by a hydrau-
lic line to a directional control valve. The working ports
of this valve are connected to the main ports of the
motor. When the valve is actuated, fluid flows first
from the pump to the valve. The valve then directs the
fluid to the motor in either direction. The direction of
fluid flow (and motor output shaft rotation) depends
on the direction the control valve is shifted. The speed
of fluid flow (and motor output shaft speed) depends
on pump output volume and the distance the control
valve is shifted. The system pressure is determined
by the machine load.
Fluid returning from the motor is routed through the
control valve to the reservoir. Additional components
may be necessary to provide dynamic braking and to
deal with over-running loads.
Basic Hydraulic Circuits
51000002
Fig. 0-2 - Basic Open Circuit
INPUT PUMP
MV
CASE
DRAIN
LINE
OUTPUT
FLOW
(BI-DIRECTIONAL)
RESERVOIR
FLOW
(UNI-DIRECTIONAL)
C
O
N
T
R
O
L

V
A
L
V
E
0 - 2
BOMAG 827 008 911 79
18.3
saue
5
General Description of the Series 51 Variable Displacement Motors
The Series 51 variable displacement hydraulic mo-
tors use spherical pistons and piston rings. The angle
between the cylinder block and the output shaft can
be set between 32 and 6, providing a 5 to 1
maximum to minimum displacement ratio.
At maximum displacement, the motor will provide a
certain maximum output shaft torque and minimum
speed corresponding to the pressure and flow sup-
plied to the motor. Under the same input conditions
but at minimum displacement, the shaft speed will be
approximately five (5) times faster while the available
output torque will decrease to approximately one-fifth
(1/5) the full displacement value. The displacement
is changed by a servo piston which is connected to
the valve segment.
Various hydraulic and electrohydraulic controls may
be mounted on the motor end cap to control the servo
piston and the motor displacement. Servo pressure
oil may either be supplied internally from the motor, or
externally.
For all controls except the N2 and PC, servo pressure
oil is supplied to a four (4) way spool valve in the motor
end cap. When a combination of pilot pressure (or
force) from an external control assembly and internal
spring force shifts this valve, servo pressure is routed
to move the servo piston and change the motors
displacement.
A synchronizing shaft, with spherical rollers, synchro-
nizes the rotation of the output shaft and the cylinder
block. The ball end of each piston runs in a socket
bushing, pressed into the output shaft. There are no
other parts used to connect the pistons to the shaft.
Two tapered roller bearings support the output shaft.
Fig. 10-1 - Sectional view of Series 51 variable displacement motor (SAE Flange
Configuration) with Hydraulic Proportional Control
P001 196
Pressure Compensator
Override
Servo Piston
Cylinder
Charge Pressure
Relief Valve
Piston
Synchronizing
Shaft
Tapered Roller Bearings
Bearing Plate
Valve Segment
Hydraulic
Proportional
Control
Minimum
Control
Pressure
Port
10 - 1
BOMAG 828 008 911 79
saue
6
Functional Description
Fig. 10-2 - Loop
Flushing
Components
Loop Flushing
Series 51 motors used in closed circuit applications
incorporate an integral loop flushing valve as stan-
dard equipment. Installations that require additional
fluid to be removed from the main hydraulic circuit
because of fluid cooling requirements, or circuits
requiring the removal of excessive contamination
from the high pressure circuit, can benefit from loop
flushing. Series 51 motors used in open circuit appli-
cations may have the optional loop flushing defeat
components installed.
Series 51 motors equipped with an integral loop
flushing valve also include a charge pressure relief
valve. The setting of the motor charge relief valve
affects the function of the flushing circuit. Higher
motor charge relief settings reduce the loop flushing
flow and increase the flow over the pump charge
pressure relief valve when the circuit is operating.
Lower motor charge relief settings increase the loop
flushing flow and may increase the motor case pres-
sure when the circuit is operating.
An appropriate combination of pump and motor charge
pressure settings should be maintained to insure the
proper function of the loop flushing circuit. Correct
charge pressure must be maintained under all condi-
tions of operation to maintain pump control perfor-
mance in closed loop systems.
NOTE: An optional orifice may be installed between
the motor charge relief and the motor case to
limit the maximum flushing oil flow.
51000003
Fig. 10-3 - Loop
Flushing Defeat
Components
51000004
10 - 2
BOMAG 829 008 911 79
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Functional Description (Continued)
Fig. 10-4 - Minimum Displacement Limiter
with Tamper Resistant Cap (Cartridge
Motor Configuration Shown)
Fig. 10-6 - Internal Servo Pressure Supply
Screen with Multi-function Block and/or
Control Removed (Plug for External
Supply)
5100007
Fig. 10-7 - External Servo Pressure Supply
Fitting (Plug for Internal Supply)
51000008
Fig. 10-5 - Maximum Displacement Limiter
Screw
51000006
51000005
All Series 51 motors incorporate mechanical dis-
placement limiters. The minimum displacement of
the motor can be limited within the standard range by
a set screw in the motor housing. The maximum
displacement can be limited with spacers installed on
the servo piston.
Controls - General
A wide range of control options is available for the
Series 51 motors. These include pilot operated
Electrohydraulic 2-Position Controls, Hydraulic Pro-
portional Controls (single or two [2] connection), and
Electrohydraulic Proportional Controls. A directly op-
erated Hydraulic 2-Position Control and a Pressure
Compensator regulator are also available.
The Series 51 variable motor servo piston (except
when equipped with N2 control or the PC regulator)
may be operated either by servo pressure oil supplied
internally from the main ports of the motor, or by servo
pressure oil supplied from an external source. (The
N2 control uses servo pressure supplied by an exter-
nal control valve. The PC regulator obtains servo
pressure from the main ports of the motor.)
Orifice plugs are installed in the control spool sleeve
in the end cap to regulate the flow of oil from the servo
piston to the motor housing. Orifice plugs may be
installed in the end cap to regulate the flow of servo
pressure supply oil to the control valve, and to regu-
late the flow of oil from the control valve to the servo
piston.
10 - 3
BOMAG 830 008 911 79
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8
Fig. 10-8 - Series 51 Motor with N2 Control
Hydraulic 2-Position Control (Type N2)
This is a two (2) position (maximum - minimum
displacement) control, consisting of a cover plate
mounted on the end cap. An external control valve
supplies servo pressure from an external source
directly to the servo piston. PCOR is not available
with the N2 control.
When servo pressure is supplied to port Y1, the
setting piston moves to the maximum motor displace-
ment position. When servo pressure is supplied to
port Y2, the setting piston moves to the minimum
motor displacement position.
Orifices may be installed in the external control valve
or its connections to regulate the speed of servo
piston movement.
51000011
Fig. 10-10 - N2 Control Schematic
U4 (opt.)
max.
disp.
M2
M1
(M4) Y1 Y2 (M3) M6 L2
B
A
L1
Fig. 10-9 - N2 Control Components
51000010
51000009
10 - 4
BOMAG 831 008 911 79
18.3
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9
51000013
Fig. 10-11 - Series 51 Motor with E1E2 or
F1F2 Control
51000012
Fig. 10-12 - E1E2 and F1F2 Control
Components
X3 (M5)
Servo press,
external
M9
U5
(plug for
ext. servo
press.)
T1
T7,
T8
T2
T3
max.
disp.
B1
A1
M2
M1
M4 M3 M6 L2
B
A
Servo
Pressure
internal
L1
E1E2
M7
M8
U4 (opt.)
F1F2
51000014
Schematic
Electrohydraulic 2-Position Control (Types
E1E2 and F1F2)
A 12 or 24 VDC solenoid valve, mounted on the multi-
function block, connects the end of the control valve
spool in the end cap with pilot pressure (provided by
the shuttle spool in the multi-function block) or with
the motor case. The control valve in the end cap is
biased by a threshold spring, and controls oil flow to
the ends of the servo piston. Servo pressure may be
supplied from an external source or internally by the
shuttle spool in the multi-function block. PCOR is
available with these controls.
With the E1 and E2 controls, energizing the solenoid
will cause the motor to shift to minimum displace-
ment. When the solenoid is not energized, the motor
is held at maximum displacement.
With the F1 and F2 controls, energizing the solenoid
causes the motor to shift to maximum displacement.
When the solenoid is not energized, the motor is held
at minimum displacement.
10 - 5
BOMAG 832 008 911 79
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10
Electric 2-Position Control (Type S1)
A 12 VDC solenoid valve, mounted on the multi-
function block, directly operates the control valve
spool in the end cap. The control valve in the end cap
is biased by a threshold spring, and controls oil flow
to the ends of the servo piston. Servo pressure may
be supplied from an external source or internally by
the shuttle spool in the multi-function block. PCOR is
available with this control.
With the S1 control, energizing the solenoid causes
the motor to shift to maximum displacement. When
the solenoid is not energized, the motor is held at
minimum displacement.
51000163
Fig. 10-14 - Series 51 Motor with S1 Control
51000162
Fig. 10-15 - S1 Control Components
X3 (M5)
Servo press,
external
M9
U5
(plug for
ext. servo
press.)
T1
T7,
T8
T2
T3
max.
disp.
B1
A1
M2
M1
M4 M3 M6 L2
B
A
Servo
Pressure
internal
L1
S1
U4 (opt.)
51000085
Fig. 10-16 - S1 Control Schematic
10 - 6
BOMAG 833 008 911 79
18.3
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11
Fig. 10-17 - Series 51 Motor with HZ
Control
Hydraulic Proportional Control (Type HZ)
The HZ control consists of a cover plate mounted
directly on the end cap. A ball type shuttle valve
provides internal servo pressure supply to the control
valve in the end cap. PCOR is not available with the
HZ control.
Feedback springs (single spring for 060, 080 and
110) and a threshold spring are installed in the end
cap. The feedback springs and threshold spring
provide a force on the end of the control spool. The
force of the threshold spring is externally adjustable
with an adjusting screw. The feedback spring is
positioned between the control spool and a feedback
lug attached to the servo piston. The force of the
feedback spring increases as the motors displace-
ment decreases.
Pilot oil pressure from an external source is applied to
the end of the control spool opposite the feedback
and threshold springs. An increase in pilot pressure
(above the threshold pressure and within the modu-
lating pressure range) will result in a decrease in
motor displacement, while a decrease in pilot pres-
sure will result in an increase in motor displacement.
51000017
Fig. 10-19 - HZ Control Schematic
U4 (opt.)
X3 (M5)
Servo press,
external
M9 U5 (plug for
ext. servo press.)
T1
T7,
T8
T2
T3
Servo
Pressure
internal
max.
disp.
M2
B
M1
A
L2 M4 M3 M6
L1
M7 X1
51000015
51000016
Fig. 10-18 - HZ Control Components
10 - 7
BOMAG 834 008 911 79
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12
Fig. 10-20 - Series 51 Motor with HS
Control
Hydraulic Proportional Control (Type HS)
The HS control consists of a cover plate (with a
hydraulic port) mounted on the multi-function block.
Servo pressure may be supplied from an external
source or internally by the shuttle spool in the multi-
function block. PCOR is available with this control.
The function of the HS control is identical to the
function of the HZ control.
51000018
Servo
Pressure
internal
max.
disp.
M2
B
M1
A
L2 M4 M3 M6
B1
A1
L1
M7 X1
U4 (opt.)
X3 (M5)
Servo press,
external
M9 U5 (plug for
ext. servo press.)
T1
T7,
T8
T2
T3
X1 M7
X1 M7
HS
H1H2
K1K2
Fig. 10-22 - HS, H1H2, and K1K2 Control
Schematic
51000022
Fig. 10-21 - HS Control Components
51000019
10 - 8
BOMAG 835 008 911 79
18.3
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13
51000020
Fig. 10-23 - Series 51 Motor with H1H2
Control
Hydraulic Proportional Control with
Electric Override (Types H1H2 and K1K2)
The function of the H1H2 and K1K2 controls is
similar to the function of the HS control. A 12 or 24
VDC solenoid valve is installed between the external
pilot pressure source and the control spool.
With the H1H2 controls, energizing the solenoid
allows the control to function as an HS control. When
the solenoid is not energized, pilot pressure is blocked
and the end of the control spool is drained to the motor
case, causing the motor to shift to maximum displace-
ment.
With the K1K2 controls, energizing the solenoid
blocks pilot pressure and drains the end of the control
spool to the motor case, causing the motor to shift to
maximum displacement. When the solenoid is not
energized, the control functions as an HS control.
51000021
Fig. 10-25 - H1H2 and K1K2 Control
Components
51000167
Fig. 10-24 - Series 51 Motor with K1K2
Control
10 - 9
BOMAG 836 008 911 79
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14
Fig. 10-26 - Series 51 Motor with HP
Control
U4 (opt.)
Servo
Press,
internal
max.
disp.
M2
M1
L2 M4 M3 M6
X2 X1
B1
A1
B
A
X3 (M5)
Servo press,
external
L1
M9 U5 (plug for
ext. servo press.)
T1
T7,
T8
T2
T3
Fig. 10-28 - HP Control Schematic
51000025
Fig. 10-27 - HP Control Components
51000024
51000023
Two Line Hydraulic Proportional Control
(Type HP)
This control consists of a valve block with two (2)
hydraulic ports mounted on the multi-function block.
The valve block incorporates a shuttle spool and a
pilot piston with centering springs. A pin transmits
force from the pilot piston to the control spool in the
end cap. Feedback springs (single spring for 060,
080, and 110) and a threshold spring are installed in
the end cap. These springs function similar to the HS
control. Servo pressure may be supplied from an
external source or internally by the shuttle spool in the
multi-function block. PCOR is available with this
control.
Two pilot pressures are provided to the control. The
shuttle spool directs the higher pilot pressure to the
end of the pilot piston opposite the feedback spring,
and the lower pressure to the opposite side of the pilot
piston. The rod transmits a force, proportional to the
difference of the pilot pressures, to the control spool.
An increase in the difference between the pilot pres-
sures will result in a decrease in motor displacement,
while a decrease will result in an increase in displace-
ment.
10 - 10
BOMAG 837 008 911 79
18.3
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15
Fig. 10-29 - Series 51 Motor with HC
Control
51000158
for Dual-Path Vehicles (Type HC)
The HC control operates in a similar manner to the HP
control, however the HC control is optimized for use
in dual-path drive vehicles. This control consists of
a valve block with two (2) hydraulic ports mounted on
the end cap. The valve block incorporates a shuttle
spool and a pilot piston with centering springs. A pin
transmits force from the pilot piston to the control
spool in the end cap.
A bleed valve is provided to eliminate any air which
might become trapped in the pilot piston oil passages.
Feedback springs are installed in the end cap. Servo
pressure is supplied internally by a ball type shuttle
valve in the control housing. PCOR is not available
with this control.
Two pilot pressures are provided to the control. The
shuttle spool directs the higher pilot pressure to the
end of the pilot piston opposite the feedback springs,
and the lower pressure to the opposite side of the pilot
piston. The pin transmits a force, proportional to the
difference of the pilot pressures, to the control spool.
An increase in the difference between the pilot pres-
sures will result in a decrease in motor displacement,
while a decrease will result in an increase in displace-
ment. The feedback springs in the end cap have
differing spring rates and operate in parallel (060,
080, and 110) or series (160 or 250) to provide a linear
relationship between motor displacement and pilot
pressure differential.
51000111
Fig. 10-30 - HC Control Components
U4 (opt.)
max.
disp.
M2
M1
L2 M4 M3 M6
X2 X1
B
A
M5
L1
M9
T1
T7,
T8
T2
T3
Fig. 10-31 - HC Control Schematic
51000160
10 - 11
BOMAG 838 008 911 79
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16
Electrohydraulic Proportional Control
(Types EP and EQ)
This control consists of a valve block and PCP (Pres-
sure Control Pilot) valve mounted on the multi-func-
tion block. The valve block incorporates a pilot piston
with centering springs. A pin transmits force from the
pilot piston to the control spool in the end cap.
Feedback springs (single spring for 060, 080, and
110) and a threshold spring are installed in the end
cap. These springs function similar to the HS control.
Servo pressure may be supplied from an external
source or internally by the shuttle spool in the multi-
function block. PCOR is available with this control.
An external pilot pressure source is connected to the
inlet of the PCP valve, which produces differential
pilot pressures proportional to the current through it.
These pressures are applied to the pilot piston. The
operation of this control is similar to that of the HP
Control, with the motor displacement being propor-
tional to the current through the PCP valve.
An increase in current (above the threshold current)
will result in a decrease in motor displacement, while
a decrease will result in an increase in displacement.
Fig. 10-32 - Series 51 Motor with EP Control
(EQ Similar)
51000026
U4 (opt.)
X3 (M5)
Servo press,
external
M9 U5 (plug for
ext. servo press.)
T1
T7,
T8
T2
T3
Servo
Pressure
internal
max.
disp.
M2
M1
L2 M4 M3 M6
M7 X1 M8
B1
A1
B
A
L1
Fig. 10-34 - EP and EQ Control Schematic
51000028
Fig. 10-33- EQ Control Components (EP
Similar)
51000027
10 - 12
BOMAG 839 008 911 79
18.3
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17
Fig. 10-36 - Multi-function Block with Servo
Pressure Supply Shuttle Spool
Fig. 10-35 - Multi-function Block (Without
Control)
51000029
51000030
Multi-function Block Components
The Multi-function Valve Block includes a shuttle
valve which provides internally supplied servo pres-
sure, and an optional Pressure Compensator Over-
Ride (PCOR) function with optional brake pressure
defeat.
Servo Pressure Supply
For internal supply, the multi-function block incorpo-
rates a shuttle spool with internal check ball valve that
routes oil from the main circuit ports of the motor to the
control valve in the end cap. High side pressure is
provided to the servo control valve in the end cap.
For external supply, the connection between the
shuttle spool and the servo control valve is blocked in
the end cap. The external pressure supply to the
servo control valve connects to a port (M5) on the
end cap.
Pressure Compensator Over-Ride (PCOR)
The Pressure Compensator Over-Ride (PCOR) sys-
tem includes a spool valve located in the PCOR block
which is attached to the multi-function block. This
system increases the motor displacement at system
pressures above the PCOR valve setting. (Pressure
Compensator Over-Ride is not available with the N2
and HZ controls, or the PC regulator.)
For bi-directional PCOR operation, the shuttle valve
in the multi-function block routes system high pres-
sure to the PCOR spool valve. For single direction
PCOR operation, the PCOR spool valve is connected
to one (1) side of the closed loop through passages in
the multi-function block
When system pressure exceeds the PCOR setting,
the spool valve moves to connect the displacement
reducing end of the servo piston to the motor case,
and the displacement increasing end of the servo
piston to system pressure. This increases the motor
displacement, which reduces the motor output speed.
When the PCOR valve closes, control of the servo
piston returns to the control spool in the motor end
cap.
Fig. 10-37 - Multi-function Block with PCOR
Block and Spool Valve (K1K2 Control
Shown)
51000031
10 - 13
BOMAG 840 008 911 79
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18
Fig. 10-38 - Multi-function Block with PCOR
Defeat Spool Components
51000032
Standard with Defeat
Pressure Compensator Override
XA XB
Shuttle Valve
PCOR
Valve
Defeat
Spool
A1
B1
A1
B1
Shuttle Valve
PCOR
Valve
U7
T5
U6
U7
U6
T6
T4
Fig. 10-39 - PCOR and PCOR with Defeat
Schematic
51000033
An optional brake pressure defeat spool may be
installed in the multi-function block. When used with
the PCOR, this spool assures that the PCOR does
not cause the motor displacement to increase during
deceleration (which could cause pump overspeed).
Pressure from a source such as the pump servos or
an external valve, shifts the defeat spool to block the
high pressure supply to the PCOR valve from the
deceleration side of the closed loop. Either bi-
directional or single direction PCOR operation can be
specified when PCOR defeat is installed.
PCOR Brake Pressure Defeat Operation
Rotation High pressure Control pressure
port on port
CW A XB
CCW B XA
10 - 14
BOMAG 841 008 911 79
18.3
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19
Pressure Compensator Regulator (Type
PC)
In this regulator, the Pressure Compensator system
in the multi-function block assembly controls the
motor displacement. At system pressures below the
compensator setting, the servo piston is maintained
in the minimum motor displacement position. When
system pressure exceeds the POR setting, hydraulic
pressure acts on the servo piston to increase the
motor displacement.
With the Pressure Compensator regulator, an in-
crease in system pressure (above the setting pres-
sure) will result in an increase in motor displacement
and output torque, and a decrease in motor shaft
speed.
Fig. 10-40 - Series 51 Motor with PC
Regulator
51000034
U4 (opt.)
M9
T1
T7
max.
disp.
M2
M1
L2 M4 M3 M6
B
A
L1
M5
T5
U7
U6
51000036
Fig. 10-42 - PC Regulator Schematic
Fig. 10-41 - PC Regulator Components
51000035
10 - 15
BOMAG 842 008 911 79
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20
Frame Size
Dimension 060 080 110 160 250
Displacement maximum cm
3
60.0 80.7 109.9 160.9 250.0
in
3
3.66 4.92 6.71 9.82 15.26
minimum cm
3
12.0 16.1 22.0 32.2 50.0
in
3
0.73 0.98 1.34 1.96 3.05
Continuous speed at max disp min
-1
(rpm) 3600 3100 2800 2500 2200
at min disp min
-1
(rpm) 5600 5000 4500 4000 3400
Max. speed at max disp min
-1
(rpm) 4400 4000 3600 3200 2700
at min disp min
-1
(rpm) 7000 6250 5600 5000 4250
Theoretical at max disp Nm / bar 0.95 1.28 1.75 2.56 3.98
torque lbfin / 1000 psi 583 784 1067 1563 2428
at min disp Nm / bar 0.19 0.26 0.35 0.51 0.80
lbfin / 1000 psi 117 156 214 313 486
Max. continuous Q max L / min 216 250 308 402 550
flow gal / min 57 66 81 106 145
Max. corner power Pcorner max kW 336 403 492 644 850
hp 450 540 660 864 1140
Mass moment J kg m
2
0.0046 0.0071 0.0128 0.0234 0.0480
of inertia lbf ft
2
0.1092 0.1685 0.3037 0.5553 1.1580
Weight m kg 28 32 44 56 86
(with control N2) lb 62 71 97 123 190
Technical Specifications and Data - Variable Displacement Motors
Design
Piston motor with variable displacement, bent axis
construction.
Type of Mounting
SAE four (4) bolt flange SAE Flange Configuration.
Two (2) bolt flange Cartridge Motor Configuration.
Pipe Connections
Main pressure ports: SAE flange
Remaining ports: SAE O-ring thread
Direction of Rotation
Clockwise and counter-clockwise.
Installation Position
Installation position discretionary. The housing must
always be filled with hydraulic fluid.
System Pressure Range, Input
Max: 480 bar (6960 psi)
Min: 10 bar (145 psi)
Case Pressure
Max. Continuous: 3 bar (44 psi)
Intermittent (Cold start): 5 bar (73 psi)
Hydraulic Fluid
Refer to Sauer-Sundstrand publication BLN-9887 or
697581.
Temperature
1)
min = -40C (-40F), intermittent, cold start
nominal = 104C (220F), continuous
max = 115C (240F), intermittent
1)
at the hottest point, normally the case drain line.
Hydraulic fluid viscosity must be as shown below.
Fluid Viscosity Limits
min = 5 mm
2
/s (42 SUS) intermittent
min = 6.4 mm
2
/s (47 SUS) min. continuous
min = 13 mm
2
/s (70 SUS) optimum
max = 110 mm
2
/s (510 SUS) max. continuous
max = 1600 mm
2
/s (7400 SUS) intermittent, cold start
Filtration
Acceptable contamination level: ISO Code 18/13 or
better. Refer to Sauer-Sundstrand publication BLN-9887
or 697581.
10 - 16
BOMAG 843 008 911 79
18.3
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Safety Precautions
When Series 51 units are used in vehicular
hydrostatic drive systems, the loss of hy-
drostatic drive line power in any mode of
operation may cause a loss of hydrostatic
braking capacity. A braking system, redun-
dant to the hydrostatic transmission must,
therefore, be provided which is adequate to
stop and hold the system should the condi-
tion develop.
Certain service procedures may require the
vehicle/machine to be disabled (wheels
raised off the ground, work function discon-
nected, etc.) while performing them in order
to prevent injury to the technician and by-
standers.
Use caution when dealing with hydraulic
fluid under pressure. Escaping hydraulic
fluid under pressure can have sufficient
force to penetrate your skin causing seri-
ous injury. This fluid may also be hot enough
to burn. Serious infection or reactions can
develop if proper medical treatment is not
administered immediately.
Some cleaning solvents are flammable. To
avoid possible fire, do not use cleaning
solvents in an area where a source of igni-
tion may be present.
20 - 1
BOMAG 844 008 911 79
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22
Notes
20 - 2
BOMAG 845 008 911 79
18.3
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23
Snubbers are recommended to protect pressure
gauges. Frequent gauge calibration is necessary to
insure accuracy.
Various pressure gauge readings can be a great
asset in troubleshooting problems with the Series 51
motor or support system.
Fig. 30-2- Gauge Ports, Motor with E1E2, F1F2, H1H2, and K1K2 Controls
Gauge Installation
B
Port Y1:
Servo press., external
(N2 Control Only)
Gauge port M4:
Servo pressure
max. displacement
Gauge port M1:
Port "A" system
pressure
Gauge port M2:
Port "B" system
pressure
Gauge port M6:
Charge pressure
9/16 18 UNF-2B
Port Y2:
Servo press., external
(N2 Control Only)
Gauge port M3;
Servo pressure
min. displacement
A
M1
M2
Side Port End Cap Axial Port End Cap
"
X
"
Port "L1"
Port "L2"
View in Direction "X" Right Side View
Port X3:
servo press., external
Gauge port M5:
servo press., internal
View"T"
"T"
Control E1/E2 F1/F2
Control H1/H2 K1/K2
Gauge port M7
control pressure
XA
Control E1/E2F1/F2
Gauge port M8
Control H1/H2
Control pressure port X1
XB
XA
XB
Control K1/K2
Control pressure port X1
51000037
Fig. 30-1 - Gauge Ports, Motor with N2 Control
51000038
Fig. 30-3 - Gauge Ports, Motor with HS and HZ Controls
51000039
"U"
View"U"
(HS)
Control pressure
port X1
Gauge port M7:
Control pressure
XA
XB
XA
XB
Port X3:
servo press., ext.
Gauge port M5:
servo press., int.
View"U"
(HZ)
Control pressure
port X1
Gauge port M7:
Control pressure
30 - 1
BOMAG 846 008 911 79
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24
Gauge Installation (Continued)
System 600 bar or 10,000 psi Gauge
M1 Pressure
Port A 9/16 18 O-Ring Fitting
System 600 bar or 10,000 psi Gauge
M2 Pressure
Port B 9/16 18 O-Ring Fitting
Servo 600 bar or 10,000 psi Gauge
M3 Pressure
(Min. Angle) 9/16 18 O-Ring Fitting
M4 Pressure
(Max. Angle) 9/16 18 O-Ring Fitting
M5 Supply 9/16 18 O-Ring Fitting or
(M9) Pressure Tee into Control Pressure Line
Motor 60 bar or 1000 psi Gauge
M6 Charge
Pressure 9/16 18 O-Ring Fitting
M7 Control 60 bar or 1000 psi Gauge
M8 Test Port 9/16 18 O-Ring Fitting
L1 Case 60 bar or 1000 psi Gauge
L2 Pressure 060, 080, 110:
1-1/16 12 O-Ring Fitting
160, 250:
1-5/16 12 O-Ring Fitting
X1 Control 60 bar or 1000 psi Gauge
X2 Pressure 9/16 18 O-Ring Fitting
X3
XA Defeat 60 bar or 1000 psi Gauge
XB Pressure Tee into Defeat Pressure
Line(s)
Gauge Information
Fig. 30-4 - Gauge Ports, Motor with HP Control
51000040 "V"
View"V"
XA
XB
X1 X2 Ports X1, X2:
Control pressure
9/16 18 UNF-2B
XA
XB
Port X3:
servo press., ext.
Gauge port M5:
servo press., int.
Fig. 30-5 - Gauge Ports, Motor with EPEQ Control
51000041
Packard
Connector
View"W"
Port X1:
External PCP
supply pressure
XA
"W"
Manual override
MS-Connector (MS3102C)
7/8 20 UNEF
XA XB
XB
Port X3:
servo press., ext.
Gauge port M5:
servo press., int.
30 - 2
BOMAG 847 008 911 79
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25
Start-Up Procedure and Maintenance
Fill the reservoir with recommended hydraulic fluid,
which should be passed through a 10 micron (nomi-
nal, no bypass) filter prior to entering the reservoir.
The use of contaminated fluid will cause damage to
the components, which may result in unexpected
vehicle/machine movement.
The inlet line leading from the reservoir to the pump
must be filled prior to start up. Check inlet line for
properly tightened fittings and make sure it is free of
restrictions and air leaks.
Be certain to fill the pump and motor housing with
clean hydraulic fluid prior to start up. Fill the
housing by pouring filtered oil into the upper case
drain port.
Install a 0 to 60 bar or 0 to 1000 psi pressure gauge
in the charge pressure gauge port to monitor the
charge pressure during start-up.
The external control input signal should be discon-
nected at the pump control during initial start-up. This
will allow the pump to remain in its neutral position.
Jog or slowly rotate prime mover until charge pres-
sure starts to rise. Start the prime mover and run at
the lowest possible RPM until charge pressure is
established. Excess air may be bled from the high
pressure lines through the high pressure gauge ports.
Once charge pressure is established, increase speed
to normal operating RPM. Note the charge pressure.
If charge pressure is incorrect, shut down and deter-
mine cause for improper pressure.
Shut down prime mover and connect external control
input signal. Start prime mover, checking to be
certain pump remains in neutral. With prime mover at
normal operating speed, slowly check for forward and
reverse machine operation.
Charge pressure should be maintained during for-
ward or reverse operation. Continue to cycle slowly
between forward and reverse for at least five (5)
minutes.
Shut down prime mover, remove gauges, and plug
ports. Check reservoir level and add fluid if neces-
sary.
The transmission is now ready for operation.
Start-Up Precautions
Cleanliness
Ensure that all system components, including fittings,
pipes, and hoses, are completely clean. If cloths are
used for cleaning components, they must be made of
lint-free materials.
Follow the guidelines presented in Sauer-Sundstrand
publication BLN-9887 or 697581 for required fluid
cleanliness levels at machine start-up.
Reservoir and Fluid Level
The reservoir should be designed to accommodate
maximum volume changes during all system operat-
ing modes, and to promote de-aeration of the fluid as
it passes through the tank. The reservoir outlet (charge
pump inlet) and the reservoir inlet (fluid return) must
always be below the normal fluid level. A sight glass
is the preferred method for checking fluid level.
The reservoir inlet (fluid return) should be positioned
so that flow to the reservoir is directed into the interior
of the reservoir for maximum dwell and efficient de-
aeration. A baffle (or baffles) between the reservoir
inlet and outlet ports will promote de-aeration and
reduce surging of the fluid.
No funnel-shaped eddying at the reservoir outlet
(charge pump inlet) or formation of foam at the
reservoir inlet (fluid return) is permitted.
Start-Up Procedure
The following start-up procedure should always be
followed when starting-up a new Series 51 installa-
tion or when restarting an installation in which either
the pump or motor has been removed from the
system.
WARNING
The following procedure may require the ve-
while performing the procedure in order to
prevent injury to the technician and bystand-
ers. Take necessary safety precautions before
operating the vehicle/machine.
Prior to installing the motor, inspect the unit for
damage incurred during shipping and handling. Make
certain all system components (reservoir, hoses,
valves, fittings, heat exchanger, etc.) are clean prior
to filling with fluid.
30 - 3
BOMAG 848 008 911 79
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26
Start-Up Procedure and Maintenance (Continued)
Maintenance
Cleanliness
The reservoir breather air filter (if equipped) must be
kept clean. Clean the area around the filler cap before
opening the reservoir. The hydraulic fluid should be
filtered before it enters the reservoir.
Follow the guidelines presented in Sauer-Sundstrand
publication BLN-9887 or 697581 for required fluid
cleanliness levels during machine operation.
Recommended Fluids
Hydraulic fluids used with Sauer-Sundstrand prod-
ucts should be carefully selected with assistance
from a reputable supplier, following the guidelines
presented in Sauer-Sundstrand publication BLN-9887
or 697581.
Checking for Leaks
Check the system components for leakage at regular
intervals. Tighten any leaking connections while the
system is not under pressure. Replace any defective
seals and gaskets.
Check hydraulic hoses for damage or aging. When
installing replacements, be certain that the hoses are
clean and connected properly.
Checking the Fluid Level
Check the reservoir daily for proper fluid level, the
presence of water (noted by a cloudy or milky appear-
ance, or free water in bottom of reservoir), and rancid
fluid odor (indicating excessive heat).
Changing the Fluid and Filter
To insure optimum service life on Series 51 products,
regular maintenance of the fluid and filter must be
performed.
The fluid and filter must be changed per the vehicle/
machine manufacturers recommendations. In the
absence of such recommendations, the following
intervals may be used:
System with a sealed type reservoir - 2000 hrs.
System with a breathing type reservoir - 500 hrs.
It may be necessary to change the fluid more fre-
quently if the fluid becomes contaminated with for-
eign matter (dirt, water, grease, etc.) or if the fluid has
been operating at temperature levels greater than the
maximum recommended. Never reuse fluid.
The filter should be changed when changing the fluid,
or whenever the filter indicator shows that it is neces-
sary to change the filter.
30 - 4
BOMAG 849 008 911 79
18.3
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27
Component Inspection and Adjustment
Fig. 30-7 - Tighten Charge Pressure Relief
Valve Lock Nut
51000043
51000042
Fig. 30-6 - Adjusting Charge Pressure
Relief Valve
Charge Pressure Relief Valve Adjustment
An appropriate combination of pump and motor charge
pressure settings should be maintained to insure the
proper function of the loop flushing circuit. Correct
charge pressure must be maintained under all
conditions of operation to maintain pump control
performance in closed loop systems.
To measure motor charge pressure, install a 0 to 60
bar or 0 to 500 psi pressure gauge in the motor charge
pressure gauge port. Install a gauge to measure case
pressure. Operate the system with the prime mover
at normal operating speed and the pump at half
stroke (forward or reverse) when measuring motor
charge pressure.
In most applications, the motor charge relief valve is
set 2 to 4 bar (29 to 58 psi) below the setting of the
pump charge relief valve (measured with the pump in
its neutral or zero-angle position). This setting as-
sumes a reservoir temperature of 50 C (122 F), and
is referenced to case pressure.
Series 51 motors are equipped with an external screw
adjustable charge pressure relief valve. To adjust the
charge pressure, loosen the lock nut (with a 1-1/16"
hex wrench) and turn the adjustment plug with a large
screwdriver. Clockwise rotation of the plug increases
the setting, and counter-clockwise rotation decreases
the setting (at a rate of approximately 3.4 bar [50 psi]
per turn). The lock nut should be torqued to 52 Nm (38
ftlbsf).
Once the desired charge pressure setting is achieved,
remove the gauges and reinstall the port plugs.
WARNING
The following procedures may require the ve-
while performing the adjustments to prevent
injury to the technician and bystanders.
30 - 5
BOMAG 850 008 911 79
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28
Component Adjustment (Continued)
Minimum Displacement Limiter Adjustment
The minimum displacement is set at the factory, and
the adjustment screw is covered with a tamper-
resistant cap
WARNING
Care should be taken in adjusting displace-
ment limiters to avoid undesirable speed con-
ditions. The sealing lock nut must be retorqued
after every adjustment to prevent an unex-
pected change in operating conditions and to
prevent external leakage during unit operation.
NOTE: Changes in motor displacement can be de-
tected by providing a constant flow of fluid to
the motor, while maintaining the motor at
minimum displacement and monitoring the
motor output shaft speed. An increase in
displacement will result in a decrease in shaft
speed, while a decrease in displacement will
result in an increase in shaft speed.
To adjust the minimum displacement, first remove
and discard the cap covering the adjusting screw.
Using a 17 mm hex wrench for 060 and 080 frame
size motors or a 19 mm hex wrench for 110 through
250 frame size motors, loosen the lock nut retaining
the minimum displacement limiter adjusting screw.
Using a 5 mm internal hex wrench for 060 and 080
frame size motors or a 6 mm internal hex wrench for
110 through 250 frame size motors, rotate the adjust-
ing screw to limit the minimum displacement of the
motor.
Rotating the adjusting screw clockwise will increase
the minimum displacement of the motor, while rotat-
ing the adjusting screw counter-clockwise will de-
crease the minimum displacement.
For each full revolution, of the adjusting screw, the
displacement will change according to the accompa-
nying chart.
Different minimum displacements may require differ-
ent length adjusting screws. The various lengths are
shown in the accompanying chart.
After establishing the desired minimum displacement
setting, tighten the lock nut on the adjusting screw to
51 Nm (38 ftlbsf) for 060 and 080 frame size motors
or 86 Nm (63 ftlbsf) for 110 through 250 frame size
motors. Install a new tamper-resistant cap on the
adjusting screw.
Fig. 30-8 - Loosen Minimum Displacement
Limiter Lock Nut
510000434
Fig. 30-9 - Rotate Minimum Displacement
Adjusting Screw
51000045
Approximate Change in
Frame Per Revolution
Size of Adjusting Screw
060 1.5 cc/Rev (.09 in3/Rev)
080 2.1 cc/Rev (.13 in3/Rev)
110 3.1 cc/Rev (.19 in3/Rev)
180 4.0 cc/Rev (.24 in3/Rev)
250 6.2 cc/Rev (.38 in3/Rev)
Min. Displacement Screw Size
Frame Range and Length
Size cc/Rev (in
3
/Rev) mm (in)
060 12 to 29 (.73 to 1.77) M10x65 (2.56)
30 to 40 (1.83 to 2.44) M10x80 (3.15)
080 16 to 35 (.98 to 2.14) M10x65 (2.56)
36 to 54 (2.20 to 3.20) M10x80 (3.15)
110 22 to 46 (1.34 to 2.81 ) M12x70 (2.76)
47 to 74 (2.87 to 4.52) M12x80 (3.15)
160 32 to 72 (1.95 to 4.39) M12x75 (2.95)
73 to 107 (4.45 to 6.53) M12x90 (3.54)
250 50 to 90 (3.05 to 5.49) M12x75 (2.95)
91 to 130 (5.55 to 7.93) M12x90 (3.54)
131 to 167 (7.99 to 10.19) M12x100 (3.94)
30 - 6
BOMAG 851 008 911 79
18.3
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29
Fig. 30-10 - Remove Minimum Angle Servo
Cover Screws
51000046
Approximate Change in
Frame Maximum Displacement
Size with Change in Spacer Thickness
cc/mm (in
3
/.1 in)
060 0.98 (.15)
080 1.14 (.18)
110 1.48 (.23)
160 1.93 (.30)
250 2.63 (.41)
Fig. 30-11 - Torque Maximum Displacement
Limiter Screw
51000070
30 - 7
Maximum Displacement Limiter
Adjustment
The maximum displacement of the Series 51 motors
can be limited by limiting the stroke of the setting
piston, and the resulting movement of the valve
segment. A displacement stop screw is installed on
the setting piston (under the minimum angle servo
cover) to limit the stroke of the piston.
Spacers may be installed on the displacement stop
screw to limit the stroke. A longer or shorter screw
must be used to retain a thicker or thinner spacer.
WARNING
ditions. The stop screw must be retorqued
after adjustment to prevent an unexpected
change in operating conditions.
NOTE: Changes in motor displacement can be de-
the motor, while maintaining the motor at
maximum displacement and monitoring the
motor output shaft speed. An increase in
displacement will result in a decrease in shaft
speed, while a decrease in displacement will
result in an increase in shaft speed.
To adjust the maximum displacement, first remove
the screws retaining the minimum angle servo cover
to the end cap with an 8 mm internal hex wrench (060,
080, 110, and 160 units), or a 10 mm internal hex
wrench (250 units). Remove the minimum angle
servo cover and O-rings. Remove the displacement
limiter screw with an 8 mm internal hex wrench.
Installing a thicker spacer on the end of the setting
piston will reduce the maximum displacement of the
motor. Installing a thinner spacer will increase the
maximum displacement. The displacement will
change according to the accompanying chart.
Torque the displacement limiter screw to 54 Nm (40
ftlbsf).
Install the minimum angle servo cover and its O-rings.
Install the cover screws and torque to 78 Nm (58
ftlbsf) for 060, 080, 110, and 160 motors, or 110 Nm
(81 ftlbsf) for 250 motors.
BOMAG 852 008 911 79
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30
Displacement Control Adjustments
NOTE: A change in motor displacement can be de-
the motor and monitoring the motor output
shaft speed while adjusting the control. An
increase in displacement will result in a de-
crease in shaft speed, while a decrease in
displacement will result in an increase in shaft
speed.
Fig. 30-12 - Hydraulic 2-Position Control,
Type N2)
Fig. 30-13 - Electrohydraulic 2-Position
Control, Types E1E2 and F1F2
50000009
50000012
No adjustments are provided for the N2 control.
A minimum of 25 bar (360 psi) servo pressure is
required to change the motor displacement with the
motor shaft turning. A minimum of 70 bar (1015 psi)
servo pressure is required to change the motor dis-
placement with the motor shaft locked.
Electrohydraulic 2-Position Control (Types E1E2
and F1F2) and Electric 2-Position Control (Type
S1)
These controls do not require adjustment.
CAUTION
Do not tamper with the adjusting screw in the
end cap (opposite the control).
Pilot pressure for the E1E2 or F1F2 electric sole-
noid valve is internally supplied. When the solenoid is
energized, motor charge pressure should be present
at test ports M7 and M8. When the solenoid is not
energized, test port M8 should drop to case pressure.
The S1 control utilizes a direct acting solenoid to
operate the control valve spool in the end cap.
Servo pressure supply oil is usually provided inter-
nally from the main system ports of the motor. If
external servo pressure supply is utilized, a minimum
of 25 bar (360 psi) is required to change the motor
displacement with the motor shaft turning, and a
minimum of 70 bar (1015 psi) is required with the
motor shaft locked.
Fig. 30-14 - Electric 2-Position Control,
Type S1
50000162
30 - 8
BOMAG 853 008 911 79
18.3
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31 30 - 9
Fig. 30-15 - Hydraulic Proportional Control,
Type HZ
51000015
Fig. 30-17 - Hydraulic Proportional Control
with Electric Override, Type H1H2 (K1K2
Similar)
51000020
Fig. 30-18 - Adjusting Control Threshold,
Types HS, HZ, H1H2, and K1K2
51000047
Fig. 30-16 - Hydraulic Proportional Control,
Type HS
51000018
Hydraulic Proportional Control (Types HZ, HS,
H1H2, and K1K2)
The control start pressure for these controls may be
adjusted with the adjusting screw on the end cap
(opposite the control block). Control start is that pilot
pressure at which the motor displacement starts to
decrease.
To check the control start setting, install a gauge to
monitor the pilot pressure (connect to port M7 or tee
into the pilot line connected to port X1), and the
minimum angle servo pressure (port M3). If adjusting
an H1 or H2 control, the override solenoid must be
energized. If adjusting a K1 or K2 control, the sole-
noid must not be energized.
NOTE: The pilot signal may be determined by prime
mover speed, other shaft speeds, or other
control pressures, depending upon the de-
sign of the vehicle / machine control circuit.
Increase the pilot signal to the required control start
pressure. An increase in minimum angle servo pres-
sure will be noted as the motor displacement starts to
decrease.
To adjust the control start pressure, loosen the lock
nut using a 10 mm hex wrench and turn the adjusting
screw with a 4 mm internal hex wrench. Turning the
screw clockwise increases the control start pressure.
Torque the lock nut to 9 Nm (6.6 ftlbsf) after adjust-
ing.
For the H1H2 controls, the pilot signal pressure
supplied to port X1 should also be present at test port
M7 when the solenoid is energized. When the sole-
noid is not energized, test port M7 should drop to case
pressure.
For the K1K2 controls, the pilot signal pressure
supplied to port X1 should also be present at test port
M7 when the solenoid is not energized. When the
solenoid is energized, test port M7 should drop to
case pressure.
Shut down the prime mover. Remove the gauges and
install the gauge port plugs. Return the pump and
motor controls to their normal operation.
motor shaft locked.
BOMAG 854 008 911 79
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32 30 - 10
Fig. 30-20 - Adjusting Control Threshold
(Type HP)
Fig. 30-19 - Two Line Hydraulic
Proportional Control, Type HP
51000023
51000047
(Type HP)
The differential control start pressure for this control
may be adjusted with the adjusting screw on the end
cap (opposite the control block). Control start is that
differential pilot pressure at which the motor displace-
ment starts to decrease.
To check the control start setting, install gauges to
monitor the pilot pressures (tee into the pilot lines
connected to ports X1 and X2), and the minimum
angle servo pressure (port M3).
NOTE: The pilot signals may be determined by prime
Increase the pilot signal differential to the required
control start pressure. An increase in minimum angle
servo pressure will be noted as the motor displace-
The differential control start pressure should be the
same no matter which pilot pressure is higher. Differ-
ences in control operation when the pilot pressure
differential is reversed indicate a problem with the
shuttle spool in the control block.
To adjust the control start differential pressure, loosen
the lock nut using a 10 mm hex wrench and turn the
adjusting screw with a 4 mm internal hex wrench.
Turning the screw clockwise increases the control
start pressure. Torque the lock nut to 9 Nm (6.6 ftlbsf)
after adjusting.
motor shaft locked.
BOMAG 855 008 911 79
18.3
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33 30 - 11
(Type HC)
Fig. 30-21 - Two Line Hydraulic
Proportional Control, Type HC
51000158
51000159
for Dual Path Vehicles (Type HC)
The differential control start pressure for this control
may be adjusted with the adjusting screw on the
control housing. Control start is that differential pilot
pressure at which the motor displacement starts to
decrease.
To check the control start setting, install gauges to
monitor the pilot pressures (tee into the pilot lines
connected to ports X1 and X2), and the minimum
angle servo pressure (port M3).
NOTE: The pilot signals may be determined by prime
Increase the pilot signal differential to the required
control start pressure. An increase in minimum angle
servo pressure will be noted as the motor displace-
The differential control start pressure should be the
same no matter which pilot pressure is higher. Differ-
ences in control operation when the pilot pressure
differential is reversed indicate a problem with the
shuttle spool in the control block.
To adjust the control start differential pressure, loosen
the lock nut using a 10 mm hex wrench and turn the
adjusting screw with a 4 mm internal hex wrench.
Turning the screw counter-clockwise (CCW) increases
the control start pressure. Torque the lock nut to 9 Nm
(6.6 ftlbsf) after adjusting.
Servo pressure supply oil is provided internally from
the main system ports of the motor.
BOMAG 856 008 911 79
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34 30 - 12
(Types EP and EQ)
The control start current for the EP and EQ controls
may be adjusted with the adjusting screw on the end
cap (opposite the control block). Control start is that
current supplied to the PCP (Pressure Control Pilot)
valve at which the motor displacement starts to de-
crease.
To check the threshold setting, install instruments to
monitor the PCP current, and the minimum angle
servo pressure (port M3).
NOTE: The current supplied to the PCP may be
determined by prime mover speed, other
shaft speeds, control pressures, or other elec-
trical signals, depending upon the design of
the vehicle / machine control circuit.
Increase the PCP current to the required control start
current. An increase in minimum angle servo pres-
sure will be noted as the motor displacement starts to
decrease.
To adjust the control start current, loosen the lock nut
using a 10 mm hex wrench and turn the adjusting
screw with a 4 mm internal hex wrench. Turning the
screw clockwise increases the control start current.
Torque the lock nut to 9 Nm (6.6 ftlbsf) after adjust-
ing.
PCP supply pressure oil is provided externally. PCP
supply pressure must be a minimum of 20 bar (290
psi) and no more than 70 bar (1015 psi).
motor shaft locked.
Fig. 30-23 - Electrohydraulic Proportional
Control, Type EP (EQ Similar)
51000026
(Type EPEP)
51000047
BOMAG 857 008 911 79
18.3
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35 30 - 13
Pressure Compensator Over-Ride (PCOR)
and Pressure Compensator Regulator
(Type PC) Adjustment
The PCOR or PC regulator valve setting may be
adjusted with the adjusting screw on the PCOR/PC
valve block attached to the multi-function block. The
regulator start pressure is that system pressure at
which the PCOR or PC regulator starts to increase
the motor displacement.
In order to measure the regulator start pressure
setting of the PCOR or the PC regulator, the motor
output shaft must be loaded to increase the system
working pressure. This can accomplished by apply-
ing the vehicles brakes or by loading the work func-
tion.
WARNING
The following procedures may require the ve-
while performing the adjustment to prevent
Install gauges to monitor system pressure (connect
to ports M1 and M2), the minimum angle servo
pressure (port M3), and the maximum angle servo
pressure (port M4).
Start the prime mover and operate at normal speed.
Provide a signal to the pump control to provide a
constant flow of hydraulic fluid to the motor. Provide
a signal to the motor control to maintain the motor at
its minimum displacement.
Increase the load on the motor to increase the system
pressure to the required regulator start pressure. The
maximum angle servo pressure (M4) will increase
and the minimum displacement servo pressure (M3)
will decrease as the PCOR or PC regulator operates.
The servo pressures will equalize, and the maximum
angle servo pressure continue to increase, as the
motor displacement starts to increase.
During the transition from minimum to maximum
displacement, an additional 10 bar (145 psi) increase
in system pressure may be noted.
Once the motor is at maximum displacement, further
increases in load will result in increasing system
pressure until the maximum system pressure (deter-
mined by the system relief valve or pump pressure
limiter) is reached.
Fig. 30-25 - PCOR Block on Multi-Function
Block (K1K2 Control Shown)
51000031
Fig. 30-26 - Pressure Compensator
Regulator (Type PC)
51000034
Fig. 30-27 - System Pressure Gauge Ports
(Side Port End Cap)
51000048
BOMAG 858 008 911 79
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36 30 - 14
Allow the pump to return to its neutral position.
Repeat the procedure for the other side of the closed
circuit if so configured. The PCOR or PC regulator
must operate at the same start pressure as noted
previously. Any noticeable difference in operation
from side to side may indicate a problem with the
pressure supply shuttle spool or brake pressure de-
feat spool in the multi-function block.
NOTE: Some motors may be configured for the
PCOR or PC regulator to function on only
one (1) side of the closed loop. Refer to the
nomenclature on the motor nameplate.
In order for the PCOR or PC regulator to function
properly on motors equipped with a brake pressure
defeat spool, the defeat spool must be positioned
correctly. The control pressure for the defeat spool
should be applied to the appropriate port (XA or XB)
as shown in the following table to shift the defeat
spool and permit PCOR or PC regulator operation.
Maximum pressure across the brake pressure defeat
ports XA and XB is 50 bar (725 psi).
Pressure Compensator Override Defeat Operation
Rotation High system Control
pressure port pressure on port
CW A XB
CCW B XA
The PCOR or PC regulator valve is screw adjustable.
To adjust, loosen the locknut with a 1-1/16" hex
wrench. Turn the adjusting screw with a large screw-
driver until the desired pressure setting is estab-
lished. Clockwise rotation of the adjustment screw
will increase the pressure setting at a rate of approxi-
mately 70 bar (1000 psi) per turn.
CAUTION
A stop pin is installed in the adjusting screw to
prevent overtravel of the PCOR/PC valve
spool. The stop pin must protrude (distance
X) 19 mm (.75 in.) from the spring seat for
settings of 270 to 370 bar (3900 to 5350 psi), or
24 mm (.94 in.) for settings of 110 to 260 bar
(1600 to 3750 psi). Refer to the appropriate
Service Parts Manual for further information.
While holding the adjusting screw from turning, torque
the lock nut to 52 Nm (38 ftlbsf). Recheck the PCOR
or PC regulator setting.
Fig. 30-28 - Loosen PCOR/PC Lock Nut
51000050
Fig. 30-29 - Rotate PCOR/PC Adjusting
Screw
51000049
51000051
Fig. 30-30 - PCOR/PC Adjusting Screw Stop
Pin
"X"
BOMAG 859 008 911 79
18.3
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37 30 - 15
Troubleshooting
Fault-Logic Diagrams Closed Circuit
Check Pump
Inlet Pressure
Adjust or
Replace
Fill to Proper
Level
Check Oil Level
in Reservoir
Check System
Internal Leakage
Inspect Inlet Filter
and Replace if
Necessary
Check System
Relief Valve
Pressure
Settings
Repair as Required
OK OK OK
High
Low
Defective
Low
SYSTEM RESPONSE IS SLUGGISH
Check Prime Mover
Speed
Low
Adjust
OK
Replace
Transmission
(Pump and Motor)
OK
Check Charge and
Control Pressures
Repair as Required
Incorrect
OK
Check Pump
Inlet Pressure
Fill to Proper
Level
Check Oil
Level in
Reservoir
and Replace if
Necessary
OK OK
Low
Low
EXCESSIVE NOISE AND/OR VIBRATION
Purge Air and
Tighten
Fittings
Air in System
OK
Loose Fitting
Repair or
Replace
Inspect Shaft
Couplings
OK
Defective
Align Shafts
Inspect Shaft
Alignment
Defective
Check Charge
Pressure
Clean, Repair
or Replace
Fill to Proper
Level
Check Oil Level
in Reservoir
Check for Internal
System Leakage
Repair as
Required
Inspect Heat
Exchanger
Repair as Required
OK OK OK
High
Incorrect Defective Low
SYSTEM OPERATING HOT
Check Pump Inlet
Pressure
Low OK
Check System
Pressure
Replace
Transmission
(Pump and Motor)
Reduce Load on
Transmission
High
OK OK
Check System Relief
Pressure Settings
Adjust or Replace
Low
OK
and Replace if
Necessary
BOMAG 860 008 911 79
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38 30 - 16
Repair or Replace Repair or Replace
Appropriate Valve
Check Pump
Control System
Check Charge
Pressure
Replace
Transmission
(Pump and
Motor)
Inspect and Repair
Loop Flushing
Valve
OK
Defective
MOTOR OPERATES NORMALLY IN ONE DIRECTION ONLY
Decays in One
Direction (Forward
or Reverse) Only
Problem Changes
Direction
Interchange System
Relief Valves and/or
Charge Check
Valves
OK OK
Correct System
Check Inlet
Pressure at
Motor
Repair or Replace
Motor
OK
Low
LOW MOTOR OUTPUT TORQUE
Correct System
Check Outlet
Pressure at
Motor
OK
High / Low
Motor at Incorrect
(Minimum) Displacement
OK
Incorrect
Check Control Supply
Pressure and/or Repair
Fill to Proper
Level
Check Oil
Level in
Reservoir
Repair or Replace
Motor
OK
Low
IMPROPER MOTOR OUTPUT SPEED
Repair Pump
Control and/or
Pump
Check Pump
Output Flow
OK
Improper
Check Motor Displacement
Incorrect
Check and Repair
Control System and
Displacement Controls
(Pump and Motor)
OK
Repair Charge
System
Check Charge
Pressure
Incorrect OK
Troubleshooting (Continued)
Fault-Logic Diagrams Closed Circuit (Continued)
BOMAG 861 008 911 79
18.3
saue
39 30 - 17
Notes
BOMAG 862 008 911 79
saue
40 30 - 18
Notes
BOMAG 863 008 911 79
18.3
saue
41 40 - 1
Exploded View of the Series 51 Variable Motor
The following information is for general parts identi-
fication ONLY. Refer to the applicable Service Parts
List when ordering service parts.
Name Plate (German Production)
Model Number
Model Code Typ
Model No. Ident Nr
Serial No. Fabr Nr
saue
MADE IN GERMANY
Serial Number
51V160 RF1N
E1A2 ANE1 NNN
050AA210322
Model Code
Name Plate
Base Unit
516-40104 786673
N 91 25 67890
L50
Y20
Y10
Y30
B71
B71A
L70
L35
L40
L50
L40
L75
L80
B80
B80
B70
B70A
B70A
B70
B70A
B70
Y20
Y10
Y30
OPTION
WNNT
W50
W25
W10
W10
OPTION
WNNS
W50
W25
Y20
Y10
BOMAG 864 008 911 79
saue
42 40 - 2
Exploded View of the Series 51 Variable Motor (Continued)
End Cap
K18
F32
J20/S70
J30
J10A-D
K16
(060160)
K14
G20A
G20
S20
S10
(060, 080,
110)
G20A
K14
K16
(060160)
G20
G50A
G50
K90
K50
K10
K70
J60
J70
G36
G24
G26
G38
G30A
G30
F10N, F10AG
J40
F33
G12
G12A
M16/M96
M18/M98
G30A
G30
M11/T2A1-A9
T2B0-B6
T2C2-C7
G30
(250)
G30A
(250)
G12
G12A
G12A
G12
G12A
G12
G30A
G30
G30A
(250)
G30
(250)
J50
S10
(160, 250)
G12
G12A
G80
(060, 080)
G80A
(060, 080)
OR
G44
G38
G42
G38
G36
G38
G42
G30A
(250)
G30
(250)
K80
F20AG
K90A
K90N
OR
K18N
OR
OR
OR
(....) = Applies to the indicated
frame size(s).
N1U5
G90
G18
Q40
T7A1-A9
T7B0-B6
T7C2-C7
T8A1-A9
T8B0-B6
T8C2-C7
M11/T1A1-A9
T1B0-B6
T1C2-C7
M11/T3A1-A9
T3B0-B6
T3C2-C7
Y40
Y50
K16
(250)
K16
(250)
BOMAG 865 008 911 79
18.3
saue
43
40 - 3
N28
N90
N66
N58
N90A
N34A
N34
N28A
N34
N34A
N66A
N72A
N72
N30
N26A
N26
N34
N28
N28A
N34A
N34
N32
N66A
N66
N1A1-A6
N34A
N52/T6
N34
N34A
N46/T5
N52/T4
N34A
N34
N84A
N84
N84A
N84
N29
N24
N82
N29
N23
N23A
N11
N11 & N21
N22 & N20
N14
N18
N16
Z10 & Z20
OR
N27A
N27
N27
N27A
N52
OR
OR
OR
U7
U6
N82
N24
Q60
Q50
BOMAG 866 008 911 79
saue
44 40 - 4
Controls
M38
M32
M32A
M36
M28
M30
M24
M18
M14
M12
M26
M16
M1EPEQ
M10
M18
M14
M28
M26
M32
M12
M10
M36
M16
M1HP
M10
M1E1E2E5
M1F1F2
M1H1H2
M1K1K2
M14
M20
M18A
M18
M28
M1HS
M14
M16
M18
M24
M30
M30
M22A
M22
M16
EPEQ
E1E2E5 / F1F2 / H1H2 / K1K2
HP
HS
S1
M20
M22
M1S1
M14
M16
M18
M10
M2E5
BOMAG 867 008 911 79
18.3
saue
45 40 - 5
Controls (Continued)
M14
M12
M18
M16
M28
M20
M22
M24
M25
J10
M26
M34A
M34
M10
M11
(060, 080, 110)
M32
M1HC
M47
M46
M48A
M48
M34A
M34
M34A
M34
M44
M38
M40
HC
M1HZ
M16
M18
M18
M18A
M16
M16A
M16A
M18
M18A
M18A
M14
M22
M12
M10
M1N2
M14
N2
HZ
M50A
M50
(....) = Applies to the indicated
frame size(s).
S10
(060, 080,
110)
S10T
(060, 080,
110)
S20
S11T
(060, 080,
110)
S10
(160, 250)
OR
S70
S30
S50
S40
S60
S11T
(160, 250)
S10T
(160, 250)
M12
M10
BOMAG 868 008 911 79
saue
46 40 - 6
PC Regulator
M28
M90
M66
M58
M90A
M34
M34A
M28A
M34
M34A
M66A
M72A
M72
M30
M26A
M26
M34
M28
M28A
M34A
M34
M28A
M28
M10
M34A
T6
M34
M34A
T5
T4
M34A
M34
M84A
M84
M84A
M84
M24
M82
M29
M23
M23A
M1PC & M21
M22 & M20
M14
M18
M16
Z10 & Z20
M27A
M27
M27
M27A
U7
U6
Q60
M52
F33
T7
F32
BOMAG 869 008 911 79
18.3
saue
47 40 - 7
B000 COMMON PARTS GROUP (SAE FLNG)
B80 O-RING 1
L35 FLANGE- SAE 1
L40 SEAL- SHAFT 1
L50 O-RING 1
L70 SCREW- SOC HD 8
C000 COMMON PARTS GROUP (CARTRIDGE)
L40 SEAL- SHAFT 1
L50 O-RING 1
L75 COVER- SEAL 1
L80 RING- RETAINING 1
F MAXIMUM DISPLACEMENT
F10 SPACER- MAX DISPL LMTR 1
F20 SCREW-SOC HD - MAX DISPL LMTR 1
G00A END CAP-AXIAL (160-250)
G00B END CAP-AXIAL, CODE 61 (160-250)
G00R END CAP-SIDE, LOOP FL
G00S END CAP-SIDE, LOOP FL, CODE 61
G12 PLUG-STR THD HEX 7
G14 PLUG-EXP 1
G16 PLUG-MANDREL 2
G18 SCREW-SET, FLAT PT 2
G20 PLUG- SPECIAL 2
G20N PLUG- STR THD HEX 2
G24 SCREW-SOC HD 4
G26 COVER-SERVO PISTON 1
G30 PLUG-STR THD HEX 3
G36 O-RING 2
G38 O-RING 4
G42 O-RING 2
G44 O-RING 1
G50 PLUG-ST THD HEX 2
G70 COVER-PORT 2
G90 CONTROL SCREEN FILTER 1
K10 ADJ PLUG ASSY-CHG RLF 1
K14 SPRING-HELICAL COMP 2
K16 GUIDE-SPRING (060 160) 2
K16 GUIDE-SPRING (250) 2
K18 SHUTTLE VALVE SPOOL 1
K18N LOOP FLUSH SPOOL- DEFEAT 1
K50 O-RING 1
K70 SPRING-HELICAL COMPRESSION 1
K80 POPPET-CHG RELIEF 1
K90 NUT-HEX LOCK 1
K90N PLUG- ST THD HEX 1
J00A-K CONTROL START SETTING
J10A-K SPRING-HEL COMP- CONT START 1
J20 SEAT-SPRING 1
J30 SEAT-SPRING 1
J40 SCREW-ADJUSTING 1
J50 O-RING 1
J60 NUT-ADJUSTING SCREW 1
J70 NUT-LOCK 1
J00N CONT START N/A (FOR 2 POS CONT)
M0EP CONTROL- ELHYD PRP, PACKARD
M0EQ CONTROL- ELHYD PRP, MS
F32 BUSHING- VALVE ASSY 1
M1EP PCP VALVE, PACKARD CONN 1
M1EQ PCP VALVE, MS CONN 1
M10 HOUSING- CONTROL 1
M12 SCREW- SOC HD 4
M14 COVER 1
M16 GASKET 1
M18 SCREW- SOC HD 4
M24 PISTON- SHUTTLE, DELTA P 1
M26 SPRING- HEL COMPRESSION 1
M28 PIN 1
M30 O-RING 1
M32 PLUG-SOC HD 2
M34 PLUG-MANDREL 6
M36 O-RING 1
M38 O-RING 1
M40 CONTROL SCREEN FILTER 1
M42 PLUG-SOC HD 1
M44 PLUG-PLASTIC 1
N90 PLUG-STR THD HEX 1
M0E1/E2 CONTROL- ELHYD 2 POS
M0F1/F2 CONTROL- ELHYD 2 POS, MAX ANG
M1E1 VALVE ASSY- SOLENOID,12V 1
M1E2 VALVE ASSY- SOLENOID,24V 1
M10 HOUSING-CONT, ELHYD, 2 POS (E) 1
M10 HOUSING-CONT, ELHYD, 2 POS (F) 1
M12 PLUG-EXP 7
M14 SCREW-SOC HD 4
M16 O-RING 2
M18 PLUG-STR THD HEX 1
M20 O-RING 1
Item Description Quantity Item Description Quantity
BOMAG 870 008 911 79
saue
48 40 - 8
M0HC CONTROL- HYD PRPNL 2LN, DUAL PATH
M1HC HOUSING- HYD PRPNL (2LN),DUAL 1
M10 SCREW-SOC HD 4
M11 WASHER, FLAT (060, 080, 110) 4
M12 COVER 1
M14 GASKET 1
M16 NUT-SEAL LOCK 1
M18 SCREW-SET, FL PT 1
M20 GUIDE- SPRING 1
M22 SPRING-HELICAL COMPRESSION 1
M24 PISTON- DELTA P 1
M25 SEAT- SPRING 1
M26 PIN 1
M28 SCREW-SOC HD 4
M34 PLUG-SOC HD 4
M38 VALVE- BLEED 1
M40 NUT- SEAL LOCK 1
M44 VALVE, SHUTTLE- DELTA P 1
M46 SEAT- BALL CHECK 1
M47 BALL- SHUTTLE 1
M0HP CONTROL- HYD PRPNL 2LN, W/BLD
M1HP HOUSING- HYD PRPNL (2LN),W/BLD 1
M10 COVER 1
M12 GASKET 1
M14 PISTON-SHUTTLE, DELTA P 1
M18 PIN 1
M24 O-RING 1
M26 VALVE SHUTTLE,DELTA P 1
M28 PLUG-SEALING 1
M30 O-RING 2
M32 PLUG-SEALING 1
M34 PLUG-EXP 6
M36 SCREW-SOC HD 4
M0HS CONTROL- HYD PRP, 1 LN
F32 BUSHING-VALVE ASSY 1
M1HS HOUSING- VALVE, HYD PRPRNL 1 LN 1
M10 SCREW-SOC HD 4
M12 O-RING 1
M16 PLUG-PLASTIC 1
M0HZ CONTROL- HYD PRP, 1 LN, CMPCT
M1HZ HOUSING- VALVE, HYD PRP, 1 LN, CPT 1
M10 VALVE ASSY- DBL CHECK 1
M12 SCREW- SOC- DRILLED 1
M0H1/H2 CONTROL- HYD PRP, 1 LN, MAX ANG
M0K1/K2 CONTROL- HYD PRP, 1 LN, MIN ANG
F32 BUSHING-VALVE ASSY 1
M1H1 VALVE ASSY-SOLENOID,12V 1
M1H2 VALVE ASSY-SOLENOID,12V 1
M10 HSG-CONT,ELHYD, 2 POS 1
M12 PLUG-EXP 8
M14 SCREW-SOC HD 4
M16 O-RING 2
M20 O-RING 1
M22 PLUG-PLASTIC 1
N90 PLUG-STR THD,SOC HD 1
M0N2 CON-HYD, 2 POS, DIRECT
M1N2 COVER 1
M10 PLUG 1
M11 SCREW- SET,FLT PT 3
M12 O-RING 1
M14 SCREW-SOC 4
M16 GASKET 1
M18 PLUG 1
BOMAG 871 008 911 79
18.3
saue
49 40 - 9
Item Description Quantity
M0PC REGULATOR- PRESS COMP
F32 PLUG- VALVE BUSHING BORE 1
F33 O-RING 1
M1PC HOUSING- VALVE 1
M10 HOUSING- MULTI FUNCTION BLOCK 1
M14 NUT-HEX LOCK 1
M16 O-RING 1
M20 SEAT-SPRING, PC 1
M21 BUSHING-VALVE 1
M22 SPOOL-PC VALVE 1
M26 PLUG-SOC HD 1
M29 SCREW-SOC 4
M30 SPOOL, BI-DIRECTIONAL CHECK 1
M36 SCREW-SET,FLT PT 5
M38 PLUG-EXP 11
M50 PLUG-EXP 8
M54 PLUG-EXP 1
M58 SCREW-SOC HD 4
M62 PLUG-EXP 1
M72 PLUG-STR THD,SOC HD 1
M82 O-RING 1
M86 SCREW-FL PT 1
M96 GASKET 1
M98 PLUG 1
N24 O-RING 5
M0S1 CONTROL- ELECTRIC 2 POS, DIRECT
M1S1 SOLENOID,12V 1
M10 ADAPTER PLATE- SOLENOID 1
M14 SCREW-SOC HD 4
M16 O-RING 1
M18 O-RING 1
M20 PIN 1
M22 O-RING 1
N0A1-6 SVO PRS SPLY, PCOR, DFT
N1A1-6 HOUSING-MULTI FUNCTION BLOCK 1
N11 HOUSING-VALVE 1
N14 NUT-HEX LOCK 1
N16 O-RING 1
N18 SPRING-HELICAL COMPRESSION 1
N20 SEAT-SPRING, PCOR 1
N21 BUSHING-VALVE 1
N22 SPOOL-PCOR VALVE 1
N24 O-RING 5
N26 PLUG-SOC HD (W/PCOR) 1
N26 PLUG-STR THD HEX (WO/PCOR) 1
N28 PLUG-PLASTIC (W/DFT) 2
N28 PLUG-STR THD HEX (WO/DFT) 2
N29 SCREW-SOC 4
N30 SPOOL, BI-DIRECTIONAL CHECK 1
N32 PISTON 1
N36 SCREW-SET,FLT PT 5
N38 PLUG-EXP (060 - 110 ONLY) 11
N50 PLUG-EXP (060 - 110 ONLY) 6
N52 CONTROL SCREEN FILTER 2
N54 PLUG-EXP 1
N58 SCREW-SOC HD 4
N62 PLUG-EXP 1
N66 PLUG-STR THD HEX (060-110) 2
N66 PLUG-STR THD HEX (160-250) 1
N72 PLUG-STR THD,SOC HD 1
N74 SCREW-SET, FL PT 3
N82 O-RING 1
N84 PLUG, SPECIAL 2
N86 SCREW-SET 1
U5 PLUG- SOC (EXT SUPPLY) 1
U6 ORIFICE, PCOR DAMPING 1
U7 ORIFICE, PCOR DAMPING 1
N0NN SERVO PRESS SPLY- NONE
P0AA SYS PRESS PROTECT- NONE
Item Description Quantity
BOMAG 872 008 911 79
saue
50 40 - 10
S00D-G CONTROL RAMP- HP, HS, H1/H2, K1/K2
S10 GUIDE-SPRING (160-250) 1
S10D-G CONT RAMP SPRING (060-110) 1
S10D-G CONT RAMP SPRING ASSY (160-250) 2
S20 GUIDE-SPRING 1
S70 SEAT-SPRING 1
S00N CONTROL RAMP-NONE
S00T CONTROL RAMP- HC
S10 GUIDE-SPRING 1
S10T CONT RAMP SPRING 1
S11T CONT RAMP SPRING 1
S20 GUIDE-SPRING 1
S30 NUT- ADJUSTING SCREW 1
S40 O-RING 1
S50 NUT- LOCK 1
S60 SCREW- ADJUSTING 1
S70 SEAT-SPRING 1
S00U-Z CONTROL RAMP- EP/EQ
S10 GUIDE-SPRING (160-250) 1
S10U-Z CONT RAMP SPRING (060-110) 1
S10U-Z CONT RAMP SPRING ASSY (160-250) 1
T0A0 CON ORIFICE (A0)- NONE
T0A1 CON ORIFICE (A1)
T1 ORIFICE 1
T2 ORIFICE 2
T3 ORIFICE 1
T4 SCREW 2
T5 ORIFICE 1
T6 SCREW 1
T7 ORIFICE 2
T8 ORIFICE 1
U3 SCREW-FL PT 1
T0A2 CON ORIFICE (A2)
T1 ORIFICE 1
T2 ORIFICE 2
T3 ORIFICE 1
T4 ORIFICE 2
T5 SCREW 1
T6 ORIFICE 1
T7 ORIFICE 2
T8 ORIFICE 1
WNNN SPCL HDW-NONE
A10 SPEED SENSOR 51V 0
B70 PLUG-SOC HD 1
B71 PLUG-PLASTIC 1
Y MINIMUM DISPLACEMENT
Y10 SCREW- SET, FLT PT 1
Y20 NUT- HEX, SEAL LOCK 1
Y30 TAMPER RESISTANT CAP 1
Z000 PRS COMP SET- NONE
Z0 PCOR / PRESS COMP SETTING
Z10 ADJUSTER- THREADED 1
Z20 PIN-STRAIGHT 1
BOMAG 873 008 911 79
18.3
saue
51 50 - 1
Minor Repair and Replacement - Variable Motor
Shaft
Seal
Control
Orifices
Control
Limiter
Variable Displacement Motor (SAE Flange Configuration)
Fig. 50-1 - Minor Repairs
Charge Pressure
Relief Valve
Loop Flushing
Valve
51000052
Multi-function
Block
Minor Repairs may be performed, following the proce-
dures in this section, without voiding the unit war-
ranty. Although specific products are illustrated,
these procedures apply to all units in the Series 51
family.
General
Cleanliness is a primary means of insuring satisfac-
tory transmission life, on either new or repaired units.
Cleaning parts by using a solvent wash and air drying
is adequate, providing clean solvent is used. As with
any precision equipment, the internal mechanism
and related items must be kept free of foreign mate-
rials and chemicals.
Protect all exposed sealing surfaces and open cavi-
ties from damage and foreign material.
It is recommended that all gaskets and O-rings be
replaced. All gasket sealing surfaces must be cleaned
prior to installing new gasket. Lightly lubricate all O-
rings with clean petroleum jelly prior to assembly.
BOMAG 874 008 911 79
saue
52 50 - 2
Minor Repair and Replacement - Variable Motor (Continued)
Fig. 50-3 - Remove
Flange (SAE)
Fig. 50-2 - Remove
Screws Holding
Flange to Housing
(SAE)
51000179 51000178
Remove the old seal from the flange. Once removed,
the seal is not reusable.
Inspect the flange and the new seal for any damage
or nicks.
Using an arbor press, press the new seal into the
flange. Be careful not to damage seal.
NOTE: The outside diameter of the seal may be
lightly coated with a sealant (such as Loctite
High Performance Sealant #59231) prior to
installation. This will aid in preventing leaks
caused by damage to the seal bore in the
flange.
Inspect the sealing area on the shaft for rust, wear, or
contamination.
Fig. 50-5 - New Seal
Installed in Flange
(SAE)
Fig. 50-4 - Remove
Old Seal from Flange
(SAE)
51000053 51000054
Shaft Seal (SAE Flange Configuration)
Lip type shaft seals are used on the Series 51 motors.
Replacement of the shaft seal usually requires re-
moval of the motor from the machine.
Remove the screws holding the flange to the housing,
using a 6 mm internal hex wrench (060 and 080 units),
an 8 mm internal hex wrench (110 units), a 10 mm
internal hex wrench (160 units), or a 12 mm internal
hex wrench (250 units).
Remove the flange from the housing using a suitable
puller. Care must be taken so as to not damage the
housing bore or shaft.
CAUTION
Do not allow the output shaft to move out of the
housing while removing the flange. After the
flange is removed, do not attempt to remove
the shaft from the housing. If the output shaft
moves out of the housing, the synchronizing
shaft and rollers could fall out of position,
requiring major disassembly of the unit.
BOMAG 875 008 911 79
18.3
saue
53 50 - 3
51000056 51000055
Fig. 50-6 - Install
Flange onto Housing
(SAE)
Fig. 50-7 - Torque
Flange Screws (SAE)
51000058 51000057
Fig. 50-8 - Remove
Carrier Retaining
Ring (Cartridge)
Fig. 50-9 - Remove
Seal Carrier
(Cartridge)
51000060 51000059
Fig. 50-10 - Seal
Carrier Removed
(Cartridge)
Fig. 50-11 - Seal
Installed in Carrier
(Cartridge)
Install a new O-ring on the flange. Prior to assembly,
lubricate the flange O-ring and the I.D. of the seal with
petroleum jelly.
Protect the seal lip from damage during installation by
wrapping the spline or key end of shaft with plastic
film, or by using a seal installation tool.
Assemble the flange and seal over the shaft and into
the housing bore. Install four (4) of the flange screws,
and tighten them evenly to pull the flange into posi-
tion. Take care to not damage the O-ring or seal lip
during installation.
Install the flange screws and torque evenly to 32 Nm
(24 ftlbsf) for 060 and 080 motors, 63 Nm (46 ftlbsf)
for 110 motors, 110 Nm (81 ftlbsf) for 160 motors,
and 174 Nm (128 ftlbsf) for 250 motors.
Shaft Seal (Cartridge Configuration)
Lip type shaft seals are used on the Series 51 motors.
These seals can be replaced without major disas-
sembly of the unit. However, replacement of the shaft
seal requires removal of the motor from the wheel
drive or track drive gearbox.
Remove the seal carrier retaining ring from the hous-
ing.
Carefully pull the seal cover out of the housing. Care
must be taken so as not to damage the housing bore
or shaft.
Remove the O-ring from the housing.
Remove the old seal from the carrier. Once removed,
the seal is not reusable.
Inspect the carrier and the new seal for any damage
or nicks.
Using an arbor press, press the new seal into the
carrier. Be careful not to damage seal.
NOTE: The outside diameter of the seal may be
lightly coated with a sealant (such as Loctite
High Performance Sealant #59231) prior to
installation. This will aid in preventing leaks
caused by damage to the seal bore in the seal
carrier.
Inspect the sealing area on the shaft for rust, wear, or
contamination.
BOMAG 876 008 911 79
saue
54 50 - 4
Install the carrier O-ring into the groove in the hous-
ing. Prior to assembly, lubricate the carrier O-ring and
the I.D. of the seal with petroleum jelly.
Protect the seal lip from damage during installation by
wrapping the spline or key end of shaft with plastic
film, or by using a seal installation tool.
Assemble the carrier and seal over the shaft and into
the housing bore. Take care to not damage the O-ring
or seal lip during installation.
Install the seal carrier retaining ring.
51000057 51000061
Fig. 50-12 - Install
Seal Carrier
(Cartridge)
Carrier Retaining
Ring (Cartridge)
51000063 51000062
Fig. 50-14 - Remove
Shuttle Valve Plugs
Fig. 50-15 - Remove
Valve Spool
Loop Flushing Shuttle Valve (Option)
Using an 11/16" wrench, remove the hex plugs from
both sides of end cap.
Remove springs and spring seat washers. Note the
orientation of the washers.
NOTE The 250 frame size motors use thicker spring
seat washers.
Remove flushing valve spool.
Valve Spool and
Washers
51000065 51000064
Plugs and Springs
51000066
Fig. 50-16 - Loop Flushing Shuttle Valve
Components
Inspect parts for damage or foreign material.
Install flushing valve spool in end cap, then install the
spring seat washers (thick washers on 250 frame size
motors) on each end of the spool. The step on the
spring seat washers should face out, toward the
springs.
Install the spool springs and hex plugs. Torque the
plugs to 41 Nm (30 ftlbsf).
BOMAG 877 008 911 79
18.3
saue
55 50 - 5
Fig. 50-19 - Remove
Charge Relief Valve
Plug
Fig. 50-20 - Remove
Charge Relief Valve
51000068 51000067
Fig. 50-22 - Remove
Servo Cover Screws
Servo Cover
51000006 51000046
Fig. 50-21 - Charge Relief Valve
Components
51000069
Charge Pressure Relief Valve
plug, mark the plug, lock nut, and end cap to allow
maintaining the original adjustment when assem-
bling. Remove the screw adjustable charge relief
valve plug by loosening the lock nut (with a 1-1/16"
hex wrench), and unscrewing the plug with a large
screwdriver.
Remove the spring and relief valve poppet.
Inspect the poppet and mating seat in the end cap for
damage or foreign material.
Install the poppet and spring. Install the plug with its
and torque the lock nut to 52 Nm (38 ftlbsf).
Check and adjust, if necessary, the charge pressure.
Minimum Angle Servo Cover
Thoroughly clean external surfaces prior to removal
of cover.
Remove the four (4) screws retaining the cover to the
end cap with an 8 mm internal hex wrench (060, 080,
110, and 160 units) or a 10 mm internal hex wrench
(250 units). Remove the cover. Remove the O-rings
between the cover and end cap.
Install new O-rings on the end cap and retain with
petroleum jelly. Install the cover onto the end cap and
install the screws. Torque the screws to 78 Nm (58
ftlbsf) for 060, 080, or 110 units, or 110 Nm (81 ftlbsf)
for 160 or 250 units.
The plug in the cover may be removed with a 7/16"
hex wrench. Torque this plug to 9 Nm (7 ftlbsf).
BOMAG 878 008 911 79
saue
56 50 - 6
Fig. 50-24 - Remove
Cover Plate Screws
Fig. 50-25 - Remove
Cover Plate
51000072 51000071
of cover plate.
Remove the four (4) screws retaining the cover plate
(160 and 250 units). Remove the cover plate.
Remove the solid plug from the valve sleeve bore in
the end cap. (An 8 mm threaded hole is provided in
the plug for a puller screw.) Remove the O-ring from
the plug.
Remove the O-rings from the end cap.
Install new O-rings on the end cap and retain with
petroleum jelly.
Install a new O-ring on the solid plug and install the
solid plug into the end cap.
51000010
Fig. 50-29 - Torque
Plug in End Cap
51000074
Fig. 50-28 - Torque
Cover Plate Screws
51000073
Fig. 50-26 - Remove Valve Sleeve Bore
Plug
51000168
Fig. 50-27 - N2 Control Components
Install the cover plate onto the end cap and install the
screws. Torque the screws to 78 Nm (58 ftlbsf) for
060, 080, or 110 units, or to 110 Nm (81 ftlbsf) for 160
or 250 units.
Set screws are installed in control orifice holes in the
end cap to plug the valve sleeve bore passages. To
gain access to the screw plugs, remove the outer
plugs from the end cap with a 7/16" or 11/16" hex
wrench. Remove the screw plugs with a 3 mm internal
hex wrench. When installing, torque the screw plugs
to 4 Nm (35 inlbsf). Torque the 5/16" outer plugs to
9 Nm (7 ftlbsf), and the 9/16" outer plugs to 37 Nm (27
ftlbsf). Refer to the Control Orifices topic for addi-
tional information.
The special plug and seal washer on the end cap
opposite the control may be removed with a 13 mm
hex wrench. When installing, torque this plug to 20
Nm (15 ftlbsf).
BOMAG 879 008 911 79
18.3
saue
57 50 - 7
Fig. 50-30 - Remove
E1E2 or F1F2
Control Solenoid
Fig. 50-31 - Remove
Solenoid Valve
51000076 51000075
Components
Fig. 50-33 - Install E1E2 or F1F2 Control
Valve Housing
51000077
51000013
Solenoid
Solenoid Valve
51000079 51000078
Electrohydraulic 2-Position Controls
(Types E1E2 and F1F2)
Thoroughly clean external surfaces prior to removing
the control.
The solenoid may be removed from the valve by
removing the nut with a 3/4" hex wrench. The
solenoid valve may be removed from the control
valve housing with a 7/8" hex wrench.
Remove the screws retaining the valve housing to the
multi-function block with a 4 mm internal hex wrench.
Remove the valve housing.
The plugs on the control housing may be removed
with an 11/16" hex wrench. When reinstalling, torque
the plugs to 37 Nm (27 ftlbsf).
Install new O-rings onto the valve housing. Install the
valve housing onto the multi-function block, and
install the screws. Torque the screws to 6.4 Nm (4.7
ftlbsf).
When installing the solenoid valve into the valve
housing, the valve should be torqued to 20 Nm (15
ftlbsf). When installing the solenoid onto the valve,
torque the nut to 15 Nm (11 ftlbsf.).
BOMAG 880 008 911 79
saue
58 50 - 8
Fig. 50-36 - Remove
S1 Control Screws
Fig. 50-37 - Remove
Adapter Plate and
Solenoid
51000165 51000164
Fig. 50-38 - S1 Control Components
Electric 2-Position Controls (Type S1)
the control.
Remove the screws retaining the solenoid and sole-
noid adapter plate to the multi-function block with a 4
mm internal hex wrench. Remove the solenoid and
the solenoid adapter plate from the multi-function
block.
Remove the solenoid pin from the multi-function
block.
Fig. 50-39 - Install S1 Control Solenoid Pin
51000086
51000163
Fig. 50-41 - Torque
Control Solenoid
Screws
Adapter Plate and
Solenoid
51000166 51000165
Install new O-rings onto the adapter plate and the
solenoid.
Install the solenoid pin into the hole in the multi-
function block.
Install the adapter plate with O-rings onto the multi-
function block.
Install the solenoid with O-ring onto the adapter plate.
Install the screws and torque to 6.4 Nm (4.7 ftlbsf).
BOMAG 881 008 911 79
18.3
saue
59 50 - 9
Fig. 50-45 - HZ
Control Housing
Screens
Fig. 50-46 - End Cap
O-Rings Installed
51000083 51000082
Fig. 50-42 - Remove
HZ Control Housing
Screws
Fig. 50-43 - Remove
HZ Control Housing
51000080 51000081
Fig. 50-44 - HZ Control Components
51000016
Fig. 50-48 - Torque
HZ Control Valve
Housing Screws
51000084
Fig. 50-47 - Install HZ
Control Housing
51000081
Hydraulic Proportional Control (Type HZ)
of control.
Remove the four (4) screws retaining the valve hous-
ing to the end cap with an 8 mm internal hex wrench
(060, 080, and 110 units) or a 10 mm internal hex
wrench (160 and 250 units). Remove the valve hous-
ing. Remove the O-rings between the valve housing
and end cap, and the O-ring on the valve spool
sleeve.
with a 7/16" or 11/16" hex wrench. When reinstalling,
torque the 5/16" plugs to 9 Nm (7 ftlbsf), and the 9/16"
plugs to 37 Nm (27 ftlbsf)
The valve housing is equipped with filter screens in
the passages between the housing and the end cap.
Units with internal servo pressure supply have a filter
screen installed in the end cap passage leading to the
valve spool sleeve. These screens should be pressed
into position (with the rounded edge of the filter
screens facing out) until they are flush to 2.0 mm
(0.08 in.) below the machined surface of the valve
housing or end cap.
Units with external servo pressure supply have a plug
installed in the end cap passage leading to the valve
spool sleeve. This plug may be removed with a 2.5
mm internal hex wrench. When installing this plug,
torque to 2 Nm (18 inlbsf).
Install a new O-ring onto the valve spool sleeve in the
end cap. Install new O-rings onto the end cap.
Install the valve housing onto the multi-function block,
and install the screws.
Torque the screws to 78 Nm (58 ftlbsf) for 060, 080,
or 110 units, or to 110 Nm (81 ftlbsf) for 160 or 250
units.
BOMAG 882 008 911 79
saue
60 50 - 10
Fig. 50-49 - Remove HS Control Housing
Screws
Hydraulic Proportional Control (Type HS)
of control.
Fig. 50-51 - Torque HS Control Housing
Screws
Fig. 50-50 - HS Control Components
51000019
51000087
51000088
The plug on the control housing may be removed with
an 11/16" hex wrench. When reinstalling, torque the
plug to 37 Nm (27 ftlbsf).
Install a new O-ring onto the valve housing.
and install the screws.
Torque the screws to 6.4 Nm (4.7 ftlbsf).
BOMAG 883 008 911 79
18.3
saue
61 50 - 11
51000021
Fig. 50-55 - H1H2 and K1K2 Control
Components
Solenoid
51000093 51000092
Solenoid Valve
Fig. 50-54 - Remove Control Housing
Screws
51000091
Hydraulic Proportional Control with
Maximum Angle Over-ride (Types H1H2 or
K1K2)
the control.
The solenoid may be removed from the valve by
removing the nut with a 3/4" hex wrench.
The solenoid valve may be removed from the control
valve housing with a 7/8" hex wrench.
with an 11/16" hex wrench. When reinstalling, torque
the plugs to 37 Nm (27 ftlbsf).
Install new O-rings onto the valve housing.
and install the screws. Torque the screws to 6.4 Nm
(4.7 ftlbsf).
When installing the solenoid valve into the valve
housing, the valve should be torqued to 20 Nm (15
ftlbsf).
When installing the solenoid onto the valve, torque
the nut to 15 Nm (11 ftlbsf.).
Fig. 50-52 - Remove
H1H2 or K1K2
Control Solenoid
51000089
Fig. 50-53 - Remove
Solenoid Valve
51000090
BOMAG 884 008 911 79
saue
62 50 - 12
Fig. 50-58 - Remove
HP Control Housing
Screws
Fig. 50-59 - Remove
Control Housing
51000095 51000094
Fig. 50-62 - HP Control Components
51000024
Fig. 50-61 - Remove
Pilot Piston Pin
51000086
Fig. 50-60 - Remove
Shuttle Spool Plug
51000096
Two Connection Hydraulic Proportional
Control (Type HP)
of control.
Hold the control housing in position, and remove the
screws retaining the cover and control housing to the
Remove the housing cover and gasket. Remove the
valve housing with shuttle valve assembly and pilot
piston from the multi-function block.
Remove the O-rings from the valve housing. Remove
the pilot piston and spring from the valve housing.
Remove the pilot piston pin from the multi-function
block.
Remove the inner shuttle spool plug from the valve
housing. (A 5 mm threaded hole is provided in the
inner plug for a puller screw.) Remove the shuttle
spool from the valve housing. Remove the outer
shuttle spool plug. Remove the O-rings from the
plugs.
Install new O-rings on the shuttle spool plugs.
Install new O-rings on the valve housing and retain
with petroleum jelly.
BOMAG 885 008 911 79
18.3
saue
63 50 - 13
Shuttle Spool and
Plugs
51000098 51000097
Fig. 50-63 - Pilot
Piston Pin Installed
Control Housing
Spring
51000101
51000099 51000100
51000102
Pilot Piston
Cover, Gasket, and
Screws
Install the pilot piston pin in the multi-function block.
Install the outer (thin) shuttle piston plug with the large
chamfer toward the shuttle valve bore. Install the
shuttle spool into its bore and install the inner (thick)
plug with the large chamfer toward the shuttle valve
bore.
Position the valve housing (with O-ring) on the multi-
function block.
Install the pilot piston into the housing and over the
pin. The end of the piston with the cross drilled hole
should engage the pin.
Install the small spring in the outer end of the pilot
piston.
Install the control cover and gasket. Align the control
assembly with the multi-function block and install the
four (4) screws.
Torque the control screws to 6.4 Nm (4.7 ftlbsf).
BOMAG 886 008 911 79
saue
64 50 - 14
Fig. 50-69 - Remove
HC Control Bleed
Valve
51000103
Two Connection Hydraulic Proportional
Control for Dual Path Vehicles (Type HC)
Bleed Valve
Loosen the seal lock nut on the bleed valve with a 10
mm hex wrench, and remove the valve with a 4 mm
internal hex wrench.
Install the bleed valve and torque to 3 Nm (27 inlbsf).
Install the seal lock nut and torque to 19 Nm (14
ftlbsf).
Servo Pressure Shuttle Valve
Remove the servo pressure shuttle plug with an
1116" hex wrench. Remove the shuttle ball seat with
a 5 mm internal hex wrench and remove the ball.
Install the servo pressure shuttle ball.
Install the shuttle ball seat and torque to 11 Nm (8
ftlbsf). Install the shuttle passage plug and torque to
37 Nm (27 ftlbsf).
HC Control Bleed
Valve
51000175
51000123 51000174
Fig. 50-72 - Remove
Servo Pressure Ball
Shuttle Valve
51000104 51000176
HC Control Bleed
Valve Seal Nut
Fig. 50-74 - Torque
Servo Pressure
Shuttle Ball Seat
Servo Pressure
Shuttle Ball Valve
51000105
Control Pressure
Shuttle Spool
Fig. 50-76 - Torque
Shuttle Spool Plugs
51000122
Control Pressure Shuttle Valve
Remove the shuttle spool plugs with a 1/4" internal
hex wrench. Remove the control pressure shuttle
spool.
Install the control pressure shuttle spool.
Install the shuttle spool plugs and torque to 20 Nm (15
ftlbsf).
BOMAG 887 008 911 79
18.3
saue
65 50 - 15
Fig. 50-79 - Remove
Adjustment Spring
and Pilot Piston
Fig. 50-80 - Remove
Pilot Piston Pin and
Control Start Spring
Fig. 50-78 - Remove
HC Control Housing
Cover
Pilot Piston and Control Housing
Thoroughly clean external surfaces prior to disas-
sembly of control.
Remove the four (4) screws retaining the cover to the
control housing with a 4 mm internal hex wrench.
Remove the housing cover and gasket (with the
adjusting screw and seal lock nut).
Remove the control start adjustor spring seat and
spring from the pilot piston.
Remove the pilot piston from the control housing.
Remove the pilot piston pin seat and pin from the
control housing (or pilot piston).
Remove the control start spring from the control
housing.
Remove the four (4) screws (and washers for 060,
080, and 110 units) retaining the control housing to
the end cap with an 8 mm internal hex wrench (060,
(160 and 250 units).
Remove the control housing from the end cap. Re-
move the O-rings between the control housing and
the end cap, and the O-ring on the valve spool sleeve.
Fig. 50-77 - Remove
HC Control Housing
Cover Screws
51000177 51000106
51000107 51000108
51000109
Fig. 50-81 - Remove
HC Control Housing
Screws
Fig. 50-82 - Remove
HC Control Housing
51000110
BOMAG 888 008 911 79
saue
66 50 - 16
51000110 51000114
HC Control Housing
Fig. 50-87 - Torque
HC Control Housing
Screws
Fig. 50-85 - End Cap
O-Rings Installed for
HC Control
51000113
Fig. 50-84 - HC
Control Housing
Screens
51000112
with a 7/16" hex wrench or a 1/4" internal hex wrench.
When reinstalling, torque the 5/16" plugs to 9 Nm (7
ftlbsf), and the 9/16" plugs to 20 Nm (15 ftlbsf).
51000111
Fig. 50-83 - HC Control Components
The control housing is equipped with filter screens in
the passages between the housing and the end cap.
(0.08 in.) below the machined surface of the valve
housing or end cap.
end cap. Install new O-rings onto the end cap.
Install the valve housing onto the end cap, and install
the screws (with flat washers on 060, 080, and 110
units).
and 110 units, or to 110 Nm (81 ftlbsf) for 160 and
250 units.
BOMAG 889 008 911 79
18.3
saue
67 50 - 17
HC Control Cover
and Gasket
51000106
Fig. 50-95 - Torque
Control Cover
Screws
51000121
Pilot Piston Pin Seat
51000117
HC Control Pilot
Piston
51000118
HC Control Start
Adjuster Spring
51000119
HC Control Start
Adjuster Spring Seat
51000120
HC Control Start
Spring
51000115
Pilot Piston Pin
51000116
Install the control start spring into the control housing.
Install the pilot piston pin. The end of the pin must
engage the recess in the end of the control valve
spool.
Install the pilot piston pin seat.
spring and spring seat. The end of the piston with the
deeper bore and the cross drilled hole should engage
the start spring and pin seat.
Install the adjustor spring in the outer end of the pilot
piston.
Install the adjustor spring seat.
Install the control cover and gasket (with adjusting
screw and seal lock nut).
Torque the control cover screws to 6.4 Nm (4.7
ftlbsf).
BOMAG 890 008 911 79
saue
68 50 - 18
51000126
Fig. 50-97 - Remove
EPEQ Control
Housing Screws
51000125 51000124
Fig. 50-99 - Remove
Pilot Piston Pin
51000086
(Types EP and EQ)
of control.
The Pressure Control Pilot (PCP) valve may be
removed from the control valve housing, as de-
scribed under the following heading.
Remove the screws retaining the control housing
cover and control valve housing to the multi-function
block with a 4 mm internal hex wrench. Remove the
housing cover and gasket.
Remove the valve housing with the pilot piston from
the multi-function block.
Remove the O-rings from the valve housing. Remove
the pilot piston and spring from the valve housing.
Remove the pilot piston pin from the multi-function
block.
Install new O-rings on the valve housing and retain
with petroleum jelly.
with a 1/4" internal hex wrench. When reinstalling,
torque the 9/16" plugs to 20 Nm (15 ftlbsf).
51000027
Fig. 50-96 - Remove
PCP Valve
Fig. 50-98 - Remove
EPEQ Control
Housing
Fig. 50-100 - EQ Control Components (EP
Similar)
BOMAG 891 008 911 79
18.3
saue
69 50 - 19
Fig. 50-101 - Pilot
Piston Pin Installed
51000097
Fig. 50-105 - Torque
Cover, Gasket, and
Screws
51000130
PCP Valve
51000131
Install the pilot piston pin in the multi-function block.
Position the valve housing (with O-rings) on the multi-
function block.
pin. The end of the piston with the cross drilled hole
should engage the pin.
Install the small spring in the outer end of the pilot
piston.
Install the control cover and gasket. Align the control
assembly with the multi-function block and install the
four (4) screws.
Torque the control screws to 6.4 Nm (4.7 ftlbsf).
Reinstall the PCP valve, if removed.
Spring
51000129
Pilot Piston
51000128
Control Housing
51000127
BOMAG 892 008 911 79
saue
70 50 - 20
Fig. 50-107 - Remove
PCP Valve Screws
51000132
Fig. 50-108 - PCP
Valve Components
51000133
Pressure Control Pilot (PCP) Valve for
(Types EP and EQ)
Thoroughly clean external surfaces of control.
Using a 4 mm internal hex wrench, remove the four
(4) screws and remove the PCP valve.
Check surfaces for nicks or damage. Clean internal
screens.
Install new O-rings on the PCP housing and retain
with petroleum jelly. Position the PCP on the control
valve housing and install the screws.
Torque the screws to 5.4 Nm (48 inlbsf).
51000124 51000131
PCP onto Control
PCP Valve Screws
BOMAG 893 008 911 79
18.3
saue
71 50 - 21
51000087 51000134
Multi-function Block
51000135
Fig. 50-114 - Multi-
function Block
Screens
51000136
Screws
External Control (HS
Shown)
Fig. 50-115 - End
Cap O-Rings
Installed
51000083
51000135
Screws
51000137
External Control (HS
Shown)
51000088
Removal and Installation
Remove the external control assembly as described
in the instructions for the specific control.
Remove the four (4) screws (and washers for 060,
080, and 110 units) retaining the multi-function block
(160 and 250 units).
Remove the multi-function block from the end cap.
Remove the O-rings between the multi-function block
and the end cap, and the O-ring on the valve spool
sleeve.
The multi-function block is equipped with filter screens
in the passages between the block and the end cap.
(0.08 in.) below the machined surface of the multi-
function block or end cap.
Units with external servo pressure supply have a plug
installed in the end cap passage leading to the valve
spool sleeve. This plug may be removed with a 2.5
mm internal hex wrench. When installing this plug,
torque to 2 Nm (18 inlbsf).
end cap.
Install new O-rings onto the end cap.
Install the multi-function block onto the end cap, and
install the screws.
or 110 units, or to 110 Nm (81 ftlbsf) for 160 or 250
units.
Reinstall the external control assembly as described
in the instructions for the specific control.
BOMAG 894 008 911 79
saue
72 50 - 22
Servo Pressure
Supply Spool Plug
51000138
Servo Pressure
Supply Shuttle Spool
51000139
51000030
Fig. 50-121 - Multi-function Block with
Servo Pressure Supply Shuttle Spool
51000139 51000140
Servo Pressure
Supply Spool Plug
Servo Pressure
Supply Shuttle Spool
Servo Pressure Supply Shuttle Spool
Remove the servo pressure supply shuttle spool plug
from the multi-function valve with a 9/16" hex wrench.
NOTE: If a pressure compensator valve block is
installed, the opposite end of the shuttle
spool bore in the multi-function valve is
plugged with an internal hex head plug lo-
cated under the valve block. If a pressure
compensator valve block is not installed, the
opposite end of the shuttle spool bore is
plugged with a hex head plug.
Remove the servo pressure supply shuttle spool from
the multi-function valve block.
Inspect the shuttle spool for burrs or scoring. The
spool must slide free in its bore. The shuttle ball in the
spool must be free to move.
Install the shuttle spool into the multi-function block.
Install the hex head plug into the multi-function valve
and torque to 37 Nm (27 ftlbsf).
NOTE: If an internal hex head plug was removed
from the opposite end of the shuttle spool
bore, torque it to 20 Nm (15 ftlbsf).
BOMAG 895 008 911 79
18.3
saue
73 50 - 23
PCORPC Spring
and Spool Valve
PCORPC Adjustor
51000143 51000142
PCORPC Valve
Block
PCORPC Plug
51000145 51000144
Fig. 50-130 - Pressure Compensator Valve
Block Components
51000146
Blocking Plate (Less
PCOR)
Blocking Plate for Multi-function Block Without
PCOR
The blocking plate may be removed by removing the
four (4) screws with a 5 mm internal hex wrench.
Remove the O-rings from the plate.
Install new O-rings on the blocking plate and retain
with petroleum jelly. Install the plate on the multi-
function block and install the screws. Torque the
screws to 11 Nm (8 ftlbsf).
Remove the valve block plug with a 1" hex wrench.
Remove the four (4) screws retaining the valve block
to the multi-function block with a 5 mm internal hex
wrench. Remove the valve block and O-rings.
Pressure Compensator Valve for Pressure
Compensator Over-Ride (PCOR) and Pressure
Compensator Regulator (Type PC)
Loosen the adjusting screw lock nut with a 1-1/16"
hex wrench. Remove the adjusting screw from the
valve block with a large screwdriver.
Remove the pressure compensator valve spring and
the spool assembly from the block.
Install new O-rings on the pressure compensator
valve block and retain with petroleum jelly. Install a
new O-ring on the adjusting screw.
The plugs on the valve block may be removed with a
716" hex wrench. When reinstalling, torque the 516"
plugs to 9 Nm (7 ftlbsf).
51000170
Blocking Plate
Screws (Less PCOR)
51000171
BOMAG 896 008 911 79
saue
74 50 - 24
51000148 51000147
51000142 51000143
PCORPC Spring
and Spool Valve
PCORPC Adjusting
Screw
PCORPC Valve
Block
PCORPC Valve Plug
Install the valve block on the multi-function block and
install the screws. Torque the screws to 11 Nm (8
ftlbsf).
Install the valve block plug and torque to 54 Nm (40
ftlbsf).
Install the pressure compensator spool assembly
and the valve spring.
Install the adjusting screw and lock nut. Perform the
PCOR or PC regulator pressure adjustment as de-
scribed under Component Adjustment."
Fig. 50-135 - PCOR and PC Regulator
Orifices
51000149
PCOR and PC Regulator Orifices
To gain access to the PCOR or PC regulator orifices,
remove the three (3) plugs located between the
defeat spool stop plugs on the multi-function block,
using a 7/16" hex wrench. Remove the PCOR brake
pressure defeat spool (if installed). Remove the ori-
fice plug(s) and plain plug(s) with a 2.5 mm internal
hex wrench.
Refer to the appropriate Service Parts Manual for
information on orifice locations and sizes.
Install the orifice plug(s) and plain plug(s), and torque
to 4 Nm (35 inlbsf). Install the outer plugs and torque
to 6 Nm (4 ftlbsf). Reinstall the PCOR defeat spool (if
removed).
Additional orifices are installed in the passages under
the pressure compensator valve block.
Fig. 50-136 - PCOR and PC Regulator
Orifices
51000172
BOMAG 897 008 911 79
18.3
saue
75 50 - 25
51000151 51000150
PCOR Defeat Spool
Stop Plug
Fig. 50-139 - Multi-function Block With
PCOR Defeat Spool Components
51000032
51000153 51000152
PCOR Defeat Spool
PCOR Defeat Spool
Stop Plug
PCOR Defeat Spool
Plug or Fitting
PCOR Brake Pressure Defeat Spool
Remove the PCOR defeat spool bore plugs or fittings
with a hex wrench.
Remove the PCOR defeat spool stop plugs with a
716" hex wrench. Remove the defeat spool.
NOTE: The defeat spool may be removed from
either end of its bore in the multi-function block.
Inspect the defeat spool for burrs or roughness. The
spool must slide freely in its bore. Inspect the pins in
the stop plugs for damage.
Install the PCOR defeat spool into its bore in the multi-
function block.
Install the spool stop plugs into the multi-function
block. Torque the stop plugs to 6 Nm (4 ftlbsf).
Install the defeat spool bore plugs or fittings and
torque to 27 Nm (20 ftlbsf).
BOMAG 898 008 911 79
saue
76 50 - 26
Pressure Compensator Regulator (Type
PC)
The PC regulator utilizes the multi-function block and
pressure compensator valve to control the motor
displacement.
Service procedures for these components are in-
cluded in the Multi-function Block section of this
manual.
Fig. 50-142 - PC Regulator Components
51000035
51000169 51000173
Valve Sleeve Bore
Plug
Fig. 50-144 - Servo
Drain Orifice (T7)
A valve sleeve bore plug is installed in the motor end
cap in place of the valve spool sleeve. Remove the
plug from the valve sleeve bore in the end cap. (An 8
mm threaded hole is provided in the plug for a puller
screw.) Remove the O-ring from the plug.
A single servo drain orifice is installed in the valve
sleeve bore plug. This orifice limits oil flow from the
maximum displacement end of the servo piston to the
motor case.
Install a new O-ring on the valve sleeve bore plug.
Install the bore plug into the end cap.
The special plug and seal washer on the end cap
opposite the multi-function block may be removed
with a 13 mm hex wrench. When installing, torque this
plug to 20 Nm (15 ftlbsf).
BOMAG 899 008 911 79
18.3
saue
77 50 - 27
Fig. 50-145 - Servo
Pressure Supply
Orifice (T1)
51000154
Fig. 50-146 - Servo
Orifice for Maximum
Displacement (T2)
51000155
Fig. 50-147 - Servo
Orifice for Minimum
Displacement (T3)
51000156
Fig. 50-148 - Servo
Drain Orifices (T7
and T8)
51000157
Control Orifices
Orifices are installed in the motor end cap to regulate
oil flow to the servo control valve and the servo piston.
To gain access to these orifice plugs, remove the
three (3) plugs located on the motor end cap nearest
the multi-function block or control, using a 716" or
916" hex wrench. Remove the orifice plugs (plain
plugs for N2 control) with a 3 mm internal hex wrench.
Install the orifice plugs, and torque to 4 Nm (35
inlbsf). Torque the 516" outer plugs to 9 Nm (7
ftlbsf), and the 916" outer plug to 37 Nm (27 ftlbsf).
Orifices are also installed in the servo control valve
sleeve to control oil flow from the servo piston to the
motor case.
Plug / Fitting Torques
If any plugs or fittings are removed from the unit
during servicing, they should be torqued as indicated
in the accompanying table.
Item Torque
Pressure Gauge Ports 37 Nm
(9/1618 O-Ring Hex) (27 ftlbsf)
Construction Plugs 20 Nm
(9/1618 O-Ring Int. Hex) (15 ftlbsf)
Construction Plugs 9 Nm
(5/1624 O-Ring) (7 ftlbsf)
Screw Plugs 4 Nm
(M6 Int. Hex) (35 inlbsf)
BOMAG 900 008 911 79
78
saue
a
4-Way Valve and Feedback Springs
Genuine
Service Parts
J
6
0
J
7
0
J
4
0
J
5
0
T
7
J
1
0
F
3
2
T
8
S
7
0
J
3
0
S
1
0
S
2
0
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1
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J
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2
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S
7
0
F
3
3
Series 51 MV
Sheet 1 of 2
T
1
T
3
T
2
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!
BOMAG 901 008 911 79
18.3
79
saue
a
4-Way Valve and Feedback Springs - HC Control
Genuine
Service Parts
S
3
0
S
5
0
S
6
0
S
4
0
T
7
S
1
0
T
F
3
2
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8
S
7
0
S
1
0
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T
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1
1
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BOMAG 902 008 911 79
F000 685 F000 688 F000 690
F000 686
F000 691 F000 692
F000 684
F000 693 F000 689 F000 687
SAUER-SUNDSTRAND Hydraulic Power Systems - Market Leaders Worldwide
SAUER-SUNDSTRAND specializes in integrating a full
range of system components to provide vehicle
designers with the most advanced total-design system.
SAUER-SUNDSTRAND is Your World Source for
Controlled Hydraulic Power Systems.
Worldwide Service Support
SAUER-SUNDSTRAND provides comprehensive worldwide service for its
products through an extensive network of Authorized Service Centers
strategically located in all parts of the world.
Look to SAUER-SUNDSTRAND for the best in WORLDWIDE SERVICE.
Hydrostatic Transmission
Packages
Genuine Service Parts Gear Pumps and Motors
Cartridge Motors/
Compact Wheel Drives
Medium Duty Axial Piston
Pumps and Motors
Microcontrollers and
Electrohydraulic Controls
Open Circuit Axial Piston Pumps
SAUER-SUNDSTRAND GMBH & CO.
Postfach 2460 D-24531 Neumnster
Krokamp 35 D-24539 Neumnster Germany
Phone: (04321) 871-0 FAX: (04321) 871 122
SAUER-SUNDSTRAND is a world leader in the design
and manufacture of Hydraulic Power Systems. Research
and development resources in both North America and
Europe enable SAUER-SUNDSTRAND to offer a wide
range of design solutions utilizing hydraulic power
system technology.
Heavy Duty Bent Axis
Variable Motors
Heavy Duty Axial Piston
Pumps and Motors
saue
saue
SAUER-SUNDSTRAND COMPANY
2800 East 13th Street Ames IA 50010 U.S.A.
Phone: (515) 239-6000 FAX: (515) 239-6618
TWX: 9105201150
SM-VMV51E 11/97 300 043A
BLN-10043 November 1997
BOMAG 903 008 911 79
18.4 Transmission CR
BOMAG 904 008 911 79
Transmission CR
BOMAG 905 008 911 79
18.4
Series CP
Compact
Poller Drive
Service Manual and
Pepair |nstruction
BOMAG 906 008 911 79
2 DKMH.PS.370.D2.02 520L0462 Pev. A - l2/200l
Series CP - Compact Poller Drive
Service Manual and Pepair |nstruction
This brochure represents information for normal service as well as an instruction for
minor repairs of Sauer-Danfoss planetary designed compact gears Series CP.
Minor repairs includes replacement of brake, gears, carriers and bearings of the CP gear
drive.
The assembling of the spindle group (80l0) requires a special tool in order to handle the
torque of 6000 Nm |53 l00 lbfin| for CP 3l and 8000 Nm |70 8000 lbfin| for the CP 5l.
|n any case of an economically repairable failure at this group the whole gearbox should
be returned to Sauer-Danfoss Neumunster.
|ntroduction
D l999-200l, Sauer-Danfoss
Sauer-Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Sauer -Danfoss reserves the
right to alter its products without prior notice. This also applies to products already ordered provided that such alterations can be made without
subsequent changes being necessary in specications already agreed. All trademarks in this material are properties of the respective companies.
Sauer-Danfoss and the Sauer-Danfoss logotype are trademarks of the Sauer-Danfoss Group. All rights reserved.
Pront page: P000 7l4, P000 65l, P000 643, P000 795, P005 028.
IN7RDDUC7IDN
Transmission CR
BOMAG 907 008 911 79
18.4
3 DKMH.PS.370.D2.02 520L0462 Pev. A - l2/200l
Introduction..................................................................................................................................... 2
ModeI Code...................................................................................................................................... 4
Description....................................................................................................................................... 5
Power FIow Diagram....................................................................................................................... 5
7echnicaI Features ........................................................................................................................... 6
Schematic........................................................................................................................................................................ 6
Design .............................................................................................................................................................................. 6
Type of Mounting......................................................................................................................................................... 6
Direction of Potation .................................................................................................................................................. 6
|nstallation Position..................................................................................................................................................... 6
Lubricants ....................................................................................................................................................................... 6
Temperature Pange..................................................................................................................................................... 6
Lubricant viscosity Limits.......................................................................................................................................... 6
Technical Data............................................................................................................................................................... 7
rake................................................................................................................................................. 7
Start-Up and Maintenance Procedure.................................................................................................................. 8
Mechanical Peleasing of the 8rake........................................................................................................................ 8
Peestablish 8raking Capability................................................................................................................................ 9
DutIine Drawings...........................................................................................................................10
Poller Drive Gearbox with Cartridge Motor - CP 3l..................................................................................... l0
Poller Drive Gearbox with Cartridge Motor - CP 5l..................................................................................... ll
Repair Instruction..........................................................................................................................12
General.......................................................................................................................................................................... l2
Disassembly ................................................................................................................................................................ l2
Gear and Planet Carriers Disassembly......................................................................................................... l2
8rake Assembly.................................................................................................................................................... l3
Assembly...................................................................................................................................................................... l3
Gear and Planet Carriers................................................................................................................................... l4
8rake Assembly.................................................................................................................................................... l5
Screw Torque ........................................................................................................................................................ l5
xpIoded Views..............................................................................................................................16
Lxploded view - CP 3l Al ..................................................................................................................................... l6
Lxploded view - CP 3l A2 ..................................................................................................................................... l7
Lxploded view - CP 5l............................................................................................................................................ l8
Cross Section Views.......................................................................................................................19
Cross Section view - CP 3l Al ............................................................................................................................. l9
Cross Section view - CP 3l A2 ............................................................................................................................. 20
Cross Section view - CP 5l.................................................................................................................................... 2l
Parts List.........................................................................................................................................22
Contents
CDN7N7S
BOMAG 908 008 911 79
4 DKMH.PS.370.D2.02 520L0462 Pev. A - l2/200l
Model Code
7YP DSICNA7IDN AND DRDR CDD
) l A ( l 3
m N 0 0 0 l 3
| n i f b l 0 7 3 4 7 2 |
) 2 A ( l 3
m N 0 5 2 3 2
| n i f b l 0 8 7 5 0 2 |
l 5
m N 0 0 0 l 5
| n i f b l 0 8 3 l 5 4 |
1 5 1 3
0 5 l A
e s a e l e r e k a r b . h c e m h t i w
0 l l C l 5

0 l 2 A
e s a e l e r e k a r b l a i c e p s h t i w
5 5 0 K 0 9
-
0 2 2 A
5 7 0 K 0 9
-
0 4 2 A
0 8 0 C l 5
-
O e k a r b e l b a l i a v a t o n
K
, e k a r b h t i w
| n i f b l 0 2 4 6 | m N 5 2 7 t f a h s t u p n i e u q r o t e k a r b c i t a t s
C R A 0 0 -
P C s e i r e S
r e l l o P t c a p m o C
s e v i r D
0 0 e r a w d r a h l a i c e p s t u o h t i w
8 T
r e m o t s u c g a t e m a n l a i c e p s
D T
o i t a P 1 3 1 5
6 4 0 C
0 8 4 5 N | D
l : 7 5 . 5 4 -
4 7 0 C l : 0 5 . 3 7 -
6 4 0 4
4 2 / 2 l h t e e t 4 l
| S N A h c t i p
l : 7 5 . 5 4 -
- e l b a l i a v a t o N
l a n o i t p O
Revision status of unit
SpeciaI hardware features
Shaft spIine motor
rake
Series or Product
CR
Dutput torque
SpindIe and motor configuration
w40x2x30xl8
Transmission CR
BOMAG 909 008 911 79
18.4
5 DKMH.PS.370.D2.02 520L0462 Pev. A - l2/200l
Description, Power Plow Diagram
Poller Drives consist of two (2) or three (3) simple planetary stages connected in series.
Lach planetary stage consists of a sun pinion (input) gear, an internal tooth ring gear and
a set of planet or satellite gears mounted to a planet carrier. The sun gear "noats within
the planet gears to allow uniform load distribution at the multiple gear mesh points.
A hydrostatic cartridge motor drives the sun pinion which in turn drives the planet gears
within the ring gear causing rotation of the planet carrier. The planet carrier is coupled
directly to the sun gear of the next stage.
The output planet carrier is xed (non-rotating) and the ring gear transmits main torque
to the output. Output hub rotation is opposite to the input rotation.
The planet gears are supported on full complement roller bearings. The output hub is
supported on tapered roller bearings to provide large external load carrying capability.
All gears and shafts are machined from case hardened steel or high tensile alloy steel and
all housings are cast iron or nodular iron or steel according to load requirements.
DSCRIP7IDN
PDWR FLDW DIACRAM Compact RoIIer Drive - CR51
P005 0l7
Power now
|nput
Output
BOMAG 910 008 911 79
6 DKMH.PS.370.D2.02 520L0462 Pev. A - l2/200l
Technical Peatures
n o i s n e m i D 1 A 1 3 R C 2 A 1 3 R C 1 5 R C
m u m i x a M
e u q r o t t u p t u o
t n e t t i m r e t n |
m N
| n i f b l |
0 0 0 l 3
| 0 7 3 4 7 2 |
0 5 2 3 2
| 0 8 7 5 0 2 |
0 0 0 l 5
| 0 8 3 l 5 4 |
s u o u n i t n o C
m N
| n i f b l |
0 0 0 3 2
| 0 6 5 3 0 2 |
5 3 4 7 l
| 0 0 3 4 5 l |
0 0 0 8 3
| 0 3 3 6 3 3 |
m u m i x a m y t i c a p a c d a o l . n y D | f b l | N k | 0 l 6 4 l | 5 6 | 0 l 6 4 l | 5 6 | 0 3 2 0 2 | 0 9
m u m i x a m , d e e p s t u p t u O n i m
l -
) m p r ( 0 5 0 5 0 5
) c i t a t s ( m u m i x a m , e u q r o t e k a r 8 | n i f b l | m N | 6 l 4 6 | 5 2 7 | 6 l 4 6 | 5 2 7 | 6 l 4 6 | 5 2 7
o i t a P i l : 7 5 . 5 4 l : 7 5 . 5 4 l : 0 5 . 3 7
) . x o r p p a ( y t i c a p a c t n a c i r b u L | l a g S U | l | l 7 . 0 | 7 . 2 | l 7 . 0 | 7 . 2 | 9 7 . 0 | 0 . 3
t n a c i r b u l t u o h t i w t h g i e w | b l | g k | 5 8 4 | 0 2 2 | 5 8 4 | 0 2 2 | l 5 5 | 0 5 2
7echnicaI data
SCHMA7IC
Two (2) or three (3) stage series planetary gearing combined with optional xed displace-
ment axial piston and variable displacement bent axis hydrostatic motors.
Prame mounting and drum mounting, piloted and internally threaded holes on a bolt
circle diameter.
Clockwise and counterclockwise, output rotation opposite to the input rotation.
Normal installation is horizontal, contact manufacturer for other positions.
Gear lubricants, see 520l0463 lyJtoul|c llu|Js onJ luot|conts.

min
- 30 C | -22 P|

max
l00 C |2l2 P|

min
25 mm
2
/s |ll9 SUS`|

max
20 000 mm
2
/s |92 600 SUS`|
` SUS (Saybolt Universal Second)
DSICN
7YP DF MDUN7INC
DIRC7IDN DF RD7A7IDN
INS7ALLA7IDN PDSI7IDN
LURICAN7S
7MPRA7UR RANC
LURICAN7 VISCDSI7Y
LIMI7S
7CHNICAL DA7A
P00l 237
Note: Por further details see Outl|ne Jtow|ns on oes 10-11.
Transmission CR
BOMAG 911 008 911 79
18.4
7 DKMH.PS.370.D2.02 520L0462 Pev. A - l2/200l
8rake
|nput brakes have been designed to be used as static holding or parking brakes. These
brakes are mechanically spring applied and hydraulic pressure is required to release
them.
|n addition, the units are equipped with an easy mechanical brake release for towing
conditions. There is no special tooling required for applying the mechanical brake
release. Care must be taken, when sizing an application, to ensure that the brake torque
and gear ratio selected match the capacity of the hydrostatic motor and gearbox.
The table below shows brake options:
RAk
s e k a r b t u p n I
n o i s n e m i D
e z i s e m a r P
1 3 R C 1 5 R C
n o i t p O k
e u q r o t c i t a t S | n i f b l | m N | 6 l 4 6 | 5 2 7
m u m i n i M , e r u s s e r p e s a e l e P | i s p | r a b | 3 0 2 | 4 l
m u m i x a M , e r u s s e r p e s a e l e P | i s p | r a b | 0 8 5 | 0 4
BOMAG 912 008 911 79
8 DKMH.PS.370.D2.02 520L0462 Pev. A - l2/200l
S7AR7-UP AND
MAIN7NANC
Start-up and Maintenance Procedure
The gearbox is shipped without oil.
8efore start-up ll gear with LP-gear lubricant SAL 90, AP|-Classication GL5, PZG power
stage >l2 according D|N 5l354. At higher temperatures we recommend gear lubricants
with SAL-viscosity grade l40.
Pill with lubricant to level of control bore L4 (approx. 2,7 l |0.7l US gal| for CP 3l, 3,0 l
|0.79 US gal| for CP 5l) and check oil level regularly. Pirst oil change after 200 working
hours, then after every 2000 hours, but at least once a year.
Periodically clean the gear housing and inspect for loosened screws and bolts.
|t is recommended to check the oil level every 250 working hours and add it if necessary.
SRVICINC 7H
CDMPAC7 CARS
while the brake is
mechanically released, the
piston motor loses its
mechanical braking
capability. The mechanical
braking capability of the
vehicle must be
maintained by means of
a vehicle brake, or for
stationary equipment,
must be maintained by
means of an equipment
brake in order to avert any
danger to life and limb.
MechanicaI reIeasing of the brake
|n case of lacking brake bleeding pressure it may be necessary to move a stationary
machine. Por this purpose it is possible to release the brake mechanically.
For mechanicaI reIeasing, two socket head screws are located at the spindle-front side
(see chapter Outl|ne Jtow|ns on oes 10-11). Por brake releasing the two socket head
screws must be turned uniformly in a clockwise direction (alternately l/2 rotation) in
order to avoid cocking of the piston.
Turning the screws inward pushes the piston against the effect of the cup spring and
thus the braking effect is neutralized.
Turn the screws inward until they come into a contact with the piston and continue until
the piston comes against the stop. The brake has been released.
Transmission CR
BOMAG 913 008 911 79
18.4
9 DKMH.PS.370.D2.02 520L0462 Pev. A - l2/200l
ReestabIish braking capabiIity
ReestabIish braking capabiIity by unscrewing the screws for the loosening of the brake
to the point where contact with the piston is |ust lost. After this, the screws must be
turned outward counter-clockwise against stop.
Check braking effect according the instructions of the manufacturer of the machine or
vehicle.
The compact gear CP3l A2 is equipped with an adapter nange for the smaller size of
hydromotor. Por mechanical brake releasing at this compact gear remove the (4) screws
(|tem 8260) that x the adapter nange and move motor adapter (with motor) 5 mm out
against the stop which is given by the (2) screws (|tem 8250).
After reestablish of braking capability the (4) screws (8260) have to be torqued to
l00
+20
Nm |885
+177
lbfin|.
Start-up and Maintenance Procedure
SRVICINC 7H
CDMPAC7 CARS
(continued)
|f the screws for
mechanical releasing of
the brake are not ad|usted
in the way described, in
case of wear of the brake
disks, the piston may come
to rest prematurely on the
screws. |n that case the
braking effect will be
considerably reduced or
completely neutralized.
BOMAG 914 008 911 79
l0 DKMH.PS.370.D2.02 520L0462 Pev. A - l2/200l
Outline Drawings
RDLLR DRIV CARDX WI7H CAR7RIDC MD7DR - CR31
P005 0l8L
Lubrication oil outlet
Ml8 x l,5 - D|N 9l0
Ml8 x l,5 - D|N 9l0
Control bore for oil level
Ml8 x l,5 - D|N 9l0
8rake release pressure port
Ml8 x l,5 - Porm X - D|N 3852 Tl
3
o
2
2
,
5
o
l
6

x

2
2
,
5
o
Thread M20 x l,5 (l6x)
Thread T (2x)
Thread depth L4 min.
L2
L3
Ll
32
|l.26|
98
|3.86|
206
|8.ll|
7
|0.28|
20
|0.79|
P20
|0.79|
D
4
5
0

-
0
,l
3
l

(
f
7
)
|
l
7
.
7
l
7

-
0
.0
0
5
|
3
9
2
|
l
5
.
4
3
|
4
4
4
|
l
7
.
4
8
|
5
3
0
|
2
0
.
8
7
|
l44,2
|5.677|
7

x

l
2
o

(
2
x
)
4
2
o
l
2
o
Name plate
2
3
|0
.9
l
|
6
2
|
2
.
4
4
|
l
5
o
A
494
|l9.449|
408
|l6.063|
-
0
,0
6
8
-
0
,0
0
3
Mechanical brake release:
To release the brake turn screws
alternately clockwise to the stop.
s e i r e S
e m a r P
e z i s
n g i s e D
l L
| n i | m m
2 L
| n i | m m
3 L
| n i | m m
4 L
| n i | m m
T D
| n i | m m
A
o
5 5 0 k
6 9 2
| 5 6 . l l |
3 4 4
| 4 4 . 7 l |
0 0 2
| 4 7 8 . 7 |
9 l
| 8 4 7 . 0 |
2 x 6 l M - 8 7
5 7 0 k
5 0 3
| l 0 . 2 l |
0 6 4
| l l . 8 l |
4 2 2
| 9 l 8 . 8 |
8 2
| 2 0 l . l |
5 , 2 x 0 2 M
4 6 2
| 9 3 . 0 l |
8 7
0 8 0 C
5 0 3
| l 0 . 2 l |
7 l 5
| 5 3 . 0 2 |
4 2 2
| 9 l 8 . 8 |
8 2
| 2 0 l . l |
5 , 2 x 0 2 M
4 6 2
| 9 3 . 0 l |
8 7
0 l l C
4 l 3
| 6 3 . 2 l |
3 3 5
| 8 9 . 0 2 |
0 5 2
| 3 4 8 . 9 |
7 3
| 5 4 . l |
5 , 2 x 0 2 M
2 4 3
| 6 4 . 3 l |
6 6
CR31
51
90
Transmission CR
BOMAG 915 008 911 79
18.4
ll DKMH.PS.370.D2.02 520L0462 Pev. A - l2/200l
Outline Drawings
RDLLR DRIV CARDX WI7H CAR7RIDC MD7DR - CR51
P005 0l9L
Ml8 x l,5 - D|N 9l0
Lubrication oil intlet
Ml8 x l,5 - D|N 9l0
Control bore for oil level
Ml8 x l,5 - D|N 9l0
8rake release pressure port
Ml8 x l,5 - Porm X - D|N 3852 Tl
3
o
2
2
,
5
o
l
6

x

2
2
,
5
o
Thread M20 x 2,5 (2x)
Thread depth 37 mm min.
Thread depth 37 mm min.
98
|3.86|
232
|9.l3|
340
|l3.39|
559
|22.0|
7
|0.28|
20
|0.79|
P30
|l.l8l|
4
5
0

-
0
,l
3
l

(
f
7
)
|
l
7
.
7
l
7

-
0
.0
0
5
|
3
9
2
|
l
5
.
4
3
|
4
4
4
|
l
7
.
4
8
|
3
4
2
|
l
3
.
4
6
|
5
3
0
|
2
0
.
8
7
|
l45,3
|5.72|
250
|9.843|
7

x

l
2
o

(
2
x
)
4
2
o
l
2 o
Name plate
2
3
|0
.9
l
|
6
2
|
2
.
4
4
|
l
5
o
494
|l9.449|
408
|l6.063|
-
0
,0
6
8
-
0
.0
0
3
Mechanical brake release:
To release the brake turn screws
alternately clockwise to the stop.
6
6
o

5
o
BOMAG 916 008 911 79
CNRAL
Pepair of spindle-group
(80l0) requires special
assembly tools (to tighten
the nut), hence we
recommend that any
repairs of this group
should be performed by
Sauer-Danfoss, Neumunster.
Sauer-Danfoss expressly
disclaims any liability for
workmanship related
failures resulting from
repairs performed
by any person.
DISASSMLY
Pepair |nstruction
This instruction describes procedures for replacement of brake, gears, carriers and
bearings of planet gearboxes for CP-series Compact Gear drives.
The gearbox must be removed from the vehicle, oil drained and the exterior cleaned
before performing this service procedure.
Disassembly and assembly of gearbox must be done in clean and dustless places.
|tem numbers of the parts used in this instruction are related to drawings - see chotet
lxloJeJ v|ews on oes 16-18.
Cears and pIanet carriers disassembIy
CR31
l. Pemove screws (Dl80) from back cover (Dl70).
2. Pemove back cover (Dl70).
3. Pemove sun pinion gear (D020).
4. Pemove spacer ring (D030).
5. Pemove l
st
stage carrier (D040) with planet gears (D060) and 2
nd
stage sun gear (D080).
6. Pemove retaining rings (D070) and pull out the planet gears (D060) with bearings
using suitable tool.
7. Pemove retaining rings (Dll5) from planet gears (D060) and push out the bearing
(D050) using suitable tool.
8. Pemove retaining ring (D090) and pull out the 2
nd
stage sun gear (D080) from the
carrier (D040).
9. Pemove retaining rings (8050) and pull out the planet gears (8040) from the spindle
group (80l0) using suitable tool.
CR51
l. Pemove screws (Dl80) from back cover (Dl70).
2. Pemove back cover (Dl70).
3. Pemove sun pinion gear (D020).
4. Pemove l
st
stage planet carrier (D040) with planet gears (D060) and 2
nd
stage sun
gear (D080).
5. Pemove retaining rings (D070) and press out the 2
nd
stage planet gear (D060) from
planet carrier using a suitable tool.
6. Pemove retaining ring (D090) and pull out the 2
nd
stage sun gear (D080) from carrier
(D040).
7. Pull out 2
nd
stage carrier (Dl00) with planet gears (Dl20) and 3
rd
stage sun gear (Dl40).
8. Pemove retaining rings (Dl30) and pull out planet gears (Dl20) with bearings from
carrier using a suitable tool.
9. Pemove the retaining rings (Dll5) from planet gears (Dl20) and push out the bear-
ing (Dll0) using a suitable tool.
l0. Pemove the retaining ring (Dl50) and pull out the 3
rd
stage sun gear (Dl40) from
the carrier (Dl00).
ll. Pemove the retaining rings (8050) and pull out the planet gears (8040) from the
spindle group (80l0) using a suitable tool.
Transmission CR
BOMAG 917 008 911 79
18.4
Lvery part must be clean, especially must be rustless on the bearing seating and sliding
surfaces. Parts must be tted to unit easy, when they are oiled by transmission oil.
|t is necessary to easy coat the O-rings with grease (e.g. Shell ALvAN|A G3).
Pollowing parts are orderable only as subassemblies:
rake disassembIy
CR31 A1, CR51
l. Push spacer ring (8l30) using a suitable tool to release retaining ring (8l40).
2. Pemove retaining ring (8l40).
3. Using a suitable tool remove spacer ring (8l30) and springs (C080).
4. Pemove brake piston (C070) and O-rings (C050, C060).
5. Pemove brake plates (C025).
6. Pemove clutch (D0l0).
CR31 A2
l. Pemove screws (8250).
2. Pemove bushing (8230).
3. Pemove screws (8260).
4. Pull out adapter (8200) with brake piston (C070).
5. Pemove O-rings (C050, C060).
6. Pemove screws (8240) and remove bushings (8230).
7. Pemove springs (C080).
8. Pemove brake plates (C025).
9. Pemove clutch (D0l0).
DISASSMLY
(continued)
ASSMLY
Lvery O-ring and seal
has to be replaced.
Pepair |nstruction
Polling bearings must be unpacked from original package only directly to installation.
|t must be installed only using the suitable installing tools.
Screw torque - see chotet 5ctew totque on oe 15.
p u o r g - e l d n i p S 0 l 0 8 0 l 0 8
y l b m e s s a r a e g t e n a l P
l
t s
e g a t s
- 0 6 0 D
2
d n
e g a t s
0 4 0 8 -
3
d r
e g a t s
- - 0 4 0 8
SubassembIies
CR31 CR51
BOMAG 918 008 911 79
Cear and pIanet carriers assembIy
CR31
l. Heat the planet gears (8040) to temperature 90 - l00 C |l94 - 2l2 P|, press planet
gears on pins of spindle group (80l0) using press and insure it using retaining-ring
(8050).
2. Clean up inner surface of the gear (D060) and gently oil it. |nstall retaining ring
(Dll5) from one side. Unpack bearing (D050) and insert it into gear until retaining
ring using a tool. |nstall second retaining ring (Dll5).
3. |nstall 2
nd
stage sun gear (D080) to l
st
stage carrier (D040) and insure it using
retaining ring (D090).
4. |nstall planet gear (D060) according to step 2 on carrier (D040) using inner ring of
the bearing and press. |nsure it using retaining ring (D070). Planet carrier must be
supported on the pitch circle zone during press of planet gear.
5. |nstall carrier (D040) according to step 4 to spindle group (80l0). Turn hub to check
smooth turn.
6. |nstall spacer ring (D030) between planet gear (D060) and carrier (D040) so that the
spacer inside diameter is located opposite the inside diameter of 2
nd
stage sun gear.
7. |nstall sun gear (D020).
8. |nstall cover with O-ring on hub and install screws (Dl80) retaining cover to the
hub.
CR51
l. Heat the planet gears (8040) to temperature 90 - l00 C |l94 - 2l2 P|, press planet
gears on pins of spindle group (80l0) using press and insure it using retaining ring
(8050).
2. Clean up inner surface of the gear (Dl20) and gently oil it. |nstall retaining ring
(Dll5) from one side. Unpack bearing (Dll0) and insert it into the gear until
retaining ring using suitable tool. |nstall second retaining ring (Dll5).
3. |nstall 3
rd
stage sun gear (Dl40) to 2
nd
stage carrier (Dl00) and insure it using
retaining ring (Dl50).
4. |nstall planet gear (Dl20) according to step 2 on 2
nd
stage planet carrier (Dl00) using
inner ring of the bearing and press. |nsure it using retaining ring (Dl30). Planet carrier
must be supported on the pitch circle zone during press of planet gear.
5. |nstall carrier (Dl00) according to step 4 into spindle-group (80l0). Turn hub to check
smooth turn.
6. |nstall 2
nd
stage sun gear (D080) to l
st
stage carrier (D040) and insure it using
retaining ring (D090).
7. |nstall planet gear (D060) on carrier (D040) using inner ring of the bearing and press.
|nsure it using retaining ring (D070). Planet carrier must be supported on the pitch
circle zone during press of planet gear.
8. |nstall carrier (D040) according to step 7 to spindle group (80l0). Turn hub to check
smooth turn.
9. |nstall sun gear (D020).
l0. |nstall cover with O-ring on hub and install screws (Dl80) retaining cover to the
hub.
ASSMLY
(continued)
Never install bearing
with the gear using strike.
Use always new screws
(Dl80) for cover assembly.
Never install bearing
with the gear using strike.
Use always new screws
(Dl80) for cover assembly.
Pepair |nstruction
Transmission CR
BOMAG 919 008 911 79
18.4
rake assembIy
CR31 A1, CR51
l. |nstall O-rings (C050, C060) into spindle group (80l0).
2. |nstall clutch (D0l0) into spindle group (80l0).
3. |nstall outer and inner brake plates (C025), start with outer plate. |nstall inner plates
on the clutch (D0l0).
4. Lightly oil brake piston (C070) on the outer surface. Carefully push it until the plates
(C025).
5. |nstall springs (C080) into brake piston (C070).
6. |nstall spacer ring (8l30) and retaining ring (8l40).
7. Press spacer ring (8l30) using tool as retaining ring expose the groove in spindle
group (80l0). |nspect that retaining ring seats properly in the groove.
CR31 A2
l. |nstall O-rings (C050, C060) into spindle group (80l0).
2. |nstall clutch (D0l0) into spindle group (80l0).
3. |nstall outer and inner brake plates (C025), start with outer plate. |nstall inner plates
on the clutch (D0l0).
4. |nstall springs (C080) into brake piston (C070).
5. |nstall O-rings (82l0 and 8220) on adapter (8200). Put adapter (8200) on springs
(C080) so that screw holes in adapter are located opposite the piston one's.
6. |nstall screws (8240) with bushings (8230) through adapter (8200) into piston (C070).
Push springs (C080) using consecutive round tightening of screws.
7. Lightly oil brake piston (C070) on the outer surface and carefully push it together
with screwed adapter (8200) until plates (C025).
8. |nstall screws (8260).
9. |nstall screws (8250) with bushings (8230) through adapter (8200) into the spindle
group (80l0).
Screw torque
Pepair |nstructions
DISASSMLY
(continued)
e u q r o 7 w e r c S
x o b r a e C
f b l | m N | n i
r e b m u N w e r c S d a e r h T
f b l | m N | n i
R C
0 6 0 8
5 6 0 8
g u l P 5 . l x 8 l M 5 4
0 l +
8 9 3 | |
0 8 l D w e r c S 8 M 0 2
3 +
7 7 l |
6 . 6 2 +
|
1 A 1 3 R C , 1 5 R C
0 2 l 8 g u l P 8 2 - P N U 4 l - 5 7 8 . 0 5 4
0 l +
8 9 3 | |
0 4 2 8
0 5 2 8
t e k c o s - w e r c S 6 M 0 l
2 +
5 . 8 8 |
7 . 7 l +
|
0 6 2 8 t e k c o s - w e r c S 2 l M 0 0 l
0 2 +
5 8 8 |
7 7 l +
|
Name
7orque
CR31 A2
+88.5
+88.5
BOMAG 920 008 911 79
Lxploded views
XPLDDD VIW - CR 31 A1
040
050
L000 003
065
D160
D170
D180
D020
070
C080
C070
C060
C050
C025
C010
C020
D010
D015
L000 296
120
110
090
100
060
070
080
080
L000 004
140
130
D080
D040
D090
D030
D050
D060
D070
L000 058
D070
D050
D060
D045
010
Transmission CR
BOMAG 921 008 911 79
18.4
Lxploded views
XPLDDD VIW - CR 31 A2
040
050
L000 003
065
D160
D170
D180
D020
070
C080
C070
C060
C050
C025
C010
C020
D010
D015
L000 296
D080
D040
D090
D030
D050
D060
D070
L000 058
D070
D050
D060
D045
L000 005
060
070
220
200
260
230
250
230
230
240
250
210
010
BOMAG 922 008 911 79
Lxploded views
XPLDDD VIW - CR 51
040
050
L000 003
065
D160
D170
D180
D020
070
C080
C070
C060
C050
C025
C010
C020
D090
D060
D070
D070
D060
D045
D050
D045
D140
D100
D110
D120
D130
D130
D120
D110
D150
D115
D040
D080

L000 057
120
110
090
100
060
070
080
080
L000 004
140
130
D010
D015
L000 296
010
Transmission CR
BOMAG 923 008 911 79
18.4
Cross Section views
CRDSS SC7IDN VIW - CR 31 A1
P005 032
80l5
8065 8070
8020
8070
8060
L030
L0l0
L020
8090
8l00
8l20
8ll0
8l60
8l80
8l40
C060
C080
C050
C070
C025
C0l0
C020 D0l0 D080
D020
D030
D090
D040
D070
D050
D060
D045
Dl70
Dl80
Dl60 8050 8035 8030
8l30
8l50
8l70
8l75
010
A0l0
A020
A040
040
BOMAG 924 008 911 79
20 DKMH.PS.370.D2.02 520L0462 Pev. A - l2/200l
Cross Section views
CRDSS SC7IDN VIW - CR 31 A2
P005 033
80l5
8065 8070 8020
8070
8060
L030
L0l0
L020
8220
82l0
8200
8260 8240 8230
8l60
C060
C080
C050
C070
C025
C0l0
C020 D0l0 D0l5 D080
D020
D030
D090
D040
D070
D050
D060
D045
Dl70
Dl80
Dl60 8050 8035 8030
8l50
8l70
8l75
010
A0l0
A020
A040
040
Transmission CR
BOMAG 925 008 911 79
18.4
2l DKMH.PS.370.D2.02 520L0462 Pev. A - l2/200l
Cross Section views
CRDSS SC7IDN VIW - CR 51
P005 03l
80l5 8065 8070
8020
8070
8060
L030
L0l0
L020
8090
8l00
8l20
8ll0
8l60
8080
8l40
C060
C080
C050
C070
C025
C0l0
D020
Dl30
Dl00
D0l0 C020 D0l5 Dl40 Dl50 D080
Dll5 Dll0
Dl20
D055
D090
D040
D070
D050
D060
D045
Dl70
Dl80
Dl60
8050 8035 8030
8l30
8l50
8l70
8l75
010
A0l0
A020
A040
040
BOMAG 926 008 911 79
22 DKMH.PS.370.D2.02 520L0462 Pev. A - l2/200l
Parts List
PAR7S LIS7
l A l 3 P C 2 A l 3 P C l 5 P C
0 l 0 A l a e s l a c i n a h c e m g n i t a t o P l l l
0 2 0 A g n i r a e b r e l l o r d e r e p a T l l l
0 4 0 A t u N l l l
0 l 0 8 p u o r g e l d n i p S l l l
5 l 0 8 e l d n i p S l l l
0 2 0 8 b u H l l l
0 3 0 8 g n i r a e b r e l l o P 4 3, 4` 5
5 3 0 8 r a e g t e n a l P 4 3, 4` 5
0 4 0 8 y l b m e s s a b u s r a e g t e n a l P 4 3, 4` 5
0 5 0 8 g n i r g n i n i a t e P 4 3, 4` 5
0 6 0 8 g u l P 2 2 2
5 6 0 8 g u l P 2 2 2
0 7 0 8 g n i r g n i l a e S 4 4 4
0 8 0 8 m a C 2 - 2
0 9 0 8 e l d n i p S 2 - 2
0 0 l 8 g n i r - O 2 - 2
0 l l 8 g n i r - O 2 - 2
0 2 l 8 g u l P 2 - 2
0 3 l 8 g n i r r e c a p S l - l
0 4 l 8 g n i r g n i n i a t e P l - l
0 0 2 8 r e t p a d A - l -
0 l 2 8 g n i r - O - l -
0 2 2 8 g n i r - O - l -
0 3 2 8 g n i h s u 8 - 5 -
0 4 2 8 w e r c S - 3 -
0 5 2 8 w e r c S - 2 -
0 6 2 8 w e r c S - 4 -
0 l 0 C g n i r r e c a p S l l l
0 2 0 C g n i r g n i n i a t e P l l l
5 2 0 C y l b m e s s a b u s s e t a l p e k a r 8 l l l
0 5 0 C g n i r - O l l l
0 6 0 C g n i r - O l l l
0 7 0 C n o t s i p e k a r 8 l l l
0 8 0 C g n i r p S 0 l 0 l 0 l
0 l 0 D h c t u l C l l l
5 l 0 D g n i r g n i n i a t e P l ) l ( l
0 2 0 D r a e g n u S l l l
0 3 0 D g n i r r e c a p S l l -
0 4 0 D r e i r r a C l l l
5 4 0 D g n i r g n i n i a t e P - - 3
0 5 0 D g n i r a e b r e l l o P 3 3 3
5 5 0 D r a e g t e n a l P - - 3
0 6 0 D r a e g t e n a l P 3 3 -
0 6 0 D y l b m e s s a b u s r a e g t e n a l P - - 3
0 7 0 D g n i r g n i n i a t e P 3 3 3
0 8 0 D r a e g n u S l l l
Description Item
uantity
Transmission CR
BOMAG 927 008 911 79
18.4
23 DKMH.PS.370.D2.02 520L0462 Pev. A - l2/200l
Parts List
PAR7S LIS7
(continued)
l A l 3 P C 2 A l 3 P C l 5 P C
0 9 0 D g n i r g n i n i a t e P l l l
0 0 l D r e i r r a C - - l
0 l l D g n i r a e b r e l l o P - - 4
5 l l D g n i r g n i n i a t e P 6 6 8
0 2 l D r a e g t e n a l P - - 4
0 3 l D g n i r g n i n i a t e P - - 4
0 4 l D r a e g n u S - - l
0 5 l D g n i r g n i n i a t e P - - l
0 6 l D g n i r - O l l l
0 7 l D r e v o C l l l
0 8 l D w e r c S 2 l 2 l 2 l
uantity
Item Description
` valid from 1anuary 2, 2002
BOMAG 928 008 911 79
Sauer-Danfoss HydrauIic Power Systems
- Market Leaders WorIdwide
Sauer-Danfoss is a comprehensive supplier providing complete
systems to the global mobile market.
Sauer-Danfoss serves markets such as agriculture, construction, road
building, material handling, municipal, forestry, turf care, and many
others.
we offer our customers optimum solutions for their needs and
develop new products and systems in close cooperation and
partnership with them.
Sauer-Danfoss specializes in integrating a full range of system
components to provide vehicle designers with the most advanced
total system design.
Sauer-Danfoss provides comprehensive worldwide service for its
products through an extensive network of Authorized Service
Centers strategically located in all parts of the world.
DUR PRDDUC7S
Hydrostatic transmissions
Hydraulic power steering
Llectric power steering
Closed and open circuit axial piston
pumps and motors
Gear pumps and motors
8ent axis motors
Padial piston motors
Orbital motors
Transit mixer drives
Planetary compact gears
Proportional valves
Directional spool valves
Cartridge valves
Hydraulic integrated circuits
Hydrostatic transaxles
|ntegrated systems
Pan drive systems
Llectrohydraulic controls
Digital electronics and software
8attery powered inverter
Sensors
Sauer-Danfoss (US) Company
2800 Last l3th Street
Ames, |A 500l0, USA
Phone: +l 5l5 239-6000, Pax: +l 5l5 239 66l8
Sauer-Danfoss (Neumunster) GmbH & Co. OHG
Postfach 2460, D-2453l Neumunster
Krokamp 35, D-24539 Neumunster, Germany
Phone +49 432l 87l-0, Pax: +49 432l 87l l22
Sauer-Danfoss (Nordborg) A/S
DK-6430 Nordborg, Denmark
Phone: +45 7488 4444, Pax: +45 7488 4400
www.sauer-danfoss.com DKMH.PS.370.D2.02 520L0462 Pev. A - l2/200l
BOMAG 929 008 911 79
18.5 Axle DANA 193
18.5 Axle DANA 193
BOMAG 930 008 911 79
Axle DANA 193
BOMAG 931 008 911 79
18.5
18.5 Axle DANA 193
BOMAG 932 008 911 79
Axle DANA 193
BOMAG 933 008 911 79
18.5
1
18.5 Axle DANA 193
BOMAG 934 008 911 79
2
PRINTED IN ITALY
Copyright By DANA ITALIA S.p.A.
Vietata la riproduzione anche parziale di testo ed illustrazioni
Realizzazione a cura dell'Ufficio Post Vendita della DANA ITALIA S.p.A.
Impaginazione: TEMAS s.r.l. - Gallarate (Va)
Stampa: Agosto 1999 (N.L. 7416)
Data subject to change without notice. We decline all responsability for the use of non-original components, or accessories which have
not been tested and submitted for approval.
Dati soggetti a modifiche senza impegno di preavviso. Si declina ogni responsabilita per l'utilizzo di componenti non originali o accessori
non collaudati ed approvati.
A
nderungen ohne vorherige Anku ndingung vorbehalten. Es wird jede Verantwortung fu r die Verwendung von Nichtoriginalteilen oder
nicht abgenommenem und genehmigtem Zubehor abgelehnt.
Los datos pueden ser modificados sin aviso previo. Se declina toda responsabilidad en el caso de uso de componentes no originales o
bien de accesorios no ensayados y aprobados.
Le constructeur se reserve le droit d'apporter des modifications a sa production, sans pour cela e tre tenu d'en donner pre avis. Nous
de clinons toute responsabilite pour l'utilisation de pie ces non originales ou d'accessoires non teste s et homologues.
Axle DANA 193
BOMAG 935 008 911 79
18.5
3
INTRODUCTION..........................................................5
MAINTENANCE AND LUBRICANTS
. Definition of viewpoints............................................7
. Data plate ..............................................................................7
. Maintenance points ................................................................7
. Maintenance intervals.............................................................8
. Adjustment and checks ..........................................................8
. Conversion tables...................................................................9
. Tightening torques .................................................................9
. Screw-locking, sealing, and lubricating materials ................... 10
NOTES ON SAFETY PRECAUTIONS ........................................13
CHECKING WEAR AND REPLACING THE BRAKING DISKS
. Disassembling the braking units............................................ 14
. Assembling the braking units ................................................ 20
. Mechanical and manual release of the axle ........................... 28
PLANETARY REDUCTION AND AXLE SHAFT
. Disassembly......................................................................... 30
. Assembly............................................................................. 38
DIFFERENTIAL UNIT
. Removal and disassembly .................................................... 44
. Assembly and installation ..................................................... 54
REDUCTION GEAR AND BEVEL PINION
. Disassembly......................................................................... 68
. Installation and adjustment ................................................... 74
SPECIAL TOOLS ...................................................................... 82
INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX
GB
INTRODUZIONE.......................................................5
MANUTENZIONE E LUBRIFICANTI
. Definizione viste ..................................................7
. Targa matricola ......................................................................7
. Punti di manutenzione............................................................7
. Intervalli di manutenzione .......................................................8
. Registrazione e controlli .........................................................8
. Tabelle di conversione............................................................9
. Coppie di serraggio ................................................................9
. Materiali per bloccaggio viti, tenuta e lubrificazione................ 10
NOTE RIGUARDANTI LA SICUREZZA ...................................... 13
CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO
. Smontaggio gruppi di frenatura............................................. 14
. Assemblaggio dei gruppi di frenatura .................................... 20
. Sbloccaggio meccanico manuale dell'assale.......................... 28
RIDUTTORE EPICICLOIDALE E SEMIASSE
. Smontaggio.......................................................................... 30
. Assemblaggio ...................................................................... 38
ITA
GRUPPO DIFFERENZIALE
. Rimozione e smontaggio....................................................... 44
. Assemblaggio ed installazione .............................................. 54
RIDUTTORE E PIGNONE CONICO
. Smontaggio.......................................................................... 68
. Installazione e registrazione.................................................. 74
ATTREZZI SPECIALI................................................................. 82
VORAUSSETZUNG.................................................5
WARTUNG UND SCHMIERSTOFFE
. Definition der Ansichten......................................7
. Kennummernschild.................................................................7
. Wartungsstellen .....................................................................7
. Wartungsintervalle..................................................................8
. Einstellungen und Kontrollen ..................................................8
. Umrechnungstabellen.............................................................9
. Anziehdrehmomente...............................................................9
. Material zur Blockierung von Schrauben und
fu r Dichtungen und Schmiermittel ......................................... 10
BEMERKUNGEN ZUR SICHERHEIT........................................... 13
VERSCHLEISS KONTROLLIEREN UND BREMSSCHEIBEN
AUSWECHSELN
. Bremsaggregate abmontieren ............................................... 14
. Bremsaggregate montieren................................................... 20
. Achse mechanisch manuell entsichern.................................. 28
PLANETENGETRIEBE UND HALBACHSE
. Abmontieren ........................................................................ 30
. Montieren ............................................................................ 38
DIFFERENTIAL
. Abmontieren und zerlegen.................................................... 44
. Montieren und installieren..................................................... 54
REDUZIERER UND KEGELRAD
. Abmontieren ........................................................................ 68
. Installieren und einstellen ..................................................... 74
SONDERWERZZEUGE .............................................................. 82
D
18.5 Axle DANA 193
BOMAG 936 008 911 79
INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX
4
PROLOGO................................................................ 5
MANTENIMIENTO Y LUBRICANTES
. Definicion vistas................................................... 7
. Matricula ............................................................................... 7
. Puntos de manutencion.......................................................... 7
. Intervalos de manutencio n...................................................... 8
. Ajuste y controles .................................................................. 8
. Tablas de conversion ............................................................. 9
. Pares de torsion .................................................................... 9
. Materiales para el bloqueo, estanqueidad y lubricacion ......... 10
NORMAS CONCERNIENTES A LA SEGURIDAD ....................... 13
CONTROL DEL DESGASTE Y SUSTITUCION DE LOS
DISCOS DEL FRENO
. Montaje de los grupos de frenado......................................... 14
. Desmontaje de los grupos de frenado................................... 20
. Desbloqueo manual de los axal ............................................ 28
REDUCTOR EPICICLOIDAL Y SEMIEJES
. Desmontaje ......................................................................... 30
. Montaje ............................................................................... 38
GRUPO DIFERENCIAL
. Remocion y desmontaje ....................................................... 44
. Montaje e instalacion ........................................................... 54
REDUCTOR Y PIN
ON CONICO
. Remocion ............................................................................ 68
. Instalacion y ajuste .............................................................. 74
HERRAMIENTAS ESPECIALES................................................. 82
INTRODUCTION....................................................... 5
ENTRETIEN ET LUBRIFIANTS
. De finition vues..................................................... 7
. Plaque d'immatriculation ........................................................ 7
. Points d'entretien................................................................... 7
. Intervalle de service ............................................................... 8
. Reglages et controles............................................................. 8
. Tableaux de conversion ......................................................... 9
. Couples de serrage................................................................ 9
. Mate riaux pour le blocage vis, e tanche ite et lubrification........ 10
NOTES EN MATIERE DE SECURITE......................................... 13
CONTROLE D'USURE ET SUBSTITUTION DES
DISQUES DE FREINAGE
. Desassemblage des groupes de freinage.............................. 14
. Assemblage des groupes de freinage ................................... 20
. Deblocage mecanique manuel de l'essieu............................. 28
REDUCTEUR EPICICLOIDALE ET DU DEMI-ESSIEU
. Demontage.......................................................................... 30
. Assemblage......................................................................... 38
GROUPE DIFFERENTIEL
. Depose et demontage .......................................................... 44
. Assemblage et installation.................................................... 54
REDUCTEUR ET PIGNON CONIQUE
. Depose................................................................................ 68
. Installation et reglage........................................................... 74
OUTILS SPECIAL..................................................................... 82
ESP
F
Axle DANA 193
BOMAG 937 008 911 79
18.5
5
Il rendimento e la continuita degli organi meccanici
dipendono oltre che da una costante e corretta
manutenzione, anche dal tempestivo intervento,
nell'eventualita di guasti o anomalie.
Nel proporre questo manuale si e considerata l'ipotesi di una
revisione generale del gruppo ma e il meccanico a valutare la
necessita di montare solo i singoli componenti nel caso di
riparazione. Il manuale e una guida rapida e sicura che
consente interventi precisi, tramite le fotografie ed i disegni
prospettici che illustrano le varie fasi delle operazioni. Di
seguito sono riportate tutte quelle informazioni ed avvertenze
necessarie al corretto disassemblaggio, alle relative verifiche
ed all'assemblaggio dei singoli componenti. Per la rimozione
del ponte differenziale dal veicolo, e necessario consultare i
manuali forniti dal costruttore del veicolo. Nel descrivere le
operazioni seguenti, si presuppone che il ponte sia gia stato
rimosso dal veicolo.
IMPORTANTE: In tutte le operazioni, e consigliabile usare
attrezzature idonee quali cavalletti o banchi di sostegno,
martelli in plastica o rame, leve appropriate estrattori e chiavi
specifiche, al fine di facilitare il lavoro salvaguardando nel
contempo le superfici lavorate e la sicurezza degli operatori.
Prima di procedere al disassemblaggio delle parti e scaricare
l'olio, e opportuno eseguire un'accurata pulizia del ponte,
asportando incrostazioni ed accumuli di grasso.
PREMESSA: Tutti gli organi meccanici smontati, devono
essere accuratamente puliti con prodotti appropriati, quindi
ripristinati o sostituiti nel caso presentino danni, usura,
incrinature, grippaggi, ecc. In particolare, verificare l'integrita
di tutte quelle parti in movimento (cuscinetti, ingranaggi, coppia
conica, alberi) e di tenuta (anelli OR, paraolio), soggette a
maggiori sollecitazioni ed usura. E
consigliabile, comunque, la
sostituzione degli organi di tenuta ogni qualvolta si proceda alla
revisione o riparazione dei componenti. Al momento del
montaggio, gli anelli di tenuta devono essere lubrificati sui
bordi di tenuta. Nel caso della coppia conica, la sostituzione di
uno dei suoi ingranaggi comporta anche la sostituzione
dell'altro. In fase di montaggio sono da rispettare scrupolosa-
mente i giochi, i precarichi e le coppie prescritte.
VALIDITA
: Il manuale fornisce le validita dei gruppi sotto forma

di matricola. Al fine di una corretta interpretazione, le validita
sono indicate come:
= fino alla matricola
= dalla matricola
Se non sono indicate validita , le operazioni di smontaggio ed
assemblaggio sono comuni a tutte le versioni.
MANUTENZIONE E RIPARAZIONE: Al fine di facilitare
interventi sui gruppi ponte differenziali e cambi di velocita la
SPICER CLARK-HURTH, ha ritenuto opportuno compilare
queste istruzioni di manutenzione e riparazione. I disegni delle
attrezzature specifiche eventualmente necessarie per l'esecu-
zione di interventi di manutenzione e riparazione possono
essere acquistati direttamente presso il costruttore; i ricambi
possono essere ordinati tramite il costruttore della macchina o
direttamente presso la DANA ITALIA S.p.A..
Die Leistung und Lebensdauer der mechanischen
Teile ha ngt nicht nur von einer standigen und
richtig durchgefu hrten Wartung sondern auch von
einem sofortigen Eingriff im Sto rungsfall ab. Um dieses
Handbuch zu erstellen sind wir von einer allgemeinen U
ber-
pru fung der Einheit ausgegangen, doch entscheidet der
Mechaniker ob die einzelnen Teile bei Reparaturen montiert
werden mu ssen oder nicht. Das Handbuch ist schnell und
einfach nachzuschlagen und ermo glicht es anhand der Abbild-
ungen und der Zeichnungen, die die verschiedenen Vorga nge
darstellen, gezielt einzugreifen. Nachstehend sind alle Infor-
mationen und Hinweise aufgefu hrt, die zur Zerlegung, Pru fung
und Montage der Einzelteile no tig sind. Um die Differentia-
lachse des Fahrzeugs abzumontieren, lesen Sie bitte die
Anweisungen in den Handbu chern des Fahrzeugherstellers.
Die nachstehenden Beschreibungen gehen davon aus, da die
Fahrzeugachse schon abmontiert worden ist.
WICHTIG: Um die Arbeit zu erleichtern und gleichzeitig die
verarbeiteten Fla chen zu schu tzen und die Sicherheit der
Arbeiter zu gewahrleisten, empfehlen wir geeignete Werk-
zeuge wie Bocke, Tisch, Gummi- oder Kupferhammer, geeig-
nete Abzieher und Schlu ssel zu verwenden.
Bevor mit der Zerlegung der Teile begonnen und das O
l
abgelassen wird, mu die Achse sorgfa ltig gereinigt und
Verkrustungen und Fettablagen abgetragen werden.
VORAUSSETZUNG: Alle abmontierten mechanischen Teile
mu ssen sorgfa ltig mit geeigneten Reinigungsmitteln gereinigt
oder, wenn bescha digt, verschleit, gerissen, festgefressen
usw. ausgewechselt werden. Insbesondere mu der einwand-
freie Zustand aller beweglichen Teile (Lager, Zahnra der,
Kegelradpaare, Wellen) und der Dichtungen (O-Ringe, O
lab-
dichtungen), die am meisten beansprucht werden und ver-
schleien, kontrolliert werden. Wir empfehlen auf jeden Fall die
Abdichtungselemente immer auszuwechseln, wenn eine U
ber-
holung oder eine Reparatur der Teile vorgenommen wird. Bei
D
ITA
The efficiency and continued operation of mechan-
ical units depend on constant, correct maintenance
and also on efficient repair work, should there be a
break-down or malfunction. The instructions contained in this
manual have been based on a complete overhaul of the unit.
However, it is up to the mechanic to decide whether or not it is
necessary to assemble only individual components, when
partial repair work is needed. The manual provides a quick
and sure guide which, with the use of photographs and
diagrams illustrating the various phases of the operations,
allows accurate work to be performed.
All the information needed for correct disassembly, checks and
assembly of each individual component is set out below. In
order to remove the differential unit from the vehicle, the
manuals provided by the vehicle manufacturer should be
consulted. In describing the following operations it is presumed
that the unit has already been removed from the vehicle.
IMPORTANT: In order to facilitate work and protect both
working surfaces and operators, it is advisable to use proper
equipment such as: trestles or supporting benches, plastic or
copper hammers, appropriate levers, pullers and specific
spanners or wrenches.
Before going on to disassemble the parts and drain the oil, it is
best to thoroughly clean the unit, removing any encrusted or
accumulated grease.
INTRODUCTORY REMARKS: All the disassembled mechan-
ical units should be thoroughly cleaned with appropriate
products and restored or replaced if damage, wear, cracking or
seizing have occurred.
In particular, thoroughly check the condition of all moving parts
(bearings, gears, crown wheel and pinion, shafts) and sealing
parts (O-rings, oil shields) which are subject to major stress and
wear. In any case, it is advisable to replace the seals every time
a component is overhauled or repaired. During assembly, the
sealing rings must be lubricated on the sealing edge. In the
case of the crown wheel and pinion, replacement of one
component requires the replacement of the other one. During
assembly, the prescribed pre-loading, backlash and torque of
parts must be maintained.
CLASSIFICATION: This manual classifies units according to
part numbers. For a correct interpretation, classification is
indicated as follows:
= up to the part number
= from the part number on
When no classification is given, disassembly and assembly
operations are the same for all versions.
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of
all specific tools required for maintenance and repair work can
be found at the end of this manual ; spare parts may be ordered
either from the vehicle manufacturer or directly from the
Service Centers or Authorised Distributors of DANA ITALIA
S.p.A..
GB
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION
18.5 Axle DANA 193
BOMAG 938 008 911 79
der Montage mu ssen die Rander der Dichtringe geschmiert
werden. Wenn beim Kegelradpaar ein Zahnrad ausgewechselt
werden mu, mu auch das andere Zahnrad ausgewechselt
werden. Bei der Montage mu ssen die vorgeschriebenen
Spiele, Vorspannungen und Drehmomente strengstens ein-
gehalten werden.
GU
LTIGKEIT: Das Handbuch gibt an zu welchen Kennummern

die Einheiten geho ren. Der Einfachheit halber sind die
Angeho rigkeiten folgendermaen aufgefu hrt:
= bis Kennummer
= ab Kennummer
Wenn keine Angeho rigkeit angegeben ist, verstehen sich die
Arbeiten zur Zerlegung und Montage fu r alle Ausfu hrungen
gu ltig.
SPEZIFISCHE WERKZEUGE UND ERSATZTEILE: die Zeich-
nungen der fu r Wartungsarbeiten erforderlichen spezifischen
Werkzeuge, sind am Ende des Handbuchs aufgefu hrt; Ersatz-
teile ko nnen beim Fahrzeughersteller oder direkt bei der
Kundendienststelle oder bei einem zugelassenen Handler der
DANA ITALIA S.p.A. bezogen werden.
El rendimiento y la duracio n de los o rganos meca nicos
depende, adema s que del constante y correcto
mantenimiento, tambie n de la intervencion inmediata
en caso de aver as o anomal as.
Al proponer este manual, ha sido considerada la suposicio n de una
revisio n general del grupo, pero es el meca nico quien tiene que
valorar la necesidad de montar cada uno de los componentes en
caso de reparacion. El manual es una gu a ra pida y segura que
permite intervenciones precisas por medio de fotograf as y de
planos que muestran las distintas fases de las operaciones. A
continuacio n figuran todas las informaciones y advertencias
necesarias para ejecutar un montaje correcto, para las comproba-
ciones y el montaje de cada uno de los componentes. Para
remover el puente diferencial del veh culo hay que consultar los
manuales de los fabricantes del veh culo. En la descripcio n de las
operaciones siguientes se supone que el puente ya ha sido sacado
del vah culo.
IMPORTANTE: Para facilitar el trabajo salvaguardando al mismo
tiempo las superficies mecanizadas y la seguridad de los
operadores, se aconseja que se usen equipos y herramientas
adecuados como caballetes y bancos de soporte, martillos de
pla stico o de cobre, palancas adecuadas, extractores y llaves
espec ficas.
Antes de desmontar las partes y descargar el aceite, es
conveniente que se haga una limpieza minuciosa del puente
sacando las incrustaciones y acumulaciones de grasa.
INTRODUCCION: Todos los o rganos meca nicos desmontados
tienen que ser limpiados minuciosamente con productos adecua-
dos y restaurados o sustituidos en el caso de que presenten dan os,
desgaste, rajaduras, agarrotamientos, etc. En particular, compro-
bar la integridad de todas las partes en movimiento (cojinetes,
engranajes, par co nico, ejes) y de estanqueidad (anillos OR,
detenedor de aceite) sujetas a mayores solicitaciones y desgaste.
Se aconseja, de todas formas, que se sustituyan los o rganos de
estanqueidad cada vez que se ejecute la revisio n o reparacio n de
los componentes.
Al volver a montar, los segmentos de compresio n tienen que estar
lubricados en los bordes de estanqueidad. En el caso del par
co nico, la sustitucio n de uno de sus engranajes comporta tambien
la sustitucio n del otro. Al montar hay que tener en cuenta
escrupulosamente los juegos, las precargas y los pares descriptos.
VALIDEZ: El manual suministra la validez de los grupos en forma
de matr cula. Para poder tener una interpretacio n correcta, la
validez esta indicada:
= hasta la matr cula
= desde la matr cula en adelante
Si no ha sido indicada validez, las operacio n de desmontaje y
montaje son comunes a todas las versiones.
HERRAMIENTAS ESPECIFICAS Y RECAMBIOS: Los planos de
las herramientas especificas necesarias para la ejecucio n de las
intervenciones de mantenimiento figuran al final del manual; los
recambios se pueden pedir al fabricante de la ma quina o
directamente al Service Center o a Distribuidores autorizados de
DANA ITALIA S.p.A..
ESP
Le rendement et la continuite des organes me ca-
niques de pendent, non seulement d'une mainte-
nance correcte et constante, mais e galement de la
rapidite d'intervention en cas de pannes ou d'anomalies. En
vous proposant ce manuel, on envisage l'hypothe se d'une
re vision ge ne rale du groupe, mais c'est au me canicien
d'e valuer la ne cessite de monter ou non chacun des
composants en cas de re paration. Le manuel est un guide
rapide et su r consentant des interventions pre cises, au travers
de photographies et de dessins prospectifs qui illustrent les
diffe rentes phases des ope rations. Ensuite, sont reporte es
toutes les informations et precautions ne cessaires pour un
de montage correct et les ve rifications et assemblage de
chaque composant. En ce qui concerne le de placement du
pont d'e tai du ve hicule, il est ne cessaire consulter les manuels
fournis par le constructeur du vehicule. En de crivant les
ope rations suivantes, on presume que le pont ait deja e te
enleve du ve hicule.
IMPORTANT: Pour faciliter le travail en sauvegardant en
me me temps les surfaces usine es et la se curite des ope ra-
teurs, il est pre conise d'utiliser des installations approprie es
telles que des e tais ou banc de support, maillets en plastique
ou cuivre, leviers approprie s, extracteurs et cle s spe cifiques.
Avant de proce der au de montage des parties et vidanger
l'huile, il vaut mieux nettoyer soigneusement le pont, en
enlevant incrustations et blocs de gras.
PRELIMINAIRE: Tous les organes me caniques de monte s
doivent e tre soigneusement nettoye s a l'aide de produits
approprie s et re pare s ou remplace s dans le cas ou ils seraient
ab me s, use s, fe le s, grippe s, etc. Ve rifier, l'inte grite , en
particulier, de toutes les parties en mouvement (paliers,
engrenages, couple conique, arbres) et l'e tanche ite des
bagues (bagues OR, parahuile), qui sont sujettes a plus de
sollicitations et a l'usure. Il est pre conise , de toute facon, de
substituer les organes d'etancheite , chaque fois que l'on
effectue une re vision ou une reparation des composants. Au
moment du montage, les bagues d'e tanche ite doivent e tre
lubrifie es sur les bords e tanches. Dans le cas du couple
conique, la substitution de l'un de ses engrenages comporte
egalement la substitution de l'autre. En phase de montage, il
faut respecter scrupuleusement les jeux, les precharges et les
couples prescrits.
VALIDITE: Le manuel fournit la validite des groupes sous
forme de matricule. Pour une meilleure interpre tation, les
validite s sont indique es comme:
= jusqu'a l'immatriculation
= a partir de l'immatriculation et apre s
Si les validite s ne sont pas indique es, les ope rations de
de montage et d'assemblage sont pareilles dans toutes les
versions.
INSTALLATIONS SPECIFIQUES ET PIECES DETACHEES:
Les dessins des installations spe cifiques necessaires pour
effectuer des interventions d'entretien sont reporte es a la fin du
manuel, les pie ces detache es peuvent etre commande es au
constructeur de la machine ou directement aux Centres de
Services, ou Distributeurs agre e s de la Socie te DANA ITALIA
S.p.A..
F
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION
6
Axle DANA 193
BOMAG 939 008 911 79
18.5
7
MAINTENANCE AND LUBRICANT - MANUTENZIONE E LUBRIFICANTI - WARTUNG UND SCHMIERSTOFFE
MANTENIMIENTO Y LUBRICANTES - ENTRETIEN ET LUBRIFIANTS
DEFINITION OF VIEWPOINTS - DEFINIZIONE VISTE - DEFINITION DER ANSICHTEN - DEFINICION VISTAS - DE
FINITION VUES
DATA PLATE - TARGA MATRICOLA - KENNUMMERNSCHILD - MATRICULA - PLAQUE D'IMMATRICULATION
Type and model unit - modification index
Tipo e modello gruppo - indice di modifica
Typ und Modelleles Antriebes - A
nderungsverzeichnis
Tipo y modelo grupo - indice de modificacion
Type et modele de ensemble - tableau des modifications
Serial number
Numero di serie
Seriennummer
Numero de serie
Numero de serie
Lubricant
Lubrificante
Schmieroel
Lubricante
Lubrificant
1
2
3
MAINTENANCE POINTS - PUNTI DI MANUTENZIONE - WARTUNGSSTELLEN - PUNTOS DE MANUTENCION - POINTS D'ENTRETIEN
MFG. BY CLARK-HURTH COMPONENTS S.P.A.
38062 Arco (Trento)
MADE IN ITALY
D1240011
3
2 1
D1240139
2
1 3 1
1 3
2
2 2 2
1 3
2
Oil filling plug - Tappo di carico
Einfullstopfen - Tapon de carga
Bouchon de ravitaillement
Oil draining plug - Tappo di scarico
Ablasstopfen - Tapon de descarga
Bouchon de vidange
Check level plug - Tappo controllo livello
Stopfen zur O
lpegelkontrolle -
Tapon de contrl de nivel - Jauge de niveau
1
2
3
D1240138
LEFT SIDE
LATO SINISTRO
LINKE SEITE
LADO IZQUIERDO
COTE GAUCHE
RIGHT SIDE
LATO DESTRO
RECHTE SEITE
LADO DERECHO
COTE DROITE
18.5 Axle DANA 193
BOMAG 940 008 911 79
8
OPERATION - OPERAZIONE -
ARBEITSVORGANG -
OPERACION - OPERATION
FREQUENCY - PERIODICITA
- ZEITABSTAND -
FRECUENCIA - PERIODICITE
LUBRICANTS - LUBRIFICANTI - SCHMIERSTOFFE -
LUBRICANTES - LUBRIFIANTS
. Check levels:
. Controllo livelli:
. O
lstandkontrolle:
. Control niveles:
. Contro le niveaux:
Differential
Differenziale
Im differential
Diferencial
Differentiel
monthly
mensile
monatlich
cada mes
mensuel
. SAE85W90 (API GL4 - MIL L-2105)
With additives for oil-bath brakes
Con additivi per freni a bagno d'olio
Mit Zusatzmittel fu r Bremsen in O
lbad
Con aditivos para frenos de ban o de aceite
Avec adjuvants pour freins en bain d'huile
. SAE85W90 (API GL5 - MIL 2105-B)
With additives for oil-bath brakes, for units pre-
senting hypoid crown wheel and pinion and /or
self-locking differential gear
Per esecuzioni con coppia conica ipoide e/o con
differenziale autobloccante, con additivi per freni
a bagno d'olio
Bei Ausfu hrungen mit Kegel- und Telleradpaar
und/oder Selbstsperrdifferential, mit Zusatzmit-
teln fu r Bremsen in O
lbad
Para ejecuciones con par co nico hipoide y/o con
diferencial autobloqueante con aditivos para fre-
nos de ban o de aceite.
Pour exe cutions avec couple conique hypo de et/
ou differentiel autobloquant, avec adjuvants pour
freins en bain d'huile
Planetary reduction
Riduzione epicicloidale
Planetengetrieb
Reduccion epicicloidal
Reduction epicycloidale
every 200 hours
ogni 200 ore
alle 200 Std.
cada 200 horas
toutes les 200 heures
. Oil change:
. Cambio olio:
. O
lwechsel:
. Cambio aceite:
. Vidange huile:
Differential
Differenziale
Im differential
Diferencial
Differentiel
every 800 hours ]
ogni 800 ore
alle 800 Std.
cada 800 horas
Planetary reduction
Riduzione epicicloidale
Planetengetrieb
Reduccion epicicloidal
Reduction epicycloidale
every 1000 hours ]
ogni 1000 ore
alle 1000 Std.
cada 1000 horas
Self-locking differential gear
Differenziale autobloccante
Selbstsperrdifferential
Diferencial autobloqueante
Differentiel autobloquant
every 700 hours ] r
ogni 700 ore
alle 700 Std.
cada 700 horas
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despue s de 100 horas
de trabajo - Initialement apre s 100 heures de travail
r When it starts sounding noisy - Anche ai primi cenni di rumorosita - Auch falls ungewo hnliche Gera usche zu bemerken sind - Tambie n al primer
indicio de ruido - Me me aux premiers signaux de bruit
OPERATION- OPERAZIONE -
ARBEITSVORGANG -
MEMBER - ORGANO -
ELEMENT -
ORGANO - ORGANE
CONDITIONS - CONDIZIONI -
BEDINGUNG -
CONDICIONES - CONDITIONS
-
ZEITABSTAND -
LUBRICANTS - LUBRIFICANTI -
SCHMIERSTOFFE -
LUBRICANTES - LUBRIFIANTS
Greasing
Ingrassaggio
Schmieren
Engrase
Graissage
Articulations
Snodi
Gelenk
Ro tula
Articulations
Normal work
Lavori normali
Normale Arbeit
Trabajos normales
Ta ches ordinaires
monthly
mensile
monatlich
cada mes
mensuel
MOLIKOTE
Awkward work
Lavori gravosi
Schwere Arbeit
Trabajos pesados
Ta ches extraordinaires
Weekly
Settimanale
Wochentlich
Semanal
Hebdomadaire
UNIT - GRUPPO -
AGGREGAT -
GRUPO - GROUPE
OPERATION - OPERAZIONE
ARBEITSVORGANG -
-
ZEITABSTAND -
SERVICE BRAKE CIRCUIT - CIRCUITO COMANDO FRENI -
BREMSKREISLAUF - CIRCUITO MANDOS FRENOS -
CIRCUIT DE COMMANDE DES FREINS
Negative brake
Freno negativo
Federspeicherbremse
Freno negativo
Frein ne gatif
Adjustment
Registrazione
Einstellen
Ajuste
Re glage
every 1000 hours ]
ogni 1000 ore
alle 1000 Std.
cada 1000 horas
toutes les 1000 hours
Only for mineral oil use e.g. ATF Dexron II. Make sure
that master cylinder seals are suitable for mineral oil.
Usare esclusivamente olio minerale ATF Dexron II. Ac-
certarsi che le guarnizioni del cilindro master siano
adatte a questo olio.
Nur mineralisches O
l verwenden, z.B.: ATF Dexron II.

Achtung: Dichtringe des Hauptbremszylinders mu s-
sen fu r dieses O
l geeignet sein.
Usar exclusivamente aceite mineral ATF Dexron II.
Asegurarse de que las juntas del cilindro principal
son adecuadas para este aceite.
Utiliser exclusivement huile mine rale ATF Dexron II.
Verifier que les joints du ma tre-cylindre, soien compa-
tibles avec cette huile.
Service brake
Freni di servizio
Hilfsbremse
Frenos de ejercicio
Freins de service
Adjustment
Registrazione
Einstellen
Ajuste
Re glage
every 500 hours
ogni 500 ore
alle 500 Std.
cada 500 horas
Wheel nuts
Dadi ruota
Radmuttern
Tuercas rueda
Ecrous de roue
Tightening
Serraggio -
Festziehen
Apriete
Serrage
every 200 hours
ogni 200 ore
alle 200 Std.
cada 200 horas
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despue s de 100
horas de trabajo - Initialement apre s 100 heures de travail
MAINTENANCE INTERVALS - INTERVALLI DI MANUTENZIONE - WARTUNGSINTERVALLE - INTERVALOS DE MANUTENCIO
N - INTERVALLE DE SERVICE
ADJUSTMENT AND CHECKS - REGISTRAZIONE E CONTROLLI - EINSTELLUNGEN UND KONTROLLEN - AJUSTE Y CONTROLES - REGLAGES ET CONTROLES
Axle DANA 193
BOMAG 941 008 911 79
18.5
9
Units of pressure - Unita di pressione - Druckeinheiten
Unidad de presio n - Unite s de pression: 1 Atm%1 bar%10
5
PA%14.4 PSi
Units of weight - Unita di peso - Gewichtseinheiten
Unidad de peso - Unite s de poids
Units of torque - Unita di coppia - Drehmomenteinheiten
Unidad de par - Unite s de couple
N daN kN kg lbs Nm daNm kNm kgm lb-in
1N 1 0,1 0,001 0,102 0,225 1Nm 1 0,1 0,001 0,102 8,854
1daN 10 1 0,01 1,02 2,25 1daNm 10 1 0,01 1,02 88,54
1kN 1000 100 1 102 225 1kNm 1000 100 1 102 8854
1kg 9,81 0,981 0,00981 1 2,205 1kgm 9,81 0,981 0,00981 1 86,8
1lb-in 0,1129 0,01129 0,0001129 0,01152 1
Unit - Unita di misura - Meeinheiten - Unidad de medida - Unite s de mesure: Nm
SIZE OF BOLT
MISURA VITE
SCHRAUBENMASS
TAMAN
O TORNILLO
MESURE VIS
TYPE OF BOLT - TIPO VITE - GEWINDE - TIPO DE TORNILLO - TYPE DE VIS
8.8 10.9 12.9
Normali
+ Loctite 242
Normali
+ Loctite 270
Normali
+ Loctite 242
Normali
+ Loctite 270
Normali
+ Loctite 242
Normali
+ Loctite 270
M6 x 1 9,5-10,5 10,5-11,5 14,3-15,7 15,2-16,8 16,2-17,8 18,1-20,0
M8 x 1,25 23,8-26,2 25,6-28,4 34,2-37,8 36,7-40,5 39,0-43,0 43,7-48,3
M10 x 1,5 48-53 52-58 68-75 73-81 80-88 88-97
M12 x 1,75 82-91 90-100 116-128 126-139 139-153 152-168
M14 x 2 129-143 143-158 182-202 200-221 221-244 238-263
M16 x 2 200-221 219-242 283-312 309-341 337-373 371-410
M18 x 2,5 276-305 299-331 390-431 428-473 466-515 509-562
M20 x 2,5 390-431 428-473 553-611 603-667 660-730 722-798
M22 x 2,5 523-578 575-635 746-824 817-903 893-987 974-1076
M24 x 3 675-746 732-809 950-1050 1040-1150 1140-1260 1240-1370
M27 x 3 998-1103 1088-1202 1411-1559 1539-1701 1710-1890 1838-2032
M30 x 3,5 1378-1523 1473-1628 1914-2115 2085-2305 2280-2520 2494-2757
M8 x 1 25,7-28,3 27,5-30,5 36,2-39,8 40,0-44,0 42,8-47,2 47,5-52,5
M10 x 1,25 49,4-54,6 55,2-61,0 71,5-78,5 78,0-86,0 86,0-94,0 93,0-103,0
M12 x 1,25 90-100 98-109 128-142 139-154 152-168 166-184
M12 x 1,5 86-95 94-104 120-132 133-147 143-158 159-175
M14 x 1,5 143-158 157-173 200-222 219-242 238-263 261-289
M16 x 1,5 214-236 233-257 302-334 333-368 361-399 394-436
M18 x 1,5 312-345 342-378 442-489 485-536 527-583 580-641
M20 x 1,5 437-483 475-525 613-677 674-745 736-814 808-893
M22 x 1,5 581-642 637-704 822-908 903-998 998-1103 1078-1191
M24 x 2 741-819 808-893 1045-1155 1140-1260 1235-1365 1363-1507
M27 x 2 1083-1197 1178-1302 1520-1680 1672-1848 1834-2027 2000-2210
M30 x 2 1511-1670 1648-1822 2138-2363 2332-2577 2565-2835 2788-3082
CONVERSION TABLES - TABELLE DI CONVERSIONE - UMRECHNUNGSTABELLEN
TABLAS DE CONVERSION - TABLEAUX DE CONVERSION
TIGHTENING TORQUES - COPPIE DI SERRAGGIO - ANZIEHDREHMOMENTE
PARES DE TORSION - COUPLES DE SERRAGE
C
O
A
R
S
E
P
I
T
C
H
-
P
A
S
S
O
G
R
O
S
S
O
-
G
R
O
E
R
S
C
H
R
I
T
T
-
P
A
S
O
G
R
U
E
S
O
-
G
R
O
S
P
A
S
F
I
N
E
P
I
T
C
H
-
P
A
S
S
O
F
I
N
E
-
K
L
E
I
N
E
R
S
C
H
R
I
T
T
P
A
S
O
F
I
N
O
-
P
A
S
F
I
N
18.5 Axle DANA 193
BOMAG 942 008 911 79
10
1 - Locking, sealing and lubricating materials referred to in this manual are the same used in the shop-floor.
I materiali per il bloccaggio, tenuta e lubrificazione specifica indicati nel manuale, sono quelli usati in fabbrica.
Die Materialien zur Blockierung von Schrauben, fu r Dichtungen und Schmiermittel, die im Handbuch aufgefu hrt sind, sind
dieselben die auch vom Hersteller verwendet werden.
Los materiales para el bloqueo, estanqueidad y lubricacion espec fica indicados en el manual, son los que se usan en la fabrica
Les mate riaux de blocage, d'e tanche ite et de lubrification spe cifie s indiques dans ce manuel sont ceux employe s a l'usine.
2 - The table below gives an account of the typical applications of each single material, in order to facilitate replacement with similar
products marketed by different brand names with different trade marks.
Di questi materiali, vengono riportate le applicazioni tipiche che li distinguono, in modo da poterli sostituire con prodotti similari
commercializzati da altre marche e quindi con altre sigle.
Von diesen Materialien werden die typischen Anwendungen genannt, um sie mit a hnlichen Materialien zu ersetzen, die unter
anderen Namen und Kennzeichnungen im Handel erha ltlich sind.
De estos materiales damos las aplicaciones t picas que los distinguen, de manera que se puedan sustituir con productos similares
comercializados por otras marcas y por tanto con otras siglas.
De ces mate riaux ne sont reporte es que les applications typiques qui les distinguent de telle sorte qu'ils puissent e tre substitue s
par des produits semblables se trouvant dans le commerce sous d'autres marques et par consequent sous d'autres sigles.
DENOMINATION
DENOMINAZIONE
BEZEICHNUNG
DENOMINACION
DENOMINATION
APPLICATION - APPLICAZIONE - ANWENDUNG - APLICACION - APPLICATION
Loctite 242
. Anaerobic product apt to prevent the loosening of screws, nuts and plugs. Used for medium-strength loc-
king. Before using it, completely remove any lubricant by using the specific activator.
. Prodotto anaerobico adatto a prevenire l'allentamento di viti, dadi e tappi. Usato per la frenatura a media re-
sistenza. Deve essere usato dopo aver asportato ogni traccia di lubrificante con l'attivatore specifico.
. Anaerobes Produkt, um das Lockern von Schrauben, Muttern und Stopfen zu verhindern. Fu r mittlere Wi-
derstandskra fte geeignet. Darf erst aufgetragen werden, wenn die Flachen von Schmiermittel richtig sauber
sind. Dazu das entsprechende Produkt verwenden.
. Producto anaerobico apto para prevenir el aflojamiento de tornillos, tuerca y tapones. Usado para el frenado
de media resistencia. Tiene que ser usado solo despues de haber quitado todo residuo de lubricante con el
activador espec fico.
. Produit anareobic servant a prevenir le relachement des vis, ecrous et bouchons. Utilise pour le freinage
demi resistant. Il doit etre utilise apre s avoir enleve toute trace de lubrifiant a l'aide d'un activeur special.
Loctite 243
. The oleocompatible alternative to 242. Does not require the activation of lubricated surfaces.
. Prodotto alternativo al 242 che, essendo oleocompatibile, non richiede l'attivazione di superfici lubrificate.
. Alternatives Produkt zu Loctite 242. Da es olkompatibel ist mu ssen die geschmierten Flachen nicht aktiviert
werden.
. Producto alternativo al 242 que, siendo oleocompatible, no requiere la activacion de superficies lubricadas.
. Produit en alternance avec le 242 lequel etant oleocompatible ne requiert aucune activation des surfaces
lubrifie es.
Loctite 270
. Anaerobic product for very-high strength locking of screws and nuts. Before using it, completely remove any
lubricant by using the specific activator. To remove parts, it may be necessary to heat them at 80C approx.
. Prodotto anaerobico adatto per la frenatura ad altissima resistenza di viti e dadi. Deve essere usato dopo aver
asportato ogni traccia di lubrificante con l'attivatore specifico.
La rimozione delle parti, puorichiedere un riscaldamento a circa 80C.
. Anaerobes Produkt fu r hohe Widerstandskrafte fu r Schrauben und Muttern geeignet. Zuerst die Fla che sorg-
fa ltig aktivieren. Um die Fla chen zu saubern, diese auf ca. 80C erwa rmen.
. Producto anaerobico apto para el frenado de alta resistencia de tornillos y tuercas. tiene que ser usado de-
spues de haber quitado todo residuo de lubricante con el activador espec fico.
La remocion de las partes, puede requerir un calentamiento a unos 80C.
. Produit anareobic apte au freinage a tres haute re sistance des vis et des ecrous. Il doit etre utilise apres avoir
enleve toute trace de lubrifiant a l'aide d'un activeur special.
Loctite 275
. Anaerobic product suitable for high-strength locking and sealing of large threaded parts, bolts and stud bolts,
for pipe sealing and for protecting parts against tampering; suitable for sealing coupling surfaces with a max.
diametrical clearance of 0.25 mm.
. Prodotto anaerobico adatto per la frenatura e sigillatura ad alta resistenza di parti filettate, bulloni e prigionieri
di grandi dimensioni, protezione antimanomissione e sigillatura di tubazioni; puosigillare accoppiamenti con
gioco diametrale massimo di 0,25 mm.
. Anaerobes Produkt zum Bremsen und Siegeln von groen Gewinden, Muttern und Stiftschrauben , sehr
widerstandsfahig, verschleierungsbestandig, und zum Siegeln von Rohrleitungen geeignet; kann Kupplun-
gen mit einer maximalen Lagerluft von 0,25 mm siegeln.
. Producto anaerobico apto para el frenado y selladura a alta resistencia de tornillos, tuercas y prisioneros de
grandes dimensiones, protecion anti manomision y selladura de tubaciones ; puede sellar encolcados con
juego diametral.
. Produit anae robie adapte au freinage et au scellage a haute re sistance des parties filetees, boulons et pri-
sonniers de grandes dimensions, protection anti-alteration et scellage de tuyauteries; il peut sceller des ac-
couplements ayant un jeu diame tral maximal de 0,25 mm.
SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS - MATERIALI PER BLOCCAGGIO VITI, TENUTA E LUBRIFICAZIONE - MATERIAL ZUR
BLOCKIERUNG VON SCHRAUBEN UND FU
R DICHTUNGEN UND SCHMIERMITTEL - MATERIALES PARA EL BLOQUEO, ESTANQUEIDAD Y LUBRICACION -

MATE
RIAUX POUR LE BLOCAGE VIS, E
TANCHE
ITE
ET LUBRIFICATION
Axle DANA 193
BOMAG 943 008 911 79
18.5
11

MATE
TANCHE
ITE
ET LUBRIFICATION
DENOMINATION
DENOMINAZIONE
BEZEICHNUNG
DENOMINACION
DENOMINATION
Loctite 510
. Anaerobic product for the hermetic sealing of flanged units and screw holes communicating with fluids. Can
seal clearances between flanges up to 0.2 mm.
. Prodotto anaerobico adatto alla tenuta ermetica di fluidi tra assiemi flangiati e di viti a foro comunicante con i
fluidi. Puosigillare giochi tra le flange fino a 0,2 mm.
. Anaerobes Produkt zur Abdichtung von Flu ssigkeiten an Flanschen und Schrauben mit Locher, die mit Flu s-
sigkeiten in Kontakt stehen. Kann ein Spiel zwischen Flanschen bis 0,2 mm abdichten.
. Producto anaerobico apto para le estanqueidad de fluidos entre grupos bridados y de tornillos de orificio co-
municante con los fluidos. Puede sellar juegos entre las bridas hasta 0,2 mm.
. Produit anareobic apte a la tenue etanche des fluides entre les pieces a brides et des vis a trou en contact
avec les fluides. Il peut sceller un jeu parmi les flasques jusqu'a 0,2 mm.
Loctite 577
. Quick anaerobic sealant for sealing threaded portions of conical or cylindrical unions up to M80. Before using
it, remove any lubricant with the specific activator. After polymerisation, disassembly may result rather dif-
ficult, so heating may be necessary for larger diameters.
. Prodotto anaerobico sigillante rapido per la tenuta di filettature di raccordi conici o cilindrici fino a M80.
Deve essere usato dopo aver asportato ogni traccia di lubrificante con l'attivatore specifico.
Dopo la polimerizzazione presenta una moderata difficoltadi smontaggio per cui puorichiedere, per i diametri
maggiori, un riscaldamento.
. Anaerobes Produkt zum schnellen Siegeln und Abdichten von Kegel- oder Zylinderkupplungen bis M80.
Darf erst aufgetragen werden, nachdem mit einem spezifischen Wirkstoff jede Spur von Schmiermittel ab-
getragen worden ist.
Nach der Polymerisation konnte das Abmontieren etwas schwierig sein weshalb groere Durchmesser
zuerst erhitzt werden mu ssen.
. Producto anaerobico sellante rapido para el estanqueido de tornillos de empalme conico o cilindrico hasta
M80. Debe de ser utilisado despues de haber quitado cada mancha de lubrificante con activador especifico.
Despues de la polimeracion presenta una moderada dificultade desmontaje por lo tanto puede necesitar, para
los diametros majores, un calientamiento.
. Produit anae robie collage rapide assurant l'etancheite des filetages des raccords coniques ou cylindriques
jusqu'a M80. Il doit e tre utilise apres qu'on ait enleve toute trace de lubrifiant a l'aide d'un activeur special.
Une certaine difficulte de de montage se presente apres la polymerisation, on peut donc avoir la necessite de
devoir chauffer prealablement pour de plus amples diametres.
Loctite 638
. Anaerobic adhesive for fast and high-strength gluing of cylindrical metal joints (hub on shaft). Can glue to-
gether parts with clearance ranging between 0.1 and 0.25 mm.
. Adesivo anaerobico per l'incollaggio rapido ad alta resistenza di giunti cilindrici in metallo (mozzo su albero).
Puoincollare particolari con gioco tra 0,1 e 0, 25 mm.
. Anaerober Klebstoff fu r groe Widerstandskrafte fu r Zylinderkupplungen aus Metall geeignet (Wellenna-
ben). Kann Einzelteil mit einem Radialspiel zwischen 0,1 mm und 0,25 mm zusammenkleben.
. Adhesivo anaerobico para el encolado rapido de alta resistencia de juntas cil ndricas de metal (cubo en el eje).
Puede encolar piezas con juego entre 0,1 mm y 0,25 mm.
. Adhesif anaerobic servant a un collage rapide et hautement resistant des joints cylindriques en metal
(moyeu sur l'arbre). Il peut servir a coller des pieces avec un jeu allant de 0,1 a 0,25 mm.
Loctite 648
. Anaerobic adhesive for fast and medium-strength gluing of cylindrical metal joints (hub on shaft). Can glue
together parts with radial clearance below 0.1 mm.
. Adesivo anaerobico per l'incollaggio rapido a media resistenza di giunti cilindrici in metallo (mozzo su albero).
Puoincollare particolari con gioco radiale inferiore a 0,1 mm.
. Anaerober Klebstoff fu r mittlere Widerstandskrafte fu r Zylinderkupplungen aus Metall geeignet (Wellenna-
ben). Kann Einzelteil mit einem Radialspiel von weniger als 0,1 mm zusammenkleben.
. Adhesivo anaerobico para encolado rapido de media resistencia juntas cil ndricas de metal (cubo en el eje).
Puede encolar piezas con juego radial inferior a 0,1 mm.
. Adhesif anae robic servant a un collage rapide moyennement re sistant des joints cylindriques en metal
(moyeu sur l'arbre).
Il peut servir a coller des pieces avec un jeu radial inferieur a 0,1 mm.
(AREXONS)
Repositionable jointing
compound for seals
Mastice per guarnizioni
riposizionabile
Klebstoff fu r verstellbare
Dichtungen
Pasta para juntas
reposicionable
Mastic pour garnitures a
remettre en place
. Solvent-based sealing compound for elastic seals, drying through evaporation. Used for sealing the outer
diameter of sealing rings for rotating shafts with outer metal reinforcement.
. Mastice sigillante per guarnizioni elastiche a base di solvente, essicante per evaporazione.
Viene utilizzato per la tenuta sul diamentro esterno di anelli di tenuta per alberi rotanti con armatura metallica
esterna.
. Klebstoff fu r Gummidichtung auf Lo semittelbasis, trocknet durch Verdampfung.
Wird am aueren Durchmesser von Dichtungsringe bei rotierenden Wellen mit Metallmantel verwendet.
. Pasta para juntas de sellado para juntas elasticas a base de disolvente, deshidratante por evaporacion.
Se utiliza para la estanqueidad en el diametro externo de segmentos de compresion, para ejes giratorios con
armadura metalica exterior.
. Mastic adhe sif a base de solvants pour garnitures e lastiques, sechant par e vaporation.
Il sert garder e tanche le diame tre exte rieur des bagues d'e tanche ite des arbres rotatifs ayant une arma-
ture me tallique externe.
18.5 Axle DANA 193
BOMAG 944 008 911 79
12
DENOMINATION
DENOMINAZIONE
BEZEICHNUNG
DENOMINACION
DENOMINATION
Silicone
Silicone
Silikon
Silicona
Silicone
. Semi-fluid adhesive material used for sealing and filling and to protect components from environmental and
physical elements. Polymerises with non-corrosive dampness.
. Materiale adesivo semifluido usato per sigillatura, riempimenti e per la protezione di componenti dagli elementi
ambientali e fisici. Polimerizza con umiditanon corrosiva.
. Halbflu ssiger Klebstoff zum Befestigen, Fu llen und zum Schutz von Bestandteilen vor a ueren Einwirkun-
gen. Polymerisiert durch nicht korrosive Feuchtigkeit
. Material adhesivo semifluido usado para el sellado, llenado y para la proteccion de componentes de elemen-
tos ambientales y f sicos. Polimeriza con humedad no corrosiva.
. Produit adhesif semi-fluide utilise pour le scellage, remplissage et protection des elements ambiants et phy-
siques. Polymerise a une humidite non corrosive.
(TECNO LUPE/101)
Silicone-based grease
Grasso al silicone
Silikonfett
Grasa a la silicona
Graisse au silicone
. Highly adhesive synthetic grease, with silicone compounds added.
Applied to adjustment screws with hole communicating with oil-type fluids.
Used when frequent adjusting is required.
. Grasso sintetico con elevato grado di adesivita, additivato con composti siliconici.
Applicato su viti di registrazione a foro comunicante con fluidi di tipo oleoso.
Usato quando si richiedono frequenti interventi di registrazione.
. Synthetisches Fett mit hoher Haftfestigkeit, mit silikonhaltigen Stoffen legiert.
Wird auf Stellschrauben mit Loch, die mit olhaltigen Flu ssigkeiten in Kontakt stehen, angebracht.
Wird verwendet, wenn die Schraub ofters eingestellt werden mu.
. Grasa sintetica con elevado grado de adhesion, aditivada con componentes siliconicos.
Aplicada en tornillos de ajuste de orificio comunicante con fluidos de tipo oleoso.
Se usa cuando se requieren frecuentes intervenciones de ajuste.
. Graisse synthe tique ayant un degre d'adhesivite eleve, adjuve de compose s au silicone.
Applique sur les vis de reglage a trou communiquant avec des fluides du type huileux.
Utilise quand il y a besoin de reglages fre quents.
Molikote
(DOW CORNING)
. Lubricating compound containing molybdenum disulphide, used to lubricate articulation pins and to prevent
sticking and oxidation of parts that are not lubricated on a regular basis.
. Composto lubrificante contenente bisolfuro di molibdeno, usato per la lubrificazione di perni snodo e per pre-
venire incollamenti ed ossidazioni di particolari non lubrificati in modo continuo.
. Schmierstoff mit Molybidandisulfid; wird zum Schmieren von Gelenkstiften und gegen Ankleben und Oxy-
dation von nicht dauergeschmierten Einzelteilen verwendet.
. Compuesto lubricante que contiene bisulfuro de molibdeno, usado para la lubricacion de rotulas y para pre-
venir encoladuras y oxidaciones de piezas no lubricadas de manera continua.
. Compose lubrifiant contenant du bisulfure de molybde ne, utilise pour lubrifier les axes d'articulation et pre-
venir collages et oxydations des pieces qui ne sont pas continuellement lubrifiees.
(Lithium-based) Grease
Grasso (al Litio)
(Lithium) Fett
Grasa (al Litio)
Graisse (au Lithium)
. Applied to bearings, sliding parts and used to lubricate seals or parts during assembly
. Applicato a cuscinetti, parti scorrevoli e per lubrificare guarnizioni o pezzi in fase di montaggio.
. Wird auf Lager, Gleitteilen aufgetragen und zum Schmieren von Dichtungen oder von Teilen bei der Mon-
tage verwendet.
. Aplicada a cojinetes, partes deslizables o para lubricar juntas o piezas en fase de montaje.
. Applique sur les paliers, parties coulissantes et pour lubrifier les garnitures ou pie ces pendant la phase de
montage.

MATE
TANCHE
ITE
ET LUBRIFICATION
Axle DANA 193
BOMAG 945 008 911 79
18.5
NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR
SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE
1 - During all operations described in this manual, the
axle should be fastened onto a trestle, while the
other parts mentioned should rest on supporting
benches.
2 - When removing one of the arms, an anti-tilting safety trestle
should be placed under the other arm.
3 - When working on an arm that is fitted on the machine, make sure
that the supporting trestles are correctly positioned and that the
machine is locked lengthways.
4 - Do not admit any other person inside the work area; mark off the
area, hang warning signs and remove the ignition key from the
machine.
5 - Use only clean, quality tools; discard all worn, damaged, low-
quality or improvised wrenches and tools. Ensure that all
dynamometric wrenches have been checked and calibrated.
6 - Always wear gloves and non-slip rubber shoes when performing
repair work.
7 - Should you stain a surface with oil, remove marks straight away.
8 - Dispose of all lubricants, seals, rags and solvents once work has
been completed. Treat them as special waste and dispose of them
according to the relative law provisions obtaining in the country
where the axles are being overhauled.
9 - Make sure that only weak solvents are used for cleaning
purposes; avoid using turpentine, dilutants and toluol-, xylol-
based or similar solvents; use light solvents such as Kerosene,
mineral spirits or water-based, environment friendly solvents.
10 - For the sake of clarity, the parts that do not normally need to be
removed have not been reproduced in some of the diagrams.
11 - The terms RIGHT and LEFT in this manual refer to the position of
the operator facing the axle from the side opposite the drive.
12 - After repair work has been completed, accurately touch up any
coated part that may have been damaged.
1 - Le operazioni descritte sono riferite all'assale bloc-
cato su cavalletto ed alcuni particolari appoggiati su
un banco di lavoro.
2 - Quando si asporta un braccio dell'assale, sistemare sotto l'altro
braccio un cavalletto di sicurezza antiribaltamento.
3 - Se si opera su un'assale montato sulla macchina, assicurarsi di
aver sistemato dei cavalletti di sostentamento e di aver immobi-
lizzato longitudinalmente la macchina.
4 - Non permettere che persone estranee entrino nella zona di lavoro;
delimitare questa zona, appendere dei cartelli di avviso di lavori in
corso ed asportare le chiavi di avviamento della macchina.
5 - Usare solo ed esclusivamente attrezzi puliti e di buona qualita;
scartare chiavi od attrezzi usurati o danneggiati, di bassa qualita
od improvvisati. Assicurarsi che le chiavi dinamometriche siano
state controllate e tarate.
6 - Durante le operazioni di riparazione, indossare sempre guanti e
scarpe antiscivolo.
7 - Pulire immediatamente le zone eventualmente imbrattate d'olio.
8 - I lubrificanti, le guarnizioni, gli eventuali stracci di pulizia ed i
solventi usati devono essere smaltiti come rifiuti speciali e
comunque secondo le normative vigenti nel Paese ove vengono
revisionati gli assali.
9 - Per la pulizia, usare solo solventi deboli escludendo categorica-
mente trielina, diluenti e solventi a base di toluolo, xilolo, ecc.;
usare solo solventi leggeri quali cherosene, ragie minerali o
solventi ecologici a base d'acqua.
10 - Per chiarezza di illustrazione ed esposizione, sulle figure di alcuni
gruppi mancano dei particolari che, normalmente, possono essere
lasciati montati. Rimuovere solo i particolari descritti.
11 - I termini DESTRA e SINISTRA usati nel manuale sono riferiti alla
persona che guarda l'assale dal lato opposto alla presa di moto.
12 - Al termine delle riparazioni, per evitare dannose ossidazioni,
ritoccare con cura le parti verniciate eventualmente danneggiate.
ITA
13
GB
1 - Die beschriebenen Vorga nge werden an der Achse
vorgenommen, wenn diese auf einem Bock blockiert
ist. Zur Bearbeitung der Einzelteile, werden diese
auf die Werkbank gelegt.
2 - Wenn eine Achse abgenommen wird, einen Sicherheitsbock unter
den zweiten Arm legen.
3 - Werden Arbeiten an der Achse vorgenommen, wenn diese noch
an der Maschine montiert ist, Bo cke zur Halterung unter die
Achse stellen und die Maschine der Lange nach blockieren.
4 - Es du rfen sich keine fremde Personen in der Na he der Maschine
wahrend der Arbeiten aufhalten; diesen Bereich absperren und
mit Schilder kennzeichnen, die auf die laufenden Arbeiten
hinweisen. Zu ndschlu ssel von der Maschine abnehmen.
5 - Nur saubere Werkzeuge guter Qualitat verwenden; alte, bescha -
digte oder improvisierte Hilfsmittel nicht verwenden. Sicher-
stellen, da die Dynamometer gepru ft und geeicht worden sind.
6 - Bei Reparaturen, stets Handschuhe und rutschfeste Schuhe tragen.
7 - Mit O
l beschmutzte Stellen, sofort reinigen.

8 - Gebrauchte Schmiermittel, Dichtungen, Reinigungslappen und
D
Lo semittel mu ssen als Sondermu ll und auf jeden Fall laut den
o rtlich geltenden Vorschriften entsorgt werden.
9 - Zur Reinigung ausschlielich schwache Lo semittel wie Petroleum,
Terpentin oder wasserhaltige Lo semittel verwenden. Auf keinen
Fall Trichlora thylen, tuolol- oder xylolhlatige Lo semittel usw.
verwenden.
10 - Um die Arbeitsvorga nge versta ndlich abzubilden, werden in
einigen Fotos die Aggregate ohne Einzelteile gezeigt, die sonst
bei der Arbeit nicht abmontiert werden mu ssen.
Nur die beschriebenen Teile abmontieren.
11 - Unter RECHTS und LINKS versteht man in diesem Handbuch die
Seite einer Person, die zur Achse schaut und zwar dem Antrieb
entgegengesetzt.
12 - Nach beendeten Arbeiten und um Rostbildungen zu vermeiden,
die Teile an denen der Lack ggf. bescha digt worden ist,
anstreichen.
1 - Las operaciones descritas se refieren al eje blo-
queado en un caballete y a algunas partes apoyadas
en el banco de trabajo.
2 - Cuando se saca un brazo del eje, colocar debajo del otro un
caballete de seguridad antivuelco.
3 - Si se trabaja con un eje montado en la maquina, asegurarse de
haber colocado caballetes soporte y de haber inmovilizado
longitudinalmente la ma quina.
4 - No permitir que personas extran as entren en la zona de trabajo;
delimitar esta zona, colgar carteles de aviso de hombres
trabajando y sacar las llaves de arranque de la maquina.
5 - Usar so lo y exclusivamente herramientas limpias y de buena
cualidad; descartar llaves o herramientas gastadas o dan adas, de
calidad mediocre o improvisadas. Asegurarse de que las llaves
dinamometricas han sido controladas y calibradas.
6 - Durante las operaciones de reparacion, llevar siempre guantes y
calzado antideslizamiento.
7 - Limpiar inmediatamente las zonas que pudieran estar sucias de
aceite.
8 - Los lubricantes, las juntas, los trapos para la limpieza y los
disolventes usados hay que eliminarlos como desechos especia-
les y, de todas formas, de acuerdo con las normativas vigentes en
el pa s en el que se revisan los ejes.
9 - Para limpiar, utilizar so lo disolventes de biles excluyendo en
absoluto tricloroetileno, diluyentes y disolventes a base de toluol,
silol, etc.; usar solo disolventes ligeros como queroseno, aguarra s
minerales o disolventes ecologicos a base de agua.
10 - Para que resulte clara la exposicion y la ilustracion, en las figuras
de algunos grupos faltan algunas piezas que por lo general se
pueden dejar montadas. Sacar solo las partes descritas.
11 - Las palabras DERECHA E IZQUIERDA usadas en el manual se
refieren a la persona que mira el eje del lado opuesto a la toma de
movimiento.
12 - Al final de las reparaciones, para evitar oxidaciones, retocar
cuidadosamente las partes pintadas que estuvieran dan adas.
ESP
1 - Les ope rations decrites se rapportent a l'essieu
bloque sur chevalet et de quelques pieces pose es
sur un etabli de travail.
2 - Quand on enleve un essieu monte sur la machine, ajuster sous
l'autre bras un chevalet de se curite contre tout basculement.
3 - Si on oeuvre sur un essieu monte sur la machine, s'assurer
d'avoir ame nage des chevalets de soutien et d'avoir bloque la
machine en longueur.
4 - Ne jamais permettre a des etrangers de pe netrer dans la zone de
travail; delimiter cette zone, mettre des pancartes de signalisation
de travaux en cours et enlever les cle s de contact de la machine.
5 - N'utiliser que des outils propres et de bonne qualite ; eliminer cle
ou autres outils uses, ab me s, de mauvaise qualite ou improvise s.
Veiller a ce que les cles dynamometriques aient e te contro le es et
calibre es.
6 - Pendant les ope rations de reparation, endosser toujours gants et
chaussures antiderapantes.
7 - Nettoyer tout de suite les e ventuelles zones souillees d'huile.
8 - Les lubrifiants, les garnitures, les e ventuels chiffons servant au
nettoyage et les solvants utilises devront e tre re coltes et traite s
comme rebut special conforme ment aux lois en vigueur dans le
pays ou les essieux sont en re vision.
9 - Pour le nettoyage, n'utiliser que des solvants a base de toluol,
xylol, etc.; n'utiliser que des solvants legers tels que kerose ne,
essences minerales, ou solvants ecologiques a base d'eau.
10 - En ce qui concerne la clarte en matie re d'illustration et exposition,
sur les figures de certains groupes, il y a des pie ces manquantes
qui normalement peuvent rester monte es.
Enlever uniquement les pieces de crites.
11 - Les termes DROITE et GAUCHE utilises dans ce manuel se
rapportent a la personne regardant l'essieu du co te oppose a celui
de la prise de mouvement.
12 - A la fin des ope rations, afin d'e viter un risque d'oxydation
nuisible, retoucher soigneusement les parties vernies eventuelle-
ment ab me es.
F
18.5 Axle DANA 193
BOMAG 946 008 911 79
CHECKING WEAR
CAUTION! Perform operations on both arms.
Remove the oil-level plug (1).
Introduce tool T1 between the disks and check shim "S".
Minimum size of "S": 4.5 mm.
ADJUSTING THE BRAKES
Connect an external pump to the union piece "P" of the negative
brake and introduce a pressure of 15 30 bar to eliminate the
pressure of the Belleville washers (11).
Remove screw (2) and safety plate (3).
Turn the brake clearance adjustment pinion (4) clockwise and as
far as the limit stop.
Release pressure and disconnect the tubes.
NOTE. Remove the lower plug (5) and drain the oil.
REPLACING THE BRAKING DISKS
Sling the arm (6) to be removed and connect it to a hoist.
Loosen and remove screws (7) and nuts (8).
bar
bar
GB GB
GB GB
GB GB
a
b
c d
f e
14
CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTRO
LE USURE ET SUBSTITUTION DES DISQUES FREINS

Disassembly of assembly groups
Smontaggio di sottogruppi
Zerlegen von Baugruppen
Desmontaje de subgrupos
Demontage des sous-groupes
Reassemble to from assembly groups
Montaggio di sottogruppi
Zusasmmenbauen von Baugruppen
Ensamblaje de subgrupos
Montage des sous-groupes
Remove obstruction parts
Smontaggio di particolari ingombri
Abbauen-Ausbauen
Desmontaje de componentes abultados
Demontage des pieces encombrante
Reinstall-remount parts which had obstructed disassembly
Montaggio di particolari ingombri
Einbauen-Ausbauen
Montaje de componentes abultados
Montage des pieces encombrante
Attention! Important notice
Attenzione, indicazione importante
Achtung, wichtiger Hinweis
Cuidado ! Indicacion importante
Attention, indication importante
Check - adjust e.g. torque, dimensions, pressures, etc.
Controllare - regolare p.e. coppie, misure, pressioni ecc.
Pru fen - Einstellen z.B. Momente, Mae, Drucke u.s.cs.
Controlar y ajustar, por ej. pares, medidas, presiones, etc.
Controler, regler p.e. couples, mesures, pressions ecc.
T=Special tool P=page
T=Attrezzature speciali P=Pagina
T=Spezialwerkzeug P=Seite
T=Herramientas especiales P=Pagina
T=Outils P=Page
Note direction of installation
Rispettare direzione di montaggio
Einbaurichtung beachten
Respetar la direccion de ensamblaje
Respecter direction de montage
Visual inspection
Esaminare con controllo visuale
Kontrollieren -Pru fen
Examinar mediante inspeccion visual
Controler, examiner, controle visuel
Possibly still serviceable, renew if necessary
Eventualmente riutilizzare (sostituire se necessario)
Bedingt weiderverwendbar
Puede volver a utilizarse (reemplazar, si es preciso)
Eventuellement a utiliser a noveau (remplacer si necessaire)
Renew at each reassembly
Sostituire ad ogni montaggio
Beim Zusammenbau immer erneuern
Puede reemplazarse a cada ensamblaje
Remplacer avec chaque montage
Unlock - lock e.g. split pin, locking plate, etc.
Togliere-mettere la sicura
Entsichern-Sichern
Quitar-colocar el seguro
Enlever-mettre la securite
Lock-adhere (liquid sealant)
Mettere la sicura, incollare (mastice liquido)
Sichern-Kleben (flu ssige Dichtung)
Colocar el seguro, pegar (mastique l quido)
Mettre la securite, coller (mastic liquide)
Guard against material damage, damage to parts
Evitare danni materiali, danni a pezzi
Materialschaden verhu ten
Evitar dan ar los materials o las piezas
Eviter dommages au materiaux, dommages au pieces
Mark before disassembly, observe marks when reassembly
Marchiare prima dello smontaggio (per il montaggio)
Vor dem Ausbau markieren (fu r den Zusammenbau)
Marcar antes de desmontar (para facilitar el ensamblaje)
Marquer avant le demontage (pour le montage)
Filling - topping up - refilling e.g. oil, cooling water, etc.
Caricare - riempire (olio - lubrificante)
Einfu llen - Auffu llen - Nachfu llen (O
l-Schmiermittel)
Cargar - llenar (aceite lubricante)
Charger - remplir (huile - lubrifiant)
Drain off oil, lubricant
Scaricare olio, lubrificante
O
l, bzw. Schmiermittel Ablassen

Descargar aceite lubricante
Vidanger, lubrifiant
Tighten
Tendere
Spannen
Tensar
Tendre
Apply pressure into hydraulic circuit
Inserire pressione nel circuito idraulico
Leitung unter Druck setzen
Introducir presion en el circuito hidraulico
Inserer pression dans le circuit hydraulique
To clean
Pulire
Reinigen
Limpiar
Nettoyer
Lubricate - grease
Lubrificare - ingrassare
Schmieren - einfetten
Lubrificar - Engrasar
Lubrifier - Graisser
SIMBOLI
F1241070 F1241071
T1
S
F1241073
F1241075
F1241072
P
F1241074
Axle DANA 193
BOMAG 947 008 911 79
18.5
15
CONTROLLO USURA
ATTENZIONE! Eseguire le operazioni per i due
bracci.
Asportare il tappo (1) di livello olio.
CONTROL DESGASTE
ATENCION! Efectuar las operaciones por los dos
ejes.
Sacar el tapon (1) de nivel aceite.
CONTROLE USURE
ATTENTION! Effectuer les ope rations aux deux bras.
Enlever le bouchon (1) du niveau d'huile.
Introdurre l'attrezzo T1 tra i dischi e controllare lo
spessore "S".
"S" minimo: 4,5 mm
Introducir la herramienta T1 entre los discos y
controlar el espesor "S".
S minimo: 4,5 mm.
Introduire l'outil T1 entre les disques et contro ler la
cale "S".
"S" minimum: 4,5 mm
REGISTRAZIONE FRENI
Collegare al raccordo "P" del freno negativo una pompa
esterna ed immettere una pressione di 15v30 bar per
eliminare la pressione delle molle a tazza (11).
REGISTRACION FRENOS
Conectar al empalme P del freno negativo una
pompa esterna y introducir una presion de 15v30 bar
para eliminar la presion de los muelles a taza (11).
REGLAGE DES FREINS
Brancher au raccord "P" du frein ne gatif une pompe
externe et envoyer une pression de 15v30 bar pour
e liminer la pression des ressorts belleville (11).
Asportare la vite (2) e la piastrina di sicurezza (3).
Sacar el tornillo (2) y la placa de securidad (3).
Enlever les vis (2) et la plaquette de se curite (3).
Ruotare in senso orario il pignone (4) di regolazione
gioco freni fino a fondo corsa.
Rilasciare la pressione e scollegare i tubi.
NOTA. Rimuovere il tappo inferiore (5) e scaricare l'olio.
Girar en sentido horario el pinon (4) de regulacio n
juego frenos hasta final carrera.
Dejar la presion y desconectar los tubos.
NOTA. Remover el tapon inferior (5) y descargar el aceite.
Tourner le pignon de re glage du jeu des freins (4) dans
le sens des aiguilles d'une montre jusqu'en fin de
course.
Libe rer la pression et de brancher les tubes.
REMARQUE: Enlever le bouchon infe rieur (5) et vidanger l'huile.
SOSTITUZIONE DISCHI FRENO
Imbragare il braccio (6) da asportare e collegarlo ad un
mezzo di sollevamento.
Allentare ed asportare le viti (7) ed i dadi (8).
SUBSTITUCION DISCOS FRENOS.
Atar el eje (6) de sacar y conectarlo a un medio de
levantamiento.
Aflojar y sacar los tornillos (7) y las tuercas (8).
Substitution des disques frein
Elinguer le bras (6) a enlever et brancher celui-ci a un
moyen de relevage.
Desserrer et enlever les vis (7), les e crous (8).
ITA
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VERSCHLEISS KONTROLLIEREN
ACHTUNG! Die Vorga nge an beiden Armen vorneh-
men.
O
leinfu llstopfen (1) abnehmen.

Werkzeug T1 zwischen den Scheiben einsetzen und
die Sta rke "S" kontrollieren.
"S" Minimum: 4,5 mm
BREMSEN EINSTELLEN
Anschlustu ck "P" der Federspeicherbremse an eine
a uere Pumpe anschlieen und Druck bei 15v30 bar
einlassen, um Tellerfedern (11) zu entlasten.
Schraube (2) und Sicherheitspla ttchen (3) abnehmen.
Das Kegelrad (4) zur Einstellung des Bremsspiels bis
zum Endanschlag drehen.
Druck ablassen und die Leitungen abtrennen.
BEMERKUNG. Unteren Stopfen (5) abnehmen und das O
l.
BREMSSCHEIBEN AUSWECHSELN
Den abzunehmenden Arm (6) anschlagen und an eine
Hebezeug befestigen.
Schrauben (7) und Muttern (8) lockern und abschrauben.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 948 008 911 79
Remove arm (6) together with brakes and axle shafts; lay down the
arm vertically.
Loosen screws (9) in an alternate manner and remove them.
Move the cylinder (10) outwards while supporting the Belleville
washers (11).
Remove the Belleville washers (11) and note down direction of
assembly.
Remove the cylinder (10) complete with piston (12).
Slowly introduce low-pressure compressed air through the con-
nection member for the negative brake, in order to extract the
piston (12).
CAUTION! Hold the piston (12) back, as it may be suddenly ejected
and damaged.
Remove O-rings (13) and (14) from the piston (12).
NOTE. The O-rings (13) and (14) must be replaced each time the
unit is disassembled.
bar
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CONTRO

F1241076 F1241077
F1241079
F1241081
F1241078
F1241080
Axle DANA 193
BOMAG 949 008 911 79
18.5
17
Rimuovere il braccio (6) completo di freni e semiassi;
deporre il braccio in modo verticale.
Remover el eje (6) completo de frenos y semi-ejes;
colocar el eje de manera vertical.
Enlever le bras (6) complet de freins et demi-essieux;
deposer le bras en vertical.
Allentare in modo alternato le viti (9) ed asportarle.
Aflojar de manera alternada los tornillos (9) y sacarlas.
Desserrer les vis (9) en alternance, puis les enlever.
Spostare verso l'esterno il cilindro (10) sostenendo le
molle a tazza (11).
Rimuovere le molle (11) ed annotare il senso di
montaggio.
Desplazar hacia el esterior el cilindro (10) sosteniendo
los muelles a taza (11).
Remover los muelles (11) y anotar el sentido de
montaje.
De placer le cylindre (10) vers l'exterieur en soutenant
le ressort belleville (11).
Enlever le ressort (11) et prendre note du sens de son
montage.
Rimuovere il cilindro (10) completo di pistone (12).
Remover el cilindro (10) completo de piston (12).
Enlever le cylindre (10) complet de piston (12).
Immettere lentamente aria compressa a bassa pres-
sione attraverso l'attacco per il freno negativo per
estrarre il pistone (12).
ATTENZIONE! Trattenere il pistone (12) che puo essere espulso
velocemente ed essere danneggiato.
Introducir lentamente aire comprimida a baja presio n
atraves el empalme por el freno negativo para sacar el
piston (12).
ATENCION! Tener el piston (12) que puede ser expulso rapida-
mente y estropearse.
Envoyer lentement de l'air comprime a basse pression
a travers le raccord du frein ne gatif pour extraire le
piston (12).
ATTENTION! Tenir le piston (12) qui pourrait e tre expulser
rapidement et endommager.
Rimuovere dal pistone (12) gli anelli OR (13) e (14).
NOTA. Gli anelli OR (13) e (14) devono essere
sostituiti ad ogni smontaggio.
Remover del piston (12) los anillos OR (13) y (14).
NOTA. Los anillos OR (13) y (14) deben de ser
sobstituidos cada desmontaje.
Enlever le piston (12), les anneaux O'RING (13) et
(14).
REMARQUE. Les anneaux O'RING (13) et (14) sont a
substituer a chaque de montage.
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Den Arm (6) samt Bremsen und Halbachsen ab-
nehmen; den Arm senkrecht ablegen.
Abwechselnd die Schrauben (9) lockern und ab-
schrauben.
Den Zylinder (10) nach auen verstellen und dabei die
Tellerfedern (11) stu tzen.
Federn (11) abnehmen und die Montagerichtung
notieren.
Zylinder (10) samt Kolben (12) abnehmen.
Langsam Druckluft bei Niederdruck durch den An-
schlu der Federspeicherbremse einlassen, um den
Kolben (12) heraus zu dru cken.
ACHTUNG! Den Kolben (12) halten, da er plo tzlich heraus springen
und bescha digt werden ko nnte.
Kolben (12) und O-Ringe (14) und (14) abnehmen.
BEMERKUNG. Die O-Ringe (13) und (14) mu ssen
jedesmal ausgewechselt werden, wenn das Teil zer-
legt wird.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 950 008 911 79
Remove checking and guiding screws (15) from the pressure plate
(16).
NOTE. Loosen screws (15) in sequence and proportionally.
Remove the pressure plate (16).
CAUTION! Note down the direction of assembly; flow regulator wall
"A" and oil drain holes must face the oil drain plug.
Remove springs (17).
NOTE. Accurately check the condition of springs. They should not
be warped.
Any deformation of the springs requires spring replacement.
Remove braking discs (18) and (19), noting down direction of
assembly.
NOTE. If disks are not to be replaced, avoid changing their
position.
Remove pinion (4) complete with O-ring (20).
NOTE. The O-ring must be replaced each time the unit is
disassembled.
Unscrew and extract the braking disk clearance adjustment crown
wheel (21).
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CONTRO

F1241082 F1241083
A
F1241085
F1241087
F1241084
F1241086
Axle DANA 193
BOMAG 951 008 911 79
18.5
19
Rimuovere le viti (15) di ritegno e guida dello
spingidisco (16).
NOTA. Allentare le viti (15) in modo sequenziale ed in
uguale misura.
Remover los tornillos (15) de retencio n y gu a del
empuya-disco (16).
NOTA. Aflojar los tornillos (15) de manera secuencial
y en la misma mesura.
Enlever vis (15) de fixation et guide du plateau de
pression (16).
REMARQUE: Desserrer les vis (15) en se quence et en
e gale mesure.
Rimuovere lo spingidisco (16).
ATTENZIONE! Annotare il senso di montaggio; la
parete frangiflusso "A" e gli scarichi olio, devono
essere rivolti verso il tappo di scarico olio.
Remover el empuja-disco (16).
ATENCION. Anotar el sentido de montaje; la pared
rompe-flujo "A" y los descarge aceite, deben de ser
dirijidos hacia el tapon de descarga aceite.
Enlever le plateau de pression (16).
ATTENTION! Prendre noter du sens du montage; la
paroi brise-jet "A" et les e coulements d'huile sont
tourne s vers le bouchon de vidange d'huile.
Rimuovere le molle (17).
NOTA. Controllare attentamente lo stato delle molle
che non devono essere deformate.
Ogni deformazione deve portare alla sostituzione.
Remover los muelles (17).
NOTA. Controlar atentamente el estado de los
muelles que no deben de ser deformes.
A cada deformacion deben de ser cambiados.
Enlever les ressorts (17).
REMARQUE. Contro ler attentivement l'e tat des res-
sorts, ils ne doivent pas etre deforme s.
Toute de formation veut dire substitution.
Rimuovere i dischi di frenatura (18) e (19) annotando
l'ordine di montaggio.
NOTA. Se i dischi non devono essere sostituiti, evitare
lo scambio di posizione.
Remover los discos de frenadura (18) y (19) anotando
el orden de montaje.
NOTA. Si los discos no deben de ser sobstituidos,
evitar el cambio de possicio n.
Enlever les disques de freinage (18) et (19) et prendre
note de l'ordre du montage.
REMARQUE. Si les disques doivent e tre substitue s,
e viter d'e changer leur position.
Rimuovere il pignone (4) completo di anello OR (20).
NOTA. L'anello OR deve essere sostituito ad ogni
smontaggio.
Remover el pinon (4) completo de anillo OR (20).
NOTA. El anillo OR debe de ser sobstituido a cada
desmontaje.
Enlever le pignon (4) complet de l'anneau O'RING
(20).
REMARQUE. L'anneau O-Ring est a remplacer a
chaque de montage.
Svitare ed asportare la corona (21) di regolazione del
gioco dischi di frenatura.
Destornillar y sacar la corona (21) de regulacion del
juego discos de frenadura.
De visser et enlever la couronne (21) de re glage du jeu
des disques de freinage.
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Befestigungsschrauben (15) und die Fu hrung der
Druckplatte (16) abnehmen.
BEMERKUNG. Abwechselnd Schrauben (15) im
gleichen Ma lockern.
Druckplatte (16) abnehmen.
ACHTUNG! Montagerichtung notieren; der Strahlreg-
ler "A" und die O
lablao ffnungen mu ssen in Richtung

des O
lablastopfens gerichtet sein.

Federn (17) abnehmen.
BEMERKUNG. Die Federn sorgfaltig kontrollieren; sie
du rfen nicht verformt sein. Sollte dies der Fall sein,
Federn auswechseln.
Bremsscheiben (18) und (19) abnehmen und Monta-
gerichtung notieren.
BEMERKUNG. Falls die Scheiben ausgewechselt
werden mu ssen, ihre Position nicht verwechseln.
Das Kegelrad (4) samt O-Ring (20) entfernen.
BEMERKUNG. Den O-Ring bei jedem Zerlegen aus-
wechseln.
Den Kranz (21) zur Einstellung des Bremsscheibens-
piels abnehmen.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 952 008 911 79
Lubricate the threaded portion of the crown wheel (21) and screw it
down into the arm (6) as far as it will go.
Replace the O-ring (20) of pinion (4).
Lubricate and install the pinion in the slot provided on the arm (6),
inserting the toothing into crown wheel (21).
GB GB a
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ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS - MONTAJE DE LOS
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS
20
D1240130
F1241133 F1241134
Axle DANA 193
BOMAG 953 008 911 79
18.5
b
a
Das Gewinde des Kranzes (21) schmieren und in den
Arm (6) festschrauben.
Lubrificar la rosca de la corona (21) y atornillar a
hondo en el eje (6).
Lubrifier le filetage de la couronne (21), puis visser
celle-ci a fond dans le bras (6).
O-Ring (20) des Kegelrads (4) auswechseln. Kegelrad
schmieren und in den Sitz des Arms (6) montieren;
dabei die Za hne des Kranzes (21) einrasten.
Sobstituir el anillo OR (20) del pinon (4).
Lubrificar el pinon y montarlo en la sed del eje (6)
introduciendo la dentadura en la corona (21).
Substituer l'anneau O'RING (20) du pignon (4).
Lubrifier le pignon, puis monter celui-ci dans le
logement du bras (6) en introduisant en me me temps
la denture dans la couronne (21).
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F
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ITA
Lubrificare la filettatura della corona (21) ed avvitarla a
fondo nel braccio (6).
ITA
Sostituire l'anello OR (20) del pignone (4).
Lubrificare il pignone e montarlo nella sede del braccio
(6) innestando la dentatura nella corona (21).
ITA
21
GB
18.5 Axle DANA 193
BOMAG 954 008 911 79
Lightly lubricate the first steel braking disk (18), then install it on the
arm (6).
Lubricate the first friction disk (19) and install it on the axle shaft .
Complete the assembly, alternating steel disks and friction disks.
CAUTION! Oval holes "B" of friction disks must be lined up.
Position springs (17) in the appropriate slots of the arm (6). Fit the pressure plate (16).
CAUTION! Accurately check orientation: flow regulator "A" and oil
drains must be oriented towards the arm's oil drain plug.
Lock the pressure plate into position (16) with screws (15).
CAUTION! Tighten screws in sequence and a little at a time.
Lock screws (15) with a dynamometric wrench.
Torque wrench setting: 20 30 Nm.
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F1241088 F1241089
B
F1241083
A
F1241090
F1241084
F1241082
Axle DANA 193
BOMAG 955 008 911 79
18.5
23
Lubrificare leggermente il primo disco di frenatura in
acciaio (18) e montarlo nel braccio (6).
Lubrificar ligermente el primer disco de frenadura en
acero (18) y montarlo en el eje (6).
Lubrifier le ge rement le premier disque de freinage en
acier (18), puis monter celui-ci dans le bras (6).
Lubrificare il primo disco di attrito (19) e montarlo sul
semiasse.
Completare il montaggio alternando dischi di acciaio e
dischi di attrito.
ATTENZIONE! I dischi di attrito devono avere il foro ovale "B"
allineato.
Lubrificar el primer disco de strito (19) y montarlo
sobre el semi-eje.
Completar el montaje alternando discos de acero y
discos de atrito.
ATENCION! Los discos de atrito deben tener el agujero oval B en
linea.
Lubrifier le premier disque de friction (19), puis monter
ce dernier sur le demi-essieu.
Achever le montage en alternant les disques en acier
et les disques de friction.
ATTENTION! Les disques de friction doivent avoir le trou ovale "B"
aligne .
Posizionare nelle sedi del braccio (6) le molle (17).
Colocar en las sedes del eje (6) los muelles (17).
Mettre en place les ressorts (17) dans les logements
du bras (6).
Montare lo spingidisco (16).
ATTENZIONE! Controllare attentamente l'orientamen-
to; il frangiflusso "A" e gli scarichi olio, devono essere
orientati verso il tappo di scarico olio del braccio.
Montar el empuja-disco (16).
ATENCION! Controlar atentamente el orientamiento;
el rompe-flujo "A" y los descarga aceite, deben de ser
orientados hacia el tapon de descarga aceite del eje.
Monter le plateau de pression (16).
ATTENTION! Contro ler attentivement la direction; la
paroi brise-jet "A" et les e coulements d'huile doivent
e tre dirige s vers le bouchon de vidange d'huile du bras.
Fissare la posizione dello spingidisco (16) con le viti
(15).
ATTENZIONE! Serrare le viti in modo sequenziale ed
in piu tempi.
Fijar la posicio n del empuja-disco (16) con los tornillos
(15).
ATENCION! Apretar los tornillos de manera secuen-
cial y en mas tiempos.
Fixer le plateau de pression (16) a sa place avec les
vis (15).
ATTENTION! Serrer les vis en plusieurs temps en
ordre se quentiel.
Bloccare le viti (15) con chiave dinamometrica.
Coppia di serraggio: 20v30 Nm
Bloquear los tornillos (15) con llave dinamometrica.
Par de serraje: 20v30 Nm.
Bloquer les vis (15) a l'aide de la cle dynamome trique.
Couple de serrage: 20v30 Nm.
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Die erste Bremsscheibe aus Stahl (18) etwas schmie-
ren und in den Arm (6) montieren.
Die erste Reibscheibe (19) schmieren und auf die
Halbachse montieren.
Dann die Stahlscheiben abwechselnd mit den Reibs-
cheiben montieren.
ACHTUNG! Die Langlo cher "B" der Reibscheiben mu ssen ge-
fluchtet sein.
In den Sitz des Arms (6) die Federn (17) einsetzen. Die Druckplatte (16) montieren.
ACHTUNG! Sorgfa ltig die Montagerichtung kontroll-
ieren; den Stahlregler "A" und die O
lablao ffnungen
mu ssen zum Ablastopfen des Arms gerichtet sein.
Die Druckplatte (16) mit den Schrauben (15) be-
festigen.
ACHTUNG! Die Schrauben der Reihe nach und
schrittweise festziehen.
Schrauben (15) mit dem Dynamometer blockieren.
Anzugsmoment: 20v30 Nm.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 956 008 911 79
Fit O-rings (13) and (14) onto the piston (12).
Lubricate the piston and the O-rings and install the unit into the
cylinder (10).
NOTE. Piston relief C must face downwards.
Using a plastic hammer, ram the piston (12) into the cylinder (10).
NOTE. Lightly hammer all around the edge in an alternate
sequence.
Check the condition and the position of the O-ring (22); lubricate
the O-ring and position the cylinder on the studs without fastening.
Position the Belleville washers (11) and engage the cylinder (10).
NOTE. Check the sense of direction of washers (11) and relative
centring.
Lock the cylinder (10), tightening the screws (9) with a dynamo-
metric wrench set to a torque of 86 89 Nm.
Check integrity and position of the arm's O-ring (23); install the
complete arm (6).
NOTE. To assist axle shaft centring, slightly move the wheel hub.
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F1241091
C
F1241092
F1241078
F1241094
F1241079
F1241093
Axle DANA 193
BOMAG 957 008 911 79
18.5
25
Montare sul pistone (12) gli anelli OR (13) e (14).
Lubrificare il pistone e gli anelli OR e montare il
gruppo nel cilindro (10).
NOTA. Lo scarico "C" del pistone deve essere rivolto verso il
basso.
Montar sobre el piston (12) los anillos OR (13) y (14).
Lubrificar el piston y los anillos OR y montar el grupo
en los cilindros (10).
NOTA. El escargo "C" del piston debe de ser dirijido hacia el bajo.
Monter sur le piston (12), les anneaux O'RING (13) et
(14).
Lubrifier le piston et les anneaux O'RING, puis monter
le groupe dans le cylindre (10).
REMARQUE. L'e coulement "C" du piston doit e tre tourne vers le
bas.
Utilizzando un mazzuolo in materiale plastico, inserire
a fondo il pistone (12) nel cilindro (10).
NOTA. Battere leggeri colpi distribuiti in modo
alternato su tutta la circonferenza.
Utilizando un martillo de materia plastica, introducir a
fondo el piston (12) en el cilindro (10).
NOTA. Pegar ligeros golpes distribuidos de manera
alternada sobre toda la circonferencia.
A l'aide d'un maillet en matiere plastique, introduire le
piston (12) a fond dans le cylindre (10).
REMARQUE. Donner de le gers coups re guliers tout
autour de la circonfe rence.
Controllare lo stato ed il posizionamento dell'anello
OR (22); lubrificare l'anello OR e posizionare il cilindro
sui prigionieri senza mandarlo in battuta.
Controlar el estado y la colocacio n del anillo OR (22);
lubrificar el anillo OR y colocar el cilindro sobre los
prigioneros sin llevarlo a tope.
Contro ler l'e tat et la position de l'anneau O'RING (22);
lubrifier l'anneau O'RING et positionner le cylindre sur
les prisonniers sans l'envoyer en bute e.
Posizionare le molle a tazza (11) e mandare in battuta
il cilindro (10).
NOTA. Controllare il senso di orientamento delle molle
a tazza (11) e la loro centratura.
Colocar los muelles a taza (11) y mandar a tope el
cilindro (10).
NOTA. Controlar el sentido de orientamiento de los
muelles a taza (11) y su centraje.
Positionner les ressorts belleville (11) et inse rer a fond
le cylindre (10).
REMARQUE. Contro ler l'orientation des ressorts
belleville (11) et leur centrage.
Bloccare il cilindro (10) con le viti (9) serrate con chiave
dinamometrica ad un coppia di 86v89 Nm.
Bloquear el cilindro (10) con los tornillos (9) apretados
con llave dinamometrica a un par de 86v89 Nm.
Bloquer le cylindre (10) avec les vis (9), serrer a l'aide
de la cle dynamome trique a un couple de 86v89 Nm.
Verificare l'integrita ed il posizionamento dell'anello
OR (23) del braccio; installare il braccio completo (6).
NOTA. Per agevolare la centratura del semiasse,
muovere lentamente il mozzo portaruota.
Averiguar la integridad y la colocacio n del anillo OR
(23) del eje; colocar el eje completo (6).
NOTA. Para facilitar el centraje del semi-eje, mover
lentamente el cubo porta-rueda.
Ve rifier le bon e tat et le positionnement de l'anneau
O'RING (23) du bras; installer le bras complet (6).
REMARQUE. Afin de rendre plus aise le centrage du
demi-essieu, bouger lentement le moyeu porte-roue.
ITA
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Auf den Kolben (12) die O-Ringe (13) und (14)
montieren.
Den Kolben und die O-Ringe schmieren und das
Aggregat in den Zylinder (10) montieren.
BEMERKUNG. Die Ablao ffnung "C" des Kolbens mu nach unten
gerichtet sein.
Mit einem Gummihammer den Kolben (12) in den
Zylinder (10) bis zum Anschlag einschlagen.
BEMERKUNG. Den Kolben abwechselnd rund um die
gesamte Kreislinie leicht schlagen.
Den Zustand und die Position des O-Ringes (22)
kontrollieren; den O-Ring schmieren und den Zylinder
auf die Stiftschrauben positionieren, ohne ihn bis zum
Anschlag ganz einzusetzen.
Tellerfedern (11) positionieren und den Zylinder (10)
bis zum Anschlag einsetzen.
BEMERKUNG. Orientierung der Tellerfedern (11) und
ihre Zentrierung kontrollieren.
Den Zylinder (10) mit den Schrauben (9) mit einem
Dynamometer und einem Anzugsmoment von 86v89 Nm
blockieren.
Am Arm den Zustand und die Position des O-Ringes
(23) kontrollieren; den gesamten Arm (6) installieren.
BEMERKUNG. Um die Halbachse leichter zentrieren
zu ko nnen, die Radhalternabe etwas bewegen.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 958 008 911 79
Temporarily lock the arm (6) with nuts (8) previously coated with
Loctite 242; tighten lightly to make the unit touch the main body.
Check the flatness of the arms, using tool T2; then lock the arms
into their final position, using screws (7) adequately coated with
Loctite 242.
NOTE. Tighten using the criss-cross method.
Connect an external pump to the union piece "A" of the negative
brake and introduce pressure to 15 30 bar.
Rotate the adjustment pinion (4) anticlockwise () to eliminate all
existing clearance between the braking disks.
Rotate up to a torque of 8 10 Nm.
Rotate pinion (4) clockwise (+) to determine the required clearance
of 1 mm.
NOTE. A turn of the adjuster produces a clearance of 0.25 mm
(1mm = 4 turns).
Install safety plate (3) and lock with screw (2).
bar
GB GB
GB GB
GB GB
a
b
c d
f e
26
F1241095 F1241096
T2
F1241074
F1241073
F1241097
P
D1240132
+
--
Axle DANA 193
BOMAG 959 008 911 79
18.5
27
Fissare provvisoriamente il braccio (6) con i dadi (8)
spalmati con Loctite 242 e serrati leggermente per
frizionare il gruppo sul corpo centrale.
Fijar provisoriamente el eje (6) con las tuercas (8)
pasados con Loctite 242 y apretados ligermente para
fricionar el grupo sobre el cuerpo central.
Fixer provisoirement le bras (6) avec les e crous (8)
enduits avec du Loctite 242, et serrer ceux-ci pour
frotter le groupe du corps central.
Controllare la planarita dei bracci con l'attrezzo T2 e
fissarli definitivamente con le viti (7) spalmate con
Loctite 242.
NOTA. Serrare con il metodo incrociato.
Controlar la planaridad de los ejes con la herramienta
T2 y fijarlos definitivamente con los tornillos (7) pasar
con Loctite 242.
Par de serraje: 182v202 Nm
NOTA. Apretar de manera cruzada.
Contro ler la plane ite des bras a l'aide de l'outil T2,
puis fixer ceux-ci de finitivement avec les vis (7)
enduites de Loctite 242.
Couple de serrage: 182v202 Nm.
REMARQUE. Serrer avec la me thode croise e.
Collegare al raccordo "P" del freno negativo una pompa
esterna ed immettere una pressione di 15v30 bar.
Conectar al empalme "P" del freno negativo una
pompa externa y introducir presion de 15v30 bar.
Brancher au raccord "P" du frein ne gatif une pompe
externe et envoyer une pression de 15v30 bar.
Ruotare in senso antiorario () il pignone di registro (4)
per eliminare totalmente il gioco tra i dischi di frenatura.
Ruotare fino ad ottenere una coppia di 8v10 Nm.
Girar en sentido anti-horario () el pinon de registro (4)
para eliminar totalmente el juego entre discos de
frenadura.
Girar hasta obtener un par de 8v10 Nm.
Tourner le pignon de re glage (4) dans le sens contraire
aux aiguilles d'une montre(-) le re gleur (4) pour faire
dispara tre entie rement le jeu existant entre les
disques de freinage.
Tourner jusqu'a obtenir un couple de 8v10 Nm.
Ruotare il pignone (4) in senso orario (+) per
determinare il gioco prescritto di 1 mm.
NOTA. Un giro del registro crea un gioco di 0,25 mm
(1 mm=4 giri).
Girar el pinon (4) en sentido horario (+) para
determinar el juego prescrito de 1 mm.
NOTA. Un giro del registro crea un juego de 0,25 mm
(1mm=4 giros).
Tourner le pignon (4) dans le sens des aiguilles d'une
montre (+) pour de finir le jeu prescrit de 1 mm.
REMARQUE. Un tour de re gleur donne un jeu de 0,25
mm (1mm=4 tours).
Montare la piastrina di sicurezza (3) e bloccarla con la
vite (2).
Montar la plaqua de seguridad (3) y bloquearla con los
tornillos 829.
Par de serraje: 10v11 Nm
Monter la plaquette de se curite (3), bloquer celle-ci a
l'aide de la vis (2).
Couple de serrage: 10v11 Nm
ITA
ESP
F
ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
f
e
d c
b
a
Voru bergehend den Arm (6) mit den mit Loctite 242
geschmierten Muttern (8) befestigen und Muttern
zuschrauben bis das Aggregat an dem Zentralko rper
anliegt.
Die Ebenheit der Arme mit dem Werkzeug T2 kontroll-
ieren und endgu ltig mit den mit Loctite 242 ge-
schmierten Schrauben (7) befestigen.
Anzugsmoment: 182v202 Nm
BEMERKUNG. Im Kreuz fest drehen.
An das Anschlustu ck "P" der Federspeicherbremse
eine a uere Pumpe schlieen und Druck bei 15v30 bar
einlassen.
Gegen den Uhrzeigersinn () das Kegelrad (4),
drehen, bis kein Spiel zwischen den Bremsscheiben
mehr u brig bleibt. Anzugsmoment: 8v10 Nm.
Das Kegelrad (4) in den Uhrzeigersinn (+) drehen, bis
das vorgeschriebene Spiel von 1 mm erreicht ist.
BEMERKUNG. Eine Umdrehung gleicht einem Spiel
von 0,25 mm (1 mm=4 Umdrehungen).
Die Sicherheitsplatte (3) montieren und mit der
Schraube (2) blockieren.
Anzugsmoment: 10v11 Nm
D D
D D
D D
18.5 Axle DANA 193
BOMAG 960 008 911 79
MANUAL EMERGENCY RELEASE
Loosen nuts (24) of screws (25) provided for the mechanical and
manual release of the braking units, then move the nuts backwards
by approx. 8 mm.
Tighten screws (25) so as to fasten them onto the pressure plate
(16).
Using a wrench, tighten the screws (25) in an alternate sequence
by 1/4 turn at a time so as to compress the Belleville washers (11)
and disengage the braking disks.
IMPORTANT. Tighten max. by one turn.
ADJUSTMENT AFTER MANUAL RELEASE
Remove screws (25) complete with nuts (24) and seals (26).
Replace seals (26), apply silicone-based Tecno Lupe /101 grease
to the screws (25) and install all parts into the arm.
Adjust screws (25) to obtain a jut of 34
+0.5
mm in relation to the arm. 0 Lock into position with nuts (24).
CAUTION! Hold screws (25) into position while locking the nuts
(24); after locking, check the jut of screws (25) once more.
GB GB
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28
MECHANICAL AND MANUAL RELEASE OF THE AXLE - SBLOCCAGGIO MECCANICO MANUALE DELL'ASSALE -
ACHSE MECHANISCH MANUELL ENTSICHERN - DESBLOQUEO MANUAL DE LOS AXAL -
DEBLOCAGE MECANIQUE MANUEL DE L'ESSIEU
F1241098
D1240133
F1241100
F1241102
F1241099
F1241101
34
+ 0,5
0
Axle DANA 193
BOMAG 961 008 911 79
18.5
29
SBLOCCAGGIO MANUALE D'EMERGENZA
Allentare i dadi (24) delle viti (25) per lo sblocco
meccanico manuale dei gruppi di frenatura e far
arretrare i dadi di circa 8 mm.
DESBLOQUEO MANUAL DE EMERGENCIA
Aflojar las tuercas (24) de los tornillos (25) para el
desbloqueo mecanico manual de los grupos de
frenadura y hacer pasar las tuercas de 8 mm approx.
DEBLOCAGE MANUEL D'EMERGENCE
Desserrer les e crous (24) des vis (25) pour le
deblocage me canique manuel des groupes de frei-
nage en faisant reculer les e crous d'environ 8 mm.
Avvitare le viti (25) fino a mandarle in battuta sullo
spingidisco (16).
Atornillar los tornillos (25) hasta llegar al tope sobre el
empuja-disco (16).
Visser les vis (25) puis les envoyer en bute e sur le
plateau de pression (16).
Utilizzando una chiave, avvitare le viti (25) in modo
alternato di 1/4 di giro alla volta, per comprimere le
molle a tazza (11) e liberare i dischi di frenatura.
IMPORTANTE. Avvitare per max. un giro.
Utilizando una llave, atornillar los tornillos (25) de
manera alternada de 1/4 de giro a la vez, para
comprimir los muelles a taza (11) y librar los discos
de frenadura.
IMPORTANTE. Atornillar por max. un giro.
A l'aide d'une cle , visser les vis (25) alternativement 1/
4 de tour a la fois, pour contraindre le ressort belleville
(11) et de gager les disques de freinage.
IMPORTANT. Visser pour max. un tour.
REGOLAZIONE DOPO LO SBLOCCAGGIO MANUALE
Rimuovere le viti (25) complete dei dadi (24) e delle
guarnizioni (26).
Sostituire le guarnizioni (26), lubrificare le viti (25) con grasso al
silicone Tecno Lupe /101 e montare il tutto nel braccio.
REGULACION DESPUES DEL DESBLOQUEO MANUAL
Remover los tornillos (25) completas de guarniciones
(26).
Sobstituir las guarniciones (26), lubrificar los tornillos (25) con
grasa al silicone Tecno Lupe/101 y montar todo en el eje.
REGLAGE FAISANT SUITE AU DEBLOCAGE MANUEL
Enlever les vis (25) comple tes d'e crous (24) et de
garnitures (26).
Substituer les garnitures (26), lubrifier les vis (25) avec de la graisse
au silicone Tecno Lupe/101, monter le tout dans le bras.
Regolare le viti (25) fino ad avere una sporgenza
rispetto al braccio di 34
+0,5
mm 0
Regular los tornillos (25) hasta obtener una parte
saliente respecto al eje de 34
+0,5
mm 0
Re gler les vis (25) jusqu'a avoir une saillie de 34
+0.5
mm
par rapport au bras.
0
Bloccare la posizione con i dadi (24).
ATTENZIONE! Mantenere la posizione delle viti (25)
quando si bloccano i dadi (24); dopo il bloccaggio,
ricontrollare la sporgenza delle viti (25).
Bloquear la colocacio n con las tuercas (24).
ATENCION! Mantener la posicion de los tornillos (25)
cuando se bloquean las tuercas (24); despues del
bloqueo, recontrolar la parte saliente de los tornillos (25).
Bloquer dans la position a l'aide des e crous (24).
ATTENTION! Tenir les vis (25) en place quand on
bloque les e crous (24); apre s avoir fixe , contro ler la
saillie des vis (25).
ITA
ESP
F
ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
f
e
d c
b
a
MANUELLE NOT-ENTSICHERUNG
Die Muttern (24) der Schrauben (25) zur mechani-
schen manuellen Entsicherung der Bremsaggregate
lockern und die Muttern um 8 mm zuru ck drehen.
Schrauben (25) bis zum Anschlag an die Druckplatte
(16) zudrehen.
Mit einem Schlu ssel, die Schrauben (25) abwechselnd
jeweils um 1/4 Umdrehung zudrehen, um die Tellerfe-
dern (11) einzudru cken und die Bremsscheiben frei-
zusetzen.
WICHTIG. Maximal um eine Umdrehung zuschrauben.
EINSTELLUNG NACH DER MANUELLEN ENTSICHERUNG
Die Schrauben (25) mit den Muttern (24) und den
Dichtungen (26) abnehmen.
Die Dichtungen (26) auswechseln, die Schrauben (25) mit Silikon-
fett Tecno Lupe/101 schmieren und das ganze Teil in den Arm
montieren.
Schrauben (25) einstellen, bis der U
berstand zum Arm

34
+0.5
mm betra gt. 0
Die Position mit den Muttern (24) blockieren.
ACHTUNG! Die Position der Schrauben (25) darf sich
beim Festziehen der Muttern (24) nicht a ndern; nach
der Blockierung den U
berstand der Schrauben (25) nochmals

kontrollieren.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 962 008 911 79
Remove the locking screws (1) of planetary cover (2). Using two screwdrivers or two levers inserted in the slots provided,
pry the planetary cover (2) away from the wheel hub (3).
GB GB a
b
DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU
30
D1240131
F1241103 F1241104
Axle DANA 193
BOMAG 963 008 911 79
18.5
b
a
SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE
NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR
Schrauben (1) abschrauben, die den Deckel des
Planetenradhalters (2) befestigen.
Remover los tornillos (1) de fisaje de la tapa porta-
satelites (2).
Enlever les vis (1) de fixation du couvercle porte-
satellites (2).
Zwei Schraubenzieher oder zwei Hebel in die vorge-
sehenen Nuten stecken und den Deckel (2) des
Planetenradhalters von den Radhalternaben (3) ab-
heben.
Utilizando dos destornilladores o dos palancas inser-
tadas en las ranuras predispuestas, destacar la tapa
lleva-satelites (2) del cubo lleva-rueda (3).
A l'aide de deux tournevis ou de deux leviers dans les
creux pre dispose s, degager le couvercle porte-satel-
lites (2) du moyeu porte-roue (3).
D
ESP
F
D
ESP
F
La remocio n de los semi-ejes puede ser efectuada solo
despues de la remocio n de las tapas lleva-satelites y de
manera deversificada, en funcion del tipo de repara-
cion de efectuar:
1 - Desmontaje con axal montado sobre la maquina colocada sobre
caballetes de seguridad;
2 - Desmontaje con axial desmontado desde la maquina y susten-
tado de apositas herramientas (al banco).
Las explicaciones reportadas se refieren a la remocio n efectuada al
banco, ma las fases son comunes. La rimozione dei semiassi puo essere eseguita solo
dopo la rimozione del coperchio portasatelliti ed in
modo diversificato, in funzione del tipo di riparazione
da eseguire:
1 - Smontaggio con assale montato sulla macchina appoggiata su
cavalletti di sicurezza.
2 - Smontaggio con assale smontato dalla macchina e sostenuto da
apposita attrezzatura (al banco).
Le spiegazioni riportate si riferiscono alla rimozione eseguita al
banco, ma le fasi sono comuni.
Le de gagement des demi-essieux ne peut se faire
qu'apre s avoir enleve le couvercle porte-satellites
d'une fac on diversifie e, en fonction du type de
re parations a effectuer:
1 - De montage essieu monte sur machine de pose e sur des ba tis de
se curite .
1 - De montage essieu de monte de la machine et soutenu par un
outil special (sur banc).
Les explications reporte es se re ferent au de gagement effectue au
banc, mais les phases sont communes.
F
Die Halbachse kann erst abmontiert werden, wenn der
Deckel des Planetenradhalters abgenommen worden
ist; auerdem wird sie je nach Reparatur unterschied-
lich abmontiert:
1 - Mit Achse abmontieren, die an der Maschine montiert und durch
Sicherheitsblo cke gestu tzt ist.
2 - Achse zuerst von der Maschine abmontieren und auf eine
Werkbank legen.
Nachstehende Beschreibung bezieht sich auf das Zerlegen an der
Werkbank, doch ist die Vorgehensweise in beiden Fa llen dieselbe.
D
ESP
The axle shafts can only be removed once the
extraction of the planetary cover has been performed.
Different procedures need to be followed depending on
the kind of repair work required:
1 - Disassembly with axle connected to the machine with machine
resting on safety stands.
2 - Disassembly with the axle disconnected from the machine and
supported by the appropriate equipment (at the bench).
The explanations given herein refer to the removal operation as is
carried out on the bench, but the stages apply to all versions.
ITA
Rimuovere le viti (1) di fissaggio del coperchio
portasatelliti (2).
ITA
Utilizzando due cacciaviti o due leve inserite nelle
cave predisposte, staccare il coperchio portasatelliti
(2) dal mozzo portaruota (3).
ITA
31
GB
18.5 Axle DANA 193
BOMAG 964 008 911 79
Rotate the wheel hub (3) until one of the screw holes (1) appears at
the top.
Apply a "U" piece to the screw hole; connect to a hoist and remove
the cover (2).
Only in case of replacement of component parts not requiring
the disassembly of the crown wheel (5).
Countermark the position between one of the teeth of the axle shaft
(4) and the crown wheel (5).
Remove the axle shaft (4).
NOTE. The removal of the axle shaft allows for the substitution of
the snap ring as described in the following paragraphs.
Loosen the screws (6) and remove them.
Remove the safety flange (7). Partially tighten five of the ten screws (6) in an alternate and
proportional manner.
Using an extractor and applying a counter pressure to the screws
(6), disengage the crown wheel (5) from the hub (3).
GB GB
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F1241105 F1241106
F1241108
F1241110
F1241107
F1241109
Axle DANA 193
BOMAG 965 008 911 79
18.5
33
Ruotare il mozzo portaruota (3) fino a portare un foro
per le viti (1) in posizione alta.
Applicare un grillo ad "U" nel foro vite; collegare un
mezzo di sollevamento e rimuovere il coperchio (2).
Girar el cubo lleva-rueda (3) hasta hacer un agujero
para los tornillos (1) en posicio n alta.
Aplicar un grillo a "U" en el agujero tornillos; conectar
un medio de levantamiento y remover la tapa (2).
Tourner le moyeu porte-roue (3) jusqu'a a amener un
des trous pour les vis (1) en haut.
Appliquer une manille en "U" dans le trou de vis;
appliquer un moyen de relevage et enlever le couvercle (2).
Solo se si devono sostituire dei componenti che
non richiedono lo smontaggio della corona (5).
Contrassegnare la posizione tra un dente del semias-
se (4) e la corona (5).
Solo si se deben de sobstituir algunos componentes
que no comportan el desmontaje de la corona (5).
Senalar la colocacio n entre un diente del semi-eje (4) y
la corona (5).
Uniquement si on doit substituer des composants qui
ne veulent pas le de montage de la couronne (5).
Marquer la position entre une dent du demi-essieu (4)
et la couronne (5).
Asportare il semiasse (4).
NOTA. L'asportazione del semiasse permette la
sostituzione dell'anello di tenuta come descritto di
seguito.
Sacar el semi-eje (4).
NOTA. Sacar el semi-eje permite la sobstitucio n del
anillo de tenida como descrito a seguir.
Enlever le demi-essieu (4).
REMARQUE. Le de gagement du demi-essieu consent
la substitution de l'anneau d'e tanche ite comme de crit
par la suite.
Allentare le viti (6) ed asportarle.
Aflojar los tornillos (6) y sacarlos.
Desserrer les vis (6) puis les enlever.
Asportare la flangia di sicurezza (7).
Sacar la arandela de seguridad (7).
Enlever la flasque de se curite (7).
Avvitare parzialmente, in modo alternato ed in uguale
misura, cinque delle dieci viti (6).
Utilizzando un estrattore e facendo reazione sulle viti
(6) disimpegnare la corona (5) dal mozzo (3).
Atornillar parcialmente, de manera alternada y en
igual mesera, cinco de las diez tornillos (6).
Utilizando un extractor y haciendo reacio n sobre los
tornillos (6) desempenar la corona (5) del cubo (3).
Visser partiellement, en alternance et de la me me
facon cinq des dix vis (6).
A l'aide d'un extracteur, tout en faisant reagir les vis
(6), de gager la couronne (5) du moyeu (3).
ITA
ESP
F
ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
f
e
d c
b
a
Die Radhalternabe (3) drehen bis ein Loch fu r die
Schrauben (1) in der oberen Position liegt.
Einen U-fo rmigen Bu gel in das Schraubenloch stecken; ein
Hebezeug anschlieen und den Deckel (2) abnehmen.
Nur wenn Bestandteile ausgewechselt werden
mussen, fur die der Kranz (5) nicht abmontiert
werden mu.
Die Position zwischen einem Zahn der Halbachse (4) und dem
Kranz (5) markieren.
Die Halbachse (4) abnehmen.
BEMERKUNG. Bei abgenommener Halbachse kann
der Dichtring, wie nachstehend beschrieben, ausge-
wechselt werden.
Schrauben (6) abschrauben.
Sicherheitsflansch (7) abnehmen. Abwechselnd und im gleichen Ma fu nf von den zehn
Schrauben (6) zuschrauben.
Mit einem Abzieher den Kranz (5) aus der Nabe (3)
ziehen und dabei auf die Schrauben (6) wirken.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 966 008 911 79
Remove screws (6) and crown wheel (5). Sling the hub (3) and connect it to a hoist; partially tighten a screw
(6) and with the help of a hammer, shift the hub (3) and the external
bearing (8).
Remove the bearing (8) and the hub (3). Extract the hub (3) complete with snap ring (9) and internal bearing
(10).
Using an extractor, remove at the same time the snap ring (11) and
the centring ring (12).
NOTE. Note down the direction of assembly of snap and centring
rings.
Remove the safety spring rings (13) of the planetary gears (14).
GB GB
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34
F1241111 F1241112
F1241114
F1241116
F1241113
F1241115
Axle DANA 193
BOMAG 967 008 911 79
18.5
35
Rimuovere le viti (6) e la corona (5).
Remover los tornillos (6) y la corona (5).
Enlever les vis (6) et la couronne (5).
Imbragare il mozzo (3) e collegarlo ad un mezzo di
sollevamento; avvitare parzialmente una vite (6) e, con
un mazzuolo, smuovere il mozzo (3) ed il cuscinetto
esterno (8).
Atar el cubo (3) y conectarlo a un medio de
levantamiento; atornillar parcialmente un tornillo (6)
y, con un martillo, mover el cubo (3) y el cojinete
externo (8).
Elinguer le moyeu (3) puis relier celui-ci a un moyen de
relevage; visser partiellement une vis (6), puis a l'aide
d'un maillet, bouger le moyeu (3) et le palier externe
(8).
Rimuovere il cuscinetto (8) ed il mozzo (3).
Remover el cojinete (8) y el cubo (3).
Enlever le palier (8) et le moyeu (3).
Asportare il mozzo (3) completo di anello di tenuta (9) e
cuscinetto interno (10).
Sacar el cubo (3) completo de anillo de retencio n (9) y
cojinete interno (10).
Enlever le moyeu (3) complet de bague d'e tanche ite
(9) et de palier interne (10).
Utilizzando un estrattore, rimuovere contemporanea-
mente l'anello di tenuta (11) e l'anello centratore (12).
NOTA. Annotare il senso di montaggio degli anelli di
tenuta e di centratura.
Utilizando un extractor, remover contemporaneamen-
te el anillo de retencion (11) y el anillo centrador (12).
NOTA. Anotar el sentido de montaje de los anillos de
retencio n y de centraje.
A l'aide d'un extracteur enlever en me me temps
l'anneau d'e tanche ite (11) et l'anneau centreur (12).
REMARQUE. Prendre note du sens de montage des
anneaux d'etanche ite et de centrage.
Rimuovere gli anelli elastici (13) di ritegno satelliti (14).
Remover los anillos elasticos (13) de retencio n
satelites (14).
Enlever les anneaux ressorts (13) de fixation des
satellites (14).
ITA
ESP
F
ESP
F
ITA
ESP
F
ITA
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F
ITA
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F
ITA
ESP
F
ITA
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a
Schrauben (6) und Kranz (5) abnehmen. Nabe (3) anschlagen und an ein Hebezeug befestigen;
Schrauben (6) etwas zudrehen und mit einem Ham-
mer die Naben (3) und das a uere Lager (8) bewegen.
Lager (8) und Nabe (3) abnehmen. Nabe (3) samt Dichtring (9) und inneres Lager (10)
abnehmen.
Mit einem Abzieher gleichzeitig den Dichtring (11) und
den Zentrierring (12) abnehmen.
BEMERKUNG. Montagerichtung der Dicht- und Zen-
trierringe notieren.
Kolbenringe (13) und Planetenhalter (14) abnehmen.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 968 008 911 79
Remove the planetary gears (14).
NOTE. Note down direction of assembly of planetary gears.
Only if necessary.
Using an extractor, remove the shim washer (15) from the planet
carrier.
Remove the snap ring (9) from the hub (3).
NOTE. Note down direction of assembly.
CAUTION! The snap ring may not be reused.
Remove the internal bearing (10).
Remove the external thrust blocks of bearings (8) and (10), using a
pin-driver.
NOTE. Hammer in an alternate sequence to prevent crawling and
deformation of the thrust blocks.
GB GB
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GB GB
a
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F1241117 F1241118
F1241120 F1241119
F1241121
Axle DANA 193
BOMAG 969 008 911 79
18.5
37
Asportare gli ingranaggi satelliti (14).
NOTA. Annotare il senso di montaggio dei satelliti.
Sacar los engranajes satelites (14).
NOTA. Anotar el sentido de desmontaje de los
satelites.
Enlever les engrenages satellites (14).
REMARQUE. Prendre note du sens de montage.
Solo se necessario.
Utilizzando un estrattore, rimuovere dal portasatelliti la
rondella di rasamento (15).
Solo si necesario.
Utilizando un extractor, remover del lleva-satelites la
arandela de rasamiento (15).
Uniquement si besoin.
A l'aide d'un extracteur, enlever du porte-satellite la
rondelle de rasage (15).
Rimuovere dal mozzo (3) l'anello di tenuta (9).
NOTA. Annotare il senso di montaggio.
ATTENZIONE! L'anello di tenuta non puo essere
riutilizzato.
Remover del cubo (3) los anillos de retencio n (9).
NOTA. Anotar el sentido de montaje.
ATENCION! El anillo de retencio n no puede ser
reutilizado.
Oter du moyeu (3) l'anneau d'e tanche ite (9).
REMARQUE. Prendre note du sens de montage.
ATTENTION! L'anneau d'e tanche ite ne peut pas e tre
re utilise .
Rimuovere il cuscinetto interno (10).
Remover el cojinete interior (10).
Enlever le palier interne (10).
Rimuovere le ralle esterne dei cuscinetti (8) e (10)
utilizzando un cacciaspine.
NOTA. Battere in modo alternato per evitare impunta-
menti e deformazioni delle ralle.
Remover las ranguas externas de los cojinetes (8) y
(10) utilizando un extractor de clavijas.
NOTA. Pegar de manera alternada para evitar
empuntamientos y deformacio nes de las ranguas.
Enlever les crapaudines externes des paliers (8) et
(10) a l'aide d'un chasse-clou.
REMARQUE. Donner des coups alterne s pour e viter
talonnages et de formations des crapaudines.
ITA
ESP
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ESP
F
ITA
ESP
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ITA
ESP
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ITA
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ITA
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ITA
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Planetengetriebe (14) abnehmen.
BEMERKUNG. Montagerichtung notieren.
Nur wenn notwendig.
Mit einem Abzieher vom Planetenradhalter die Zwi-
schenlegscheibe (15) abnehmen.
Von der Nabe (3) den Dichtring (9) abnehmen.
BEMERKUNG. Montagerichtung notieren.
ACHTUNG! Der Dichtring darf nicht wieder verwendet
werden.
Das innere Lager (10) abnehmen.
Die a ueren Scheiben (8) und (10) mit einem Du bel
abnehmen.
BEMERKUNG. Abwechselnd schlagen, um ein Durch-
schlagen und Verformungen der Scheiben zu vermeiden.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 970 008 911 79
Position the wheel hub (3) under a press; lubricate the seat of the
external bearing and, using tool T3, install the thrust block of the
bearing (10).
Install the bearing (10).
Apply an appropriate sealant to the outer surface of the snap ring
(9).
Position the snap ring (9) into the hub (3).
NOTE. Check orientation of the ring.
Position tool T4 and press the snap ring (9) down into its seat. Turn the hub (3) upside down, lubricate the seat of the bearing and,
using tool T3, install the thrust block of the bearing (8).
Only if shim washer has previously been removed.
Apply a sealant for removable seals to the outer surface of the shim
washer (15) and, using a driver, fit it into the planetary gear cover
(2).
Fit the planetary gear (14) onto the planetary gear cover (2).
CAUTION! The jointed portion of the internal ring of the bearings
must face the bottom of the pin.
GB GB
GB GB
GB GB
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ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-
TRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR
F1241122
T3
F1241123
F1241125
T3
F1241117
F1241124
T4
F1241126
Axle DANA 193
BOMAG 971 008 911 79
18.5
39
Posizionare il mozzo ruota (3) sotto una pressa;
lubrificare la sede del cuscinetto esterno e, utilizzando
l'attrezzo T3, montare la ralla del cuscinetto (10).
Colocar el cubo rueda (3) bajo una prensa; lubrificar la
sed del cojinete externo y, utilizando la herramienta
T3, montar la rangua del cojinete (10).
Positionner le moyeu roue (3) sous la presse; lubrifier
le logement du palier externe, puis a l'aide de l'outil
T3, monter la crapaudine du palier (10).
Installare il cuscinetto (10).
Spalmare la superficie esterna dell'anello di tenuta (9)
con sigillante per guarnizioni.
Posizionare l'anello di tenuta (9) nel mozzo (3).
NOTA. Controllare l'orientamento dell'anello.
Colocar el cojinete (10).
Pasar la superficie externa del anillo de retencio n (9)
con sigilante para guarniciones.
Colocar el anillo de retencio n (9) en el cubo (3).
NOTA. Controlar el orientamiento del anillo.
Installer le palier (10).
Enduire la superficie externe de l'anneau d'etanche ite
(9) avec de la colle a garnitures.
Positionner l'anneau d'e tanche ite (9) dans le moyeu (3).
REMARQUE. Contro ler la bonne direction de l'anneau.
Posizionare l'attrezzo T4 e pressare in sede l'anello di
tenuta (9).
Colocar la herramienta y apretar en sed el anillo de
retencio n (9).
Placer l'outil T4 et presser dans son logement
l'anneau d'e tanche ite (9).
Capovolgere il mozzo (3), lubrificare la sede cuscinetto
e, utilizzando l'attrezzo T3, montare la ralla del
cuscinetto (8).
Volcar el cubo (3), lubrificar la sed cojinete y,
utilizando la herramienta T3, montar la rangua del
cojinete (8).
Faire basculer le moyeu (3), lubrifier le logement du
palier, puis a l'aide de l'outil T3, monter la crapaudine
dans le palier (8).
Solo se e stata rimossa.
Spalmare la superficie esterna della rondella di
rasamento (15) con sigillante per guarnizioni removibili
e, utilizzando uno spintore, montarla nel coperchio portasatelliti (2).
Solo si ha sido desplazada.
Pasar la superficie externa de la arandela de
rasamiento (15) con sigilante para guarnicio nes
removibles y, utilizando un empuje, montarla en la tapa lleva-
satelites (2).
Uniquement si elle a e te enleve e.
Enduire la superficie externe de la rondelle de rasage
(15) avec de la colle pour garnitures amovibles, a
l'aide d'un poussoir monter celle-ci dans le couvercle porte-
satellites (2).
Montare sui perni del coperchio portasatelliti (2) gli
ingranaggi planetari (14).
ATTENZIONE! La parte raccordata dell'anello interno
dei cuscinetti deve essere rivolta verso il fondo del perno.
Montar sobre los pernos de la tapa lleva-satelites (2)
los engranajes planetares (14).
ATENCION! La parte empalmada del anillo interno de
los cojinetes debe de ser dirijida hacia el fondo de la rotula.
Monter sur les pivots du couvercle porte-satellites (2)
les engrenages plane taires (14).
ATTENTION! La partie raccorde e de l'anneau a
l'inte rieur du palier doit e tre tourne e vers la partie basse du pivot.
ITA
ESP
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ESP
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ITA
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ITA
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ITA
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Die Radnabe (3) unter eine Presse positionieren; den
Sitz des a ueren Lagers schmieren und mit dem
Werkzeug T3 die Scheibe des Lagers (10) montieren.
Lager (10) installieren.
A
uere Fla che des Dichtringes (9) mit etwas Dicht-

masse schmieren.
Dichtring (9) in die Nabe (3) positionieren.
BEMERKUNG. Richtung des Ringes kontrollieren.
Das Werkzeug T4 positionieren und den Dichtring (9)
in seinen Sitz dru cken.
Die Nabe (3) wenden, den Lagersitz schmieren und
mit dem Werkzeug T3 die Nabe des Lagers (8)
montieren.
Nur wenn zuvor abgenommen.
A
uere Fla che der Zwischenlegscheibe (15) mit

Dichtmasse fu r abnehmbare Dichtungen schmieren
und mit einem Sto el diese Zwischenlegscheibe in den Deckel des
Planetenradhalters (2) montieren.
Auf die Stifte des Deckels des Planetenradhalters (2)
die Planetengetriebe (14) montieren.
ACHTUNG! Das Anschlustu ck des inneren Lagerrin-
ges mu zur unteren Seite des Stiftes gerichtet sein.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 972 008 911 79
Lock into position the planetary gears (14) with the snap rings (13). Lubricate and fit the centring ring (12) and snap ring (11) onto tool
T5; install the rings into the arm.
CAUTION! Pay particular attention to the direction of assembly of
the rings.
Grease the snap ring (9) and the hub of the arm.
Install the wheel hub (3).
Install the external bearing (8).
NOTE. Move the bearing to the limit stop by hammering lightly all
around the edge.
Install the crown wheel (5) and, using a driver with adequate
diameter, fasten it onto the hub of the arm.
Using Tecno Lupe /101, grease the surface of the safety flange (7)
that touches the crown wheel.
GB GB
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F1241127 F1241128
T5
F1241113
F1241109
F1241114
F1241129
Axle DANA 193
BOMAG 973 008 911 79
18.5
41
Fissare la posizione degli ingranaggi satelliti (14) con
gli anelli elastici (13).
Fijar la posicio n de los engranajes satelites (14) con
los anillos elasticos (13).
Fixer les engrenages porte-satellites (14) a leur place
avec les anneaux ressorts (13).
Lubrificare e montare sull'attrezzo T5 l'anello centra-
tore (12) e l'anello di tenuta (11); montare gli anelli nel
braccio.
ATTENZIONE! Controllare attentamente il senso di montaggio
degli anelli.
Lubrificar y montar sobre la herramienta T5 el anillo
central (12) y el anillo de retencio n (11); montar los
anillos en el eje.
ATENCION! Controlar atentamente el sentido de montaje de los
anillos.
Lubrifier et monter sur l'outil T5 l'anneau centreur (12)
et l'anneau d'e tanche ite (11); monter les anneaux
dans le bras.
ATTENTION! Contro ler attentivement le sens du montage des
anneaux.
Lubrificare con grasso l'anello di tenuta (9) ed il mozzo
del braccio.
Montare il mozzo portaruota (3).
Lubrificar con grasa el anillo de retencio n (9) y el cubo
del eje.
Montar el cubo lleva-rueda (3).
Lubrifier avec de la graisse l'anneau d'e tanche ite (9),
le moyeu du bras.
Monter le moyeu porte-roue (3).
Montare il cuscinetto esterno (8).
NOTA. Mandare a fondo corsa il cuscinetto con
leggeri colpi di mazzuolo distribuiti su tutta la
circonferenza.
Montar el cojinete esterno (8).
NOTA. Mandar a tope el cojinete con ligeros colpes de
martillo repartidos sobre toda la circonferencia.
Monter le palier externe (8).
REMARQUE. Envoyer en bute e le palier avec de
legers coups de maillet distribue s tout autour de la
circonfe rence.
Montare la corona (5) e, utilizzando uno spintore di
diametro adatto, mandarla in battuta sul mozzo del
braccio.
Montar la corona (5) y, utilizando un empuje de
diametro apto, mandarla a tope sobre el cubo del eje.
Monter la couronne (5), puis a l'aide d'un poussoir
d'un diame tre adapte , envoyer celle-ci en bute e sur le
moyeu du bras.
Lubrificare con grasso Tecno Lupe /101 la superficie
della flangia di sicurezza (7) a contatto con la corona.
Lubrificar con grasa Tecno Lupe/101 la superficie de
la brida de seguridad (7) a contacto con la corona.
Lubrifier avec de la graisse Tecno Lupe/ 101 la
superficie de la flasque de se curite (7) au contact de
la couronne.
ITA
ESP
F
ESP
F
ITA
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Die Position der Planetengetriebe (14) mit den
Kolbenringen (13) festigen.
Das Werkzeug T5 schmieren und darauf den Zen-
trierring (12) und den Dichtring (11) montieren; die
Ringe in den Arm montieren.
ACHTUNG! Montagerichtung der Ringe sorgfa ltig kontrollieren.
Mit Fett den Dichtring (9) und die Armnabe schmieren.
Radhalternabe (3) montieren.
A
ueres Lager (8) montieren.

BEMERKUNG. Das Lager bis zum Anschlag mit
leichten Hammerschla gen an der gesamten Kreislinie
einsetzen.
Den Kranz (5) montieren und mit einem geeigneten
Sto el den Kranz bis zum Anschlag an der Armnabe
einsetzen.
Mit Fett Typ Tecno Lupe/ 101 die Fla che des Sicher-
heitsflanschs (7), der am Kranz anliegt, schmieren.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 974 008 911 79
Coat the screws (6) with Loctite 270 and screw them.
Tighten screws (6) in two stages, using the criss-cross method.
Initial torque wrench setting: 120 Nm
Final torque wrench setting: 219 242 Nm
Lubricate the snap ring (11), the toothed portions and the sealing
surface of the axle shaft.
Install the axle shaft (4), making sure that it is properly inserted into
braking disks and differential unit.
Fit the planetary gear cover (2) onto the wheel hub (3).
CAUTION! 1 - Check the condition and position of the O-ring (16).
2 - Line up the locating release points.
Lock the planetary gear cover (2) onto the wheel hub (3) with
screws (1).
Screws torque wrench setting: 40 0 Nm.
GB GB
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GB GB
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F1241130 F1241107
F1241132 F1241131
Axle DANA 193
BOMAG 975 008 911 79
18.5
43
Spalmare le viti (6) con Loctite 270 ed avvitarle.
Serrare le viti (6) in due tempi e con il metodo del
serraggio incrociato.
Coppia di serraggio iniziale: 120 Nm
Coppia di serraggio finale: 219v242 Nm
Pasar los tornillos (6) con Loctite 270 y atornillarlos.
Apretar los tornillos (6) en doss tiempos con el metodo
de torsion cruzada.
Par de torsion inicial: 120 Nm.
Par de torsion final: 219v242 Nm.
Enduire les vis (6) avec du Loctite 270 puis visser.
Serrer les vis (6) en deux temps avec la me thode du
serrage croise .
Couple de serrage initial: 120Nm
Couple de serrage final: 219v242 Nm.
Lubrificare l'anello di tenuta (11), le dentature e la
superficie di tenuta del semiasse.
Montare il semiasse (4) assicurandosi che si innesti
nei dischi freni e nel differenziale.
Lubrificar el anillo de retencio n (11), las dentaduras y
la superficie del semieje.
Montar el semieje (4) asegurandose que se encaje en
los discos y en el diferencial.
Lubrifier l'anneau d'e tanche ite (11), les dents, la
superficie e tanche des demi-essieux.
Monter le demi-essieu (4) en veillant a ce qu'il
s'enclenche bien dans les disques freins et dans le diffe rentiel.
Montare il coperchio portasatelliti (2) sul mozzo
portaruota (3).
ATTENZIONE! 1 - Controllare lo stato e la posizione
della guarnizione OR (16).
2 - Allineare gli scarichi di riferimento.
Montar la tapa lleva-satelites (2) sobre el cubo lleva-
rueda (3).
ATENCION! 1 - Controlar el estado y la posicion de la
guarnicio n OR (16).
2 - Alinear los descarges de referencia.
Monter le couvercle porte-satellite (2) sur le moyeu
porte-roue (3).
ATTENTION! 1 - Contro ler l'e tat et la position des
garnitures O'Ring (16).
2 - Aligner les points de de charge de re fe rence.
Bloccare il coperchio portasatelliti (2) sul mozzo
portaruota (3) con le viti (1).
Coppia di serraggio viti: 40v50 Nm
Bloquear la tapa lleva-satelietes (2) sobre el cubo
lleva-rueda (3) con los tornillos (1).
Par de torsion tornillos: 40v50 Nm
Bloquer le couvercle porte-satellite (2) sur le moyeu
porte-roue (3) a l'aide des vis (1).
Couple de serrage des vis: 40v50 Nm.
ITA
ESP
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ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
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F
ITA
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F
ITA
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Die Schrauben (6) mit Loctite 270 schmieren und
festschrauben.
Schrauben (6) im Kreuz schrittweise festziehen.
Anzugsmoment zuerst: 120Nm
Anzugsmoment am Ende: 219v242 Nm
Dichtring (11), Za hne und Dichtfla che der Halbachse
schmieren.
Halbachse (4) montieren und darauf achten, da sie in
die Bremsscheiben und in das Differential einrastet.
Den Deckel des Planetenradhalters (2) auf die Nabe
des Radhalters (3) montieren.
ACHTUNG! 1 - Zustand und Position der O-Ringe (16)
kontrollieren.
2 - Die Bezugsstellen bzw. Ablao ffnung fluchten.
Den Deckel des Planetenradhalters (2) an der Rad-
halternabe (3) mit den Schrauben (1) blockieren.
Anzugsmoment der Schrauben: 40v50 Nm
D D
D D
D D
18.5 Axle DANA 193
BOMAG 976 008 911 79
REMOVAL OF THE DIFFERENTIAL UNIT
Remove the whole arms, the cylinders, and the whole reduction
unit.
For details, see CHECKING WEAR AND REPLACING THE
BRAKING DISKS and REMOVAL OF REDUCTION GEAR.
Apply tool T6 - for crown wheel side centring - with relative distance
pieces and lock it with two nuts.
Apply centring tool T7A as well.
Remove the stud screws and remove the intermediate cover (1) on
the crown wheel opposite side.
Install centring tool T7B on the opposite side of the crown wheel.
Remove centring tools T6 and T7A from crown wheel side; remove
the studs and the intermediate cover (2) on the crown wheel side.
Position a stop block A made from tender material (aluminium,
etc.) between the main body (3) and the toothed portion of the
crown wheel (4).
With the crown (4) resting on block "A", remove and extract the
screws (5) and the spring washers (6).
GB GB
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REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE -
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL
F1241141 F1241142
T7A
T6
F1241144
T7B
F1241146
A
T7B
F1241143
F1241145
Axle DANA 193
BOMAG 977 008 911 79
18.5
45
RIMOZIONE DIFFERENZIALE
Rimuovere i bracci completi, i cilindri freni ed il
riduttore completo.
Per i dettagli, vedere CONTROLLO USURA E SOSTITUZIONE
DISCHI FRENO e RIMOZIONE RIDUTTORE.
REMOCION DIFERENCIAL
Remover los ejes completos, los cilindros frenos y el
reductor completo.
Para los detalles, vease CONTROL DESGASTE Y SOBSTITU-
CION DISCOS FRENOS y REMOCION REDUCTOR.
DEGAGEMENT DU DIFFERENTIEL
Enlever les bras entie rement, les cylindres freins et le
re ducteur tout entier.
Pour de plus amples de tails, voir "CONTROLE DE L'USURE ET
SUBSTITUTION DU DISQUE FREIN" et "DEGAGEMENT DU
REDUCTEUR".
Applicare l'attrezzo T6 di centraggio dal lato corona
con i relativi distanziali e fissarlo con due dadi.
Applicare anche l'attrezzo T7A di centratura.
Aplicar la herramienta T6 de centraje del lado corona
con los relativos distanciales y fijarla con dos tuercas.
Aplicar tambien la herramienta T7A de centradura.
Appliquer l'outil T6 de centrage du co te couronne
avec les entretoises correspondantes et fixer l'outil
avec deux e crous.
Appliquer egalement l'outil de centrage T7A.
Rimuovere le viti prigioniere e rimuovere il coperchio
intermedio (1) dal lato opposto corona.
Remover los tornillos prigioneros y remover la tapa
intermedia (1) del lado opuesto corona.
Enlever les vis prisonnieres et enlever le couvercle
interme diaire (1) du co te oppose a la couronne.
Montare l'attrezzo T7B di centraggio sul lato opposto
corona.
Montar la herramienta T7B de centraje sobre el lado
opuesto corona.
Monter l'outil de centrage T7B du co te oppose a la
couronne.
Rimuovere gli attrezzi T6 e T7A di centraggio del lato
corona; asportare i prigionieri e rimuovere il coperchio
intermedio (2) lato corona.
Remover las herramientas T6 y T7A de centraje del
lado corona; sacar los prigioneros y remover la tapa
intermedia (2) lado corona.
Enlever les outils T6 et T7A de centrage du co te
couronne; enlever les prisonniers et de placer le
couvercle interme diaire (2) du co te couronne.
Posizionare tra il corpo centrale (3) e la dentatura della
corona (4) un blocchetto "A" di contrasto in materiale
tenero (alluminio ecc.).
Mantenendo in appoggio la corona (4) sul blocchetto "A",
rimuovere ed asportare le viti (5) e le rondelle elastiche (6).
Colocar entre el cuerpo central 83) y la dentadura de
la corona (4) un bloque "A" de contraste de material
tierno (aluminio ect.).
Manteniendo en apoyo la corona (4) sobre el bloque "A", remover y
sacar los tornillos (5) y las arandelas elasticas (6).
Placer entre le corps central (3) et la denture de la
couronne (4) un petit bloc "A" en mate riel le ger
(aluminium etc.) de contraste.
En maintenant la couronne (4) sur le petit bloc "A", devisser et
enlever les vis (5), et ensuite les rondelles e lastiques (6).
ITA
ESP
F
ESP
F
ITA
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DIFFERENTIAL ABNEHMEN
Die kompletten Arme, die Bremszylinder und den
kompletten Reduzierer abnehmen.
Siehe VERSCHLEISS KONTROLLIEREN UND BREMSSCHEI-
BEN AUSWECHSELN und REDUZIERER ABNEHMEN.
Das Werkzeug T6 zur Zentrierung an der Kranzseite
mit den entsprechenden Distanzstu cken anbringen
und das Werkzeug mit zwei Muttern befestigen.
Das Werkzeug T7A zur Zentrierung anbringen.
Die Stiftschrauben und den Zwischendeckel (1) von
der dem Kranz entgegengesetzte Seite abnehmen.
Das Werkzeug T7B zur Zentrierung an der dem Kranz
entgegengesetzte Seite montieren.
Die Werkzeuge T6 und T7A zur Zentrierung an der
Kranzseite entfernen; die Stiftschrauben und den
Zwischendeckel (2) an der Kranzseite abnehmen.
Zwischen dem Zentralkorper (3) und den Za hnen des
Kranzes (4) den Block "A" aus weichem Material
(Aluminium usw.) legen.
Den Kranz (4) am Block "A" anliegen lassen und die Schrauben (5)
und die Federscheiben (6) abnehmen.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 978 008 911 79
Using a driver, push the differential unit (7) or (8) towards the
opposite side of the crown so as to disengage it from the crown (4).
Extract the whole differential unit (7) or (8).
Remove tool T7B from the crown opposite side. Extract the crown (4).
DISASSEMBLY OF THE DIFFERENTIAL UNIT
Using an extractor, remove bearings (9) from the differential unit.
DISASSEMBLY OF THE NO-SPIN DIFFERENTIAL UNIT
Insert stay "B" provided for holding into position the no-spin unit
(14) and screw tight the wing nut.
GB GB
GB GB
GB GB
a
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c d
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46
F1241147 F1241148
F1241174
F1241150
B
F1241223
T7B
F1241149
Axle DANA 193
BOMAG 979 008 911 79
18.5
47
Utilizzando uno spintore, spingere il differenziale (7) o
(8) verso il lato opposto corona fino a disimpegnarlo
dalla corona (4).
Utilizando un empuje, empujar el diferencial (7) o (8)
hacia el lado opuesto corona hasta desempenarlo de
la corona (4).
A l'aide d'un poussoir, pousser le differentiel (7) ou (8)
du co te oppose a la couronne jusqu'a le de gager de la
couronne (4).
Estrarre il gruppo differenziale (7) o (8) completo.
Sacar el grupo diferencial (7) o (8) completo.
Extraire le groupe diffe rentiel (7) ou (8) tout entier.
Rimuovere l'attrezzo T7B montato sul lato opposto
corona.
Remover la herramienta T7B montado sobre el lado
opuesto corona.
De placer l'outil T7B monte du co te oppose a la
couronne.
Estrarre la corona (4).
Extraer la corona (4).
Extraire la couronne (4).
SMONTAGGIO DIFFERENZIALE
Utilizzando un estrattore, asportare i cuscinetti (9) dal
gruppo differenziale.
DESMONTAJE DIFERENCIAL
Utilizando un extractor, sacar los cojinetes (9) del
grupo diferencial.
DEMONTAGE DU DIFFERENTIEL
A l'aide d'un extracteur, enlever les paliers (9) du
groupe diffe rentiel.
SMONTAGGIO DIFFERENZIALE NO-SPIN
Inserire il tirante "B" di trattenimento del gruppo no-
spin (14) ed avvitare a fondo il dado ad alette.
DESMONTAJE DIFERENCIAL NO-SPIN
Introducir el tirante "B" de detencion del grupo no-spin
(14) y atornillar hasta el fondo la tuerca a aletas.
DEMONTAGE DU DIFFERENTIEL NO-SPIN
Introduire la tringle "B" de retenue du groupe no-spin
(14), puis visser l'e crou a ailettes a fond.
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Mit einem Sto el das Differential (7) oder (8) in die dem
Kranz entgegengesetzte Seite dru cken und aus dem
Kranz (4) freisetzen.
Das komplette Differentialaggregat (7) oder (8) ab-
ziehen.
Das Werkzeug T7B abnehmen, das an der dem Kranz
entgegengesetzte Seite montiert ist.
Kranz (4) abziehen.
DIFFERENTIAL ABMONTIEREN
Mit einem Abzieher die Lager (9) vom Differentialag-
gregat abnehmen.
DAS NO-SPIN DIFFERENTIAL ABMONTIEREN
Sie Spannstange "B" einsetzen, um das No-Spin
Aggregat (14) festzuhalten und die Flu gelmutter fest-
ziehen.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 980 008 911 79
Remove the screws (10) and the spring washers (11) jointing the
differential unit half box (12).
Using a plastic hammer, take the half box (12) to pieces.
NOTE. Note down the coupling marks.
Extract the no-spin unit (13). Unscrew the wing nut of stay "B" and take the no-spin unit to
pieces in order to remove the distance piece (14) that prevents the
axial sliding of the axle shafts.
DISASSEMBLY OF THE 45% SELF-LOCKING DIFFERENTIAL UNIT
Remove the screws (16) and the spring washers (17) jointing the
differential unit.
Remove the differential cover (18), any shims (19) and the friction
(20) complete with ring (21).
CAUTION! 1 - Do not change the position of the disks forming the
friction.
2 - Check that the overall thickness of friction exceeds 17.3 mm; if
lower, substitute both friction units.
GB GB
GB GB
GB GB
a
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F1241151 F1241152
F1241154
F1241156
F1241153
F1241155
Axle DANA 193
BOMAG 981 008 911 79
18.5
49
Rimuovere le viti (10) e le rondelle elastiche (11) di
unione della semiscatola differenziale (12).
Remover los tornillos (10) y las arandelas elasticas
(11) de union de la semi-caja diferencial (12).
Enlever les vis (10) et les rondelles elastiques (11)
d'union de la moitie du bo tier diffe rentiel (12).
Utilizzando un mazzuolo in materiale plastico scom-
porre la semiscatola differenziale (12).
NOTA. Annotare la marcatura di accoppiamento.
Utilizando un martillo en material plastico decomponer
la semicaja diferencial (12).
NOTA. Anotar la marcatura de acoplamiento.
A l'aide d'un maillet en matie re plastique de composer
la moitie du bo tier diffe rentiel (12).
REMARQUE. Prendre note de la marque d'accou-
plement.
Estrarre il gruppo no-spin (13).
Sacar el grupo no-spin (13).
Extraire le groupe no-spin (13).
Svitare il dado ad alette del tirante "B" e scomporre il
gruppo no-spin per rimuovere il distanziale (14) contro
lo scorrimento assiale dei semiassi.
Destornillar la tuerca a aletas del tirante "B" y
decomponer el grupo no-spin para remover el distan-
cial (14) contra el deslizamiento axial de los semi-ejes.
De visser l'e crou a ailettes de la tringle "B" et
de composer le groupe no-spin pour enlever le
diffe rentiel (14) contre le coulisseau axial des demi-
essieux.
SMONTAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45%
Rimuovere le viti (16) e le rondelle elastiche (17) di
unione del corpo differenziale.
DESMONTAJE DIFERENCIAL AUTOBLOQUEO AL 45%
Remover los tornillos (16) y las arandelas elasticas
(17) de union del cuerpo diferencial.
DEMONTAGE DU DIFFERENTIEL AUTOBLOQUANT A 45%
Enlever les vis (16), les rondelles e lastiques (17)
d'union du corps diffe rentiel.
Rimuovere il coperchio differenziale (18), gli eventuali
spessori (19) e la frizione (20) completa dell'anello (21).
ATTENZIONE! 1 - Non scambiare di posizione i dischi
componenti la frizione.
2 - Controllare che lo spessore totale della frizione sia superiore a
17,3 mm; se e inferiore sostituire ambedue le frizioni.
Remover la tapa diferencial (18), los eventuales
espesores (19) y la fricion (20) completa del anillo (21).
ATENCION! 1 - No cambiar de posicion los discos
componentes la fricion.
2 - Controlar que el espesor total de la fricion sea superior a 17,3
mm; si es inferior sobstituir las dos friciones.
Enlever le couvercle diffe rentiel (18), les e ventuelles
cales (19) et la friction (20) comple te d'anneau (21).
ATTENTION! 1 - Ne pas changer la position des
disques composant la friction.
2 - Controler que la calage total de la friction soit superieur a
17,3 mm; s'il est inferieur substituer les deux frictions.
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Schrauben (10) und Federscheiben (11) abnehmen,
die das halbe Differentialgeha use (12) zusammen
halten.
Mit einem Gummihammer das halbe Differentialge-
hause (12) zerlegen.
BEMERKUNG. Die Kupplungsmarkierung notieren.
Das No-Spin Aggregat (13) abziehen. Die Flu gelmutter der Spannstange "B" abschrauben
und das No-Spin Aggregat zerlegen, um das Differen-
tial (14) an der Achsengleitung der Halbachsen
abnehmen zu ko nnen.
DAS ZU 45% SELBSTHEMMENDE DIFFERENTIAL ABMONTIEREN
Schrauben (16) und Federscheiben (17), die den
Differentialko rper verbinden, abnehmen.
Differentialdeckel (18) und evtl. Unterlegscheiben (19)
und die Kupplung (20) mit dem Ring (21) abnehmen.
ACHTUNG! 1 - Die Position der Kupplungsscheiben
nicht verwechseln.
2 - Die Gesamtstarke der Kupplung mu mehr als 17,3 mm betragen;
sollte dies nicht der Fall sein, beide Kupplungen auswechseln.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 982 008 911 79
Remove the planetary gear (22).
Mark the 37 mm value on a pin-driver; using the same pin-driver,
insert the spring pins (25) into the journals (23) and (24).
NOTE. The spring pins are centred in journals (23) and (24) when
the countermark is lined up with the edge of the body of the
differential unit (26).
Remove the long planetary carrier journal (23) and the two short
journals (24).
Extract the cross journal (27), the planet wheels (28) complete with
shim washers (29) and the second planetary gear (22).
Remove the 2nd friction (20) complete with ring (21). Also remove
any shims (19).
CAUTION! 1 - Do not change the position of the disks forming the
friction.
2 - Check that the overall thickness of friction exceeds 17.3 mm; if
lower, substitute both friction units.
Extract the spring pins (25) from journals (23) and (24). Only if bearings are replaced.
Remove the thrust blocks of bearings (9) from the intermediate
covers (1) and (2).
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F1241157 F1241158
F1241160
F1241162
F1241159
F1241161
Axle DANA 193
BOMAG 983 008 911 79
18.5
51
Rimuovere l'ingranaggio planetario (22).
Segnare su un cacciaspine un contrassegno a 37 mm;
utilizzando lo stesso cacciaspine, inserire nei perni
(23) e (24) le spine elastiche (25).
NOTA. Le spine elastiche sono centrate nei perni (23) e (24)
quando il contrassegno arriva a filo del corpo differenziale (26).
Remover el engranaje planetario (22). Senalizar sobre
un extractor de clavijas un contra-segno a 37 mm;
utilizando el mismo extractor de clavijas, introducir en
los pernos (23) y (24) las clavijas elasticas (25).
NOTA. Las clavijas elasticas son centradas en los pernos (23) y
(24) cuando el contrasegno llega al hilo del cuerpo diferencial (26).
Enlever l'engrenage planetaire (22). Marquer d'une
estampille le chasse-clou a 37 mm; a l'aide de ce me me
chasse-clou, introduire dans les pivots (23) et (24) les
goupilles elastiques (25).
REMARQUE. Les goupilles elastiques sont centre es dans les pivots
(23) et (24) quand l'estampille atteint le bord du corps diffe rentiel (26).
Rimuovere il perno porta satelliti lungo (23) ed i due
perni corti (24).
Remover la rotula porta satelites largo (23) y las dos
rotulas cortas (24).
Enlever le pivot porte-satellite long (23) et les deux
pivots courts (24).
Estrarre la crociera (27), i satelliti (28) completi delle
rondelle di rasamento (29) ed il 2 ingranaggio
planetario (22).
Sacar la cruceta (27), los satelites (28) completos de
las arandelas de rasamiento (29) y el 2 engranaje
planetario (22).
Extraire le croisillon (27), les satellites (28) complet de
rondelles de rasage (29), puis le 2 engrenage
planetaire (22).
Rimuovere la 2 frizione (20) completa dell'anello (21).
Rimuovere anche gli eventuali spessori (19).
ATTENZIONE! 1 - Non scambiare di posizione i dischi
componenti la frizione.
2 - Controllare che lo spessore totale della frizione sia superiore a
17,3 mm; se e inferiore sostituire ambedue le frizioni.
Remover la 2 fricion (30) completa del anillo (21).
Remover tambien los eventuales espesores (19).
ATENCION! 1 - No cambiar de posicion los discos
componentes la fricion.
2 - Controlar que el espesor total de la fricion sea superior a 17,3 mm;
si es inferior sobstituir las dos friciones.
Enlever la 2 friction (20) comple te d'anneau (21).
Enlever e galement les e ventuelles cales (19).
ATTENTION! 1 - Ne pas changer la position des
disques composant la friction.
2 - Controler que la calage total de la friction soit superieur a
17,3 mm; s'il est inferieur substituer les deux frictions.
Estrarre le spine elastiche (25) dai perni (23) e (24).
Sacar las clavijas elasticas (25) de las rotulas (23) y
(24).
Extraire les goupilles elastiques (25) des pivots (23) et
(24).
Solo se si sostituiscono i cuscinetti
Rimuovere le ralle dei cuscinetti (9) dai coperchi
intermedi (1) e (2).
Solo si se sobstituiyen los cojinetes
Remover las ranguas de los cojinetes (9) de las tapas
intermedias (1) y (2).
Uniquement en cas de substitution des paliers.
Enlever les crapaudines des paliers (9) des couvercles
interme diaires (1) et (2).
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Das Planetengetriebe (20) abnehmen. An einem Du -
bel das Ma von 37 mm markieren; mit diesem Du bel
die Federstifte (25) in die Stifte (23) und (24) einsetzen.
BEMERKUNG. Die Federstifte sind in den Stiften (23) und (24)
zentriert, wenn das markierte Ma auf der Ho he des Differential-
ko rpers (26) liegt.
Den langen Planetenradhalterstift (23) und die beiden
kurzen Planetenradhalterstifte (24) entfernen.
Das Kreuz (27), die Planetengetriebe (28) samt
Zwischenlegscheiben (29) und das 2. Planetengetrie-
be (30) abziehen.
Die 2. Kupplung (20) mit Ring (21) abnehmen.
Eventuelle Unterlegscheiben (19) auch entfernen.
ACHTUNG! 1 - Die Position der Kupplungsscheiben
nicht verwechseln.
2 - Kontrollieren, ob die Gesamtsta rke der Kupplung mehr als 17,3 mm
betra gt; anderenfalls beide Kupplungen auswechseln.
Die Federstifte (25) von den Stiften (23) und (24)
abziehen.
Nur falls die Lager ausgewechselt werden.
Die Scheiben von den Lagern (9) der Zwischendeckel
(1) und (2) abnehmen.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 984 008 911 79
GB GB
GB GB
GB GB
a
b
c d
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52
D1240134
Axle DANA 193
BOMAG 985 008 911 79
18.5
53
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D D
D D
D D
D1240135
18.5 Axle DANA 193
BOMAG 986 008 911 79
ASSEMBLY OF THE NO-SPIN DIFFERENTIAL UNIT
Assemble the no-spin unit (13), inserting the distance piece (14)
and using stay "B".
Fit the no-spin unit into the differential unit half box (15).
Centre the half box (12) and fasten.
CAUTION! Make sure the connection marks coincide.
Fit the spring washers (11) onto the screws (10).
Coat the screws (10) with Loctite 270 and screw tight to form the
differential box. Tighten screws using the criss-cross method and a
torque of 86 89 Nm.
Remove stay "B".
ASSEMBLY OF THE 45% SELF-LOCKING DIFFERENTIAL UNIT
Using a depth gauge, check the shim of friction units complete with
rings (21). If thickness is lower than 17.6 mm, add more shims (19).
CAUTION! Shims must be placed right behind the body of the
differential unit (26).
Insert in the body of the differential unit (26) any required shims
(19) and the friction (20) complete with ring (21).
CAUTION! Ring (21) must touch the planetary gear (22).
GB GB
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REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE -
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL
F1241154 F1241163
F1241150
B
F1241160
F1241164
F1241224
17,6
Axle DANA 193
BOMAG 987 008 911 79
18.5
55
ASSEMBLAGGIO DIFFERENZIALE NO-SPIN
Assemblare il gruppo no-spin (13) inserendo il distan-
ziale (14) ed utilizzando il tirante "B".
MONTAJE DIFERENCIAL NO-SPIN
Asemblaje el grupo no-spin (13) introduciendo el
diferencial (14) y utilizando el tirante "B".
ASSEMBLAGE DU DIFFERENTIEL NO-SPIN
Assembler le groupe no-spin (13) en introduisant
l'entretoise (14), puis a l'aide de la tringle "B".
Montare il gruppo no-spin nella semiscatola differen-
ziale (15).
Centrare la semiscatola (12) e mandarla in battuta.
ATTENZIONE! Controllare che le marcature di accoppiamento
coincidano.
Montar el grupo no-spin en la semi-caja diferencial
(15).
Centrar la semi-caja (12) y mandarla a tope.
ATENCION! Controlar que las marcaduras de acoplamiento
coincidan.
Monter le groupe no-spin dans la moitie du bo tier
diffe rentiel (15).
Centrer la moitie du bo tier (12) et l'envoyer en bute e.
ATTENTION! Contro ler que les estampilles d'accouplement
correspondent.
Infilare sulle viti (10) le rondelle elastiche (11).
Spalmare le viti (10) con Loctite 270 ed avvitarle a
fondo per comporre la scatola differenziale.
Serrare le viti con il metodo incrociato ad una coppia di serraggio di
86v89 Nm.
Insertar sobre tornillos (10) las arandelas elasticas
(11).
Pasar los tornillos (10) con Loctite 270 y atornillar
hasta el fondo para componer la caja diferencial.
Apretar los tornillos con el metodo cruzado y un par de serraje de
86v89 Nm.
Passer sur les vis (10) les rondelles e lastiques (11).
Enduire les vis (10) avec du Loctite 270, puis visser
celles-ci a fond pour recomposer le bo tier diffe rentiel.
Serrer les vis avec la me thode croise e a un couple de serrage de
86v89 Nm.
Rimuovere il tirante "B".
Remover el tirante "B".
Enlever la tringle "B".
ASSEMBLAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45%
Controllare con un calibro di profondita lo spessore
delle frizioni complete degli anelli (21). Se lo spessore
e inferiore a 17,6 mm, aggiungere degli spessori (19).
ATTENZIONE! Gli spessori devono essere posizionati a ridosso del
corpo differenziale (26).
MONTAJE DIFERENCIAL AUTO-BLOQUEO AL 45%
Controlar con un calibro de profundidad el espesor de
las friciones completas de los anillos (21). Si el
espesor es inferior a 17,6 mm, sumar de los espesorees (19).
ATENCION! Los espesores deben de ser colocados detras del
cuerpo diferencial (26).
ASSEMBLAGE DU DIFFERENTIEL AUTOBLOQUANT A 45%
Contro ler a l'aide d'un calibre de profondeur l'e pais-
seur des frictions completes d'anneaux (21). Si le
calage est infe rieur a 17,6 mm, ajouter des cales (19).
ATTENTION! Les cales doivent e tre place es a l'abri du corps
diffe rentiel (226).
Inserire nella corpo differenziale (26) gli eventuali
spessori (19) e la frizione (20) completa dell'anello
(21).
ATTENZIONE! L'anello (21) deve rimanere a contatto dell'ingra-
naggio planetario (22).
Introducir en el cuerpo diferencial (26) los eventuales
espesores (19) y la fricion (20) completa del anillo (21).
ATENCION! El anillo (33) debe quedar a contacto del
engranaje planetario (22).
Introduire le corps diffe rentiel (26), les e ventuelles
cales (19) et la friction (20) comple te d'anneau (21.
ATTENTION! L'anneau (21) doit rester au contact de
l'engrenage planetaire (22).
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NO-SPIN DIFFERENTIAL ZUSAMMENBAUEN
Das No-Spin (13) Aggregat zusammenbauen; dazu
das Distanzstu ck (14) mit der Spannstange "B"
einsetzen.
Das No-Spin Aggregat in das halbe Differentialge-
hause (15) montieren.
Das halbe Geha use (12) zentrieren und bis zum
Anschlag einsetzen.
ACHTUNG! Kontrollieren, ob die Kupplungsmarkierungen u berein-
stimmen.
Federscheiben (11) in die Schrauben (10) einsetzen.
festziehen, um das Differentialgehause zusammenzu-
bauen.
Die Schrauben im Kreuz und mit einem Anzugsmoment von 86v89
Nm festziehen.
Spannstange "B" abnehmen.
ZU 45% SELBSTHEMMENDE DIFFERENTIAL ZUSAMMENBAUEN
Mit Hilfe einer Tiefenlehre die Sta rke der Kupplungen
mit den Ringen (21) messen. Sollte das Ma weniger
als 17,6 mm betragen, noch Unterlegscheiben (19) hinzufu gen.
ACHTUNG! Die Unterlegscheiben mu ssen am Differentialko rper
(26) anliegen.
In den Differentialko rper (26) eventuelle Unterleg-
scheiben (19) und die Kupplung (20) samt Ring (21)
einsetzen.
ACHTUNG! Der Ring (21) mu am Planetengetriebe (22) anliegen.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 988 008 911 79
Install the planetary gear (22) and three of the planet wheels (28),
complete with shim washers (29).
Hold the planet wheels (28) and relative washers (29) into position
with pins (24).
Install the cross journal (27), holding it into position with the long
journal (23).
Before inserting journal (23) completely, install the last planet
wheel (28) and the relative washer (29).
Countermark a point at 25.5 mm on a pin-driver; using the same
pin-driver, engage the journals (23) and (24) with the spring pins
(25).
NOTE. When the countermark is lined up with the edge of the body
of the differential unit (26), the journals are engaged by half.
Install the second planetary gear (22) and the friction (20) complete
with ring (21) and any shims required (19).
CAUTION! Ring (21) must be installed right behind the planetary
gear (22) and the shims (19) right behind the differential cover (18).
Position the differential cover (18).
NOTE. Make sure that the assembly marks coincide.
Fit the spring washers (17) onto the screws (16).
Coat the screws (16) with Loctite 270 and screws tight.
Tighten screws using the criss-cross method and a torque of
135 138 Nm.
GB GB
GB GB
GB GB
a
b
c d
f e
56
F1241165 F1241166
F1241168
F1241170
F1241167
2
5
,
5
F1241169
Axle DANA 193
BOMAG 989 008 911 79
18.5
57
Montare l'ingranaggio planetario (22) e tre degli
ingranaggi satelliti (28) completi di rondelle di rasa-
mento (29).
Mantenere in posizione gli ingranaggi satelliti (28) e le relative
rondelle (29) con i perni (24).
Montar el engranaje planetario (22) y tres de los
engranajes satelites (28) completos de las arandelas
de rasadura (29).
Mantener en posicion los engranajes satelites (28) y las relativas
arandelas (29) con las rotulas (24).
Monter l'engrenage plane taire (22) et trois des
engrenages satellites (28) complets de rondelles de
rasage (29).
Maintenir les engrenages satellites (28) et relatives rondelles (29) a
leur place avec les pivots (24).
Montare la crociera (27) e mantenerla in posizione con
il perno lungo (23).
Prima di inserire completamente il perno (23), montare
l'ultimo satellite (28) e la relativa rondella (29).
Montar la cruceta (27) y mantenerla en posicion con la
rotula larga (28).
Antes de insertar completamente la rotula (23), montar
el ultimo satelite (28) y la relativa arandela (29).
Monter le croisillon (27) et maintenir celui-ci a sa place
a l'aide du pivot long (23).
Avant d'introduire entie rement le pivot (23), monter le
dernier satellite (28) et sa rondelle (29).
Segnare sul cacciaspine un contrassegno a 25,5 mm;
utilizzando lo stesso cacciaspine impegnare i perni
(23) e (24) con le spine elastiche (25).
NOTA. Le spine impegnano meta dei perni quando il contrassegno
arriva a filo del corpo differenziale (26).
Senalar sobre el extractor de clavijas un contra-segno
a 25,5 mm; utilizando el mismo extractor de clavijas
empegnar las rotulas (23) y (24) con las clavijas
elasticas (25).
NOTA! Las clavijas empegnan midad de las rotulas cuando el
contra-segno llega al borde del cuerpo diferencial (26).
Marquer d'une estampille le chasse-clou a 25,5 mm;
a l'aide de ce me me chasse-clou, engager les pivots
(23) et (24) et les goupilles e lastiques (25).
REMARQUE. Les goupilles arrivent a la moitie des pivots quand
l'estampille atteint le bord du corps diffe rentiel (26).
Montare il secondo ingranaggio planetario (22) e la
frizione (20) completa dell'anello (21) e degli eventuali
spessori (19).
ATTENZIONE! L'anello (21) deve essere montato a ridosso
dell'ingranaggio planetario (22) e gli eventuali spessori (19) a
ridosso del coperchio differenziale (18).
Montar el segundo engranaje planetario (22) y la
fricion (20) completa del anillo (21) y de los eventuales
espesores (19).
ATENCION! El anillo (21) debe deser montado detras del
engranaje planetario (22) y los eventuales espesores (19) detras
de la tapa diferencial (18).
Monter le second engrenage plane taire (22), la friction
(20) comple te d'anneau (21) et des eventuelles cales
(19).
ATTENTION! L'anneau (21) est a monter a l'abri de l'engrenage
planetaire (22) et les e ventuelles cales (19) a l'abri du couvercle
diffe rentiel (18).
Posizionare il coperchio differenziale (18).
NOTA. Controllare che le marcature di montaggio
coincidano.
Colocar la tapa diferencial (18).
NOTA. Colocar que las marcaduras de montaje
coincidan.
Mettre le couvercle diffe rentiel (18) en place.
REMARQUE. Contro ler que les estampilles de mon-
tage co ncident.
Infilare sulle viti (16) le rondelle elastiche (17).
Spalmare le viti (16) con Loctite 270 ed avvitarle a
fondo.
Serrare le viti con il metodo incrociato ad una coppia di serraggio di
135v138 Nm.
Introducir sobre los tornillos (16) las arandelas
elasticas (17).
Pasar los tornillos (16) con Loctite 270 y atornillarlos a
fondo.
Apretar los tornillos con el metodo cruzado a un par de serraje de
135v138 Nm.
Passer sur les vis (16) les rondelles e lastiques (17).
Enduire les vis (16) avec du Loctite 270 et visser
celles-ci a fond.
Serrer les vis avec la me thode croise e a un couple de serrage de
135v138 Nm.
ITA
ESP
F
ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
f
e
d c
b
a
Das Planetengetriebe (22) und drei der Planetenge-
triebe (28) samt Zwischenlegscheiben (29) montieren.
Die Planetengetriebe (28) und die Zwischenlegschei-
ben (29) mit den Stiften (24) in der Position festhalten.
Das Kreuz (27) montieren und in der Position mit
einem langen Stift (23) festhalten.
Bevor der Stift (23) ganz eingesetzt wird, das letzte
Planetengetriebe (28) und die Unterlegscheibe (29) montieren.
An dem Du bel das Ma von 25,5 mm markieren; mit
demselben Du bel die Stifte (23) und (24) mit den
Federstiften (25) einsetzen.
BEMERKUNG. Die Stifte sind durch die Federstifte zur Ha lfte
eingesetzt, wenn die Markierung auf halber Ho he des Differential-
ko rpers (26) liegt.
Das zweite Planetengetriebe (22) und die Kupplung
(20) mit dem Ring (21) und eventuelle Unterlegschei-
ben (19) montieren.
ACHTUNG! Der Ring (21) mu nach der Montage am Planetenge-
triebe (22) und die eventuellen Unterlegscheiben (19) mu ssen am
Differentialdeckel (18) anliegen.
Den Differentialdeckel (18) positionieren.
BEMERKUNG. Kontrollieren, ob die Montagemarkie-
rungen u bereinstimmen.
Auf die Schrauben (16) die Federscheiben (17)
montieren.
festziehen. Die Schrauben im Kreuz mit einem Anzugsmoment von
135v138 Nm festziehen.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 990 008 911 79
INSTALLATION OF THE DIFFERENTIAL UNIT
Position the differential unit (7) or (8) under a press and, using a
driver with an adequate diameter, install the first bearing (9).
Turn the unit upside down and install the second bearing (9).
CAUTION! Pay particular attention; position a shim with adequate
diameter in order to engage the internal ring of bearing (9) without
engaging the cage.
Only if bearings are replaced
Using tool T8, insert the thrust blocks of the bearings (9) into the
intermediate covers (1) and (2).
Position the crown wheel (4) in the main body (3).
Fit tool T7B on the crown wheel opposite side, holding it in position
with two studs and two nuts.
NOTE. Engage the crown (4) onto tool T7B.
Install the differential unit (7) or (8), by fitting it into the hole of tool
T7B.
Install the crown (4) onto the differential unit (7) or (8), and fasten it
to the flange.
NOTE. Make sure the holes of the flange match those of the crown.
GB GB
GB GB
GB GB
a
b
c d
f e
58
F1241171 F1241172
F1241174
F1241176
F1241173
T8
F1241175
T7B
Axle DANA 193
BOMAG 991 008 911 79
18.5
59
INSTALLAZIONE DIFFERENZIALE
Posizionare il differenziale (7) o (8) sotto una pressa ed
utilizzando uno spintore di diametro adatto montare il
primo cuscinetto (9).
INSTALACION DIFERENCIAL
Colocar el diferencial (7) y (8) bajo una prensa y
utilizando un empuje de diametro adapto montar el
primer cojinete (9).
INSTALLATION DU DIFFERENTIEL
Mettre le diffe rentiel (7) ou (8) en place sous la presse,
a l'aide d'un poussoir au diame tre ade quat, monter le
premier palier (9).
Capovolgere il gruppo e montare il secondo cuscinetto
(9).
ATTENZIONE! Prestare molta attenzione e posiziona-
re uno spessore di diametro adatto al fine di impegnare l'anello
interno del cuscinetto (9) senza impegnare la gabbia.
Volcar el grupo y montar el segundo cojinete (9).
ATENCION! Tener mucho cuidado y colocar un
espesor de diametro apto al fin de empegnar el anillo
interno del cojinete (9) si empegnar la jaula.
Faire basculer le groupe et monter le second palier (9).
ATTENTION! Faire tre s attention, mettre une cale au
diame tre ade quat afin d'engager l'anneau interne du
palier (9) sans y engager la cage.
Solo se si sostituiscono i cuscinetti
Utilizzando l'attrezzo T8 inserire le ralle dei cuscinetti
(9) nei coperchi intermedi (1) e (2).
Solo si se sobstituyen los cojinetes
Utilizando la herramienta T8 Introducir las ranguas de
los cojinetes (9) en las tapa intermedias (1) y (2).
Uniquement en cas de substitution des paliers
A l'aide de l'outil T8, introduire la crapaudine des
paliers (9) dans les couvercles interme diaires (1) et (2).
Posizionare la corona (4) dentro il corpo centrale (3).
Colocar la corona (4) dentro del cuerpo central (3).
Mettre la couronne (4) en place dans le corps central
(3).
Montare l'attrezzo T7B sul lato opposto corona,
trattenendolo con due prigionieri e due dadi.
NOTA. Impegnare la corona (4) sull'attrezzo T7B.
Montar la herramienta T7B sobre el lado opuesto
corona, deteniendo con dos prigionieros y dos
tuercas.
NOTA. Empegnar la corona (4) sobre la herramienta T7B.
Monter l'outil T7B du co te oppose a la couronne, en le
tenant a l'aide de deux prisonniers et de deux ecrous.
REMARQUE. Engager la couronne (4) sur l'outil T7B.
Montare il gruppo differenziale (7) o (8) impegnandolo
nel foro dell'attrezzo T7B.
Montare la corona (4) sul differenziale (7) o (8)
mandandola in battuta sulla flangia.
NOTA. Far coincidere i fori della flangia con i fori della corona.
Montar el grupo diferencial (7) o (8) empegnandolo en
el agujero de la herramienta T7B.
Montar la corona (4) sobre el diferencial (7) y (8)
mandandola a tope sobre la brida.
NOTA. Hacer coincidir los agujeros de la brida con los agujeros de
la corona.
Monter le groupe diffe rentiel (7) ou (8) en l'engageant
dans le trou de l'outil T7B.
Monter la couronne (4) sur le diffe rentiel (7) ou (8) puis
l'envoyer en bute e sur la flasque.
REMARQUE. Faire correspondre les trous de la flasque avec les
trous de la couronne.
ITA
ESP
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DIFFERENTIAL ZUSAMMENBAUEN
Das Differential (7) oder (8) unter eine Presse legen
und mit einem geeigneten Dynamometer-Sto el das
erste Lager (9) montieren.
Das Aggregat wenden und das zweite Lager montie-
ren (9).
ACHTUNG! Den Vorgang mit groer Sorgfalt durch-
fu hren und einen fu r die Sta rke geeigneten Dynamometer
verwenden, um den Ring des inneren Lagers (9) einzusetzen,
ohne den Kafig einzuklemmen.
Nur wenn die Lager ausgewechselt werden.
Mit dem Werkzeug T8 die Scheiben der Lager (9) in
die Zwischendeckel (1) und (2) einsetzen.
Den Kranz (4) in den zentralen Ko rper (3) einsetzen.
Das Werkzeug T7B auf der dem Kranz entgegen-
gesetzten Seite montieren und mit zwei Stiftschrauben
und zwei Muttern festhalten.
BEMERKUNG. Den Kranz (4) in das Werkzeug T7B einrasten.
Das Differentialaggregat (7) oder (8) montieren und im
Loch des Werkzeuges T7B einrasten.
Den Kranz (4) auf das Differential (7) oder (8)
montieren und bis zum Anschlag am Flansch einsetzen.
BEMERKUNG. Die Flanschlo cher mu ssen mit den Kranzlo chern
u bereinstimmen.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 992 008 911 79
Fit spring washers (6) onto the screws (5).
Coat screws with Loctite 270 and screw them tight into the crown.
Position the stop block "A"; while holding the crown resting on the
block, tighten the screws (5) to a torque of 135 138 Nm.
CAUTION! Tighten screws using the criss-cross method.
Check the condition and position of the O-ring (30); lubricate the
seal and install the intermediate cover (2) on crown wheel side.
Lock the intermediate cover (2) with the journals (31) tightened to a
torque of 129 143 Nm.
Install tool T6 on the journals (31) on the crown wheel side, placing
distance pieces and locking with two nuts. Insert differential
centring and support tool T7A into tool T6.
NOTE. Make sure that the differential unit is tightly engaged in the
intermediate cover (2).
Remove tool T7B on crown opposite side. Check state and position of O-ring (30); lubricate the seal and fit the
intermediate cover (1) on the crown opposite side.
Lock the intermediate cover (1) with journals (31) tightened to a
torque of 129 143 Nm and remove tools T6 and T7A.
GB GB
GB GB
GB GB
a
b
c d
f e
60
F1241177
A
F1241145
F1241179
T7A
T6
F1241181
F1241178
F1241180
T7B
Axle DANA 193
BOMAG 993 008 911 79
18.5
61
Montare sulle viti (5) le rondelle elastiche (6).
Spalmare le viti con Loctite 270 ed avvitarle a fondo
nella corona. Posizionare il blocchetto "A" di contra-
sto; mantenendo in appoggio la corona sul blocchetto, serrare le
viti (5) ad una coppia di 135v138 Nm.
ATTENZIONE! Serrare le viti con il metodo incrociato.
Montar sobre los tornillos (5) las arandelas elasticas (6).
Pasar los tornillos con Loctite 270 y atornillarlos a
fondo en la corona. Colocar el bloque "A" de contraste;
manteniendo en apoyo la corona sobre el bloque, apretar los
tornillos (5) y un par de 135v138 Nm.
ATENCION! Apretar los tornillos con el metodo cruzado.
Monter les vis (5), les rondelles e lastiques (6).
Enduire les vis avec du Loctite 270, puis visser celles-
ci a fond dans la couronne. Mettre le petit bloc "A" de
contraste; en maintenant la couronne pose e sur le petit bloc, serrer
les vis (5) a un couple de 135v138 Nm.
ATTENTION! Serrer les vis avec la me thode croise e.
OR (30); lubrificare la guarnizione e montare il
coperchio intermedio (2) lato corona.
Controlar el estado y la colocacion del anillo OR (30);
lubrificar la guarnicion y montar la tapa intermedia (2)
lado corona.
Contro ler l'e tat et le positionnement de l'anneau
O'Ring (30); lubrifier la garniture, puis monter le
couvercle interme diaire (2) du co te couronne.
Bloccare il coperchio intermedio (2) con i prigionieri
(31) serrati ad una coppia di 129v143 Nm.
Bloquear la tapa intermedia(2) con los prigioneros (31)
apretados a un par de 129v143 Nm.
Bloquer le couvercle interme diaire (2) a l'aide des
prisonniers (31) serre s a un couple de 129v143 Nm.
Montare l'attrezzo T6 sui prigionieri (31) lato corona,
interponendo i relativi distanziali e bloccandolo con
due dadi. Inserire nell'attrezzo T6 l'attrezzo T7A di
centratura e sostegno del differenziale.
NOTA. Assicurarsi che il differenziale sia impegnato a fondo nel
coperchio intermedio (2).
Montar la herramienta T6 sobre los prigioneros (31)
lado corona, interponiendo de los distanciales y
bloqueando con dos tuercas. Introducir en la herramienta T6 la
herramienta T7A de centradura y sosten del diferencial.
NOTA. Asegurarse que el diferencial sea empegnado a fondo en la
tapa intermedia (2).
Monter l'outil T6 sur les prisonniers (31) co te cou-
ronne, en y intercalant des entretoises, puis bloquer
celui-ci avec deux ecrous. Introduire dans l'outil T6,
l'outil T7A de centrage et de support du diffe rentiel.
REMARQUE. S'assurer que le diffe rentiel soit engage a fond dans
le couvercle interme diaire (2).
Rimuovere l'attrezzo T7B del lato opposto corona.
Remover la herramienta T7B del lado opuesto corona.
Enlever l'outil T7B du co te oppose a la couronne.
OR (30); lubrificare la guarnizione e montare il
coperchio intermedio (1) lato opposto corona.
Fissare il coperchio intermedio (1) con i prigionieri (31) serrati ad
una coppia di 129v143 Nm e rimuovere gli attrezzi T6 e T7A.
Controlar el estado y la colocacion del anillo OR (30);
lubrificar la guarnicion y montar la tapa intermedia (1)
lado opuesto corona.
Fijar la tapa intermedia (1) con los prigioneros (31) apretados a un
par de 129v143 Nm y remover las herramientas T6 y T7A.
Contro ler l'e tat et le positionnement de l'anneau
O'Ring (30); lubrifier la garniture, puis monter le
couvercle interme diaire (1) du co te oppose a la
couronne.
Fixer le couvercle interme diaire (1) a l'aide des prisonniers (31)
serre s a un couple de 129v143 Nm, enlever les outils T6 et T7A.
ITA
ESP
F
ESP
F
ITA
ESP
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ITA
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ITA
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ITA
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F
ITA
f
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a
Auf die Schrauben (5) die Federscheiben (6) montieren.
Die Schrauben mit Loctite 270 schmieren und in den
Kranz schrauben. Den Block "A" positionieren; den
Kranz am Block anliegen lassen und die Schrauben (5) mit einem
Anzugsmoment von 135v138 Nm festziehen.
ACHTUNG! Die Schrauben im Kreuz festziehen.
kontrollieren; die Dichtung schmieren und den Zwi-
schendeckel (2) an der Kranzseite montieren.
Den Zwischendeckel (2) mit den Stiftschrauben (31)
blockieren und mit einem Anzugsmoment von
129v143 Nm festziehen.
Das Werkzeug T6 an den Stiftschrauben (31) an der
Kranzseite montieren und dabei Distanzstu cke einsetzen
und mit zwei Muttern befestigen. In das Werkzeug T6 das Werkzeug
T7A zur Zentrierung und Halterung des Differentials einsetzen.
BEMERKUNG. Sicherstellen, da das Differential fest im Zwischen-
deckel (2) sitzt.
Werkzeug T7B an der dem Kranz entgegengesetzten
Seite abnehmen.
kontrollieren; die Dichtung schmieren und den Zwi-
schendeckel (1) an der dem Kranz entgegengesetzten
Seite montieren. Den Zwischendeckel (1) mit den Stiftschrauben
(31) und einem Anzugsmoment von 129v143 Nm befestigen und
die Werkzeuge T6 und T7A entfernen.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 994 008 911 79
Remove the screws (33) and remove the safety tabs (34). Using wrench T9, extract the adjustment ring nuts (32) and remove
any residue of thread locking substances.
Screw ring nuts again after applying Loctite 242.
Remove the spring ring (35) and extract the cap (36) to allow
checking of the clearance between pinion and crown to take place.
Coat the surface of the main body (3) with Loctite 510 and install
the reduction gear (37) complete with pinion.
NOTE. Make sure that a continuous layer of sealant runs around
the locking holes.
Coat screws (38) with Loctite 242 and screw tight. Tighten screws
(38), using the criss-cross method and a tightening torque of
129 143 Nm.
Screw ring nut (32) on crown wheel side until clearance between
pinion and crown equals zero, then unscrew by 1/4 turn approx.
GB GB
GB GB
GB GB
a
b
c d
f e
62
F1241182 F1241183
T9
F1241185
F1241183
T9
F1241184
F1241186
Axle DANA 193
BOMAG 995 008 911 79
18.5
63
Asportare le viti (33) e rimuovere le linguette di
sicurezza (34).
Sacar los tornillos (33) y remover les lengues de
seguridad (34).
Enlever le vis (33), puis de placer le languettes de
se curite (34).
Utilizzando la chiave T9 rimuovere le ghiere (32) di
registrazione ed asportare ogni traccia di frenafiletti.
Riavvitare le ghiere dopo averle spalmate con
Loctite 242.
Utilizando la llave T9, remover las virolas (32) de
registracion y sacar cada senal de frenaroscas.
Restornillas las virolas despues de haberias pasadas
con Loctite 242.
A l'aide de la cle T9, enlever les ecrous annulaires (32)
de re glage et toute trace de l'agent d'arre t de vis.
Enduire les e crous annulaires avec Loctite 242 et
visser.
Asportare l'anello elastico (35) e rimuovere il tappo
(36) per poter controllare il gioco tra pignone e corona.
Sacar el anillo elastico (35) y remover la tapa (36) para
poder controlar el juego entre pignon y corona.
Enlever l'anneau e lastique (35), enlever le bouchon
(36) pour contro ler le jeu existant entre pignon et
couronne.
Spalmare la superficie del corpo centrale (3) con
Loctite 510 ed installare il riduttore (37) completo di
pignone.
NOTA. Assicurarsi che il sigillante crei un velo continuo attorno ai
fori di fissaggio.
Pasar la superficie del cuerpo central (3) con Loctite
510 y instalar el reductor (37) completo de pignon.
NOTA. Asegurarse que el sigilante cree una pelicula
continua alrededor a los agujeros de fisaje.
Enduire la superficie du corps central (3) avec du
Loctite 510, installer le re ducteur (37) complet de
pignon.
REMARQUE. S'assurer que la couche de colle entoure bien les
trous de fixation.
Spalmare le viti (38) con Loctite 242 e avvitarle a fondo.
Serrare le viti (38) con il metodo incrociato ad una
coppia di serraggio di 129v143 Nm.
Pasar los tornillos (38) con Loctite 242 y atornillas a
fondo.
Apretar los tornillos (38) con el metodo cruzado y un
par de torsion de 129v143 Nm.
Enduire les vis (38) avec du Loctite 242, puis visser
celles-ci a fond.
Serrer les vis (38) avec la me thode croise e a un couple
de serrage de 129v143 Nm.
Avvitare la ghiera (32) lato corona fino ad azzerare i
giochi tra pignone e corona e poi svitare per circa 1/4
di giro.
Atornillar las virolas (32) lado corona hasta acerar los
juegos entre el pinion y corona y despues destornillar
por cerca 1/4 de giro.
Visser l'e crou annulaire (32) du co te couronne jusqu'a
annuler le jeux entre pignon et couronne, puis
devisser 1/4 de tour.
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Die Schraube (33) abschrauben und den Sicherheits-
keil (34) abnehmen.
Mit einem Schlu ssel T9, die Nutmuttern (32) zur
Einstellung entfernen und jede alle u berschu ssigen
Reste der Schraubensicherungslo sung sorgfa ltig ent-
fernen.
Nutmuttern mit Loctite 242 schmieren und wieder festschrauben.
Den Kolbenring (35) abnehmen und den Stopfen (363)
entfernen, um das Spiel zwischen Kegelrad und Kranz
kontrollieren zu konnen.
Die Fla che des Zentralko rpers (3) mit Loctite 510
schmieren und den Reduzierer (37) samt Kegelrad
installieren.
BEMERKUNG. Sicherstellen, da die Dichtmasse einen gleich-
ma igen Film um die Befestigungslo cher herum bildet.
festziehen. Die Schrauben (38) im Kreuz mit einem
Anzugsmoment von 129v143 Nm festziehen.
Nutmuttern (32) an der Kranzseite zuschrauben bis
zwischen Rad und Kranz kein Spiel mehr u brig bleibt;
danach um 1/4 Umdrehung aufschrauben.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 996 008 911 79
Allow pinion to turn a few times in both directions to allow bearings
to set. Pre-load the bearings through the ring nut on crown opposite
side to increase pinion torque up to a value of 140 210 Ncm
checked by means of a torque meter.
CAUTION! If bearings are old, check static torque. If new, check
continuous torque.
Introduce a comparator with rotary key "C" through the rear cap
hole (43).
Position comparator on the centre of one of the crown teeth (4), pre-
set it to 1 mm and reset it to zero.
Manually move the crown (4) in both directions to check the
existing clearance between pinion and crown.
Mark the position of the ring nuts (32) in relation to the intermediate
covers.
Using wrench T9, adjust clearance between pinion and crown by
loosening one ring nut (32) and tightening the opposite proportion-
ally.
Normal clearance: see table.
Install safety tabs (41) and lock them with screws (40).
Screws tightening torque: 10 11 Nm.
Using a driver, fit the cap (36) and position it in its seat with the
snap ring (35).
GB GB
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F1241188
C
F1241187
T3
F1241183
T9
F1241190 F1241189
RATIO - RAPPORTO
VERHA
LTNIS
RAPORTE - RAPPORT
CLEARANCE - GIOCO - SPIEL
JUEGO - JEU
MIN. MAX.
6v43 0,18 0,23
Difference between MIN and MAX clearance for whole circumference
should not exceed 0.09 mm.
La differenza tra gioco MIN e MAX rilevata sull'intera circonferenza
non deve superare il valore di 0,09 mm.
Der Unterschied zwischen dem MIN e MAX Spiel der gesamten
Kreislinie darf den Wert von 0,09 mm nicht u berschreiten.
La diferencia entre el juego Min y Max determinada sobre la entera
circonferencia no debe de superar el valor de 0,09 mm.
La diffe rence de jeu entre MIN et MAX releve e sur toute la
circonfe rence ne doit pas aller au-dela de la valeur de 0,09 mm.
Axle DANA 193
BOMAG 997 008 911 79
18.5
65
Far compiere al pignone alcuni giri nei due sensi per
assestare i cuscinetti. Precaricare i cuscinetti tramite la
ghiera lato opposto corona, per incrementare la coppia di
rotazione pignone fino a 140v210 Ncm controllati con un torsiometro.
ATTENZIONE! Con cuscinetti usati, controllare la coppia di spunto;
con cuscinetti nuovi, controllare la coppia di rotazione continua.
Hacer efectuar al pignon algunos giros en los dos sentidos
para ordenar los cojinetes. Precargar los cojinetes a
traves de las virolas lado opuesto corona, para crecer el par de rotacion
pignon hasta 140v210 Ncm controlados con un torsiometro.
ATENCION! Con cojinetes usados, controlar el par de principio; con
cojinetes nuevos, controlar el par de rotacion continua.
Faire tourner le pignon plusieurs fois dans les deux sens
pour ajuster les paliers. Pre charger les paliers au moyen de
l'e crou annulaire, du co te oppose a la couronne, pour augmenter le couple
de rotation du pignon jusqu'a 140v210 Ncm contro le s par un torsiome tre.
ATTENTION! Avec des paliers usage s, contro ler le couple de pointe; avec
des paliers neufs, controler le couple de rotation continu.
Posizionare, attraverso il foro per il tappo posteriore
(43), un comparatore a tasto orientabile "C".
Posizionarlo sul centro di un dente della corona (4),
precaricarlo di circa 1 mm ed azzerarlo.
Muovere manualmente nei due sensi la corona (4) per controllare il
gioco esistente tra pignone e corona.
Colocar, atraves el agujero para la tapa posterior (43),
un comparador a tecla orientable "C".
Colocarlo sobre el centro de un diente de la corona (4),
precargarlo de 1 mm aprox y azerarlo.
Mover manualmente en los dos sentidos la corona (4) para
controlar el juego esistente entre pignon y corona.
Placer a travers le trou servant au bouchon arrie re
(43), un comparateur a touche orientable "C".
Positionner celui-ci au centre d'une des dents de la
couronne (4), pre charger celui-ci d'environ 1 mm et mettre a ze ro.
De placer manuellement la couronne (4) dans les deux sens pour
controler le jeu existant entre pignon et couronne.
Contrassegnare la posizione delle ghiere (32) rispetto i
coperchi intermedi.
Con la chiave T9, regolare il gioco tra pignone e
corona allentando una ghiera (32) e serrando la ghiera opposta in
egual misura.
Gioco normale: vedere tabella.
Contrasenalr la colocacion de las virolas (32) respecto
a las tapaderas intermedias.
Con la llave T9, regular el juego entre el pignon y la
corona aflojando una virola (32) y apretando la virola opuesta en la
misma mesura.
Juego normal: vease el prospecto.
Marquer la position de l'ecrou annulaire (32) par
rapport aux couvercles interme diaires.
A l'aide de la cle T9, regler le jeu entre pignon et
couronne en de vissant l'ecrou annulaire (32) et en vissant l'e crou
annulaire oppose de la me me mesure.
Jeu normal: voir tableau.
Montare le linguette di sicurezza (41) e fissarle con le
viti (40).
Coppia di serraggio viti: 10v11 Nm
Montar las lenguetas de seguridad (41) y fijarlas con
los tornillos (40).
Par de serraje tornillos: 10v11 Nm
Monter les languettes de se curite (41), fixer celles-ci a
l'aide des vis (40).
Couple de serrage des vis: 10v11 Nm.
Con uno spintore, montare il tappo (36) ed assicurarlo
in sede con l'anello elastico (35).
Con un empujador, montar la tapa (36) y asegurarlo en
sed con el anillo elastico (36).
A l'aide d'un poussoir, monter le bouchon (36), ajuster
celui-ci dans son logement avec l'anneau elastique
(35).
ITA
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ITA
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ITA
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F
ITA
ESP
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ITA
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Das Kegelrad um einige Umdrehungen in beide Richtungen
drehen, um das Lager in die richtige Position zu bringen. Die
Lager durch die Nutmutter an der dem Kranz entgegengesetzte Seite
vorbelasten, um das Gegenmoment des Kegelrads bis auf 140v210 Ncm
zu erho hen. Den Wert mit einem Drehungsmesser kontrollieren.
ACHTUNG! Bei gebrauchten Lagern, das Anlaufdrehmoment kontrollieren;
bei neuen Lagern, das kontinuierliche Gegenmoment kontrollieren.
Durch das Loch des hinteren Stopfens (43) eine
Meuhr mit schwenkbarer Taste "C" einsetzen.
Die Meuhr auf die Mitte eines Zahnes des Kranzes (4)
positionieren und um 1mm vorbelasten; danach zuru ckstellen.
Von Hand in beide Richtungen den Kranz (4) bewegen, um das
Spiel zwischen Kegelrad und Kranz zu kontrollieren.
Die Position der Nutmuttern (32) im Verha ltnis zu den
Zwischendeckeln markieren.
Mit dem Schlu el T9, das Spiel zwischen Rad und
Kranz einstellen, in dem eine Nutmutter (32) gelockert und die
entgegengesetzte festgezogen wird.
Normales Spiel: siehe Tabelle.
Den Sicherheitskeil (41) montieren und mit den
Schrauben (40) befestigen.
Anzugsmoment der Schrauben: 10v11 Nm
Mit einem Sto el den Stopfen (36) montieren und in
seinem Sitz mit dem Kolbenring (35) befestigen.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 998 008 911 79
Using a driver and a plastic hammer, install the driving gear (39). Apply Loctite 510 to the surface of the reduction gear body (37) and
install the cover (40).
NOTE. Make sure that a continuous layer of sealant runs around
the locking holes.
Lock the cover (40), using the snap washers (43) and the screws
(42) and (41) adequately tightened to a torque of 82 91 Nm.
Tighten screws (42) and (41) with a tightening torque of 82 91 Nm.
Install the breath union piece (44) with the relative sealing washers
(45) and plugs (47) and (46); tighten to a torque of 35 50 Nm.
Complete assembly of the axle by installing, in the following order,
brake cylinders and complete arms.
For details, see ASSEMBLING THE BRAKING UNITS.
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F1241190 F1241192
F1241194 F1241193
Axle DANA 193
BOMAG 999 008 911 79
18.5
67
Utilizzando uno spintore ed un mazzuolo in materiale
plastico, montare l'ingranaggio conduttore (39).
Utilizando un empujador y un martillo en material
plastico, montar el engranaje conductor (39).
A l'aide d'un poussoir et d'un maillet en matie re
plastique, monter l'engrenage conducteur (39).
Spalmare la superficie del corpo riduttore (37) con
Loctite 510 ed installare il coperchio (40).
NOTA. Assicurarsi che il sigillante crei un velo
continuo attorno ai fori di fissaggio.
Pasar la superficie del cuerpo reductor (37) con Loctite
510 y instalar la tapa (40).
NOTA. Asegurarse que el sigilante cree una pelicula
continua alrededor de los agujeros de fisaje.
Enduire la superficie du corps re ducteur (37) avec du
Loctite 510, installer le couvercle (40).
REMARQUE. S'assurer que la couche de colle
entoure bien les trous de fixation.
Bloccare il coperchio (40) utilizzando le rondelle
elastiche (43) e le viti (42) e (41) serrate con una
coppia di 82v91 Nm.
Bloquear la tapa (40) utilizando las arandelas elasti-
cas (43) y los tornillos (42) y (41) apretadas con un par
de 82v91 Nm.
Bloquer le couvercle (40) a l'aide des rondelles
e lastiques (43) et des vis (42) et (41) serre es a un
couple de 82v91 Nm.
Montare il raccordo di sfiato (44) con le relative rosette
di tenuta (45) ed i tappi (47) e (46); serrarli con una
coppia di 35v50 Nm.
Montar el recorde de escape (441) con las relativas
rosas de tenida (45) y las tapas (47) y (46); apretarlos
con un par de 35v50 Nm.
Monter le raccord d'e vent (44), les relatives rosettes
d'etancheite (45) et les bouchons (47) et (46), serrer
ceux-ci a un couple de 35v50 Nm.
Completare l'assemblaggio dell'assale installando
nell'ordine i cilindri freni ed i bracci completi.
Per i dettagli, vedere ASSEMBLAGGIO GRUPPI
FRENO.
Completar el asemblaje del axial instalando en el
orden los cilindros frenos y los ejes completos.
Para los detalles, vease ASEMBLAJE GRUPOS
FRENOS.
Achever l'assemblage de l'essieu en y installant dans
l'ordre les cylindres freins et les bras complets.
Pour de plus amples de tails voir "ASSEMBLAGE DU
GROUPE FREIN".
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Mit einem Sto el und einem Gummihammer das
Getriebe (39) montieren.
Die Fla che des Ko rpers des Reduzierers (37) mit
Loctite 510 schmieren und den Deckel (40) installie-
ren.
BEMERKUNG. Sicherstellen, da die Dichtmasse einen gleich-
ma igen Film um die Befestigungslo cher herum bildet.
Den Deckel (40) mit den Federscheiben (42) und (41)
und den Schrauben (42) und (41) bei einem Anzu-
gsmoment von 82v91 Nm blockieren.
Das abgezogene Verbindungsstu ck (44) mit den
Dichtscheiben (45) und den Stopfen (47) und (46)
montieren; Anzugsmoment 35v50 Nm.
Die Achse fertig zusammenbauen und der Reihe nach
die Bremszylinder und die kompletten Arme installie-
ren.
Siehe ZUSAMMENBAU DER BREMSAGGREGATE.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 1000 008 911 79
Remove the whole arms and the differential unit.
For details, see CHECKING WEAR AND REPLACING THE
BRAKING DISKS and REMOVAL OF DIFFERENTIAL UNIT.
Loosen and remove screws (1) and (2) and the washers (3) locking
the cover (4), the plugs (5) and (6) for oil fill and oil drain, and the
bleed union piece (7).
NOTE. Leave two screws (2) in position for safety.
Using a plastic hammer, remove the cover (4) and move it away.
NOTE. If operations on the differential unit need to be performed,
remove the complete reduction gear unit (screws (9) and (10)).
Place a block of tender material (aluminium, etc.) between the
reduction body (11) and the gear (12) of the pinion.
Loosen and remove the pinion locking nut (13).
Remove the gear of the pinion (12) and the driving gear (14)
complete with bearing (15).
NOTE. To remove the gear (14), use a lever.
Take the driving gear to pieces (14), extracting the bearing (15).
NOTE. If necessary, use an extractor.
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DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER UND KEGELRAD
ABMONTIEREN - REMOCION REDUCTOR Y PIN
ON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE

F1241141 F1241195
F1241197
A
F1241199
F1241196
F1241198
Axle DANA 193
BOMAG 1001 008 911 79
18.5
69
Rimuovere i bracci completi ed il differenziale.
Per i dettagli, vedere CONTROLLO USURA E
SOSTITUZIONE DISCHI FRENO e RIMOZIONE
GRUPPO DIFFERENZIALE.
Remover los ejes completos y el duferencial.
Para los detalles, vease CONTROL DESGASTE Y
SOBSTITUCION DISCOS FRENOS y REMOCION
GRUPO DIFERENCIAL.
Enlever les bras complets et le diffe rentiel.
Pour de plus amples de tails, voir "CONTROLE
USURE ET SUBSTITUTION DES DISQUES FREIN"
et "DEPOSE DU GROUPE DIFFERENTIEL".
Allentare ed asportare le viti (1) e (2) e le rondelle (3) di
ritegno coperchio (4), i tappi (5) e (6) di carico e scarico
olio ed il raccordo di sfiato (7).
NOTA. Lasciare in posizione per sicurezza due viti (2) contrappo-
ste.
Aflojar y sacar los tornillos (1) y (2) y las arandelas (3)
de retencion tapa (4), los tapones (5) y (6) de carga y
descarga aceite y el recorde de escape (7).
NOTA. Dejar en posicion de seguridad dos tornillos (2) contra-
puestas.
Desserrer et enlever les vis (1) et (2), les rondelles (3)
de fixation du couvercle (4), les bouchons (5) et (6) de
remplissage et vidange d'huile et le raccord d'e vent (7).
REMARQUE. Pour plus de su rete, garder deux vis (2) super-
pose es.
Utilizzando un mazzuolo in materiale plastico, rimuo-
vere il coperchio (4) ed asportarlo.
NOTA. Se si deve intervenire sul gruppo differenziale,
rimuovere il gruppo riduttore completo (viti (9) e (10)).
Utilizando un martillo en material plastico, remover la
tapa (4) y sacarla.
NOTA. Si se debe intervenir sobre el grupo diferen-
cial, remover el grupo reductor completo (tornillos (9) y (10)).
A l'aide d'un maillet en matie re plastique, de placer le
couvercle (4) et puis l'enlever.
REMARQUE. S'il faut intervenir sur le groupe diffe -
rentiel, enlever le groupe re ducteur complet (vis (9) et (10)).
Sistemare tra il corpo riduttore (11) e l'ingranaggio (12)
del pignone un blocchetto "A" di materiale tenero
(alluminio, ecc.).
Allentare ed asportare il dado (13) di ritegno pignone.
Colocar entre el cuerpo reductor (11) y el engranaje
(12) del pinon un bloquete "A" de material tierno
(aluminio, ect.).
Aflojar y sacar la tuerca (13) de retencion pinon.
Ajuster, entre le corps re ducteur (11) et l'engrenage
(12) du pignon, un petit bloc "A" en mate riel le ger
(aluminium etc.).
Desserrer et enlever l'e crou (13) de fixation pignon.
Rimuovere l'ingranaggio del pignone (12) e l'ingra-
naggio conduttore (14) completo di cuscinetto (15).
NOTA. Per rimuovere l'ingranaggio (14), utilizzare una
leva.
Remover el engranaje del pinon (12) y el engranaje
conductor (14) completo de cojinete (15).
NOTA. Para remover el engranaje (14), utilizar una
palanca.
De placer l'engrenage du pignon (12) et l'engrenage
conducteur (14) complet de palier (15).
REMARQUE. Pour de placer l'engrenage (14), utiliser
un levier.
Scomporre l'ingranaggio conduttore (14) estraendo il
cuscinetto (15).
NOTA. Se necessario, usare un estrattore.
Descomponer el engranaje conductor (14) sacando el
cojinete (15).
NOTA. Si necesario, usar un extractor.
De composer l'engrenage conducteur (14) en de ga-
geant le palier (15).
REMARQUE. Si besoin, utiliser un extracteur.
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Die kompletten Arme und das Differential abnehmen.
Siehe VERSCHLEISS KONTROLLIEREN UND
BREMSSCHEIBEN AUSWECHSELN und DIFFE-
RENTIALAGGREGAT ABNEHMEN.
Schrauben (1) und (2) abschrauben und die Unter-
legscheiben (3) zur Halterung des Deckels (4), die
O
leinfu ll- und Ablastopfen (5) und (6) sowie das

Endlu ftungsstu ck (7) abnehmen.
BEMERKUNG. Die entgegengesetzten Schrauben (2) zur Sicher-
heit zuru ck lassen.
Mit einem Gummihammer den Deckel (4) ausrasten
und abnehmen.
BEMERKUNG. Soll am Differentialaggregat gearbeitet
werden, das komplette Reduzieraggregat abnehmen (Schrauben
(9) und (10)).
Zwischen dem Reduziererko rper (11) und dem Getrie-
be (12) des Kegelrads einen Block aus weichen
Material einsetzen (Aluminium usw.)
Mutter (13) zur Halterung des Kegelrads abschrauben.
Das Getriebe (12) des Kegelrads und das Getriebe
(14) samt Lager (15) entfernen.
BEMERKUNG. Um das Getriebe (14) abnehmen zu
ko nnen, einen Hebel verwenden.
Das Getriebe (14) zerlegen; dazu das Lager (15)
abziehen.
BEMERKUNG. Wenn no tig, einen Abzieher verwen-
den.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 1002 008 911 79
Loosen all screws (9) and (10) and remove the upper check screws
(9) of the reduction gear body.
NOTE. Leave the two lower screws (10) in position for safety.
Connect the whole reduction gear body (11) to a hoist and remove
the screws (10) previously left in place for safety.
Using a plastic hammer, pull away the whole reduction gear body
(11).
Position the reduction gear body (11) under a press and, using a
driver, extract the pinion (16) complete with internal bearing (17),
shims (19) and distance piece (20).
Remove distance piece (20) and shims (19) from the pinion(16).
Position the pinion under a press and remove the internal bearing
(17).
With the help of an extractor, remove the thrust blocks (17) and (21)
of the bearings, and the snap ring (22).
NOTE. Note down direction of assembly of snap ring (22).
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F1241200 F1241201
F1241203 F1241202
F1241204
Axle DANA 193
BOMAG 1003 008 911 79
18.5
71
Allentare tutte le viti (9) e (10) ed asportare le viti (9)
superiori di ritegno del corpo riduttore.
NOTA. Lasciare in sede le due viti (10) inferiori per
sicurezza.
Aflojar todos los tornillos (9) y (10) y sacar los tornillos
(9) superiores de retencion del cuerpo reductor.
NOTA. Dejar en su lugar los dos tornillos (10)
inferiores para seguridad.
Desserrer toutes les vis (9) et (10), enlever les vis
supe rieures (9) de fixation du corps reducteur.
REMARQUE. Garder les deux vis infe rieures (10) dans
leur sie ge pour plus de se curite .
Collegare il corpo riduttore completo (11) ad un mezzo
di sollevamento ed asportare le viti (10) lasciate in
sede per sicurezza.
Utilizzando un mazzuolo in materiale plastico, rimuovere il corpo
riduttore (11) completo.
Conectar el cuerpo reductor completo (11) a un medio
de elevacion y sacar los tornillos (10) dejadas en su
lugar para seguridad.
Utilizando un martillo en material plastico, remover el cuerpo
reductor (11) completo.
Brancher le corps reducteur complet (11) a un moyen
de relevage, puis enlever les vis laisse e (10) dans leur
sie ge pour plus de se curite .
A l'aide d'un maillet en matie re plastique, enlever le corps
re ducteur (11) complet.
Posizionare il corpo riduttore (11) sotto una pressa e,
utilizzando uno spintore, estrarre il pignone (16)
completo di cuscinetto interno (17), spessori (19) ed
il distanziale (20).
Colocar el cuerpo reductor (11) debajo de una prensa
y, utilizando un empujador (16) completo de cojinete
interno (17), espesores (19) y el distancial (20).
Placer le corps re ducteur (11) sous une presse, a
l'aide d'un poussoir extraire le pignon (16) complet de
palier interne (17), cales (19) et entretoise (20).
Rimuovere dal pignone (16) il distanziale (20) e gli
spessori (19).
Posizionare il pignone sotto una pressa e rimuovere il
Remover del pinon (16) el distancial (20) y los
espesores (19).
Colocar el pinon bajo una prensa y remover el cojinete
interno (17).
Enlever du pignon (16) l'entretoise (20) et les cales
(19).
Placer le pignon sous une presse et enlever le palier
interne (17).
Con un estrattore, rimuovere dal corpo riduttore (11) le
ralle dei cuscinetti (17) e (21) e l'anello di tenuta (22).
NOTA. Annotare il senso di montaggio dell'anello di
tenuta (22).
Con un extractor, remover del cuerpo reductor (11) las
ranguas de los cojinetes (17) y (21) y el anillo de
retencion (22).
NOTA. Anotar el sentido de desmontaje del anillo de retencion
(22).
A l'aide d'un extracteur, enlever le corps re ducteur
(11), les crapaudines des paliers (17) et (21) et
l'anneau d'e tanche ite (22).
REMARQUE. Prendre note du sens de montage de l'anneau
d'e tanche ite (22).
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Alle Schrauben (9) und (10) lockern und die oberen
Schrauben (9) zur Halterung des Reduziererko rpers
abnehmen.
BEMERKUNG. Die beiden unteren Schrauben (10) zur Sicherheit
zuru ck lassen.
Den kompletten Reduziererko rper (11) an ein Hebe-
zeug befestigen und die zuvor zur Sicherheit zuru ck-
gelassenen Schrauben (10) abschrauben.
Mit einem Gummihammer, den kompletten Reduziererko rper (11)
abnehmen.
Den Reduziererko rper (11) unter eine Presse legen
und mit einem Sto el das Kegelrad (16) samt dem
inneren Lager (17), den Unterlegscheiben (19) und
dem Distanzstu ck (20) abziehen.
Vom Kegelrad (16) das Distanzstu ck (20) und die
Unterlegscheiben (19) abnehmen.
Das Kegelrad unter eine Presse legen und das innere
Lager (17) abnehmen.
Mit einem Abzieher vom Reduziererko rper (11) die
Scheiben der Lager (17) und (21) und den Dichtring
(22) entfernen.
BEMERKUNG. Montagerichtung des Dichtringes (22) notieren.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 1004 008 911 79
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D1240136
Axle DANA 193
BOMAG 1005 008 911 79
18.5
73
ATTENZIONE! 1 - Se lo smontaggio e stato eseguito
solo per la sostituzione dell'anello di tenuta (22),
procedere al posizionamento del nuovo anello e
rimontare il gruppo rispettando le coppie di serraggio indicate nel
paragrafo seguente ed utilizzando i prodotti di bloccaggio e tenuta
prescritti.
2 - Se lo smontaggio viene eseguito per la sostituzione della coppia
conica, dei cuscinetti o degli ingranaggi satelliti, procedere alla
scomposizione ed alla ricerca degli spessori e dei giochi come
indicato nei paragrafi riguardanti la rimozione, lo smontaggio,
l'assemblaggio e l'installazione del differenziale e del pignone
conico.
ACHTUNG! 1 - Falls das Teil zum Auswechseln des
Dichtringes (22) zerlegt wurde, den neuen Ring
einsetzen und das Aggregat wieder montieren; dabei
die Anzugsmomente einhalten, die im nachstehenden Kapitel
angegeben sind und die vorgeschriebenen Materialien zur Blok-
kierung und Abdichtung verwenden.
2 - Falls das Zerlegen zum Auswechseln des Kegelradpaars, der
Lager oder der Planetengetriebe vorgenommen wird, den An-
weisungen der Paragraphen zum Zerlegen, Abmontieren und
Zusammenbauen sowie zur Installation des Differentials und des
Kegelrads folgen und die Sta rken und Spiele einhalten.
ATENCION! 1 - Si el desmontaje ha sido efectuado
solo para la sobstitucion del anillo de retencion (22),
proceder al alojamiento del nuevo anillo y remontar el
grupo respectando los pares de serraje indicadas en el paragrafo
siguiente y utilizando los productos de bloqueo y tenida prescritos.
2 - Si el desmontaje viene efectuado para la sobstitucion del par
conico, de los cojinetes o de los engranajes satelites, proceder a la
descomposicion y a la busqueda de los espesores y de los juegos
como indicados en los paragrafos concernientes la remocion, el
desmontaje, el asemblaje y la instalacion del diferencial y del pinon
conico.
ATTENTION! 1 - Si le de montage n'est effectue que
pour substituer l'anneau d'e tanche ite (22), positionner
le nouvel anneau et remonter le groupe en respectant
les couples de serrage indique s dans le paragraphe suivant a l'aide
des produits de blocage et d'e tanche ite prescrits.
2 - Si le montage est effectue pour substituer le couple conique des
paliers et des engrenages satellites, passer a la de composition et a
la recherche des cales et des jeux comme indique dans les
paragraphes concernant la de pose, le de montage, l'assemblage et
l'installation du diffe rentiel et du pignon conique.
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CAUTION! 1 - If disassembly has only been carried
out to replace the snap ring (22), position the new ring
and reassemble the unit, respecting the tightening
torques specified in the following section and using the specified
locking and sealing products.
2 - If disassembly is performed to replace either crown wheel and
pinion, bearings, or planetary gears, take the unit to pieces and find
shims and clearances as specified in the sections relative to the
removal, disassembly, assembly and installation of the differential
unit and bevel pinion.
GB
18.5 Axle DANA 193
BOMAG 1006 008 911 79
Mark the thrust block and the internal bearing (17) on a faceplate,
allow the bearing to set by rotating them in both directions and by
applying a vertical thrust. With a centesimal, digital depth gauge
"B", check overall thickness of bearing (e.g.: 42.35 mm) and set the
gauge to zero again.
Lay two 20 mm gauged blocks "C" on the face of the reduction gear
body (11). With depth gauge "B" (set to zero at the previous point),
measure space between the "C" blocks and the striking surface of
internal bearing (17). The size obtained (e.g.: 0.81 mm) is the
theoretical shim "St" (18) to be inserted under the thrust block of
bearing (17).
On the bar-hold of pinion (16), check the value "X" (in brackets)
relative to the deviation from the theoretical centre distance.
NOTE. "Y" is the number of pinion/crown coupling.
To calculate final thickness "S", add the negative value of "X" to
"St" or, alternatively, subtract the positive value of "X".
For ex.: Deviation X=(0.13 mm): S=St+X=0.81+0.13=0.94 mm
Deviation X=(+0.12 mm): S=St X=0.81 0.12=0.69 mm
CAUTION! Round off to as close to 0.05 mm as possible.
Using a driver, mount the sealing ring (22) in the reduction unit (11).
NOTES. 1 - Carefully check the direction of assembly.
2 - Lubricate the outer surface of the sealing ring.
Place the reduction gear body (11) under a press and, using tool
T10, insert the thrust block of external bearing (21).
CAUTION! Insert the thrust block of the bearing that is not
countermarked.
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INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UND
EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PIN
ON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE

F1241205
B
MARK
CONTRASSEGNO
KENNZEICHEN
CONTRASENALACION
MARQUAGE
MEASURE (42.35)
MISURA (42,35)
MA (42,35)
MESURA (42,35)
MESURE (42,35)
F1241206
B
C
C
St
D1240137
S
+ --
DIFFERENTIAL AXIS
ASSE DIFFERENZIALE
DIFFERENTIALACHSE
EJE DEFERENCIAL
ESSIEU DIFFERENTIEL
DEVIATION "X"
SCOSTAMENTI "X"
ABWEICHUNG "X"
DESPLAZAMIENTOS "X"
ECARTS "X"
S = St + ( X)
F1241207
T10
F1241225
X
Y
F1241227
Axle DANA 193
BOMAG 1007 008 911 79
18.5
75
Contrassegnare la ralla ed il cuscinetto (17) interno su
un piano di riscontro, assestare il cuscinetto con delle
rotazioni parziali nei due sensi ed esercitando una
spinta verticale. Con un calibro di profondita digitale centesimale
"B", rilevare lo spessore totale del cuscinetto (es 42,35 mm) ed
azzerare il calibro.
Senalar la rangua t el cojinete (17) interno sobre una
superficie de rescontre, ordenar el cojinete con unas
rotaciones parciales en los dos sentidos y ejercitando
un empuje vertical. Con un calibre de profundidad digital centesimal
"B", relevar el espesor total del cojinete (es.:42,35 mm) y azerar el
calibre.
Estampiller la crapaudine et le palier (17) interne sur
un marbre de contro le, ajuster les paliers par des
rotations partielles dans les deux sens tout en
poussant verticalement. A l'aide d'un calibre de profondeur
nume rique cente simal "B", relever le calage total des paliers (ex.
42,35 mm), mettre le calibre a zero.
Appoggiare sul piano di appoggio del corpo riduttore
(11) due blocchetti calibrati da 20 mm "C". Con il
calibro di profondita "B" (azzerato nella fase precedente), rilevare la
misura tra i blocchetti "C" ed il piano di battuta del cuscinetto
interno (17). La misura risultante (es. 0,81 mm) e lo spessore "St"
(18) teorico da inserire sotto la ralla del cuscinetto (17).
Colocar sobre la superficie de apoyo del cuerpo reductor
(11) dos bloques calibrados de 20 mm "C". Con el calibre
de profundidad "B" (azerando en la fase precediente),
relevar la mesura entre los bloquetes "C" y la superficie del tope del
cojinete interno (17). La mesura resultante (es.: 0,81 mm) es el
espesor "St" (18) teorico de introducir bajo la rangua del cojinete (17).
De poser sur un plan d'appui du corps re ducteur (11),
deux petits blocs calibre s a 20 mm "C". A l'aide du
calibre de profondeur "B" (mis a ze ro pre ce demment),
relever la mesure existante entre les petits blocs "C" et le plan de
butee du palier interne (17). La mesure re sultante (ex. 0,81 mm) est
le calage "St" (18) a introduire sous la crapaudine du palier (17).
Controllare sul codolo del pignone (16) il valore "X"
(racchiuso tra parentesi) dello scostamento rispetto
l'interasse teorico.
NOTA. Il numero "Y" e il numero di accoppiamento pignone-
corona.
Controlar sobre al espigon del pinon (16) el valor "X"
(serrado entre parantesis) del desplazamiento respec-
to al intereje teorico.
NOTA. El numero "Y" y el numero de acoplamiento pinon-corona.
Contro ler sur la queue du pignon (16) la valeur "X"
(entre parenthe ses) de l'e cart par rapport a l'entraxe
the orique.
REMARQUE. Le numero "Y" est le numero de l'accouplement
pignon-couronne.
Per calcolare lo spessore "S" definitivo, aggiungere a
"St", il valore "X" negativo oppure sottrarre il valore
"X" positivo.
Es.: Scostamento X=( 0,13 mm): S=St+X=0,81+0,13=0,94 mm
Scostamento X=(+0,12 mm): S=St X=0,81 0,12=0,69 mm
ATTENZIONE! Arrotondare al valore piu prossimo dei 0,05 mm.
Para calcolar el espesor "S" definitivo, adicionar a
"St", el valor "X" negativo o detraer el valor "X"
positivo.
Es.: Desplazamiento X=( 0,13mm): S=St+X=0,81+0,13=0,94 mm
Desplazamiento X=(0,12mm): S=St X=0,81 0,12=0.69 mm
ATENCION! Acercar al valor mas cerca de 0,05 mm.
Pour calculer l'e paisseur "S" de finitif, additionner a
"St" la valeur "X" negative ou soustraire la valeur "X"
positive.
Ex. Ecart X=( 0,13 mm): S=St+X=0,81+0,13=0,94 mm
Ecart X=(+0,12 mm): S=St X 0,81 0,12=0,69 mm
ATTENTION! Arrondir a la valeur plus proche a 0,05 mm.
Utilizzando uno spintore, montare nel corpo riduttore
(11) l'anello di tenuta (22).
NOTE. 1 - Controllare attentamente il senso di
montaggio.
2 - Lubrificare la superficie esterna dell'anello di tenuta.
Utilizando un espesor, montar en el cuerpo reductor
(11) el anillo de retencion (22).
NOTA. 1 - Controlar atentamente el sentido de
montaje.
2 - Lubrificar la superficie exterior del anillo de retencion.
A l'aide d'un poussoir, monter dans le corps re ducteur
(11) l'anneau d'e tanche ite (22).
NOTE. 1 - Contro ler attentivement le sens de
montage.
2 - Lubrifier la surface externe de l'anneau d'etanche ite .
Sistemare il corpo riduttore (11) sotto una pressa e,
utilizzando l'attrezzo T10 inserire la ralla del cusci-
netto esterno (21).
ATTENZIONE! Inserire la ralla del cuscinetto non contrassegnato.
Colocar el cuerpo reductor (11) debajo de una prenso
y, utilizando la herramienta T10 insertar la rangua del
cojinete esterno (21).
ATENCION! Introducir la rangua del cojinete no segnalado.
Ajuster le corps re ducteur (11) sous la presse, a l'aide
de l'outil T10 introduire la crapaudine du palier
externe (21).
ATTENTION! Introduire la crapaudine du palier non estampille e.
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Die Scheibe und das innere Lager (17) an einer
Bezugsfla che markieren, das Lager durch hin und her
Drehen und einem senkrechten Druck richtig ein-
setzen. Mit einer digitalen hundertteiligen Tiefenlehre "B" die
Gesamtsta rke des Lagers messen (z.B. 42,35 mm) und die Lehre
zuru ckstellen.
Auf eine Auflageflache des Reduziererko rpers (11) zwei
kalibrierte Blocke zu 20 mm "C" legen. Mit einer Tiefen-
lehre "B" (zuvor zuru ckgestellt) das Ma zwischen den Blocken "C" und
der Anschlagflache des inneren Lagers (17) messen. Das ermittelte Ma
(z.B. 0,81 mm) entspricht der theoretischen Unterlegscheibe "St" (18),
die unter die Scheibe des Lagers (17) gelegt werden mu.
Den Wert "X" der Gleitung am Kegelradschaft (16) (in
Klammern angegeben) im Verha ltnis zum theoreti-
schen Achsenabstand kontrollieren.
BEMERKUNG. Die Zahl "Y" entspricht dem Kegelrad-Kranz-
Kopplungsgrad.
Um die endgu ltige Sta rke "S" auszurechnen, "St" und
"X" addieren, wenn "X" ne gatif ist oder "X" von "St"
abziehen, falls "X" postif ist.
Beispiel: Abweichung X=( 0,13 mm): S=St+X=0,81+0,13=0,94 mm
Abweichung X=(+0,12 mm): S=St X 0,81 0,12=0,69 mm
ACHTUNG! Auf einen Wert abrunden, der 0,05 mm am na chsten liegt.
Mit einem Stoel den Dichtring (22) in den Reduzierer-
ko rper (11).
BEMERKUNG. 1 - Sorgfa ltig die Montagerichtung des
Dichtrings kontrollieren.
2 - A
uere Fla che des Dichtrings schmieren.

Den Reduziererko rper (11) unter eine Presse legen
und mit dem Werkzeug T10 die Scheibe des aueren
Lagers (21) einsetzen.
ACHTUNG! Die Scheibe des nicht gekennzeichneten Lagers
einsetzen.
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18.5 Axle DANA 193
BOMAG 1008 008 911 79
Turn the reduction gear body (11) upside down and insert shim "S";
then, with tool T10, insert the thrust block of the internal bearing
(17).
CAUTION! Insert the thrust block of the countermarked bearing.
Fit tool T12 onto tool T11. Then, install bearings (17) and (21) so
that they are opposed to each other and spaced by the distance
piece (20).
Position the depth comparator in one of the four radial holes; pre-
set the comparator to 3 4 mm, then set it to zero.
Remove the bearings from tool T11 and fit them in the thrust blocks
of the reduction gear body.
CAUTION! Check that the countermarked bearing is fitted in the
centring hub of the body of the reduction gear and in the
countermarked thrust block too.
Install tool T11 and tighten it manually to obtain a safe rolling
torque.
NOTE. During tightening, perform a few rotations to set the
bearings.
Introduce the previously reset comparator, in one of the four radial
holes and measure. The deviation from zero indicates the nominal
value "H" relative to the shims that are to be inserted.
The deviation found is to be added to a fixed value of 0.13(0.15
mm. in order to: obtain shim "S1" (to be inserted between internal
bearing (17) and distance piece (20)) and, hence, produce the
specified pre-load of bearings.
CAUTION! Perform accurate measurements - a variation of 0.001 mm
causes a variation in the torque by 20 40 Nm
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F1241208 F1241209
T11
F1241211
T11
F1241221
S
H + 0,13 0,15 = S1
F1241210
T11
F1241212
Axle DANA 193
BOMAG 1009 008 911 79
18.5
77
Capovolgere il corpo riduttore (11) ed inserire lo
spessore "S" e con l'attrezzo T10 la ralla del
ATTENZIONE! Inserire la ralla del cuscinetto contrassegnato.
Volcar el cuerpo reductor (11) y introducir el espesor
"S" y con la herramienta T10 la rangua del cojinete
interno (17).
ATENCION! Introducir la rangua del cojinete segnalado.
Faire basculer le corps re ducteur (11), introduire la
cale "S", et a l'aide de l'outil T10 la crapaudine du
palier interne (17).
ATTENTION! Introduire la crapaudine du palier estampille .
Montare sull'attrezzo T11 l'attrezzo T12. Quindi mon-
tare i cuscinetti (17) e (21) contrapposti ed intervallati
con il distanziale (20).
Posizionare un comparatore di profondita in uno dei quattro fori
radiali; precaricare il comparatore di 3v4 mm ed azzerarlo.
Montar sobre la herramienta T11 la herramienta T12.
Entonces colocar los cojinetes (17) y (12) contra-
puestos y intervalados con el distancial (20).
Colocar un comparador de profundidad en uno de los cuatro
agujeros radiales, precargar el comparador de 3-4 mm y acerarlo.
Monter sur l'outil T11, l'outil T12. Ensuite monter les
paliers (17) et (21) en les superposant et intercalant
avec l'entretoise (20).
Placer un comparateur de profondeur dans l'un des quatre trous
radiaux; pre charger le comparateur a 3v4 mm, puis le mettre a
ze ro.
Rimuovere i cuscinetti dall'attrezzo T11 e montarli
nelle ralle del corpo riduttore.
ATTENZIONE! Controllare che il cuscinetto contras-
segnato sia montato nel mozzo di centratura del corpo riduttore e
quindi nella ralla contrassegnata.
Remover los cojinetes de la herramienta T11 y
montarlos en las ranguas del cuerpo reductor.
ATENCION! Controlar que el cojinete segnalado sea
colocado en el cubo central del cuerpo reductor y por lo tanto en la
rangua segnalada.
Oter les paliers de l'outil T11, puis monter ces
derniers dans les crapaudines du corps re ducteur.
ATTENTION! Contro ler que le palier estampille soit
monte dans le moyeu de centrage du corps re ducteur, donc, dans
la crapaudine estampille e.
Montare l'attrezzo T11 e serrarlo manualmente fino ad
avere una sicura coppia di rotolamento.
NOTA. Durante il serraggio, eseguire alcune rotazioni
per assestare i cuscinetti.
Montar la herramienta T11 y apretarla manualmente
hasta obtener una segura pareja de rotacion.
NOTA. Durante la torsion, efectuar algunas rotaciones
para ordenar los cojinetes.
Monter l'outil T11 et serrer celui-ci a la main jusqu'a
obtenir un couple de roulement assure .
REMARQUE. En serrant, effectuer quelques tours de
rotation pour ajuster les paliers.
Introdurre in uno dei fori radiali il comparatore
azzerato precedentemente ed eseguire la lettura.
Lo scostamento rispetto lo zero, indica il valore
nominale "H" degli spessori da inserire.
Introducir en uno de los agujeros radiales el compa-
rador acerado precedentemente y efectuar la lectura.
El desplazamiento respecto a lo cero, indica el valor
nominal "H" de los espesores de introducir.
Introduire dans l'un des trous radiaux le comparateur
mis a ze ro pre cedemment et en faire la lecture.
L'e cart par rapport au ze ro, indique la valeur nominale
"H" des cales a introduire.
Lo scostamento rilevato e da sommare ad una misura
fissa di 0,13v0,15 mm, per ottenere lo spessore "S1"
(19) da inserire tra cuscinetto interno (17) e distanziale (20) e
quindi, determinare il precarico stabilito per i cuscinetti.
ATTENZIONE! Curare le misurazioni in quanto la variazione di
0,01 mm fa variare la coppia di rotazione di 20v40 Ncm.
El desplazamiento relevado es de sumarse a una
mesura fija de 0,13-0,15 mm, para obtener el espesor
"S1" (19) de introducir entre cojinete interno (17) y distancial (20) y
entonces, determinar el precario establecido para los cojinetes.
ATENCION! Poner atencion a las mesuraciones porque la variacion
de 0,01 mm hace cambiar de ratacion de 20v40Ncm.
L'ecart releve est a additionner a la mesure fixe 0,13v0,15 mm
pour obtenir la cale "S1" (19) a introduire entre le palier interne
(17) et l'entretoise (20) et de finir la pre charge e tablie pour les paliers.
ATTENTION! Effectuer soigneusement les mesurages parce qu'une diffe -
rence de 0,01 mm ame ne une variation du couple de rotation de 20v40 Ncm.
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Den Redurziererko rper (11) wenden und die Unter-
legscheibe "S" einsetzen; mit dem Werkzeug T10 die
Scheibe des inneren Lagers (17) einsetzen.
ACHTUNG! Die Scheibe des gekennzeichneten Lagers einsetzen.
Auf das Werkzeug T11 das Werkzeug T12 montieren.
Dann die entgegengesetzten Lager (17) und (21)
montieren und dazwischen das Distanzstu ck (20)
legen.
Eine Meuhr in eines der vier Radiallo cher positionieren; die
Meuhr auf 3v4 mm vorbelasten und dann zuru ckstellen.
Die Lager vom Werkzeug T11 abnehmen und in den
Scheiben des Reduziererko rpers montieren.
ACHTUNG! Kontrollieren, ob das markierte Lager in
den Zentriernaben des Reduziererko rpers und folglich in der
markierten Scheibe montiert ist.
Das Werkzeug T11 montieren und von Hand fest-
ziehen bis ein sicheres Gegenmoment erreicht ist.
BEMERKUNG. Beim Festziehen einige Umdrehungen
vornehmen, um die Lager richtig in ihren Sitz zu bringen.
In eines der Radiallo cher die zuvor zuru ckgestellte
Meuhr einsetzen und das Ma ablesen.
Die Abweichung im Verha ltnis zur Null, gibt den
Nennwert "H" der einzulegenden Unterlegscheiben an.
Die ermittelte Abweichung mu mit einem Festma von 0,3 (0,15
mm zusammengerechnet werden, um die Unterlegscheibe "S1"
(19) zu ermitteln, die zwischen dem inneren Lager (17) und das Distanzstu ck (20)
gelegt werden mu und um die Vorbelastung der Lager festlegen zu ko nnen.
ACHTUNG! Die Messungen sehr sorgfa ltig vornehmen, da ein Unter-
schied von 0,01 mm das Gegenmoment um 20v40 Ncm vera ndert.
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18.5 Axle DANA 193
BOMAG 1010 008 911 79
With the help of the press, install the internal, countermarked
bearing (17) onto the pinion (16).
CAUTION! Lubricate pinion with oil.
Fit the pinion (16), the shims (19), the distance piece (20) and the
external bearing (21) into the body of the reduction gear (11) and
assemble the unit with a press.
CAUTION! Lubricate pinion with oil.
Fit the reduction gear (11) into the main body (23) without
differential unit; lock temporarily with the two lower screws (9).
Fit the bearing (15) of the motion in gear and lock it.
Fit the gear (12) of the pinion; coat the nut (13) with Loctite 242 and
hand-screw it.
Between the body of the reduction gear (11) and the gear (12) of the
pinion, place block "A" used for disassembling, and tighten the nut
(13) to a minimum required tightening torque of 500 Nm, using a
box wrench and a dynamometric wrench.
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F1241213 F1241214
F1241216 F1241215
F1241217
A
Axle DANA 193
BOMAG 1011 008 911 79
18.5
79
Con la pressa, montare il cuscinetto interno e
contrassegnato (17) sul pignone (16).
ATTENZIONE! Lubrificare il pignone con olio.
Con la prensa, montar el cojinete interno y segnalado
(17) sobre el pinon (16).
ATENCION! Lubrificar el pinon con aceite.
A l'aide de la presse, monter le palier interne
estampille (17) sur le pignon (16).
ATTENTION! Lubrifier le pignon avec de l'huile.
Montare nel corpo riduttore (11) il pignone (16), gli
spessori (19), il distanziale (20) ed il cuscinetto esterno
(21) ed assemblare il gruppo con la pressa.
ATTENZIONE! Lubrificare il pignone con olio.
Montar en el cuerpo reductor (11) el pinon (16) los
espesores (19), el distancial (20) y el cojinete esterno
(21) y asemblar el grupo con la prensa.
ATENCION! Lubrificar el pinon con aceite.
Monter dans le corps re ducteur (11), le pignon (16), les
cales (19), l'entretoise (20) et le palier externe (21),
assembler le groupe a l'aide de la presse.
ATTENTION! Lubrifier le pignon avec de l'huile.
Montare il corpo riduttore (11) sul corpo centrale (23)
privo di differenziale e fissarlo provvisoriamente con le
due viti inferiori (9).
Montare il cuscinetto (15) dell'ingranaggio di entrata del moto e
mandarlo in battuta.
Montar el cuerpo reductor (11) sobre el cuerpo central
(23) sin el diferencial y fijarlo provisoriamente con los
dos tornillos inferiores (9).
Asemblar el cojinete (15) del engranaje de entrada del movimiento
y mandarlo a tope.
Monter le corps re ducteur (11) sur le corps central (23)
sans diffe rentiel et fixer provisoirement ce dernier
avec les deux vis inferieures (9).
Monter le palier (15) de l'engrenage d'acce s au mouvement, puis
l'envoyer en bute e.
Montare l'ingranaggio (12) del pignone; spalmare il
dado (13) con Loctite 242 ed avvitarlo manualmente.
Asemblar el engranaje (12) del pinon, pasar la tuerca
(13) con Loctite 242 y atornillarla manualmente.
Monter l'engrenage (12) du pignon; enduire l'e crou
(13) avec du Loctite 242 et visser celui-ci a la main.
Sistemare tra il corpo riduttore (11) e l'ingranaggio (12)
del pignone il blocchetto "A" usato per lo smontaggio
e serrare il dado (13) alla coppia minima di 500 Nm,
utilizzando una chiave a bussola ed una chiave dinamometrica.
Colocar entre el cuerpo reductor (11) y el engranaje
(12) del pinon el bloquete "A" usado para el
desmontaje y apretar la tierca (13) al valor minimo
de 500 Nm, utilizando una llave a manguito y una llave
dinamometrica.
Placer, entre le corps re ducteur (11) et l'engrenage
(12) du pignon, le petit bloc "A" utilise au de montage,
serrer l'ecrou (13) au couple minimum de 500 Nm a
l'aide d'une cle a pipe et d'une cle dynamome trique.
ITA
ESP
F
ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
ESP
F
ITA
f
e
d c
b
a
Mit einer Presse, das innere und markierte Lager (17)
auf das Kegelrad (16) montieren.
ACHTUNG! Rad mit O
l schmieren.
In den Reduziererko rper (11) das Kegelrad (16), die
Unterlegscheiben (19), das Distanzstu ck (20) und das
a uere Lager (21) montieren und das Aggregat mit der
Presse zusammenbauen.
ACHTUNG! Rad mit O
l schmieren.
Den Reduziererko rper (11) auf den zentralen Ko rper
(23) ohne Differential montieren und voru bergehend
mit den zwei unteren Schrauben (9) befestigen.
Das Lager (15) des Einganggetriebes montieren und bis zum
Anschlag einsetzen.
Das Getriebe (12) des Kegelrads montieren; Mutter
(13) mit Loctite 242 schmieren und von Hand
zuschrauben.
Zwischen dem Reduziererko rper (11) und dem Getrie-
be (12) des Kegelrads den Block A legen, der zum
Abmontieren verwendet wurde, und Mutter (13) mit
einem Anzugsmoment von mindestens 500 Nm mit einem
Inbuschlu ssel und einem Dynamometer festziehen.
D D
D D
D D
18.5 Axle DANA 193
BOMAG 1012 008 911 79
GB b
GB a
Allow the pinion to rotate a few times in both directions to enable
bearings to set.
Apply bar-hold T13 onto pinion (16) and, with a torque meter, check
the torque of the pinion.
Torque: 140 150 Ncm.
CAUTION! If torque exceeds the maximum value, then the shim
"S1" (19) placed between bearing (17) and distance piece (20)
needs to be increased.
If torque does not reach the set value, increase the tightening
torque setting of nut (13), in different stages, until the maximum
admitted value of 700 Nm is obtained.
CAUTION! If torque does not reach the minimum value, then the
shim "S1" (19) needs to be reduced.
CAUTION! In order to be able to calculate the increase or reduction
of shim "S1", it is necessary to bear in mind that a 0.01 mm
variation in the size of shim (19) results in the torque of the pinion
(16) varying by 20 40 Ncm.
Remove the whole reduction gear body (11) and continue with the
assembly of the differential unit and arms.
For details, see ASSEMBLY AND INSTALLATION OF THE
DIFFERENTIAL UNIT - ASSEMBLING THE BRAKING UNIT.
80

F1241226
F1241217
T13
Axle DANA 193
BOMAG 1013 008 911 79
18.5
a
b
Hacer efectuar al pinon algunos giros en los dos
sentidos para ordenar los cojinetes.
Aplicar sobre el pinon (16) el codolo T13 y con un
torsiometro, controlar el par de rotacion del pinon.
Par de rotacion: 140v150 Ncm.
ATENCION! Si el par supera el valor maximo hay que augmentar el
espesor "S1" (19) entre cojinete (17) y distancial (20).
Si el par de rotacion no llega al valor establecido, augmentar el par
de torsion de la tuerca (13) en mas tiempos hasta llegar al valor
maximo admitido de 700 Nm.
ATENCION! Si el par de rotacion no llega al valor minimo, es
necesario disminuir el espesor "S1" (19).
ATENCION! Al fin de poder calcular los encrementos o la
disminuciones del espesor "S1", es necesario considerar que la
variacion del espesor (19) de 0,01 mm, hacer cambiar el par de
rotacion del pinon (16) de 20v40 Ncm.
Faire faire quelques tours au pignon dans les deux
sens de manie re a ajuster les paliers.
Appliquer sur le pignon (16), la queue T13, puis a
l'aide d'un torsiome tre, contro ler le couple de rotation du pignon.
Couple de rotation: 140v150 Ncm.
ATTENTION! Si le couple de rotation de passe la valeur maximum,
augmenter la cale "S1" (19) entre le palier (17) et l'entretoise (20).
Si le couple de rotation n'atteint pas la valeur e tablie, augmenter le
couple de serrage de l'ecrou (13), en plusieurs temps, jusqu'a
atteindre la valeur maximum admise de 700 Nm.
ATTENTION! Si le couple de rotation n'atteint pas la valeur
minimum, diminuer la cale "S1" (19).
ATTENTION! Pour pouvoir calculer les augmentations et les
diminutions de la cale "S1", tenir compte que la diffe rence de
0,01 de la cale (19) fait varier le couple de rotation du pignon (16) de
20v40 Ncm.
Das Kegelrad um einige Umdrehungen in beide
Richtungen drehen, um die Lager richtig einzusetzen.
Am Kegelrad (16) den Schaft T13 anbringen und mit
einem Drehungsmesser das Gegenmoment des Ke-
gelrads kontrollieren.
Gegenmoment: 140v150 Ncm.
ACHTUNG! Falls der Wert den Maximalwert u berschreitet, braucht
es eine gro ere Unterlegscheibe "S1" (19) zwischen Lager (17) und
Distanzstu ck (20).
Falls das Gegenmoment den festgelegten Wert nicht erreicht, das
Anzugsmoment der Mutter (13) schrittweise erho hen, bis der
maximal zula ssige Wert von 700 Nm erreicht worden ist.
ACHTUNG! Falls das Gegenmoment den Mindestwert nicht
erreicht, mu die Unterlegscheibe "S1" (19) kleiner sein.
ACHTUNG! Um das ho here oder niedrigere Ma der Unter-
legscheibe "S1" ausrechnen zu ko nnen, darauf achten, da ein
Unterschied von 0,01 mm der Unterlegscheibe (19) das Gegen-
moment des Kegelrads (16) um 20v40 Ncm a ndert.
D
ESP F
Far compiere al pignone alcuni giri nei due sensi per
assestare i cuscinetti.
Applicare sul pignone (16) il codolo T13 e con un
torsiometro, controllare la coppia di rotazione del pignone.
Coppia di rotazione: 140v150 Ncm
ATTENZIONE! Se la coppia supera il valore massimo bisogna
aumentare lo spessore "S1" (19) tra cuscinetto (17) e distanziale
(20).
Se la coppia di rotazione non raggiunge il valore stabilito,
aumentare la coppia di serraggio del dado (13) in piu tempi fino a
raggiungere il valore massimo ammesso di 700 Nm.
ATTENZIONE! Se la coppia di rotazione non raggiunge il valore
minimo, e necessario diminuire lo spessore "S1" (19).
ATTENZIONE! Al fine di poter calcolare gli incrementi o la
diminuzione dello spessore "S1", e necessario considerare che la
variazione dello spessore (19) di 0,01 mm, fa variare la coppia di
rotazione del pignone (16) di 20v40 Ncm.
ITA
81
Rimuovere il corpo riduttore completo (11) e procedere
con il montaggio del differenziale e dei bracci.
Per i dettagli, vedere ASSEMBLAGGIO ED INSTAL-
LAZIONE GRUPPO DIFFERENZIALE - ASSEMBLAGGIO GRUP-
PO FRENO.
Den kompletten Reduziererko rper (11) abnehmen und
das Differential und die Arme montieren.
Siehe ZUSAMMENBAU UND INSTALLATION DES
DIFFERENTIALAGGREGATS - ZUSAMMENBAU DES BREMSAG-
GREGATS.
Remover el cuerpo reductor completo (11) y proceder
con el montaje del diferencial y de los ejes.
Para los detalles, vease ASEMBLAJE Y INSTALA-
CION GRUPO DIFERENCIAL - ASEMBLAJE GRUPO FRENO.
Enlever le corps re ducteur complet (11) et aller de
l'avant avec le montage du differentiel et des bras.
Pour de plus amples de tails, voir "ASSEMBLAGE ET
INSTALLATION DU GROUPE DIFFERENTIEL - ASSEMBLAGE
DU GROUPE FREIN".
D
ESP
F
ITA
18.5 Axle DANA 193
BOMAG 1014 008 911 79
82
SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL
3
2
3
2
3
2
3
2
10
4.5
2
5
4
5
1
1
0
1
6
0
2
5 1
4.3
4
5
8
1
T1
2313 D1240046
2
0
0
=
=
90
==
2
0
5
0
1
2
0
0
.
1
840
930
1
2
0
0
.
1
T2
2305 D1240043
32
125
3
2
3
2
178
20
184
4
5
2
5
1
5
0
40
x
4
5
3
R
1
0
1
9
5
T3
1502 D1240120
1
5
0
40
x
4
5
3
R
1
0
1
0
8
x
4
5
3
153
154
178
189
200
4
0
1
7
1
3
1
9
0
32
32
32
T4
1742 D1240121
-- 0.2
-- 0.3 107.5
3
5 --
0
.
4
--
0
.
6
4
5
--
0
.
0
5
--
0
.
1
4
6
--
0
.
3
--
0
.
4
6
3
6
1
8
0
2
5
295
x45 3
150 10 136
65
27.5
20
x15 3
R
1
0
3
2
32
32
32
T5
1501 D1240122
Axle DANA 193
BOMAG 1015 008 911 79
18.5
83
A
A
3
2
68
80
12
3
2
2
2
3
1
8
12
x15 3
5
75
12
1
6
2
6
271
290
4
3
.
6
0
8
2
.
1
3
1
1
3
.
4
8
1
3
4
.
9
1
53.14
90.26
119.50
139.29
20
Sez. A - A
32
32
21 30'
1
7
1
7
3
0
'
2 1 3 0 '
B
B
1
7
1
7
1
7
3
0
'
1
7
1
7
1
7
2
2
1
5
82
Sez. B - B
n2 pezzi
1
6
H

7
1
5
0
H

7
n

6
1
5
0
T6
1545 D1240124
32
32
32
32 32
3
2
21 30'
1
7
3
0
'
1
7
1
7
1
7
1
7
3
0
'
1
7
1
7
1
7
2 1 3 0 '
A
2
5
1
6
190
9
2
0
20
x30 2
1
7
2
2
5
0
1
6
16 20
x15 5
110
143
153
1
5
1
6
1
.
5
0
.
1
--
0
.
0
8
--
0
.
1
2
1
8
5
--
0
.
1
5
--
0
.
2
5
2
6
2
--
0
.
1
5
--
0
.
2
5
2
6
4
3
2
0
4
3
.
6
0
8
2
.
1
3
1
3
4
.
9
1
1
1
3
.
4
9
119.50
53.14
90.26
138.29
290
0.15
70
30 30
x15 3
3
0
40
200
74
200
400
2
4
3
8
1
4
0
--
0
.
0
8
--
0
.
1
2
1
5
0
R
1
0
R
1
0
R
5
R
5
R
1
0
R
1
0
1
5
H

7
g

6
2
5
2
3
,
9
1.2
h 11
2
4
2
PROFILO HURT 45.5 x 40.5
Particolare A
T7
T7B
T7A
1769 D1240125
18.5 Axle DANA 193
BOMAG 1016 008 911 79
84
SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL
0
.
8
0.8
x
4
5
3
25
1
9
2
129
1
6
0
1
0
2
2

R
1
0
T8
] Bearing ref. 32017 DIN720
] Ref. cuscinetto 32017 DIN720
] Lager Ref. 32017 DIN720
] Ref. cojinete 32017 DIN720
] Re f. palier 32017 DIN720
0355 D1240123
A A
0
-- 0.05 23.9
H7
g7 25
30
80
92
-- 0.1
-- 0.15 40.5
1
.
5
3
3
5
.
5
4
0
4
0
1
3
5
1
6
1
5
2
0
3
0
4
9
0
40
600
1
2
0
+

0
--
0
.
2
1
0
2

0
.
.2
1
3
85.5
1
0
2
2
4
8
3
0
7
8
R
1
0
R
2
4
.
5
+
0
-- 0
.5
9
5
Acciaio 18 Ni Cr Mo 5
Cementazione 0.60.8
Temprato HRC 6063
Acciaio Fe 42
Acciaio Fe 42
Es Ch 22
40
3
2
3
2
Sez. A-A
32
T9
1495 D1240128
3
2
32
x
4
5
3
25
1
8
8
109
1
5
0
8
3
0
R
1
0
104
20
T10
1487/B D1240126
Axle DANA 193
BOMAG 1017 008 911 79
18.5

85
+ 0
-- 0.03 41.2
20
x1 M14
2
5
5
0
2
5
9
5
5
0
1
0
1
9
5
110
x1 M14
65
2
0
4
1

0
.
0
1

0
.
0
2
6
1
3
0
R
5
40
1
5
300
x
4
5
4
20
9
8
0
3
5
1
1
6.5
x1 M14
T11
2312 D1240075
9
3
49.8
41.5
T12
2323 D1240127
1
/
4
"
3/4"
2
5
1
0
2
5
35
C
h
2
2
14
4
5
6
0
T13
0870 D1240129
18.5 Axle DANA 193
BOMAG 1018 008 911 79
BOMAG 1019 008 911 79
18.6 Auxiliary pump for plate, series
BOMAG 1020 008 911 79
Auxiliary pump for plate, series
BOMAG 1021 008 911 79
18.6
BOMAG 1022 008 911 79
2
1. Introduction
1.1 Using This Manual
1.2 Safety Precautions
Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury.
The following general precautions should be taken into consideration whenever servicing a hydrostatic system.
The Adjustment and Minor Repair procedures de-
tailed herein may be performed by trained personnel
without voiding the unit warranty.
Cleanliness is a primary means of assuring satisfac-
tory 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 per-
forming service activities, protect all exposed sealing
surfaces and open cavities from damage and foreign
material.
Whenever removing a service component, it is rec-
ommended that any gaskets and O-rings be re-
placed. Lightly lubricate all O-rings with clean petro-
leum jelly prior to assembly. All gasket sealing sur-
faces must be cleaned prior to installing new gaskets.
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:
Loss of Hydrostatic Braking Ability
WARNING
When Series 42 units are used in vehicular
hydrostatic drive systems, the loss of hydro-
static drive line power in any mode of opera-
tion (e.g. acceleration, deceleration or neu-
tral 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 con-
dition develop.
Disable Work Function
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
Fluid Under High Pressure
WARNING
Use caution when dealing with hydraulic fluid
under pressure. Escaping hydraulic fluid un-
der pressure can have sufficient force to pen-
etrate 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 immedi-
ately.
Flammable Cleaning Solvents
WARNING
Some cleaning solvents are flammable. To
avoid possible fire, do not use cleaning sol-
vents in an area where a source of ignition may
be present.
Copyright 1996-1998, Sauer-Sundstrand GmbH & Co.
All rights reserved. Contents subject to change. Printed in Germany.
Apply petroleum jelly.
Lubricate with clean hydraulic oil.
F000719
BOMAG 1023 008 911 79
18.6
3
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
BOMAG 1024 008 911 79
BOMAG 1025 008 911 79
18.6
5
Series 42 Component and Port Locations
3. Component and Port Locations
3.1 Component Locations
Shaft
Seal
Charge Relief Valve
Filtration Options
(No Filtration Adapter Shown Here)
System Check
Relief Valves
Auxiliary
Mounting Pad (Loop Flushing
Valve)
Charge
Pump
Right Side View (Side "1") Left Side View (Side "2")
Control Module
(MDC Shown)
Displacement
Limiters
Control Neutral Adjustment
(MDC/EDC)
Servo Piston
Covers
Pump Neutral Adjustment
Control Module
(MDC Shown)
Displacement
Limiters
Shaft Seal
Charge
Pump
Auxiliary
Mounting
Pad
(Loop Flushing Valve)
System Check
Relief Valves
Charge Relief Valve
Left Side View (Side "2") Right Side View (Side "1")
Filtration Options
(No Filtration Adapter
Shown Here)
Control Neutral Adjustment
(MDC/EDC)
Servo Piston
Covers
Pump Neutral Adjustment
Series 42 28cc Variable Pump
Series 42 41cc Variable Pump
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).
P100101 E
P100102 E
BOMAG 1026 008 911 79
6
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-
ments. The following outlines show the locations of
the various gauge ports. The tables show the recom-
mended gauge size and the fitting size for each port.
Refer to this page when installing pressure gauges.
Right Side View (Side "1") Left Side View (Side "2")
Case Drain
Port L1
Charge Pump
Inlet Port S
Charge Pressure
Gauge Port M3
(Charge Pressure
Supply For
No Charge Pump
Option)
Servo Pressure
Gauge Port M4
Case Drain
Port L2
Servo Pressure
Gauge Port M5
System
Pressure
Port B
System Pressure
Gauge Port M2
System Pressure
Gauge Port M1
System
Pressure
Port A
Case Drain Port L2
(Non-Feedback
Controls)
Case Drain Port L1
(Non-Feedback
Controls)
28cc Base Unit with MDC and No Filtration Adapter
P100103 E
e g u a G
e m a N t r o P
d e r u s a e M e r u s s e r P
e z i S e g u a G
g n i t t i F
8 2 0 1 4 0
2 M & 1 M
r o f e r u s s e r P m e t s y S
B d n a A s t r o P
i s p 0 0 0 0 1 r o r a b 0 0 6 g n i t t i F g n i R - O 8 1 - 6 1 / 9 g n i t t i F g n i R - O 8 1 - 6 1 / 9
3 M e r u s s e r P e g r a h C i s p 0 0 0 1 r o r a b 0 6 g n i t t i F g n i R - O 6 1 - 4 / 3 g n i t t i F g n i R - O 6 1 - 4 / 3
5 M & 4 M e r u s s e r P o v r e S i s p 0 0 0 1 r o r a b 0 6 g n i t t i F g n i R - O 8 1 - 6 1 / 9 g n i t t i F g n i R - O 8 1 - 6 1 / 9
2 L & 1 L e r u s s e r P e s a C i s p 0 0 5 r o r a b 5 3 g n i t t i F g n i R - O 2 1 - 6 1 / 1 - 1 g n i t t i F g n i R - O 2 1 - 6 1 / 5 - 1
S
t e l n I p m u P e g r a h C
m u u c a V
e t u l o s b a , r a b 1
m u u c a V g H n i 0 3 r o
g n i t t i F g n i R - O 2 1 - 6 1 / 1 - 1 g n i t t i F g n i R - O 2 1 - 6 1 / 5 - 1
E 5 2 0 0 0 0 T
BOMAG 1027 008 911 79
18.6
7
Left Side View (Side "2") Right Side View (Side "1")
Charge Pump
Inlet Port S
Charge Pressure
Gauge Port M3
(Charge Pressure
Supply For
No Charge Pump
Option)
Servo Pressure
Gauge Port M4
Servo Pressure
Gauge Port M5
System
Pressure
Port B
System Pressure
Gauge Port M2
System Pressure
Gauge Port M1
System
Pressure
Port A
Case Drain
Port L2
Case Drain
Port L1
To Filter, Port D
(Pressure Filtration)
Charge Pressure
Gauge Port M3
(Partial Flow Pressure Filtration)
Charge Pressure
Gauge Port M3
(Full Flow Pressure Filtration)
From Filter, Port E
(Pressure Filtration)
Charge Pressure
Gauge Port M3
(Suction Filtration)
41cc Base Unit with MDC and No Filtration Adapter
Filtration Adapter (28cc and 41cc Models)
P100105 E
P100104 E
BOMAG 1028 008 911 79
8
Series 42 Adjustments and Minor Repairs
Servo Gage
Port M4
Servo Gage
Port M5
Case Drain
Port L1
Case Drain
Port L2
System Gage
Ports M1 and M2
Charge Pressure Gage
Port M3 (Position Varies,
Refer to Filtration Options)
Charge Pump Inlet
Port S
Torque: 115 Nm (85 ftlbf)
11/16 in Hex
27-47 Nm
(20-35 ftlbf)
11/16 in Hex
27-47 Nm
(20-35 ftlbf)
11/16 in Hex
27-47 Nm
(20-35 ftlbf)
11/16 in Hex
27-47 Nm
(20-35 ftlbf)
System Ports
A and B
115 Nm (85 ftlbf)
9/16 in Int. Hex
95-135 Nm
(70-100 ftlbf)
28cc:
5/8 in Int. Hex
125-250 Nm
(90-190 ftlbf)
41cc:
Port N
(Unused)
9/16 in Int. Hex
95-135 Nm
(70-100 ftlbf)
28cc:
5/8 in Int. Hex
125-250 Nm
(90-190 ftlbf)
41cc:
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.
E100001 E
BOMAG 1029 008 911 79
18.6
9
4.2 Pump Neutral Adjustment
Pump "Neutral"
Adjustment Seal
Lock Nut
Pump "Neutral"
Adjustment Screw
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.
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.
6. Turn the adjustment screw clockwise until one of
the gauges registers an increase in system pres-
sure. Note the position of the adjustment screw.
Turn the screw counterclockwise until the other
gauge registers an increase in system pressure.
Note the position of the adjustment screw.
7. Turn the adjustment screw clockwise to a posi-
tion halfway between the positions noted above.
The system pressure gauges should indicate
equal pressures.
8. While holding the adjustment screw in position,
torque the seal lock nut [28cc 20-26 Nm (15-19
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).
Pump Neutral Adjustment Screw
(MDC Control Shown)
E100002 E
BOMAG 1030 008 911 79
1 0
4.3 Control Neutral Adjustment for MDC/EDC Controls
The control neutral adjustment aligns the pump swash-
plate 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.
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.
4. Loosen the CONTROL "neutral" adjustment seal
lock nut (see drawing) [17 mm Hex] . Turn the
control "neutral" adjustment screw [5 mm Int.
Hex] until the servo piston pressure gauge read-
ings are as close to equal as possible.
5. Turn the adjustment screw clockwise until one of
the gauges registers an increase in pressure on
the servo piston. Note the position of the adjust-
ment screw.
Turn the screw counterclockwise until the other
gauge registers an increase in pressure on the
servo piston. Note the position of the adjustment
screw.
6. Turn the adjustment screw clockwise to a posi-
tion halfway between the positions noted above.
The servo piston pressure gauges should indi-
cate nearly equal pressures.
7. While holding the adjustment screw in position,
torque the seal lock nut [14-24 Nm (10-18 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.
Control Neutral Adjustment Screw
(EDC Control Shown)
MDC / EDC Control
"Neutral" Adjustment Screw
MDC / EDC Control "Neutral"
Adjustment Seal Lock Nut
E100003 E
BOMAG 1031 008 911 79
18.6
1 1
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 nec-
essary, 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.
Note: See section 4.6 for instructions on remov-
ing/installing the control spool and linkage.
3. Clean the sealing surfaces of the control and the
pump housing. Place a new gasket in position on
the housing.
CAUTION
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 install-
ing the control. (The spring on the control spool
will tend to push the link to an extreme position.)
The link pin MUST engage the slot in the control
cam. A plug is provided on the MDC housing to
permit visual inspection of linkage pin engage-
ment.
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 Adjust-
ment (Section 4.3).
WARNING
Failure to properly engage the link pin with the
control cam will result in incorrect control
operation, which may lead to loss of control of
the vehicle / machine.
4.4 MDC Control Module
Plug for
Visual
Inspection
Control
Retaining
Screws
Nut
Lock Washer
MDC Handle
Hold summing link
(and control spool)
in position
Control
Gasket
MDC Control Module Assembly
Link Pin Into Cam Slot
Summing
link pin
MUST enter
the slot in
the control
cam!
Link Pin Into Cam Slot
E100004 E
E100005 E
F100201
BOMAG 1032 008 911 79
1 2
Summing
link pin
MUST enter
the hole in
the control
piston fork!
Hold summing
link (and control
spool) in
position
Control
Gasket
Control Retaining
Screws (note different sizes)
EDC Control Module Assembly
The Electric Displacement Control (EDC) provides a
control function through connections to the summing
link pin within the pump housing. The following pro-
cedure 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 nec-
essary, remove control input signal.
2. Remove the seven (7) control retaining screws
[Torx T30] that secure the control to the pump
housing. Note the position of the different length
screws. Remove the control and control gasket
from the pump.
Note: See next section for instructions on remov-
ing/installing the control spool and linkage.
3. Clean the sealing surfaces of the control and the
pump housing. Place a new gasket in position on
the housing.
CAUTION
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 install-
ing the control. (The spring on the control spool
will tend to push the link to an extreme position.)
The link pin MUST engage the hole in the control
piston fork.
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 Adjust-
ment (Section 4.3).
WARNING
Failure to properly engage the link pin with
control piston fork will result in incorrect con-
trol operation, which may lead to loss of con-
trol of the vehicle / machine.
4.5 EDC Control Module
EDC Control
Pressure Gauge
Port X2
EDC Control
Pressure Gauge
Port X1
EDC Module Showing Port Locations
P100106 E
E100006 E
BOMAG 1033 008 911 79
18.6
1 3
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.
Removal of Spool, Linkage, and Adjustment
Screw
1. Clean the external surfaces of the pump.
2. Remove the MDC or EDC module and the control
gasket from the pump housing (see previous two
sections).
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.
5. Remove the linkage pivot screw [4 mm Int. Hex],
feedback link, and neutral adjustment link.
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.
2. Assemble the "neutral" adjustment link and feed-
back link, and install as shown. Install and torque
the linkage pivot screw [8-15 Nm (6-11 ftlbf)].
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 [41-
94 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.
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).
Control Spool
Bore Plug
Seal Lock
Nut
Feedback Link
Neutral
Adjustment
Link
Summing Link
Linkage Pivot Screw
Control Neutral
Adjust Screw
Opposite
Bore Plug
Control
Spool
and Spring
Gasket
Control Spool
Bore Cover
Housing without
Filtration Adapter
Housing with
Filtration Adapter
Note
orientation!
Pivot screw
Slot in "neutral" adjust link
must engage groove in
adjusting screw
Fork on summing link
must engage flats on
control spool
Feedback link
must enter slot in
servo piston
MDC/EDC Control Spool and Linkage
Servo Piston Linkage and Control Spool
(Internal Parts Shown with Housing Removed)
E100007 E
E100008 E
BOMAG 1034 008 911 79
1 4
Knurl
2.000
.354
1.250
.306
.236.030
R.125
9/16 -18UNF 2A THD
35.0
.04 x 45 Chamfer
Material: .75 DIA x 3 ETD150
(All Dimensions in inches)
Alignment Tool
4.7 MDC Neutral Start/Backup Alarm Switch
NSS Cover
NSS Control Nut
NSS Cam
NSS Cavity
NSS with
Weatherpack
NSS with Screw
Terminals
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.
The Backup Alarm Switch (BUA) outputs an elec-
tronic 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.
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).
The Neutral Start / Backup Alarm Switch assembly
can be configured for three different settings.
i. A Neutral Start Switch only.
ii. A Neutral Start Switch with Backup Alarm for
units where clockwise (CW) handle rotation re-
sults in "reverse" motion.
iii. A Neutral Start Switch with Backup Alarm for
units where counterclockwise (CCW) handle ro-
tation results in "reverse" motion.
The setting must be in accordance with the configu-
ration of the unit. See the model code (section 2) if
uncertain of the type of NSS you have.
Alignment of the NSS requires a special alignment
tool. Dimensions are given at right.
(continued)
NSS only NSS with BUA
(CW = Reverse)
NSS with BUA
(CCW = Reverse)
Control
Cam
Yolk
NSS Assembly on MDC
Top View of NSS Showing Cam Positions
E100009 E
P100107 E
P100108 E
BOMAG 1035 008 911 79
18.6
1 5
NSS Cover
NSS Control Nut
NSS Cam
NSS
Side View of NSS and NSS Cavity
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.
2. Remove NSS [7/8 in Hex].
3. Remove the NSS cover by inserting a screw-
driver into the NSS cavity and popping off the
cover with a hammer. Be careful not to damage
the internal hardware.
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)).
11. Remove the alignment tool and the 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).
Underside of MDC Module Showing Where to Clamp
Locking Pliers
P100109 E
F100202
BOMAG 1036 008 911 79
1 6
4.8 MDC Solenoid Override Valve
The solenoid override valve is a safety feature that
connects both ends of the servo control piston to-
gether when the solenoid is de-energized. Thus the
pump can be put into stroke only when the solenoid
is energized.
The solenoid override with brake release includes
hydraulic control of a safety brake. When de-ener-
gized, a spring-applied, hydraulically-released brake
is drained through port X7. For conditions where case
back-pressure on the spring-applied brake is critical,
an external drain to the reservoir can be connected
through port L4.
The solenoid override valve can be removed to
inspect and remove foreign matter.
Removal
1. Remove retaining nut [9/16 in Hex].
2. Remove solenoid housing.
3. Remove retaining ring at base of solenoid.
4. Remove solenoid. This should be connected to
internal spool.
Installation
1. Replace O-ring.
2. Place spring and plunger inside of solenoid.
3. Attach spool (male notch) to plunger (female
notch).
4. Insert solenoid/spool assembly in solenoid over-
ride bore.
5. Snap retaining ring over base of solenoid.
6. Place washer at base of solenoid.
7. Install housing and retaining nut [2-4 Nm (1.5-3.5
ftlbf)].
Solenoid Override Valve
Assembly
Port X7
Port L4
Solenoid Override Valve Assembly
Solenoid
Retaining Ring
Washer
Solenoid
Housing
Retaining Nut
O-Ring
Spring
Plunger
Spool
Exploded View of Solenoid Override Assembly
E100010 E
E100011 E
BOMAG 1037 008 911 79
18.6
1 7
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].
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.
Note: Future models may contain orifice plate
between module and pump housing.
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.
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].
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.
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)].
Non-Feedback
Control Orifice
Location of Non-Feedback Control Orifice
NFPE Assembly (FNR Similar)
Control Solenoid
Control Module
Control Ports
Locator Pin
NFPH Ports
(Ports X1 and X2)
Position of NFPH Ports
E100014 E
E100013 E
E100012 E
BOMAG 1038 008 911 79
1 8
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.
1. Remove the valve seat plugs [9 mm Int. Hex] or
valve seat/bypass plugs [1 in Hex] from the pump
housing.
2. Remove the check poppet or relief valve assem-
blies 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.
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.
5. Install a new outer O-ring, new backup ring, and
new inner O-ring on each valve seat plug.
6. Check that the conical springs are properly re-
tained on the check poppets or relief valves.
Install the check poppet or high pressure relief
valve assemblies into the pump housing .
CAUTION
The conical springs MUST be correctly posi-
tioned on the check poppets or relief valves
after installation for proper pump operation.
7. Install the valve seat plugs or valve seat/bypass
plugs into the pump housing and torque [40-95
Nm (30-70 ftlbf)].
Valve
Seat
Backup
Ring
Inner
O-Ring
Check Poppet or
High Pressure
Relief Valve
Conical Spring
Outer
O-Ring
Without
Bypass
With
Bypass
Retaining
Ring
Standard
Bypass
Plunger
O-Ring
Valve
Seat
Plug
Valve
Seat
Plug
Outer
O-Ring
Backup
Ring
Inner
O-Ring
System Check Relief Valve Components
E100015 E
BOMAG 1039 008 911 79
18.6
1 9
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.
2. Remove the spring and poppet from the housing.
3. Do not alter the shims which may be installed
between the spring and valve plug, or inter-
change parts with another valve. Inspect the
poppet and mating seat in the housing for dam-
age or foreign material.
4. If desired, the charge relief valve setting can be
changed. An 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, mea-
sure 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 O-
ring) into the pump housing [55-135 Nm (40-100
ftlbf)].
(continued)
Shim Adjustable
Charge Relief Valve Plug
Spring
Poppet
Shims
O-Ring
Shim Adjustable Charge Relief Valve Components
E100016 E
s s e n k c i h T m i h S s v g n i t t e S f e i l e R e t a m i x o r p p A
m m 5 2 . 1 / r a b 4 ) n i 0 5 0 . 0 / i s p 8 5 (
E 3 2 0 0 0 0 T
BOMAG 1040 008 911 79
2 0
Charge Relief Lock Nut
Screw Adjustable
Charge Relief Valve Plug
O-Ring
Spring
Poppet
Screw Adjustable Charge Relief Valve Components
Screw Adjustable Style
1. Before removing the screw adjustable relief valve
plug, mark the plug, lock nut, and housing so as
to approximately maintain the original adjust-
ment when assembling, Remove the screw ad-
justable charge relief valve plug by loosening the
lock nut [1-1/16 in Hex] and unscrewing the plug
[8 mm Int. Hex]. Remove the O-ring from the plug.
3. Inspect the poppet and mating seat in the hous-
ing 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.
5. Check and adjust, if necessary, the charge pres-
sure. For screw adjustable "anti-stall" charge
relief valves, an approximate rule of thumb is 2.8
bar / quarter turn (40 psi / quarter turn).
To confirm the charge relief valve setting, mea-
sure charge pressure (port M3) with the pump in
stroke. The charge pressure should level off
when the relief setting is reached.
E100017 E
n o i t u l o v e R w e r c S s v g n i t t e S f e i l e R e t a m i x o r p p A
1 / r a b 8 . 2 n r u t 4 1 / i s p 0 4 ( ) n r u t 4
E 4 2 0 0 0 0 T
BOMAG 1041 008 911 79
18.6
2 1
4.12 Loop Flushing Valve
The loop flushing function consists of the loop flush-
ing shuttle valve and the loop flushing relief valve. The
assemblies may be removed for cleaning and instal-
lation 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 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.
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 be-
tween the spring and valve plug, or interchange
parts with another valve. Inspect the poppet and
mating seat in the housing for damage or foreign
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)].
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)].
Spring
Poppet
Shims
O-Ring
O-Ring
Loop Flushing Relief
Plug (Defeat)
O-Ring
Loop Flushing
Plug (Defeat)
Defeat
Spool
O-Ring
Loop
Flushing
Plug
Loop
Flushing
Spool
Assembly
Loop Flushing
Relief Plug
Loop Flushing Valve and Loop Flushing Defeat
Components
E100018 E
BOMAG 1042 008 911 79
2 2
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 re-
quires removal of the pump from the machine.
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 diffi-
cult.
2. Remove the retaining ring from the housing.
3. Pull out seal carrier assembly.
4. Remove the O-ring from the seal carrier. To
install a new shaft only, proceed to step 8.
5. Place the seal carrier in an arbor press with the
shaft bearing side down, and press out the old
seal. An appropriately sized pipe spacer or socket
wrench can be used as a press tool. Once re-
moved, the seal is not reusable.
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.
(continued)
Retaining
Ring
Seal Carrier
Assembly
Shaft Seal Components
Installation of Shaft Seal
Press Seal
to bottom of Seal Carrier
Seal
Seal Carrier
O-Ring
Sealant may
be used on
outside diameter
Inside Lip
(face down)
E100019 E
E100020 E
BOMAG 1043 008 911 79
18.6
2 3
If the shaft is not being replaced proceed to step
11.
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).
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.
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.
Retaining Ring
Roller Bearing
Key
Shaft Assembly
OR
OR
Shaft
Shaft Components
E100021 E
BOMAG 1044 008 911 79
2 4
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
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.
2. Orient pump so that charge pump cover (auxiliary
pad) is facing up.
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 re-
moving 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.
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 produc-
tion 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.
6. Attach the auxiliary pump. If no pump is to be
attached on an auxiliary mounting pad, the pad
should be protected with a flange cover and O-
ring to prevent leakage.
Locating
Pin 2
Locating
Pin 1
Gasket
Auxiliary
Mounting
Pad "B"
Retaining
Screws
Aux Mount Pad Cover
O-Ring
Pad Cover Screws
OR
OR
Auxiliary
Mounting
Pad "A"
Charge
Pump
Cover
No Charge
Pump Defeat
Charge Pump
Components
Auxiliary Pad Options and Components
E100022 E
BOMAG 1045 008 911 79
18.6
2 5
4.15 Charge Pump
Charge Pump
Cover Locating
Pin
Geroter Drive Pin
Gasket
Cover
Retaining
Screws
O-Rings
Geroter
Cover
Geroter
Assembly
Drive Coupling
Geroter Cover
Locating Pin
Charge Pump
Cover
Locating
Pin
(Screw used with
"No Pad" and
"A Pad" Only)
C
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g
e

P
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p

C
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p
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s
C
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P
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p

C
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A
u
x
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P
a
d
The charge pump may be disassembled to inspect
and clean, or to change the auxiliary shaft drive
coupling.
Note: For units without integral charge pumps
see the last page of this section for additional
information.
1. Remove auxiliary pump, if necessary.
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 locat-
ing 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.)
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.
7. Prior to assembly, lubricate the gerotor assembly
with clean hydraulic oil.
8. Install the gerotor drive pin into the hole in the
drive coupling, and retain with grease or petro-
leum jelly.
9. Install the drive coupling onto the pump shaft with
the smaller outside diameter oriented away from
the pump shaft. Different couplings are used
with the different auxiliary pad options.
10. Install the gerotor assembly onto the coupling.
(continued)
Charge Pump Components
E100023 E
BOMAG 1046 008 911 79
2 6
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.
For units without an integral charge pump see the
next section.
(continued)
CW CCW
Determining Charge Pump Orientation Looking
Inside of Gerotor Pump Cover
P100110 E
BOMAG 1047 008 911 79
18.6
2 7
Geroter
Cavity
Outlet Plug
(Charge
Pump Defeat)
Charge Pump Inlet Plug
Charge Pump
Inlet Plug
Charge Inlet
Charge
Inlet
Gasket
Cover
Retaining
Screws
O-Rings
Geroter
Cover
Drive Coupling
Charge Pump
Cover Locating
Pin 2
(Screw used with
"No Pad" and
"A Pad" Only)
"
N
o

C
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P
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p
"

C
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C
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P
a
d
Charge Pump
Cover Locating
Pin 1
(For Wrench Sizes
and Torquing
See Filtration Section)
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.
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).
CAUTION
A "Partial Filter Flow" (charge relief valve be-
fore filter) adapter must not be used on variable
pumps without an integral charge pump. If this
design adapter is used, the charge relief valve
will be defeated.
No Charge Pump Option Components
(Housing without Filtration Adapter)
No Charge Pump Option Components
(Housing with Filtration Adapter)
E100024 E
BOMAG 1048 008 911 79
2 8
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.
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 pro-
vides a filtration adapter to provide for each type of
filtration configuration. If filtration is provided for
elsewhere in the hydraulic circuit, the pump will not
have a filtration adapter.
Pumps equipped with housings without filtration
adapters have an additional construction bore next to
the charge relief valve which is unused and plugged
[5/8 in Hex, 21-33 Nm (15-25 ftlbf)]. When these
pumps are equipped with suction filtration, the exter-
nal charge inlet is plugged [5/16 in Int. Hex, 41-94 Nm
(30-70 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.
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 mainte-
nance interval. A filter capable of controlling the fluid
cleanliness to ISO 4406 Class 18/13 or better is
recommended and may be located either on the inlet
(suction filtration) or discharge (charge pressure
filtration) side of the charge pump.
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.
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.
Filtration Plate
Retaining Screws
M3 Gauge
Port Plug
Suction
Filtration
Charge Inlet
Plug
Plug
Construction
Bore Plug
Housing with
Filtration Adapter
Housing without
Filtration Adapter (Suction Filtration Only)
Full Flow
Pressure
Filtration
Partial Flow
Pressure
Filtration
* 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.
E100025 E
e p y T n o i t a r t l i F o i t a r -
r o n o i t a r t l i F n o i t c u S t i u c r i C d e s o l C
n o i t a r t l i F e n i L n r u t e R t i u c r i C n e p O
0 1
2
h t i w r i o v r e s e R a g n i r a h S s m e t s y S
s r e d n i l y C r o , s e h c t u l C , s r a e G r e h t O
0 1
0 1
n o i t a r t l i F e r u s s e r P e g r a h C
0 1
0 1
BOMAG 1049 008 911 79
18.6
2 9
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).
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].
3. The left side (side "2") servo cover can be re-
moved directly.
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 adjust-
ment screw [5 mm Hex] clockwise (inward) far
enough for the servo cover to clear the nearby
drain port. Then pull the cover away from the
housing and turn the cover counterclockwise to
disengage it from the adjustment screw.
4. Remove the gasket.
Note: FNR and NFPE control orifice plugs are
located here, see section 4.9 for more informa-
tion.
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 adjust-
ment screw CCW to engage the cover to the
screw threads.
7. Install servo piston cover screws (15-17 Nm (11-
13 ftlbf)].
8. On the right side (side "1"), loosely install neutral
adjustment seal lock nut. Perform pump neutral
adjustment (section 4.2).
WARNING
After installing the servo piston cover on right
side (side 1) of the pump, the pump neutral
adjustment and control neutral adjustment
MUST be performed before the vehicle / ma-
chine is put back into service.
CAUTION
Performance of the above procedure may ad-
just the position of the displacement limiter
somewhat.
4.17 Servo Piston Covers
Pump Neutral Ajustment
Seal Lock Nut
Servo Piston
Cover Screw
Servo Piston Cover
Servo Piston Cover
(Non-Feedback and
Automotive controls only)
Servo Piston
Cover Screws
Servo Piston
Cover
Pump "Neutral"
Adjustment Screw
Servo Piston Cover Right Side (Side "1")
Servo Piston Cover Left Side (Side "2")
Servo Piston Cover Components
E100026 E
BOMAG 1050 008 911 79
3 0
Displacement limiters can limit the maximum swash-
plate position. For Series 42 pumps, displacement
limiters are available on one or both sides of the servo
piston.
Adjustment of the displacement limiters should be
performed on a test stand.
WARNING
ditions. The limiter screw must have full thread
engagement in the servo piston cover, and the
seal lock nut must be retorqued after every
adjustment to prevent unexpected changes in
operating conditions and external leakage dur-
ing unit operation.
1. Mount pump on test stand.
2. Loosen displacement limiter seal lock nut [13 mm
Hex]. Do not remove.
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 adjust-
ment screw will change the displacement of the
pump approximately as follows.
4. After reaching proper displacement tighten the
seal lock nut [20-26 Nm (15-19 ftlbf)].
If necessary, repeat procedure for displacement lim-
iter on other side.
4.18 Displacement Limiter Adjustment
Seal Lock Nut
Seal Lock Nut
Displacement
Limiter
Displacement Limiter Right Side (Side "1")
(Exploded View, No Need to Remove Limiter or Nut)
Displacement Limiter Left Side (Side "2")
(Exploded View, No Need to Remove Limiter or Nut)
Servo Piston
Cover
Servo Piston
Cover
E100027 E
c c 8 2 v e r / c c 6 . 3 n i 2 2 . 0
3
v e r /
c c 1 4 v e r / c c 0 . 5 n i 1 3 . 0
3
v e r /
E 6 2 0 0 0 0 T
BOMAG 1051 008 911 79
18.6
3 1
Series 42 Exploded View Parts Drawings
5. Exploded View Parts Drawings
5.1 Shaft Options
C002
C003
C015
C015
C005
OR
OR
C001
C001
C001
F096
C020
C017
C018
F001
E100028
BOMAG 1052 008 911 79
3 2
5.2 Filtration, Charge Relief, System Relief, and Loop Flushing
F093A
F093
F093A
F093
F030
F030A
F043
F042
(F042)
F040
(F040)
F041
F043A
(F043)
(F043A)
F091
F091A
J002
J005
J003
(F091)
G043
G042
G041
G040A
G040
(F091A)
OR
OR
045A
G045
F061
F062
F063
F060A
F060
(F060A)
(F060)
(F050A)
(F050)
(F051)
F050A
F050
F0512
F0513
F0514
F0515
F051
OR
OR
H002
H005
H003
(F042)
(F040)
(F043)
(F043A)
(F086)
(F086A)
N002
N002A
K001
K009
K010
K008
K005
K002
K006
K007
K001
K001A
K001B
K001C
G043
G042
G040
G040A
G041
F0511
OR
OR
E100029
BOMAG 1053 008 911 79
18.6
3 3
G075
(G075)
G002
G005
G010
G015
G020
(G021)
G022
G023
G030
(G001)
(G036)
G036
G085
(G080)
(G085)
G090
(G090)
OR
OR
(G001)
(G036)
(G080)
G001
M020
M025
F009
(M010)
(M005)
M005
M001
(M001)
(M010A)
M010
M010A
L010
L010A
F020A
F020
G065
OR
5.3 Charge Pump, Auxiliary Pads, and Servo Covers
E100030
BOMAG 1054 008 911 79
3 4
5.4 Control Options
D090
D032
D032A
D015
D014
F035A
F035
F035
F034
F036
F010
(F010)
OR
D081
D081
D060
OR
OR
D081
D082 D080
OR
D011
E001
D013
D012
D010
D002
(D017)
D017
D016
D019
OR
D040
D056
D037
D038
D039
D003
D070
D003A
D004
E100031
BOMAG 1055 008 911 79
18.6
3 5
Notes
BOMAG 1056 008 911 79
BOMAG 1057 008 911 79
19 Circuit diagrams
BOMAG 1058 008 911 79
Circuit diagrams
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.
BOMAG 1059 008 911 79
19.1 Wiring diagram
19.1 Wiring diagram
BOMAG 1060 008 911 79
Wiring diagram 582 702 07 from serial number

101 582 121 001 Variocontrol
101 582 511 081 BW 213 DH-4
101 582 521 013 BW 213 PDH-4
101 582 531 083 BW 213 DH-4 BVC
101 582 541 035 BW 213 DH-4 BVC /P
101 582 581 041 BW 214 DH-4
101 582 591 001 BW 214 PDH-4
101 582 641 001 BW 216 DH-4
101 582 651 001 BW 216 PDH-4
101 582 771 001 BW 219 DH-4
101 582 821 022 BW 226 DH-4 BVC
101 582 851 003 BW 226 DH-4 BVC
101 582 861 001 BW 226 DH-4 BVC
101 582 881 001 BW 226 DH-4
101 583 061 001 BW 213 DH-4 BVC /P
101 583 141 001 BW 213 DH-4
101 583 151 001 BW 213 PDH-4
101 583 161 001 BW 213 DH-4 BVC
101 583 191 001 BW 214 DH-4
Wiring diagram
BOMAG 1061 008 911 79
19.1
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D
e
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t
z

E
M
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I
I
0
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7
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M
o
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D
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s
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c
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w
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D
a
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a
m
m
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L
C
D
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c
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C
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0
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V
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M
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C
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0
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1
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7
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0
7
D
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R
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T
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c
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19.1 Wiring diagram
BOMAG 1062 008 911 79
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
0
0
2
V
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t
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s
1
1
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t
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n
,

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t
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u
n
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s
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n
a
l

h
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n
G
0
2
G
e
n
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r
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t
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r
B
+
B
D
+
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S
0
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S
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c
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3
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3
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5
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K
0
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w
w
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h
m a i n f u s e
M
K
6
1
8
6
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6
1
2
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7
3
08
7
a
8
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3
1
3
1
3
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1
1 2 5 m A
A n z u g s w . : 5 0 A / H a l t e w . : 1 0 A
F
1
3
3
0
A
12
F
9
5
12
K
0
9
8
6
8
5
n u r b e i K l i m a a n l a g e
o n l y a c c . t o a i r c o n d i t i o n i n g
1
9
.
1
0
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2
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5
D
+
6
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2
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m
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t
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h e a t i n g f l a n g e / g l o w p l u g s
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k

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w
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+
1
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6
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1
0
A
K
1
1
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2
3
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7
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1
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53
S
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N
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T
A
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s
2
1
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4
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5
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6
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0
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H a u p t s i c h e r u n g
1 2
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4
8
S i c h e r u n g H e i z f l a n s c h / G l h s t i f t k e r z e n
1 2
2 x 1 0 q m m
X 3 6 : A
X 3 6 : B
X
1
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1
X
1
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0
9
X
1
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1
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1
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6
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1
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1
2
3
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5
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X
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X
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X
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7
X
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X
3
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X
3
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X
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X
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2
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A
X
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1
5
1
X
1
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1
5
2
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0
1
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2
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3
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T
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H
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1
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1
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9
7
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1
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X
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5
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3
X
3
7
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A
X
1
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7
9
D
+

M
E
S
X
9
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2
X
1
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3
0
E
F
3
9
12
K
3
2
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8
6
1
3
:
1
X
1
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3
0
A
1
5
A
X 3 4 : P
1 6 7 A
3
1

E
M
R
3
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3
X
3
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S
S
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c
k
d
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t
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b
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G
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r
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t

h
a
n
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l
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n
r
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f
R
1
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8
2

O
H
M
12
X 1 : 1 0
X 1 : 9
K
3
0
1
3
:
1
3
0
4
:
1
n i c h t b e i E M R I I I , b e i B W 1 7 7 D H 4 O p t i o n
n o t a t E M R I I I , a t B W 1 7 7 D H 4 o p t i o n
R 8 6
12
R 8 5
12
R 8 4
12
R 8 3
G
l
h
s
t
i
f
t
k
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n
12
R 8 2
12
R 8 1
12
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1
4
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2
4
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2
0
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n
u
r

b
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M
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I
I
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y

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I
I
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p
l
u
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s
O p t i o n
o p t i o n
1
4
:
7
2
:
1
0
2
:
1
6
Wiring diagram
BOMAG 1063 008 911 79
19.1
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
0
0
3
V
o
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t
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9
.
1
0
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2
0
0
5
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1
1
M
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r

D
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M
R

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I
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n
g
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n
e

D
e
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z

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M
R

I
I
3
1
2
:
2
0
3
1
4
:
1
X 3 0 : 1
X 3 0 : 2
X 3 0 : 1 0
X 3 0 : 1 1
X 3 0 : 1 2
X 3 0 : 1 3
X 3 2 : A
X 3 2 : L
X 3 2 : K
X 3 2 : H
X 3 2 : G
X 3 2 : B
D
i
a
g
n
o
s
e
s
t
e
c
k
e
r

E
M
R
d
i
a
g
n
o
s
i
s

i
n
t
e
r
f
a
c
e

E
M
R
X 3 0 : 1 4
A
4
8
M
o
t
o
r
s
t
e
u
e
r
u
n
g

E
M
R
2
X 5 7 : 9
X 5 7 : 8
B
1
1
3
E
M
R

K
h
l
m
i
t
t
e
l
t
e
m
p
e
r
a
t
u
r
1
2
X 5 7 : 2 3
X 5 7 : 2 4
X 5 7 : 2 5
X 3 1 : 2 3
X 3 1 : 2 5
X 3 1 : 2 4
A G N D
S i g n a l
A G N D
S i g n a l D r u c k
+ 5 V
X 3 1 : 2 0
X 3 1 : 2 1
X 3 1 : 2 2
X 5 7 : 2 0
X 5 7 : 2 1
X 5 7 : 2 2
A G N D
S i g n a l
+ 5 V
B
8
8
E
M
R

M
o
t
o
r
l
d
r
u
c
k
3
1
2
X 3 1 : 1 0
X 3 1 : 1 1
X 5 7 : 1 0
X 5 7 : 1 1
A G N D
S i g n a l
X 3 1 : 1 2
X 3 1 : 1 3
X 5 7 : 1 2
X 5 7 : 1 3
A G N D
S i g n a l
X 3 1 : 1 4
X 3 1 : 1 5
X 3 1 : 1 7
X 3 1 : 1 8
X 3 1 : 1 9
X 5 7 : 1 4
X 5 7 : 1 5
X 5 7 : 1 7
X 5 7 : 1 8
X 5 7 : 1 9
Y
1
3
7
E
M
R

S
t
e
l
l
g
l
i
e
d5 1
6
2
7
S T G
S T G +
R F
R F R E F
R F M E S S
X 3 1 : 9
m a x 7 A
E
M
R

c
o
o
l
a
n
t

t
e
m
p
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r
a
t
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E
M
R

e
n
g
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n
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o
i
l

p
r
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s
s
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E
M
R

c
o
m
m
a
n
d
e
r
c
h
a
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g
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g

a
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r

p
r
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s
s
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+

t
e
m
p
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r
a
t
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r
e
s
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n
d
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r

e
n
g
i
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e

r
p
m

1
X 3 1 : 2
X 3 1 : 4
X 3 1 : 5
X 5 7 : 4
X 3 1 : 6
X 3 1 : 1 6
X 3 1 : 8
X 3 1 : 7
r
e
l
a
y

h
e
a
t
i
n
g
f
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B
1
1
4
M
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r
d
r
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h
z
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r
1
2
s
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n
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r

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g
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r
p
m

2
X 5 7 : 1 6
X 5 7 : 1
X 5 7 : 6
X 3 1 : 1
X 3 3 : 3
X 3 3 : 5
X 3 3 : 6
X 3 3 : 1
X 3 3 : 2
X 3 3 : 7
S
t
e
c
k
e
r
s
c
h
n
i
t
t
s
t
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l
l
e

D
e
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t
z
c
o
n
n
e
c
t
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r

i
n
t
e
r
f
a
c
e

D
e
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t
z
X 3 3 : 8
E
P
C
S
t
e
c
k
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r
S
0
1
:
2
2
2
:
1
7
S
0
1
:
2
2
4
:
1
B
1
3
0
M
o
t
o
r
d
r
e
h
z
a
h
l
s
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n
s
o
r
1
2
S i g n a l T e m p e r a t u r
B
1
1
5
L
a
d
e
l
u
f
t
d
r
u
c
k

+

T
e
m
p
1
2
4
3
C
A
N
2
+
4
:
1
5
C
A
N
2
4
:
1
5
C A N h i g h
C A N l o w
L
K
U b a t
X
1
:
9
5
X
1
:
9
6
X 1 : 1 8 2
X 1 : 1 8 3
X 1 : 1 8 4
X 3 3 : 4
X 3 1 : 3
X 1 : 1 8 0
X 1 : 1 8 1
X
1
:
1
8
5
K
1
4
R
e
l
a
i
s

H
e
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z
f
l
a
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s
c
h
2 1
e
n
g
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c
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r
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r

E
M
R
2
E S X F a h r s t .
X
1
:
1
7
9
3
1

E
M
R
2
:
6
3
1

E
M
R
4
:
1
8
X 1 : 1 8 6
X 3 4 : N
2
:
4
19.1 Wiring diagram
BOMAG 1064 008 911 79
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
0
0
4
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
1
1
M
o
t
o
r

D
e
u
t
z

E
M
R

I
I
I
e
n
g
i
n
e

D
e
u
t
z

E
M
R

I
I
I
3
1
3
:
2
0
3
1
5
:
1
X 3 0 : 3
X 5 7 : 3 0
X 5 7 : 2 4
B
1
1
3
E
M
R

K
h
l
m
i
t
t
e
l
t
e
m
p
e
r
a
t
u
r
1
2
X 5 7 : 2 8
X 5 7 : 2 3
X 3 1 : 4 0
X 3 1 : 5 1
X 3 1 : 5 6
X 3 1 : 1 3
X 5 7 : 2 7
X 5 7 : 2 6
X 5 7 : 3 3
B
8
8
E
M
R

M
o
t
o
r
l
d
r
u
c
k
3
1
2
X 3 1 : 5 8
X 5 7 : 2 9
X 3 1 : 4 1
S
0
1
:
2
2
3
:
2
0
S
0
1
:
2
2
7
:
1
B
1
4
5
E
M
R

N
i
e
d
e
r
d
r
u
c
k

K
r
a
f
t
s
t
o
f
f
1
4
2
3
D
i
a
g
n
o
s
e
s
t
e
c
k
e
r

E
M
R
d
i
a
g
n
o
s
i
s

i
n
t
e
r
f
a
c
e

E
M
R
A G N D
S i g n a l
A G N D
A G N D
S i g n a l
m
a
x
.

K
a
b
e
ll
n
g
e

v
o
n

B
a
t
t
e
r
ie

z
u
m

S
t
e
u
e
r
g
e
r
t

(
V
e
r
s
o
r
g
u
n
g
s
le
it
u
n
g
)

m
a
x
.

1
0
m
b
e
i
e
in
e
r

K
a
b
e
lb
a
u
m
u
m
g
e
b
u
n
g
s
t
e
m
p
e
r
a
t
u
r

v
o
n

8
5

G
r
a
d

C
.

(
Q
u
e
r
s
c
h
n
it
t

4
x
2
,
5
q
m
m
)
E
M
R

c
o
o
l
a
n
t

t
e
m
p
e
r
a
t
u
r
e
E
M
R

e
n
g
i
n
e

o
i
l

p
r
e
s
s
u
r
e
s
e
n
d
e
r

e
n
g
i
n
e

r
p
m

1
s
e
n
d
e
r

e
n
g
i
n
e

r
p
m

2
e
n
g
i
n
e
c
o
n
t
r
o
l
l
e
r

E
M
R
3

(
E
D
C
1
6
)
Y
1
6
9
I
n
j
e
k
t
o
r

A
6
12
Y
1
4
9
I
n
j
e
k
t
o
r

A
3
12
Y
1
7
0
I
n
j
e
k
t
o
r

A
5
12
Y
1
4
8
I
n
j
e
k
t
o
r

A
2
12
Y
1
6
6I
n
j
e
k
t
o
r

A
4
12
Y
1
4
7
I
n
j
e
k
t
o
r

A
1
12
j
e
t

p
u
m
p

A
1
j
e
t

p
u
m
p

A
2
j
e
t

p
u
m
p

A
3
j
e
t

p
u
m
p

A
4
j
e
t

p
u
m
p

A
5
j
e
t

p
u
m
p

A
6
X 3 1 : 1 6
X 3 1 : 4 7
X 3 1 : 4 6
B
1
1
4
M
o
t
o
r
d
r
e
h
z
a
h
l
s
e
n
s
o
r
1
3
2
X 3 1 : 1 0
X 3 1 : 5 0
X 3 1 : 2 0
X 5 7 : 1 4
X 5 7 : 1 3
A G N D
B
1
3
0
M
o
t
o
r
d
r
e
h
z
a
h
l
s
e
n
s
o
r
2
3
1
X 3 1 : 1 2
X 3 1 : 2 7
X 3 1 : 7
X 5 7 : 2 1
X 5 7 : 1 5
A G N DX 5 7 : 1
X 5 7 : 9
S i g n .
S i g n .
Y
1
3
7
E
M
R

S
t
e
l
l
g
l
i
e
d
12
E
M
R

c
o
m
m
a
n
d
e
r
X 3 1 : 1 9
X 3 1 : 4 9
S i g n a l
A G N D
X 5 7 : 1 9
X 5 7 : 2 0
B
4
0
.
1
B
4
0
.
2
Y
1
9
Y
1
5
.
1
Y
1
5
.
5
Y
1
5
.
6
Y
1
5
.
2
Y
1
5
.
4
Y
1
5
.
3
X 5 7 : 3 4
X 5 7 : 3 5
X 5 7 : 3 9
X 5 7 : 3 6
X 5 7 : 4 0
X 5 7 : 4 2
X 5 7 : 3 7
X 5 7 : 4 1
B
5
1
X 3 1 : 2 6
X 3 1 : 4 3
X 3 1 : 8
X 5 7 : 3 2
X 5 7 : 2 5
X 5 7 : 3 1
B
9
3
E
M
R

K
r
a
f
t
s
t
o
f
f
d
r
u
c
k
3
1
2
A G N D
S i g n a l
r
a
i
l

p
r
e
s
s
u
r
e

s
e
n
s
o
r
B
4
9
B
4
3
B
6
X 5 7 : 2 8
X 5 7 : 2 3
X 5 7 : 2 2
X 3 1 : 2 3
X 3 1 : 1 4
X 3 1 : 4 0
X 5 7 : 2 9
L
a
d
e
l
u
f
t
d
r
u
c
k

+

T
e
m
p
1
2
4
3
A G N D
c
h
a
r
g
i
n
g

a
i
r

p
r
e
s
s
u
r
e

+

t
e
m
p
e
r
a
t
u
r
e
B
4
8
X 3 1 : 1 3
X 3 1 : 2 3
E
M
R

f
u
e
l

l
o
w

p
r
e
s
s
u
r
e

s
e
n
s
o
r
3
0
2
:
1
5
3
0
5
:
1
F
9
3
12
2
5
A
X 3 0 : 7 2
K
4
1
8
6
8
5
K
4
1
4
:
2
3
0
8
7
a
8
7
X 3 0 : 5
X 3 0 : 1
X
1
:
1
4
E
X
1
:
1
4
A
X
1
:
1
8
5
X
1
:
1
8
3
2
.
5

q
m
m
X 3 0 : 2 8
m a x 7 A
X 3 0 : 2
X 3 0 : 4
X 3 0 : 6
3
1

E
M
R
3
:
5
3
x
2
.
5
X 1 : 9 0
X 1 : 9 1
X 1 : 9 2
X 1 : 1 8 0
X 1 : 1 8 1
G N D
G N D
G N D
X 3 2 : A
X 3 2 : K
X 3 2 : M
X 3 2 : F
X 3 2 : H
X 3 2 : G
X 3 2 : B
X 3 0 : 8 2
X 3 0 : 6 0
X 3 0 : 6 2
X 3 0 : 6 1
X 3 0 : 2 5
C A N 1 H i g h
C A N 1 L o w
C A N 2 H i g h
C A N 2 L o w
K L i n e
X 1 : 1 8 2
X 1 : 1 8 6
m
a
x
.

K
a
b
e
ll
n
g
e

v
o
n

B
a
t
t
e
r
ie

z
u
m

S
t
e
u
e
r
g
e
r
t

(
V
e
r
s
o
r
g
u
n
g
s
le
it
u
n
g
)

m
a
x
.

3
.
5
m
in

d
e
r

h
ie
r

d
a
r
g
e
s
t
e
llt
e
n

I
n
s
t
a
lla
t
io
n

(
Q
u
e
r
s
c
h
n
it
t

2
,
5
q
m
m
)
C
A
N
2
+
3
:
4
C
A
N
2
+
5
:
1
1
C
A
N
2
3
:
4
C
A
N
2
5
:
1
1
A
4
8
M
o
t
o
r
s
t
e
u
e
r
u
n
g

E
M
R
3

(
E
D
C

1
6
)
w
a
t
e
r
s
e
p
e
r
a
t
o
r
X 3 0 : 6 4
X 3 0 : 6 3
B
1
2
4
W
a
s
s
e
r
a
b
s
c
h
e
i
d
e
r
X
1
:
1
0
7
X
1
:
1
0
8
X
1
:
1
9
8
X
1
:
1
9
9
X
1
:
1
7
9
N u r b e i E M R I I I
o n l y E M R I I I
X 1 : 1 8 4
X 1 : 1 9 3
X 1 : 1 9 4
X 1 : 1 9 1
X 1 : 1 9 2
X 3 1 : 3 3
X 3 1 : 3 1
X 3 1 : 4 8
X 3 1 : 1
X 3 1 : 3 2
X 3 1 : 5 3
X 3 1 : 2 4
X 3 1 : 3 4
K
1
4
.
2
8
5
8
6
X 6 6 : 2
X 6 6 : 3
2
:
2
4
:
3
Wiring diagram
BOMAG 1065 008 911 79
19.1
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
0
0
5
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
1
1
1
F
a
h
r
a
n
t
r
i
e
b
,

N
e
i
g
u
n
g
s
s
e
n
s
o
r
,

S
i
t
z
k
o
n
t
a
k
t
d
r
i
v
i
n
g

s
y
s
t
e
m
,

s
l
o
p
e

s
e
n
s
o
r
,

s
e
a
t

c
o
n
t
a
k
t

s
w
i
t
c
h
X 3 5 : 6 4
L e i s t u n g
A
3
4
F
a
h
r
S
t
e
u
e
r
u
n
g
Y
1
6
P
r
o
p
.
P
u
m
p
e

R
c
k
w
.
12
Y
1
7
P
r
o
p
.
P
u
m
p
e

V
o
r
w
.
12
X 3 5 : 2 4
4 0 0 . . . 1 . 2 0 0 m A
4 0 0 . . . 1 . 2 0 0 m A
4 0 0 . . . 1 . 2 0 0 m A
4 0 0 . . . 1 . 2 0 0 m A
B
6
0
S
e
n
s
o
r

A
c
h
s
e
+
d
i
r
.
s p e e d
B
5
9
S
e
n
s
o
r

B
a
n
d
a
g
e
+
d
i
r
.
s
p
e
e
d
X 3 5 : 3 8
X 3 5 : 1 2
X 3 5 : 3 7
X 3 5 : 3 4
b rs w
w s
b l
R c k f a h r w a r n s u m .
b rs w
w s
b l
B
5
7
N
e
i
g
u
n
g
s
s
e
n
s
o
r
+
4
5
_
G
=
4
,
5
V
4
5
_
G
=
0
,
5
V
+
S
1
V
2
,
5
V
4
V
N e i g u n g
X 3 5 : 5 3
X 3 5 : 3 3
C A N 2 +
C A N 2
E l e k t r o n i k
X 3 5 : 2 8
3
0
4
:
2
0
3
0
6
:
1
1
5
A
1
0
A
X 3 5 : 2 6
X 3 5 : 2 7
F
2
4
:
2
6
:
3
C
A
N
2
+
4
:
2
0
C
A
N
2
+
8
:
6
C
A
N
2
4
:
2
0
C
A
N
2
8
:
6
C
A
N
1
6
:
8
C
A
N
1
+
6
:
8
S
0
1
2
:
1
6
3
1
3
2
C A N 1 +
C A N 1
B
1
1
2
D
r
u
c
k
s
e
n
s
o
r

F
a
h
r
p
u
m
p
e
r
t
s
w
X 5 2 : 1
X 3 5 : 3 1
D r u c k s e n s o r
X
1
:
1
1
9
X
1
:
1
2
0
p
r
e
s
s
u
r
e

s
e
n
s
o
r

d
r
i
v
e

p
u
m
p
X 1 : 5 2
X 1 : 5 4
X 1 : 4 8
X 1 : 5 0
X
1
:
1
7
E
X
1
:
1
7
A
X
1
:
3
4
E
X
1
:
3
4
A
X
1
:
1
4
6
X
1
:
1
4
5
X 1 : 1 7 1
X 1 : 1 7 3
X 1 : 1 7 5
X 1 : 1 7 6
X 1 : 1 7 7
s
e
n
d
e
r

a
x
l
e
s
e
n
d
e
r

d
r
u
m
s
l
o
p
e

s
e
n
s
o
r
X
1
:
1
2
1
X
1
:
1
2
2
X
1
6
:
1
X
1
6
:
2
X
1
5
:
1
X
1
5
:
2
X
1
:
1
2
3
X
1
:
1
2
3
X
1
:
1
4
4
X
1
:
1
2
4
X
1
:
1
4
3
X
1
:
1
4
1
d
r
i
v
i
n
g

c
o
n
t
r
o
l
l
e
r
s p e e d
R i c h t u n g
s p e e d
R i c h t u n g
F a h r p u m p e v o r w .
F a h r p u m p e r c k w .
B a n d a g e n m o t o r
A c h s m o t o r
X 3 5 : 6 5
X 3 5 : 6 6
X 3 5 : 6 7
X 3 5 : 6 8
X 3 5 : 5 5
G e h u s e
h o u s i n g
p
r
o
p
.
p
u
m
p

f
o
r
w
a
r
d
s
p
r
o
p
p
u
m
p

b
a
c
k
w
a
r
d
s
3
1
4
:
2
0
3
1
6
:
1
F
6
7
12
F
8
4
12X 3 5 : 3 0
X 3 5 : 4 9
X 3 5 : 5 6
X 3 5 : 5 7
X 3 5 : 5 8
X 3 5 : 5 9
X 3 5 : 6 0
X 3 5 : 5 4
H
1
4
R
c
k
f
a
h
r
w
a
r
n
s
u
m
m
e
r
+
b
a
c
k

u
p

a
l
a
r
m

b
u
z
z
e
r
0 , 4 6 A
L
C
D
is
p
la
y
,

O
P
U
S

2
1
F
a
h
r
h
e
b
e
l
E
M
R

D
e
u
t
z
S
0
6
S
i
t
z
k
o
n
t
a
k
t
s
c
h
a
l
t
e
r
+
X 3 5 : 1 5
S i t z k o n t a k t
X
1
:
1
5
8
X
1
:
1
4
9
s
w
i
t
c
h
,

s
e
a
t

c
o
n
t
a
c
t
X
1
:
1
1
4
X
1
:
1
1
7
X
1
4
:
B
X
1
4
:
A
X 3 5 : 4 6
X 3 5 : 4 7
X 1 : 8 2
X 1 : 1 2 4
X 1 : 1 4 2
X 1 : 1 4 2
X 1 : 1 4 3
X 1 : 1 4 3
p
r
o
p
.
V
a
l
v
e

d
r
u
m

m
o
t
o
r
p
r
o
p
.
V
a
l
v
e

a
x
l
e

m
o
t
o
r
X 1 : 4 7
X 1 : 4 9
X
3
4
:
A
X
3
4
:
B
X 1 : 5 1
X 1 : 5 3
X
3
4
:
C
X
3
4
:
D
X 3 5 : 4
R x D
X 3 5 : 5
T x D
X
3
4
:
H
X
3
4
:
G
R
2
2
1
2
0

O
H
M
1
2
R
2
3
1
2
0

O
H
M
1
2
R
2
0
1
2
0

O
H
M
1
2
R
2
1
1
2
0

O
H
M
1
2
X
9
:
1
X
9
:
2
D
i
a
g
n
o
s
e
s
t
e
c
k
e
r

F
a
h
r
z
e
u
g
d
i
a
g
n
o
s
i
s

i
n
t
e
r
f
a
c
e

e
q
u
i
p
m
e
n
t
X
1
:
3
4
A
9
:
2
X
1
:
4
6
P
I
T
C
H

M
E
S
X
9
:
2
X 5 2 : 2
Y
3
0
P
r
o
p
.
V
e
n
t
i
l

B
a
n
d
a
g
e
n
m
o
t
o
r
12
Y
3
1
P
r
o
p
.
V
e
n
t
i
l

A
c
h
s
m
o
t
o
r
12
X
1
:
2
X
1
:
1
7
2
X
1
:
5
5
7
:
4
P o t . 1 5
a
b
X
1
:
1
7
4
X
1
:
1
7
8
D
I
R

M
E
S
X
9
:
2
S
P
E
E
D

T
A
C
1
3
:
6
S
P
E
E
D

M
E
S
X 9
:
2
X
1
:
4
5
X
1
:
4
4
F
M
3
7
:
5
19.1 Wiring diagram
BOMAG 1066 008 911 79
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
0
0
6
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
1
1
D
a
t
e
n
s
a
m
m
l
e
r
,

L
C
D
i
s
p
l
a
y
d
a
t
a
c
o
l
l
e
c
t
o
r
,

L
C
d
i
s
p
l
a
y
3
0
5
:
2
0
3
0
9
:
1
3
1
5
:
2
0
3
1
7
:
1
B
0
3
L u f t f i l t e r
P
12
h y d r a u l i c o i l f i l t e r
a i r c l e a n e r
B
5
5
K h l m i t t e l v o r r a t
Q
B
2
1
H y d r a u l i k l f i l t e r
P
12
d
a
t
a
c
o
l
l
e
c
t
o
r
D
+
2
:
8
C
A
N
1
+
5
:
1
7
C
A
N
1
+
8
:
1
4
C
A
N
1
5
:
1
7
C
A
N
1
8
:
1
4
K
1
1
:
8
7
2
:
2
0
K
1
1
:
8
7
8
:
1
4
R
0
3
0 . . 6 7 O H M
F l l s t a n d D i e s e l
f u e l l e v e l
F
2
4
12
1
0
A
X 2 6 : 1
X 2 6 : 5
X 2 6 : 6
X 2 6 : 8
X 2 6 : 1 0
X 2 6 : 1 1
X 2 6 : 1 2
X 2 7 : 1
X 2 7 : 2
X 2 7 : 3
X 2 7 : 5
X
2
7
:
8
X 2 7 : 1 0
X 2 7 : 1 1
X 2 7 : 1 2
A
8
0
D
a
t
e
n
s
a
m
m
l
e
r
D I N 1
D I N 2
D I N 3
D I N 4
D I N 5
D I N 6
D I N 8
D I N 9
D I N 1 1
G N D
A I N 1
U I N 1
G N D / U I N 3
G N D
C A N 1 h i g h
C A N 1 l o w
V C C
U I N 3
U I N 2
A I N 2
X 2 7 : 6
X 2 7 : 7
F
2
4
:
2
5
:
3
F
2
4
:
2
7
:
1
5
A
8
1
L
C
D
i
s
p
l
a
y
L
C
d
i
s
p
l
a
y
X 2 8 : 3
X 2 8 : 4
X 2 8 : 1
X 2 8 : 2
X 2 8 : 5
C A N 1 l o w
n o t c o n n e c t e d
U b " 1 5 "
C A N 1 h i g hG N D
U b " 3 0 "
X 2 9 : 7
U b o u t
X 2 9 : 5
X 2 9 : 6
X 2 8 : 6
X 2 9 : 8
D I N 1
D I N 2
D I N 4
D I N 3
D I N 5
D I N 6
S
1
2
7
S
c
h
a
l
t
e
r

M
o
t
o
r
d
r
e
h
z
a
h
l
2
3
2
4
1
4
1
3
s
w
i
t
c
h

e
n
g
i
n
e
r
p
m

m
o
d
e
L
o
w
X
1
:
2
9
E
X
1
:
2
9
A
X 1 : 3 9
X 1 : 4 0
X
1
:
8
7
X
1
:
8
8
X
1
:
8
0
X
1
:
8
6
X
1
:
8
2
X
1
:
1
6
4
X
1
0
:
2
X
1
0
:
3
X
1
:
1
0
5
X
1
:
1
1
7
X
1
:
1
4
9
X
2
1
:
1
X
2
1
:
2
X
1
:
9
4
X
1
:
9
4
X
1
:
1
1
7
X
1
:
1
0
6
X
1
:
1
1
1
X
1
:
1
1
2
B
E
L
1
2
:
4
E
S
X

F
a
h
r
s
t
e
u
e
r
u
n
g
D
I
O
S

P
la
t
t
e
n
X 2 6 : 9
X 2 6 : 3
X 2 6 : 4
B
L
1
2
:
1
7
B
R
1
2
:
1
7
X 2 9 : 2
X 2 9 : 1
X 2 9 : 3
X 2 9 : 4
X
3
4
:
R
X 2 6 : 2
X 1 : 4 1
S
t
e
c
k
e
r
f
a
r
b
e
:

X
2
6
g
r
a
u
;

X
2
7
s
c
h
w
a
r
z
c
o
n
n
e
c
t
o
r
c
o
lo
u
r
:

X
2
6
g
r
e
y
;

X
2
7
b
la
c
k
H
i
g
h
E
C
O
F
0
5
:
2
2
:
1
7
1
1
:
1
B
1
2
4
W a s s e r a b s c h e i d e r
X 2 7 : 4
X 2 7 : 9
X
1
:
1
0
7
X
1
:
1
0
8
X
8
:
1
X
8
:
2
c o o l a n t s t o c k l e v e l
w a t e r s e p e r a t o r
D I N 1 0
S e p a 1
S e p a 2
N u r b e i E M R I I
o n l y E M R I I
Wiring diagram
BOMAG 1067 008 911 79
19.1
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
0
0
7
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
1
1
L
e
n
k
u
n
g
,

V
i
b
r
a
t
i
o
n
s
t
e
e
r
i
n
g
,

v
i
b
r
a
t
i
o
n
X 3 5 : 3
3
1
6
:
2
0
3
1
8
:
1
K
4
3
8
6
8
5
X 3 5 : 4 0
X 3 5 : 4 1
X 3 5 : 2 9
X 3 5 : 1 8
X 3 5 : 4 8
X 3 5 : 1 9
K
4
3
7
:
1
2
3
0
8
7
a
8
7
P r o p . o u t
W a r n s u m m e r
4 0 0 . . . 1 . 2 0 0 m A
4 0 0 . . . 1 . 2 0 0 m A
4 0 0 . . . 1 . 2 0 0 m A
L e n k w i n k .
B
6
5
L
e
n
k
w
i
n
k
e
l
s
e
n
s
o
r
+
S
B
1
6
A
u
f
n
e
h
m
e
r

V
i
b
r
a
t
i
o
n
s
m
o
t
o
r
+
X
2
2
:
1b
r
b
e
i
B
W
1
7
7

s
w

/

b
e
i
B
W
2
1
3

b
l
b
e
i
B
W
1
7
7

b
l
/

b
e
i
B
W
2
1
3

s
w
w
s
X 3 5 : 3 5
V i b . F r e q u e n z
V i b . R i c h t u n g
A
4
5
L
e
n
k
e
i
n
h
e
i
t
S
1
S
2
V
C
C
V
C
C
0
V
0
V
BBAA
B T S B r e m s e
X 3 5 : 1 7
X 3 5 : 2
U m s c h . A m p l i t u d e
X 3 5 : 6 1
B r e m s e
s
o
l
e
n
o
i
d

v
a
l
v
e

b
r
a
k
e
w
a
r
n
i
n
g

b
u
z
z
e
r
,

f
a
i
l
u
r
e
p
r
o
p
.

v
a
l
v
e

s
t
e
e
r
i
n
g

l
e
f
t
p
r
o
p
.

v
a
l
v
e

s
t
e
e
r
i
n
g

r
i
g
h
t
p
r
o
p
.

v
a
l
v
e

v
i
b
r
a
t
i
o
n

s
m
a
l
l
p
r
o
p
.

v
a
l
v
e

v
i
b
r
a
t
i
o
n

b
i
g
A G N D
X 3 5 : 2 3
8
,
5
V
X
1
:
8
2
X 1 : 1 8 8
X 1 : 1 8 9
X
2
2
:
2
X
2
2
:
4
X
1
:
1
8
7
X
1
:
1
9
0
X
1
:
1
1
7
S
0
1
2
:
1
6
1
1
1
2
X
1
:
1
1
3
X
1
:
1
5
0
X
1
:
1
1
5
X
1
:
1
1
6
X 1 : 2 0 2
X 1 : 2 0 3
X
1
:
1
9
7
X
1
:
1
9
7
X
1
:
1
1
8
S
1
X 1 : 2 0 8
X 1 : 2 0 6
X 1 : 2 0 5
X 1 : 2 0 7
X 4 1 : 6
X 4 1 : 8
X 4 1 : 5
X 4 1 : 7
X
1
:
1
4
8
s
t
e
e
r
i
n
g

u
n
i
t
s
t
e
e
r
i
n
g

a
n
g
l
e

s
e
n
s
o
r
s
e
n
s
o
r

v
i
b
r
a
t
i
o
n

m
o
t
o
r
X 5 1 : 3
X
4
3
:
1
X
3
9
:
3
X
1
:
1
4
9
H
0
7
W
a
r
n
s
u
m
m
e
r

S
t
r
u
n
g
+
X 1 : 5 5
n u r B V C
o n l y B V C
S
0
1
:
2
2
4
:
2
0
S
0
1
:
2
2
X
1
:
4
1
F
2
4
:
2
6
:
2
0

X 3 4 : J
X
6
:
2
X
6
:
1
X
7
:
1
X
7
:
2
X
2
2
:
3
V
I
B
1
3
:
6
B
R
A
K
E

M
E
S
X
9
:
2
X 1 : 4 2
B
T
S

B
R
E
M
S
E
8
:
2
X
2
3
:
1
8
:
1
X 3 5 : 2 2
X
3
5
:
2
2
8
:
1
3
X
1
:
2
0
1
F M 5
1 2
X 1 : 6 1X 1 : 6 0
Y
0
8
P
r
o
p
.
V
e
n
t
i
l

V
i
b
r
a
t
i
o
n

k
l
e
i
n
12
Y
0
7
P
r
o
p
V
e
n
t
i
l

V
i
b
r
a
t
i
o
n

g
r
o
12
X 1 : 5 8
X 1 : 5 6
F M 2
1 2
F M 1
1 2
X 1 : 5 9
X 1 : 5 7
X
4
1
:
1
X
4
1
:
3
X
3
9
:
1
X
4
0
:
1
X
4
1
:
4
X
4
1
:
2
X
4
0
:
4
X
3
9
:
4
X
1
:
1
5
9
X
1
:
1
6
2
X
4
3
:
2
X 5 1 : 2
X
5
1
:
1
X
1
:
1
6
1
X
1
:
1
6
0
X 3 5 : 1
X
4
0
:
3
X
4
0
:
2
X
3
9
:
2
Y
0
4
M
a
g
n
e
t
v
e
n
t
i
l

B
r
e
m
s
e
12
d
r
i
v
i
n
g

c
o
n
t
r
o
l
l
e
r
Y
9
3
P
r
o
p
.

V
e
n
t
i
l

l
e
n
k
e
n

l
i
n
k
s
12
Y
9
2
P
r
o
p
.

V
e
n
t
i
l

l
e
n
k
e
n

r
e
c
h
t
s
12
A r m l e h n e
P u m p e V i b . P l a t t e n
B
1
3
2
S c h a l t e r A r m l e h n e
Sig.
a r m r e s t s w i t c h
1 5 0 m A
m a x . 1 . 8 A
X
1
:
1
5
4
G
A

M
E
S
X
9
:
2
X
1
:
3
8
X
1
:
3
7
X
1
:
8
9
K
A

M
E
S
X
9
:
2
A
n
b
a
u

1
7
7
D
H
:

h
.
r
.

a
A
n
b
a
u

2
1
3
D
H
:

u
n
t
e
n
A
n
b
a
u

1
7
7
D
H
:

h
.
l.

b
A
n
b
a
u

2
1
3
D
H
:

o
b
e
n
X
1
:
5
5
5
:
6
X 3 5 : 2 0
X 3 5 : 2 1
b
r
b
l
s
w
g
g
X 3 5 : 1 6
X 3 5 : 4 3
X
3
5
:
4
3
8
:
1
3
S c h n e l l v e r s c h l . P l a t t e n
b
d
a
1
K
4
8
8
:
2
3
0
8
7
a
8
7
A
3
4
F
a
h
r
S
t
e
u
e
r
u
n
g
F M 3
1 2
X 1 : 6 3X 1 : 6 2
F
M
3
5
:
4
X
1
:
1
4
7
X
1
:
1
9
6
X
1
:
1
9
5
7
:
1
4
19.1 Wiring diagram
BOMAG 1068 008 911 79
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
0
0
8
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
1
1
F
a
h
r
h
e
b
e
l
,

V
i
b
r
a
t
i
o
n
s
p
l
a
t
t
e
n
j
o
y
s
t
i
c
k
,

v
i
b
r
a
t
i
o
n
p
l
a
t
e
s
S
5
5
F
a
h
r
h
e
b
e
l
S
t
e
c
k
e
r

X
2
3
S
t
e
c
k
e
r

X
2
4
134291
0
76581
1
1
2
1
2
3
4
5
6
7
8
C
A
N
2
+
5
:
1
7
C
A
N
2
5
:
1
7
K
4
8
8
6
8
5
K
0
5
8
6
8
5
X 1 : 1 5 7
X 1 : 1 5 6
X
1
:
1
5
3
X
1
:
1
4
9
S
3
5
S
c
h
a
l
t
e
r

A
m
p
l
i
t
u
d
e
1
3
1
4
2
3
2
4
T
a
s
t
e
r

1

=

P
la
t
t
e
n

r
e
c
h
t
s
p
u
s
h

b
u
t
t
o
n

1

=

p
la
t
e
s

r
ig
h
t
T
a
s
t
e
r

2

=

P
la
t
t
e
n

h
e
b
e
n
p
u
s
h

b
u
t
t
o
n

2

=

lif
t

p
la
t
e
s
T
a
s
t
e
r

3

=

V
ib
r
a
t
io
n

E
I
N
/
A
U
S
p
u
s
h

b
u
t
t
o
n

3

=

v
ib
r
a
t
io
n

O
N
/
O
F
F
T
a
s
t
e
r

4

=

P
la
t
t
e
n

lin
k
s
p
u
s
h

b
u
t
t
o
n

4

=

p
la
t
e
s

le
f
t
T
a
s
t
e
r

5

=

p
la
t
t
e
n

s
e
n
k
e
n
p
u
s
h

b
u
t
t
o
n

5

=

lo
w
e
r

p
la
t
e
s
T
a
s
t
e
r

7

=

I
n
f
o
t
a
s
t
e

1
p
u
s
h

b
u
t
t
o
n

7

=

in
f
o

b
u
t
t
o
n

1
T
a
s
t
e
r

8

=

I
n
f
o
t
a
s
t
e

2
p
u
s
h

b
u
t
t
o
n

8

=

I
n
f
o

b
u
t
t
o
n

2
4 3
7
8
U
b

in
0
V

in
B
T
S

z
u
s
.
+
5
V

o
u
t
C
A
N
+
C
A
N
0
V

(
R
e
f

P
I
N
5
)
A
d
d
1
A
d
d
2
A
K

E
x
t
1
A
K

E
x
t
2
D K E x t 1
D K E x t 2
D K E x t 3
D K E x t 4
D K E x t 5
D K E x t 6
U b o u t
O V o u t
B
T
S

B
r
e
m
s
e
B
r
e
m
s
e

a
u
f

=

U
b
B
r
e
m
s
e

z
u

=

0
V
t
r
a
v
e
l

l
e
v
e
r
s
p
e
e
d

r
a
n
g
e

s
e
l
e
c
t
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r
K
0
G
s
w
i
t
c
h

a
m
p
l
i
t
u
d
e
s
1
25
3
1
7
:
2
0
3
1
9
:
1
X
2
3
:
1
7
:
2
B
T
S

B
R
E
M
S
E
7
:
1
8
S
1
3
9
F
r
e
q
u
e
n
z
v
e
r
s
t
e
l
l
u
n
g

P
l
a
t
t
e
n
S
+
f
r
e
q
.

a
d
j
u
s
t

p
l
a
t
e
s
S
0
9
S
c
h
a
l
t
e
r

V
i
b
r
a
t
i
o
n

E
i
n
/
A
u
s
1
3
1
4
s
w
i
t
c
h

v
i
b
r
a
t
i
o
n

o
n
/
o
f
f
N
u
r

b
e
i

B
V
C
O
n
l
y

a
t

B
V
C
S
6
4
S
c
h
a
l
t
e
r

S
c
h
w
i
m
m
s
t
e
l
l
u
n
g

P
l
a
t
t
e
n
1
3
1
4
S
4
2
F
a
h
r
s
t
u
f
e
n
s
c
h
a
l
t
e
r
S
+
X 2 5 : 3
X 2 5 : 4
X 2 5 : 2
s
w
.

s
w
i
m
m
i
n
g

p
o
s
.

p
l
a
t
e
s
m
o
d
e
s
w
.

p
l
a
t
e
s
X 5 0 : 2
X 5 0 : 3
X 5 0 : 1
C
A
N
1
+
6
:
1
4
C
A
N
1
+
9
:
1
6
C
A
N
1
6
:
1
4
C
A
N
1
9
:
1
6
K
1
1
:
8
7
6
:
2
0
K
1
1
:
8
7
9
:
1
X
3
5
:
2
2
7
:
1
1
Y
9
8
P
r
o
p
P
u
m
p
e

P
l
a
t
t
e
n
12
p
r
o
p
.
v
a
l
v
e

p
l
a
t
e
s
A
5
4
P
l
a
t
t
e
n

S
t
e
u
e
r
u
n
g

Y
1
2
2
M
V

P
l
a
t
t
e
n

h
e
b
e
n
12
Y
1
4
2
M
V

P
l
a
t
t
e
n

l
i
n
k
s
12
Y
1
4
4
.
1
M
V

P
l
a
t
t
e
n

S
c
h
w
i
m
m
s
t
12
Y
1
2
3
M
V

P
l
a
t
t
e
n

s
e
n
k
e
n
12
Y
1
4
3
M
V

P
l
a
t
t
e
n

r
e
c
h
t
s
12
p
l
a
t
e
s

u
pp
l
a
t
e
s

d
o
w
np
l
a
t
e
s

l
e
f
t
p
l
a
t
e
s

r
i
g
h
tp
l
a
t
e
s

f
l
o
a
t
p
o
s
.
p
l
a
t
e
s

p
r
i
o
r
i
t
y
X
1
:
3
1
E
F
1
4
5
12
X
1
:
3
1
A
B
1
3
5
N
h
e
r
u
n
g
s
s
c
h
.

P
l
a
t
t
e
n

M
i
t
t
e
+
S
B
1
3
4
N
h
e
r
u
n
g
s
s
c
h
.

P
l
a
t
t
e
n

o
b
e
n
+
S
s
e
n
s
o
r

p
l
a
t
e
s

c
e
n
t
e
r
e
d
s
e
n
s
o
r

p
l
a
t
e
s

u
p
X
1
:
2
0
9
p
l
a
t
e
c
o
n
t
r
o
l
l
e
r
E
S
X

F
a
h
r
s
t
.
L
C
D
is
p
la
y
B
T
M
2
0
A
n
i
c
h
t

b
e
i

B
V
C
n
o
t

a
t

B
V
C
X 6 2 : 4
X
6
2
:
1
2
X 6 2 : 3
X 6 2 : 9
X 6 2 : 1 0
X 6 2 : 1
X 6 2 : 2
X 6 2 : 1 1
X 6 2 : 5
X 6 2 : 6
X 6 2 : 8
X 6 2 : 1 3
X 6 2 : 1 4
X 6 2 : 7
4 0 0 . . 1 . 2 0 0 m A
X 1 : 2 1 4
X 1 : 2 1 3
X
1
:
2
1
1
X
1
:
2
1
2
X 6 3 : 1X 6 3 : 2
X 6 3 : 2 X 6 3 : 1
S c h n e l l v e r s c h l u s s K u p p l u n g
q u i c k c o n n e c t i n g c l u t c h
X
3
5
:
4
3
7
:
1
1
X
1
:
2
1
5
b r
b r
b
l
b
l
w s
s w
X
1
:
2
1
0
S
3
6
S
c
h
a
l
t
e
r

B
e
t
r
i
e
b
s
a
r
t

P
l
a
t
t
e
n
1
3
1
4
Y
1
4
5
M
V

P
l
a
t
t
e
n

P
r
i
o
r
i
t
t
12
Y
1
4
4
.
2
12
X 6 2 : 1 5
2
:
1
3
7
:
1
7
Wiring diagram
BOMAG 1069 008 911 79
19.1
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
0
0
9
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
1
1
V
a
r
i
o
c
o
n
t
r
o
l
,

M
e
s
s
t
e
c
h
n
i
k
V
a
r
i
o
c
o
n
t
r
o
l
,

m
e
a
s
u
r
e
m
e
n
t

e
q
u
i
p
m
.
X 4 4 : 4 7
X 4 4 : 2 9
A u f n . v o r n e 1 5 g
X 4 4 : 3 3
X 4 4 : 5 3
X 4 4 : 4 6
X 4 4 : 5 6
X 4 4 : 5 7
X 4 4 : 5 8
X 4 4 : 5 9
X 4 4 : 6 0
X 4 4 : 5 4
L e i s t u n g
P r o p .
E l e k t r o n i k
m
e
a
s
u
r
e
m
e
n
t

c
a
l
c
.

u
n
i
t
P r o p .
C
A
N
3
C
A
N
3
+
C
A
N
1
3
1
8
:
2
0
3
1
1
0
:
1
X
2
:
7
5
X
2
:
7
6
X
2
:
7
3
X
2
:
7
4
s
o
l
e
n
o
i
d
v
a
l
v
e

e
x
c
i
t
e
r

u
p
s
o
l
e
n
o
i
d

v
a
l
v
e

e
x
c
i
t
e
r

d
o
w
n
B
6
2
B
e
s
c
h
l
e
u
n
i
g
u
n
g
s
s
e
n
s
o
r
e
n
+ / s w
/
g
g
1
5
g
/
b
l
2 0 g / b r
X 4 4 : 3 1
B
6
2
B
e
s
c
h
l
e
u
n
i
g
u
n
g
s
s
e
n
s
o
r
e
n
+ / s w
/
g
g
1
5
g
/
b
l
2 0 g / b r
X 4 4 : 3 0
A u f n . h i n t e n 1 5 g
X 4 4 : 7
X
2
:
5
4
X
2
:
5
5
X
2
:
5
8
X
2
:
5
9
X
4
8
:
3
X
4
8
:
4
X
4
9
:
3
X
4
9
:
4
X 4 4 : 9
E r r e g e r p o s .
P
1
1
D
r
u
c
k
e
r
R
x
D
X 4 4 : 5 T
x
D
C
A
N
1
+
P
3
3
D
i
s
p
l
a
y

M
e
s
s
t
e
c
h
n
i
k

B
O
P
X
2
:
5
0
X
2
:
5
1
X
4
2
:
4
X
4
2
:
5
X
4
2
:
3
X
4
2
:
2
X
4
2
:
1
X 4 4 : 1
A G N D M E S X
P
0
7
E
V
I
B
M
e
t
e
r
+
E
V
I
B
E V I B
X 4 4 : 2 3
8 . 5 V
X 4 4 : 2 8
P o t . 1 5
X
2
:
5
7
X
1
:
3
4
A
5
:
9
G N D
X 4 4 : 5 5
X
2
:
5
2
X
1
:
3
5
A
X
1
:
3
5
E
X 4 4 : 6 5
X 4 4 : 6 6
X 4 4 : 6 7
X 4 4 : 6 8
X
2
:
6
3
X
2
:
6
6
3
0
6
:
2
0
3
0
1
2
:
1
C
A
N
1
+
8
:
2
0
C
A
N
1
8
:
2
0
G
A

M
E
S
X
7
:
1
5
X 4 4 : 3 8
S
P
E
E
D

M
E
S
X
5
:
3
X 4 4 : 3 5
X 4 4 : 1 4
D
I
R

M
E
S
X
5
:
3
X 4 4 : 3 2
P
I
T
C
H

M
E
S
X
5
:
8
X 4 4 : 3 6
X 4 4 : 3 7
A
8
3
M
e
s
s
t
e
c
h
n
i
k
R
e
c
h
n
e
r
X 4 4 : 4 1
B
R
A
K
E

M
E
S
X
7
:
1
7
D
+

M
E
S
X
2
:
8
X
2
:
7
7
F
M
4
12
X
2
:
7
8
B
6
1
A
u
f
n
e
h
m
e
r

V
e
r
s
t
e
l
l
m
o
t
o
r
S
/
w
s
+
/
r
t
/ s w
X
2
:
6
8
P
o
t

1
5
X
4
8
:
2
X
4
8
:
1
X
4
9
:
2
X
4
9
:
1
X
2
:
5
6
X
2
:
5
3
X
2
:
6
0
X
2
:
5
7
P
o
t

3
0
a
c
c
.

s
e
n
s
o
r

f
r
o
n
t
a
c
c
.

s
e
n
s
o
r

r
e
a
r
s
e
n
s
.

a
d
j
u
s
t
.

m
o
t
o
r
p
r
i
n
t
e
rE
V
I
B
m
e
t
e
r
X
2
:
6
9
X
4
7
:
A
X
4
7
:
B
X
4
7
:
C
X
2
:
6
7
F
1
4
6
12
Y
1
4
0
P
r
o
p
V
e
n
t
i
l

E
r
r
e
g
e
r

a
u
f
12
Y
1
4
1
P
r
o
p
V
e
n
t
i
l

E
r
r
e
g
e
r

a
b
12
X
1
:
8
2
X 4 4 : 3
X
1
:
8
5
1
5
A
D I O S P l a t t e n
d
i
s
p
l
a
y

m
e
a
s
u
r
e
m
.

B
O
P
K
A

M
E
S
X
7
:
1
5
X 4 4 : 1 5
B
E
L

M
E
S
X
1
2
:
4
v . l .
v . r .
F
1
4
8
12
1
0
A
X
1
:
3
2
E
X
1
:
3
2
A
K
1
1
:
8
7
8
:
2
0
K
1
1
:
8
7
1
2
:
1
X
2
:
7
1
X
2
:
6
6
X
2
:
7
0
X 4 : C
X 4 : D
X 4 : E
X 4 4 : 4
X
2
:
6
4
X
2
:
6
5
X
4
:
A
X
4
:
B
X 7 4 : 3
X 7 4 : 5
X 7 4 : 4
X
7
4
:
1
X
7
4
:
2
P
1
6
B
e
d
i
e
n
e
i
n
h
e
i
t

B
E
M
F
1
F
2
+
C A N +
C A N
n u r b e i B E M
o n l y a t B E M
R
2
4
6
0

O
H
M
1
2
X 4 4 : 2 7
X 4 4 : 2 6
n u r b e i B T M + / B T M p r o f
o n l y a t B T M + / B T M p r o f
n u r b e i B T M p r o f
o n l y a t B T M p r o f
X
2
:
4
8
X
2
:
4
7
X
2
:
4
9
c
o
n
t
r
o
l
u
n
i
t

B
E
M
C
A
N
3
1
0
:
1
5
C
A
N
3
+
1
0
:
1
5
F
1
4
8
:
2
1
0
:
1
5
0 . . 6 V D C
4 0 0 . . 1 . 2 0 0 m A
4 0 0 . . 1 . 2 0 0 m A
X
4
6
:
B
X
4
6
:
A
X
4
6
:
E
X
4
6
:
D
X
4
6
:
F
n
u
r

b
e
i

B
E
M
o
n
l
y

a
t

B
E
M
X
2
:
4
9
19.1 Wiring diagram
BOMAG 1070 008 911 79
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
0
1
0
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
1
1
B
o
m
a
g

C
o
m
p
a
c
t
i
o
n

M
a
n
a
g
e
m
e
n
t

B
C
M
B
o
m
a
g

C
o
m
p
a
c
t
i
o
n

M
a
n
a
g
e
m
e
n
t

B
C
M
C
A
N
3
C
A
N
3
+
R
2
5
6
0

O
H
M
1
2
X
2
:
6
3
B
C
M

0
5
B
C
M

0
5
n
u
r

b
e
i

B
C
M
o
n
l
y

a
t

B
C
M
C
A
N
3
+
9
:
1
8
C
A
N
3
9
:
1
8
X
2
:
6
1
X
2
:
6
2
3
1
9
:
2
0
3
1
1
1
:
1
X
4
:
N
X
4
:
M
X
7
5
:
7
X
7
5
:
2
U
S
B
C
A
N

I
n
t
e
r
f
a
c
e

B
C
M
X
7
6
:
1
X
7
6
:
2
X
4
:
F
X
4
:
G
X
2
:
7
0
F
1
4
8
:
2
9
:
4
P
1
5
B
C
M

0
5
A
8
7
U
S
B
C
A
N

S
c
h
n
i
t
t
s
t
.
Wiring diagram
BOMAG 1071 008 911 79
19.1
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
0
1
2
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
1
1
B
e
l
e
u
c
h
t
u
n
g

u
n
d

S
t
v
Z
O
i
l
l
u
m
i
n
a
t
i
o
n

a
n
d

S
t
v
Z
O
3
1
1
1
:
1
2
3
1
1
3
:
1
K
1
1
:
8
7
9
:
3
K
1
1
:
8
7
E
1
7
S
c
h
e
i
n
w
e
r
f
e
r

r
e
c
h
t
s
12
E
1
6
S
c
h
e
i
n
w
e
r
f
e
r

l
i
n
k
s
12
K
1
6
1
2
:
9
3
0
8
7
a
8
7
S
1
5
S
c
h
a
l
t
e
r

S
t
v
Z
O3
1
3
2
1
1
2
3
1
2
2
4
K
1
6
8
6
8
5
K
0
6
8
6
8
5
0

1

2
4 , 6 A
4 , 6 A
0 , 1 2 5 A
1
5
A
1
0
A
0 , 1 2 5 A
h
e
a
d

l
i
g
h
t

L
H
h
e
a
d

l
i
g
h
t

R
H
s w i t c h , w o r k i n g h e a d l i g h t s
s
w
i
t
c
h
,

S
t
v
Z
O
3
0
9
:
1
9
3
0
F
1
1
F
1
8
F
0
7
E
1
3
S
c
h
l
u
l
e
u
c
h
t
e

l
i
n
k
s
12
E
1
2
P
a
r
k
l
e
u
c
h
t
e

l
i
n
k
s
12
E
1
4
P
a
r
k
l
e
u
c
h
t
e

r
e
c
h
t
s
12
E
1
5
S
c
h
l
u
l
e
u
c
h
t
e

r
e
c
h
t
s
12
F
0
9
F
1
0
L

0

R
0 , 4 2 A
0 , 4 2 A
0 , 4 2 A
0 , 4 2 A
1 , 7 5 A
1 , 7 5 A
1 , 7 5 A
1 , 7 5 A
1
0
A
1
5
A
1
0
A
s
w
i
t
c
h

i
n
d
i
c
a
t
o
r
i
n
d
i
c
a
t
o
r

f
r
o
n
t
,

R
H
i
n
d
i
c
a
t
o
r

r
e
a
r
,

L
H
i
n
d
i
c
a
t
o
r

f
r
o
n
t
,

L
H
i
n
d
i
c
a
t
o
r

r
e
a
r
,

R
H
t
a
i
l

l
i
g
h
t
,

L
H
p
a
r
k
i
n
g

l
i
g
h
t
,

L
H
p
a
r
k
i
n
g

l
i
g
h
t
,

R
H
t
a
i
l

l
i
g
h
t
,

R
H
F
0
8
1
5
A
E
0
8
B
l
i
n
k
l
e
u
c
h
t
e

V
L
12
E
0
9
B
l
i
n
k
l
e
u
c
h
t
e

H
L
12
E
1
0
B
l
i
n
k
l
e
u
c
h
t
e

V
R
12
w
e
r
f
e
r

o
h
n
e

S
t
v
Z
O
c
o
n
n
e
c
t
i
o
n

w
o
r
k
i
n
g

h
e
a
d
l
i
g
h
t
s

w
i
t
h
o
u
t

S
t
v
Z
O
A
n
s
c
h
l
u

A
r
b
e
i
t
s
s
c
h
e
i
n
B
L
6
:
9
B
R
6
:
9
E
1
1
B
l
i
n
k
l
e
u
c
h
t
e

H
R
12
S
3
7
S
c
h
a
l
t
e
r

B
l
i
n
k
e
r
1
3
1
4
2
4
2
3
A
0
2
3
1
3
0
8
2
L
R
4
9
L
4
9
R
S
1
4
W
a
r
n
b
l
i
n
k
s
c
h
a
l
t
e
r
1
3
1
4
2
4
2
3
H
0
6
B
e
l
.

W
a
r
n
b
i
n
k
s
c
h
a
l
t
e
r
+
0

1
s
w
i
t
c
h
,

h
a
z
a
r
d

l
i
g
h
t
i
l
l
u
m
i
n
a
t
i
o
n
,

s
w
i
t
c
h

h
a
z
a
r
d

l
i
g
h
t
E
2
5
A r b e i t s s c h e i n w e r f e r v o r n e r e c h t s12
E
2
3
A r b e i t s s c h e i n w e r f e r v o r n e l i n k s12
E
2
7
A r b e i t s s c h e i n w e r f e r h i n t e n l i n k s12
b
e
i

K
a
b
i
n
e
C
o
n
n
e
c
t
i
o
n

h
e
a
d

l
i
g
h
t
s
E
2
8
A r b e i t s s c h e i n w e r f e r h i n t e n r e c h t s12
1
5
A
1
5
A
4 , 6 A
4 , 6 A
4 , 6 A
4 , 6 A
w o r k i n g h e a d l i g h t s , r e a r r h .
w o r k i n g h e a d l i g h t s , f r o n t r h .
F
2
2
5E
F
1
9
4D
K
0
6
1
2
:
4
3
0
8
7
a
8
7
S
T
V
2
1
3
:
1
7
S
T
V
1
1
3
:
1
7
C
o
n
n
e
c
t
i
o
n

h
e
a
d

l
i
g
h
t
s
w o r k i n g h e a d l i g h t s , r e a r l h .
w o r k i n g h e a d l i g h t s , f r o n t l h .
b
e
i

R
O
P
S
/
S
D

A
u
f
b
a
u
a
c
c
.
t
o

R
O
P
S
/
S
D
A
n
s
c
h
l
u

A
r
b
e
i
t
s
s
c
h
e
i
n
w
e
r
f
e
r
A
n
s
c
h
l
u

A
r
b
e
i
t
s
s
c
h
e
i
n
w
e
r
f
e
r
w
i
t
h

c
a
b
i
n
X
1
:
1
8
E
X
1
:
1
8
A
X
1
:
2
6
E
X
1
:
2
6
A
X
1
:
2
3
E
X
1
:
2
3
A
X
1
:
2
4
E
X
1
:
2
4
A
X
1
:
2
1
E
X
1
:
2
1
A
X
1
:
2
2
E
X
1
:
2
2
A
X
1
:
1
9
E
X
1
:
1
9
A
X
1
:
2
5
E
X
1
:
2
5
A
X
1
:
2
X 1 : 3 1 9
X 1 : 3 2 0
X 1 : 3 2 1
X 1 : 3 2 2
X 1 : 3 2 3
X 1 : 3 2 4
X 1 : 3 2 4
X 1 : 3 2 3
X
1
:
8
3
S
1
6
S c h a l t e r A r b e i t s b e l e
1
3
1
4
B
E
L
6
:
9
X
1
:
8
4
A n s c h l u A r b e i t s s c h e i n
w e r f e r o h n e S t v Z O
c o n n e c t i o n w o r k i n g h e a d
l i g h t s w i t h o u t S t v Z O
X 1 : 3 0 9
X 1 : 3 1 0
X 1 : 3 1 5
X 1 : 3 1 6
X 1 : 3 1 1
X 1 : 3 1 2
X 1 : 3 1 5
X 1 : 3 1 6
X 1 : 3 0 3
X 1 : 3 1 3
X 1 : 3 1 4
X 1 : 3 1 5
X 1 : 3 1 6
X 1 : 3 0 2 X 1 : 3 0 1
X
3
:
4
X
3
:
5
X 1 : 3 0 4
X
1
:
3
0
5
X 1 : 3 0 6
X 1 : 3 0 7
X
3
:
1
B
E
L

M
E
S
X
9
:
7
X
1
:
4
3
X 5 8 : 6 X 5 8 : 5
X 5 8 : 6 X 5 8 : 3
X 5 8 : 6 X 5 8 : 2
X 5 9 : 6
X 5 9 : 6
X 5 9 : 6 X 5 9 : 2
X 5 9 : 3
X 5 9 : 5
X 6 0 : 4 X 6 0 : 3
X 6 0 : 2 X 6 0 : 1
X 6 1 : 1X 6 1 : 2
X 6 1 : 3X 6 1 : 4
1
2
:
1
0
1
2
:
2
19.1 Wiring diagram
BOMAG 1072 008 911 79
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
0
1
3
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
1
1
K
a
b
i
n
e
n
a
u
s
r
s
t
u
n
g
,

B
e
l
e
u
c
h
t
u
n
g
,

R
a
d
i
o
,

T
a
c
h
o
g
r
a
p
h
c
a
b
i
n
e
q
u
i
p
m
e
n
t
,

h
e
a
d
l
i
g
h
t
s
,

r
a
d
i
o
,

t
a
c
h
o
g
r
a
p
h
A
1
2
R
a
d
i
o
3
0
3
1
+
+
B
5
1
+
B
5
1
+
M
M
3 , 8 A
3 , 8 A
w
a
s
h
e
r

f
r
o
n
t
w
a
s
h
e
r

r
e
a
r
M
0
6
W
a
s
c
h
e
r

v
o
r
n
+
M
0
7
W
a
s
c
h
e
r

h
i
n
t
e
n
+
S
T
V
1
1
2
:
1
3
S
T
V
2
1
2
:
1
3
r
a
d
i
o
F
4
3
A1
S
2
1
2
5
7
4
0

1

W
0
1
S
2
0
2
5
7
4
0

1

W
0
1
M
0
5
W
i
s
c
h
e
r

h
i
n
t
e
n
M
0
4
W
i
s
c
h
e
r

v
o
r
n
e
M
M
E
2
7
A
r
b
e
i
t
s
s
c
h
e
i
n
w
e
r
f
e
r

h
i
n
t
e
n
12
E
2
8
12
E
2
3
A
r
b
e
i
t
s
s
c
h
e
i
n
w
e
r
f
e
r

v
o
r
n
12
E
2
5
12
w
i
n
d
s
c
r
e
e
n

w
i
p
e
r
,

r
e
a
r
w
i
n
d
s
c
r
e
e
n

w
i
p
e
r
,

r
e
a
r
w
o
r
k
i
n
g

h
e
a
d

l
i
g
h
t
s
,

r
e
a
r
w
o
r
k
i
n
g

h
e
a
d

l
i
g
h
t
s
,

f
r
o
n
t
4 , 6 A
4 , 6 A
4 , 6 A
4 , 6 Ar
o
t
a
r
y

b
e
a
c
o
n
E
3
2
R
u
n
d
u
m
k
e
n
n
l
e
u
c
h
t
e
+
Z
A
o
p
t
i
o
n
4 , 7 A
2 , 9 A
0 , 8 3 A
5 A
F
4
1
E5
3
1
1
2
:
2
0
3
1
1
4
:
1
S
1
5
8
S
c
h
a
l
t
e
r

N
a
c
h
t
l
e
u
c
h
t
e
34
S
4
5
S c h a l t e r I n n e n l e u c h e
T
K
+
S
8
6
T
r
k
o
n
t
a
k
t
s
c
h
a
l
t
e
r
+
E
7
0
N a c h t l e u c h t e
12
1 , 7 5 A
K
3
0
2
:
1
5

E
2
9
I n n e n l e u c h t e
12
F
4
2
H8
F
1
3
0
C3
F
4
4
B2
F
1
4
3
G7
R
8
0
H e i z u n g H e c k s c h e i b e
12
F
4
2
1
4
:
8
K
1
4
1
1
5
3
1
A b f a l l v e r z g e r t
3 m i n
K
1
4
1
1
3
:
1
6
3
0
8
7
a
8
7
n i g h t i l l u m i n a t i o n
s
w
i
t
c
h
,

n
i
g
h
t

i
l
l
u
m
i
n
a
t
i
o
n
i n s i d e l i g h t , c a b i n
s w i t c h e s i n t e r i o r l i g h t s
d
o
o
r

s
w
i
t
c
h
h e a t i n g r e a r s c r e e n
A
0
1
i n d i c a t o r
S
3
8
51
S
1
6
3
51
K
3
2
:
8
7
1
4
:
2
A
1
6
T
a
c
h
o
g
r
a
p
h
e
n
m
o
d
u
l
5
3 2 1 6
7
,
8
,
9
4
P
0
9
T
a
c
h
o
g
r
a
p
h
A
5
+
A
6
C
3
B
4
B
3
A
1
A
2
+
A
3
t
a
c
h
o
g
r
a
p
h
F
1
3
0
1
3
:
9
F
1
3
0
1
4
:
7
F
1
3
0
1
3
:
1
4
m
o
d
u
l
e
,

t
a
c
h
o
g
r
a
p
h
X 5 5 : 4
X 5 5 : 3
X 5 5 : 1
X
5
5
:
2
X 5 6 : 3
X 5 6 : 1
X
5
6
:
2
X 5 6 : 4
I
X
3
:
6
X
3
:
7
X
3
:
8
V
I
B
7
:
1
8
X
3
:
1
8
S
P
E
E
D

T
A
C
5
:
3
X
3
:
1
7
X 3 : 2
X 3 : 1
K
A
B
I
N
E

3
1
1
4
:
1
8
1
5
X
S
S t e c k d o s e
1
2
V
+
s o c k e t
F
1
4
4
F6
1
5
A
1
0
A
1
5
A
1
5
A
1
0
A
1
0
A
1
5
A
E
7
1
K o n t r o l l e u c h t e
12
r
e
l
a
i
s

c
a
b
i
n
K
3
2
:
8
6
2
:
1
9
K
3
2
R
e
l
a
i
s

K
a
b
i
n
e
8
6
8
5
E
7
2
S
c
h
a
l
t
e
r
b
e
l
.
12
s
w
i
t
c
h

i
l
l
u
m
.
K
3
2
1
3
:
1
3
0
8
7
a
8
7
m a x . 1 3 A
3
:
6
1
3
:
2
Wiring diagram
BOMAG 1073 008 911 79
19.1
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
0
1
4
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
1
1
K
a
b
i
n
e
n
h
e
i
z
u
n
g
,

K
l
i
m
a
a
n
l
a
g
e
,

Z
u
s
a
t
z
h
e
i
z
u
n
g
c
a
b
i
n
h
e
a
t
e
r
,

a
i
r

c
o
n
d
i
t
i
o
n
i
n
g
,

a
d
d
.

h
e
a
t
e
r
3
1
1
3
:
2
0
3
1
M
0
9
K
a
b
i
n
e
n
l
f
t
e
r
g
e
b
r
r
t
o
r
M
0
9
K
a
b
i
n
e
n
l
f
t
e
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19.1 Wiring diagram
BOMAG 1074 008 911 79
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
1
0
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Name Benennung title TYP
Bl. Pf.
004 12

A02 012 17 Blinkrelais indicator relay
A12 013 5 Radio Radio
A16 013 6 Elektronik Tachograph Electronic system, tachograph
A34 005 6 Prozessorplatine Prozessing circuit board
A45 007 9 Lenkrad Steering wheel
A48 003 3 Elektronische Motorsteuerung Electronic engine management
A54 008 17 Modul Pumpenansteuerung Modul pump control
A66 011 9 Elektronik Steuereinheit Electronic control unit
A67 011 15 Eingabeeinheit Keyboard
A72 014 11 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A80 006 3 Modul Datensammler modul datacollector
A81 006 18 Anzeigeeinheit DisplayUnit
A83 009 6 Elektronik Messtechnik electronic measurementequipment
A87 010 15 USBCAN Schnittstelle BCM USBCAN Interface BCM

B03 006 3 Unterdruckschalter Luftfilter Vacuum switch, air cleaner
B11 002 16 Signalhorn Warning horn
B16 007 16 Aufnehmer Vibrationsfrequenz vorne Transducer, vibration frequency, front
B21 006 2 Differenzdruckschalter Hydr.Oelfilter Pressure diff. switch, hydr. oil filter
B51 013 4 Lautsprecher Radio Speaker radio
B55 006 4 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B57 005 6 Neigungssensor Stufenumschaltung Slope sensor, speed range selection
B59 005 4 Aufnehmer Bandagengeschwindigkeit Sensor, drum speed
B60 005 2 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 009 12 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 009 8 Beschleunigungsaufnehmer Acceleration sensor
B65 007 4 Sensor, Lenkwinkel vorn Sensor, angularity steering, front
B88 003 6 Druckgeber Motoroel Sender, engine oil pressure
B93 004 13 Leistungskraftstoffdruck Sensor RPS Rail pressure sensor
B103 014 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning
B104 014 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B112 005 3 Druckgeber Fahrpumpe pressure sender, driving pump
B113 003 13 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B114 003 7 EMR Aufnehmer, Motordrehzahl 1 EMR Trancducer, engine speed 1
B115 003 11 Geber Ladeluftdruck Sender, charging air pressure
B124 004 5 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B126 003 14 EMR Temperaturgeber Kraftstoff EMR fuel temperature sender
B131 014 10 Temperaturschalter Heizung Temperature switch, heating
B132 007 2 Inititator Armlehne links proximity switch left arm rest
B134 008 17 Nherungsschalter Platten oben proximity switch, plate up
B135 008 16 Nherungsschalter Platten mitte proximity switch, plate middle
B145 004 17 Sensor Niederdruck Kraftstoff fuel low pressure sensor

E08 012 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
E09 012 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 012 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 012 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 012 7 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 012 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 012 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 012 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
E16 012 2 Scheinwerfer links Head light, lh. MAX. 4,6A
E17 012 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
E23 012 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 013 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 012 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 013 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 012 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 013 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 012 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 013 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 013 3 Innenleuchte Kabine Inside light, cabin 1,75A
E30 014 13 Heizgeraet Heating unit
E32 013 19 Kennleuchte Warning light 5A
E70 013 15 Nachtleuchte Night lamp 0,83A
E71 013 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 013 16 Beleuchtung Bedienschalter illum. Switches

F00 002 6 Hauptsicherung Batterie Fuse, main, battery 125A
F05 002 14 Sicherung Steckdose Fuse, socket 10A
F07 012 15 Sicherung Warnblinker Fuse, hazard light 15A
F08 012 18 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 012 6 Sicherung Park u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 012 8 Sicherung Park u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 012 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 002 11 Sicherung Startschalter Fuse, starter switch 30A
F15 014 18 Sicherung Heizgeraet Fuse, heating unit 5A
F18 012 5 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
F19 012 12 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 15A
F22 012 10 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 15A
F23 002 18 Sicherung Signalhorn Fuse, warning horn 15A
F24 006 2 Sicherung Ueberwachungsmodul Fuse, monitoring module 10A
F31 014 3 Sicherung Kabinenluefter Fuse, cabin ventilator 20A
F39 002 19 Hauptsicherung Kabine Main fuse, cab 15A
F40 014 13 Sicherung Kabinenheizung Fuse, heating unit cab 20A
F41 013 19 Sicherung Rundumkennleuchte Fuse, rotary beacon 10A
Wiring diagram
BOMAG 1075 008 911 79
19.1
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
1
0
2
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
2
1
1
B
a
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t
e
i
l
l
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s
t
e
c
o
m
p
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n
e
n
t

l
i
s
t
i
n
g
Bl. Pf.
F42 013 3 Sicherung Kabineninnenleuchte Fuse, inside light cab 10A
F43 013 10 Sicherung Wischermotor hinten Fuse, wipermotor rear 15A
F44 013 13 Sicherung Wischermotor vorn Fuse, wipermotor front 15A
F48 002 5 Sicherung Gluehanlage Fuse, glow plug system 125A
F67 005 7 Sicherung Steuerung (Potential 30) Fuse, controller (pot.30) 15A
F68 002 8 Sicherung Potential 30 Fuse, potential 30 5A
F84 005 9 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
F93 004 3 Sicherung Steuerung (Potential 30) Fuse, controller (pot. 30) 25A
F95 002 16 Sicherung Motormanagement intern Fuse, engine controller (internal) 10A
FM1 007 6 Platinensicherung Multifuse MULTIFUSE
F130 013 15 Sicherung Nachtleuchte Fuse, night lamp 10A
F143 013 2 Sicherung Heckscheibenheizung fuse rear screen heating unit 15A
F144 013 20 Sicherung Kabinensteckdose Fuse cabinsocket 15A
F145 008 18 Sicherung Anhngeplatten fuse vibration plates 20A
F146 009 5 Sicherung Steuerung MESX (Potential 30) Fuse Controller (Pot. 30) 15A

G01 002 6 Batterie Battery 103A
G02 002 7 Generator Generator

H06 012 15 Meldeleuchte Warnblinker Indicator light, hazard light LED ROT
H07 007 16 Warnsummer Betriebsstoerung Warning buzzer, breakdown 0.15A
H14 005 11 Warnsummer Rueckwaertsfahrt Backup alarm buzzer MAX O,46A

K05 008 3 Relais Startstrom Relay, starting current BOSCHW
K06 012 4 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 10 Relais Klimageraet Relay, air conditioning BOSCHW
K11 002 12 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHL
K14 003 19 Relais Vorgluehen Relay, glow plug system TYCOX
K16 012 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K32 013 1 Relais Kabine Relay, cabin BOSCHW
K41 004 2 Trennrelais Relay, separation BOSCHW
K43 007 12 Relais Vibration Relay, vibration BOSCHW
K48 008 2 Relais Fahrhebel 0Stellung Relay, travel lever 0position BOSCHW
K61 002 7 Relais Ladekontrolle Relay, charge control BOSCHW
K14.2 004 20 TYCOX
K141 013 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW

M01 002 13 Starter Starter 2.3 KW
M04 013 12 Scheibenwischermotor vorne Windscreen wiper motor, front 4,7A
M05 013 10 Scheibenwischermotor hinten Windscreen wiper motor, rear 2,9A
M06 013 13 Scheibenwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 013 11 Scheibenwaschermotor hinten Windscreen washer motor, rear MAX. 3,8A
M09 014 3 Kabinenluefter Cabin ventilator

P07 009 15 Omegameter Omegameter
P09 013 8 Frequenz und Geschwindigkeitsanzeige Frequency and Speedometer
P11 009 14 Drucker Printer
P15 010 16 BCM 03 Bildschirm BCM 03 terminal
P16 009 16 Diagnose, Variomatic Diagnostics, varimatic
P33 009 18 Opus 21 Opus 21

R03 006 5 Geber Tankanzeige Sender, level gauge 0 .. 67 OHM
R10 002 8 Parallelwiderstand Parallel resistor 82 OHM
R19 002 4 Heizflansch heater flange 167A
R20 005 15 Widerstand Resistor 120 OHM
R80 013 2 Heizung Heckscheibe heating rear screen MAX. 13A
R81 002 1 Gluehstiftkerze 1 glow plug 1

S00 002 11 Startschalter Starter switch
S01 002 16 Schalter NOT AUS Switch, emergency off NOTAUSH
S03 002 18 Taster Signalhorn Push button, warning horn
S06 005 10 Sitzkontaktschalter links Switch, seat contact, lh.
S09 008 8 Vibrationsschalter vorne Switch, vibration, front
S14 012 15 Warnblinkschalter Switch, hazard light
S15 012 4 Beleuchtungsschalter StVZO Switch, lighting StVZO
S16 012 4 Schalter Arbeitsbeleuchtung vorne Switch, working head lights, front
S20 013 13 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 013 10 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S28 014 18 Schalter Kabinenheizung Switch, cabin heating
S30 002 5 Batterietrennschalter Switch, battery disconnect
S35 008 7 Vibrationsschalter klein/gross Switch, vibration low/high
S36 008 11 Vibrationsschalter Switch, vibration
S37 012 18 Schalter Blinker Switch, indicator
S38 013 19 Schalter Kennleuchte Switch, warning light
S42 008 11 Stufenumschalter schnelllangsam Speed range selector, fastslow
S44 014 3 Schalter Kabinenluefter Switch, cabin ventilator
S45 013 3 Schalter Kabineninnenleuchte Switch, cabin inside light
S55 008 6 Schalter Fahrhebel Switch, travel control lever
S64 008 10 Schalter Schwimmstellung Switch, float position
S86 013 3 Schalter Tuer, links Switch door, lh.
S127 006 17 Schalter Motordrehzahl Switch, engine rpm
S139 008 13 Schalter Frequenzverstellung Switch, frequency control
19.1 Wiring diagram
BOMAG 1076 008 911 79
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
1
0
3
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
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s
3
1
1
B
a
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e
i
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l
i
s
t
e
c
o
m
p
o
n
e
n
t

l
i
s
t
i
n
g
Bl. Pf.
S158 013 15 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 013 16 Schalter Heckscheibenheizung switch rear screen heating unit

V01 002 9 Diode Diode FE5B
V06 014 9 Diode Diode

X1:1 002 7 WAGO ZENTRALELEKTRIK WAGO EBOX
Wiring diagram
BOMAG 1077 008 911 79
19.1
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
1
0
4
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
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s
4
1
1
B
a
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e
i
l
l
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c
o
m
p
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e
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t

l
i
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t
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g
Bl. Pf.
X1:14A 004 3 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:14E 004 3 WAGO ZENTRALELEKTRIK WAGO EBOX
19.1 Wiring diagram
BOMAG 1078 008 911 79
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
1
0
5
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
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s
5
1
1
B
a
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e
i
l
l
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c
o
m
p
o
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e
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t

l
i
s
t
i
n
g
Bl. Pf.
X2:47 009 18 WAGOMESSTECHNIK Wagomeasurement equip.
X3:1 012 11 STECKER ROPS/SD conn. ROPS/SR
Wiring diagram
BOMAG 1079 008 911 79
19.1
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
1
0
6
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
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s
6
1
1
B
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e
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l
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c
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p
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t

l
i
s
t
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n
g
Bl. Pf.
X3:1 013 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:3 002 19 SETCKER KABINE/ROPS Con cabin/ROPS
X4:A 009 14 KABINENST. MESST. con. measurem.equipm.
X4:B 009 14 KABINENST. MESST. con. measurem.equipm.
X4:C 009 14 KABINENST. MESST. con. measurem.equipm.
X4:D 009 14 KABINENST. MESST. con. measurem.equipm.
X4:E 009 15 KABINENST. MESST. con. measurem.equipm.
X4:F 010 18 KABINENST. MESST. con. measurem.equipm.
X4:G 010 18 KABINENST. MESST. con. measurem.equipm.
X4:M 010 16 KABINENST. MESST. con. measurem.equipm.
X4:N 010 15 KABINENST. MESST. con. measurem.equipm.
X6:1 007 13 STECKER VIBRATION GRO conn. vibration big
X7:1 007 15 STECKER VIBRATION KLE conn. vibration small
X8:1 006 6 STECKER WASSERABSCHEI connector water separator
X9:1 005 11 STECKER RCKFAHRALARM conn. backupalarm
XS 002 19 Steckdose Socket
X10:2 006 5 STECKER TAUCHROHRGEBE connector fuel level sensor
X14:A 005 10 STECKER SITZKONTAKT connector seat contact switch
X14:B 005 10 STECKER SITZKONTAKT connector seat contact switch
X15:1 005 13 STECKER FAHRPUMPE RC connectoe driving pump back
X16:1 005 12 STECKER FAHRPUMPE VOR connector driving pump front
X17:1 014 3 STECKER LFTER HKL conn. blower
X18:1 014 10 STECKER THERMOFHLER conn. sender temp.
X19:1 014 7 STECKER EISSCHUTZ HKL conn. antiice aircond.
X20:1 014 7 STECKER DRUCKSCH. KLI conn. pressuresitch aircond.
X21:1 006 4 STECKER KHLMITTEL connector coolant sensor
X22:1 007 16 ST. VIBRATIONSAUFNEHM connector vibration sensor
X25:2 008 10 ST. FAHRSTUFENSCHALTE connector switch speed ranges
X26:1 006 8 STECKER DATENSAMMLER connector data collector
X28:1 006 16 STECKER LCDISPLAY 1 connector LCdisplay 1
19.1 Wiring diagram
BOMAG 1080 008 911 79
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
1
0
7
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
7
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
o
n
e
n
t

l
i
s
t
i
n
g
Bl. Pf.
X30:1 003 5 EMRStecker Fahrzeug EMRconnector compactor
X31:1 003 16 EMRStecker Motor EMRconnector engine
X32:A 003 2 EMR Diagnose EMRdiagnosis
X32:B 003 3 EMR Diagnose EMRdiagnosis
X32:F 004 13 EMR Diagnose EMRdiagnosis
X32:G 003 3 EMR Diagnose EMRdiagnosis
X32:H 003 3 EMR Diagnose EMRdiagnosis
Wiring diagram
BOMAG 1081 008 911 79
19.1
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
1
0
8
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
8
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
o
n
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n
t

l
i
s
t
i
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Bl. Pf.
X32:K 003 2 EMR Diagnose EMRdiagnosis
X32:L 003 2 EMR Diagnose EMRdiagnosis
X32:M 004 13 EMR Diagnose EMRdiagnosis
X33:1 003 19 Trennstelle EMR II conector EMR II
X34:A 005 14 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:B 005 16 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:C 005 12 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:D 005 13 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:G 005 10 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:H 005 11 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:J 007 3 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:N 003 4 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:P 002 14 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:R 006 2 DIAGNOSESTECKER ESX connector diagnosis ESX
X35:1 007 4 ESX STECKER esx connector
X36:A 002 5 EINSPEISUNG SCHALTKAS supply ebox
X36:B 002 6 EINSPEISUNG SCHALTKAS supply ebox
X37:A 002 11 ST. ZNDSCHLOSS EKAS connector ignition switch, ebox
X37:B 002 13 ST. ZNDSCHLOSS EKAS connector ignition switch, ebox
X38:A 002 13 STECKER STARTER EKAS connector starter, eBox
X39:1 007 9 STECKER 1 LENKRAD connector 1 steering unit
X41:1 007 8 ST. LENKRADKABELBAUM conn. steer. wire harn.
X42:1 009 18 STECKER ADAPTER BOP conector adapter BOP
X43:1 007 2 STECKER SCHALTER ARML connector switch arm rest
19.1 Wiring diagram
BOMAG 1082 008 911 79
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
1
0
9
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
9
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
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p
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n
t

l
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Bl. Pf.
X44:1 009 13 MESX STECKER MESX Stecker
X46:A 009 19 STECKER BOP Connector BOP
X46:B 009 18 STECKER BOP Connector BOP
X46:D 009 18 STECKER BOP Connector BOP
X46:E 009 19 STECKER BOP Connector BOP
X46:F 009 18 STECKER BOP Connector BOP
X47:A 009 11 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:B 009 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:C 009 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X48:1 009 8 STECKER AUFN. VORNE conn. sender front
X49:1 009 10 STECKER AUFN. HINTEN conn. sender rear
X50:1 008 13 ST. PLATTENFREQ. conn. platefreq.
X51:1 007 2 ST. 1 LENKRADKABELBAU connector 1 steering wiring
X52:1 005 3 STECKER DRUCKSENSOR connector pressure sensor
X53:B 014 3 STECKER LFTERSCHALTE conn. blowerswitch
X53:C 014 4 STECKER LFTERSCHALTE conn. blowerswitch
X53:H 014 4 STECKER LFTERSCHALTE conn. blowerswitch
X53:L 014 3 STECKER LFTERSCHALTE conn. blowerswitch
X53:M 014 3 STECKER LFTERSCHALTE conn. blowerswitch
X54:1 014 11 STECKER HEIZSTEUERUNG conn. heating controller
X55:1 013 11 STECKER WISCHER HINTE connector wiper rear
X56:1 013 14 STECKER WISCHER VORNE conn. wiper front
X57:1 003 15 Stecker Motor connector engine
Wiring diagram
BOMAG 1083 008 911 79
19.1
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
1
1
0
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
1
0
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
o
n
e
n
t

l
i
s
t
i
n
g
Bl. Pf.
X58:2 012 17 STECKER STVZO VL Con. STVZO FL
X59:2 012 19 STECKER STVZO VR Con. STVZO FR
X60:1 012 18 STECKER STVZO HL Con. STVZO BL
X61:1 012 19 STECKER STVZO HR Con. STVZO BR
X62:1 008 19 STECKER DIOS PLATTEN con. DIOSplates
X63:1 008 13 SCHNELLVERSCHLUSSKUPP quick connecting clutch
X65:1 011 5 KEYBOARD Keyboard
X66:2 004 19 ANSCHLU EMR3 VORGLH connector EMR3 preglow
X74:1 009 14 STECKER DRUCKER con. printer
X75:2 010 16 SUBD STECKER BCM INT con. SUBD BCM
X75:7 010 15 SUBD STECKER BCM INT con. SUBD BCM
X76:1 010 17 STECKER VERS. BCM con. Powersup. BCM

Y04 007 17 Magnetventil Bremse Solenoid valve, brake MAX. 1.8A
19.1 Wiring diagram
BOMAG 1084 008 911 79
5
8
2

7
0
2

0
7
1
9
.
1
0
.
2
0
0
5
1
1
1
V
o
g
t
1
9
.
1
0
.
2
0
0
5
S
e
i
s
1
1
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
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n
e
n
t

l
i
s
t
i
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g
Bl. Pf.
Y07 007 15 Magnetventil Vibration vorne gross Solenoid valve, vibration, front, high 0.4 .. 1.2A
Y08 007 13 Magnetventil Vibration vorne klein Solenoid valve, vibration, front, low 0.4 .. 1.2A
Y14 014 14 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 014 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y16 005 13 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 0.4 .. 1.2A
Y17 005 12 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 0.4 .. 1.2A
Y30 005 15 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 0.4 .. 1.2A
Y31 005 16 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear 0.4 .. 1.2A
Y92 007 6 Magnetventil Lenkung vorne rechts Solenoid valve, steering, front rh. 0.4 .. 1.2A
Y93 007 5 Magnetventil Lenkung vorne links Solenoid valve, steering, front lh. 0.4 .. 1.2A
Y98 008 14 Magnetventil Vibrationsfrequenz, hinten Solenoid valve, vibrat.freq.,rear 0.4 .. 1.2A
Y122 008 16 Magnetventil Platten heben Solenoid valve, lift plates MAX. 1.8A
Y123 008 17 Magnetventil Platten senken Solenoid valve, let down plates MAX. 1.8A
Y137 003 10 EMR Verstellung EMR adjustment
Y138 014 10 Magnetveentil Heizung Solenoid valve, heating unit 1A
Y140 009 10 Magnetventil Erreger auf solenoid valve exciter up 0.4 .. 1.2A
Y141 009 11 Magnetventil Erreger ab solenoid valve exciter down 0.4 .. 1.2A
Y142 008 17 Magnetventil Plattenverschieben Links solenoid valve, plate displace left MAX. 1.8A
Y143 008 18 Magnetventil Plattenverschieben rechts solenoidvalve, plate displace right MAX. 1.8A
Y144.1 008 19 MAX. 1.8A
Y144.2 008 19 MAX. 1.8A
Y145 008 20 Magnetventil Platten (Prioritt) solenoidvalve, plate (priority) MAX. 1.8A
Y147 004 1 Injektor A1 jet pump A1

Wiring diagram
BOMAG 1085 008 911 79
19.1
X
3
8
X
3
7
G
e
z
.
:

1
9
.
1
0
.
2
0
0
5
N
a
m
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:

V
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G
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p
r
.
:

1
9
.
1
0
.
2
0
0
5
N
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S
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S
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:

1
v
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:

2
p
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1
f
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2
E
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s
.

f
.
:
R
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p
la
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:
5
8
2

7
0
2

0
7
B
la
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N
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:

2
0
1
S
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2
0
1
X
3
6
A
8
0
X
3
2
:
1
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1
2
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B
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1
7
7
.
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2
2
6

D
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B
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1
7
7
.
.
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2
2
6

D
H
/
B
V
C
-
4
K
4
3
K
4
8
K
6
1
K
1
6
K
0
9
K
1
1
K
0
5
K
0
6
B
5
7
A
0
2
N
u
r

b
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4
1
X
3
4
:
1
-
1
9
19.1 Wiring diagram
BOMAG 1086 008 911 79
G
e
z
.
:

1
9
.
1
0
.
2
0
0
5
N
a
m
e
:

V
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t
G
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p
r
.
:

1
9
.
1
0
.
2
0
0
5
N
a
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:

S
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S
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:

2
v
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:

2
p
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2
f
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:

2
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.

f
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la
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:
B
la
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N
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.
:

2
0
1
S
h
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t

N
o
.
:

2
0
1
A
8
3
M
e
s
s
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c
h
n
i
k

S
t
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u
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r
u
n
g
C
A
N

1
C
A
N

1
C
A
N

2
C
A
N

3
E
M
R

+

F
a
h
r
h
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b
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l
B
C
M
O
P
U
S

2
1
A
3
4
F
a
h
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s
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u
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F
1

F
2

N
u
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b
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V
M
8
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a
c
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.

T
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M
8
b
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a
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a
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-
T
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B
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1
7
7
.
.
.
2
2
6

D
H
-
4
o
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v
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-
b
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d
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B
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1
7
7
.
.
.
2
2
6

D
H
-
4
5
8
2

7
0
2

0
7
C
A
N

1
L
C
D
+
D
a
t
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n
s
a
m
m
l
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r
Wiring diagram
BOMAG 1087 008 911 79
19.1
Seite 1
WAGO smart DESIGNER 4.1
Copyright WAGO. Technische nderungen vorbehalten.
30.11.2005 08:36:29
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Absicherung DH-4 komplett
Stahl-Tragschiene 35x7,5 mm, 1 mm dick
210-112
5.20 x 25.00 [mm]
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Projektgruppe : Walzenzge -4 Klemmenleisten Optional1 :
Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
057 564 17 1
280-315 2
2 x 057 564 25 "L" +793-501 3
2 x 057 564 25 "L" +057 564 20 +793-501 5
057 564 22 7
4 x 057 564 23 "L" +057 564 19 +793-501 8
18 x 057 564 36 "R" +057 564 19
+793-501
F93 Flachsicherung DIN 72581-C25 / 057
511 09 (Nur bei EMR III)
12 12
510 99
13
510 97
14
510 98
15
510 98 (Nur bei E2 StvZO Beleuchtung)
16
17
511 73 (Nur bei Diebstahlschutz)
18
510 98
19
510 98
20
21
22
23
510 97
24
510 97
25
510 98
26
510 97
27
510 98
28
511 00 (Nur bei AG28 Plattenanbau)
29
19.1 Wiring diagram
BOMAG 1088 008 911 79
Seite 2
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Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
3 x 057 564 36 "R" +793-501 F148 Flachsicherung DIN 72581-C10 / 057
510 97 (Nur bei VM8-11 Messtechnik)
30 30
31
32
057 564 35 33
2 x 057 564 17 34
057 564 21 36
2 x 057 564 25 "L" +793-501 37
3 x 057 564 25 "L" +057 564 20 +793-501 39
5 x 057 564 25 "L" +793-501 42
8 x 057 564 25 "L" +057 564 20 +793-501 47
057 564 25 "L" +793-501 55
4 x 057 564 38 "L" +793-501 Nur bei BVC 56 56
Nur bei BVC 57
057 564 17 60
Wiring diagram
BOMAG 1089 008 911 79
19.1
Seite 3
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Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
19.1 Wiring diagram
BOMAG 1090 008 911 79
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Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
Wiring diagram
BOMAG 1091 008 911 79
19.1
Seite 1
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Kabelbume DH-4 komplett
210-112
5.20 x 25.00 [mm]
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Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
05756417 1
3 x 05756540 "R" +793-501 2
05756535 "R" +793-501 5
05756537 6
3 x 05756540 "R" +793-501 7
05756537 10
05756540 "R" +793-501 11
05756535 "R" +793-501 12
05756537 13
2 x 05756538 "R" +793-501 14
2 x 05756539 "R" +793-501 16
05756537 18
4 x 05756540 "R" +793-501 19
05756537 23
4 x 05756540 "R" +793-501 24
2 x 05756539 "R" +793-501 28
05756537 30
05756540 "R" +793-501 31
05756539 "R" +793-501 32
05756537 33
4 x 05756540 "R" +793-501 34
05756535 "R" +793-501 38
05756537 39
4 x 05756540 "R" +793-501 40
05756537 44
05756540 "R" +793-501 45
05756535 "R" +793-501 46
05756537 47
05756540 "R" +793-501 48
05756535 "R" +793-501 49
05756537 50
19.1 Wiring diagram
BOMAG 1092 008 911 79
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Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
05756538 "R" +793-501 51
2 x 05756540 "R" +793-501 52
05756538 "R" +793-501 54
05756537 55
3 x 05756540 "R" +793-501 56
05756538 "R" +793-501 59
05756537 60
3 x 05756540 "R" +793-501 61
05756535 "R" +793-501 64
05756537 65
2 x 05756540 "R" +793-501 Bei DH-4 TierIII und BVC 66 66
Bei DH-4 TierIII und BVC 67
05756535 "R" +793-501 68
05756537 Bei DH-4 TierIII und BVC 69 69
3 x 05756540 "R" +793-501 Nur bei Variocontrol 70 70
Nur bei Variocontrol 71
Nur bei Variocontrol 72
05756535 "R" +793-501 Nur bei Variocontrol 73 73
05756537 Nur bei Variocontrol 74 74
2 x 05756540 "R" +793-501 Nur bei AG28 Anbau-Vibrationsplatten 75 75
Nur bei AG28 Anbau-Vibrationsplatten 76
2 x 05756535 "R" +793-501 Nur bei AG28 Anbau-Vibrationsplatten 77 77
Nur bei AG28 Anbau-Vibrationsplatten 78
05756537 Nur bei AG28 Anbau-Vibrationsplatten 79 79
05756417 80
Wiring diagram
BOMAG 1093 008 911 79
19.1
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19.1 Wiring diagram
BOMAG 1094 008 911 79
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BOMAG 1095 008 911 79
19.1
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05756417 1
2 x 05756540 "R" +793-501 2
05756539 "R" +793-501 4
05756537 5
05756538 "R" +793-501 6
2 x 05756540 "R" +793-501 7
05756538 "R" +793-501 9
05756537 10
2 x 05756540 "R" +793-501 11
05756539 "R" +793-501 13
05756537 14
05756540 "R" +793-501 15
05756538 "R" +793-501 16
05756540 "R" +793-501 17
05756537 18
19.1 Wiring diagram
BOMAG 1096 008 911 79
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210-112
5.20 x 25.00 [mm]
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geprft: :
Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
05756540 "R" +793-501 Nur bei BVC 19 19
05756539 "R" +793-501 Nur bei BVC 20 20
05756537 Nur bei BVC 21 21
2 x 05756438 "R" +793-501 Nur bei BVC 22 22
Nur bei BVC 23
05756421 Nur bei BVC 24 24
05756417 25
Wiring diagram
BOMAG 1097 008 911 79
19.1
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Optional2 :
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Optional6 :
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19.1 Wiring diagram
BOMAG 1098 008 911 79
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Wiring diagram
BOMAG 1099 008 911 79
19.1
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Option E2 StvZO Beleuchtung
210-112
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05756417 Nur bei ZA E2 StvZO Beleuchtung 1 1
4 x 05756540 "R" +793-501 Nur bei ZA E2 StvZO Beleuchtung 2 2
Nur bei ZA E2 StvZO Beleuchtung 3
19.1 Wiring diagram
BOMAG 1100 008 911 79
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Optional3 :
Optional4 :
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Optional6 :
Optional7 :
Wiring diagram
BOMAG 1101 008 911 79
19.1

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.
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19.1 Wiring diagram
BOMAG 1102 008 911 79
BOMAG 1103 008 911 79
19.2 Wiring diagram
19.2 Wiring diagram
BOMAG 1104 008 911 79
Wiring diagram 582 702 32 from serial number

101 582 121 002 Variocontrol
101 582 641 060 BW 216 DH-4
101 582 651 005 BW 216 PDH-4
101 582 771 171 BW 219 DH-4
101 582 861 026 BW 226 DH-4 BVC
101 582 881 003 BW 226 DH-4
101 583 061 014 BW 213 DH-4 BVC /P
101 583 141 076 BW 213 DH-4
101 583 151 006 BW 213 PDH-4
101 583 161 027 BW 213 DH-4 BVC
101 583 191 005 BW 214 DH-4
101 583 201 001 BW 214 PDH-4
Wiring diagram
BOMAG 1105 008 911 79
19.2
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19.2 Wiring diagram
BOMAG 1106 008 911 79
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O p t i o n W i n t e r p a k e t
o p t i o n w i n t e r p a c k a g e
1
4
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7
2
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0
2
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1
5
Wiring diagram
BOMAG 1107 008 911 79
19.2
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
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0
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D
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I
I
3
1
2
:
2
0
3
1
4
:
1
X 3 0 : 1
X 3 0 : 2
X 3 0 : 1 0
X 3 0 : 1 1
X 3 0 : 1 2
X 3 0 : 1 3
X 3 2 : A
X 3 2 : L
X 3 2 : K
X 3 2 : H
X 3 2 : G
X 3 2 : B
D
i
a
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n
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s
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s
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c
k
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d
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i
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X 3 0 : 1 4
A
4
8
M
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E
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2
X 5 7 : 9
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B
1
1
3
E
M
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K
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1
2
X 5 7 : 2 3
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X 5 7 : 2 5
X 3 1 : 2 3
X 3 1 : 2 5
X 3 1 : 2 4
A G N D
S i g n a l
A G N D
+ 5 V
X 3 1 : 2 0
X 3 1 : 2 1
X 3 1 : 2 2
X 5 7 : 2 0
X 5 7 : 2 1
X 5 7 : 2 2
A G N D
S i g n a l
+ 5 V
B
8
8
E
M
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M
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l
d
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3
1
2
X 3 1 : 1 0
X 3 1 : 1 1
X 5 7 : 1 0
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A G N D
S i g n a l
X 3 1 : 1 2
X 3 1 : 1 3
X 5 7 : 1 2
X 5 7 : 1 3
A G N D
S i g n a l
X 3 1 : 1 4
X 3 1 : 1 5
X 3 1 : 1 7
X 3 1 : 1 8
X 3 1 : 1 9
X 5 7 : 1 4
X 5 7 : 1 5
X 5 7 : 1 7
X 5 7 : 1 8
X 5 7 : 1 9
Y
1
3
7
E
M
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S
t
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g
l
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6
2
7
S T G
S T G +
R F
R F R E F
R F M E S S
X 3 1 : 9
m a x 7 A
E
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c
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1
X 3 1 : 2
X 3 1 : 4
X 3 1 : 5
X 5 7 : 4
X 3 1 : 6
X 3 1 : 1 6
X 3 1 : 8
X 3 1 : 7
r
e
l
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h
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B
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2
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S
t
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2
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C A N h i g h
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L
K
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X
1
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6
X 1 : 1 8 2
X 1 : 1 8 3
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X 3 3 : 4
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X
1
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2
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3
1

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2
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4
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8
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K
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2 1
X
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5
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7
9
2
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19.2 Wiring diagram
BOMAG 1108 008 911 79
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
0
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4
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D
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I
I
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D
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I
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3
1
3
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2
0
3
1
5
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1
X 3 0 : 3
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X 5 7 : 2 4
B
1
1
3
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K
h
l
m
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1
2
X 5 7 : 2 8
X 5 7 : 2 3
X 3 1 : 5 7
X 3 1 : 5 1
X 3 1 : 5 6
X 3 1 : 1 3
X 5 7 : 2 7
X 5 7 : 2 6
X 5 7 : 3 3
B
8
8
E
M
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M
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l
d
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3
1
2
X 3 1 : 5 8
X 5 7 : 2 9
X 3 1 : 4 1
S
0
1
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2
2
3
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2
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S
0
1
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2
2
7
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B
1
4
5
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N
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d
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A G N D
S i g n a l
A G N D
A G N D
S i g n a l
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a
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K
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3

(
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1
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1
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A
6
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Y
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3
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Y
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A
5
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A
2
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5
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A
6
X 3 1 : 1 6
X 3 1 : 4 7
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B
1
1
4
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A G N D
B
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3
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S i g n .
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Y
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B
4
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Y
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1
5
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1
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1
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5
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6
Y
1
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2
Y
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4
Y
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3
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X 5 7 : 3 5
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X 5 7 : 3 6
X 5 7 : 4 0
X 5 7 : 4 2
X 5 7 : 3 7
X 5 7 : 4 1
B
5
1
X 3 1 : 2 6
X 3 1 : 4 3
X 3 1 : 8
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X 5 7 : 2 5
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B
9
3
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K
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4
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B
6
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X 3 1 : 2 3
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B
1
3
3
L
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4
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E
M
R

f
u
e
l

l
o
w

p
r
e
s
s
u
r
e

s
e
n
s
o
r
3
0
2
:
1
4
3
0
5
:
1
F
9
3
12
2
5
A
X 3 0 : 7 2
K
4
1
8
6
8
5
K
4
1
4
:
2
3
0
8
7
a
8
7
X 3 0 : 5
X 3 0 : 1
X
1
:
1
4
E
X
1
:
1
4
A
X
1
:
1
8
5
X
1
:
1
8
3
2
.
5

q
m
m
X 3 0 : 2 8
m a x 7 A
X 3 0 : 2
X 3 0 : 4
X 3 0 : 6
3
1

E
M
R
3
:
5
3
x
2
.
5
X 1 : 9 0
X 1 : 9 1
X 1 : 9 2
X 1 : 1 8 0
X 1 : 1 8 1
G N D
G N D
G N D
X 3 2 : A
X 3 2 : K
X 3 2 : M
X 3 2 : F
X 3 2 : H
X 3 2 : G
X 3 2 : B
X 3 0 : 8 2
X 3 0 : 6 0
X 3 0 : 6 2
X 3 0 : 6 1
X 3 0 : 2 5
C A N 1 H i g h
C A N 1 L o w
C A N 2 H i g h
C A N 2 L o w
K L i n e
X 1 : 1 8 2
X 1 : 1 8 6
m
a
x
.

K
a
b
e
ll
n
g
e

v
o
n

B
a
t
t
e
r
ie

z
u
m

S
t
e
u
e
r
g
e
r
t

(
V
e
r
s
o
r
g
u
n
g
s
le
it
u
n
g
)

m
a
x
.

3
.
5
m
in

d
e
r

h
ie
r

d
a
r
g
e
s
t
e
llt
e
n

I
n
s
t
a
lla
t
io
n

(
Q
u
e
r
s
c
h
n
it
t

2
,
5
q
m
m
)
C
A
N
2
+
3
:
4
C
A
N
2
+
5
:
1
1
C
A
N
2
3
:
4
C
A
N
2
5
:
1
1
A
4
8
M
o
t
o
r
s
t
e
u
e
r
u
n
g

E
M
R
3

(
E
D
C

1
6
)
w
a
t
e
r
s
e
p
e
r
a
t
o
r
X 3 0 : 6 4
X 3 0 : 6 3
B
1
2
4
W
a
s
s
e
r
a
b
s
c
h
e
i
d
e
r
X
1
:
1
0
7
X
1
:
1
0
8
X
1
:
1
9
8
X
1
:
1
9
9
X
1
:
1
7
9
o n l y E M R I I I
X 1 : 1 8 4
X 1 : 1 9 3
X 1 : 1 9 4
X 1 : 1 9 1
X 1 : 1 9 2
X 3 1 : 3 3
X 3 1 : 3 1
X 3 1 : 4 8
X 3 1 : 1
X 3 1 : 3 2
X 3 1 : 5 3
X 3 1 : 2 4
X 3 1 : 3 4
K
1
4
.
2
8
6
8
5
X 6 6 : 2
X 6 6 : 3
2
:
2
4
:
3
Wiring diagram
BOMAG 1109 008 911 79
19.2
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
0
0
5
V
o
g
t
0
8
.
0
3
.
2
0
0
7
S
e
i
s
1
1
1
F
a
h
r
a
n
t
r
i
e
b
,

N
e
i
g
u
n
g
s
s
e
n
s
o
r
,

S
i
t
z
k
o
n
t
a
k
t
d
r
i
v
i
n
g

s
y
s
t
e
m
,

s
l
o
p
e

s
e
n
s
o
r
,

s
e
a
t

c
o
n
t
a
k
t

s
w
i
t
c
h
X 3 5 : 6 4
L e i s t u n g
A
3
4
F
a
h
r
S
t
e
u
e
r
u
n
g
Y
1
6
P
r
o
p
.
P
u
m
p
e

R
c
k
w
.
12
Y
1
7
P
r
o
p
.
P
u
m
p
e

V
o
r
w
.
12
X 3 5 : 2 4
4 0 0 . . . 1 . 2 0 0 m A
4 0 0 . . . 1 . 2 0 0 m A
4 0 0 . . . 1 . 2 0 0 m A
4 0 0 . . . 1 . 2 0 0 m A
B
6
0
S
e
n
s
o
r

A
c
h
s
e
+
d
i
r
.
s p e e d
B
5
9
S
e
n
s
o
r

B
a
n
d
a
g
e
+
d
i
r
.
s
p
e
e
d
X 3 5 : 3 8
X 3 5 : 1 2
X 3 5 : 3 7
X 3 5 : 3 4
b rs w
w s
b l
b rs w
w s
b l
B
5
7
N
e
i
g
u
n
g
s
s
e
n
s
o
r
+
4
5
_
G
=
4
,
5
V
4
5
_
G
=
0
,
5
V
+
S
1
V
2
,
5
V
4
V
N e i g u n g
X 3 5 : 5 3
X 3 5 : 3 3
C A N 2 +
C A N 2
E l e k t r o n i k
X 3 5 : 2 8
3
0
4
:
2
0
3
0
6
:
1
1
5
A
1
0
A
X 3 5 : 2 6
X 3 5 : 2 7
F
2
4
:
2
6
:
3
C
A
N
2
+
4
:
2
0
C
A
N
2
+
8
:
6
C
A
N
2
4
:
2
0
C
A
N
2
8
:
6
C
A
N
1
6
:
8
C
A
N
1
+
6
:
8
S
0
1
2
:
1
5
3
1
3
2
C A N 1 +
C A N 1
B
1
1
2
D
r
u
c
k
s
e
n
s
o
r

F
a
h
r
p
u
m
p
e
r
t
s
w
X 5 2 : 1
X 3 5 : 3 1
X
1
:
1
1
9
X
1
:
1
2
0
p
r
e
s
s
u
r
e

s
e
n
s
o
r

d
r
i
v
e

p
u
m
p
X 1 : 5 2
X 1 : 5 4
X 1 : 4 8
X 1 : 5 0
X
1
:
1
7
E
X
1
:
1
7
A
X
1
:
3
4
E
X
1
:
3
4
A
X
1
:
1
4
6
X
1
:
1
4
5
X 1 : 1 7 1
X 1 : 1 7 3
X 1 : 1 7 5
X 1 : 1 7 6
X 1 : 1 7 7
s
e
n
d
e
r

a
x
l
e
s
e
n
d
e
r

d
r
u
m
s
l
o
p
e

s
e
n
s
o
r
X
1
:
1
2
1
X
1
:
1
2
2
X
1
6
:
1
X
1
6
:
2
X
1
5
:
1
X
1
5
:
2
X
1
:
1
2
3
X
1
:
1
2
3
X
1
:
1
4
4
X
1
:
1
2
4
X
1
:
1
4
3
X
1
:
1
4
1
d
r
i
v
i
n
g

c
o
n
t
r
o
l
l
e
r
s p e e d
R i c h t u n g
s p e e d
R i c h t u n g
A c h s m o t o r
X 3 5 : 6 5
X 3 5 : 6 6
X 3 5 : 6 7
X 3 5 : 6 8
X 3 5 : 5 5
G e h u s e
h o u s i n g
p
r
o
p
.
p
u
m
p

f
o
r
w
a
r
d
s
p
r
o
p
p
u
m
p

b
a
c
k
w
a
r
d
s
3
1
4
:
2
0
3
1
6
:
1
F
6
7
12
F
8
4
12X 3 5 : 3 0
X 3 5 : 4 9
X 3 5 : 5 6
X 3 5 : 5 7
X 3 5 : 5 8
X 3 5 : 5 9
X 3 5 : 6 0
X 3 5 : 5 4
H
1
4
R
c
k
f
a
h
r
w
a
r
n
s
u
m
m
e
r
+
b
a
c
k

u
p

a
l
a
r
m

b
u
z
z
e
r
0 , 4 6 A
L
C
D
is
p
la
y
,

O
P
U
S

2
1
F
a
h
r
h
e
b
e
l
E
M
R

D
e
u
t
z
S
0
6
S
i
t
z
k
o
n
t
a
k
t
s
c
h
a
l
t
e
r
+
X 3 5 : 1 5
X
1
:
1
5
8
X
1
:
1
4
9
s
w
i
t
c
h
,

s
e
a
t

c
o
n
t
a
c
t
X
1
:
1
1
4
X
1
:
1
1
7
X
1
4
:
B
X
1
4
:
A
X 3 5 : 4 6
X 3 5 : 4 7
X 1 : 8 2
X 1 : 1 2 4
X 1 : 1 4 2
X 1 : 1 4 2
X 1 : 1 4 3
X 1 : 1 4 3
p
r
o
p
.
V
a
l
v
e

d
r
u
m

m
o
t
o
r
p
r
o
p
.
V
a
l
v
e

a
x
l
e

m
o
t
o
r
X 1 : 4 7
X 1 : 4 9
X
3
4
:
A
X
3
4
:
B
X 1 : 5 1
X 1 : 5 3
X
3
4
:
C
X
3
4
:
D
X 3 5 : 4
R x D
X 3 5 : 5
T x D
X
3
4
:
H
X
3
4
:
G
R
2
2
1
2
0

O
H
M
1
2
R
2
3
1
2
0

O
H
M
1
2
R
2
0
1
2
0

O
H
M
1
2
R
2
1
1
2
0

O
H
M
1
2
X
9
:
1
X
9
:
2
D
i
a
g
n
o
s
e
s
t
e
c
k
e
r

F
a
h
r
z
e
u
g
d
i
a
g
n
o
s
i
s

i
n
t
e
r
f
a
c
e

e
q
u
i
p
m
e
n
t
X
1
:
3
4
A
9
:
2
X
1
:
4
6
P
I
T
C
H

M
E
S
X
9
:
2
X 5 2 : 2
Y
3
0
P
r
o
p
.
V
e
n
t
i
l

B
a
n
d
a
g
e
n
m
o
t
o
r
12
Y
3
1
P
r
o
p
.
V
e
n
t
i
l

A
c
h
s
m
o
t
o
r
12
X
1
:
2
X
1
:
1
7
2
X
1
:
5
5
7
:
4
P o t . 1 5
a
b
X
1
:
1
7
4
X
1
:
1
7
8
D
I
R

M
E
S
X
9
:
2
S
P
E
E
D

T
A
C
1
3
:
6
S
P
E
E
D

M
E
S
X 9
:
2
X
1
:
4
5
X
1
:
4
4
F
M
3
7
:
5
19.2 Wiring diagram
BOMAG 1110 008 911 79
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
0
0
6
V
o
g
t
0
8
.
0
3
.
2
0
0
7
S
e
i
s
1
1
D
a
t
e
n
s
a
m
m
l
e
r
,

L
C
D
i
s
p
l
a
y
d
a
t
a
c
o
l
l
e
c
t
o
r
,

L
C
d
i
s
p
l
a
y
3
0
5
:
2
0
3
0
9
:
1
3
1
5
:
2
0
3
1
7
:
1
B
0
3
L u f t f i l t e r
P
12
a i r c l e a n e r
B
5
5
Q
B
2
1
P
12
d
a
t
a
c
o
l
l
e
c
t
o
r
D
+
2
:
8
C
A
N
1
+
5
:
1
7
C
A
N
1
+
8
:
1
4
C
A
N
1
5
:
1
7
C
A
N
1
8
:
1
4
K
1
1
:
8
7
2
:
2
0
K
1
1
:
8
7
8
:
1
4
R
0
3
0 . . 6 7 O H M
f u e l l e v e l
F
2
4
12
1
0
A
X 2 6 : 1
X 2 6 : 5
X 2 6 : 6
X 2 6 : 8
X 2 6 : 1 0
X 2 6 : 1 1
X 2 6 : 1 2
X 2 7 : 1
X 2 7 : 2
X 2 7 : 3
X 2 7 : 5
X
2
7
:
8
X 2 7 : 1 0
X 2 7 : 1 1
X 2 7 : 1 2
A
8
0
D
a
t
e
n
s
a
m
m
l
e
r
D I N 1
D I N 2
D I N 3
D I N 4
D I N 5
D I N 6
D I N 8
D I N 9
D I N 1 1
G N D
A I N 1
U I N 1
G N D / U I N 3
G N D
C A N 1 h i g h
C A N 1 l o w
V C C
U I N 3
U I N 2
A I N 2
X 2 7 : 6
X 2 7 : 7
F
2
4
:
2
5
:
3
F
2
4
:
2
7
:
1
3
A
8
1
L
C
D
i
s
p
l
a
y
L
C
d
i
s
p
l
a
y
X 2 8 : 3
X 2 8 : 4
X 2 8 : 1
X 2 8 : 2
X 2 8 : 5
C A N 1 l o w
U b " 1 5 "
U b " 3 0 "
X 2 9 : 7
U b o u t
X 2 9 : 5
X 2 9 : 6
X 2 8 : 6
X 2 9 : 8
D I N 1
D I N 2
D I N 4
D I N 3
D I N 5
D I N 6
s
w
i
t
c
h

e
n
g
i
n
e
r
p
m

m
o
d
e
L
o
w
X
1
:
2
9
E
X
1
:
2
9
A
X 1 : 3 9
X 1 : 4 0
X
1
:
8
7
X
1
:
8
8
X
1
:
8
0
X
1
:
8
6
X
1
:
8
2
X
1
:
1
6
4
X
1
0
:
2
X
1
0
:
3
X
1
:
1
0
5
X
1
:
1
1
7
X
1
:
1
4
9
X
2
1
:
1
X
2
1
:
2
X
1
:
9
4
X
1
:
9
4
X
1
:
1
1
7
X
1
:
1
0
6
X
1
:
1
1
1
X
1
:
1
1
2
B
E
L
1
2
:
4
E
S
X

F
a
h
r
s
t
e
u
e
r
u
n
g
D
I
O
S

P
la
t
t
e
n
X 2 6 : 9
X 2 6 : 3
X 2 6 : 4
B
L
1
2
:
1
7
B
R
1
2
:
1
7
X 2 9 : 1
X 2 9 : 2
X 2 9 : 4
X 2 9 : 3
X
3
4
:
R
X 2 6 : 2
X 1 : 4 1
S
t
e
c
k
e
r
f
a
r
b
e
:

X
2
6
g
r
a
u
;

X
2
7
s
c
h
w
a
r
z
c
o
n
n
e
c
t
o
r
c
o
lo
u
r
:

X
2
6
g
r
e
y
;

X
2
7
b
la
c
k
H
i
g
h
E
C
O
F
0
5
:
2
2
:
1
6
1
1
:
1
B
1
2
4
X 2 7 : 4
X 2 7 : 9
X
1
:
1
0
7
X
1
:
1
0
8
X
8
:
1
X
8
:
2
D I N 1 0
S e p a 1
S e p a 2
o n l y E M R I I
S
1
3
9
S
c
h
a
l
t
e
r

F
r
e
q
u
e
n
z
v
e
r
s
t
e
l
l
u
n
g
1
3
1
4
2
4
2
3
S
1
2
7
S
c
h
a
l
t
e
r

M
o
t
o
r
d
r
e
h
z
a
h
l
1
3
1
4
2
3
2
4
s
w
i
t
c
h

f
r
e
q
u
e
n
c
y
c
o
n
t
r
o
l
u
p
d
o
w
n
Wiring diagram
BOMAG 1111 008 911 79
19.2
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
0
0
7
V
o
g
t
0
8
.
0
3
.
2
0
0
7
S
e
i
s
1
1
L
e
n
k
u
n
g
,

V
i
b
r
a
t
i
o
n
s
t
e
e
r
i
n
g
,

v
i
b
r
a
t
i
o
n
X 3 5 : 3
3
1
6
:
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a
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P r o p . o u t
W a r n s u m m e r
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19.2 Wiring diagram
BOMAG 1112 008 911 79
5
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4 0 0 . . 1 . 2 0 0 m A
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X
1
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3
6
S
c
h
a
l
t
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r

B
e
t
r
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e
b
s
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t

P
l
a
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n
1
3
1
4
Y
1
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5
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l
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r
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12
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2
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c
h
w
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12
X 6 2 : 1 5
2
:
1
2
7
:
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7
Wiring diagram
BOMAG 1113 008 911 79
19.2
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
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7
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9
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3
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2
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1
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s
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t
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c
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k
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l
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m
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a
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e
q
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.
X 4 4 : 4 7
X 4 4 : 2 9
X 4 4 : 3 3
X 4 4 : 5 3
X 4 4 : 4 6
X 4 4 : 5 6
X 4 4 : 5 7
X 4 4 : 5 8
X 4 4 : 5 9
X 4 4 : 6 0
X 4 4 : 5 4
L e i s t u n g
P r o p .
E l e k t r o n i k
m
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c
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3
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3
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3
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8
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2
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3
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1
X
2
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5
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2
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6
X
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4
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X
2
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4
X
2
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5
5
X
2
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5
8
X
2
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9
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4
8
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4
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1
1
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B
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X
2
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2
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1
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4
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X
4
2
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X
4
2
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X 4 4 : 1
A G N D M E S X
P
0
7
E
V
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r
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2
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7
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1
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5
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1
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X 4 4 : 6 5
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2
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3
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6
3
0
6
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0
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A

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X
7
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5
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P
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5
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D
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R

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5
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P
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T
C
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A
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3
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7
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7
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4
7
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1
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8
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2
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6
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2
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0
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X
2
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4
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2
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5
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4
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X
4
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B
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7
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7
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6
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2
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n u r b e i B E M
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R
2
4
6
0

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H
M
1
2
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2
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8
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2
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7
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2
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9
c
o
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t
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l
u
n
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t

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E
M
C
A
N
3
1
0
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2
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A
N
3
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0
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1
4
8
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2
1
0
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2
0 . . 6 V D C
4 0 0 . . 1 . 2 0 0 m A
4 0 0 . . 1 . 2 0 0 m A
X
4
6
:
B
X
4
6
:
A
X
4
6
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E
X
4
6
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X
4
6
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F
n
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r

b
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i

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M
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n
l
y

a
t

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X
2
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9
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2
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9
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X
4
4
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2
5
1
0
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2
F
1
4
6
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1
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0
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2
19.2 Wiring diagram
BOMAG 1114 008 911 79
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
0
1
0
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t
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8
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0
3
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2
0
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1
1
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p
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M
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C
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C
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3
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3
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b
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3
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1
4
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7
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2
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3
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4
4
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7
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7
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7
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7
3
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X
7
3
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X
7
2
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X
7
2
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X
7
2
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C
X
7
2
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D
X
7
2
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X 7 8 : 4
X 7 8 : 2
X
4
H
X
4
J
X
4
G
X
4
N
X
4
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X
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2
n
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c
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Wiring diagram
BOMAG 1115 008 911 79
19.2
5
8
2

7
0
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3
2
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8
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3
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2
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6
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2
369
V
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580
H
8
0
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6
8
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2
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6
8
:
1
19.2 Wiring diagram
BOMAG 1116 008 911 79
5
8
2

7
0
2

3
2
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8
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0
3
.
2
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7
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X
1
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3
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1
6
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4
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X 1 : 3 1 5
X 1 : 3 1 6
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X 1 : 3 1 2
X 1 : 3 1 5
X 1 : 3 1 6
X 1 : 3 0 3
X 1 : 3 1 3
X 1 : 3 1 4
X 1 : 3 1 5
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X 1 : 3 0 2 X 1 : 3 0 1
X
3
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4
X
3
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5
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5
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3
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1
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9
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1
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3
X 5 8 : 6 X 5 8 : 5
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X 5 9 : 3
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X 6 0 : 4 X 6 0 : 3
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X 6 1 : 1X 6 1 : 2
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1
2
:
1
0
1
2
:
2
Wiring diagram
BOMAG 1117 008 911 79
19.2
5
8
2

7
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2

3
2
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3
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2
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5
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5
6
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2
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X
3
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3
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1
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1
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5
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S t e c k d o s e
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2
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1
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1
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4
2
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1
4
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3
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6
1
3
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2
19.2 Wiring diagram
BOMAG 1118 008 911 79
5
8
2

7
0
2

3
2
0
8
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0
3
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2
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7
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a
t
e
r
Y
1
4
K
r
a
f
t
s
t
o
f
f
p
u
m
p
e
12
X
7
7
:
2
X
7
7
:
1
F
4
2
:
H
1
3
:
4
S
2
8
S c h a l t u h r H e i z u n g
h e a t e r t i m e r
5
7
1
1
3
1
0
1
2
6
8
9
4
1
2
F
4
1
:
5
1
3
:
1
9
M
1
7
F
r
i
s
c
h
l
u
f
t

L
f
t
e
r
+
X
6
9
:
1
X
6
9
:
2
F
9
7
12
I n l i n e S i c h e r u n g
i n l i n e f u s e
f
u
e
l

p
u
m
p

h
e
a
t
i
n
g

u
n
i
t
2
0
A
5
A
2 . 5 q m m
2 . 5 q m m
3
A
O p t i o n
o p t i o n
b
l
o
w
e
r

f
r
e
s
c
h

a
i
r
M
K
A
B
I
N
E

3
1
1
3
:
1
9
Wiring diagram
BOMAG 1119 008 911 79
19.2
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
1
0
1
V
o
g
t
0
8
.
0
3
.
2
0
0
7
S
e
i
s
1
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
o
n
e
n
t

l
i
s
t
i
n
g
Bl. Pf.
A02 012 17 Blinkgeber flasher
A93 010 7 GPS Antenne GPS antenna

B133 004 12 Sensor Ladeluftdruck / temperatur sesnor charging air prssure / temperature


F15 014 19 Sicherung Heizgeraet Fuse, heating unit BOX2
F40 014 15 Sicherung Kabinenheizung Fuse, heating unit cab BOX2
19.2 Wiring diagram
BOMAG 1120 008 911 79
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
1
0
2
V
o
g
t
0
8
.
0
3
.
2
0
0
7
S
e
i
s
2
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
o
n
e
n
t

l
i
s
t
i
n
g
Bl. Pf.
F97 014 13 Sicherung Frischluftluefter fuse, blower fresh air 3A
F124 002 17 Sicherung Kraftstoffvorwrmung Fuse, fuel preheating 25A
F150 010 14 Sicherung GPS Receiver Fuse, GPS receiver 5A


H80 011 15 Meldeleuchte Wegfahrsperre Indicator light, antitheft device LED

K43 007 12 D*Relais Vibration E*relay, vibration BOSCHW
K14.2 004 20 TYCOX

M17 014 13 Zusatzluefter Additional blower

P33 009 18 Opus 21 Opus 21

R79 002 15 Kraftstoffvorwrmung fuel preheater 250W

Wiring diagram
BOMAG 1121 008 911 79
19.2
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
1
0
3
V
o
g
t
0
8
.
0
3
.
2
0
0
7
S
e
i
s
3
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
o
n
e
n
t

l
i
s
t
i
n
g
Bl. Pf.


19.2 Wiring diagram
BOMAG 1122 008 911 79
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
1
0
4
V
o
g
t
0
8
.
0
3
.
2
0
0
7
S
e
i
s
4
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
o
n
e
n
t

l
i
s
t
i
n
g
Bl. Pf.
X1:190 011 12 WAGO,EKasten WAGO,EBOX
Wiring diagram
BOMAG 1123 008 911 79
19.2
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
1
0
5
V
o
g
t
0
8
.
0
3
.
2
0
0
7
S
e
i
s
5
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
o
n
e
n
t

l
i
s
t
i
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g
Bl. Pf.
19.2 Wiring diagram
BOMAG 1124 008 911 79
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
1
0
6
V
o
g
t
0
8
.
0
3
.
2
0
0
7
S
e
i
s
6
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
o
n
e
n
t

l
i
s
t
i
n
g
Bl. Pf.
X2:80A 010 14 WAGOMESSTECHNIK Wagomeasurement equip.
X2:80E 010 14 WAGOMESSTECHNIK Wagomeasurement equip.
X4:H 010 14 KABINENST. MESST. con. measurem.equipm.
X4:J 010 15 KABINENST. MESST. con. measurem.equipm.
Wiring diagram
BOMAG 1125 008 911 79
19.2
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
1
0
7
V
o
g
t
0
8
.
0
3
.
2
0
0
7
S
e
i
s
7
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
o
n
e
n
t

l
i
s
t
i
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g
Bl. Pf.
19.2 Wiring diagram
BOMAG 1126 008 911 79
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
1
0
8
V
o
g
t
0
8
.
0
3
.
2
0
0
7
S
e
i
s
8
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
o
n
e
n
t

l
i
s
t
i
n
g
Bl. Pf.
Wiring diagram
BOMAG 1127 008 911 79
19.2
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
1
0
9
V
o
g
t
0
8
.
0
3
.
2
0
0
7
S
e
i
s
9
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
o
n
e
n
t

l
i
s
t
i
n
g
Bl. Pf.
19.2 Wiring diagram
BOMAG 1128 008 911 79
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
1
1
0
V
o
g
t
0
8
.
0
3
.
2
0
0
7
S
e
i
s
1
0
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
o
n
e
n
t

l
i
s
t
i
n
g
Bl. Pf.
Wiring diagram
BOMAG 1129 008 911 79
19.2
5
8
2

7
0
2

3
2
0
8
.
0
3
.
2
0
0
7
1
1
1
V
o
g
t
0
8
.
0
3
.
2
0
0
7
S
e
i
s
1
1
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
o
n
e
n
t

l
i
s
t
i
n
g
Bl. Pf.
X67:1 002 15 STECKER KRAFTSTOFFHEI connector fuel preheater
X68:1 011 15 STECKER LED connector led
X69:1 014 13 STECKER FRISCHLUFT L connector fresh air blower
X70:2 010 16 SUBD STECKER SUBD Connector
X71:3 010 9 STECKER GPS ANTENNE connector GPS Receiver
X72:A 010 12 STECKER ANSCHL. GPS Connector GPS
X72:B 010 12 STECKER ANSCHL. GPS Connector GPS
X72:C 010 12 STECKER ANSCHL. GPS Connector GPS
X72:D 010 12 STECKER ANSCHL. GPS Connector GPS
X72:E 010 12 STECKER ANSCHL. GPS Connector GPS
X73:A 010 13 STECKER VERS. GPS Connector Supply GPS
X73:B 010 13 STECKER VERS. GPS Connector Supply GPS
X73:C 010 13 STECKER VERS. GPS Connector Supply GPS
X75:2 010 18 SUB D STECKER BCM INT SUB D Connector BCM
X77:1 014 15 STECKER PUMPE STANDHE Conn. pump add. heater
X78:1 010 10 STECKER RTKMODUL GPS Connector RTKmodule GPS

Y07 007 15 D*Prop. Ventil Vibration gro E*prop. Valve vibration high 0.4 .. 1.2A
Y144.1 008 19 MAX. 1.8A
Y144.2 008 19 MAX. 1.8A

19.2 Wiring diagram
BOMAG 1130 008 911 79
X
3
8
X
3
7
G
e
z
.
:

0
8
.
0
3
.
2
0
0
7
N
a
m
e
:

V
o
g
t
G
e
p
r
.
:

0
8
.
0
3
.
2
0
0
7
N
a
m
e
:

S
e
is
S
e
it
e
:

1
v
o
n
:

2
p
a
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:

1
f
r
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m
:

2
E
r
s
.

f
.
:
R
e
p
la
c
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s
:
5
8
2

7
0
2

3
2
B
la
t
t

N
r
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:

2
0
1
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h
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2
0
1
X
3
6
A
8
0
X
3
2
:
1
-
1
2
b
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r
s
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t

S
c
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B
W

1
7
7
.
.
.
2
2
6

D
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/
B
V
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4
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1
7
7
.
.
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2
2
6

D
H
/
B
V
C
-
4
K
4
3
K
4
8
K
6
1
K
1
6
K
0
9
K
1
1
K
0
5
K
0
6
B
5
7
A
0
2
N
u
r

b
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K
l
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a
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1
0
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r

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a
c
c
.

T
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l
l
u
m
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n
a
t
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n
K
4
1
X
3
4
:
1
-
1
9
Wiring diagram
BOMAG 1131 008 911 79
19.2
G
e
z
.
:

0
8
.
0
3
.
2
0
0
7
N
a
m
e
:

V
o
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t
G
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p
r
.
:

0
8
.
0
3
.
2
0
0
7
N
a
m
e
:

S
e
is
S
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it
e
:

2
v
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n
:

2
p
a
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:

2
f
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m
:

2
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r
s
.

f
.
:
R
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p
la
c
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s
:
B
la
t
t

N
r
.
:

2
0
1
S
h
e
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t

N
o
.
:

2
0
1
A
8
3
M
e
s
s
t
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c
h
n
i
k

S
t
e
u
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r
u
n
g
C
A
N

1
C
A
N

1
C
A
N

2
C
A
N

3
E
M
R

+

F
a
h
r
h
e
b
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l
B
C
M
O
P
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S

2
1
A
3
4
F
a
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r
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r

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8
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c
.

T
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M
8
b
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c
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S
c
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a
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t
k
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-
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B
W

1
7
7
.
.
.
2
2
6

D
H
-
4
o
v
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-
b
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x

d
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r

B
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1
7
7
.
.
.
2
2
6

D
H
-
4
5
8
2

7
0
2

3
2
C
A
N

1
L
C
D
+
D
a
t
e
n
s
a
m
m
l
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r
F
1

F
2

19.2 Wiring diagram
BOMAG 1132 008 911 79
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057 564 17 1
280-315 2
2 x 057 564 25 "L" +793-501 3
2 x 057 564 25 "L" +057 564 20 +793-501 5
057 564 22 7
4 x 057 564 23 "L" +057 564 19 +793-501 8
18 x 057 564 36 "R" +057 564 19
+793-501
12
Wiring diagram
BOMAG 1133 008 911 79
19.2
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4 x 057 564 36 "R" +793-501 30
057 564 35 34
057 564 17 35
057 564 21 36
2 x 057 564 25 "L" +793-501 37
3 x 057 564 25 "L" +057 564 20 +793-501 39
5 x 057 564 25 "L" +793-501 42
8 x 057 564 25 "L" +057 564 20 +793-501 47
057 564 25 "L" +793-501 55
4 x 057 564 38 "L" +793-501 56
057 564 17 60
19.2 Wiring diagram
BOMAG 1134 008 911 79
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Wiring diagram
BOMAG 1135 008 911 79
19.2
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19.2 Wiring diagram
BOMAG 1136 008 911 79
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057 564 17 1
3 x 057 565 40 "R" +793-501 2
057 565 35 "R" +793-501 5
057 565 37 6
3 x 057 565 40 "R" +793-501 7
057 565 37 10
057 565 40 "R" +793-501 11
057 565 35 "R" +793-501 12
057 565 37 13
2 x 057 565 38 "R" +793-501 14
2 x 057 565 39 "R" +793-501 16
057 565 37 18
4 x 057 565 40 "R" +793-501 19
057 565 37 23
4 x 057 565 40 "R" +793-501 24
2 x 057 565 39 "R" +793-501 28
057 565 37 30
057 565 40 "R" +793-501 31
057 565 39 "R" +793-501 32
057 565 37 33
4 x 057 565 40 "R" +793-501 34
057 565 35 "R" +793-501 38
057 565 37 39
4 x 057 565 40 "R" +793-501 40
057 565 37 44
057 565 40 "R" +793-501 45
057 565 35 "R" +793-501 46
057 565 37 47
057 565 40 "R" +793-501 48
057 565 35 "R" +793-501 49
057 565 37 50
Wiring diagram
BOMAG 1137 008 911 79
19.2
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Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
057 565 38 "R" +793-501 51
2 x 057 565 40 "R" +793-501 52
057 565 38 "R" +793-501 54
057 565 37 55
3 x 057 565 40 "R" +793-501 56
057 565 38 "R" +793-501 59
057 565 37 60
3 x 057 565 40 "R" +793-501 61
057 565 35 "R" +793-501 64
057 565 37 65
2 x 057 565 40 "R" +793-501 66
057 565 35 "R" +793-501 68
057 565 37 69
3 x 057 565 40 "R" +793-501 70
057 565 35 "R" +793-501 73
057 565 37 74
2 x 057 565 40 "R" +793-501 75
2 x 057 565 35 "R" +793-501 77
057 565 37 79
057 565 40 "R" +793-501 80
057 565 39 "R" +793-501 81
057 565 37 82
057 564 17 83
19.2 Wiring diagram
BOMAG 1138 008 911 79
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Wiring diagram
BOMAG 1139 008 911 79
19.2
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Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
19.2 Wiring diagram
BOMAG 1140 008 911 79
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Optional7 :
057 564 17 1
2 x 057 565 40 "R" +793-501 2
057 565 37 4
2 x 057 565 40 "R" +793-501 +057 565 36 5
057 565 39 "R" +793-501 7
057 565 37 8
057 565 38 "R" +793-501 9
2 x 057 565 40 "R" +793-501 10
057 565 38 "R" +793-501 12
057 565 37 13
2 x 057 565 40 "R" +793-501 14
057 565 39 "R" +793-501 16
057 565 37 17
057 565 40 "R" +793-501 18
057 565 38 "R" +793-501 19
057 565 40 "R" +793-501 20
057 565 37 21
057 565 40 "R" +793-501 22
057 565 39 "R" +793-501 23
057 565 37 24
057 564 21 25
2 x 057 564 38 "L" +793-501 26
057 564 25 "L" +793-501 28
057 564 36 "R" +793-501 29
057 564 35 30
057 564 17 31
Wiring diagram
BOMAG 1141 008 911 79
19.2
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19.2 Wiring diagram
BOMAG 1142 008 911 79
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Optional3 :
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Optional7 :
057 564 17 1
4 x 057 565 40 "R" +793-501 2
057 565 37 6
2 x 057 565 40 "R" +793-501 7
4 x 057 565 38 "R" +793-501 9
2 x 057 565 39 "R" +793-501 13
057 565 37 15
057 564 17 16
Wiring diagram
BOMAG 1143 008 911 79
19.2
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Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
19.2 Wiring diagram
BOMAG 1144 008 911 79
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BOMAG 1145 008 911 79
19.3 Wiring diagram
19.3 Wiring diagram
BOMAG 1146 008 911 79
Serial number for wiring diagram 582 702 39 not yet available at the printing deadline.
Wiring diagram
BOMAG 1147 008 911 79
19.3
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19.3 Wiring diagram
BOMAG 1148 008 911 79
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3
X
1
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1
5
E
X
1
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2
8
E
X
1
:
2
8
A
X
1
:
7
X
1
:
8
X
3
7
:
B
X
3
8
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A
X
1
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2
7
E
X
1
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2
7
A
X
1
:
1
5
1
X
1
:
1
5
2
S
0
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2
2
3
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1
B
1
1
12
B
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S
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12
V
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h
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b
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h
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X
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5
5
X
1
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X
1
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2
1
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A
F
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12
X
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6
E
X
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6
A
X
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A
X
1
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4
X
1
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3
X
3
7
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X
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9
D
+

M
E
S
X
9
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2
X
1
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3
0
E
F
3
9
12
X
1
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3
0
A
1
5
A
X 3 4 : P
1 6 7 A
3
1

E
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R
3
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3
X
3
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3
X
S
S
t
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c
k
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2
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+
s
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b
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12
X 1 : 1 0
X 1 : 9
R 8 6
12
R 8 5
12
R 8 4
12
R 8 3
G
l
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b
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p
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O p t i o n
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K
3
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3
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K
1
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8
7
6
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5
A
F
1
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12
X
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3
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X
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R
7
9
K
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12X
1
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X
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X
6
7
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X
6
7
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2
f
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p
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O p t i o n W i n t e r p a k e t
o p t i o n w i n t e r p a c k a g e
K
3
2
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6
1
3
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1
S
0
3
T
a
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t
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r

H
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34
X
1
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8
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1
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8
6
8
5
K
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8
3
08
7
a
8
7
X
1
1
0
0
X
1
1
0
3
X
1
1
0
4
X
1
1
0
4
2
:
1
6
1
4
:
7
2
:
1
0
2
:
1
5
Wiring diagram
BOMAG 1149 008 911 79
19.3
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
0
0
3
V
o
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t
2
3
.
0
7
.
2
0
0
7
S
e
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s
1
1
M
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r

D
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z

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M
R

I
I
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n
g
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D
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z

E
M
R

I
I
3
1
2
:
2
0
3
1
4
:
1
X 3 0 : 1
X 3 0 : 2
X 3 0 : 1 0
X 3 0 : 1 1
X 3 0 : 1 2
X 3 0 : 1 3
X 3 2 : A
X 3 2 : L
X 3 2 : K
X 3 2 : H
X 3 2 : G
X 3 2 : B
D
i
a
g
n
o
s
e
s
t
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c
k
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r

E
M
R
d
i
a
g
n
o
s
i
s

i
n
t
e
r
f
a
c
e

E
M
R
X 3 0 : 1 4
A
4
8
M
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t
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s
t
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u
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u
n
g

E
M
R
2
X 5 7 : 9
X 5 7 : 8
B
1
1
3
E
M
R

K
h
l
m
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t
t
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l
t
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m
p
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t
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r
1
2
X 5 7 : 2 3
X 5 7 : 2 4
X 5 7 : 2 5
X 3 1 : 2 3
X 3 1 : 2 5
X 3 1 : 2 4
A G N D
S i g n a l
A G N D
+ 5 V
X 3 1 : 2 0
X 3 1 : 2 1
X 3 1 : 2 2
X 5 7 : 2 0
X 5 7 : 2 1
X 5 7 : 2 2
A G N D
S i g n a l
+ 5 V
B
8
8
E
M
R

M
o
t
o
r
l
d
r
u
c
k
3
1
2
X 3 1 : 1 0
X 3 1 : 1 1
X 5 7 : 1 0
X 5 7 : 1 1
A G N D
S i g n a l
X 3 1 : 1 2
X 3 1 : 1 3
X 5 7 : 1 2
X 5 7 : 1 3
A G N D
S i g n a l
X 3 1 : 1 4
X 3 1 : 1 5
X 3 1 : 1 7
X 3 1 : 1 8
X 3 1 : 1 9
X 5 7 : 1 4
X 5 7 : 1 5
X 5 7 : 1 7
X 5 7 : 1 8
X 5 7 : 1 9
Y
1
3
7
E
M
R

S
t
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l
l
g
l
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d5 1
6
2
7
S T G
S T G +
R F
R F R E F
R F M E S S
X 3 1 : 9
m a x 7 A
E
M
R

c
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l
a
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t

t
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m
p
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a
t
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E
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R

e
n
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o
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p
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s
s
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E
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c
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m
m
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c
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a
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g

a
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r

p
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s
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+

t
e
m
p
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t
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s
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n
d
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e
n
g
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r
p
m

1
X 3 1 : 2
X 3 1 : 4
X 3 1 : 5
X 5 7 : 4
X 3 1 : 6
X 3 1 : 1 6
X 3 1 : 8
X 3 1 : 7
r
e
l
a
y

h
e
a
t
i
n
g
f
l
a
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B
1
1
4
M
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r
d
r
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h
z
a
h
l
s
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s
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r
1
2
s
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n
d
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e
n
g
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n
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r
p
m

2
X 5 7 : 1 6
X 5 7 : 1
X 5 7 : 6
X 3 1 : 1
X 3 3 : 3
X 3 3 : 5
X 3 3 : 6
X 3 3 : 1
X 3 3 : 2
X 3 3 : 7
S
t
e
c
k
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r
s
c
h
n
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t
t
s
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D
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c
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i
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f
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D
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z
X 3 3 : 8
E
P
C
S
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k
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S
0
1
:
2
2
2
:
1
6
S
0
1
:
2
2
4
:
1
B
1
3
0
M
o
t
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r
d
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h
z
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1
2
B
1
1
5
L
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f
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+

T
e
m
p
1
2
4
3
C
A
N
2
+
4
:
1
5
C
A
N
2
4
:
1
5
C A N h i g h
C A N l o w
L
K
U b a t
X
1
:
9
6
X 1 : 1 8 2
X 1 : 1 8 3
X 1 : 1 8 4
X 3 3 : 4
X 3 1 : 3
X 1 : 1 8 0
X 1 : 1 8 1
X
1
:
1
8
5
e
n
g
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c
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t
r
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l
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2
E S X F a h r s t .
3
1

E
M
R
2
:
6
3
1

E
M
R
4
:
1
8
X 1 : 1 8 6
X 3 4 : N
K
1
4
R
e
l
a
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H
e
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z
f
l
a
n
s
c
h
2 1
X
1
:
9
5
X
1
:
1
7
9
2
:
4
19.3 Wiring diagram
BOMAG 1150 008 911 79
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
0
0
4
V
o
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t
2
3
.
0
7
.
2
0
0
7
S
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s
1
1
M
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r

D
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z

E
M
R

I
I
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n
g
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D
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t
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E
M
R

I
I
I
3
1
3
:
2
0
3
1
5
:
1
X 3 0 : 3
X 5 7 : 3 0
X 5 7 : 2 4
B
1
1
3
E
M
R

K
h
l
m
i
t
t
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l
t
e
m
p
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r
a
t
u
r
1
2
X 5 7 : 2 8
X 5 7 : 2 3
X 3 1 : 5 7
X 3 1 : 5 1
X 3 1 : 5 6
X 3 1 : 1 3
X 5 7 : 2 7
X 5 7 : 2 6
X 5 7 : 3 3
B
8
8
E
M
R

M
o
t
o
r
l
d
r
u
c
k
3
1
2
X 3 1 : 5 8
X 5 7 : 2 9
X 3 1 : 4 1
S
0
1
:
2
2
3
:
2
0
S
0
1
:
2
2
7
:
1
B
1
4
5
E
M
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N
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d
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r
d
r
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k

K
r
a
f
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1
4
2
3
D
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d
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A G N D
S i g n a l
A G N D
A G N D
S i g n a l
m
a
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K
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3

(
E
D
C
1
6
)
Y
1
6
9
I
n
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A
6
12
Y
1
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A
3
12
Y
1
7
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A
5
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Y
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A
2
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Y
1
6
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4
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1
12
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p
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1
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2
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A
3
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4
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5
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A
6
X 3 1 : 1 6
X 3 1 : 4 7
X 3 1 : 4 6
B
1
1
4
M
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h
z
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r
1
3
2
X 3 1 : 1 0
X 3 1 : 5 0
X 3 1 : 2 0
X 5 7 : 1 4
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A G N D
B
1
3
0
M
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t
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h
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3
1
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X 5 7 : 1 5
A G N DX 5 7 : 1
X 5 7 : 9
S i g n .
S i g n .
Y
1
3
7
E
M
R

S
t
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l
l
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d
12
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R

c
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m
m
a
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d
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r
X 3 1 : 1 9
X 3 1 : 4 9
S i g n a l
A G N D
X 5 7 : 1 9
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B
4
0
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1
B
4
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.
2
Y
1
9
Y
1
5
.
1
Y
1
5
.
5
Y
1
5
.
6
Y
1
5
.
2
Y
1
5
.
4
Y
1
5
.
3
X 5 7 : 3 4
X 5 7 : 3 5
X 5 7 : 3 9
X 5 7 : 3 6
X 5 7 : 4 0
X 5 7 : 4 2
X 5 7 : 3 7
X 5 7 : 4 1
B
5
1
X 3 1 : 2 6
X 3 1 : 4 3
X 3 1 : 8
X 5 7 : 3 2
X 5 7 : 2 5
X 5 7 : 3 1
B
9
3
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K
r
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f
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s
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f
f
d
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1
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r
a
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p
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B
4
9
B
4
3
B
6
X 5 7 : 2 8
X 5 7 : 2 3
X 5 7 : 2 2
X 3 1 : 2 3
X 3 1 : 1 4
X 3 1 : 4 0
X 5 7 : 2 9
B
1
3
3
L
a
d
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l
u
f
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d
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+

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1
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c
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+

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B
4
8
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X 3 1 : 5 4
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f
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l
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p
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s
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3
0
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1
4
3
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5
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1
F
9
3
12
2
5
A
X 3 0 : 7 2
K
4
1
8
6
8
5
K
4
1
4
:
2
3
0
8
7
a
8
7
X 3 0 : 5
X 3 0 : 1
X
1
:
1
4
E
X
1
:
1
4
A
X
1
:
1
8
5
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1
:
1
8
3
2
.
5

q
m
m
X 3 0 : 2 8
m a x 7 A
X 3 0 : 2
X 3 0 : 4
X 3 0 : 6
3
1

E
M
R
3
:
5
3
x
2
.
5
X 1 : 9 0
X 1 : 9 1
X 1 : 9 2
X 1 : 1 8 0
X 1 : 1 8 1
G N D
G N D
G N D
X 3 2 : A
X 3 2 : K
X 3 2 : H
X 3 2 : G
X 3 2 : M
X 3 2 : F
X 3 2 : B
X 3 0 : 8 2
X 3 0 : 6 0
X 3 0 : 6 2
X 3 0 : 6 1
X 3 0 : 2 5
C A N 1 H i g h
C A N 1 L o w
C A N 2 H i g h
C A N 2 L o w
K L i n e
X 1 : 1 8 2
X 1 : 1 8 6
m
a
x
.

K
a
b
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ll
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v
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3
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r

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I
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c
h
n
it
t

2
,
5
q
m
m
)
C
A
N
2
+
3
:
4
C
A
N
2
+
5
:
1
1
C
A
N
2
3
:
4
C
A
N
2
5
:
1
1
A
4
8
M
o
t
o
r
s
t
e
u
e
r
u
n
g

E
M
R
3

(
E
D
C

1
6
)
w
a
t
e
r
s
e
p
e
r
a
t
o
r
X 3 0 : 6 4
X 3 0 : 6 3
B
1
2
4
W
a
s
s
e
r
a
b
s
c
h
e
i
d
e
r
X
1
:
1
0
7
X
1
:
1
0
8
X
1
:
1
9
8
X
1
:
1
9
9
X
1
:
1
7
9
o n l y E M R I I I
X 1 : 1 8 4
X 1 : 1 9 3
X 1 : 1 9 4
X 1 : 1 9 1
X 1 : 1 9 2
X 3 1 : 3 3
X 3 1 : 3 1
X 3 1 : 4 8
X 3 1 : 1
X 3 1 : 3 2
X 3 1 : 5 3
X 3 1 : 2 4
X 3 1 : 3 4
K
1
4
.
2
8
6
8
5
X 6 6 : 2
X 6 6 : 3
2
:
2
4
:
3
Wiring diagram
BOMAG 1151 008 911 79
19.3
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
0
0
5
V
o
g
t
2
3
.
0
7
.
2
0
0
7
S
e
i
s
1
1
1
F
a
h
r
a
n
t
r
i
e
b
,

N
e
i
g
u
n
g
s
s
e
n
s
o
r
,

S
i
t
z
k
o
n
t
a
k
t
d
r
i
v
i
n
g

s
y
s
t
e
m
,

s
l
o
p
e

s
e
n
s
o
r
,

s
e
a
t

c
o
n
t
a
k
t

s
w
i
t
c
h
X 3 5 : 6 4
L e i s t u n g
A
3
4
F
a
h
r
S
t
e
u
e
r
u
n
g
Y
1
6
P
r
o
p
.
P
u
m
p
e

R
c
k
w
.
12
Y
1
7
P
r
o
p
.
P
u
m
p
e

V
o
r
w
.
12
X 3 5 : 2 4
4 0 0 . . . 1 . 2 0 0 m A
4 0 0 . . . 1 . 2 0 0 m A
4 0 0 . . . 1 . 2 0 0 m A
4 0 0 . . . 1 . 2 0 0 m A
B
6
0
S
e
n
s
o
r

A
c
h
s
e
+
d
i
r
.
s p e e d
B
5
9
S
e
n
s
o
r

B
a
n
d
a
g
e
+
d
i
r
.
s
p
e
e
d
X 3 5 : 3 8
X 3 5 : 1 2
X 3 5 : 3 7
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b rs w
w s
b l
b rs w
w s
b l
B
5
7
N
e
i
g
u
n
g
s
s
e
n
s
o
r
+
4
5
_
G
=
4
,
5
V
4
5
_
G
=
0
,
5
V
+
S
1
V
2
,
5
V
4
V
N e i g u n g
X 3 5 : 5 3
X 3 5 : 3 3
C A N 2 +
C A N 2
E l e k t r o n i k
X 3 5 : 2 8
3
0
4
:
2
0
3
0
6
:
1
1
5
A
1
0
A
X 3 5 : 2 6
X 3 5 : 2 7
F
2
4
:
2
6
:
3
C
A
N
2
+
4
:
2
0
C
A
N
2
+
8
:
6
C
A
N
2
4
:
2
0
C
A
N
2
8
:
6
C
A
N
1
6
:
8
C
A
N
1
+
6
:
8
S
0
1
2
:
1
5
3
1
3
2
C A N 1 +
C A N 1
B
1
1
2
D
r
u
c
k
s
e
n
s
o
r

F
a
h
r
p
u
m
p
e
r
t
s
w
X 5 2 : 1
X 3 5 : 3 1
X
1
:
1
1
9
X
1
:
1
2
0
p
r
e
s
s
u
r
e

s
e
n
s
o
r

d
r
i
v
e

p
u
m
p
X 1 : 5 2
X 1 : 5 4
X 1 : 4 8
X 1 : 5 0
X
1
:
1
7
E
X
1
:
1
7
A
X
1
:
3
4
E
X
1
:
3
4
A
X
1
:
1
4
6
X
1
:
1
4
5
X 1 : 1 7 1
X 1 : 1 7 3
X 1 : 1 7 5
X 1 : 1 7 6
X 1 : 1 7 7
s
e
n
d
e
r

a
x
l
e
s
e
n
d
e
r

d
r
u
m
s
l
o
p
e

s
e
n
s
o
r
X
1
:
1
2
1
X
1
:
1
2
2
X
1
6
:
1
X
1
6
:
2
X
1
5
:
1
X
1
5
:
2
X
1
:
1
2
3
X
1
:
1
2
3
X
1
:
1
4
4
X
1
:
1
2
4
X
1
:
1
4
3
X
1
:
1
4
1
d
r
i
v
i
n
g

c
o
n
t
r
o
l
l
e
r
s p e e d
R i c h t u n g
s p e e d
R i c h t u n g
A c h s m o t o r
X 3 5 : 6 5
X 3 5 : 6 6
X 3 5 : 6 7
X 3 5 : 6 8
X 3 5 : 5 5
G e h u s e
h o u s i n g
p
r
o
p
.
p
u
m
p

f
o
r
w
a
r
d
s
p
r
o
p
p
u
m
p

b
a
c
k
w
a
r
d
s
3
1
4
:
2
0
3
1
6
:
1
F
6
7
12
F
8
4
12X 3 5 : 3 0
X 3 5 : 4 9
X 3 5 : 5 6
X 3 5 : 5 7
X 3 5 : 5 8
X 3 5 : 5 9
X 3 5 : 6 0
X 3 5 : 5 4
H
1
4
R
c
k
f
a
h
r
w
a
r
n
s
u
m
m
e
r
+
b
a
c
k

u
p

a
l
a
r
m

b
u
z
z
e
r
0 , 4 6 A
L
C
D
is
p
la
y
,

O
P
U
S

2
1
F
a
h
r
h
e
b
e
l
E
M
R

D
e
u
t
z
S
0
6
S
i
t
z
k
o
n
t
a
k
t
s
c
h
a
l
t
e
r
+
X 3 5 : 1 5
X
1
:
1
5
8
X
1
:
1
4
9
s
w
i
t
c
h
,

s
e
a
t

c
o
n
t
a
c
t
X
1
:
1
1
4
X
1
:
1
1
7
X
1
4
:
B
X
1
4
:
A
X 3 5 : 4 6
X 3 5 : 4 7
X 1 : 8 2
X 1 : 1 2 4
X 1 : 1 4 2
X 1 : 1 4 2
X 1 : 1 4 3
X 1 : 1 4 3
p
r
o
p
.
V
a
l
v
e

d
r
u
m

m
o
t
o
r
p
r
o
p
.
V
a
l
v
e

a
x
l
e

m
o
t
o
r
X 1 : 4 7
X 1 : 4 9
X
3
4
:
A
X
3
4
:
B
X 1 : 5 1
X 1 : 5 3
X
3
4
:
C
X
3
4
:
D
X 3 5 : 4
R x D
X 3 5 : 5
T x D
X
3
4
:
H
X
3
4
:
G
R
2
2
1
2
0

O
H
M
1
2
R
2
3
1
2
0

O
H
M
1
2
R
2
0
1
2
0

O
H
M
1
2
R
2
1
1
2
0

O
H
M
1
2
X
9
:
1
X
9
:
2
D
i
a
g
n
o
s
e
s
t
e
c
k
e
r

F
a
h
r
z
e
u
g
d
i
a
g
n
o
s
i
s

i
n
t
e
r
f
a
c
e

e
q
u
i
p
m
e
n
t
X
1
:
3
4
A
9
:
2
X
1
:
4
6
P
I
T
C
H

M
E
S
X
9
:
2
X 5 2 : 2
Y
3
0
P
r
o
p
.
V
e
n
t
i
l

B
a
n
d
a
g
e
n
m
o
t
o
r
12
Y
3
1
P
r
o
p
.
V
e
n
t
i
l

A
c
h
s
m
o
t
o
r
12
X
1
:
2
X
1
:
1
7
2
X
1
:
5
5
7
:
4
P o t . 1 5
a
b
X
1
:
1
7
4
X
1
:
1
7
8
D
I
R

M
E
S
X
9
:
2
S
P
E
E
D

T
A
C
1
3
:
6
S
P
E
E
D

M
E
S
X 9
:
2
X
1
:
4
5
X
1
:
4
4
F
M
3
7
:
5
F M 3
2 1
X 1 : 6 3 X 1 : 6 2
19.3 Wiring diagram
BOMAG 1152 008 911 79
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
0
0
6
V
o
g
t
2
3
.
0
7
.
2
0
0
7
S
e
i
s
1
1
D
a
t
e
n
s
a
m
m
l
e
r
,

L
C
D
i
s
p
l
a
y
d
a
t
a
c
o
l
l
e
c
t
o
r
,

L
C
d
i
s
p
l
a
y
3
0
5
:
2
0
3
0
9
:
1
3
1
5
:
2
0
3
1
7
:
1
B
0
3
L u f t f i l t e r
P
12
a i r c l e a n e r
B
5
5
Q
B
2
1
P
12
d
a
t
a
c
o
l
l
e
c
t
o
r
D
+
2
:
8
C
A
N
1
+
5
:
1
7
C
A
N
1
+
8
:
1
4
C
A
N
1
5
:
1
7
C
A
N
1
8
:
1
4
K
1
1
:
8
7
2
:
2
0
K
1
1
:
8
7
8
:
1
4
R
0
3
0 . . 6 7 O H M
f u e l l e v e l
F
2
4
12
1
0
A
X 2 6 : 1
X 2 6 : 5
X 2 6 : 6
X 2 6 : 8
X 2 6 : 1 0
X 2 6 : 1 1
X 2 6 : 1 2
X 2 7 : 1
X 2 7 : 2
X 2 7 : 3
X 2 7 : 5
X
2
7
:
8
X 2 7 : 1 0
X 2 7 : 1 1
X 2 7 : 1 2
A
8
0
D
a
t
e
n
s
a
m
m
l
e
r
D I N 1
D I N 2
D I N 3
D I N 4
D I N 5
D I N 6
D I N 8
D I N 9
D I N 1 1
G N D
A I N 1
U I N 1
G N D / U I N 3
G N D
C A N 1 h i g h
C A N 1 l o w
V C C
U I N 3
U I N 2
A I N 2
X 2 7 : 6
X 2 7 : 7
F
2
4
:
2
5
:
3
F
2
4
:
2
7
:
1
3
A
8
1
L
C
D
i
s
p
l
a
y
L
C
d
i
s
p
l
a
y
X 2 8 : 3
X 2 8 : 4
X 2 8 : 1
X 2 8 : 2
X 2 8 : 5
C A N 1 l o w
U b " 1 5 "
U b " 3 0 "
X 2 9 : 7
U b o u t
X 2 9 : 5
X 2 9 : 6
X 2 8 : 6
X 2 9 : 8
D I N 1
D I N 2
D I N 4
D I N 3
D I N 5
D I N 6
s
w
i
t
c
h

e
n
g
i
n
e
r
p
m

m
o
d
e
L
o
w
X
1
:
2
9
E
X
1
:
2
9
A
X 1 : 3 9
X 1 : 4 0
X
1
:
8
7
X
1
:
8
8
X
1
:
8
0
X
1
:
8
6
X
1
:
8
2
X
1
:
1
6
4
X
1
0
:
2
X
1
0
:
3
X
1
:
1
0
5
X
1
:
1
1
7
X
1
:
1
4
9
X
2
1
:
1
X
2
1
:
2
X
1
:
9
4
X
1
:
9
4
X
1
:
1
1
7
X
1
:
1
0
6
X
1
:
1
1
1
X
1
:
1
1
2
B
E
L
1
2
:
4
E
S
X

F
a
h
r
s
t
e
u
e
r
u
n
g
D
I
O
S

P
la
t
t
e
n
X 2 6 : 9
X 2 6 : 3
X 2 6 : 4
B
L
1
2
:
1
7
B
R
1
2
:
1
7
X 2 9 : 1
X 2 9 : 2
X 2 9 : 4
X 2 9 : 3
X
3
4
:
R
X 2 6 : 2
X 1 : 4 1
S
t
e
c
k
e
r
f
a
r
b
e
:

X
2
6
g
r
a
u
;

X
2
7
s
c
h
w
a
r
z
c
o
n
n
e
c
t
o
r
c
o
lo
u
r
:

X
2
6
g
r
e
y
;

X
2
7
b
la
c
k
H
i
g
h
E
C
O
F
0
5
:
2
2
:
1
6
1
1
:
1
B
1
2
4
X 2 7 : 4
X 2 7 : 9
X
1
:
1
0
7
X
1
:
1
0
8
X
8
:
1
X
8
:
2
D I N 1 0
S e p a 1
S e p a 2
o n l y E M R I I
S
1
3
9
S
c
h
a
l
t
e
r

F
r
e
q
u
e
n
z
v
e
r
s
t
e
l
l
u
n
g
1
3
1
4
2
4
2
3
S
1
2
7
S
c
h
a
l
t
e
r

M
o
t
o
r
d
r
e
h
z
a
h
l
1
3
1
4
2
3
2
4
s
w
i
t
c
h

f
r
e
q
u
e
n
c
y
c
o
n
t
r
o
l
u
p
d
o
w
n
Wiring diagram
BOMAG 1153 008 911 79
19.3
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
0
0
7
V
o
g
t
2
3
.
0
7
.
2
0
0
7
S
e
i
s
1
1
L
e
n
k
u
n
g
,

V
i
b
r
a
t
i
o
n
s
t
e
e
r
i
n
g
,

v
i
b
r
a
t
i
o
n
X 3 5 : 3
3
1
6
:
2
0
3
1
8
:
1
K
4
3
8
6
8
5
X 3 5 : 4 0
X 3 5 : 4 1
X 3 5 : 2 9
X 3 5 : 1 8
X 3 5 : 4 8
X 3 5 : 1 9
K
4
3
7
:
1
2
3
0
8
7
a
8
7
P r o p . o u t
W a r n s u m m e r
4 0 0 . . . 1 . 2 0 0 m A
4 0 0 . . . 1 . 2 0 0 m A
4 0 0 . . . 1 . 2 0 0 m A
L e n k w i n k .
B
6
5
L
e
n
k
w
i
n
k
e
l
s
e
n
s
o
r
+
S
B
1
6
A
u
f
n
e
h
m
e
r

V
i
b
r
a
t
i
o
n
s
m
o
t
o
r
+
X
2
2
:
1b
r
b
e
i
B
W
1
7
7

u
.

2
1
3

m
.

S
a
u
e
r

M
o
t
o
r

s
w

/

b
e
i
B
W
2
1
3
2
2
6

m
.

R
e
x
r
o
t
h

M
o
t
o
r

b
l
b
e
i
B
W
1
7
7

u
.

2
1
3

m
.

S
a
u
e
r

M
o
t
o
r

b
l
/

b
e
i
B
W
2
1
3
2
2
6

m
.

R
e
x
r
o
t
h

M
o
t
o
r

s
w
w
s
X 3 5 : 3 5
A
4
5
L
e
n
k
e
i
n
h
e
i
t
S
1
S
2
V
C
C
V
C
C
0
V
0
V
BBAA
B T S B r e m s e
X 3 5 : 1 7
X 3 5 : 2
X 3 5 : 6 1
B r e m s e
s
o
l
e
n
o
i
d

v
a
l
v
e

b
r
a
k
e
w
a
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b
u
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,

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p
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v
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v
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v
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b
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m
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v
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v
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b
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b
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A G N D
X 3 5 : 2 3
8
,
5
V
X
1
:
8
2
X 1 : 1 8 8
X 1 : 1 8 9
X
2
2
:
2
X
2
2
:
4
X
1
:
1
8
7
X
1
:
1
9
0
X
1
:
1
1
7
S
0
1
2
:
1
5
1
1
1
2
X
1
:
1
1
3
X
1
:
1
5
0
X
1
:
1
1
5
X
1
:
1
1
6
X 1 : 2 0 2
X 1 : 2 0 3
X
1
:
1
9
7
X
1
:
1
9
7
X
1
:
1
1
8
S
1
X 1 : 2 0 8
X 1 : 2 0 6
X 1 : 2 0 5
X 1 : 2 0 7
X 4 1 : 6
X 4 1 : 8
X 4 1 : 5
X 4 1 : 7
X
1
:
1
4
8
s
t
e
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r
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n
g

u
n
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t
s
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a
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n
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r

v
i
b
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n

m
o
t
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r
X 5 1 : 3
X
4
3
:
1
X
3
9
:
3
X
1
:
1
4
9
H
0
7
W
a
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n
s
u
m
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r

S
t
r
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g
+
X 1 : 5 5
n u r B V C
o n l y B V C
S
0
1
:
2
2
4
:
2
0
S
0
1
:
2
2
X
1
:
4
1
F
2
4
:
2
6
:
2
0

X 3 4 : J
X
6
:
2
X
6
:
1
X
7
:
1
X
7
:
2
X
2
2
:
3
V
I
B
1
3
:
6
B
R
A
K
E

M
E
S
X
9
:
2
X 1 : 4 2
B
T
S

B
R
E
M
S
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8
:
2
X
2
3
:
1
8
:
1
X 3 5 : 2 2
X
3
5
:
2
2
8
:
1
3
X
1
:
2
0
1
F M 5
1 2
X 1 : 6 1X 1 : 6 0
Y
0
8
P
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p
.
V
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t
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l

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i
b
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a
t
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k
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n
12
Y
0
7
P
r
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p
V
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n
t
i
l

V
i
b
r
a
t
i
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n

g
r
o
12
X 1 : 5 8
X 1 : 5 6
F M 2
1 2
F M 1
1 2
X 1 : 5 9
X 1 : 5 7
X
4
1
:
1
X
4
1
:
3
X
3
9
:
1
X
4
0
:
1
X
4
1
:
4
X
4
1
:
2
X
4
0
:
4
X
3
9
:
4
X
1
:
1
5
9
X
1
:
1
6
2
X
4
3
:
2
X 5 1 : 2
X
5
1
:
1
X
1
:
1
6
1
X
1
:
1
6
0
X 3 5 : 1
X
4
0
:
3
X
4
0
:
2
X
3
9
:
2
Y
0
4
M
a
g
n
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t
v
e
n
t
i
l

B
r
e
m
s
e
12
d
r
i
v
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n
g

c
o
n
t
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l
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r
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9
3
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p
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e
n
t
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l

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n

l
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9
2
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p
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n
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n

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e
c
h
t
s
12
A r m l e h n e
B
1
3
2
Sig.
1 5 0 m A
m a x . 1 . 8 A
X
1
:
1
5
4
G
A

M
E
S
X
9
:
2
X
1
:
3
8
X
1
:
3
7
X
1
:
8
9
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A

M
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S
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9
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2
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n
b
a
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1
7
7
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H
:

h
.
r
.

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A
n
b
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1
3
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n
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1
7
7
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h
.
l.

b
A
n
b
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2
1
3
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b
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X
1
:
5
5
5
:
6
X 3 5 : 2 0
X 3 5 : 2 1
b
r
b
l
s
w
g
g
X 3 5 : 1 6
X 3 5 : 4 3
X
3
5
:
4
3
8
:
1
3
b
d
a
1
K
4
8
8
:
2
3
0
8
7
a
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4
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1
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1
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1
9
6
X
1
:
1
9
5
F
M
3
5
:
3
7
:
1
4
19.3 Wiring diagram
BOMAG 1154 008 911 79
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
0
0
8
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o
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t
2
3
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0
7
.
2
0
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1
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,

v
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b
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p
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a
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s
S
5
5
F
a
h
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b
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l
S
t
e
c
k
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r

X
2
3
S
t
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c
k
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r

X
2
4
134291
0
76581
1
1
2
1
2
3
4
5
6
7
8
C
A
N
2
+
5
:
1
7
C
A
N
2
5
:
1
7
K
4
8
8
6
8
5
K
0
5
8
6
8
5
X 1 : 1 5 7
X 1 : 1 5 6
X
1
:
1
5
3
X
1
:
1
4
9
S
3
5
S
c
h
a
l
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r

A
m
p
l
i
t
u
d
e
1
3
1
4
2
3
2
4
T
a
s
t
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r

1

=

P
la
t
t
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n

r
e
c
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p
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b
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1

=

p
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ig
h
t
T
a
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2

=

P
la
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h
e
b
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p
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b
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t
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n

2

=

lif
t

p
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3

=

V
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b
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3

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v
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O
N
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F
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4

=

P
la
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lin
k
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b
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4

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p
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f
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T
a
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5

=

p
la
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s
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b
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5

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lo
w
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p
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7

=

I
n
f
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t
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1
p
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b
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n

7

=

in
f
o

b
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n

1
T
a
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r

8

=

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n
f
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t
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2
p
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b
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8

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b
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2
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7
8
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b

in
0
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in
B
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z
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+
5
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u
t
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V

(
R
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f

P
I
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5
)
A
d
d
1
A
d
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2
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x
t
1
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K

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x
t
2
D K E x t 1
D K E x t 2
D K E x t 3
D K E x t 4
D K E x t 5
D K E x t 6
U b o u t
O V o u t
B
T
S

B
r
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m
s
e
B
r
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m
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a
u
f

=

U
b
B
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z
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=

0
V
t
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l

l
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1
25
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1
7
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3
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9
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X
2
3
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1
7
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2
B
T
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B
R
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7
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1
8
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1
3
9
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q
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g

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9
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b
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1
3
1
4
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a
t

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V
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6
4
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c
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a
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c
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P
l
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n
1
3
1
4
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4
2
F
a
h
r
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s
c
h
a
l
t
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S
+
X 2 5 : 3
X 2 5 : 4
X 2 5 : 2
s
w
.

s
w
i
m
m
i
n
g

p
o
s
.

p
l
a
t
e
s
m
o
d
e
s
w
.

p
l
a
t
e
s
X 5 0 : 2
X 5 0 : 3
X 5 0 : 1
C
A
N
1
+
6
:
1
4
C
A
N
1
+
9
:
1
6
C
A
N
1
6
:
1
4
C
A
N
1
9
:
1
6
K
1
1
:
8
7
6
:
2
0
K
1
1
:
8
7
9
:
1
X
3
5
:
2
2
7
:
1
1
Y
9
8
P
r
o
p
P
u
m
p
e

P
l
a
t
t
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n
12
p
r
o
p
.
v
a
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v
e

p
l
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5
4
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t
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Y
1
2
2
M
V

P
l
a
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n

h
e
b
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n
12
Y
1
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2
M
V

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l
a
t
t
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n

l
i
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k
s
12
Y
1
4
4
.
1
M
V

P
l
a
t
t
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n

S
c
h
w
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m
m
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t
12
Y
1
2
3
M
V

P
l
a
t
t
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n

s
e
n
k
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n
12
Y
1
4
3
M
V

P
l
a
t
t
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n

r
e
c
h
t
s
12
p
l
a
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u
pp
l
a
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s

d
o
w
np
l
a
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s

l
e
f
t
p
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s

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a
t
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s
.
p
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s

p
r
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r
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t
y
X
1
:
3
1
E
F
1
4
5
12
X
1
:
3
1
A
B
1
3
5
N
h
e
r
u
n
g
s
s
c
h
.

P
l
a
t
t
e
n

M
i
t
t
e
+
S
B
1
3
4
N
h
e
r
u
n
g
s
s
c
h
.

P
l
a
t
t
e
n

o
b
e
n
+
S
s
e
n
s
o
r

p
l
a
t
e
s

c
e
n
t
e
r
e
d
s
e
n
s
o
r

p
l
a
t
e
s

u
p
X
1
:
2
0
9
p
l
a
t
e
c
o
n
t
r
o
l
l
e
r
E
S
X

F
a
h
r
s
t
.
L
C
D
is
p
la
y
B
T
M
2
0
A
n
i
c
h
t

b
e
i

B
V
C
n
o
t

a
t

B
V
C
X 6 2 : 4
X
6
2
:
1
2
X 6 2 : 3
X 6 2 : 9
X 6 2 : 1 0
X 6 2 : 1
X 6 2 : 2
X 6 2 : 1 1
X 6 2 : 5
X 6 2 : 6
X 6 2 : 8
X 6 2 : 1 3
X 6 2 : 1 4
X 6 2 : 7
4 0 0 . . 1 . 2 0 0 m A
X 1 : 2 1 4
X 1 : 2 1 3
X
1
:
2
1
1
X
1
:
2
1
2
X 6 3 : 1X 6 3 : 2
X 6 3 : 2 X 6 3 : 1
X
3
5
:
4
3
7
:
1
1
X
1
:
2
1
5
b r
b r
b
l
b
l
w s
s w
X
1
:
2
1
0
S
3
6
S
c
h
a
l
t
e
r

B
e
t
r
i
e
b
s
a
r
t

P
l
a
t
t
e
n
1
3
1
4
Y
1
4
5
M
V

P
l
a
t
t
e
n

P
r
i
o
r
i
t
t
12
Y
1
4
4
.
2
M
V

P
l
a
t
t
e
n

S
c
h
w
i
m
m
s
t
12
X 6 2 : 1 5
2
:
1
2
7
:
1
7
Wiring diagram
BOMAG 1155 008 911 79
19.3
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
0
0
9
V
o
g
t
2
3
.
0
7
.
2
0
0
7
S
e
i
s
1
1
V
a
r
i
o
c
o
n
t
r
o
l
,

M
e
s
s
t
e
c
h
n
i
k
V
a
r
i
o
c
o
n
t
r
o
l
,

m
e
a
s
u
r
e
m
e
n
t

e
q
u
i
p
m
.
X 4 4 : 4 7
X 4 4 : 2 9
X 4 4 : 3 3
X 4 4 : 5 3
X 4 4 : 4 6
X 4 4 : 5 6
X 4 4 : 5 7
X 4 4 : 5 8
X 4 4 : 5 9
X 4 4 : 6 0
X 4 4 : 5 4
L e i s t u n g
P r o p .
E l e k t r o n i k
m
e
a
s
u
r
e
m
e
n
t

c
a
l
c
.

u
n
i
t
P r o p .
C
A
N
3
C
A
N
3
+
C
A
N
1
3
1
8
:
2
0
3
1
1
0
:
1
X
2
:
7
5
X
2
:
7
6
X
2
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7
3
X
2
:
7
4
s
o
l
e
n
o
i
d
v
a
l
v
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e
x
c
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r

u
p
s
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n
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d

v
a
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e
x
c
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r

d
o
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n
B
6
2
B
e
s
c
h
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n
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g
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n
g
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n
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n
+ / s w
/
g
g
1
5
g
/
b
l
2 0 g / b r
X 4 4 : 3 1
B
6
2
B
e
s
c
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n
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+ / s w
/
g
g
1
5
g
/
b
l
2 0 g / b r
X 4 4 : 3 0
X 4 4 : 7
X
2
:
5
4
X
2
:
5
5
X
2
:
5
8
X
2
:
5
9
X
4
8
:
3
X
4
8
:
4
X
4
9
:
3
X
4
9
:
4
X 4 4 : 9
P
1
1
D
r
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c
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R
x
D
X 4 4 : 5 T
x
D
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1
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3
3
D
i
s
p
l
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M
e
s
s
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c
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k

B
O
P
X
2
:
5
0
X
2
:
5
1
X
4
2
:
4
X
4
2
:
5
X
4
2
:
3
X
4
2
:
2
X
4
2
:
1
X 4 4 : 1
A G N D M E S X
P
0
7
E
V
I
B
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+
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X 4 4 : 2 3
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X 4 4 : 2 8
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2
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5
7
X
1
:
3
4
A
5
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9
G N D
X 4 4 : 5 5
X
2
:
5
2
X
1
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3
5
A
X
1
:
3
5
E
X 4 4 : 6 5
X 4 4 : 6 6
X 4 4 : 6 7
X 4 4 : 6 8
X
2
:
6
3
X
2
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6
6
3
0
6
:
2
0
3
0
1
2
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1
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8
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2
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1
8
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0
G
A

M
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X
7
:
1
5
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P
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D

M
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X
5
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3
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X 4 4 : 1 4
D
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M
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X
5
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3
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P
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T
C
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M
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5
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8
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A
8
3
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+

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6
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4
7
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1
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X
2
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6
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2
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0
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X
2
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4
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2
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5
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4
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X
4
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7
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R
2
4
6
0

O
H
M
1
2
X 4 4 : 2 7
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2
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8
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9
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2
0 . . 6 V D C
4 0 0 . . 1 . 2 0 0 m A
4 0 0 . . 1 . 2 0 0 m A
X
4
6
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X
4
6
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6
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19.3 Wiring diagram
BOMAG 1156 008 911 79
5
8
2

7
0
2

3
9
2
3
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0
7
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2
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X
4
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X
4
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X
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X
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n
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Wiring diagram
BOMAG 1157 008 911 79
19.3
5
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3
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6
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6
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19.3 Wiring diagram
BOMAG 1158 008 911 79
5
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2

3
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2
3
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T
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1
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3
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1
7
C
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n
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e
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t
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n

h
e
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d

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A
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1
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1
8
E
X
1
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1
8
A
X
1
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2
6
E
X
1
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2
6
A
X
1
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2
3
E
X
1
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2
3
A
X
1
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2
4
E
X
1
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2
4
A
X
1
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1
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X
1
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2
1
A
X
1
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2
2
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X
1
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2
2
A
X
1
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9
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1
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1
9
A
X
1
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2
5
E
X
1
:
2
5
A
X
1
:
2
X 1 : 3 1 9
X 1 : 3 2 0
X 1 : 3 2 1
X 1 : 3 2 2
X 1 : 3 2 3
X 1 : 3 2 4
X 1 : 3 2 4
X 1 : 3 2 3
X
1
:
8
3
S
1
6
1
3
1
4
B
E
L
6
:
9
X
1
:
8
4
X 1 : 3 0 9
X 1 : 3 1 0
X 1 : 3 1 5
X 1 : 3 1 6
X 1 : 3 1 1
X 1 : 3 1 2
X 1 : 3 1 5
X 1 : 3 1 6
X 1 : 3 0 3
X 1 : 3 1 3
X 1 : 3 1 4
X 1 : 3 1 5
X 1 : 3 1 6
X 1 : 3 0 2 X 1 : 3 0 1
X
3
:
4
X
3
:
5
X 1 : 3 0 4
X
1
:
3
0
5
X 1 : 3 0 6
X 1 : 3 0 7
X
3
:
1
B
E
L

M
E
S
X
9
:
7
X
1
:
4
3
X 5 8 : 6 X 5 8 : 5
X 5 8 : 6 X 5 8 : 3
X 5 8 : 6 X 5 8 : 2
X 5 9 : 6
X 5 9 : 6
X 5 9 : 6 X 5 9 : 2
X 5 9 : 3
X 5 9 : 5
X 6 0 : 4 X 6 0 : 3
X 6 0 : 2 X 6 0 : 1
X 6 1 : 1X 6 1 : 2
X 6 1 : 3X 6 1 : 4
1
2
:
1
0
1
2
:
2
Wiring diagram
BOMAG 1159 008 911 79
19.3
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
0
1
3
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3
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0
7
.
2
0
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7
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1
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,

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R
a
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a
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A
1
2
R
a
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o
3
0
3
1
+
+
B
5
1
+
B
5
1
+
M
M
3 , 8 A
3 , 8 A
w
a
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r

f
r
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t
w
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r
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M
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6
W
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v
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M
0
7
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1
1
2
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3
S
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2
1
2
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3
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F
4
3
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2
1
2
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7
4
0

1

W
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1
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2
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2
5
7
4
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1

W
0
1
M
0
5
W
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h
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4
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M
E
2
7
A
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12
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2
8
12
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2
3
A
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n
12
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2
5
12
w
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n

w
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,

r
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a
r
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n

w
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d

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k
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d

l
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f
r
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t
4 , 6 A
4 , 6 A
4 , 6 A
4 , 6 Ar
o
t
a
r
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b
e
a
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E
3
2
R
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A
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4 , 7 A
2 , 9 A
0 , 8 3 A
5 A
F
4
1
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3
1
1
2
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1
4
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1
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8
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c
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N
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4
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7
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1 , 7 5 A
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3
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2
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4

E
2
9
12
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4
2
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F
1
3
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4
4
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F
1
4
3
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R
8
0
12
F
4
2
1
4
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8
K
1
4
1
1
5
3
1
3 m i n
K
1
4
1
1
3
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6
3
0
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7
a
8
7
s
w
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0
1
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3
8
51
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1
6
3
51
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3
2
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7
1
4
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2
A
1
6
T
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4
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5
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6
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3
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4
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3
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1
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2
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3
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3
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3
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9
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1
3
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4
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3
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4
m
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t
a
c
h
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h
X 5 5 : 4
X 5 5 : 3
X 5 5 : 1
X
5
5
:
2
X 5 6 : 3
X 5 6 : 1
X
5
6
:
2
X 5 6 : 4
I
X
3
:
6
X
3
:
7
X
3
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8
V
I
B
7
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1
8
X
3
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1
8
S
P
E
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D

T
A
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5
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3
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3
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7
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K
A
B
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3
1
1
4
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1
1
1
5
X
S
S t e c k d o s e
1
2
V
+
s o c k e t
F
1
4
4
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1
5
A
1
0
A
1
5
A
1
5
A
1
0
A
1
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7
1
12
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e
l
a
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s

c
a
b
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n
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3
2
:
8
6
2
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3
2
R
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l
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K
a
b
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8
6
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5
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2
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3
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7
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m a x . 1 3 A
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4
1
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1
4
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1
4
F
4
2
:
H
1
4
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1
4
1
3
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6
1
3
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2
19.3 Wiring diagram
BOMAG 1160 008 911 79
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
0
1
4
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3
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7
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2
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1
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1

2

3

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7
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A
7
2
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12
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3
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3 , 5 A
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1
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6
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1
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6
8
X
1
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7
0
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3
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1
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X 1 7 : 2
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X
1
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1
6
4
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1
7
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4
X
1
9
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1
X
1
9
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2
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X
2
0
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2
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5
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2
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6
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6
7
A
A
n
la
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m

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im

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8
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3
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R
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0
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4
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P
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2
,
8
A
a
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h
e
a
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1
4
K
r
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m
p
e
12
X
7
7
:
2
X
7
7
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1
F
4
2
:
H
1
3
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4
S
2
8
S c h a l t u h r H e i z u n g
h e a t e r t i m e r
5
7
1
1
3
1
0
1
2
6
8
9
4
1
2
F
4
1
:
5
1
3
:
1
9
M
1
7
F
r
i
s
c
h
l
u
f
t

L
f
t
e
r
+
X
6
9
:
1
X
6
9
:
2
F
9
7
12
I n l i n e S i c h e r u n g
i n l i n e f u s e
f
u
e
l

p
u
m
p

h
e
a
t
i
n
g

u
n
i
t
2
0
A
5
A
2 . 5 q m m
2 . 5 q m m
3
A
O p t i o n
o p t i o n
b
l
o
w
e
r

f
r
e
s
c
h

a
i
r
M
K
A
B
I
N
E

3
1
1
3
:
1
9
Wiring diagram
BOMAG 1161 008 911 79
19.3
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
1
0
1
V
o
g
t
2
3
.
0
7
.
2
0
0
7
S
e
i
s
1
1
1
B
a
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t
e
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l
l
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e
c
o
m
p
o
n
e
n
t

l
i
s
t
i
n
g
Bl. Pf.
A02 012 17 Blinkgeber flasher
A93 010 7 GPS Antenne GPS antenna

B133 004 12 Sensor Ladeluftdruck / temperatur sesnor charging air prssure / temperature


F15 014 19 Sicherung Heizgeraet Fuse, heating unit BOX2
F40 014 15 Sicherung Kabinenheizung Fuse, heating unit cab BOX2
19.3 Wiring diagram
BOMAG 1162 008 911 79
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
1
0
2
V
o
g
t
2
3
.
0
7
.
2
0
0
7
S
e
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s
2
1
1
B
a
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l
l
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c
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p
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n
t

l
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g
Bl. Pf.
F97 014 13 Sicherung Frischluftluefter fuse, blower fresh air 3A
F124 002 17 Sicherung Kraftstoffvorwrmung Fuse, fuel preheating 25A
F150 010 14 Sicherung GPS Receiver Fuse, GPS receiver 5A


H80 011 15 Meldeleuchte Wegfahrsperre Indicator light, antitheft device LED

K13 002 18 Relais Signalhorn Relay, warning horn BOSCHW
K43 007 12 D*Relais Vibration E*relay, vibration BOSCHW
K14.2 004 20 TYCOX

M17 014 13 Zusatzluefter Additional blower

P33 009 18 Opus 21 Opus 21

R79 002 14 Kraftstoffvorwrmung fuel preheater 250W

Wiring diagram
BOMAG 1163 008 911 79
19.3
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
1
0
3
V
o
g
t
2
3
.
0
7
.
2
0
0
7
S
e
i
s
3
1
1
B
a
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t
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l
l
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t
e
c
o
m
p
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l
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g
Bl. Pf.


19.3 Wiring diagram
BOMAG 1164 008 911 79
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
1
0
4
V
o
g
t
2
3
.
0
7
.
2
0
0
7
S
e
i
s
4
1
1
B
a
u
t
e
i
l
l
i
s
t
e
c
o
m
p
o
n
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n
t

l
i
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t
i
n
g
Bl. Pf.
Wiring diagram
BOMAG 1165 008 911 79
19.3
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
1
0
5
V
o
g
t
2
3
.
0
7
.
2
0
0
7
S
e
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s
5
1
1
B
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l
l
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c
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m
p
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l
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Bl. Pf.
19.3 Wiring diagram
BOMAG 1166 008 911 79
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
1
0
6
V
o
g
t
2
3
.
0
7
.
2
0
0
7
S
e
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s
6
1
1
B
a
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i
l
l
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c
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p
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Bl. Pf.
X2:80A 010 14 WAGOMESSTECHNIK Wagomeasurement equip.
X2:80E 010 14 WAGOMESSTECHNIK Wagomeasurement equip.
X4:H 010 14 KABINENST. MESST. con. measurem.equipm.
X4:J 010 15 KABINENST. MESST. con. measurem.equipm.
Wiring diagram
BOMAG 1167 008 911 79
19.3
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
1
0
7
V
o
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t
2
3
.
0
7
.
2
0
0
7
S
e
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s
7
1
1
B
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l
l
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c
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m
p
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l
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g
Bl. Pf.
19.3 Wiring diagram
BOMAG 1168 008 911 79
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
1
0
8
V
o
g
t
2
3
.
0
7
.
2
0
0
7
S
e
i
s
8
1
1
B
a
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e
i
l
l
i
s
t
e
c
o
m
p
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n
t

l
i
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i
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g
Bl. Pf.
Wiring diagram
BOMAG 1169 008 911 79
19.3
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
1
0
9
V
o
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t
2
3
.
0
7
.
2
0
0
7
S
e
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s
9
1
1
B
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l
l
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c
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p
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l
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g
Bl. Pf.
19.3 Wiring diagram
BOMAG 1170 008 911 79
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
1
1
0
V
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t
2
3
.
0
7
.
2
0
0
7
S
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s
1
0
1
1
B
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l
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c
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p
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g
Bl. Pf.
Wiring diagram
BOMAG 1171 008 911 79
19.3
5
8
2

7
0
2

3
9
2
3
.
0
7
.
2
0
0
7
1
1
1
V
o
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t
2
3
.
0
7
.
2
0
0
7
S
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s
1
1
1
1
B
a
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l
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c
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Bl. Pf.
X72:A 010 12 STECKER ANSCHL. GPS Connector GPS
X72:B 010 12 STECKER ANSCHL. GPS Connector GPS
X72:C 010 12 STECKER ANSCHL. GPS Connector GPS
X72:D 010 12 STECKER ANSCHL. GPS Connector GPS
X72:E 010 12 STECKER ANSCHL. GPS Connector GPS
X73:A 010 13 STECKER VERS. GPS Connector Supply GPS
X73:B 010 13 STECKER VERS. GPS Connector Supply GPS
X73:C 010 13 STECKER VERS. GPS Connector Supply GPS

Y144.1 008 19 MAX. 1.8A
Y144.2 008 19 MAX. 1.8A

19.3 Wiring diagram
BOMAG 1172 008 911 79
X
3
8
X
3
7
G
e
z
.
:

2
3
.
0
7
.
2
0
0
7
N
a
m
e
:

V
o
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t
G
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p
r
.
:

2
3
.
0
7
.
2
0
0
7
N
a
m
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:

S
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is
S
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e
:

1
v
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n
:

2
p
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:

1
f
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m
:

2
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s
.

f
.
:
R
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la
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s
:
5
8
2

7
0
2

3
9
B
la
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N
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.
:

2
0
1
S
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N
o
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:

2
0
1
X
3
6
A
8
0
X
3
2
:
1
-
1
2
b
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s
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c
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S
c
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a
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W

1
7
7
.
.
.
2
2
6

D
H
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B
V
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4
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-
b
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W

1
7
7
.
.
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2
2
6

D
H
/
B
V
C
-
4
K
4
3
K
4
8
K
6
1
K
1
6
K
0
9
K
1
1
K
0
5
K
0
6
B
5
7
A
0
2
N
u
r

b
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i

K
l
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m
a
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1
0
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b
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a
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c
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T
o

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n
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K
4
1
X
3
4
:
1
-
1
9
K
1
3
Wiring diagram
BOMAG 1173 008 911 79
19.3
G
e
z
.
:

2
3
.
0
7
.
2
0
0
7
N
a
m
e
:

V
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G
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p
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.
:

2
3
.
0
7
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2
0
0
7
N
a
m
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:

S
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is
S
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e
:

2
v
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:

2
p
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:

2
f
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m
:

2
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s
.

f
.
:
R
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p
la
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s
:
B
la
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t

N
r
.
:

2
0
1
S
h
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t

N
o
.
:

2
0
1
A
8
3
M
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s
s
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c
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n
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k

S
t
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u
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r
u
n
g
C
A
N

1
C
A
N

1
C
A
N

2
C
A
N

3
E
M
R

+

F
a
h
r
h
e
b
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l
B
C
M
O
P
U
S

2
1
A
3
4
F
a
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r
s
t
e
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N
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r

b
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V
M
8
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n
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c
.

T
o

V
M
8
b
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c
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S
c
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a
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k
a
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n
-
T
r

B
W

1
7
7
.
.
.
2
2
6

D
H
-
4
o
v
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r
v
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w

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-
b
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x

d
o
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r

B
W

1
7
7
.
.
.
2
2
6

D
H
-
4
5
8
2

7
0
2

3
9
C
A
N

1
L
C
D
+
D
a
t
e
n
s
a
m
m
l
e
r
F
1

F
2

19.3 Wiring diagram
BOMAG 1174 008 911 79
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057 564 17 1
280-315 2
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057 564 25 "L" +793-501 6
057 564 22 7
057 564 23 "L" +057 564 19 +793-501 8
057 564 23 "L" +793-501 9
057 564 23 "L" +057 564 19 +793-501 10
057 564 23 "L" +793-501 11
057 564 36 "R" +2 x 057 564 19 +793-501 12
5 x 057 564 36 "R" +057 564 19 +793-501 13
057 564 36 "R" +793-501 18
057 564 36 "R" +057 564 19 +793-501 19
057 564 36 "R" +793-501 20
057 564 36 "R" +057 564 19 +793-501 21
057 564 36 "R" +793-501 22
6 x 057 564 36 "R" +057 564 19 +793-501 23
5 x 057 564 36 "R" +793-501 29
3
7
1
,
0

m
m
2
4
7
,
0

m
m
Wiring diagram
BOMAG 1175 008 911 79
19.3
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057 564 35 34
057 564 17 35
057 564 21 36
2 x 057 564 25 "L" +793-501 37
057 564 25 "L" +057 564 20 +793-501 39
057 564 25 "L" +793-501 40
057 564 25 "L" +057 564 20 +793-501 41
5 x 057 564 25 "L" +793-501 42
057 564 25 "L" +057 564 20 +793-501 47
057 564 25 "L" +793-501 48
057 564 25 "L" +057 564 20 +793-501 49
057 564 25 "L" +793-501 50
057 564 25 "L" +057 564 20 +793-501 51
057 564 25 "L" +793-501 52
057 564 25 "L" +057 564 20 +793-501 53
2 x 057 564 25 "L" +793-501 54
4 x 057 564 38 "L" +793-501 56
057 564 17 60
3
7
1
,
0

m
m
2
4
7
,
0

m
m
0
,
5

m
m
1
2
3
,
5

m
m
0
,
0

m
m
19.3 Wiring diagram
BOMAG 1176 008 911 79
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Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
3
7
1
,
0

m
m
2
4
7
,
0

m
m
Wiring diagram
BOMAG 1177 008 911 79
19.3
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Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
3
7
1
,
0

m
m
2
4
7
,
0

m
m
0
,
5

m
m
1
2
3
,
5

m
m
0
,
0

m
m
19.3 Wiring diagram
BOMAG 1178 008 911 79
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Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
057 564 17 1
3 x 057 565 40 "R" +793-501 2
057 565 35 "R" +793-501 5
057 565 37 6
3 x 057 565 40 "R" +793-501 7
057 565 37 10
057 565 40 "R" +793-501 11
057 565 35 "R" +793-501 12
057 565 37 13
057 565 40 "R" +793-501 +057 565 36 14
057 565 40 "R" +793-501 15
2 x 057 565 39 "R" +793-501 16
057 565 37 18
4 x 057 565 40 "R" +793-501 19
057 565 37 23
4 x 057 565 40 "R" +793-501 24
2 x 057 565 39 "R" +793-501 28
057 565 37 30
057 565 40 "R" +793-501 31
057 565 39 "R" +793-501 32
057 565 37 33
4 x 057 565 40 "R" +793-501 34
057 565 35 "R" +793-501 38
057 565 37 39
4 x 057 565 40 "R" +793-501 40
057 565 37 44
057 565 40 "R" +793-501 45
057 565 35 "R" +793-501 46
057 565 37 47
057 565 40 "R" +793-501 48
057 565 35 "R" +793-501 49
057 565 37 50
3
7
0
,
0

m
m
3
4
5
,
0

m
m
Wiring diagram
BOMAG 1179 008 911 79
19.3
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Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
057 565 38 "R" +793-501 51
2 x 057 565 40 "R" +793-501 52
057 565 38 "R" +793-501 54
057 565 37 55
3 x 057 565 40 "R" +793-501 56
057 565 38 "R" +793-501 59
057 565 37 60
3 x 057 565 40 "R" +793-501 61
057 565 35 "R" +793-501 64
057 565 37 65
2 x 057 565 40 "R" +793-501 66
057 565 35 "R" +793-501 68
057 565 37 69
3 x 057 565 40 "R" +793-501 70
057 565 35 "R" +793-501 73
057 565 37 74
2 x 057 565 40 "R" +793-501 75
2 x 057 565 35 "R" +793-501 77
057 565 37 79
057 565 40 "R" +793-501 80
057 565 39 "R" +793-501 81
057 565 37 82
057 564 17 83
3
7
0
,
0

m
m
3
4
5
,
0

m
m
2
5
,
0

m
m
19.3 Wiring diagram
BOMAG 1180 008 911 79
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Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
3
7
0
,
0

m
m
3
4
5
,
0

m
m
Wiring diagram
BOMAG 1181 008 911 79
19.3
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Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
3
7
0
,
0

m
m
3
4
5
,
0

m
m
2
5
,
0

m
m
19.3 Wiring diagram
BOMAG 1182 008 911 79
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Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
057 564 17 1
2 x 057 565 40 "R" +793-501 2
057 565 37 4
057 565 40 "R" +793-501 +057 565 36 5
057 565 40 "R" + 793-501 6
057 565 39 "R" + 793-501 7
057 565 37 8
057 565 38 "R" + 793-501 9
2 x 057 565 40 "R" +793-501 10
057 565 38 "R" + 793-501 12
057 565 37 13
2 x 057 565 40 "R" +793-501 14
057 565 39 "R" + 793-501 16
057 565 37 17
057 565 40 "R" + 793-501 18
057 565 38 "R" + 793-501 19
057 565 40 "R" + 793-501 20
057 565 37 21
057 565 40 "R" + 793-501 22
057 565 39 "R" + 793-501 23
057 565 37 24
057 564 21 25
2 x 057 564 38 "L" +793-501 26
057 564 25 "L" + 793-501 28
057 564 36 "R" + 793-501 29
057 564 35 30
057 564 17 31
2
4
0
,
0

m
m
1
0
7
,
8

m
m
1
3
0
,
5

m
m
1
,
7

m
m
Wiring diagram
BOMAG 1183 008 911 79
19.3
Seite 2
31.07.2007 09:12:17
Lieferadresse :
Projekt :
Zeichnung :
Plan :
Ort :
Tragschiene :
Artikelnummer :
Gre der Bohrung :
Klemmenleiste X2
210-112
5.20 x 25.00 [mm]
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
2
4
0
,
0

m
m
1
0
7
,
8

m
m
1
3
0
,
5

m
m
1
,
7

m
m
19.3 Wiring diagram
BOMAG 1184 008 911 79
Seite 1
31.07.2007 09:11:41
Lieferadresse :
Projekt :
Zeichnung :
Plan :
Ort :
Tragschiene :
Artikelnummer :
Gre der Bohrung :
E2 Beleuchtung
210-112
5.20 x 25.00 [mm]
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
M. Vogt TEE
Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
057 564 17 1
4 x 057 565 40 "R" +793-501 2
057 565 37 6
2 x 057 565 40 "R" +793-501 7
4 x 057 565 38 "R" +793-501 9
2 x 057 565 39 "R" +793-501 13
057 565 37 15
057 564 17 16
1
0
0
,
0

m
m
1
2
,
0

m
m
7
4
,
0

m
m
1
4
,
0

m
m
Wiring diagram
BOMAG 1185 008 911 79
19.3
Seite 2
31.07.2007 09:11:43
Lieferadresse :
Projekt :
Zeichnung :
Plan :
Ort :
Tragschiene :
Artikelnummer :
Gre der Bohrung :
E2 Beleuchtung
210-112
5.20 x 25.00 [mm]
Zeichnungsnummer :
Artikelnummer :
gezeichnet: :
geprft: :
M. Vogt TEE
Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
1
0
0
,
0

m
m
1
2
,
0

m
m
7
4
,
0

m
m
1
4
,
0

m
m
19.3 Wiring diagram
BOMAG 1186 008 911 79
G
e
z
.
:

2
3
.
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7
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1
X
7
3
X
7
0
BOMAG 1187 008 911 79
19.4 Hydraulic diagram
BOMAG 1188 008 911 79
Hydraulic diagram
BOMAG 1189 008 911 79
19.4
BOMAG 1190 008 911 79

BW213DH-4 BVC Service Manual E 00891179.l07 PDF

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Service - Manual

Before starting repair work stand the machine on

Always secure the machine against unintended roll-

Secure the engine reliably against unintentional

Mark a machine that is defective or being repaired

On machines with articulated joint keep the articu-

Use protective clothes like hard hat, safety boots

Keep unauthorized persons away from the machine

Tools, lifting gear, lifting tackle, supports and other

Use only safe and approved lifting gear of sifficient

Be careful with cleansing agents. Do not use easily

Cleaning or repair work on the fuel tank is very dan-

When performing welding work strictly comply with

Check welding equipment and cables for damage

Ensure good conductivity between earth cable and

Start the extraction fan before starting work and

Always isolate the burner when laying it down (re-

Protect cables from being damaged, use cables

Ensure sufficient fire protection, keep a fire extin-

In case of welding work in fire or explosion endan-

Remove combustible parts from the vicinity or cover

Name a fire watch during and after welding work.

Do not clamp the welding rod holder and the inert

Place the inert gas bottles in a safe place and se-

Use a protective screen or an arcing shield with

Switch the welding unit off before connecting weld-

Check electrode holders and electric cables at reg-

In case of deficiencies switch off the welding unit

In case of an extractor fan failure or any other fault

Replace damaged insulating jaws and welding rod

Replace the welding wire reels only in deenergized

Call first air helpers.

Report the accident.

In case of an electric accident: Interrupt the power

Wear protective clothes and safety gloves, if possi-

If there is a risk of eye contact you should protect

Avoid prolonged and repetitive contact with oil, es-

Apply protective cream before starting work, so that

Do not use gasoline, kerosene, diesel, thinner or

Do not put oil soaked cloths into your pockets.

Avoid clothes, especially underpants, getting soiled

Overalls must be washed at regular intervals.

If possible degrease components before handling.

Hydraulic oil escaping under pressure can pene-

Before applying pressure to the system make sure

Hydraulic oil leaking out of a small opening can

Do not step in front of or behind the drums/wheels/

Fire extinguishers charged with FOAM, SCHAUM,

The vehicle battery must always be disconnected,

Wherever fuel is stored, filled, drained off or where

Allow the fuel to cool down, to prevent any contact

Vent the system, by removing the filler cap in a well

If the material is in such a state it must only be

If the material has contacted the skin despite these

Maintenance and cleaning work on the engine must

Observe the accident prevention regulations for

Cover all electric components properly before wet

Wear safety goggles! Put on your safety goggles.

Wear safety gloves and an apron! Refrigerant are

Do not allow liquid refrigerants to come into contact

Do not inhale higher concentrations of refrigerant

Smoking is strictly prohibited! Refrigerants may be

Welding and soldering on refrigeration equipment!