SM Bomag BW218 4d

Service - Manual
BW 216 D-40 / PD-40

BW 218 D-40
S/N 101 583 39 .... / S/N 101 583 40 . . . .
S/N 101 583 41......>
Single drum roller
Catalogue number.
008 918 12 06/2012
Table of Contents
General 7
1.1 Introduction 8
1.2 Safety regulations 9
1.3 General repair instructions 14
1.4 Tightening torques 26
Technical data 31
2.1 Technical data 32
Maintenance 39
3.1 General notes on maintenance 40
3.2 Fuels and lubricants 41
3.3 Table of fuels and lubricants 44
3.4 Running-in instructions 45
Caddy wiring diagrams 47
4.1 Understanding circuit diagrams 48
4.2 Circuit symbols in the circuit diagram 53
4.3 Identification of switch blocks in the Caddy wiring diagram 54
4.4 Designation of components in the wiring diagram 55
4.5 Terminal designations in wiring diagram 56
E-Plan wiring diagrams 59
5.1 Understanding wiring diagrams 60
5.2 Circuit symbols in the circuit diagram 69
5.3 Identification of switch blocks in the wiring diagram 72
Electrics 77
6.3 Battery ground and analog ground 81
6.4 Current and voltage 81
6.5 Resistance 83
6.6 Series / parallel connection 85
6.7 Ohm's law 87
6.8 Electrical energy 88
6.9 Formula diagram 89
6.10 Metrology 90
6.11 Diodes, relays, fuses 94
6.12 Telemecanique switch 97
6.13 Plug connectors 99
6.14 Magnetic coil plug 99
6.15 Deutsch plug, series DT and DTM 101
6.16 Plugs and terminals in spring clamping technology 106
6.17 Proximity switches 110
6.18 Level sensor in diesel tank (R03) 111
6.19 Differential pressure switch for hydraulic oil filter, B21 112
6.20 Acceleration transducer 114
6.21 Batteries 115
008 918 12 BOMAG 3

Table of Contents
6.22 Service the battery 119

6.23 Main battery fuse 120
6.24 Starting with jump wires 120
6.25 Generator 121
6.26 Replacing the voltage regulator 130
6.27 Electric starter 132
6.28 Coolant temperature switch 138
6.29 Oil pressure switch and low oil pressure circuitry 139
6.30 Boost fuel solenoid valve 141
6.31 Engine shut-down solenoid 142
6.32 Electric throttle control 143
6.33 Heating flange on engine 145
6.34 Checking the heating flange control 148
6.35 Engine monitoring 149
6.36 Overview of electric components 152
6.37 Operator's stand, old design 163
6.38 Operator's stand, new design 165
6.39 Cabin 166
6.40 Fuses, old design 167
6.41 Fuses, new design 168
6.42 Electronic control units 169
6.43 Checking the voltage supply for the control unit 172
6.44 Diagnostics concept 180
Electronic modules 183
7.1 BEM, BOMAG Evib-meter 185
7.2 Electrics module A68 249
7.3 Electric module K04 257
7.4 Electric module A72, old design 261
7.5 Electric module A108 267
Speedometer Module 271
8.1 Speedometer module 272
582 502 15 dust protection / 582 502 16 gasket 275
9.1 Assembling the dust protection 276
Hydraulics 281
10.1 Hydraulic circuit 282
10.2 Connection overview 284
10.3 Travel pump 075 286
10.4 Vibration pumps 42R041 & 42R055 292
10.5 Axial piston swash plate principle / pump 295
10.6 Troubleshooting axial piston pumps 297
10.7 Travel motor 51 C/D 110 300
10.8 Trouble shooting, variable displacement axial piston motor 302
10.9 Vibration motor A10FM 45 304
10.10 Vibration motor 90M 055 305
10.11 Axial piston swash plate principle / motor 307
10.12 External gear pumps 309
10.13 Travel circuit 311
4 BOMAG 008 918 12

Table of Contents
10.14 Adjust the parking brake 316

10.15 Stopping the machine, operating the parking brake 318
10.16 Towing in case of an engine failure 318
10.17 Vibration circuit 321
10.18 Steering circuit 326
10.19 Check the hydraulic oil level 332
10.20 Changing hydraulic oil and breather filter 332
10.21 Replace hydraulic oil filter 333
10.22 Changing the bypass filter 334
Tests and adjustments 335
11.1 Special tools, tests and adjustments 336
11.2 Adjusting the solenoid for engine speed control 340
11.3 Checking the rotation speeds 341
11.4 Checking / adjusting the neutral positions of the travel pump 343
11.5 Pressure tests in the travel circuit 345
11.6 Checking / adjusting the vibrator shaft speeds 347
11.7 Pressure measurements in the vibration circuit 348
11.8 Check the leakage rate of the vibration motor 349
11.9 Pressure test in steering circuit 350
Flushing and bleeding 353
12.1 Special tools for flushing 354
12.2 Flushing - general 359
12.3 Flushing schematic travel circuit (distribution travel pump) 361
12.4 Flushing the travel circuit (travel pump distribution) 363
12.5 Flushing schematic travel circuit (distribution axle motor) 369
12.6 Flushing the travel circuit (axle motor distribution) 374
12.7 Flushing schematic for vibration drive 379
12.8 Flushing the vibration circuit 380
12.9 Bleeding the travel circuit 384
12.10 Bleeding the vibration circuit 386
Air conditioning system 389
13.1 Physical basics 390
13.2 Refrigerant R134a 393
13.3 Compressor oil / refrigeration oil 394
13.4 Working principle of the air conditioning system 395
13.5 Monitoring devices 395
13.6 Description of components 396
13.7 Measuring the compressor oil level 402
13.8 Checking the magnetic clutch 402
13.9 Inspection and maintenance work 403
13.10 Checking, replacing the refrigerant compressor V-belt 404
13.11 Air conditioning service (old design) 405
13.12 Service the air conditioning 407
13.13 Drying and evacuation 410
13.14 Emptying in case of repair 410
13.15 Leak test 411
13.16 Filling instructions 412
13.17 Trouble shooting in refrigerant circuit, basic principles 415
008 918 12 BOMAG 5

Table of Contents
13.18 Trouble shooting, refrigerant circuit diagram 419

13.19 Trouble shooting procedure 420
13.20 Steam table for R134a 430
Cabin assembly 435
14.1 Preparations 437
14.2 Cabin assembly 438
14.3 Final function tests and checks 443
Replacing the cab window panes 445
15.1 Assembly of window panes 446
15.2 Special tools, cabin windows 447
15.3 Auxiliary materials 448
15.4 Removing and installing the window pane 450
Drum 455
16.1 Special tools, drum, single drum rollers 456
16.2 Repair overview for drum 458
16.3 Removing and installing the drum 467
16.4 Repairing the drum 473
16.5 Dismantling, assembling the change-over weights 504
16.6 Changing the rubber buffers and adjusting the pretension 507
Oscillating articulated joint 511
17.1 Special tools, oscillating articulated joint (BW177 to BW 216) 512
17.2 Repair overview oscillating articulated joint 514
17.3 Removing and installing the oscillating articulated joint 518
17.4 Dismantling the oscillating articulated joint 520
17.5 Assembling the oscillating articulated joint 525
Suppliers documentation 535
18.1 Travel pump 537
18.2 Vibration pump 691
18.3 Travel motor 761
18.4 Vibration motor 855
18.5 Vibration motor 879
18.6 Drum reduction gear 899
18.7 Steering valve 925
18.8 Axle 959
18.9 Diesel engine 1049
Circuit diagrams 1347
19.1 Hydraulic diagram 581 202 01 1349
19.2 Hydraulic diagram 581 202 06 1353
19.3 Wiring diagram 582 702 41 1357
19.4 Wiring diagram 9 1394
6 BOMAG 008 918 12

1 General
008 918 12 BOMAG 7

1.1 Introduction
1.1 Introduction
This manual addresses the professionally qualified

personnel or the after sales service of BOMAG, and
should be of help and assistance in correct and effi-
cient repair and maintenance work.
This manual describes the disassembly, dismantling,
assembly, installation and repair of components and
assemblies. The repair of components and assem-
blies is only described as this makes sense under due
consideration of working means and spare parts sup-
ply.
Documentation
For the BOMAG machines described in this manual
the following documentation is additionally available:
1 Operating and maintenance instructions
2 Spare parts catalogue
3 Service information
Use only genuine BOMAG spare parts.

Spare parts needed for repairs can be taken from the
spare parts catalogue for the machine.
This manual is not subject of an updating service; for
this reason we would like to draw your attention to our
additional "Technical Service Bulletins".
In case of a new release all necessary changes will be
included.
In the course of technical development we reserve the
right for technical modifications without prior notifica-
tion.
Information and illustrations in this manual must not
be reproduced and distributed, nor must they be used
for the purpose of competition. All rights according to
the copyright law remain expressly reserved.
Danger
!
These safety regulations must be read and ap-

plied by every person involved in the repair /main-
tenance of this machine. The applicable accident
prevention instructions and the safety regulations
in the operating and maintenance instructions
must be additionally observed.
BOMAG GmbH
Printed in Germany
Copyright by BOMAG
8 BOMAG 008 918 12

Safety regulations 1.2
Important notes Block the articulated joint with the articulation lock.
1.2 Safety regulations
l
l Use protective clothes like hard hat, safety boots

These safety regulations must be read and ap-
and gloves.
plied by every person involved in the repair /main-
tenance of this machine. The applicable accident l Keep unauthorized persons away from the machine
prevention instructions and the safety regulations during repair work.
in the operating and maintenance instructions l Tools, lifting gear, lifting tackle, supports and other
must be additionally observed.
auxiliary equipment must be fully functional and in
Repair work shall only performed by appropriately safe condition.
trained personnel or by the after sales service of l Use only safe and approved lifting gear of sufficient
BOMAG. load bearing capacity to remove and install parts or
components from and to the machine.
Workshop equipment and facilities as well as the
use and waste disposal of fuels and lubricants, l Do not use easily inflammable or harmful substanc-
cleaning agents and solvent as well as gases and es, such as gasoline or paint thinners for cleaning.
chemicals are subject to legal regulations, which l Do not smoke or use open fire and avoid sparks
are intended to provide a minimum on safety. It is when cleaning or repairing a tank.
obviously your own responsibility to know and
adhere to these regulations.
l When performing welding work strictly comply with
the respective welding instructions.
This manual contains headers like "Note", "Attention",
"Danger" and "Environment", which must be strictly
complied with in order to inform about and avoid dan- Transport work with cranes and lifting
gers to persons, property and the environment. tackle
i Note i Note
Paragraphs marked like this contain technical infor- Cranes must only be operated by instructed persons
mation for the optimal economical use of the machine. who had been trained in handling cranes.
l Follow the operating instructions of the manufactur-
Caution
! er when working with cranes.
Paragraphs marked like this highlight possible l Follow the operating instructions of the operator
dangers for machines or parts of the machine. when working with cranes.
l Always comply with the applicable accident preven-
Danger
!
tion instructions when working with cranes and lift-
ing tackle.
Paragraphs marked like this highlight possible
dangers for persons.
Precautions and codes of conduct for
welding work
Environment
Welding work must only be carried out by properly
Paragraphs marked like this point out practices
trained personnel.
for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Danger
!
Observe the regulations for the protection of the
environment. Electric shock!
Sparks, fire hazard, burning of skin!
General Infrared or ultraviolet radiation (arc), flashing of
l
For repair and maintenance work move the ma- eyes!
chine on a firm base and shut it down. Health hazard caused by welding work on highly
l
Always secure the machine against unintended roll- alloyed work pieces, metal coatings, paint coat-
ing. ings, plastic coatings, oil containing dirt deposits,
grease or solvent residues, etc.!
l Secure the engine reliably against unintentional
starting.
l Check welding equipment and cables for damage
before use (also the validity of inspection stickers).
l Mark a defective machine and a machine under re-
pair by attaching a clearly visible warning label to
l Ensure good conductivity between ground cable
the dashboard. and workpiece, avoid joints and bearings.
008 918 12 BOMAG 9

l Start the extraction fan before starting work and Operation of high-voltage systems
guide with the progressing work as required.
l Always isolate the burner when laying it down (re- i Note
move possible electrode residues).
The rules and statutory regulations valid in the corre-
l Protect cables from being damaged, use cables sponding do apply in addition to the notes given here.
with insulated couplings.
l Ensure sufficient fire protection, keep a fire extin- !Caution
guisher at hand. The high-voltage system must only be operated
l Welding work in areas where there is a risk of fire or and serviced by qualified and authorized person-
explosion, must only be carried out with welding nel.
permission.
Before starting operation the operator must check
l Remove any combustible materials from the weld- the proper condition of the system.
ing area or cover such items appropriately.
l Name a fire watch during and after welding work. !Danger
l Place welding rod holders and inert gas welding Possibility of injury or even death caused by elec-
guns only on properly insulated bases. tric shock:
l Place the inert gas bottles in a safe place and se- l if persons come into contact with live parts,
cure them against falling over. l in case of faulty insulation of live parts,
l
Use a protective screen or hand shield with welding l
inadequate, unsuitable insulation,
filter, wear welding gloves and clothes. l
if melted parts flake off in case of short circuits.
l
Switch the welding unit off before connecting weld-
ing cables. Old oils
l
Check electrode holders and electric cables at reg- Prolonged and repetitive contact with mineral oils will
ular intervals. remove the natural greases from the skin and causes
Behaviour in case of faults dryness, irritation and dermatitis. Moreover, used en-
gine oils contain potentially hazardous contaminants,
l
In case of faults on the welding unit switch of the which could cause skin cancer. Appropriate skin pro-
welding unit immediately and have it repaired by ex- tection agents and washing facilities must therefore
pert personnel. be provided.
l
In case of failure of the extraction system switch the l
Wear protective clothes and safety gloves, if possi-
system off and have it repaired by expert personnel. ble.
Maintenance; waste disposal l
If there is a risk of eye contact you should protect
your eyes appropriately, e.g. chemistry goggles or
l
Replace damaged insulating jaws and welding rod
full face visor; a facility suitable for rinsing the eyes
holders immediately.
should also be available.
l
Replace the welding wire reels only in de-energized l
Avoid longer and repetitive contacts with oils. In
state.
case of open incisions and injuries seek medical ad-
What to do in case of accidents; First Aid vice immediately.
l
Keep calm. l
Apply protective cream before starting work, so that
oil can be easier removed from the skin.
l Call first air helpers.
l
Wash affected skin areas with water and soap (skin
l
Report the accident.
cleansers and nail brushes will help). Lanolin con-
l
In case of an electric accident: Interrupt the power taining agents will replace natural skin oils that were
supply and remove the injured person from the lost.
electric circuit. If breathing and heart have stopped l
Do not use gasoline, kerosene, diesel, thinner or
apply reactivation measures and call for an emer-
solvents to wash the skin.
gency doctor.
l
Do not put oil soaked cloths into your pockets.
l Avoid clothes getting soiled by oil.
l
Overalls must be washed at regular intervals. Dis-
pose of non-washable clothes environmentally.
l
If possible degrease components before handling.
10 BOMAG 008 918 12

Environment l Fire extinguishers charged with FOAM, CO2 GAS
It is strictly prohibited to drain off oil into the soil, or POWDER must be available wherever fuel is
the sewer system or into natural waters. Old oil stored, filled in, drained off, or where work on fuel
must be disposed of according to applicable envi- systems is performed.
ronmental regulations. If in doubt you should con- l The vehicle battery must always be disconnected,
sult your local authorities. BEFORE work in the fuel system is started. Do not
disconnect the battery while working on the fuel
Hydraulics system. Sparks could cause explosion of the fuel
fumes.
l Always relieve the pressure in the hydraulic system
before disconnecting any lines. Hydraulic oil escap-
l Wherever fuel is stored, filled, drained off or where
ing under pressure can penetrate the skin and work on fuel systems is carried out, all potential ig-
cause severe injury. nition sources must be extinguished or removed.
Search lights must be fire proof and well protected
l Always make sure that all screw fittings have been against possible contact with running out fuel.
tightened properly and that hoses and pipes are in
mint condition before pressurizing the system
again.
Hot fuels
Please apply the following measures before draining
l Hydraulic oil leaking out of a small opening can
of fuel to prepare for repair work:
hardly be noticed, therefore please use a piece of
cardboard or wood when checking for leaks. When l Allow the fuel to cool down, to prevent any contact
injured by hydraulic oil escaping under pressure with a hot fluid.
consult a physician immediately, as otherwise this l
Vent the system, by removing the filler cap in a well
may cause severe infections. ventilated area. Screw the filler cap back on, until
l Do not step in front of or behind the drums, wheels the tank is finally emptied.
or crawler tracks when performing adjustment work
in the hydraulic system while the engine is running. Synthetic rubber
Block drums, wheels or crawler tracks with wedges.
Many O-rings, hoses, etc. are made of synthetic ma-
Reattach all guards and safety installations after terial, a so-called fluorocarbon elastomer. Under nor-
all work has been completed. mal operating conditions this material is safe and does
not impose any danger to health.
Environment However, if this material becomes damaged by fire or
extreme heat, it may decompose and form highly
It is strictly prohibited to drain off oil into the soil,
caustic hydrofluoric acid, which can cause severe
the sewer system or into natural waters. Oil oil
burns in contact with skin.
must be disposed of according to applicable envi-
ronmental regulations. If in doubt you should con- l
If the material is in such a state it must only be
sult your local authorities. touched with special protective gloves. The protec-
tive gloves must be disposed of according to appli-
Fuels cable environmental regulations immediately after
use.
l
If the material has contacted the skin despite these
!Danger
measures, take off the soiled clothes and seek
Repair work shall only performed by appropriately medical advice immediately. In the meantime cool
trained personnel or by the after sales service of and wash the affected area of skin over a sufficient
BOMAG. time with cold water or lime water.
Follow the valid accident prevention instructions when
handling fuels. Poisonous substances
The following notes refer to general safety precau- Some of the fluids and substances used are toxic and
tions for danger free handling of fuel. must under no circumstances be consumed.
Fuel vapours not only are easily inflammable, but also Skin contact, especially with open wounds, must be
highly explosive inside closed rooms and toxic; dilu- avoided.
tion with air creates an easily inflammable mixture. These fluids and substances are, amongst others,
The vapours are heavier than air and therefore sink anti-freeze agents, hydraulic oils, fuels, washing addi-
down to the ground. Inside a workshop they may eas- tives, refrigerants, lubricants and various bonding
ily become distributed by draft. Even the smallest por- agents.
tion of spilled fuel is therefore potentially dangerous.
008 918 12 BOMAG 11

Engine air conditioning system. The development of heat

may cause the refrigerant to develop toxic and high-
ly corrosive breakdown products.
Danger
!
l Pungent smell! The toxic substances, which are re-
Do not work on the fuel system while the engine is
sponsible for the pungent smell, must not be in-
running. (Danger to life!)
haled, since this may cause damage to the
Once the engine has stopped wait approx. 1 min- respiratory system, the lung and other organs. Ex-
utes for the system to depressurize. The systems tract toxic breakdown products with a suitable ex-
are under high pressure. (Danger to life!) traction system (workshop extraction system).
Keep out of the danger zone during the initial test l
When blowing out components with compressed air
rung. Danger caused by high pressure in case of and when flushing with nitrogen the gas mixture es-
leaks. (Danger to life!) caping from the components must be extracted via
When performing work on the fuel system make suitable extraction facilities (workshop extraction
sure that the engine cannot be started uninten- systems).
tionally during repair work. (Danger to life!) Handling pressure vessels
l Maintenance and cleaning work on the engine must l Since the fluid container is pressurized, the manu-
only be performed with the engine stopped and facture and testing of these pressure vessels is gov-
cooled down. Make sure that the electric system is erned by the pressure vessel directive. The
switched off and sufficiently secured against being pressure vessels must be repetitively tested by an
switched on again (e.g. pull off ignition key, attach a expert as specified in TRB 532 Inspection by Ex-
warning label). perts, Repetitive Tests. In this case periodically re-
l Observe the accident prevention regulations for curring inspections consist of external
electric systems (e.g. -VDE-0100/-0101/-0104/- examinations, normally on containers in operation.
0105 Electric precautions against dangerous con- In combination with the inspection, the refrigerant
tact voltages). collector must be visually examined two times per
year. Special attention must thereby be paid to
l Cover all electric components properly before wet
signs of corrosion and mechanical damage. If the
cleaning.
container is in no good condition, it should be re-
placed for safety reasons, in order to protect the op-
Air conditioning system erator or third parties against the dangers when
handling or operating pressure vessels.
!Caution l
Secure pressure vessels against tipping over or roll-
Work on air conditioning systems must only be ing away.
carried out by persons who can provide sufficient l
Do not throw pressure vessels! Pressure vessels
evidence of their ability (proof of professionalism) may thereby be deformed to such an extent, that
and only with the appropriate technical equip- they will crack. The sudden evaporation and escape
ment. of refrigerant releases excessive forces. This ap-
l
Always wear goggles and protective clothing when plies also when snapping off valves on bottles. Bot-
performing maintenance and repair work on air con- tles must therefore only be transported with the
ditioning systems. Refrigerant withdraws heat from safety caps properly installed.
the environment when evaporating, which can l
Refrigerant bottles must never be placed near heat-
cause injury by freezing when in contact with skin ing radiators. Higher temperatures will cause higher
(boiling point of R134a -26,5 °C at normal pres- pressures, whereby the permissible pressure of the
sure). vessel may be exceeded.
l Perform maintenance and repair work on air condi- l Do not heat up refrigerant bottles with an open
tioning systems only in well ventilated rooms! Es- flame. Excessive temperatures can damage the
caping refrigerant vapours will mix with the ambient material and cause the decomposition of refriger-
air and displace the oxygen required for breathing ant.
(danger of suffocating).
l
Do not overfill refrigerant bottles, since any temper-
l Smoking is prohibited when performing mainte- ature increase will cause enormous pressures.
nance and repair work on air conditioning systems!
Toxic breakdown products may be generated if re-
frigerant comes into contact with heat. Environment
It is strictly prohibited to release refrigerant into
l Refrigerant should always be extracted and re-
the atmosphere during operation, maintenance
moved by flushing with nitrogen before starting
welding or soldering work near components of the
12 BOMAG 008 918 12

and repair work and when taking air conditioning l Dispose of used filters in accordance with applica-
systems into or out of service. ble environmental regulations.
l When performing repair and maintenance work col-
Battery lect oils and fuels in suitable containers and dispose
l Always wear goggles and protective clothing to of in compliance with applicable environmental reg-
service or clean batteries! Battery acid can cause ulations.
severe injury by cauterization when coming in con- l Do not heat up oils higher than 160 °C because they
tact with skin. may ignite.
l Work only well ventilated rooms (formation of oxy- l Wipe off spilled or overflown oil using suitable
hydrogen gas). cleaning means and dispose of in accordance with
l Do not lean over the battery while it is under load, applicable environmental regulations.
being charged or tested (danger of explosion). l Dispose of old batteries according to applicable en-
l Keep ignition sources away from the battery. Burn- vironmental regulations.
ing cigarettes, flames or sparks can cause explo-
sion of the battery
l There is a danger of scalding when draining off en-
gine or hydraulic oil at operating temperature! Allow
l Use battery chargers etc. only in strict compliance
engine and hydraulic system to cool down to a suf-
with the operating instructions.
ficient level.
l After an accident with acid flush the skin with a suf- l Do not exceed the max. permissible tire pressure.
ficient amount of water and seek medical advice.
l Do not allow children access to batteries.
l
When mixing battery fluid always pour acid into wa-
ter, never vice-versa.
Special safety regulations

l
Use only genuine BOMAG spare parts for repair
and maintenance work. Genuine spare parts and
original accessories were specially developed, test-
ed and approved for the machine.
l
The installation and use of non-genuine spare parts
or non-genuine accessories may therefore have an
adverse effect on the specific characteristics of the
machine and thereby impair the active and/or pas-
sive driving safety. The manufacturer explicitly ex-
cludes any liability for damage caused by the use of
non-original parts or accessories.
l Unauthorized changes to the machine are prohibit-
ed for safety reasons.
l
Do not perform any cleaning work while the engine
is running.
l If tests on the articulated joint need to be performed
with the engine running, do not stand in the articu-
lation area of the machine (danger of crushing!).
l
If tests must be performed with the engine running
do not touch rotating parts of the engine (danger of
injury!).
l
Always ensure an adequate supply of fresh air
when starting in closed rooms. Exhaust gases are
highly dangerous!
l
Refuel only with the engine shut down. Ensure strict
cleanliness and do not spill any fuel.
l Always ensure an adequate supply of fresh air
when refuelling in closed rooms.
008 918 12 BOMAG 13

1.3 General repair instructions
General Electrics
l
Before removing or disassembling parts, assem- General
blies, components or hoses mark these parts for
easier assembly. Due to the fast technical development electric and
electronic vehicle systems become more intelligent
l Before assembling and installing parts, assemblies and more comprehensive day by day, and can hardly
or components oil or grease all movable parts or be dispensed with in hydraulic and mechanical vehicle
surfaces as required and in compliance with the systems.
compatibility of materials.
Diagnostics according to plan
Well structured trouble shooting procedures can save
time and money.
Random tests have revealed that purely electronic
components or control units only very rarely are the
actual cause of failures:
l In approx. 10 % of the examined cases the prob-
lems were caused by control units.
l In approx. 15 % sensors and actuators were the
cause of the problems.
By far the highest proportion of all faults could be
traced back to wiring and connections (plugs, etc.).
General:
l
Before changing any expensive components, such
as control units, you should run a systematic trouble
shooting session to eliminate any other possible
fault sources. Knowledge in basic electrics is re-
quired for this purpose. If a fault was diagnosed
without having pulled the plug of the control unit or
inspected the wiring, this should be done before
changing any parts.
l
Check for good cable and ground contacts, there-
fore keep all mechanical transition points between
electric conductors (terminals, plugs) free of oxide
and dirt, as far as this is possible.
l
Always use the machine related wiring diagram for
testing. If one or more faults were detected, these
should be corrected immediately.
l
Do not disconnect or connect battery or generator
while the engine is running.
l
Do not operate the main battery switch under load.
l
Do not use jump leads after the battery has been re-
moved.
l Sensors and electric actuators on control units must
never be connected individually or between exter-
nal power sources for the purpose of testing, but
only in connection with the control unit in question.
l
It is not permitted to pull plugs off while the voltage
supply is switched on (terminal 15 "ON")! Switch the
voltage supply "OFF" first and pull out the plug.
l Even with an existing polarity reversal protection in-
correct polarity must be strictly avoided. Incorrect
polarity can cause damage to control units!
14 BOMAG 008 918 12

General repair instructions 1.3
l Plug-in connectors on control units are only dust Battery
and water tight if the mating connector is plugged
on! Control units must be protected against spray Rules for the handling of batteries
water, until the mating connector is finally plugged When removing a battery always disconnect the mi-
on! nus pole before the plus pole. When installing the bat-
l Unauthorized opening of control electronics (Micro- tery connect the minus pole after the plus pole to avoid
controller MC), modifications or repairs in the wiring short circuits.
can cause severe malfunctions. Fasten the terminal clamps with a little force as possi-
l
Do not use any radio equipment or mobile phones ble.
in the vehicle cab without a proper aerial or in the vi- Always keep battery poles and terminal clams clean to
cinity of the control electronics! avoid high transition resistances when starting and
the related development of heat.
Electrics and welding
Make sure the battery is properly fastened in the vehi-
cle.
!Caution
Before starting welding work you should discon-
nect the negative battery pole or interrupt the
electric circuit with the main battery switch, dis-
connect the generator and pull the plugs off all
control units in order to protect the electrical sys-
tem of the machine.
l Disconnect the minus pole of the battery or interrupt
the electric circuit with the main battery switch.
l Isolate the generator and all control units from the
electric circuit.
l Always fasten the earth clamp of the welding unit in
the immediate vicinity of the welding location.
l When choosing the location for the earth clamp
make sure that the welding current will not pass
through joints or bearings.
008 918 12 BOMAG 15

Generator Starter motor

Before removing the generator you must disconnect So-called jump starting (using an additional external
the ground cable from the minus pole of the battery battery) without the battery connected is dangerous.
while the ignition is switched off. Do not disconnect When disconnecting the cables from the poles high in-
the generator while the engine is running, because ductivities (arcs, voltage peaks) may occur and de-
this may cause extremely high voltage peaks in the stroy the electrical installation.
vehicle wiring system ("Load Dump"), which could For purposes like e.g. purging the fuel systems, start-
possibly damage control units, radios or other elec- ers may be operated for maximum 1 minute without
tronic equipment. interruption. Then you should wait for at least 30 min-
When disassembling the battery cable, the B+-nut un- utes (cooling down) until trying again. During the 1
derneath on the generator side may also be loosened. minute starting period this process should not be inter-
This nut must in this case be retightened. rupted.
When connecting e.g. the battery cable to the terminal Starter motors must not be cleaned with high pressure
of the generator you must make sure that the polarity steam cleaning equipment.
is correct (generator B+ to the + pole of the battery). The contacts on starter terminals 30, 45, 50 must be
Mixing up the polarities by mistake causes short cir- protected against unintended shorting (jump protec-
cuit and damage to the rectifier elements - the gener- tion).
ator will be out of function.
When replacing the starter the ring gear on the engine
The generator can only be operated with the battery flywheel must be checked for damage and its number
connected. Under special conditions emergency op- of teeth - if necessary replace the ring gear.
eration without battery is permitted, the lifetime of the
generator is in such cases especially limited. Always disconnect the battery before starting assem-
bly work in the starter area of the engine or on the
Plus and minus cables must be disconnected during starter itself.
rapid charging of the battery or electric welding on the
vehicle.
When cleaning the generator with a steam or water jet
make sure not to direct the steam or water jet directly
on or into the generator openings or ball bearings. Af-
ter cleaning the generator should be operated for
about 1 - 2 minutes to remove any deposits of water
from the generator.
16 BOMAG 008 918 12

Hydraulic system l Perform measurements at operating temperature of
the hydraulic oil (approx. 40 ¯C).
!Caution
l After changing a component perform a high and
charge pressure test, if necessary check the speed
Repair work on hydraulic elements shall only per-
of the exciter shaft.
formed by appropriately trained personnel or by
the after sales service of BOMAG. l The operating pressure of the exciter shaft to a
great extent depends on the base under the vibrat-
Please note ing drum. On hard ground place the drums on a suit-
able base and check the drum pressure. Do not
i Note activate the vibration on a hard, concreted base,
danger of bearing damage.
Cleanliness is of utmost importance. Dirt and other
contaminations must strictly be kept out of the system. l After the completion of all tests perform a test run
and then check all connections and fittings for leaks
l Connections and screw fittings, filler neck covers
with the engine still stopped and the hydraulic sys-
and their immediate surrounding areas must be
tem depressurized.
cleaned before removal.
l Before loosening hoses, pipe lines etc. relieve all Before commissioning
pressure from the system. l Fill the housings of hydraulic pumps and motors
l During repair work keep all openings closed with with hydraulic oil. Use only hydraulic oils according
clean plastic plugs and caps. to the specification in the maintenance instructions.
l Never run pumps, motors and engines without oil or
l
After changing a component flush the hydraulic sys-
hydraulic oil. tem as described in the flushing instructions.
l When cleaning hydraulic components take care not Taking into operation
to damage any fine machine surfaces. l
Bleed the hydraulic circuits.
l Chemical and rubber soluble cleansing agents may l
Start up the hydraulic system without load.
only be used to clean metal parts. Do not let such
substances come in contact with rubber parts.
l
Check the hydraulic oil level in the tank, if neces-
sary top up with hydraulic oil as specified in the op-
l Rinse of cleaned parts thoroughly, dry them with erating and maintenance instructions or drain oil off
compressed air and apply anti-corrosion oil immedi- into a suitable container.
ately. Do not install parts that show traces of corro-
sion. After taking into operation
l Avoid the formation of rust on fine machined caused l
Check fittings and flanges for leaks.
by hand sweat. l
After each repair check all adjustment data, system
l Use new O-rings or seal rings for reassembly. pressures, rotational speeds and nominal values in
l Use only hydraulic oil as sliding agent when reas- the hydraulic system, adjust if necessary.
sembling. Do not use any grease! l
Do not adjust pressure relief valves and control
l Use only the specified pressure gauges. Risk of valves to values above their specified values.
damaging the pressure gauges under too high pres-
sure.
l Check the hydraulic oil level before and after the
work.
l Fill in only clean oil as specified in the maintenance
instructions.
l Check the hydraulic system for leaks, if necessary
find and rectify the cause.
l Before taking new hydraulic components into oper-
ation fill these with hydraulic oil as specified in the
operating and maintenance instructions.
l After changing a hydraulic component thoroughly
flush, refill and bleed the complete hydraulic sys-
tem.
008 918 12 BOMAG 17

Air conditioning system l Damaged or leaking parts of the air conditioning

must not be repaired by welding or soldering, but
Chemicals/ozone layer regulation must generally be replaced.
The chemicals/ozone layer regulation, which became l Do not fill up refrigerant, but extract existing refrig-
effective on 01.12.2006, supplements the still directly erant and refill the system.
applicable regulation (EG) no. 2037/2000 from
29.06.2000 concerning substances, which cause de-
l Different types of refrigerant must not be mixed.
composition of the ozone layer and at the same time Only the refrigerant specified for the corresponding
replaces the previously valid German CFC-halon air conditioning system must be used.
0prohibition from 06.05.1991. l Refrigerant circuits with refrigerant type R134a
Work on air conditioning systems must only be carried must only be operated with the compressor oil / re-
out by persons who: frigeration oil approved for the compressor.
l have proven to have sufficient expert knowledge, l Used compressor oil/refrigeration oil must be dis-
l have the necessary equipment to undertake such posed of in strict compliance with applicable envi-
tasks, ronmental regulations.
l are reliable and l Due to its chemical properties compressor oil / re-
frigeration oil must never be disposed of together
l are not any directives regarding their activities when
with engine or transmission oil.
carrying out inspection and maintenance work acc.
to § 4 section 2 of the chemical/ozone layer regula- l Compressor oil / refrigeration oil is highly hydro-
tion. scopic. Oil cans must strictly be kept closed until
The inspection and maintenance tasks, including leak use. Oil rests should not be used, if the can had
tests and possible repair activities, must be recorded been opened over a longer period of time.
in the operating instructions together with information l
All O-rings/seal rings as well as pipe/ hose fittings
about the refrigerant quantities used and regained, must be oiled with compressor/refrigeration oil bfore
whereby the operator is obliged to keep these records assembly.
over a period of at least five years. l
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil/refrigeration oil
i Note lost by exchanging the components, must be re-
Cleanliness is of utmost importance. Dirt and other placed with fresh oil.
contaminations must strictly be kept out of the system. l
A too high compressor oil / refrigeration oil level ad-
l Tools used on refrigeration circuits must be of ex- versely affects the cooling performance and a too
cellent condition, thus to avoid the damage of any low oil level has a negative effect on the lifetime of
connections. the compressor.
l
During repairs on refrigerant lines and components,
l
Use new O-rings or seal rings for reassembly.
these must be kept closed, as far as this is possible, l
Always used 2 spanners to work on pipes/hoses to
to prevent the system from being contaminated by avoid damages .
air, moisture and dirt. The operational safety of the l Tighten screw fittings with the specified torque.
system can only be assured as long as all compo-
nents in the refrigerant circuit are kept internally l
Check all pipes/hoses, screw fittings or components
clean and dry. for damage, replace if necessary.
l Connections, screw fittings and their immediate sur- l Do not leave the refrigerant circuit unnecessarily
rounding areas must be cleaned before removal. open to the atmosphere.
l Before loosening hoses, pipe lines etc. relieve all l
In case of a repair on the refrigeration system you
pressure from the system. should first evacuate the air conditioning system for
at least 45 minutes to remove any moisture from the
l During repair work keep all openings closed with
system, before you start to refill. Moisture bonded in
clean plastic plugs and caps.
the compressor oil / refrigeration oil (PAG oil) can
l All parts to be reused should be cleaned with a only be removed from the system by changing the
gasoline free solvent and blow-dried with clean oil.
compressed air or dried with a lint-free cloth. l Compressor valves must only be opened after the
l Before opening all components should have system has been properly sealed.
warmed up to ambient temperature, to avoid that l The use of leak detection spray is not permitted. If
damp air is drawn into the component by the differ-
such substances are used the WARRANTY will be-
ence in temperatures.
come null and void.
18 BOMAG 008 918 12

l If the air conditioning system had been opened for Fuel hoses
repair work, a new drier should be installed in the re-
frigerant circuit.
l After completion of repair work screw locking caps
(with seals) on all valve connections service con-
nections.
l Before start up of the air conditioning system after a
new filling: - Turn the compressor approx. 10 revo-
lutions by hand using the clutch or V-belt pulley of
the magnetic clutch. - Start the engine with the com-
pressor/control valve switched off. - Once the idle
speed of the engine has stabilized switch on the
compressor and run it for at least 10 minutes at idle Fig. 1
speed and maximum cooling power.
l Never run the compressor with an insufficient ! Caution
amount of refrigerant. All fuel hoses have two layers of material, a rein-
forced rubber coating outside and an internal Vi-
ton hose. If a fuel hose has come loose one must
make absolutely sure that the internal Viton layer
has not been separated from the reinforced outer
layer. In case of a separation the hose needs to be
replaced.
008 918 12 BOMAG 19

Gaskets and mating surfaces able, you should use a plastic tube or adhesive tape
to prevent the sealing lip from being damaged.
Leaking sealing faces can mostly be traced back to in-
correct assembly of seals and gaskets. l Lubricate the outer rim (arrow 3 (Fig. 2)) of the seal
and press it flat on the housing seat.
l Before assembling a new seal or gasket make sure
that the sealing surface is free of pitting, flutes, cor-
rosion or other damage.
l Inappropriately stored or handled seals (e.g. hang-
ing from hooks or nails) must under no circumstanc-
es be used.
l Assemble seals and gaskets only with sealing com-
pound, grease or oil, if this is specifically specified
in the repair instructions.
l If necessary remove any old sealing compound be-
fore assembling. For this purpose do not use any
tools that could damage the sealing surfaces.
l Sealing compound must be applied thin and evenly
on the corresponding surfaces; take care that the
compound does not enter into oil galleries or blind Fig. 3
threaded bores.
l
Press or knock the seal into the housing, until it is
l
Examine the contact faces for scratches and burrs, flush with the housing surface.
remove these with a fine file or an oilstone; take
care that no grinding dust and dirt enters into
tapped bores or enclosed components. i Note
If possible, use a "bell" (1 (Fig. 3)), to make sure that
l
Blow out lines, ducts and gaps with compressed air,
the seal will not skew. In some cases it may be ad-
replace any O-rings and seals that have been dis-
visable to assemble the seal into the housing first, be-
lodged by the compressed air.
fore sliding it over the shaft. Under no circumstances
Assembly of radial seals should the full weight of the shaft rest on the seal.
If you have no proper service tools at hand, use a suit-
able drift punch with a diameter which is about 0,4 mm
smaller than the outer diameter of the seal. Use VERY
LIGHT blows with the hammer if no press is available.
Fig. 2
l
Lubricate the sealing lips (2) (Fig. 2) with clean
grease; in case of double seals fill the space be-
tween the sealing lips with a generous amount of
grease.
l
Slide the seal over the shaft, with the lip facing to-
wards the fluid to be sealed.
i Note
If possible, use an assembly sleeve (1 (Fig. 2)), to
protect the lip from being damaged by sharp edg-
es, threads or splines. If no assembly sleeve is avail-
20 BOMAG 008 918 12

Feather keys and keyways Ball and roller bearings
Caution
! !Caution
Feather keys may only be reused if they are free of Ball and roller bearings may only be reused if they
damage. are free of damage and do not show any signs of
wear.
Fig. 4
l Clean and thoroughly examine the feather key.
l Deburr and thoroughly clean the edges of the key-
way with a fine file before reassembling.
Fig. 5
l If a ball or roller bearing of a bearing pair shows de-
fects, both ball or roller bearings need to be re-
placed.
l
Remove any lubricant residues from the ball or roll-
er bearing to be examined by washing it with gaso-
line or any other appropriate degreasing agent.
Ensure strict cleanliness.
l
Check balls or rollers, running surfaces, outer faces
of outer races and inner faces of inner races for vis-
ible damage. Replace the ball or roller bearing if
necessary.
l
Check the ball or roller bearing for clearance and re-
sistance between the inner and outer races, replace
if necessary.
l
Lubricate the ball or roller bearing with the recom-
mended type of grease before assembly or reas-
sembly.
l
On greased bearings (e.g. wheel bearings) fill the
space between ball or roller bearing and outer seal
with the recommended type of grease before as-
sembling the seal.
008 918 12 BOMAG 21

l Check shaft and bearing housing for discolouration Screws and nuts
or other signs of movement between ball or roller
bearing and seats. Tightening torque
l Make sure that shaft and housing are free of burrs
before assembling the ball or roller bearing. !Caution
l Always mark the individual parts of separable ball or Tighten nuts or screws with the tightening tor-
roller bearings (e.g. taper roller bearings) to enable ques specified in the following tables of tighten-
correct reassembling. Never assemble the rollers to ing torques. Tightening torques deviating from
an outer race that has already been used, replace the ones in the table are specially mentioned in
the complete ball or roller bearing instead. the repair instructions.
Damaged screws must under no circumstances
be used any longer. Recutting threads with thread
cutters or taps adversely affects the strength and
leak tightness of the screw joint. Damaged or cor-
roded thread pitches can cause incorrect torque
value readings.
Self-locking nuts must generally be replaced after
disassembly.
The use of screws with too high strength can
cause damage!
l Nut of a higher strength can generally be used in-
Fig. 6
stead of nuts of a lower strength classification.
l When checking or retightening screw joints to the
!Caution
specified tightening torque you should first relieve
When assembling the ball or roller bearing to the by a quarter turn and then tighten to the correct
shaft load must only be applied to the inner race 1 torque.
(Fig. 6).
l Before tightening you should lightly oil the thread, in
When fitting the bearing into the housing load order to ensure low friction movement. The same
must only be applied to the outer race (2). applies for self-locking nuts.
l Make sure that no oil or grease will enter into blind
tapped bores. The hydraulic power generated when
turning in the screw could cause breakage of the ef-
fected part.
22 BOMAG 008 918 12

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

6, 8, 10, 12)
Fig. 8 Identification of nuts

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

nut screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
Fig. 7 Identification of screws 6 6.8
8 8.8
Example: A screw is identified with 12.9.
9 9.8
The first number corresponds with 1/100 of the nomi- 10 10.8
nal tensile strength (minimum tensile strength) in N/ 12 12.8
mm2.
Nuts for screw joints with limited load factor (04,
l
The nominal tensile strength is 12 X 100 N/mm2 = 05)
1200 N/mm2.
The preceding "0" indicates that, due to their low
The second number specifies 10-times the ration be- height, nuts 2 (Fig. 8) in this group are only able to
tween lower yield point and nominal tensile strength withstand the force of a screw to a limited extent.
(yield point ratio). Nut height below 0,8 d (d = nominal dimension).
Nuts for screw joints without specified load factor

i Note
(11H, 14H, 17H, 22H)
When exceeding the lower yield point, the material will
return to its original shape when being relieved (plas- This standard contains strength classes (hardness
tic deformation). classes) for nuts 3 (Fig. 8), for which no load values
can be specified, e.g. because of their shape and di-
When exceeding the upper yield point the material will mensions, but which can only be classified by their
not restore its original shape after being relieved. hardness.
l The lower tensile strength is 9/10 X 1200 N/mm2 = Nut height below 0,5 d (d = nominal dimension).
1080 N/mm2.
i Note
However, these values are by no means identical with
the tightening torques, which are to be set on a torque
wrench. The corresponding calculation requires a
higher effort and, in the end, depends on the materials
to be bolted together.
008 918 12 BOMAG 23

Identification in clock system Identification of UNF-threads
Fig. 9 Identification of nuts in clock system

For small nuts (Fig. 9) the clock system can be used
for identification.
l The 12 o'clock position is identified by a dot or the
manufacturer's symbol.
l
The strength class is identified by a dash (b).
Fig. 10
Screws
The screw head is marked with a stamped in, round
cavity 3 (Fig. 10).
Nuts
An uninterrupted series of stamped in circles parallel
to the axis of the nut on a hexagon area (2).
Studs and brake rods

At the outmost end a short end of the component is re-
duced to its core diameter (1).
24 BOMAG 008 918 12

Cotter pins
Fig. 11
In places where cotter pins are used, these must be
reassembled. Cotter pins must generally be renewed
after disassembly.
Cotter pins must be assembled as shown in the illus-
tration, unless specified differently.
008 918 12 BOMAG 25

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

l black oiled
l with surface protection A4C
l with surface protection DACROMET
i Note
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with metric unified thread*
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M4 3 5 5
M5 6 9 10
M6 10 15 18
M8 25 35 45
M10 50 75 83
M12 88 123 147
M14 137 196 235
M16 211 300 358
M18 290 412 490
M20 412 578 696
M22 560 785 942
M24 711 1000 1200
M27 1050 1480 1774
M30 1420 2010 2400
* Coefficient of friction μ tot. = 0,14
Tightening torques for screws with metric unified fine thread*
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
26 BOMAG 008 918 12

Tightening torques 1.4
Tightening torques for screws treated with anti-seizure paste OKS 240* (copper paste)
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 X 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
3/4“ - 10 UNC 276 388 464
3/4“ - 16 UNC 308 432 520
* Anti-seizure paste (copper paste) is used for the assembly of screw connections, which are exposed to high temperatures and corrosive
effects. Prevents seizure and corrosion.
Tightening torques for wheel nuts (fine thread) * **
Thread diameter
10.9
M12x1.5 100
M14x1.5 150
M18x1.5 300 - 350
M20x1.5 400 - 500
M22x1.5 500 - 600
** These values result in a 90% utilization of the yield point
008 918 12 BOMAG 27

The values specified in the table apply for screws:

l black oiled
l with surface protection A4C
l with surface protection DACROMET
i Note
The difference between Withworth and UNF/UNC threads is the fact that UNF and UNC threads have 60° flanks,
as the metric ISO-thread, whereas Withworth has a flank of only 55°.
DACROMET is a surface protection that mainly consists of zinc and aluminium in a chromium oxide matrix. DAC-
ROMETIZATION provides excellent corrosion protection for metal surfaces by applying a mineral coating with
metallic-silver appearance.
Tightening torques for screws with UNC thread, * UNC Unified Coarse Thread Series, American Unified
Coarse Thread
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, * 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
28 BOMAG 008 918 12

Tightening torques 1.4
Tightening torques for screws with UNF thread, * UNF Unified National Fine Thread Series, American
Unified Fine Thread
Screw dimension
8.8 10.9 12.9
1“ - 12 930 1300 1600
1 1/8“ - 12 1350 1900 2300
1 1/4“ - 12 1900 2700 3200
1 3/8“ - 12 2600 3700 4400
1 1/2“ - 12 3300 4600 5600
008 918 12 BOMAG 29

30 BOMAG 008 918 12

2 Technical data
008 918 12 BOMAG 31

2.1 Technical data
2.1 Technical data
Fig. 12
Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 216 D-40 2960 2300 1500 2268 2985 490 5930 85 85 35 2130
BW 216 PD-40 2960 2300 1480 2268 2985 490 5930 85 85 25 2130
* BW 216 D-40 BW 216 PD-40
Weights
Max. operating weight kg 17100 16400
Max. axle load, drum (CECE) kg 11700 11000
Max. axle load, wheels (CECE) kg 5400 5400
Operating weight (CECE) kg 15200 15700
Axle load, drum (CECE) kg 10200 10700
Axle load, wheels (CECE) kg 5000 5000
Max. static linear load (CECE) kg/cm 54.9 -
Travel characteristics
Travel speed (1) km/h 0 ... 4 0 ... 4
Travel speed (2) km/h 0 ... 5 0 ... 5
Travel speed (3) km/h 0 ... 7 0 ... 7
Travel speed (4) km/h 0 ... 11 0 ... 11
Max. gradability without/with vibration (soil de- % 48/45 50/47
pendent)
Drive
Engine manufacturer Deutz Deutz
Type BF4M 1013 C BF4M 1013 C
Cooling Water Water
Number of cylinders 4 4
Rated power DIN ISO 3046 kW 114 114
Rated power SAE J 1995 hp 153 153
Rated speed rpm 2200 2200
Fuel Diesel Diesel
Electrical equipment V 12 12
Drive system hydrostatic hydrostatic
Driven axles 2 2
Permissible ambient temperatures °C -20 ... +50 -20 ... +50
32 BOMAG 008 918 12

Technical data 2.1
*
BW 216 D-40 BW 216 PD-40
Brakes
Service brake hydrostatic hydrostatic
Parking brake hydr.-mech. hydr.-mech.
Steering
Type of steering articulated articulated
Steering operation hydrostatic hydrostatic
Steering/oscillation angle ±° 35/12 35/12
Inner track radius mm 3494 3494
Vibration
Drive system hydrostatic hydrostatic
Frequency (1/2) Hz 30/36 30/36
Amplitude (1/2) mm 1.80/0.90 1.70/0.86
Centrifugal force (1/2) kN 275/202 275/202
Tires
Tire size 23.1-26/12PR TL C7 23.1-26/12PR TL R1
Air pressure bar 1.4 1.4
Filling capacities
motor l approx. 14 approx. 14
Fuel l approx. 250 approx. 250
Hydraulic oil l approx. 60 approx. 60
Coolant l approx. 16 approx. 16
* The right for technical modifications remains reserved
008 918 12 BOMAG 33

2.1 Technical data
Fig. 13
Dimensions in A B D H H2 K L O1 O2 S W
mm
BW 218 D-40 2960 2480 1500 2268 2985 490 5930 175 175 35 2130
*
BW 218 D-40
Weights
Max. operating weight kg 19100
Max. axle load, drum (CECE) kg 13400
Max. axle load, wheels (CECE) kg 5700
Operating weight (CECE) kg 17200
Axle load, drum (CECE) kg 12000
Axle load, wheels (CECE) kg 5200
Static linear load (CECE) kg/cm 56.3
Max. static linear load (CECE) kg/cm 62.9
Travel characteristics
Travel speed (1) km/h 0 ... 4
Max. gradability without/with vibration % 48/45
(soil dependent)
Drive
Engine manufacturer Deutz
Type BF4M 1013 EC
Cooling Water
Number of cylinders 4
Rated power DIN ISO 3046 kW 114
Rated power SAE J 1995 hp 153
Rated speed rpm 2200
Fuel Diesel
Electrical equipment V 12
Drive system hydrostatic
Permissible ambient temperatures °C -20 ... +50
Brakes
34 BOMAG 008 918 12

Technical data 2.1
*
BW 218 D-40
Service brake hydrostatic
Parking brake hydr.-mech.
Steering
Type of steering Oscill.-articul.
Steering operation hydrostatic
Vibration
Vibrating drum 1
Drive system hydrostatic
Frequency (1/2) Hz 30/36
Amplitude (1/2) mm 1.80/0.90
Centrifugal force (1/2) kN 275/202
Tires
Tire size 23.1-26/12PR TL C7
Air pressure, nominal value bar 1.4
Air pressure, span bar 0.8 - 1.4
Filling capacities
motor l approx. 14
Fuel l approx. 250
Hydraulic oil l approx. 60
Coolant l approx. 16
* The right for technical modifications remains reserved
Additional engine data

Combustion principle 4-stroke diesel
Low idle speed rpm 900 ± 200
High idle speed rpm 2430 ± 50
Specific fuel consumption g/kWh 235
Valve clearance intake mm 0.3
Valve clearance exhaust mm 0.5
Injection valves opening pressure bar 275
Starter power kW 3.1
Travel pump
Manufacturer Sauer
Type 90R075
System Axial piston/swash plate
Max. displacement cm3/rev 75
Max. flow capacity l/min 163.65
High pressure limitation bar 420 + 20
Charge pressure, high idle bar 26 + 3
Drum reduction gear

Type CR31
Transmission ratio 45.6
Drum drive motor

Manufacturer Sauer
Type 51C 110
System Axial piston – bent axle
Displacement (stage 1) cm3/rev 110
008 918 12 BOMAG 35

2.1 Technical data
Displacement (stage 2) cm3/rev 39

Perm. leak oil rate l/min 2
Flushing rate l/min 16
Flushing limitation bar 16
Axle drive motor

Manufacturer Sauer
Type 51D 110
System Axial piston – bent axle
Max. displacement (stage 1) cm3/U 110
Min. displacement (stage 2) cm3/U 39
Perm. leak oil rate l/min 2
Flushing limitation bar 16
Vibration pump (BW216 D/PD-40)

Manufacturer Sauer
Type 42R 041
Starting pressure bar 350 + 50
Operating pressure (soil dependent) bar approx. 100
Vibration pump (BW218 D-40)

Manufacturer Sauer
Type 42R 055
Starting pressure bar 350 + 50
Operating pressure (soil dependent) bar approx. 100
Vibration motor (BW216 D/PD-40)

Manufacturer Bosch-Rexroth
Type A10FM45
Displacement cm3/U 45
Flushing pressure limitation bar 13
Vibration motor (BW218 D-40)

Manufacturer Sauer
Type 90M 055
Displacement cm3/U 45
Flushing pressure limitation bar 13
Steering/charge pump
Type HY/ZFFS11/16
System Gear pump
Displacement cm3/rev 16
Max. steering pressure when bar 200 + 20
steered against end stops
36 BOMAG 008 918 12

Technical data 2.1
Steering valve
Manufacturer Danfoss
Type OSPC 500 ON
System Rotary spool
Rear axle
Manufacturer Dana
Type CHC 193/66LD
Differential No-Spin
Degree of locking % 100
Reduction ratio 65.08
008 918 12 BOMAG 37

2.1 Technical data
38 BOMAG 008 918 12

3 Maintenance
008 918 12 BOMAG 39

3.1 General notes on maintenance
3.1 General notes on maintenance Notes on the performance of the engine

On diesel engines both combustion air and fuel injec-
When performing maintenance work always comply
with the appropriate safety regulations. tion quantities are thoroughly adapted to each other
and determine power, temperature level and exhaust
Thorough maintenance of the machine guarantees far gas quality of the engine.
longer safe functioning of the machine and prolongs
If your engine has to work permanently in "thin air" (at
the lifetime of important components. The effort need-
higher altitudes) and under full load, you should con-
ed for this work is only little compared with the prob-
sult the customer service of BOMAG or the customer
lems that may arise when not observing this rule.
service of the engine manufacturer.
The terms right/left correspond with travel direction
forward.
Notes on the cooling system
l Support the engine hood for all maintenance and
Prepare and check coolant with highest care, since
repair work.
otherwise the engine may be damaged by corrosion,
l Always clean machine and engine thoroughly be- cavitation and freezing.
fore starting maintenance work.
Coolant is prepared by adding an ethylene-glycol
l For maintenance work stand the machine on level based anti-freeze agent with corrosion inhibiting prop-
ground. erties to the cooling water.
l Perform maintenance work only with the motor Mixing with cooling system protection agent is neces-
switched off. sary in all climatic zones. It prevents corrosion, lowers
the freezing point and raises the boiling point of the
l
Relieve hydraulic pressures before working on hy-
coolant.
draulic lines.
l
Before working on electric parts of the machine dis- Notes on the hydraulic system
connect the battery and cover it with insulation ma-
terial. During maintenance work on the hydraulic system
cleanliness is of major importance. Make sure that no
l
When working in the area of the articulated joint at- dirt or other contaminating substances can enter into
tach the articulation lock (transport lock). the system. Small particles can produce flutes in
valves, cause pumps to seize, clog nozzles and pilot
Environment bores, thereby making expensive repairs inevitable.
During maintenance work catch all oils and fuels l
If, during the daily inspection of the oil level the hy-
and do not let them seep into the ground or into draulic oil level is found to have dropped, check all
the sewage system. Dispose of oils and fuels en- lines, hoses and components for leaks.
vironmentally. l
Seal external leaks immediately. If necessary in-
Keep used filters in a separate waste container form the responsible customer service.
and dispose of environmentally. l
Do not store drums with hydraulic oil outdoors, or at
Catch biodegradable oils separately. least under a cover. Water can be drawn in through
the bunghole when the weather changes.
Notes on the fuel system l We recommend to use the BOMAG filling and filter-
The lifetime of the diesel engine depends to a great ing unit with fine filter to fill the system. This ensures
extent on the cleanliness of the fuel. finest filtration of the hydraulic oil, prolongs the life-
time of the hydraulic oil filter and protects the hy-
l Keep fuel free of contaminants and water, since this draulic system.
will damage the injection elements of the engine.
l
Clean fittings, filler covers and the area around such
l Drums with inside zinc lining are not suitable to parts before disassembly to avoid entering of dirt.
store fuel.
l Do not leave the tank opening unnecessarily open,
l When choosing the storage place for fuel make but cover it so that nothing can fall in.
sure that spilled fuel will not harm the environment.
l Do not let the hose stir up the slurry at the bottom of
the drum.
l
The fuel drum must rest for a longer period of time
before drawing off fuel.
l The rest in the drum is not suitable for the engine
and should only be used for cleaning purposes.
40 BOMAG 008 918 12

Fuels and lubricants 3.2
3.2 Fuels and lubricants
Engine oil
Quality
For use in DEUTZ engines the lubrication oils are
classified in DEUTZ Lubrication Oil Quality Classes
(DQC).
Approved engine oils
Deutz ACEA* API** DHD
DQC II-05 E3-96, CG-4, DHD-1

E5-02, CH-4,
E7-08, CI-4,
E4-07 CI-4 Plus
DQC II-05 - - -
DQC IV-05 - - -
* Association des Constructeurs European d’Automobiles
** American Petroleum Institute
The list of approved lubrication oils is also available in

the Internet under the following address:
www.deutz.com
Fig. 14
de >>SERVICE >> Fuels and lubricants and Optimal operating conditions can be achieved by us-
diagnostics >> DeutzQualityClass >> ing the oil viscosity chart (Fig. 14) as a reference.
DQC-Release list
At ambient temperatures below -40 °C the lubrication
en >>SERVICE >> Fuels and lubricants and oil must be pre-heated (e.g. by parking the machine
diagnostics >> DeutzQualityClass >>DQC- indoors).
release list The viscosity is classified acc. to SAE. Multi-purpose
oils should generally be used.
Consult your local service station if in doubt.
Oil change intervals
l Use winter grade engine oil for winter operation!
The longest permissible time a lubrication oil should
Oil viscosity remain in an engine is 1 year. If the following oil
Since lubrication oil changes its viscosity with the tem- change intervals are not reached over a period of 1
perature, the ambient temperature at the operating lo- year, the oil change should be performed at least once
cation of the engine is of utmost importance when per year, irrespective of the operating hours reached.
choosing the viscosity class (SAE-class) . DQC II, DQC
Too high viscosity can cause starting difficulties, too III, DQC IV= 500 operating hours
low ´viscosity can jeopardize the lubrication effect and
result in a high lubrication oil consumption. ! Caution
When using fuels with a sulphur content of more
than 0,5% to 1% or under permanent ambient tem-
peratures below -10°C and when using biodegrad-
able diesel fuel the oil change intervals must be
halved.
Fuels
You should only use commercially available brand
diesel fuel with a sulphur content of less than 0.5%
and ensure strict cleanliness when filling in. A higher
008 918 12 BOMAG 41

3.2 Fuels and lubricants
sulphur content has a negative effect on the oil

change intervals. Fresh water analysis values
The fuel level should always be topped up in due time Conversion to other units:
so that the fuel tank is never run dry, as otherwise filter
and injection lines need to be bled. - German degree (°dH)] max. 20
Quality - English degree (°eH)] max. 25

The following fuel specifications are permitted: - French degree (°fH)] max. 36.5
l
EN 590
corresponds with the content of max. 356
l
DIN 51628 CaCO3 (mg/l) (ppm)
l
ASTM D975 Grade-No. 1-D and 2-D.
l
JIS K 2204 Grade Fuel 1 and Grade Fuel 2 with lu- Information concerning the water quality can be ob-
brication properties acc. to EN 590 tained from the waterworks.
Winter fuel If the fresh water analysis values are unknown, these
must be determined with the help of a water analysis.
For winter operation use only winter diesel fuel, to
avoid clogging because of paraffin separation. Diesel If the values of the analysis deviate, the water must be
fuels suitable for temperatures down to -44 °C (-47 treated accordingly.
°F) are available for Arctic climates. At very low tem- l pH-value too low
peratures disturbing paraffin separation can also be Adding of caustic lye of soda or caustic potash so-
expected when using winter diesel fuel. lution.
The admixture of petroleum and the addition of "flow l
Water hardness too high:
enhancing additives" (fuel additives) is not permitted. Mix with soft, distilled or fully demineralized water
l
Chlorides and/or sulphates too high:
Coolant Mix with distilled or fully demineralized water
For fluid cooled engines the cooling fluid must be pre- l
Total hardness or carbonate hardness too low:
pared by admixing a cooling system protection agent Mix with hardened water (harder water is in most
to the fresh water and should be checked within the cases available in the form of drinking water).
specified maintenance intervals.
This prevents damage caused by corrosion, cavita-
!Caution
tion, freezing and overheating.
Another analysis must be made after the fresh wa-
Fresh water quality ter has been prepared.
The correct quality of water is highly important when
Cooling system protection agent
preparing coolant. Clear and clean water within the
boundaries of the following analysis values should As a protection against frost, corrosion and boiling
generally be used. point anti-freeze agents must be used under any cli-
matic conditions.
Coolant for fluid cooled engines is prepared by adding
Fresh water analysis values an ethylene-glycol based anti-freeze agent with corro-
sion inhibiting properties to the cooling water.
pH-value at 20 °C (68 °F) 6.5 - 8.5
We therefore highly recommend our BOMAG cooling
Chloride ion content (mg/l) (ppm) max. 100 system protection agent.
Sulphate ion content (mg/l) max. 100 If our cooling system protection agent is not available
(ppm) for any important reasons, you may, in exceptional
cases, use products that have been approved by the
Water hardness (ion content of max. 3.56 engine manufacturer.
calcium and magnesium )
The list of approved cooling system protection agents
(mmol/l)]
is also available in the Internet under the following ad-
dress:
42 BOMAG 008 918 12

Fuels and lubricants 3.2
Mineral oil based hydraulic oil
www.deutz.com The hydraulic system is operated with hydraulic oil HV
46 (ISO) with a kinematic Viskosität von 46 mm2/s bei
de >>SERVICE >> Betriebsstoffe und Addi- 40 °C und 8 mm2/s bei 100 °C betrieben. For topping
tive >> Kühlsystemschutz >> Kühlsystem- up or for oil changes use only high-quality hydraulic
schutz Technisches Rundschreiben oil, type HVLP according to DIN 51524, part 3, or hy-
draulic oils type HV according to ISO 6743/3. The vis-
en >>SERVICE >> Operating Liquids and Ad- cosity index (VI) should be at least 150 (observe
ditives >> Cooling System Conditioner >> information of manufacturer).
Flyer Cooling System Conditioner Techni-
cal Circular
Bio-degradable hydraulic oil
Products of the same product group (see Deutz Tech- The hydraulic system can also be operated with a syn-
nical Circular Cooling System Protection Agents) can thetic ester based biodegradable hydraulic oil.
be mixed with each other. The biologically quickly degradable hydraulic oil Pan-
The BOMAG cooling system protection agent corre- olin HLP Synth.46 meets all demands of a mineral oil
sponds with product group A. based hydraulic oil according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.46
! Caution always use the same oil to top up.
Do not mix different coolants and additives of any When changing from mineral oil based hydraulic oil to
other kind. an ester based biologically degradable oil, you should
consult the lubrication oil service of the oil manufactur-
Before changing the product you must clean the er for details.
entire cooling system.
Consult your local service station if in doubt.
! Caution
To ensure proper corrosion protection you must use Check the filter more frequently after this change.
the cooling system protection agent all year around,
whereby the following concentration must not be fall- Perform regular oil analyses for content of water
en short of or exceeded. and mineral oil.
Replace the hydraulic oil filter element every 500
operating hours.
Mixing ratio
Cooling sys- Fresh water Cold protec- Oil for drive axle
tem protection tion down to Quality
agent
Forthe drive axle use only multi-purpose gear oils of
min. 35% 65% -22 °C (-8 °F) API-GL5-class, SAE 90.
This is a hypoid lubricant of highest quality class for
40% 60% -28 °C (-18 °F)
extremely loaded transmissions.
45% 55% -35 °C (-31 °F) The additives in this oil ensure low wear lubrication
under all operating conditions.
max. 50% 50% -41 °C (-42 °F)
Lubrication grease
! Caution
For lubrication purposes use an EP-high pressure
A proportion of more than 50% of cooling system grease, lithium saponified (penetration 2), acc. to DIN
protection agent causes a drop in cooling power. 51502 KP 2G.
The use of corrosion protection oils as cooling
system protection agents is not permitted.
i Note
When working at temperature below -41 °C(-42 °F)
you should consult our local service representative.
Environment
Coolant must be disposed of environmentally.
008 918 12 BOMAG 43

3.3 Table of fuels and lubricants
3.3 Table of fuels and lubricants
Assembly Fuel or lubricant Quantity
Summer Winter Attention

Observe the level marks
Engine
- Engine oil ACEA: E3-96, E5-02, E7-08, E4-07 approx. 14 litres

API: CG-4, CH-4, CI-4, CI-4 Plus
SAE 10W-40 (-15 °C to +40 °C)
SAE 15W-40 (-5 °C to +40 °C)
SAE 5W-40 (-30 °C to +40 °C)
- Fuel Diesel Winter diesel fuel approx. 300 litres
- Coolant Mixture of water and anti-freeze agent* approx. 16 litres
Hydraulic system Hydraulic oil (ISO), HV46, kinem. Viscosity approx. 60 litres
46 mm2/s at 40 °C with viscosity index (VI) >150 or
ester based biodegradable hydraulic oil
Vibration bearings SAE 15W-40 approx. 2 x 1.0 litres
Drive axle SAE 90, API GL5 approx. 11 litres
Wheel hubs SAE 90, API GL5 approx. 2 litres (per side)
Axle reduction gear SAE 90, API GL5 approx. 1.9 litres
Drum drive reduction gear SAE 90, API GL5 approx. 3.2 litres
Tires Water approx. 295 litres
Calcium chloride (CaCl2) or magnesium chloride approx. 100 kg

(MgCl2)
Air conditioning system Refrigerant R134a approx. 1500 g

* see chapter "Fuels and Lubricants - Colant"
44 BOMAG 008 918 12

Running-in instructions 3.4
3.4 Running-in instructions
The following maintenance work must be per-
formed when running in new machines or over-
hauled engines:
! Caution
Up to approx. 250 operating hours check the en-
gine oil level twice every day.
Depending on the load the engine is subjected to,
the oil consumption will drop to the normal level
after approx. 100 to 250 operating hours.
After a running-in time of 30 minutes

l Retighten the V-belt
After 250 operating hours

l Retighten bolted connections on intake and exhaust
tubes, oil sump and engine mounts.
l Retighten the bolted connections on the machine.
l Retighten all wheel fastening screws with the spec-
ified tightening torque.
l Change engine oil and oil filter
l 1. Oil change vibration bearings
l Oil change in drive axle
l Oil change in wheel hubs
l Oil change, axle reduction gear
l 1. Oil change in drum drive reduction gear
After 500 operating hours

l 2. Oil change vibration bearings
l
Choose 2nd Oil change in drum drive reduction
gear
008 918 12 BOMAG 45

3.4 Running-in instructions
46 BOMAG 008 918 12

4 Caddy wiring diagrams
008 918 12 BOMAG 47

4.1 Understanding circuit diagrams

Wiring diagrams are graphical representations of circuitry conditions, related to the electrical system. They do
not contain any information about the actual type of wiring, they only serve the purpose of visualizing the circuitry
logics.
The wiring diagram is indispensable for effective and systematic trouble shooting in the vehicle wiring system.
This plan provides the following information:
l Number and type of individual elements in the examined electric circuit, such as plug connectors, fuses,
switches, consumers, relays, ...
l The sequence in which current flows through the individual elements in the electric circuit.
l Connections between the examined, faulty electric circuit and other circuits in the vehicle wiring system.
l Pin assignment of plug-and-socket connections.
Structure
l Table of contents (Fig. 15)
l Function groups (Fig. 16)
l List of components (Fig. 18)
48 BOMAG 008 918 12

Understanding circuit diagrams 4.1
Table of contents (Fig. 15)
The table of contents lists all function groups.
Fig. 15 Table of contents
Example:
Function group "Warning systems“, drawing number XXX XX can be found on page no. 8.
008 918 12 BOMAG 49

Function groups (Fig. 16)

On the individual pages the electric circuits are combined to function groups.
Arrangement of current paths

The individual current paths must be read as follows:
l From top (plus potential) to bottom (minus potential).
l From left to right.
l From function group to function group.
l Via cross references for potentials and relays.
Fig. 16 Function groups
Potential cross references

Potential cross references serve the purpose of tracking signals, which are transmitted from one function group
to another.
Example:
Potential "15" on page no. 6 is continued to the left on page no. 4 in current path "10" and to the right on page
no. 8 in current path "1“.
Relay cross reference

Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing
contacts.
A mimic diagram with information about the contact types of a relay and their positions in the wiring diagram is
additionally attached to the bottom of each contactor coil.
Example:
The coil of relay (K99) is located on page no. 8 in current path "6".
The mimic diagram under the relay informs that a change-over switch with contact types 30, 87 and 87a is trig-
gered.
The changeover contact can be found on page no. 8 in current path "3".
50 BOMAG 008 918 12

Understanding circuit diagrams 4.1
Current paths
The pages of a circuit diagram are sub-divided into current paths (Fig. 17) (0 ..... 20).
Fig. 17 Current paths
008 918 12 BOMAG 51

List of components (Fig. 18)

Here you find all components used in alphabetical order, related to the name of the component (A01, A02....).
Fig. 18 List of components
Component cross references

Example:
The warning horn "B 11" is located on page no. 8 in current path 3.
52 BOMAG 008 918 12

Circuit symbols in the circuit diagram 4.2
4.2 Circuit symbols in the circuit diagram
Circuit symbol
l Circuit symbols are standardized representations for electrical appliances. They serve the purpose of a sim-
plified 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 Commis-
sion). The standardization serves the purpose of global understanding and fault free connection of appliances,
especially in automobile repairs. Since the wiring diagram is intended to show only the most essential aspects,
the circuit symbol only shows as much of the function, as is needed for easy recognition and for the avoidance
of mistakes.
Fig. 1 Example: Circuit symbol

1 Current source
2 Conductor
3 Switch
4 Ground
5 Filament lamp
6 Filament lamp with two luminous elements
7 Voltmeter
8 Amperemeter
9 Resistance
10 Backup
11 Line connection (fixed)
12 Line connection (separable)
008 918 12 BOMAG 53

4.3 Identification of switch blocks in the Caddy wiring diagram
4.3 Identification of switch blocks in the Caddy wiring diagram
Switches of modular design

l For normally open contacts the contact symbols "_3/_4" are used.
l For normally closed contacts the contact symbols "_1/_2" are used.
In combination with the contact block numbering described above each individual connection is clearly defined.
Example of terminal designations
Fig. 2 Terminal designations

l
Normally open contact 23 located on block 2
l
l
Normally closed contact 12 located on block 1
l
Normally closed contact 11 located on block 1
l
l Normally open contact 33 located on block 3
l
l
l Normally open contact 43 located on block 4
l
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 unchanged.
54 BOMAG 008 918 12

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

tion
A Interval switch, indicator relay, modules, electronic component
B Pressure, pressure differential, temperature switches and sensors, transducers
C Capacitor
E Headlights, heater, air conditioning condenser
F Fuses
G Battery, generator
H Control lights, warning buzzer, warning light
K Relays
M Starter, pumps, motors
P Operating hour meter, general gauges
R Transducers, resistors
S Switches, momentary contact switches
V Diode
X Terminal
Y Solenoid valves
008 918 12 BOMAG 55

4.5 Terminal designations in wiring diagram

l For easier connection work almost every connection on a consumer or switch used in a motor vehicle has a
terminal designation. In Germany the designation of the individual connection terminals is determined by the
standard DIN 72552. The following table shows some examples from this DIN standard.
Terminal designation Meaning
15 Switch plus (after battery) : Output of ignition switch

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

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

31a Battery changeover relay 12V / 24V return line to battery 2 minus
31b Return line to battery minus or ground via switch or relay (switched minus)
31c Battery changeover relay 12V / 24V return line to battery 1 minus
49 Input flasher relay

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

50a Battery changeover relay, output for starter control
53 Wiper motor input (+)

53a Wiper motor (+) end limit shut down
53b Wiper shunt winding
56 Head light
56a Head light, travel light and travel light control
56b Head lights, dimmed head light
56d Head lights, flash light
57 Parking light for motor cycles (abroad also for cars and trucks)
57a Parking light
57L Parking light left
57R Parking light right
58 Side lights, tail light, number plate light, dashboard light

58b Tail light changeover for single axle trailers
58c Trailer plug for single core wired and trailer fused tail light
58d Adjustable dashboard light, tail light and side light
58L Side light, left
58R Side light, right
61 Generator control
75 Radio, cigarette lighter
76 Loudspeaker
87 Relay contact on breaker and two-way contact, input
56 BOMAG 008 918 12

Terminal designations in wiring diagram 4.5
87a Relay contact on breaker and two-way contact, output 1 (breaker side)
87b Relay contact on breaker and two-way contact, output 2
87c Relay contact on breaker and two-way contact, output 3
87z Relay contact on breaker and two-way contact, input 1
87y Relay contact on breaker and two-way contact, input 2
87x Relay contact on breaker and two-way contact, input 3
88 Relay contact for maker

88a Relay contact on maker and two-way contact, (maker side) output 1
88b Relay contact on maker and two-way contact, (maker side) output 2
88c Relay contact on maker and two-way contact, (maker side) output 3
88z Relay contact on maker, input 1
88y Relay contact on maker, input 2
88x Relay contact on maker, input 3
B+ Battery positive
B- Battery minus
D+ Dynamo Plus
D- Dynamo Minus
DF Dynamo field (generator excitation current)
DF1 Dynamo field 1 (generator excitation current)
008 918 12 BOMAG 57

58 BOMAG 008 918 12

5 E-Plan wiring diagrams
008 918 12 BOMAG 59

5.1 Understanding wiring diagrams
Electric circuit diagrams

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

l Cover sheet, see section "Cover sheet"
l Table of contents, see section "Table of contents"
l Structuring symbol overview, see section "Structuring symbol overview"
i Note
The structuring symbol overview is NOT present in circuit diagrams, which are sorted by systems and local iden-
tification!
l Sheets with illustration of function, see section"Sheets with illustration of function"
l List of fuels and lubricants, see "List of fuels and lubricants"
l Terminal strip overview, see section "Terminal strip overview"
l Plug overview, see section "Plug overview"
l Pin overview, see section "Pin overview"
60 BOMAG 008 918 12

Understanding wiring diagrams 5.1
Cover sheet
The cover sheet, see example (Fig. 3), contains general information.
Fig. 3 Example: Cover sheet
008 918 12 BOMAG 61

Table of contents
The table of contents, see example (Fig. 4), lists the individual functions and identifies the corresponding sheets
in the wiring diagram.
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Fig. 4 Example: Table of contents
62 BOMAG 008 918 12

Sheets with representations of functions
l
The main reading direction is sheet by sheet, from top to bottom and from left to right.
l All sheets are successively numbered.
l BOMAG used the resolved type of representation. In this case parts and components with different functions,
which belong to the same components (e.g. relay coil and relay contact), can be represented on different
sheets. Cross-references, which refer to the sheet and current path, serve as linkage between these partial
components (Fig. 5).
Structuring symbols
Relay cross-reference Potential cross-reference
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Mimic diagram of relay Current paths

Fig. 5 Example: Sheet with functions
Current paths (Fig. 5)

l Current paths are successively numbered from 0 to 9.
Potential cross references (Fig. 5)

l Potential cross references serve the purpose of tracking signals, which are transmitted from one representa-
tion of a function to another. Potential cross-references may additionally have structuring symbols assigned
to them.
Example: Potential 15_54 +SEAT/16.1 (on sheet 4, current path 8) continues to the right on sheet 16, current
path 1. +SEAT is the structuring symbol.
008 918 12 BOMAG 63

Relay cross references (Fig. 5)

l Relay cross references serve the tracking of signals, which need to be tracked for components with outgoing
contacts. A mimic diagram with information about the contact types of a relay and their positions in the wiring
diagram is additionally attached to the bottom of each contactor coil.
Example: The relay cross-reference (-K61/4.2) (on sheet 4, current path 4) indicates that the relay coil on sheet
4 is found in current path 2.
64 BOMAG 008 918 12

List of component
The list of components, see example (Fig. 6), is the first evaluation list that follows the representation of function.
This list contains all components used in the wiring diagram, except terminal strips and plugs.
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Fig. 6 Example: List of components

An electric component is a part, assembly or device in an electrical installation.
l
Components are marked with a combination of letters and numbers. The identification with letters follows the
standard DIN - EN 61346 T1-T2. A component identification (BMK), e.g.: “S04“ always identifies the same
component. In this context the term "component" is always considered a function specific assignment and
does not represent a parts or article number. This ensures that the component with the designation "S04" al-
ways refers to the "Brake Switch", irrespective of whether the abbreviation is used in a wiring diagram for a
single drum roller, a tandem roller, a finisher or a milling machine.
l
The component identifications are alphabetically sorted in the list of components. Each component has the
corresponding cross-references assigned, identifying where it can be found in the wiring diagram, which in-
stallation location it is assigned to and to which part of the system it belongs to. Moreover, the functions (func-
tion text) and the technical characteristics are also described.
i Note
Component identifications are used in both the electrical and the hydraulic documentation and are identical.
008 918 12 BOMAG 65

Overview of terminal strips

The overview of terminal strips, see axample (Fig. 7), contains all terminal strips used in the circuit diagram.
Each terminal strip starts on a new page and can be localized via the cross-reference in the wiring diagram.
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Fig. 7 Example: Terminal strip overview X1
66 BOMAG 008 918 12

Overview of plugs
The overview of plugs, see example (Fig. 8), contains all plugs used in the circuit diagram.
The following information is listed for each plug:
l Contact numbering
l Structuring symbols
l Function text
l Use in wiring diagram.
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Fig. 8 Example: Plug overview X0
008 918 12 BOMAG 67

Overview of pins
The overview of pins, see example (Fig. 9), informs about the type of inputs and outputs of the electronic controls
(E-BOX) used in the machine, as well as their signals and potentials.
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Fig. 9 Example: Overview of pins, control A66
68 BOMAG 008 918 12

Circuit symbols
Circuit symbols are standardized representations for electrical appliances. They serve the purpose of a simpli-
fied representation of complete systems, from which, however, the function can be clearly identified. This stand-
ardization is in compliance with the globally valid regulations of the IEC (International Electrical Commission).
The standardization serves the purpose of global understanding and fault free connection of appliances, espe-
cially in automobile repairs. Since the wiring diagram is intended to show only the most essential aspects, the
circuit symbol only shows as much of the function, as is needed for easy recognition and for the avoidance of
mistakes.
Fig. 10 Example: Circuit symbol

1 Current source
2 Conductor
3 Switch
4 Ground
5 Filament lamp
6 Filament lamp with two luminous elements
7 Voltmeter
8 Amperemeter
9 Resistance
10Fuse
11Terminal strip
12Plug
Different symbols are used to simplify the differentiation of terminal strips 11 (Fig. 10) and plugs (12) in a wiring
diagram.
i Note
Plugs are mainly used to connect two wiring looms or to connect a wiring loom with a component with cable
connection and mating plug.
008 918 12 BOMAG 69

Representation of electric devices

Electronic devices and components are increasingly used in the construction equipment industry. Controls with
software, control elements (e.g. joysticks and man/machine interface (e.g. screens, LC Displays) are frequently
used to represent and control machine functions. The internal construction of such components is in most cases
protected or just too complex to be illustrated in the wiring diagram within the context of the actual machine func-
tion. There are two different ways to simplify the representation of such devices in the diagram.
Black-Box representation(Fig. 11)

The Black-Box representation shows the device as a Box with the connections required for the machine function.
Connections which are not needed do not need to be represented.
The Black-Box representation is mainly used when no differentiated information (e.g. signals on pins) is availa-
ble.
Fig. 11 Example: Central lubrication system
Identification of externally supplied documentation (Fig. 12)

In industrial technology of today it is quite common to integrate externally supplied electric sub-systems into the
projecting of machines. These systems may be composed of various components and wirings. For easier differ-
entiation of BOMAG designation and manufacturer identification the latter appears under the BOMAG designa-
tion with a text frame and a reduced character height.
Fig. 12 Example: Identification of externally supplied documentation
PLC representation(Fig. 13)

The PLC-Box representation of connecting pins uses a table with associated connecting plugs, which are used
in connection with the machine functions. The table symbols can be arranged in a line, if necessary. Connections
70 BOMAG 008 918 12

which are not needed do not need to be represented. The PLC-Box representation enables the representation
of further reaching functional descriptions to the individual component connections.
Fig. 13 PLC representation

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

In wiring diagrams you will frequently find the situation that symbols of the same type appear in a line or are
arranged just next to each other. In such cases it is common practice to reduce the identification on the subse-
quent symbol to the criteria, which are different to the previous symbol to the left.
Example: -X0 36 and -X0 37 (Fig. 13)

In the example illustrated here the component identification "-X0" for the left plug symbol is also valid for the right
plug symbol.
008 918 12 BOMAG 71

5.3 Identification of switch blocks in the wiring diagram
5.3 Identification of switch blocks in the wiring diagram
Switches of modular design

l For normally open contacts the contact symbols "_3/_4" are used.
l For normally closed contacts the contact symbols "_1/_2" are used.
In combination with the contact block numbering described above each individual connection is clearly defined.
5 C 6
3 B 4
1 A 2
Travel direction
Fig. 14
Example:
The contact block marked with the "circle" is referred to as "43"/ "44" if it is a normally open contact and "41" /
"42" if it is a normally closed contact.
The contact block marked with "X" is referred to as "23"/ "24" if it is a normally open contact and "21" / "22" if it
is a normally closed contact.
The contact block marked with "Z" is referred to as "13"/ "14" if it is a normally open contact and "11" / "12" if it
The contact block marked with "Y" is referred to as "53"/ "54" if it is a normally open contact and "51" / "52" if it
72 BOMAG 008 918 12

Designation of components in the wiring diagram 5.4

tion
C Capacitor
F Fuses
K Relays
V Diode
X Terminal
Y Solenoid valves
008 918 12 BOMAG 73








56 Head light
57a Parking light

76 Loudspeaker
74 BOMAG 008 918 12


B+ Battery positive
B- Battery minus
D+ Dynamo Plus
D- Dynamo Minus
008 918 12 BOMAG 75

76 BOMAG 008 918 12

6 Electrics
008 918 12 BOMAG 77



tion
C Capacitor
F Fuses
K Relays
V Diode
X Terminal
Y Solenoid valves
78 BOMAG 008 918 12







56 Head light
57a Parking light

76 Loudspeaker
008 918 12 BOMAG 79



B+ Battery positive
B- Battery minus
D+ Dynamo Plus
D- Dynamo Minus
80 BOMAG 008 918 12

Battery ground and analog ground 6.3
6.3 Battery ground and analog 6.4 Current and voltage
ground
General
GND, battery ground If one wants to describe electric current, this can most
simply be accomplished by means of a comparison:
The term "ground" (abbreviated GND) describes a
conductive body which is normally defined with the One simply compares electric current with water.
potential of "Zero" Volt and represents the reference
potential for operating voltages. Voltage
The positive pole of the supply voltage (symbol + ) and
all other electric voltages and electical signals in an
electrical circuitry refer to the ground potential.
On motor vehicles and also on motorbikes and bicy-
cles the ground potential is represented by the chas-
sis or the frame. As a conductive part, which covers
the entire vehicle, it also serves a return conductor for
the vehicle wiring system - the consumers only need
to be wired up.
Terminal designation for GND = terminale 31
AGND, analog ground

Apart from the "normal" battery ground there is also
the analog ground, which is solely reserved for sen-
sors.
Fig. 1
1 (Fig. 1) Charge
2 Voltage
3 Current
The equalization attempt between different electric
charges is referred to as electric voltage.
Voltage sources have two poles of different charge.
On the one side we have the plus pole with a lack of
electrons, on the opposite side the minus pole with a
surplus of electrons. This electric "pressure" is known
as electric voltage.
Fig. 2
If there is a connection between these two poles a dis-
charge will take place, resulting in the flow of an elec-
tric current.
Plus pole= lack of electrons
Minus pole = excess of electrons
008 918 12 BOMAG 81

6.4 Current and voltage
The following statements concerning electric volt- Current

age can be made
Electric current generally describes the directed
l electric voltage is the pressure or force applied to movement of charge carriers.
free electrons. l The charge carriers may either be electrons or ions.
l the electric voltage is the cause of electric current l Electric current can only flow if there is a sufficient
l electric voltage is a result of the equalization at- amount of free moving charge carriers.
tempt of electric charges. l The higher the number of electrons flowing through
Voltage is measured with a Voltmeter. a conductor per second, the higher the amperage.
Unit, Volt Current is measured with an ammeter.
The electric voltage (U) is measured in Volt (V). 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).
82 BOMAG 008 918 12

Resistance 6.5
Types of current 6.5 Resistance
Direct current (D.C.)
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 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- Fig. 1 Various size resistors
manent changes in the vehicle voltage, as soon as
Each conductor has its specific resistance, which is
consumers are switched on or off.
characteristic for the corresponding material. A good
Alternating current (A.C.) conductor has a low resistance, a poor conductor has
a high resistance.
Fig. 2 Alternating current (A.C.)

Alternating current not only changes its direction, but
also its amperage.
Fig. 2 Potentiometer, infinitely adjustable resistor

The resistance can only be measured with a Multime-
ter.
Symbol, R
Unit, Ohm Ω
The electric resistance (R) is measured in Ohm Ω.

Rule of thumb:
l
The thicker the cable cross-section, the lower the
voltage loss.
l
The shorter the cable, the better the current.
008 918 12 BOMAG 83

6.5 Resistance
l The cleaner the contacts, the better the current.

l 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. 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
Fig. 1 Screw-type terminals
keeps water away.
Copper wires are squashed and thus become faulty.
Better
Fig. 2 Spring clamps

Connecting clamps for flexible conductors Fig. 4 Balistol oil
BOMAG No. 057 565 72

Ampacity up to 20 Amp.
Cable cross-section 0.08 to 2.5 qmm
84 BOMAG 008 918 12

Series / parallel connection 6.6
Sometimes the flanks of flat plugs bend open. If these 6.6 Series / parallel connection
are closed again with the help of pliers the flanks will
be excessively strained at the bend and will definitely Series connection
break sooner or later. It is better to place a small nail In a series circuit the resistors (consumers) are lined
under the bottom of the cable lug before bending. 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.
Fig. 5
Utotal = U1 + U2 + U3
Hint for practice:
A tool you cannot buy. The pliers were converted, the Resistance
nail is permanently present. 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.
008 918 12 BOMAG 85

6.6 Series / parallel connection
l In series connection the plus pole of the first battery Parallel connection
must be connected with the minus pole of the sec- In parallel connection all resistances (consumers) are
ond battery. connected between feed and return line.
l The sum of all individual voltages is applied to the l All resistances (consumers) are supplied with the
free poles. same voltage.
l The total capacity (Ah) is identical with the capacity l Each of the resistances (consumers) draws as
of the individual battery. 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.
86 BOMAG 008 918 12

Ohm's law 6.7
l In parallel connection the plus pole of the first bat- 6.7 Ohm's law
tery is connected with the plus pole of the second
battery and the minus pole of the first battery with In a closed electric circuit voltage, current and resist-
the minus pole of the second battery. ance must always be considered in close relation.
l Plus and minus poles have the voltage of the single This relation is represented by Ohm's Law.
battery applied.
l The total capacity (Ah) is identical with the sum of
all battery capacities.
The disadvantage of a parallel connection becomes
apparent, by equalizing currents flowing between par-
allel batteries, if the batteries have different states of
charging.
Fig. 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 Ω).
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 Ω
008 918 12 BOMAG 87

6.8 Electrical energy
6.8 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
88 BOMAG 008 918 12

Formula diagram 6.9
6.9 Formula diagram
Description:
l Select the desired value from the inner circle.
l Determine the formula variables in the quarter circle
l Calculate
Example:
P = 150 Watt
U = 24 Volt
Sought for = Current in Ampere
I = P : U = 150 W : 24 Volt = 6.25 Ampere
Fig. 1 Formula diagram
Resistance, R Ohm Ω
Voltage, U Volt
Current, I Ampere
Power, P Watt
008 918 12 BOMAG 89

6.10 Metrology
6.10 Metrology Multimeter

This tester is a multimeter and can be used to meas-
Test lamps ure e.g. current, voltage and resistance. Depending
on the design it may also be suitable for transistor and
Test lamp frequency.
Fig. 1 Multimeter
In order to avoid damage:
Fig. 1 Test lamp
l
the range selector switch must be correctly set for
the corresponding measurement.
! Caution l
the test cable must be plugged into the correct
This type of tester must not be used for testing on socket.
electronic components. The high power con- l
the voltage type (AC/DC) must be set.
sumption of the test lamp may destroy electronic l
In case of direct voltage the correct polarity must be
components in the control units.
assured.
Diode test lamp l
the measuring range should be chosen higher at
This instrument is used for simple voltage measure- the beginning of the test.
ments. The test lamp consists of two test points. The l In order to avoid any influence on the circuitry to be
negative measuring cable is connected to ground and measured, the internal resistance of the voltage
the positive measuring cable to the corresponding tester should be as high as possible.
measuring location.
Fig. 2 Diode test lamp

If voltage is present, the corresponding light emitting
diode will light up.
90 BOMAG 008 918 12

Metrology 6.10
Resistance and continuity measurement with mul- Voltage and voltage drop measurement with mul-
timeter timeter
Fig. 2
The continuity tester of the multimeter can be used to Fig. 4 Measuring voltage
measure whether there is a connection between 2 l Measurement at the voltage source measures the
measuring points. currently available Voltage.
l The meter is always connected parallel to consum-
er, component or power source.
Fig. 3
The following information should be observed when
measuring resistance and continuity: Fig. 5 Voltage measurement
l The component to be measured must not be con- l
A measurement at the consumer measures the volt-
nected to the power supply during the measure- age drop at this component.
ment.
l 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.
l Polarity is of no significance.
008 918 12 BOMAG 91

6.10 Metrology
Current measurement with the multimeter Clip-on measuring instrument

The clip-on measuring instrument can be used to
measure current, voltage and resistance.
Fig. 6 Measuring current

l The meter is connected in series with the consum-
er. Fig. 1 Clip-on measuring instrument
l During the measurement the current must be able
to flow through the meter, i.e. the electric circuit
must be opened.
Fig. 2
l
For measuring current the individual conductor
must be fully enclosed by the measuring tongs, the
actual measurement takes place without contact.
Fig. 7 Current measurement
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.
92 BOMAG 008 918 12

Metrology 6.10
Magnet tester Power measurement
The electric power of a module within a circuit can be
indirectly determined (calculated) by separate meas-
uring of current and voltage.
However, there are also pure power meters with 4
connections available. The power meter has a electro-
dynamic measuring mechanism. The current circuit
must be opened for measuring. Take care when per-
forming power measurements: Voltage or current path
may already be overloaded during the measurement,
even though the end stop in the meter has not yet
been reached.
Fig. 1 Magnet tester

The magnet tester is used to test solenoid valves and
magnetic coils.
The test lamp responds to the magnetic fields of A.C-
voltage, D.C.-voltage and permanent magnets.
l
The component to be tested does not need to be re-
moved.
l The magnetic coil can also be tested under a pro-
tective cap.
Fig. 2
008 918 12 BOMAG 93

6.11 Diodes, relays, fuses
6.11 Diodes, relays, fuses Diode logics and free-wheeling diode
Diodes
Fig. 1
A diode consists of two different semi-conductors,
which are connected by a separating layer. The max.
conducting state current must not be exceeded.
Plus-voltage on diode:
l At 0.6 – 0.7 Volt (silicium diode) the diode becomes
conductive.
Negative voltage on diode:
l The diode does not allow current to pass through.
Fig. 2 Marking of the cathode

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

l The solenoid valve Y48 (Fig. 3) is supplied with
electric current when switch S34 is switched to po-
sition "1" or "2".
l Solenoid valve Y20 is supplied, if the switch is in po-
sition "1".
l 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.
94 BOMAG 008 918 12

Diodes, relays, fuses 6.11
Light emitting diodes Relays
Fig. 1 Relays
Relays are commonly used to realize switching proc-
esses.
Fig. 4 LED
A free-wheeling diode prevents induction voltage from
The light emitting diode, also referred to as LED, is a
flowing back from the coil into the vehicle wiring sys-
semi-conductor diode, which generates (emits) light
tem, which would cause interference with electronic
during operation in forward direction. A semi-conduc-
components (control units).
tor crystal thereby emits a light signal, which is con-
verged or scattered by the lenticular shape of the With the possibility of using breaker - maker contacts
head. Light emitting diodes are available in various the effect of an information can be reversed.
colours, sizes and shapes. They are for this reason
used as signal lamps. This component is constructed
of different semi-conductor crystals, depending on its
colour. It works like any other semi-conductor diode.
Fig. 2 Relay circuitry

The windscreen wiper and washer motors can only be
operated via switches S20 and S21, when relay K32
is supplied with electric current (Fig. 2).
86 = Positive supply for coil
008 918 12 BOMAG 95

6.11 Diodes, relays, fuses
85 = Ground supply for coil Fuses

30 = Supply voltage
87 = Normally open contact
87a= Normally closed contact
Fig. 1
Fuses are used to protect lines and equipment against
overloads and short circuit. If the fuse is overloaded
the fusible wire heats up with increasing current, until
it finally melts.
Caution
!
Fuses must not be repaired or bridged.

The melting time at 23 °C is:
l
approx. 1 hour with 1.5 times the rated current
l
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
96 BOMAG 008 918 12

Telemecanique switch 6.12
6.12 Telemecanique switch
Disassembly
Fig. 1 Disassembly
l
Lift up the interlock (5).
Fig. 3 Pulling out the front element

l Lift up the interlock (2) and pull out the front element
(3).
Fig. 2 Folding down the switch block
l Fold down the switch block (4).
l Loosen screw (1).
008 918 12 BOMAG 97

6.12 Telemecanique switch
Assembly
Fig. 4 Assembly
l Insert the front element (3) into the bore in the con-
trol panel.
Fig. 6 Assemble the switch block

l Clip on the switch block (4).
Fig. 5 Observe the marks.

i Note
Hook in the switch block at the bottom first (Fig. 6).
l Clip the fastening adapter (6) onto the front element
(3).
i Note
Watch the marls on front element (Fig. 5) and fasten-
ing flange.
l
Tighten the screw (1) with a tightening torque of 0.6
Nm.
98 BOMAG 008 918 12

Plug connectors 6.13
6.13 Plug connectors 6.14 Magnetic coil plug
Duties and requirements
Magnetic coil plug with LED and suppres-
Electric plug connectors must provide a reliable con-
sor diode
nection between different system components and
thus ensure the safe function of the systems under The plug is equipped with a polarized function display
any operating condition. There design ensures that and a suppressor diode as protection against over-
they will withstand the applied loads throughout the voltages.
lifetime of the machine.
Examples for these loads are:
l Vibration acceleration
l
Temperature fluctuations, high and low tempera-
tures
l Dampness
l Micro movements of the contact with resulting fric-
tion corrosion.
These loads may increase the transition resistances
Fig. 7
of the contacts, up to total interruption. Even the insu-
lation resistances may drop and thus cause short cir- The plug is reverse polarity protected, it does not mat-
cuits in neighbouring lines. Electric plug connectors ter whether Pin1 or Pin 2 is supplied with current, Pin
must therefore have the following properties: 3 is not used. The LED lights if voltage is applied to the
solenoid valve.
l
Low transition resistances of the conductive parts.
l
High insulation strength between conductive parts
with different voltage potentials.
l
Excellent leak tightness against water and mois-
ture.
Fig. 8
Fig. 9 Switching symbol in circuit diagram
Magnetic coil plug without LED and with-

out supressor diode
The plug has no LED and no suppressor diode as pro-
tection against overvoltages.
008 918 12 BOMAG 99

6.14 Magnetic coil plug
Assembly of magnetic coil plugs

These instructions are intended to explain the correct
installation of the magnetic coil plug. The objective of
the instructions is the correct installation of the plug
and to avoid malfunctions in the field caused by mois-
ture and any related corrosion damage.
Fig. 12
l
Fasten the screw with a suitable screwdriver.
Fig. 10 Solenoid valve plug with pointed cable
Fig. 13
l
Press the plug firmly on again.
Fig. 11
l Connect the plug with the coil connection and press
it firmly onto the connecting housing.
Fig. 14
l Retighten the screw.
100 BOMAG 008 918 12

Deutsch plug, series DT and DTM 6.15
6.15 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. 15
! Caution
There should be no gap between plug and sole-
noid coil!
Fig. 17 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).
Fig. 16 Correctly installed plug without gap 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.
l
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.
008 918 12 BOMAG 101

6.15 Deutsch plug, series DT and DTM
DT Series
Fig. 1 DT plug connection
Fig. 2 DT Series
Fig. 3 Sectional drawing
102 BOMAG 008 918 12

DT Series
Installing DT contacts
Fig. 4
l Insert the contacts through the rubber grommet until they click into place.
l Insert the orange wedge in direction of arrow.
!Caution
Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force
i Note
Use the same method when assembling the socket.
Disassembling DT contacts
Fig. 5
l Pull the orange wedge out with long nose pliers.
l Slightly pull the lead and unlock the interlocking hook with a screw driver.
l Pull the contact out of the socket.
i Note
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.
008 918 12 BOMAG 103

6.15 Deutsch plug, series DT and DTM
DTM Series
Fig. 6 DTM Series
Fig. 7 Sectional drawing
Installing DTM contacts
Fig. 8
l Insert the contacts through the rubber grommet until they click into place.
l Insert the orange wedge, until it clicks into place.
104 BOMAG 008 918 12

!Caution
Perform a pull test on each lead, each of the terminals and connections must withstand a pulling force
i Note
Removing DTM contacts
Fig. 9
l
Pull the orange wedge (interlock) out with long nose pliers.
l
Slightly pull the lead and unlock the interlocking hook with a screw driver.
l
Pull the contact out of the socket.
i Note
In this case the interlock disassembly tool (see special tools for electrics) serves as an aid to remove the wedges.
008 918 12 BOMAG 105

6.16 Plugs and terminals in spring clamping technology
General
Fig. 1
!Caution
The spring clamp technology is not suitable for extra fine conductors. Extra fine conductors can be eas-
ily pulled out of the spring clamp!
Spring clamp technology (Fig. 1) for quick, vibration resistant and maintenance-free connection of all conven-
tional copper conductors (single, multiple or fine stranded) with or without wire and ferrule.
Connecting terminal for quick repairs
Fig. 2 That's how it works
BOMAG part-no.: 057 565 72

The connecting clamp clamps up to 3 or 5 stripped fine conductors of 0.08 mm2 to 4 mm2, single or multiple
strand up to 2.5 mm2. And this even without tools (Fig. 2).
That's how it works

l Strip 9-10 mm of the lead.
l
Open the actuating lever and insert the strand.
l Return the actuating lever to initial position.
! Caution
Perform a pull test on each lead, each of the terminals must withstand a pulling force of 45 N without
any difficulties.
106 BOMAG 008 918 12

Plugs and terminals in spring clamping technology 6.16
Series clamp
That's how it works

l Insert a screw driver into the actuating opening until it bottoms.
l Strip 9-10 mm of the lead and insert it into the clamp.
l Pull out the screw driver.
Caution
!
any difficulties.
Measuring signals
On these terminal blocks the bridge slot is most suitable for tapping off and measuring signals. Here you may
directly insert a 4 mm test adapter (see special tools for electrics) for connecting a measuring lead. This test
adapter is standard in the central electrics of heavy equipment machines.
Fig. 4 Test adapter
008 918 12 BOMAG 107

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 introduced in 1997. All the familiar series clamping functions have thus
become pluggable.
X-COM plug clamp
That's how it works

l
Insert a screw driver into the actuating opening until it bottoms.
l
Strip 9-10 mm of the lead and insert it into the plug.
l
Pull out the screw driver.
Caution
!
any difficulties.
Fig. 6 X-COM plug with measuring cable

l The most reliable measurements on the plug can be made when using the measuring and connecting cable
with 2mm plug (see special tools for electrics).
108 BOMAG 008 918 12

Plugs and terminals in spring clamping technology 6.16
Measuring signals
Fig. 7 X-COM plug plugged onto the series clamp
008 918 12 BOMAG 109

6.17 Proximity switches
6.17 Proximity switches cillator is thus dampened and the resulting change in
current consumption is evaluated.
PNP circuitry
Fig. 3 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
Fig. 1 Proximity switches on travel control lever open contact, i.e. the contact closes when the initiator
comes in "contact" with metal.
B13 Initiator for brake
NPN circuitry
B14 Initiator for reverse detection
General
In all automated sequences the use of sensors as a
source of information for the electronic control is indis-
pensable. The sensors deliver the necessary signals
about positions, end positions, filling levels or serve as
pulse transducers for counting tasks or speed detec-
tion. In industrial applications inductive and capacitive Fig. 4 NPN circuitry
proximity switches are today indispensable. Com- On sensors with NPN-circuitry the output stage con-
pared with mechanical switches they provide almost tains a NPN-transistor, which switches the load
ideal prerequsites: contactless, wear-free operation, against the negative operating voltage. The load is
high switching frequency and switching accuracy as connected between the output and the positive oper-
well as high protection against vibration, dust and ating voltage.
moisture. Inductive sensors detect all metals without
contact, capacitive sensors detect almost all solid and Breaking and making contacts
liquid media, such as metal, glass, wood, plastic, wa-
ter, oil, etc.
Working principle
Fig. 2
The working principle is based on the principle of the
dampened LC-oscillator. The coil of the oscillation cir-
Fig. 5
cuit forms a high-frequency magnetic stray field.
Proximity switches are used as breaking or making
This stray field leaks out from the active area of the contacts. Depending on the design the switching dis-
proximity switch. If metal or non-ferrous metal enters
into the response range energy is absorbed. The os-
110 BOMAG 008 918 12

Level sensor in diesel tank (R03) 6.18
tances are 2 or 4 mm. The maximum amperage is 300 6.18 Level sensor in diesel tank
mA.
(R03)
The LED (Fig. 5) lights up, when the initiator has de-
tected metal in its stray field.
Fig. 1
The fluid of the level to be measured carries a float,
which lowers or rises with the fluid level. Contact
springs mounted on the float thereby slide along two
resistor wires arranged parallel to the movement of
the float and generate a resistance value, which is
proportionate to the fluid filling level. The correspond-
ing resistance value is measured by an electric meter
and displayed as fluid level value.
Monitoring module, old design
Fig. 6 Circuit diagram, making contact

The circuit diagram (Fig. 6) shows a proximity switch
with normally open contact.
Brown = voltage supply
Blue = ground supply
Black = switching output
The initiator switches the relay (K05)
Fig. 2 old design

n = Fuel level gauge
00 Ohm = Tank full
26 Ohm = Tank 1/2 full
65 Ohm = Tank empty
If no level switch is connected or the cable is broken,
the fuel level gauge will go out.
008 918 12 BOMAG 111

6.19 Differential pressure switch for hydraulic oil filter, B21
Monitoring module, new design 6.19 Differential pressure switch

for hydraulic oil filter, B21
Fig. 3 new design

m = Fuel level gauge
00 Ohm = Tank full
40 OHM = Tank 1/2 full
95 Ohm = Tank empty Fig. 1
If no level switch is connected or the cable is broken, l The differential pressure switches (Fig. 1) switch to
the fuel level gauge will go out. ground at a pressure differential of Δ 3.6 bar.
When the pressure switch switches , the monitoring
board (Pin13 old design, Pin17 new design) is con-
nected to ground. The warning lamp e(Fig. 2) or i (Fig.
3) lights up.
Monitoring module, old design
Fig. 2 old design

e yellow = Lights when the hydraulic oil filter is dirty,
the warning buzzer sounds. The engine
is shut down after 2 minutes. Check hy-
draulic system, replace hydraulic oil fil-
ter.
i Note
The warning buzzer is activated by the monitoring
board (Pin1).
The engine is shut down by the monitoring board
(Pin9) via relay (K22).
112 BOMAG 008 918 12

Differential pressure switch for hydraulic oil filter, B21 6.19
Monitoring module, new design
Fig. 3 new design

i yellow = Lights when the hydraulic oil filter is dirty,
the warning buzzer sounds. The engine
is shut down after 2 minutes. Check hy-
draulic system, replace hydraulic oil fil-
ter.
i Note
The warning buzzer is activated by the monitoring
board (Pin23).
The engine is shut down by the monitoring board
(Pin24) via relay (K22).
008 918 12 BOMAG 113

6.20 Acceleration transducer
Fig. 1 When this combination is set to oscillate, the seismic

BVC machines and machines with E-VIB meter are (sluggish) mass transfers a force to the piezo disc. Ac-
equipped with two piezo-electric acceleration trans- cording to NewtonsLawtheresultantforceisthepro-
ducers, which are mounted to the drum. ductofaccelerationandmass.'
During operation these transducers transmit the ac- A small wire connects the piezo element with the sen-
celeration signals to the measuring ESX. sor socket.
The function of the piezo electric acceleration trans- The piezo electric effect generates a charge on the
ducer is based on the self-charging effect of quartz electrodes, which is proportional to the force and thus
crystals under mechanical load (pressure, tension, also to the acceleration.
torsion) in vertical direction to the polar axes, which
was discovered in 1880 by J. and P. Curie.
Mode of action
The piezo electric acceleration transducer consists of
two basic components:
l
Piezo electric material
l Seismic mass
Once side of the piezo disc is connected with the so-
called seismic mass, the other one with a rigid carrier.
114 BOMAG 008 918 12

Batteries 6.21
6.21 Batteries
Battery – accumulator
Fig. 1
1 Seismic mass
2 Piezo electric material
3 Acceleration
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.
008 918 12 BOMAG 115

6.21 Batteries
Battery maintenance Batteries with screw plugs

Checking the electrolyte level
i Note
Maintenance free batteries are gaining more and
more significance, this freedom from maintenance,
however, is only limited to the fact that no water needs
to be added.
If the battery is not charged and discharged over a
longer period of time, the battery will slowly discharge
by itself.
The accumulator may only be discharged down to a fi-
nal discharging voltage of 10.5 Volt, as otherwise
there is a risk of sulphation, i.e. the generated lead
sulphate forms increasingly coarser crystals, which
will finally not react at all or only very sluggishly during Fig. 3
a subsequent charging process. 1 Upper filling level mark
In the worst case the accumulator can only be dis- 2 Lower filling level mark
posed of after such an exhaustive discharge. l If the electrolyte level only reaches up to the lower
The following therefore applies for longer downtimes: filling level mark (2), fill distilled water into the corre-
l Remove the battery and store it in a cool, dry and sponding cells.
frost protected room.
l Check the open circuit voltage on the battery at reg-
ular intervals (at least once every month).
l Recharge immediately if the open circuit voltage
has dropped to 12.25 Volt (no rapid charging).
i Note
The open circuit voltage of batteries occurs approx. 10
h after the last charging or approx. 1 h after the last
discharge.
Battery test in general

l
Is the battery leaking? Can traces of impact, shock
or compression be found in the leaking area?
l
Check for e.g. incorrect fastening, foreign bodies on
the battery mounting surface and similar.
116 BOMAG 008 918 12

Batteries 6.21
Checking the electrolyte density Do not draw too much electrolyte into the pipe.
Make sure that the float is not obstructed in its move-
ment and hold the electrolyte tester at eye level.
The electrolyte tester must be read at the highest
electrolyte level.
l If the electrolyte temperature deviates from the
electrolyte tester calibration temperature, the indi-
cated value for the specific electrolyte weight must
be corrected acc. to the formula (reference) below.
Reference
The specific weight varies slightly with temperature.
To be exact, the specific weight drops by 0.0007 per 1
°C temperature increase (by 0.0004 per 1 °F) and in-
Fig. 4
creases by 0,0007 per 1 °C temperature reduction (by
The cells are filled with diluted sulphuric acid as elec- 0,0004 per 1 °F) . If e.g. a temperature of 20 °C (68 °F)
trolyte (approx. 25 Vol% sulphuric acid in distilled wa- is used as reference, the indicated value of the specif-
ter), also referred to as accumulator acid, which has a ic weight must be corrected acc. to the following for-
density of 1.285 kg/dm3 at a temperature of +27° Cel- mula.
sius. This means that one litre of electrolyte has a l Specific weight at 20 °C = measuring value +
weight of 1.285 kg. As the cell is being discharged
0,0007 × (electrolyte temperature: 20 °C)
lead sulphate (PbSO4) will form on both electrodes
and the electrolyte will increasingly change to water.
l
Specific weight at 68 °F = measuring value + 0,0004
Since water has a lower specific weight than diluted × (electrolyte temperature: 68 °F)
sulphuric acid, the density of the electrolyte will also Acid density at 27 °C in kg/dm3
drop during the discharge and with a fully discharged
cell and a temperature of 27°C it will only be 1.18 kg/
l
1.25 -1.28, open-circuit voltage approx. 12.7 Volt.
dm3. Battery is charged.
l
1.20 -1.24, open circuit voltage approx.12.4 to 12.5
With a lead cell the acid density is therefore a meas-
Volt, is 50% discharged. Charging is necessary.
ure for the charge condition. This characteristic is
used to determine the charge condition of a lead bat- l
1.19 and less, open circuit voltage less than 12.3
tery. The so-called electrolyte tester (densimeter) is Volt. Battery is insufficiently charged. The battery
used for this purpose. needs to be recharged immediately.
l
If there is a deviation of the specific weight of more
than 0.05 between any of the cells, the battery
needs to be replaced.
l
If the current consumption during charging is not 1/
20 of the nominal capacity (example 100 Ah battery:
100Ah x 1/20 = 5 A) or full recharging of the battery
results in a final electrolyte density of only 1.24 kg/
dm3 or less, the battery shows normal wear by ag-
ing. The battery was insufficient charging or ex-
haustive discharge.
Fig. 5 Checking the electrolyte density:

1) correct
2) poor
3) poor
i Note
(Hold the pipe of the electrolyte tester vertically, with-
out taking it out of the electrolyte.
008 918 12 BOMAG 117

6.21 Batteries
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. 6 Battery and generator tester

The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) integrated ther-
mal printer.
i Note
Before testing clean the poles and ensure good con-
nection between clamps and poles.
The test program calculates the text messages "good"
or "replace" on the basis of the charge condition (de-
rived from the battery voltage) and the currently avail-
able starting power of the battery. A battery with 45%
starting power may thus be rated good and another
one with 75% starting power as poor ("replace").
The starting power represents the ratio of detected
cold testing current to the entered cold testing current
of the battery.
The starting power can exceed 100%.
118 BOMAG 008 918 12

Service the battery 6.22
6.22 Service the battery
! Danger
Danger of cauterisation ! Danger of explosion!

When working on the battery do not use open fire,
do not smoke!
The battery contains acid. Do not let acid come in
contact with skin or clothes!
Wear protective clothing!
Do not lay any tools on the battery!
Fig. 7
Environment l Remove the battery (Fig. 7) and clean the battery
Dispose of the old battery environmentally. compartment.
l Clean the outside of the battery.
i Note l Clean battery poles and pole clamps and grease
Maintenance free batteries also need care. Mainte- them with pole grease (Vaseline).
nance free only means that the fluid level does not
need to be checked. Each battery suffers under self-
l Check the fastening of the battery.
discharge, which may, in not checked occasionally, l On serviceable batteries check the acid level, if nec-
even cause damage to the battery as a result of ex- essary top up to the filling mark with distilled water.
haustive discharge.
Charging voltage recommendation
The following therefore applies for the service life:
l
Switch off all consumers (e.g. ignition, light, inside
light, radio).
l
Check open-circuit voltage of the battery at regular
intervals. At least once per month.
Reference values: 12.6 V = fully charged; 12.3 V =
50% discharged.
l Recharge the battery immediately after an open-cir-
cuit voltage of 12.25 V or less is reached. Do not
perform boost charging.
The open-circuit voltage of the battery occurs approx.
10 hours after the last charging process or one hour
after the last discharge. Fig. 8
l
After each charging process allow the battery to rest
for one hour before taking it into service.
l
For resting periods of more than one month you
should always disconnect the battery. Do not forget
to perform regular open-circuit voltage measure-
ments.
Caution
!
Exhausted batteries (batteries with formation of

sulphate on thge plates are not covered under
warranty!
l
Open the engine hood and remove the covering.
008 918 12 BOMAG 119

6.23 Main battery fuse
6.23 Main battery fuse 6.24 Starting with jump wires
Fig. 9 Fig. 10
No. 1 = Main fuse for battery
125A = (F00) Main fuse !Caution
A wrong connection will cause severe damage in
the electric system.
i Note
The main fuse is located in the battery compartment l
Bridge the machine only with a 12 Volt auxiliary bat-
tery.
l
When jump starting with an external battery connect
both plus poles first.
l
Then connect the ground cable first to the minus
pole of the current supplying auxiliary battery and
then to engine or chassis ground, as far away from
the battery as possible (Fig. 10).
l
Start as described under 'Starting the engine'.
l
Once the engine is running switch on a powerful
consumer (working light, etc.).
!Caution
If no powerful consumer is switched on voltage
peaks may occur when separating the connecting
cables between the batteries, which could dam-
age electrical components.
l
After starting disconnect the negative poles (ground
cable) first and the positive poles after.
l
Switch off the consumer.
120 BOMAG 008 918 12

Generator 6.25
6.25 Generator Three-phase generator
The AC-generator first of all produces AC-voltage /
General
AC-current.
The generator should be of light weight, have a high
rate of efficiency and supply all consumers in the ve- Why does AC-current need to be rectified?
hicle with electric current at a steady voltage already There are a few components for which can either be
at idling speed. operated with alternating current or direct current, be-
cause they work independently from the current flow
Terminal designations
direction.
l B61, L = charge control This includes :
l B+, B = battery plus, also with the designation "30" l
Incandescent lamps
l
B- = battery minus, also with the designation "31" l
Fluorescent lamps
l D+ = dynamo plus corresponds with terminal "61" l Glow lamps
and "L" l Electric heating elements.
l D- = dynamo minus (this designation is only found There are also a few components that could be oper-
on D.C. generators or A.C. generators with regula- ated either with alternating current, direct current or
tor removed) three-phase current, if the components were designed
accordingly.
l DF = dynamo field (this designation is only found on
D.C. generators or A.C. generators with regulator This includes :
removed). Note: The designation DF is also found l
Electric motors
on older alternators with externally arranged regula- l
Relays.
tor on the connection of the exciting coil to the reg-
ulator or on the regulator itself Finally, a variety of important components solely re-
quire direct current. These will under no circumstanc-
l
DF1 = dynamo field 1 es work with alternating or three-phase current.
l
DF2 = dynamo field 2 This includes :
l
IG = "15" ignition switch l
Accumulators
l
Control units
l
All electronics
l
Communication equipment.
Design and function
Fig. 11
1 Fan
2 Holding plate
3 Stator core
4 Stator winding
5 Brush
008 918 12 BOMAG 121

6.25 Generator
6 Brush holder
7 Rectifier
8 Bearing cover
9 Rotor winding
10Rotor
11V-belt pulley
Fig. 14 3-phase current
Fig. 12 Rotor with claw poles The wiring diagram (Fig. 14) shows the 3 windings in
Y-connection and the 6 associated rectifier diodes (D1
In the generator the armature windings are located in-
to D6).
side the stationary stator (Fig. 13), whereas the excit-
er winding is arranged on the internally revolving rotor The diodes D1, D2, D3 are also referred to as minus
(Fig. 12). diodes, because they have B- as common connection
(minus plate). The other diodes are the plus diodes.
The rectifier diodes have the effect that the negative
half-wave is suppressed and only the positive section
of the wave is allowed to pass, resulting in a pulsating
D.C. voltage.
Fig. 13 Stator
The three stator windings (Fig. 13) are electrically off-
set to each other by 120°. The excitation of the mag-
netic field requires direct current, which is fed to the
rotor via two carbon brushes and slip rings.
122 BOMAG 008 918 12

Generator 6.25
Charge control light Any other behaviour would indicate a defect on the
The charge control light has two duties: generator (rectifier, carbon brushes, regulator) or a
defect on the lamp, presumed the on-board battery is
l Indication of the correct generator function not discharged.
l External excitation of the generator during the start- A far more important function of the lamp is the transi-
ing phase tion and provision of field current. At standstill there is
no magnetic field in the de-energized generator. Since
this is necessary for the generation of electric current,
the rotor must be supplied with current, so that a weak
field can build up.
The current flows from the ignition switch via the
charge control light through the generator winding
against ground (terminal 31) and is limited to approx.
300 mA by the light bulb (4 W) (without the lamp the
current flow would be 2 to 5 A). While the rotor is ro-
tating current is induced into the stator winding,
whereby a small part (2–5 A, depending on speed)
flows through the charge regulator into the field wind-
ing of the rotor and the major part flows to the output
terminals (B+), where it can be tapped as useful cur-
rent. If the charge control light is defective or no bat-
Fig. 15 plus controlled charging regulator tery is available or the battery is discharged, external
(Fig. 15) shows the current flow with the ignition excitation is no longer possible at standstill and no
switched on, engine stopped. voltage will be generated, even when the generator is
running.
With used, older generators a weak permanent mag-
netic field may have developed over the lifetime,
which does even exist when no voltage is applied.
This type of machines can even start without charge
control light and produce current during operation.
However, this is an unintended effect and you should
not presume that a generator without charge control
light or external excitation can be started up.
Fig. 16 plus controlled charging regulator

(Fig. 16) shows the current flow with the ignition
switched on, engine running.
1 Battery
2 Charge controller
3 Ignition switch
4 Charge control light
5 Rectifier
6 Rotor
7 Sliprings / carbon brush
8 Auxiliary rectifier
Normally the charge control light lights with the engine
stopped and the ignition switched on and goes out at
low engine speed, but at the latest after a single,
short-term increase in engine speed from idle speed,
because there is no longer a voltage difference on the
lamp.
008 918 12 BOMAG 123

6.25 Generator
Charge controller
The charge controller has the following functions
l To regulate the voltage generated by the generator
l To protect against overloads caused by too high
output current
l Protection against reverse current
If the output voltage or the output current of the gen-
erator exceeds the determined maximum values, the
field current and thus the electric power is reduced.
Electronic charge regulator
Fig. 18 plus controlled regulator
Fig. 17
In AC-generators the electrically generated exciter
field of the generator rotor is influenced by an at-
tached electronic charge regulator. Together with the Fig. 19 minus controlled regulator
holder for the carbon brushes this regulator forms a
unit, which transfers the field current to the sliprings of
the rotor.
The regulator compares the rectified actual current of
the generator with the a stable reference voltage in
the regulator and matches the strength of the exciter
field (field current) by increasing or reducing the cur-
rent flow (PWM, switching controller) in such a way,
that the actual voltage of the generator remains con-
stant, irrespective of load and speed. The generator
voltage is thereby regulated, the generator current,
however, is not measured, but limited by the construc-
tion dependent internal resistance of the stator coils or
thermal monitoring.
124 BOMAG 008 918 12

Generator 6.25
Checking the generator Checking the pre-exciter circuit, D+ generator
First one must check whether the generator is actually The most common reason for a 3-phase alternator not
defective. charging is a too low pre-excitation current. The pre-
excitation current through connection D+ depends on
l This can be easily found out by checking whether
the connected consumer (resistance), e.g. charge
the charge control light in the dashboard lights up. If
control light or relay of a MD+ engine control.
the light does not go out, even at higher speeds,
there must be a defect on the generator, the regula- The pre-excitation current should be approx. 250 mA
tor, the wiring or the V-belt. at 12 Volt. This corresponds with a 3 Watt light bulb or
l When the engine is at rest, the charge control light an equivalent combination of light bulb + resistance or
must light up. If not, the lamp may probably be de- an LED + resistance.
fective. Defects on generator or wiring are obviously The total resistance of the disconnected dead supply
also possible. line D+ max. should not exceed 48 Ohm.
The following points allow to contain faults in the volt- In case of faults like
age supply within certain limits. l charge control light stays on
l Cable connections on the generator OK? l no voltage increase, e.g. from 12 V to 14 V
l V-belt OK?
one should check that the correct resistance is as-
l Generator ground (engine ground) OK?
sured.
l Pre-excitation from vehicle electronics OK?
Only if all criteria mentioned above are OK, the fault
must be in the generator itself. In this case it must be
replaced or the following trouble shooting procedure
must be performed.
Fig. 20 Connections on the three-phase alternator (exemplary de-

sign)
If the charge control light or LED stays on when the
engine is running, you should proceed as follows:
l Temporarily bridge connections D+ and B+ on the
three-phase alternator (Fig. 20). The bridging must
be made using an insulated cable with a cross-sec-
tion of approx. 1.0 mm, which is stripped for approx.
5 mm on either end. This cable must be fitted with a
consumer (X), e.g. a light bulb of 21 W, 12 V, in
case of a 12 V system.
If this measure does not clear the fault, the alternator
must be defective.
008 918 12 BOMAG 125

6.25 Generator
Checking the rotor

Measuring the charge current
l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact. i Note
The rotor coils can only be measured in disassembled
l The generator ground connection must be OK.
state.
l 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 switched on consumers.
Fig. 21
l Measure the resistance between the sliprings.
l If the resistance does not comply with the factory
specification, replace the rotor.
l Use the resistance range of the continuity tester to
check the continuity between slipring and core.
l Replace the rotor if no infinite value is indicated.
i Note
Factory specification for resistance: 2.8 to 5 OHM.
126 BOMAG 008 918 12

Generator 6.25
Checking the stator Checking the bearings
i Note
The stator coils can only be measured in disassem-
bled state.
Fig. 23
l Check whether the bearing rotates without obstruc-
tion.
l Replace the bearing if it does not rotate properly.
Fig. 22
measure the resistance between the individual lines
of the stator winding.
l If the measuring value does not comply with the fac-
tory specification, replace the stator.
check the continuity between the individual stator
windings and the core.
l Replace the stator if no infinite value is indicated.
i Note
Factory specification for resistance: Less than 1 OHM.
008 918 12 BOMAG 127

6.25 Generator
Checking the regulator voltage with the generator Checking the regulator voltage with the multime-
tester ter
The battery and generator tester comes with an 8-line
LC display with background illumination and is able to
print out test results via an (optional) thermal printer.
Fig. 25
l All plug-and-socket connectors must be free of cor-
rosion and intermittent contact.
Fig. 24 l The generator ground connection must be OK.
The generator test assesses the regulator voltage and l
The battery should be in good condition – the idle
the ripple factor of the generator voltage. voltage of the battery should be at least 12.6 Volt.
l
All plug-and-socket connectors must be free of cor- l
If possible switch off all consumers.
rosion and intermittent contact. l
Perform the measurement at raised engine speed.
l
The generator ground connection must be OK. l
The voltage (B+) should adjust itself at 13 to 14 Volt.
l
The battery should be in good condition – the idle
voltage of the battery should be at least 12.6 Volt.
l
If possible switch off all consumers.
l
Perform the measurement at raised engine speed.
128 BOMAG 008 918 12

Generator 6.25
Checking the regulator in disassembled state
On a Bosch generator unscrew two fastening screws
for the regulator and lift the regulator off. For this work
the generator does not need to be removed.
The Delco-Remy generator needs to be removed
and partly dismantled, if the regulator needs to be dis-
assembled. Unscrew the housing screws to do so.
Pull rotor with drive bearing and V-belt pulley out of
the stator. Unscrew the ends of the stator winding
from the diode carrier and separate the stator from the
collector ring bearing. Disassemble exciter diodes and
brush holders and remove also the regulator. Fig. 27
E.g minus controlled regulator
i Note One connects the regulator (Fig. 27) with D+ and D- to
When testing the regulator one should be aware that the power source, as shown in the illustration, and the
there are 2 different types of regulators: lamp to both carbon brushes, instead of the exciter
winding. When slowly increasing the voltage the lamp
l If the carbon brush is not connected to ground the will first become brighter, because the regulator al-
regulator is a so-called minus controlled regulator. lows all lamp current (= exciter current) to flow at volt-
The exciter winding is positioned between D+ and age values up to 14.4V. Once the regulator voltage is
DF, the regulator therefore regulates the exciter reached, the regulator switches the lamp current off.
winding on the ground side. The other carbon brush When returning the voltage back below the control
is connected with the cathodes of the exciter di- voltage, the regulator will switch the lamp back on.
odes, terminal D+. This leaves one further terminal,
With this test the major difficulty is the problem to re-
this is DF.
move the regulator an identify terminals D+, DF and
D+ (vehicle wiring system) D-.
D- (ground contact, mostly located on one of the fas-
tening screws)
DF (Dynamo Field)
Fig. 28
Fig. 29
Fig. 26
The illustrations (Fig. 28) and (Fig. 29) show two dif-
l If the carbon brush is connected to ground the reg-
ferent regulator types.
ulator is a so-called plus controlled regulator. The
exciter winding is positioned between DF and D-,
the regulator therefore regulates the exciter winding
on the plus side. The other carbon brush is then
connected with terminal DF. This leaves one further
terminal, this is D+.
The basic function of a disassembled regulator can be
easily tested with a 12V lamp and an adjustable D.C.
power supply unit (0V ... 20V).
008 918 12 BOMAG 129

6.26 Replacing the voltage regulator
Replacing carbon brushes 6.26 Replacing the voltage regula-

l On a Bosch generator unscrew two fastening tor
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 Disassembling the regulator
need to be replaced, unsolder both connection litz
wires. Solder the litz wires of the new carbon brush-
es, insert these and fasten the regulator again. For
this work the generator does not need to be re-
moved.
l
For replacing the carbon brushes in the Delco-
Remy generator the generator needs to be disas-
sembled and partly dismantled. The carbon brush
holder is located inside the collector ring bearing.
Fig. 1
l Loosen the hexagon nuts M5 (Fig. 1).
l Take off hexagon nuts and washers.
l Remove the plastic cover.
i Note
Optional:
Unscrew the hexagon nut M5 from terminal W, take
off washer and flat plug connector.
Fig. 2
l Check whether washers are present. Take off the
washers (3x) (Fig. 2), to prevent these from falling
into the generator.
130 BOMAG 008 918 12

Replacing the voltage regulator 6.26
Fig. 3
l Slacken the screws M3 (A) (Fig. 3). Fig. 2
l Loosen the hexagon nuts M5 (B). l Check whether the rubber seal is present on the
brush holder (Fig. 2).
l Remove screw and hexagon nuts.
l Take off the voltage regulator.
Assembling the voltage regulator
Fig. 3
l
Attach the voltage regulator (Fig. 3).
l Tighten the screw M3 (A).- Tightening torque 0.7-
1.0 Nm.
Fig. 1 l
Tighten the screw M5 (B).- Tightening torque 3.5-
l
Check for correct fit of sealing ring on protective 4.5 Nm.
cover (Fig. 1).
Fig. 4
l Install the washers (Fig. 4).
008 918 12 BOMAG 131

6.27 Electric starter

General
Combustion engines need to be started by means of
a special device, because they are not able to start by
themselves. Considerable resistances caused by
compression and friction must thereby be overcome.
The starter converts the electric energy stored in the
battery into mechanical energy. The starter can only
generate its power when a battery with appropriate
capacity is available.
Duties of the starter:
Fig. 5 l to accelerate the combustion engine to start speed
with lowest possible current consumption.
l Assemble the cover (Fig. 5).
l establish the gear connection between starter and
l Install the washers. combustion engine.
l Fasten the protective cover with the hexagon nuts.- l to maintain this connection.
Tightening torque for hexagon nut M5 2.1-3.1 Nm. l to switch on the starter current.
After starting the engine:
i Note l
to return the starter pinion to initial position.
Optional: l
to switch off the starter current.
Assemble flat plug connector, washer and hexagon
nut M5 to connection W.
Tightening torque for hexagon nut 2.7-3.8 Nm.
132 BOMAG 008 918 12

Electric starter 6.27
Directly acting electric starter 5 Ignition switch
This shows the design of this starter. It consists of a 6 Actuating lever
starter motor and a magnetic switch. 7 Ring gear
8 Pinion
9 Freewheeling clutch
10(Battery
Pinion meshes with the ring gear
Fig. 6
1 Magnetic switch
2 Armature
3 Actuating lever
4 Freewheeling clutch Fig. 8 Magnetic switch closed
5 Resetting spring When the pinion (3) meshes with the flywheel mount-
6 Brush ed ring gear (4) and the magnetic switch (2) is closed,
7 Exciting winding a strong current flows from the battery (7) directly into
8 Armature the exciting winding (6) and the armature winding, but
not into the pick-up winding.
9 Collector
This causes the armature (5) to rotate with high speed
Ignition switch in position "START" and drives the pinion, which in turn drives the ring gear
(4) with a speed of 200 to 300 rpm.
1 Pick-up winding
2 Magnetic switch
3 Pinion
4 Ring gear
5 Armature
6 Exciting winding
7 Battery
Fig. 7 Magnetic switch open

With the ignition switch (5) in "START" position cur-
rent flows from the battery (10) through the holding
winding (2) and the pick-up winding (3).
The armature (1) is magnetically picked up and forces
the pinion (8) with the actuating lever (6) to engage
with the ring gear (7).
1 Armature
2 Holding winding
3 Pick-up winding
4 Magnetic switch
008 918 12 BOMAG 133

Engine running 4 Resetting spring

5 Magnetic switch
6 Ignition switch
7 Pinion
8 Ring gear
9 Battery
Fig. 9
Once the engine is running and drives the pinion (1)
via the ring gear (2), the freewheeling clutch (3) will
open and prevent the armature (4) from being driven
by the engine.
1 Pinion
2 (Ring gear
3 Freewheeling clutch
4 Armature
Ignition switch released
Fig. 10
When releasing the ignition switch (6) it will return
from position "START" to "ON" and interrupt the start-
er current circuit. Current will now flow from the bat-
tery (9) through the contact plate in the pick-up
winding (3) and the holding winding (2). Since both
coils generate opposed magnetic fields, the magnetic
field will collapse and the resetting spring (4) takes the
armature (1) back to its initial position.
This opens the current circuit on the contact plate and
the pinion (7) is pulled back from the ring gear (8) and
stops.
1 Armature
2 Holding winding
3 Pick-up winding
134 BOMAG 008 918 12

Magnetic switch Freewheeling clutch
Fig. 11 Direct acting electric motor Fig. 13 Freewheeling clutch

The freewheeling clutch is designed in such a way,
that the flow of force is automatically interrupted if the
pinion (5) of the clutch rotates faster than the free-
wheeling ring (1) at higher engine speeds.
This makes sure that the armature will only drive the
ring gear, but can never be driven by the engine.
1 Freewheeling ring
2 Roller
3 Roller spring
4 Splined shaft
5 Pinion
6 Pinion
Fig. 12 Geared motor

Armature (4), contact plate (3) and armature guide (6)
form a closed unit. When the ignition switch is turned
to "START", the armature is picked up and causes the
pinion of the clutch to disengage.
This causes the pinion and the ring gear to mesh,
while the contact plate establishes a connection be-
tween the contacts, which enable the main current to
flow into the armature. Once the ignition switch is
opened, the resetting spring (5) will pull the armature
back to initial position.
1 Holding winding
2 Pick-up winding
3 Contact plate
4 Armature
5 Resetting spring
6 Armature guide
008 918 12 BOMAG 135

Trouble shooting "Starter" Testing and measuring the starter

Function control with the starter removed
i Note
The most frequent fault is definitely a fully discharged
Caution
!
battery.
Fasten the starter to make sure that it will not
If the starter rotates too slowly, either the brushes come loose during the test.
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. Fig. 14
Occasionally worn contacts are found on the magnetic l
Connect a jumper lead between start terminal (1)
return switch and battery plus (2).
Defects on the actual starter motor including pinion l
Connect a jumper cable instantaneously between
and carbon brushes are very rare. starter housing and battery minus (3).
With a trouble shooting chart the faults in the starter
system can be narrowed down. The starter system i Note
can only work when many conditions are fulfilled at
If the motor does not start, the starter is defective. Re-
the same time.
pair or replace the starter.
l Immobilizer deactivated?
l Ignition switch OK? Checking the magnetic switch
l Travel lever in correct position?
l Emergency stop not actuated?
l Battery sufficiently charged?
l Battery poles OK?
l Main battery fuse OK?
l Main battery switch closed?
l Main starter cable (terminal 30) OK?
l Starter control cable (terminal 50) OK, voltage
drop?
l Ground cable OK?
l Switching of magnetic switches OK?
Fig. 15
The sequence of these tests is generally of no signifi-
cance. It mainly depends on:
l
Connect a jumper lead between start terminal (1)
and battery plus (2).
l the experience of the specialist
l
Connect a jumper cable instantaneously between
l the failure probability of the component to be tested
starter housing and battery minus (3).
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- i Note
paired or replaced. If the pinion does not disengage, the magnetic switch
is defective. Repair or replace the starter.
136 BOMAG 008 918 12

Continuity test for the magnetic switch
Fig. 16
l
Use a continuity tester to check for continuity be-
tween terminal (1) and terminal (29 while holding
the pin depressed.
l Replace the magnetic switch if no continuity is de-
tected.
008 918 12 BOMAG 137

6.28 Coolant temperature switch
6.28 Coolant temperature switch
Fig. 1 Coolant temperature switch
Pos. Designation in Designation Technical data

circuit diagram
B152 Coolant temperature switch Contact switches at approx. 110° C
to engine ground
138 BOMAG 008 918 12

Oil pressure switch and low oil pressure circuitry 6.29
6.29 Oil pressure switch and low oil
pressure circuitry
Fig. 1
1 Oil pressure switch

circuit diagram
1 B06 Oil pressure switch Below 0.8 bar the contact switches to
engine ground, closed without pres-
sure. Tightening torque 20 ± 2 Nm
with copper ring.
008 918 12 BOMAG 139

6.29 Oil pressure switch and low oil pressure circuitry
Fig. 2 Oil pressure switch

The oil pressure switch (B06) is mounted to the en-
gine oil filter. After starting it reports when a safe op-
erating pressure has been reached and causes the
warning light in the monitoring board (A15) to light, if
the engine oil pressure drops below approx. 0.8 bar.
In case of too low engine oil pressure with the engine
running, the monitoring board (A15) will send a time
delayed (10 sec.) 12 V signal to relay (K22, terminal
86). The relay interrupts the electric power supply to
the solenoid valve (Y13) and the diesel engine is shut
down.
140 BOMAG 008 918 12

Boost fuel solenoid valve 6.30
6.30 Boost fuel solenoid valve for rising the engine torque during the acceleration
phase after starting. For this compensation and to as-
During the starting process the solenoid valve is sup- sure starting of the cold engine additional fuel needs
plied with 12 Volt. to be injected at the time of starting and accelerating.
This injection adaptation serves the purpose of com-
pensating for condensation and leakage losses and
Fig. 3
1 Boost fuel solenoid valve

circuit diagram
1 Y01 Boost fuel solenoid valve 12 Volt, approx. 3,5 Amp.
008 918 12 BOMAG 141

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

circuit diagram
1 Y13 Engine solenoid 12 Volt, approx. 4 Amp.
General
When switching the ignition on, the engine solenoid is
supplied with 12 Volt.
Interrupting this power supply shuts down the engine.
The engine shut-down can be triggered through the
ignition switch (S00), the emergency stop button
(S01) or the monitoring board in case of too low oil
pressure.
142 BOMAG 008 918 12

Electric throttle control 6.32
6.32 Electric throttle control
Fig. 1 Engine solenoid
Throttle control switch
Fig. 2 Throttle control switch

The throttle control switch (S120) is used to change
from "MIN" to "MAX" idle speed and vice versa.
008 918 12 BOMAG 143

6.32 Electric throttle control
Throttle control solenoid Y120

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

The throttle control solenoid 5 (Fig. 3)) is equipped
with a pick-up winding (4) and a holding winding (3), Fig. 5
both switched in series. The holding winding has a l
Measure the gap between stop screw 1 (Fig. 5) and
much higher resistance than the pick-up winding. The
throttle lever (2).
"aux"-connection is connected between the two wind-
ings. The engine solenoid is equipped with a limit
switch (2), which is mechanically connected with the ! Caution
governor rod (1) on the diesel engine. This switch The gap should be min. 0.1 mm and max. 0.5 mm.
bridges the holding winding until the end position of
the governor rod is reached (high engine speed) If the gap is too small, the limit switch in the sole-
noid may not be able to operate.
This bridging has the effect, that the "aux"-terminal
has the same potential as the "+"-terminal. If the In case of a too wide gap the engine will not reach
bridge is open, the "aux"-terminal has almost the its maximum speed.
same potential as the "-" terminal, because of the low
resistance of the pick-up winding and the high resist-
ance of the holding winding.
Adjusting the solenoid
Fig. 4
l Switch on the ignition.
l Turn the rotary switch (Fig. 4) to position "MAX".
144 BOMAG 008 918 12

Heating flange on engine 6.33
6.33 Heating flange on engine the engine must be avoided and trouble shooting
should be performed instead.
Several successive starting attempts can cause
overheating of the heating flange .
Fig. 1 Heating flange

The heating flange is a component with an electrically
operated heating wire and high energy density used to
heat up the intake air in case of very low ambient tem-
peratures.
The heating power is approx. 2000 Watt.
The heating power improves the cold starting charac-
teristics and the exhaust emissions (white smoke) of
the diesel engine. Fig. 2 Heating flange (R19) with hose socket BF4M 2012 C
A differentiation is made between preheating, to as-
sure the cold start ability of the engine, and subse-
quent heating.
i Note
Pre-heating is triggered by switching on the ignition
(12 Volt on control unit A13, terminals 15(7) and S(2)).
With a coolant temperature of -30°C the preheating
time will be max. 52 seconds, with +5°C the minimum
time will be 38 seconds. During the preheating period
the control light in the monitoring board is permanently
on. In case of a fault the lamp will flash.
After-heating is triggered by the starting process (12
Volt on control unit A13, terminal 50(5)). With a cool-
ant temperature of -30°C the subsequent heating time
will be max. 180 seconds, with +25°C the minimum
time will be 35 seconds. This after-heating time is not
indicated by the control light.
! Caution
Multiple activation of the heater control in short
term operation (low generator running time) dis-
charges the starter battery.
If the engine does not start properly in case of au-
tomatic starting of the heating flange because the
starter does not get energized due to a fault and
does not crank the engine, the starting process
must be completely aborted (ignition key to OFF,
voltage supply to heating flange interrupted). In
order to avoid damage to heating flange or charge
air hoses caused by overheating, another start of
008 918 12 BOMAG 145

6.33 Heating flange on engine
Fig. 3
1 Heating control unit (A13)
2 Heating relay (K14)
Fig. 4 Coolant temperature sensor

1 Temperature sensor (B113) for heating flange
control (A13)
2 Coolant temperature switch (B30)
146 BOMAG 008 918 12

Heating flange on engine 6.33

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

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

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

1 Heating start
2 Signal lamp
3 Start
4 Switching relay
5 Condition
6 Terminal 15/S
7 Terminal L
8 Terminal 50
9 Terminal R
10 Start process
11 Ready for starting: 0 sec.
008 918 12 BOMAG 147

6.34 Checking the heating flange control
6.34 Checking the heating flange perature sensor is pulled off (simulated sensor fail-
ure), a coolant temperature of 0° C is assumed.
control
l Start the heating process.
Depending on the coolant temperature the control

light (K)(Fig. 1) will light between 30s and 50s, the
heating flange relay is energized.
l Place a tong-test ammeter over the heating flange
connecting line.
Rated current: 165 Amp +- 10 Amp.
i Note
The relay must remain energized for another approx.
15 seconds, after the control light has gone out.
After the engine has started the after heating time
must continue for 35 to 180 seconds. This after-heat-
Fig. 1 Monitoring module, old design (A15)
ing time is not indicated by the control light.
Fig. 2 Monitoring module, new design (A15)
i Note
During the preheating period the control light K (Fig.
1), c (Fig. 2) is permanently on. In case of a fault the
lamp will flash.
l The lamp flashes with a frequency of 1 Hz during
the pre-heating phase.
Sensor failure: Either short circuit or cable break-

age at the input to the control unit (A13), terminal
T(4)
l The lamp flashes with a frequency of 2.5 Hz over
the entire heating phase.
Heating flange failure: Either short circuit or cable

breakage at the output of the control unit (A13),
terminal R(6)
i Note
The heating flange only becomes active at a coolant
temperature below 25°C. When the plug of the tem-
148 BOMAG 008 918 12

Engine monitoring 6.35
6.35 Engine monitoring
Fig. 1 Monitoring module, old design Tank gauge, Pin 2: (0Ω ⇒ tank fuel, 65Ω ⇒ tank emp-
Output warning buzzer, Pin 1: +UB switching. ty, 26Ω ⇒ tank ½. If no level switch is connected or the
cable is broken, the gauge will go out.
Output engine shut down, Pin 9: +UB switching.
Water separator, Pin 3 and 4: Resistance <500kΩ .
Pos. Designation Control light Warning Engine Engine Remedy

buzzer shut-down shut-down
time time
10 sec. 2 min.
a Control light, over- red, flashing X X Switch off vibration, run
heating of engine Low-active engine with idle speed or
shut down engine if nec-
essary, clean engine oil
cooler and radiator, if
necessary repair engine.
b Engine oil pressure red, flashing X X Check the engine oil lev-
control light Low-active el, if necessary repair the
engine.
c Control light for en- not used
gine air filter Low-active
d Charge control light yellow, lights Check V-belt, if neces-
High-active sary repair the generator
i Control light, water yellow, lights X X Check, clean the water
in diesel filter separator
k Control light, pre- yellow, lights
heating monitoring Low-active
j Coolant provision not used
Low-active
e Hydraulic oil filter yellow, lights X X Change the hydraulic oil
Low-active filter
008 918 12 BOMAG 149

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

buzzer shut-down shut-down
time time
10 sec. 2 min.
g Control light, over- red, flashing X X Switch off vibration, run
heating of engine Low-active engine with idle speed or
shut down engine if nec-
essary, clean engine oil
cooler and radiator, if
necessary repair engine.
d Engine oil pressure red, flashing X X Check the engine oil lev-
control light Low-active el, if necessary repair the
engine.
h Control light for en- not used
gine air filter Low-active
f Charge control light yellow, lights Check V-belt, if neces-
High-active sary repair the generator
a Control light, water in yellow, lights X X Check, clean the water
diesel filter Low-active separator
b Control light, preheat- yellow, lights
ing monitoring Low-active
e Coolant provision not used
Low-active
i Hydraulic oil filter yellow, lights X X Change the hydraulic oil
Low-active filter
150 BOMAG 008 918 12

Engine monitoring 6.35
Water separator l Push the plug back on, the plug interlock clicks into
place.
l Check the plug interlock by lightly pulling on the wir-
ing loom.
Engine overheating
Fig. 3 Sensor water separator

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

l Press on the locking wire and pull off the plug 1 (Fig.
4).
l
Apply the contact to engine ground. Fig. 6 Emergency stop switch
l
Press the emergency stop switch (Fig. 6). The en-
i Note gine should stop immediately.
The control light b (Fig. 1) d (Fig. 2) flashes. An audi-
ble warning will sound and the engine is shut down af-
ter 10 seconds.
008 918 12 BOMAG 151

6.36 Overview of electric components
1) Wiring loom cabin
152 BOMAG 008 918 12

Overview of electric components 6.36
1) Wiring loom engine
008 918 12 BOMAG 153

1) Wiring loom supply central electrics

2) Wiring loom battery-starter
3) Wiring loom ground, engine-frame
4) Wiring loom, battery-fuses
5) Wiring loom ground, battery-frame
154 BOMAG 008 918 12

1) Wiring loom rear frame
008 918 12 BOMAG 155

4) Wiring loom speedometer
156 BOMAG 008 918 12

4) Wiring loom wiring of frequency display

8) Wiring loom transducer for vibration frequency
9) Wiring loom adapter transducer
008 918 12 BOMAG 157

13) Wiring loom, tachograph-cabin
158 BOMAG 008 918 12

7) Wiring loom working lights
008 918 12 BOMAG 159

11) Wiring loom, lighting on railing
160 BOMAG 008 918 12

3) Wiring loom heating fan, new design

4) Wiring loom air conditioning, new design
008 918 12 BOMAG 161

1) Wiring loom acceleration transducer

5) Wiring (P16)
162 BOMAG 008 918 12

Operator's stand, old design 6.37
Fig. 7 7 S35, rotary switch vibration, high/low frequency

1 S00, ignition switch 8 S42, rotary switch, travel speed ranges
2 A15, instrument cluster 9 S01, Emergency stop switch
3 Vent for heating and ventilation, driver 10 S03, push button, warning horn
4 Vent for heating and ventilation, footwell 11 S120, rotary momentary contact switch for engine
5 S13, push button for vibration speed
6 Travel lever 12 S37, rotary switch for direction indicators left/right*
008 918 12 BOMAG 163

6.37 Operator's stand, old design
13 S14, rotary switch for hazard light system*

14 S15, rotary switch for lighting (StVZO)*
15 S53, rotary switch for working lights*
16 Steering wheel adjustment lever
* Optional equipment
164 BOMAG 008 918 12

Operator's stand, new design 6.38
Fig. 8 6 Vent for heating and ventilation, footwell

1 S00, start switch 7 S13, push button for vibration
2 A15, instrument cluster 8 Travel lever
3 A108, rotary switch for cabin fan 9 S35, rotary switch vibration, high/low frequency
* 10 S42, rotary switch, travel speed ranges
4 A108, rotary switch for air conditioning
5 Vent for heating and ventilation, driver 11 S01, Emergency Stop switch
* Optional equipment 12 S03, push button, warning horn
008 918 12 BOMAG 165

6.39 Cabin
13 S120, rotary momentary contact switch for engine 6.39 Cabin

speed
14 S37, rotary switch for direction indicators*
15 S14, rotary switch for hazard light system*
16 S15, rotary switch for lighting (StVZO)*
17 S53, rotary switch for working lights*
18 Steering wheel adjustment lever
19 Rotary switch for cabin heater
Fig. 9
a = S38, toggle switch for flashing beacon
b = S20, toggle switch for front windscreen wiper/

washer
up = windscreen wiper moves to end
position and stops.
down = Switches on front windscreen wip-
ing.
Push button = Front windscreen is sprayed dur-
ing wiping.
c = S21, toggle switch for rear windscreen wiper/

washer
up = windscreen wiper moves to end
position and stops.
down = Switches on wiping of rear wind-
screen.
Push button = Rear windscreen is sprayed dur-
ing wiping.
d = S163, toggle switch for rear windscreen heat-

ing
166 BOMAG 008 918 12

Fuses, old design 6.40
6.40 Fuses, old design
Fig. 10
g = E29, Reading and dashboard light Fig. 11

No. 2 = Fuse box, cabin
h = S45, Toggle switch for cabin lamp
i = S158, Toggle switch for reading and dashboard ! Danger

light
Fire hazard!
j = E70, Cabin lamp Do not use fuses with higher ampere ratings and
do not bridge fuses.
(1), 15A = (F43) Wiper/washer, rear
(2), 15A = (F44) Wiper/washer, front
(3), 10A = (F130) Relay for rear windscreen heat-
ing, reading light
(4), 20A = (F31) Cabin ventilator
(5), 10A = (F41) Flashing beacon
(6), 15A = (F144) Cab socket
(7), 15A = (F143) Rear windscreen heating
(8), 10A = (F42) Potential 30, cab light
Fig. 12
No. 3 = Fuses in electric installation box
i Note
Open the flap on the left hand side under the opera-
tor's stand
F03, 15A = Vibration
F05, 15A = Socket
008 918 12 BOMAG 167

6.41 Fuses, new design
F07, 15A = Hazard light* 6.41 Fuses, new design

F09, 10A = Parking tail light, left*
F10, 10A = Parking tail light, right*
F11, 15A = Head lights, StVZO*
F13, 30A = Starting
F14, 15A = Engine solenoid
F18, 10A = Working head lights, relay*
F19, 15A = Working head lights, front, left*
F22, 15A = Working head lights, rear*
F23, 10A = Warning horn
F24, 10A = Monitoring, gauges
F25, 10A = Solenoid valve brake/travel
Fig. 13
F39, 15A = Cab*
F70, 15A = Indicator*
! Danger
F105, 20A = Engine speed control
Fire hazard!
Do not use fuses with higher ampere ratings and
Danger
!
Fire hazard!
(1) 15A = (F43) Wiper/washer, rear
(2) 15A = (F44) Wiper/washer, front
(3) 10A = (F130) Night light
(4) 25A = (F31) Cabin ventilator
(5) 10A = (F41) Flashing beacon
(6) 15A = (F144) Cab socket
(7) 15A = (F143) Rear windscreen heating
(8) 10A = (F42) Cab lights
Fig. 14
No. 4 = Fuses in electric junction box
! Danger
Fire hazard!
(15) 30A = (F13) Start switch
(16) 5A = (F68) Electronic immobilizer
* Optional equipment (17) 20A = (F105) Engine speed
168 BOMAG 008 918 12

Electronic control units 6.42
(18) 15A = (F11) Front head lights* 6.42 Electronic control units
(19) 15A = (F07) Hazard light
(21) 15A = (F22) Working headlights, rear Control units
(22) 15A = (F19) Working headlights, rear Control units (ECU = electronic control unit or ECM =
(23) 15A = (F09) Parking and tail light, left* electronic control module) are electronic modules
which are mainly installed in places where something
(24) 15A = (F10) Parking and tail light, right*
needs to be controlled or regulated. Control units are
(25) 15A = (F08) Direction indicators* used in almost any electronic sector in the automotive
(26) 10A = (F18) Pre-fuse for working head lights industry, but also to control machines, plants and oth-
er technical processes.
(27) 15A = (F14) Engine solenoid
Control units generally work according to the IPO-
(28) 10A = (F23) Warning horn
principle. IPO stands for Input-Processing-Output.
(29) 10A = (F25) solenoid valve for driving and brak- Sensors are available for input. Sensors determine a
ing physical characteristic like e.g. rotary speed, pres-
(30) 15A = (F39) Main fuse for cabin sure, temperature, etc. This value is compared with a
setpoint entered into or calculated in the control unit.
(31) 10A = (F24) Instruments
If the measured value does not match the stored val-
(32) 15A = (F03) Vibration ue, the control unit regulates the physical process by
(33) 10A = (F148) Control MESX, potential 15* means of actors, so that the measured actual values
match the setpoint again. This means that the actors
(34) 10A = (F84) control, contact 54
correctively interfere with the ongoing process.
(35) 15A = (F146) Control MESX, potential 30*
(37) 25A = (F124) Fuel pre-heating*
Fig. 1 Electronic control (ESX)

In current vehicles control units are linked via various
system buses (CAN, LIN, MOST, Flexray). The units
exchange information about operating states and oth-
Fig. 15
er relevant data in vehicle across the system. Further-
(80) 5A = (F150) GPS Receiver* more, the on-board diagnostic or the diagnostic
system of the vehicle is connected via such busses
(and possible K-lines). Furthermore, external diag-
nostic devices (alternatively Personal Computers or
Notebooks plus matching Interface) can communicate
with the control units. In this case the system will be
interrogated to find out whether the permanent self
tests of the control unit has revealed and registered
any faults in itself or on the connected sensors.
008 918 12 BOMAG 169

6.42 Electronic control units
Modules Signals
In the latest generation of machines BOMAG uses Analog signals
machine programmable modules. A module mainly
consists of a programmable microprocessor with ad- Process states are continuous (analog) when they
ditional circuitry for inputs and outputs. can be mapped by means of a real number, e.g. tem-
perature = 65.5 °C. The sensor converts a continuous
process status into an analog signal. If the control unit
needs the numerical value of the analog signal, an an-
alog-digital conversion is required.
Analog signals are needed to control, display or mon-
itor limit values. Checking the limit values of physical
quantities leads to the binary information: limit value
reached/not reached.
Binary signals
Process states are bivalent (binary) if they have only
2 possible states of truth, such as e.g. button pressed/
not pressed, object present/not present. The two
states of truth are mapped by means of defined states
of an information carrier, e.g. 'not pressed' equals 0 V,
'pressed' equals 24 V. These states are described
with {0,1} or {false, true}
Fig. 2 Module
The modules have control lights on inputs and outputs
to monitor the applied signals.
170 BOMAG 008 918 12

Electronic control units 6.42
CAN-bus, Controller Area Network
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. 3
Why CAN?
l
Networking of control units for the realization of
complex functions.
l
Reduction of the extend of wiring and plug connec-
tions.
l
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
Measuring on the CAN

Signals transmitted through the bus line can generally
not be measured with simple measuring instruments.
Testing is therefore quite complicated for the user.
Correct connection of lines can only be checked by
means of a continuity test. BOMAG display modules
are connected to the BUS to give engineers and user
the possibility to detect faults or to receive information
from the BUS.
008 918 12 BOMAG 171

6.43 Checking the voltage supply for the control unit
Power supply for a control unit, general

All electronic switching and control units require an electric power supply to be able to work. If the plus or minus
supply is faulty, the control unit will work incorrectly or fail.
i Note
The following describes the electric power supply for the ESX-control.
(Fig. 4) shows a simplified representation of how the control unit (ESX, 68 pole) is connected. The complete rep-
resentation can be found in the wiring diagram of the machine.
The procedure can also be used for other controls. Pin assignment and voltage supply may be different, but the
procedures for line testing are generally the same.
Fig. 4 Circuitry example

1 = Engine block
ESX = Control unit
F00 = Main fuse
Fx,Fxx = Fuses potential 30
Fxxx = Fuses potential 15
G = Generator
G01 = Battery
GND = Housing earth
H08 = Charge control light
S00 = Ignition switch
S01 = Emergency stop switch
Pin 28 = Voltage supply for control
Pin 54 = if the signal (12/24 Volt) is applied, the control is switched on
Pin 55 = Ground supply for control
Pin 56 to 60 = Voltage supply for outputs
GND = Housing earth
172 BOMAG 008 918 12

Checking the voltage supply for the control unit 6.43
Fault in current supply, general
Clear interruptions in the plus or minus supply are relatively easy to detect. However, the plus and minus sides
of control units are in most cases connected to the vehicle mains supply via several cables, so that several par-
allel current branches exist. Checking the power supply is therefore slightly more difficult than expected. Another
point is the fact that every current branch has several plug connections, which could corrode over the years.
Corroded points are transition resistances and thus cause undesired voltage drops. In case of undesired voltage
drops the control unit is supplied with a lower voltage. This can lead to faulty reactions or even failure of the
control unit.
Fig. 5 Circuitry example

The arrows point to the contact locations, which may be the cause if a control unit only receives a reduced supply
voltage.
The following faults may occur:
l
Line interruption in a plus supply line
l high voltage drop in a plus supply line
l
line interruption on the minus side
008 918 12 BOMAG 173

Measuring principle for line testing

When a line conducts an electric current, a voltage drop will occur in the line (UV). The size of this voltage drop
UV depends on:
l the available amperage (I) and
l the electric resistance (Rline) of the current branch being checked.
In order to have reliable comparison possibilities at hand one should always work with the same amperage. Iden-
tical marginal conditions are therefore used in all of the following examples:
12 Volt – vehicle battery as voltage source or 24 Volt in a 24 Volt vehicle network.
12 V / 21 W – lamp as load in a 12 Volt vehicle network.
24 V / 21 W - lamp as load in a 24 Volt vehicle network.
Test steps
1. Switch off the ignition.
2. Unplug the control unit from wiring loom.
3. If available connect the Pinbox (Fig. 6) to the plug of the wiring loom, do not connect the control unit with the
Pinbox. If no Pinbox is available, provide measuring cables with appropriate plug-in contacts, e.g. spade-type
plugs.
4. Check with multimeter. If a setpoint is not reached, proceed step by step to identify the weak spot. Repair as
necessary. Repeat the measurement.
! Caution
The plug must not be pulled off or plugged on while the ignition is switched on. Switch off the ignition
first and then pull off or plug on the plug.
Only plug the wiring loom onto the control unit, when the actual value corresponds with the setpoint.
Fig. 6 Pinbox for 68 pole ESX control
174 BOMAG 008 918 12

General measuring setup to check a supply line (plus side)
Fig. 7 Measuring arrangement 12 Volt

1 = Supply line, plus side
2 = Plug contact in wiring loom plug on control or Pinbox (Fig. 6)
E = Lamp, 12V / 21 Watt
P = Multimeter
G01 = Battery as voltage source, 12V
UV = Voltage drop caused by the lamp current
Setpoint
The voltage drop UV should not exceed 0.5 V => USetpoint ≤ 0.5 V.
008 918 12 BOMAG 175

General measuring setup to check a return line (minus side)
Fig. 8 Measuring arrangement 12 Volt

1 = Return line, minus side
2 = Plug contact in wiring loom plug on control or Pinbox (Fig. 6)
E = Lamp, 12V / 21 Watt
P = Multimeter
G01 = Battery as voltage source, 12V
UV = Voltage drop caused by the lamp current
Setpoint
The voltage drop UV should not exceed 0.5 V => USetpoint ≤ 0.5 V.
176 BOMAG 008 918 12

Connection example to check the plus line between battery and plug pin 28
Fig. 9
X = Wiring loom plug disconnected from control unit or Pinbox (Fig. 6)
P = Multimeter
S00 = Ignition switched on. Setpoint : E is bright. UV max. 0.5 Volt
S00 = Ignition switched off. Setpoint : E is dark. UV = 0.0 Volt
008 918 12 BOMAG 177

Connection example to check the minus line between battery and plug pin 55
Fig. 10
P = Multimeter
X = Wiring loom plug disconnected from control unit or Pinbox (Fig. 6)
E = Setpoint : E is bright. UV max. 0.5 Volt
178 BOMAG 008 918 12

Test protocol for ESX
E lamp 12V / 21W in 12V vehicle network, to load the current branches.
E lamp 24V / 21W in 24V vehicle network, to load the current branches.
G01, battery
P multimeter, measuring range: DC
Plug pin Note Setpoints

28 Ignition ON
E between plug pin 28 and battery minus E is bright,
P between battery plus and plug pin 28 UV max. 0.5 Volt
28 Ignition OFF
E between plug pin 28 and battery plus E is dark,
P between battery minus and plug pin 28 UV = 0 Volt
54 Ignition OFF, emergency stop not operated
54 Ignition OFF, emergency stop operated
E between plug pin 54 and battery minus E is dark,
P between battery plus and plug pin 54 UV = 0 Volt
55 Ignition OFF
56, 57, 58, 59, Ignition OFF
60 E between plug pin 56, 57, 58, 59, 60 and battery minus E is bright,
P between battery plus and plug pin 56, 57, 58, 59, 60 UV max. 0.5 Volt
i Note
If one or several setpoint(s) is (are) exceeded, one must make considerations which are related to the wiring
diagram.
Example 1:
In all supply lines to the pins 56, 57, 58, 59 and 60 the voltage drop is too high. There are two possible reasons.
Either all contacts are corroded, or the supply line between battery and fuse Fxx has poor contact.
Example 2:
Only one measuring value exceeds the setpoint. In this case the fault must be located between the last branch
and the corresponding plug pin.
008 918 12 BOMAG 179

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

After the customer has explained his complaint(s) the engineer has to ask further questions to track down the
cause of the fault. If the complaint is additionally related to electric/electronic components, the visual examina-
tion and a possible test drive must be subsequently followed by an interrogation of the error log. The further pro-
cedure in this case depends on the outcome of this interrogation.
Description of fault,
Questioning of customer
Visual inspection,
possible test drive
Interrogation of error log
(1)
Fault memorized in
error log
(2)
No fault memorized in
error log
Fig. 11
(1) Fault memorized in error log

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

l
What could be the cause of the complaint?
l
Which measuring possibilities are available?
180 BOMAG 008 918 12

Diagnostics concept 6.44
Localizing faults
Line or component?
Fig. 12
l
In most cases the fault message does not clarify whether the fault is in the sensor or actor, or in one of the
connecting lines (2) between control unit and the mentioned component (1). For this purpose it makes sense
to check the component and the connecting lines between control unit and component separately.
l
Checking the voltage supply for the control unit
l
Checking the sensor lines
l
Checking the actor lines
008 918 12 BOMAG 181

Sequence after the fault is found
Fault found
Replace component or
repair the connecting line
Delete the error log, test drive

Read out the error log again
No fault memorized in
error log
Prepare the hand-over of the vehicle
Fault memorized in
error log
Check all work again,
rectify the fault
Fig. 13
182 BOMAG 008 918 12

7 Electronic modules
008 918 12 BOMAG 183

184 BOMAG 008 918 12
7.1 BEM, BOMAG Evib-meter
008 918 12 BOMAG 185

Bild 14
i Hinweis
The documentation "Service Training Electrics MESX" contains also the documentation BEM (BOMAG Evib-me-
ter).
The BOP (BOMAG Operation Panel) is only installed in connection with BVC machines, BEM-machines are
equipped wit display module. The display module is used for the output of fault codes and display values, as
well as for the input of code numbers.
186 BOMAG 008 918 12

BEM, BOMAG Evib-meter 7.1
Service Training
Electrics
MESX
P/N 00809705
Version 4.01
Status: 14.12.2009 Page 1 of 61

Author: T.Löw / TE
Dateiname: p:\schulung\elektrik_doc\wz\mesx_bvc\englisch\schulung elektrik mesx_v4.01_gb.doc
008 918 12 BOMAG 187

Service Training MESX
Table of contents
1 Document alteration list.....................................................................................................................3
2 Proof of software change MESX .......................................................................................................4
3 Proof of software change BOP..........................................................................................................6
4 Known faults......................................................................................................................................7
5 How to proceed when replacing components?.................................................................................8
5.1 How to proceed when replacing an ESX control? .....................................................................8
5.2 How to proceed when replacing a rear axle sensor? ................................................................8
5.3 Which components can be replaced without a subsequent adjustment procedure? ................8
5.4 List of machine types .................................................................................................................9
6 Possible adjustments on machines without BOP ...........................................................................12
6.1 Description of the Display Module ...........................................................................................12
6.2 Input of code numbers .............................................................................................................12
6.3 Changing the machine type (only via display module) ............................................................13
6.4 Inverting the direction signal (only via display module) ...........................................................14
6.5 Changing the bit rate (only with display module).....................................................................15
7 Adjustment/display possibilities on machines with BOP.................................................................16
7.1 Adjusting the machine type (BOP)...........................................................................................16
7.2 Inverting the direction signal via the BOP control terminal ......................................................18
7.3 Accessing the diagnostics menu .............................................................................................20
7.3.1 Extended diagnostics on machines with circular exciter (BTMplus, BTMprof) ................. 22
7.3.2 Extended diagnose BVC machines ......................................................................................... 23
7.4 Changing the printout language...............................................................................................24
7.5 Setting the machine serial number ..........................................................................................26
7.6 Teaching distance pulses ........................................................................................................28
7.7 Activating the amplitude limitation (only BVC machines) ........................................................30
7.8 Changing the display mode (metric/imperial) ..........................................................................32
7.9 Switching the GPS Receiver Voltage Supply Mode ................................................................34
8 Possible settings on the BCM05mobile ..........................................................................................36
8.1 Reading the software version ..................................................................................................36
8.2 Changing the language............................................................................................................36
8.3 Changing the unit system (metric/imperial) .............................................................................36
9 Block diagram BEM.........................................................................................................................37
10 Block diagram BTMplus / VARIOCONTROL...............................................................................38
11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile................................................39
12 Description of the signals on the ESX-control .............................................................................41
13 Fault codes of the ESX control ....................................................................................................47
13.1 Overview ..................................................................................................................................47
13.2 Description of fault reactions ...................................................................................................48
13.3 Detailed description of fault codes and their possible causes................................................49
14 Input codes for ESX control (only via BEM display module) .......................................................53
14.1 Travel system...........................................................................................................................53
14.2 Vibration ...................................................................................................................................54
14.3 Light .........................................................................................................................................54
14.4 Acceleration transducer ...........................................................................................................55
14.5 Diesel engine ...........................................................................................................................55
14.6 Setting the machine type .........................................................................................................56
14.7 Parameter change ...................................................................................................................57
15 Terminology in connection with ESX...........................................................................................58
Status:14.12.2009 Page 2 of 61
Author: T.Löw / TE
188 BOMAG 008 918 12

1 Document alteration list
Version Date Description of changes resp.

0.00 27.04.2004 Creation of version 1 Löw
1.00 05.05.2004 Î Block diagrams added Löw
Î Description of display module extended
Î "Proof of software change" added
1.01 23.07.2004 Î Description of BOP display pages added. Löw
2.00 31.08.04 Î Input code 4602 replaced by code 4606 Löw
Î Machine type BW219D added
3.00 15.10.2004 Î Item "How to proceed when replacing components?" added Löw
Î Description for ESX Pin 0:35 added
Î Description fault code 4601 and 4606 corrected
Î Description Software Version 3.00 added
3.01 14.02.2005 Î Description Code 7534 from version 3.00 added Löw,
Î Description Software change V3.01 added Horch
Î Description Code 7573 from version 3.01 added
Î Description of menus "Amplitude limitation" and "Imperial
display" added
Î Description Software Version up to 3.03 added
Î Terminal designation MESX changed from X0 to X44
Î Description of codes 7502, 7511, 7512, 7532, 7541, 7542,
7550, 7551, 7552, 7562, 7571, 7572, 7576 from version 3.03
added
Î Proof of "Software change" changed to "Software MESX"
Î Item "Proof of software change BOP" added
Î Item "Adjustment possibilities on BCM05mobile" added
Î Block diagram BTMplus / VARIOCONTROL and
BCM05mobile added
Î Serial numbers added to list of machine types
4.00 01.05.2007 Î Description of "GPS Mode" menu added Löw
Î Item "Change language" changed for BCM 05
Î Description fault code 4531 and 4532 extended
Î List of machine types extended
4.01 20.11.2009 Î further SN added Vogt,

Î List of machine types extended Löw
Î Software version history extended
Author: T.Löw / TE
008 918 12 BOMAG 189

2 Proof of software change MESX

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

BW179DH/PDH corrected
3.05 19.05.2005 Î Phase response correction acceleration transducer Löw
activated
Î "Flash Request" activated
Author: T.Löw / TE
190 BOMAG 008 918 12


4.00 01.05.2005 Î Languages Slovakian, Slovenian, Czech, Romanian Löw
added
Î Function "vCheckMMISoftwareVersion" corrected
Î Teach mode for distance via BCM implemented
Î Triggering of a relay for GPS receiver voltage supply
implemented
Î GPS mode changed: Off and ON now independent from
engine run, Automatic depending on engine run!
Î Setting of work number in serial number has been
realized
Î ATTENTION: Signal distribution for CAN message
MMI_CONFIG_DATA_2 0x156 was changed!!!
Î 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_40,21
3DHC,213PDHC,213PD_40,214DHC,214PDHC,216DHC
,216PDHC,212D_40,212PD_40
Î Pulse numbers changed to 10m for BW219D
Î VM classes taken from V3.90, VM class is sent to BCM
4.01 23.05.2007 Î Vibration detection low/high amplitude adapted Löw
4.02 07.05.2008 Î Pulse numbers for BW213DHC and PDHC adapted Löw,
Î Faulty input for VM8 for machine type BW219DHC Nick
corrected
4.03 27.01.2009 Î Minimum Evib-value limited to 1, so that BCM does no Löw
longer interpret this value incorrectly
4.04 17.11.2009 Î Machine types BW216D_40, BW216PD_40 and Löw
BW218D_40 implemented
Author: T.Löw / TE
008 918 12 BOMAG 191

3 Proof of software change BOP

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

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

Î Designation "ESX" replaced by "MESX" and "BOP" by
"BOP"
3.02 10.02.2005 Î Amplitude bar graph in imperial display mode corrected Löw
4.00 01.05.2007 Î Flags for all EU-languages and additionally Japan and Löw
China stored in OPUS
Î Page for changing over GPS Receiver Mode implemented
Î Triggering for fault LED in BVC diagnostics page 2
activated
4.01 04.11.2008 Î - additional variable for brightness control OPUS21C Löw

added
Î - Representation of SW TN instead of "High-TN"
Î - Return to diagnostic page corrected for French
version
Î - SimulScreen activated for French version
Î - Changeover of GPS-mode prevented (jump to
page GPS-mode deactivated)
4.02 13.01.2009 Î Return to selection page "Scale type" corrected. Löw
Author: T.Löw / TE
192 BOMAG 008 918 12

4 Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
Behaviour of machine Possible cause
During initial commissioning the display shows the Bit rate on bmfsa not set to 125 kBit
reading "ct0" => see "Setting the bit rate"
Author: T.Löw / TE
008 918 12 BOMAG 193

5 How to proceed when replacing components?

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

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

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

recommended.
Author: T.Löw / TE
194 BOMAG 008 918 12

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
101 583 27 1001
177 PD 101 583 43 1001 XXX XXX XX XXXX
177 DH 101 582 21 1001 XXX XXX XX XXXX 7501 1.00
101 583 32 1001
177 PDH 101 582 22 1001 XXX XXX XX XXXX 7502 3.03
101 583 31 1001
177 BVC 101 582 23 1001 XXX XXX XX XXXX 7503 1.00
101 583 28 1001
179 DH 101 582 24 1001 XXX XXX XX XXXX 7511 3.03
101 583 33 1001
101 583 35 1001
211 D 101 582 40 1001 XXX XXX XX XXXX 7520 1.03
101 582 41 1001
101 583 09 1001
211 PD 101 582 45 1001 XXX XXX XX XXXX 7529 4.00
101 583 10 1001
213 D 101 582 50 1001 XXX XXX XX XXXX 7530 1.03
101 583 08 1001
213 DH 101 582 51 1001 XXX XXX XX XXXX 7531 1.03
101 583 14 1001
101 583 37 1001
213 PD 101 582 46 1001 XXX XXX XX XXXX 7539 4.00
101 583 13 1001
101 583 15 1001
101 583 16 1001
213 BVC plates 101 582 54 1001 XXX XXX XX XXXX 7534 3.00
101 583 06 1001
213 BVC DI 101 582 53 1001 XXX XXX XX XXXX 7535 1.05
101 583 16 1001
214 D 101 583 42 1001 XXX XXX XX XXXX
214 DH 101 582 58 1001 XXX XXX XX XXXX 7541 3.03
101 583 19 1001
101 583 20 1001
216 D 101 582 62 1001 XXX XXX XX XXXX 7550 3.03
101 583 23 1001
216 DH 101 582 60 1001 XXX XXX XX XXXX 7551 3.03
101 582 64 1001
216 PD 101 582 63 1001 XXX XXX XX XXXX 7559 4.00
101 583 24 1001
Author: T.Löw / TE
008 918 12 BOMAG 195

101 582 65 1001
version
219 D 101 582 72 1001 XXX XXX XX XXXX 7560 2.00
101 582 10 1001
861 582 75 1001
219 DH 101 582 70 1001 XXX XXX XX XXXX 7561 1.05
101 582 77 1001
219 PD 101 582 73 1001 XXX XXX XX XXXX 7569 4.00
101 582 11 1001
101 582 78 1001
226 DH 101 582 80 1001 XXX XXX XX XXXX 7571 3.03
101 582 83 1001
101 582 88 1001
101 582 84 1001
101 582 89 1001
101 582 85 1001
101 582 86 1001
226 BVC DI 101 582 82 1001 XXX XXX XX XXXX 7575 1.04
101 582 85 1001
101 582 86 1001
226 BVC RC 101 582 82 1001 XXX XXX XX XXXX 7576 3.03
101 582 85 1001
101 582 86 1001
332 XL 101 583 44 1001 XXX XXX XX XXXX
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
Status:14.12.2009 Page 10 of 61
Author: T.Löw / TE
196 BOMAG 008 918 12

version
177 D-40 901 582 26 1001 XXX XXX XX XXXX 7600 4.00
177 DH-40 901 582 27 1001
177 DHC-4 101 582 00 1001 XXX XXX XX XXXX 7601 4.00
101 583 29 1001
177 PDHC-4 101 582 01 1001 XXX XXX XX XXXX 7602 4.00
101 583 30 1001
177 PDH-40 901 582 28 1001 XXX XXX XX XXXX 7609 4.00
101 583 34 1001
101 583 36 1001
211 D-40 101 582 42 1001 XXX XXX XX XXXX 7620 4.00
901 583 02 1001
901 583 25 1001
211 PD-40 101 582 47 1001 XXX XXX XX XXXX 7629 4.00
901 583 03 1001
901 583 26 1001
212 D-40 101 582 43 1001 XXX XXX XX XXXX 7680 4.00
212 PD-40 101 583 48 1001 XXX XXX XX XXXX 7689 4.00
213 D-40 101 582 44 1001 XXX XXX XX XXXX 7630 4.00
901 582 55 1001
901 583 07 1001
213 DH-40 901 582 56 1001
101 583 11 1001
101 583 12 1001
213 PD-40 101 582 49 1001 XXX XXX XX XXXX 7639 4.00
213 PDH-40 901 582 57 1001
101 583 17 1001
101 583 18 1001
216 D-40 101 583 39 1001 XXX XXX XX XXXX 7650 4.04
101 583 21 1001
216 PD-40 101 583 40 1001 XXX XXX XX XXXX 7659 4.04
101 583 22 1001
218 D-40 101 583 34 1001 XXX XXX XX XXXX 7670 4.04
Status:14.12.2009 Page 11 of 61
Author: T.Löw / TE
008 918 12 BOMAG 197

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).
Vorzeichen
057 667 72
15/54
The following description describes the input of code numbers.
6.2 Input of code numbers

For the diagnostics of control inputs and outputs various code numbers can be entered via the display
module of the control. The input of a code number is performed as follows:
1. Press both keys (F1 and F2) on the instrument cluster for 2 seconds.
) The value 0 0 0 0 will be displayed, whereby the 1st digit is flashing.
2. The value of the flashing digit can be increased by pressing the left hand key (F1). When the figure
9 is displayed and the left hand key (F1) is pressed again, the display will return to the value 0 .
3. When pressing the right hand key (F2) the flashing digit will move one digit to the right. When the
4th digit is flashing, the right hand key (F2) is pressed once again to confirm the input. The desired
function is then executed or the desired value is displayed respectively.
In order to terminate a display function you must either enter code number 0 0 0 0 or switch the
ignition off.
Status: 14.12.2009 Functiona of the ESX control Page 12 of 61

Author: T.Löw / TE
198 BOMAG 008 918 12

6.3 Changing the machine type (only via display module)

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

Author: T.Löw / TE
008 918 12 BOMAG 199

6.4 Inverting the direction signal (only via display module)

Depending on the installation position, the axle sensor used delivers a 12V output signal in forward
and reverse.
This direction signal may need to be inverted, so that exciter adjustment (only BVC machines) and
printout for the the travel direction correspond with the actual travel direction.
Enter code number 7 6 0 0 . This code number activates the function "Invert direction signal“.
The display module now permanently shows the code 7 6 0 0 .
Enter code number 7 6 0 1 . This code number inverts the direction signal.
The display module now permanently shows the code 0 0 0 1 (signal 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").

Author: T.Löw / TE
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6.5 Changing the bit rate (only with display module)

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

Author: T.Löw / TE
008 918 12 BOMAG 201

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

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

Author: T.Löw / TE
202 BOMAG 008 918 12

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

Author: T.Löw / TE
008 918 12 BOMAG 203

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 the travel direction correspond with the actual travel direction.
Press key "F1" to open the screen page "Invert direction signal". The following screen is
displayed:

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

Author: T.Löw / TE
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7.3 Accessing the diagnostics menu

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

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

Author: T.Löw / TE
008 918 12 BOMAG 207

7.3.1 Extended diagnostics on machines with circular exciter (BTMplus,

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

Author: T.Löw / TE
208 BOMAG 008 918 12

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

Author: T.Löw / TE
008 918 12 BOMAG 209

7.4 Changing the printout language

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

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

Author: T.Löw / TE
008 918 12 BOMAG 211

7.5 Setting the machine serial number

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

Author: T.Löw / TE
212 BOMAG 008 918 12

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

Author: T.Löw / TE
008 918 12 BOMAG 213

7.6 Teaching distance pulses

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

Author: T.Löw / TE
214 BOMAG 008 918 12

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

Author: T.Löw / TE
008 918 12 BOMAG 215

7.7 Activating the amplitude limitation (only BVC machines)

Press key "F3" to open the screen page "Amplitude limitation". The following screen is displayed:

Author: T.Löw / TE
216 BOMAG 008 918 12

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

Author: T.Löw / TE
008 918 12 BOMAG 217

7.8 Changing the display mode (metric/imperial)

Press key "F4" to open the screen page "Display mode". The following screen is displayed:

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

Author: T.Löw / TE
008 918 12 BOMAG 219

7.9 Switching the GPS Receiver Voltage Supply Mode

Press key "F14" to open the screen page "GPS Mode". The following screen is displayed:

Author: T.Löw / TE
220 BOMAG 008 918 12

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

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

Author: T.Löw / TE
008 918 12 BOMAG 221

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

Author: T.Löw / TE
222 BOMAG 008 918 12

Service Training MESX Block diagram
008 918 12
9 Block diagram BEM
BEM, BOMAG Evib-meter
BOMAG
Status: 14.12.2009 Block diagram Page 37 of 61
Author: T. Löw / TE
7.1
223
224
7.1
10 Block diagram BTMplus / VARIOCONTROL
BOMAG
008 918 12
008 918 12
11 Block diagram BTMplus / VARIOCONTROL and BCM05mobile
BOMAG
7.1
225
226
7.1
BOMAG
008 918 12
Service Training MESX Description of signals
008 918 12
12 Description of the signals on the ESX-control
Notes:
1. Wherever the value of 12 V is mentioned in the following text, it refers to the current battery
voltage under due consideration of voltage drops in the lines.
ESX terminal Signal description Nominal values (voltage / current)

X44:1 AGND = Analogue ground: Ground potential for sensors (steering approx. 0 V measured against ground (terminal 31)
joystick, speed range switch etc.)
X44:2
X44:3 Output Evib Display PWM signal (100Hz): ) ca. 0..6 V

PWM (max. 2.5 A)
X44:4 Interface RS 232 RxD, used for printer control. Measurement not possible!
X44:5 Interface RS 232 TxD, used for printer control. Measurement not possible!
X44:6
BOMAG
X44:7 Input acceleration transducer VH20g/HR15g Acceleration signal (measured against AGND)
Open circuit voltage (vibration off): ) 4.2 .. 4.3 V

Analog input / voltage input 0..8.5 V
X44:8
X44:9 Input exciter position front Position of front exciter (measured against AGND)
Analog input / voltage input 0..8.5 V Stop bottom ) approx. 2.2 V
Neutral position ) approx. 4.25 V
Stop top ) approx. 6.6 V
Status: 14.12.2009 Description of signals Page 41 of 61

7.1
227
228
7.1

X44:10
X44:11
X44:12
X44:13
X44:14
X44:15 Input vibration 1 On Vibration on: ) >6V

Digital input active high Vibration off: )approx.0 V
X44:16 Input button START (option) Push button pressed ) 12 V
Digital input active high Button not pressed ) 2V
X44:17 Input button STOP (option) Push button pressed ) 12 V
BOMAG
X44:18 Input button PRINT (option) Push button pressed ) 12 V
X44:19 Input button CLEAR (option) Push button pressed ) 12 V
X44:20
X44:21
X44:22
X44:23 Output voltage supply for sensors Nominal voltage = 8.5 V

This output supplies steering joystick, speed range selector switch, etc. Permissible range: approx. 7.65 .. 9.35 V
Without this voltage the control cannot work correctly and will switch to This voltage must be measured against AGND.
override mode (emergency function).
X44:24

008 918 12
008 918 12
X44:25
X44:26 Interface CAN-Bus Wire -, is used to communicate with the BOP Measurement not possible!
operating unit.
X44:27 Interface CAN-Bus Wire +, is used to communicate with the BOP Measurement not possible!
operating unit.
X44:28 Input potential terminal 15 Control switched on ) 12 V

Digital input active high Control switched off ) 12 V
This signal must be present, so that the control can work.
X44:29 Input acceleration transducer VV/VL15g Acceleration signal (measured against AGND)

X44:30 Input acceleration transducer VH/VR15g Acceleration signal (measured against AGND)
Open circuit voltage (vibration off): 4.2 .. 4.3 V
BOMAG
)
X44:31 Input acceleration transducer VV20g/HR15g Acceleration signal (measured against AGND)

X44:32
X44:33 Interface CAN-Bus2 Wire -, is used to communicate with the BCM05. Measurement not possible!
X44:34
X44:35 Input distance transducer Transducer delivers square-wave pulses Frequency depends on
machine type.
Digital input active high

7.1
229
230
7.1

X44:36
X44:37 Input D+ generator Engine running / engine being started ) 12 V

Digital input active high Engine stopped ) 0V
X44:38 Input vibration 2 On Vibration on: ) >6V
Digital input active high Vibration off: )approx.0 V
X44:39
X44:40
X44:41
X44:42
X44:43
BOMAG
X44:44
X44:45
X44:46 Output valve 1 front valid current range: approx. 0..1.5 A

PWM digital output (max. 4 A)
X44:47 Output valve 2 front valid current range: approx. 0..1.5 A
PWM digital output (max. 4 A)
X44:48
X44:49
X44:50
X44:51
X44:52

008 918 12
008 918 12
BOMAG
7.1
231
232
7.1

X44:53 Interface CAN-Bus2 Wire +, is used to communicate with the BCM05. Measurement not possible!
X44:54 Voltage supply for electronics Emergency stop not actuated ) 12 V
Emergency stop actuated ) 0V
X44:55 Ground connection electronics 0 V measured against ground
X44:56 Voltage supply for outputs approx. 12 V measured against ground
BOMAG
X44:61
X44:62
X44:63
X44:64
X44:65 Mouse port Baby Boards approx. 0 V

008 918 12
Service Training Fault codes of the ESX control
13 Fault codes of the ESX control
13.1 Overview
Fault code Description of fault

4501 - Position controller (exciter potentiometer, valves)
4540
4601 - Acceleration transducer
4620
8000 - Internal software errors
8250
Status: 14.12.2009 Fault codes of the ESX control Page 47 of 61

Author: T.Löw / TE
008 918 12 BOMAG 233

234
7.1
Service Training MESX Description of fault codes of the ESX control
13.2 Description of fault reactions
Fault reaction Description of fault reaction

1 Warning.
Fault code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
2 Impairment of function, the faulty function is overridden by an emergency function.
3 Fault of a partial function, the partial function cannot be overridden by an emergency function.
After the occurrence of the fault the machine is stopped, after returning the travel lever to neutral the machine can move
again.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
4 Fault of a partial function, the partial function cannot be overridden by an emergency function.
The machine is no longer able to drive, e.g. because parts of the travel system are defective
BOMAG
) the diesel engine is shut down.
5 Fatal fault. The function of the control is no longer assured.
The control will be switched off.
Error code is displayed.
Signal light in BOP (option) lights permanently.
Note: Errors with error reaction 1 are only warning messages and are NOT saved in the error log!
Status: 14.12.2009 Fault Code Description ESX control Page 48 of 61

008 918 12
008 918 12
13.3 Detailed description of fault codes and their possible causes
Fault Description of fault Possible cause Termina Input Fault

code l on code for reaction
ESX diagnose
4 5 0 1 Input exciter potentiometer front ) Wire breakage in current path X44:09 5
The voltage applied to the input is below the ) Current path has short circuit to ground
specified range (see signal description). ) No voltage supply to potentiometer

) Fuse FM ? has tripped or wire breakage in voltage supply
current path
) Potentiometer defective
4 5 0 2 Input exciter potentiometer front ) Current path has connection to +12 V / +8,5 V X44:09 5
The voltage applied to the input is above the ) Potentiometer not connected to ground
specified range (see signal description). ) Potentiometer defective
BOMAG
7.1
235
236
7.1

ESX diagnose
4 5 2 1 Output proportional solenoid front ) Current path has short circuit to voltage supply X44:46 2
Valve for exciter up ) Current path has non-permitted connection to another current
Output current too low. path
) Current path is interrupted
4 5 2 2 Output proportional solenoid front ) Current path has short circuit to ground X44:46 2
Valve for exciter up ) Current path has non-permitted connection to another current
Output current too high. path
4 5 2 3 Output proportional solenoid front ) Current path is interrupted X44:46 2

Valve for exciter up ) Current path has impermissible connection to another current
Fault when calibrating the valve path / ground
4 5 2 6 Output proportional solenoid front ) Current path has short circuit to voltage supply X44:47 2
Valve for exciter down ) Current path has non-permitted connection to another current
BOMAG
Output current too low. path
) Current path is interrupted
4 5 2 7 Output proportional solenoid front ) Current path has short circuit to ground X44:47 2
Valve for exciter down ) Current path has non-permitted connection to another current
Output current too high. path
4 5 2 8 Output proportional solenoid front ) Current path is interrupted X44:47 2

Valve for exciter down ) Current path has impermissible connection to another current
Fault when calibrating the valve path / ground

008 918 12
008 918 12
ESX diagnose
4 5 3 1 Position controller positive limit reached ) Supply and ground terminal on exciter potentiometer mixed up X44:09 5000 2
The exciter does not move to the desired ) Valves for "Exciter up" and "Exciter down" mixed up X44:37
direction or does not move at all. ) MD+ input has 12 V potential, even though the engine is not
running
) Air in hydraulic system, hydraulic pressure too low
4 5 3 2 Position controller negative limit reached ) Supply and ground terminal on exciter potentiometer mixed up X44:09 5000 2
The exciter does not move to the desired ) Valves for "Exciter up" and "Exciter down" mixed up X44:37
direction or does not move at all. ) MD+ input has 12 V potential, even though the engine is not
running
) Air in hydraulic system, hydraulic pressure too low
4 6 0 1 Input acceleration transducer 1 ) Current path has no connection to +12 V / +8,5 V X44:29, 4601 2
The voltage applied to the input is below the ) Current path connected to ground or
specified range (see signal description). ) Transducer defective X44:31
BOMAG
4 6 0 2 Input acceleration transducer 1 ) Current path has connection to +12 V / +8,5 V X44:29, 4601 2
The voltage applied to the input is above the ) Current path not connected to ground or
4 6 0 6 Input acceleration transducer 2 ) Current path has no connection to +12 V / +8,5 V X44:30, 4606 2
The voltage applied to the input is below the ) Current path connected to ground or
4 6 0 7 Input acceleration transducer 2 ) Current path has connection to +12 V / +8,5 V X44:30, 4606 2
The voltage applied to the input is above the ) Current path not connected to ground or

7.1
237
238
7.1

ESX diagnose
8 0 0 0 Error message "Incorrect BOP Software version" - - 2
The software version of the BOP is too old, i.e.
various functions cannot be displayed.
This fault cannot be rectified on the machine.
The BOP needs to be replaced.
8 0 0 1 Fault message "severe software fault in control" - - - 5
- This fault cannot be rectified on the machine.
8 9 9 9 The control must be immediately replaced.
9 0 0 0 Error message "Communication via CAN bus ) Wire breakage in CAN bus lines X44:26 - 2
- disturbed" ) Short circuit between CAN bus lines X44:27-
9 1 9 9 The modules controlled via the CAN bus cannot ) One or both CAN bus line(s) has (have) connection to +12 V or
be addressed by the main control (ESX). The ground
respective machine functions are not available
9 2 0 0 Fault message "Severe internal fault in control" - - - 5
BOMAG
- The control has automatically switched off. This
9 9 9 9 fault cannot be rectified on the machine. The
control must be immediately replaced.
Ct0 Display module has no connection to ESX- ) Wire breakage in CAN bus lines X44:26 - -
control. ) Short circuit between CAN bus lines X44:27
) One or both CAN bus line(s) has (have) connection to +12 V or
ground
) Incorrect bit rate in display module (nominal value: 125 kBit)

008 918 12
Service Training MESX Description of input codes of the ESX control
008 918 12
14 Input codes for ESX control (only via BEM display module)
14.1 Travel system
Input code Description of display function Display values

1000 Transducer for travel direction 0000 ) 0V
Show status of transducer. 0001 ) 12 V
1001 Travel direction 1000 ) Forward travel detected

Displays the travel direction derived by the control from the 0000 ) Neutral position
"transducer for travel direction". 000I ) Reverse travel detected
1002 Transducer for distance pulses Display value = travel distance in 10 cm

The distances pulses summarized since starting the machine are
displayed. If the machine has travel a longer distance in reverse than
in forward, the value will be negative.
1003 Travel speed Display value = max. speed in km/h
BOMAG
Shows the actual speed.
1010 Parameter "Show distance pulses per 10m" Depending on the selected machine type, e.g. 5896 for
Eeprom Parameter is displayed BW177 BVC
1011 Parameter "Invert travel direction" 0000 ) Direction signal is not inverted
Eeprom Parameter is displayed 000I ) Direction signal is inverted
Status: 14.12.2009 Description of Control Input Codes Page 53 of 61

7.1
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240
7.1
14.2 Vibration

3000 Vibration status general 0000 ) Vibration OFF
The status of vibration is displayed. 0001 ) Vibration ON
3001 Vibrations status low amplitude 0000 ) Vibration OFF
The vibration status for low amplitude is displayed. 0001 ) Vibration ON
3002 Vibrations status high amplitude 0000 ) Vibration OFF
The vibration status for high amplitude is displayed. 0001 ) Vibration ON
14.3 Light

3010 Input light switch 0000 ) Light OFF
The status of the lighting is displayed. 0001 ) Light ON
BOMAG
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008 918 12
14.4 Acceleration transducer

4601 Acceleration transducer 1 Display value = voltage in V
Shows the voltage of transducer 1.
4606 Acceleration transducer 2 Display value = voltage in V
Shows the voltage of transducer 2.
14.5 Diesel engine

5000 Input MD+ 0000 ) Engine OFF
Show status of diesel engine. 0001 ) Engine ON
BOMAG
7.1
241
242
7.1
14.6 Setting the machine type

7000 Shows the adjusted machine type
7010 Switches on function "Set machine type"
7011 Confirms entered machine type
7500..76 Pre-select machine type
99
BOMAG
008 918 12
008 918 12
14.7 Parameter change

7600 Switch on function "Invert travel direction" Display value 7 6 0 0
7601 Inverts the actually adjusted travel direction see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
BOMAG
7.1
243
15 Terminology in connection with ESX

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

loosened, slipped off
broken off,
corroded,
socket / plug faulty
Status: 14.12.2009 Terminology Page 58 of 61

Author: T.Löw / TE
244 BOMAG 008 918 12

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 states are permitted within a certain range. E.g. 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)

Author: T.Löw / TE
008 918 12 BOMAG 245

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

Author: T.Löw / TE
246 BOMAG 008 918 12

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

In the event of a major fault the control will switch off and the override function will take over.
This has the effect that the machine can still be moved and steered with reduced speed.
Steering and dozer blade movements are only possible with a constant speed.
(see also: page 38, "")
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.

Author: T.Löw / TE
008 918 12 BOMAG 247

248 BOMAG 008 918 12

7.2 Electrics module A68
008 918 12 BOMAG 249

250 BOMAG 008 918 12

Electrics module A68 7.2
Seat contact switch
Only machines with cabin are equipped with the seat contact circuitry.
This circuit also contains the vibration relay. Machines with ROPS or sun canopy are not equipped with
the seat contact circuitry.
The following applies in general:

When the seat is not occupied it can be assumed that in the worst case the machine may perform
uncontrolled movements. In such an instance the machine must be shut down at the latest after 4
seconds. During these 4 seconds the driver must be warned about this condition by the warning buzzer
in the dashboard and the area around the machine by the backup alarm. To start travel movement of
the machine the driver's seat must be occupied, as otherwise the diesel engine will be shut down
immediately. This prevents the machine from being started from the outside (e.g. through the open
window).
1. Starting of the engine should only be possible with the travel lever in position "Brake".
2. Driver standing (seat contact control light does not light up): While the engine is running shift the travel
lever to travel operation --- then engine shut be shut down immediately, the seat contact light lights up,
warning buzzer and backup alarm sound. If the travel lever is returned to "Brake" position during the
shut-down process, the fuel solenoid is switched on again and the engine will automatically start.
Otherwise the engine must be restarted.
3. Driver seated: (seat contact control light does not light up): Normal operation, no warning active.
Driver gets up --- control light comes on and both warning buzzers sound. Driver sits down again within
4 seconds --- machine returns to normal operation. Driver does not sit down again within 4 s --- engine
is shut down. If the driver sits down again while the engine is being shut down, the fuel solenoid is
switched on again and the engine will automatically start. Otherwise the engine must be restarted.
In addition to the seat monitoring system all

monitoring functions are implemented by the
Module UPM2
008 918 12 BOMAG 251

The hardware us available under BOMAG part-number 057 664 81.
Stay-Alive LED
Programmierstecker
Spannungs- Status-
versorgung Leuc htdioden
1
4
3
5
2
7
8
9
14
15
6
10
13
12
11
Vibrationstaster
Versorgungsspannung (+UB)
Sitzkontaktschalter
Versorgungsspannung (+UB)
Vibration
Haltewicklung Abstellmagnet
Masseanschluß
Generator / D+ Signal
Anzugswicklung Abstellmagnet
Bremsventil
Warnsummer
Masseanschluß
Öldruck
Fahrhebel
Fig. 1: Module
The complete module (including the specific software) is available under

BOMAG part-number 582 701 68.
The following applies when measuring the signal levels:
PIN Potential with LED on Potential with LED off

Inputs Ground 0V Input open
Output PIN8 Ground 0V Output open
Outputs general ≈ operating voltage (UB- 0,7V) Ground 0V (<< 1V)
252 BOMAG 008 918 12

Emergency operation
If a bridge is inserted between PIN 2 and PIN 3 of the module, the bias coil is permanently
supplied with current (as long as the ignition is on) and the vibration is switched on (vibration
can be switched on/off with the vibration selector switch).
Inserting a bridge between PIN 10 and the connecting cable to PIN 8 opens the brake (the
brake can then be switched on/off e.g. via the parking position of the travel lever). The
module is then bridged (only with motors without pickup winding.
Description of function
In addition to m onitoring the seat occupation this m odule can also be used to control the
hydraulic brake and the function of the vibration relay.
The following sequences were used in the UPM2 software to realize the seat occupation
m onitoring system :
Sw itching on the ignition

- The Stay-Alive-LED on the m odule shows the software version (currently version 3) once
by m eans of a flashing code (changes to perm anent light).
- W hen the travel lever is in neutral position (PIN12 = Active-LO W ) the bias coil of the
shut-down solenoid (PIN4 = Active-HIG H) is switched on and the pickup winding (PIN7 =
Active-H IG H) is energized for 2 seconds. In this situation the seat contact switch has no
effect. T here will be no visual or audible warning if the driver's seat is not occupied.
- If the travel lever is returned to neutral position after the ignition has been switched on,
the bias coil is autom atically switched on and the pickup winding is autom atically
energized for 2 seconds (starting is now possible).
- As long as no D+ signal is detected (starting has not yet been perform ed and the engine
is therefore not yet running), the vibration can be switched on by the vibration control
switch.
- Vibration is switched off.
Starting the engine is only possible with the travel lever in neutral position. Since the starter
does still rotate despite this fact, external blockage of the starter is required when the travel
lever is operated.
Starting the engine

- If running of the engine is detected through D+, the hydraulic brake is autom atically
released (if it is no longer activated by the travel lever in parking position).
- If the travel lever is not in neutral position (irrespective of the seat contact), the bias coil
of the shut-down solenoid is switched off again.
008 918 12 BOMAG 253

Engine running
- Vibration can be switched on with the vibration push button when D+ or oil pressure is
applied (OR-linkage).
- The bias coil remains switched on.
- There will be no visual or audible warning when the driver's seat is unoccupied even
though the travel lever is out of neutral position.
- If the driver's seat is not occupied and the travel lever is actuated in this condition, the
bias coil of the shut-down solenoid is immediately switched off and the engine will stop.
The signalling device (horn) is activated.
W hen D+ is no longer applied (engine not running) the signalling device is switched off
and the hydraulic brake closes after 1.5 seconds.
- W hen leaving the driver's seat after shifting the travel lever out of neutral, the signalling
device will be activated. 4 seconds later the bias coil of the shut-down solenoid will be
switched off and the engine will stop.
Engine stops
- If the engine stops, but D+ is still applied, the bias coil is switched on again and the
pickup winding is energized for 2 seconds, as soon as the driver takes his seat or the
travel lever is returned to neutral position.
- The signalling device is switched off. The module is then in Engine Running mode and
responds as described above.
Engine has stopped

The following applies in all cases (irrespective of travel lever and seat contact) if the D+
signal is missing:
- If the D+ signal is no longer applied the module will decide that the engine has stopped.
- The bias coil of the shut down solenoid is immediately switched off and the brake closes
1.5 seconds later.
- The machine can be restarted by switching the ignition off and on again (new start).
- However, if the D+ signal (for what ever reason) returns by itself, the bias coil of the shut
down solenoid is automatically switched on and the pickup winding is energized for 2
seconds, if the driver has sat down.
- If the driver is not sitting while D+ returns, the reaction will be as described above in
Engine Running mode, depending on the history (was the driver's seat left or the travel
lever actuated first?).
- If, in addition to the missing D+, there is no oil pressure, the vibration will be shut down.
The vibration is not automatically switched on if one of the signals returns!
254 BOMAG 008 918 12

New start
A new start (after the engine has been shut down) is only possible after switching the ignition
on again (see Switching on ignition) or after D+ has returned (see Engine has stopped).
Miscellaneous
Due to the design of the Perkins engines restarting of a still turning engine by returning the
travel lever to neutral or sitting down on the driver's seat is not possible.
On machines with Perkins engine restarting always requires the ignition, if the bias coil of
the shut down solenoid hd been switched off (picking up of the winding only possible after
the engine has stopped).
The pickup winding must be triggered by an additional relay, because the module is only
able to supply a current of 4 ampere.
The module works from a supply voltage of 7 Volt.
008 918 12 BOMAG 255

0 Hardware description
The seat occupation monitoring module consists of the modified UPM2 module.
The inputs are configured to match the following table:
Input Behaviour Comment

Input PIN11 LOW-active LED lights when applying ground potential (0V)!
Input PIN12 LOW- active LED lights when applying ground potential (0V)!
0.1 Pin assignment of inputs
Signal name Module Signal at input

pin
Seat contact switch 11 0V = driver sits, LED on
+U B = driver stands up, LED off
Travel lever 12 0V = travel lever neutral position LED on
+U B = travel lever actuated LED off
Oil pressure 13 0V = oil pressure fault LED on
+U B = no oil pressure fault LED off
Generator / D+ signal 14 0V = engine stopped LED on
+U B = engine running LED off
Vibration button 15 0V = Vib. on/off LED on
+U B = Vib. off/on LED off
0.2 Pin assignment of outputs
Signal name Module Signal at output

pin
Bias coil for shut down 4 +U B = ON LED on
solenoid 0V = OFF LED off
Vibration 5 +U B = Vibration should be on LED on
0V = Vibration should be off LED off
W arning buzzer/light 6 +U B = W arning buzzer on LED on
0V = W arning buzzer off LED off
Pickup winding shut 7 +U B = ON LED on
down solenoid 0V = OFF LED off
Brake valve 8 +U B = Brake applied LED off
0V = Brake released LED on
256 BOMAG 008 918 12

7.3 Electric module K04
008 918 12 BOMAG 257

258 BOMAG 008 918 12

Electric module K04 7.3
008 918 12 BOMAG 259

260 BOMAG 008 918 12

7.4 Electric module A72, old design
008 918 12 BOMAG 261

262 BOMAG 008 918 12

Electric module A72, old design 7.4
008 918 12 BOMAG 263

264 BOMAG 008 918 12

Electric module A72, old design 7.4
008 918 12 BOMAG 265

266 BOMAG 008 918 12

7.5 Electric module A108
008 918 12 BOMAG 267

268 BOMAG 008 918 12

008 918 12
Rotary switch for cabin fan Rotary switch for air conditioning system
Electric module A108
BOMAG
Cabin fan 1 Cabin fan 2
7.5
269
270 BOMAG 008 918 12

8 Speedometer Module
008 918 12 BOMAG 271

8.1 Speedometer module
Fig. 1 Speedometer module
With the programmable module BM UPM the software
realizes a speedometer function. To ensure that the
tachometer function is not only realized for one spe-
cial roller, there is a possibility to adapt the module to
any machine with the help of a self-teaching mode.
l Whenever the module is switched on the system
runs a self-test by passing through the entire dis-
play range in both directions. The display self-test
takes approx. 15 seconds.
l After this the module changes to measuring mode.
The frequency of the travel pulses of the roller is de-
tected and converted to a proportional output volt-
age that triggers the display.
l The output signal for the display is a PWM-signal.
Manual testing of the speedometer

When the module is in learning mode a manual dis-
play test can be performed via the input "Test". For
this purpose the input "IN" must be energized with 12
Volt, whereupon the speedometer is constantly trig-
gered with 3 Volt.
272 BOMAG 008 918 12

Speedometer module 8.1
Pin-no. module Pin name Description
Test E_ANZEIGENTEST Input HIGH active: Activate manual display test

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

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

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

In self-teach mode the number of arriving path pulses
is detected at the input (IN). The number of recorded
pulses is referred to as pulse number per 10 or 18 m
(machine dependent) travel distance of the roller.
l Connect the ground cable (-).
l Connect the sensor signal (speed sensor) to fre-
quency input (IN).
l Install a cable bridge from terminal "15/54" to the
connection "Teach".
l Connect potential "Ignition / 15" to connection "15/
54".
l Switch on the ignition, start the engine and travel a
distance of exactly 10 m.
Caution
!
BW24RH, BW27RH, C550H and C560H = travel 18

meters.
All other machines = travel 10 meters.
i Note
If the module is in teach mode the LED on output
"OUT +" will flash with the frequency of the path puls-
es arriving at input (IN).
l
Disconnect the cable bridge from "Teach" to "15/
54“.
l
Switch the ignition off and on again (Reset).
The module has now learned the pulses of the

speed sensor.
l
Connect the speedometer (0 to 6 Volt) to "OUT +"
and "OUT –“.
008 918 12 BOMAG 273

274 BOMAG 008 918 12

9 582 502 15 dust protection / 582 502 16 gasket
008 918 12 BOMAG 275

9.1 Assembling the dust protection

1. Unscrew the fastening screws (Fig. 1).
Fig. 1
2. Lift the operating console up and out (Fig. 2).
Fig. 2
3. Pull the wiring loom carefully out of the dash-
board(Fig. 3).
Fig. 3
4. Attach the new gasket to the back of the operat-
ing console (Fig. 4).
i Note
Pull the adhesive strip off the gasket and stick on
the gasket.
Fig. 4
276 BOMAG 008 918 12

Assembling the dust protection 9.1
5. Pull the dust protection bag over the operating
console (Fig. 5), (Fig. 6) and (Fig. 7).
Fig. 5
Fig. 6
Fig. 7
6. Tighten the screws for the operating console
hand tight (Fig. 8).
i Note
Ensure the seal/gasket is fitted correctly.
Fig. 8
008 918 12 BOMAG 277

7. Disassemble the dashboard, for this purpose un-

screw the fastening screws (4X), take off spacers
and washers (Fig. 9).
Fig. 9
8. Lift the dashboard up (Fig. 10) and.....
Fig. 10
9. ... fold it back (Fig. 11).
Fig. 11
10. Wrap the dust protection bag around the wiring
looms and fasten it with cable straps (Fig. 12).
Fig. 12
278 BOMAG 008 918 12

Assembling the dust protection 9.1
11. Assemble the dashboard (Fig. 13).
Fig. 13
12. Fasten the dashboard with fastening screws (4X),
spacers and washers (Fig. 14).
Fig. 14
13. Tighten the fastening screws (Fig. 15).
i Note
Check the function of control switches.
Fig. 15
008 918 12 BOMAG 279

280 BOMAG 008 918 12

10 Hydraulics
008 918 12 BOMAG 281

10.1 Hydraulic circuit
10.1 Hydraulic circuit
Open circuit
Fig. 1 Open circuit

Open in this case means that the suction line of a pump) (Fig. 1) normally is situated below the fluid level, the
surface of which is in open contact with atmospheric pressure. Reliable equalization of pressure between the air
in the hydraulic oil tank and the ambient air ensures problem free suction of the pump.
In an open circuit the hydraulic fluid is fed to the consumer (2 or 3) and also returned to the tank through way
valves.
282 BOMAG 008 918 12

Hydraulic circuit 10.1
Closed circuit
Filter
Cooler (option)
Fig. 2 Closed circuit

One talks about a closed hydraulic system, when the hydraulic oil flows from the consumer (3) (Fig. 2) directly
back to the pump (2).
The closed circuit consists of a high and a low pressure side, depending on the load direction (take-off moment
on the consumer).
The high pressure side is protected by pressure relief valves (4), which release oil into the low pressure side.
The medium remains in the circuit.
Only the permanent leakage on pump and motor needs to be replenished. This is accomplished by a charge
pump (1), which permanently delivers a sufficient amount of fluid (charge capacity) through a check valve (5)
into the low pressure side of the closed circuit. Any excess oil delivered by the charge pump, which works in an
open circuit, runs through a charge pressure relief valve (6) back into the tank. Charging the low pressure side
enables the pump (2) to work with higher operating data.
008 918 12 BOMAG 283

10.2 Connection overview
Fig. 1 Travel pump
284 BOMAG 008 918 12

Connection overview 10.2
1 Control solenoid, high frequency 21 Connection D, charge pressure to filter
2 Control solenoid, low frequency 22 Muliti function valve 345 bar (boost check and
3 Multi-function valve 400 bar (boost check and pressure relief valve), vibration drive high frequen-
pressure relief valve), travel system cy
4 Connection, charge pressure to brake solenoid 23 Connection S, suction line charge pump from hy-
valve, travel speed range selection and charge oil draulic oil tank
supply for vibration pump 24 Muliti function valve 345 bar (boost check and
5 Multi-function valve 400 bar (boost check and pressure relief valve), vibration drive low frequen-
pressure relief valve), travel system cy
6 Setscrew, mechanical neutral position 25 Charge pressure relief valve, vibration pump
(blocked)
7 Connection L, leak oil connection to vibration
pump 26 Connection E, charge oil from travel pump
8 Lever, travel control 27 Connection L1, leak oil connection to travel pump
9 Charge pressure test port 28 Pressure test port MB, high pressure reverse
10 High pressure port B, high pressure reverse 29 Charge oil from filter
11 Charge pressure relief valve, 26 bar 30 Pressure test port MA, high pressure forward
12 Adjustment screw, low frequency 31 High pressure port A, high pressure forward
13 Connection L2, leak oil to tank 32 Setscrew, mechanical neutral position, vibration
14 Pressure test port MB, high frequency 33 Leak oil connection D, leak oil from axle drive mo-
tor
15 High pressure test port MA, low frequency
34 Leak oil connection A, leak oil from travel pump
16 High pressure port A, low frequency
35 Leak oil connection G, leak oil from drum drive
17 High pressure port B, high frequency
motor
18 Charge pump, internal
36 Leak oil connection F, leak oil from vibration motor
19 Connection L2, to drum drive motor (flushing)
37 Radiator inlet
20 Adjustment screw, high frequency
008 918 12 BOMAG 285

Variable displacement pumps, 90R055 and 90R075

Caution
!
The variable displacement axial piston pump must be filled with pressure fluid and purged during start-
up and operation. This must also be considered for longer periods of rest, because the system may run
empty through the hydraulic lines.
The variable displacement axial piston pump generates, controls and regulates a volumetric pressure fluid flow.
It has been designed for mobile applications, e.g. in construction equipment.
The pump is a variable displacement axial piston pump in swash plate design for hydrostatic drives in closed
circuits. The volumetric flow is proportional to the drive speed and the displacement.
Mechanical displacement control (MDC)

The mechanical displacement control converts a mechanical input signal (control lever position 1 (Fig. 2)) into a
position controlling output signal by means of a spring centred 4-way servo valve. This valve opens the hydraulic
pressure to one side of the control cylinder. The control piston inside the control cylinders moves the swash plate
within a swashing angle range of ±17° and thereby changes the displacement of the pump from maximuim dis-
placement to the one direction to the maximum displacement to the opposite direction.
The mechanical displacement control has no adjustment elements. The control is held in neutral position by re-
setting springs and washers at both ends of the control piston. Since there are no further resetting springs on
the input shaft of the control, the shaft will automatically be correctly positioned when it is mounted to the pump.
Fig. 2
1 Actuating lever 5 Cylinder block

2 Drive shaft 6 Valve plate
3 Bearing for swashing cradle 7 Control piston
4 Pistons with slipper pads
286 BOMAG 008 918 12

Travel pump 075 10.3
Fig. 3
1 Drive shaft 5 Cylinder block

2 Drive shaft bearing 6 Multi-function valves
3 Swash plate 7 Charge pump ( optional)
4 Pistons with slipper pads 8 Valve plate
008 918 12 BOMAG 287

Hydraulic diagram
Servo control
Multi-function valve
Charge pressure relief valve

Fig. 4
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.
Since the control is spring centred, the swash plate will automatically return to neutral position under the follow-
ing conditions, thereby interrupting the oil flow and braking the machine:
l
when shutting the engine down
l
if the external control cable comes loose
l
if the pressure in the charge circuit drops below a certain value.
1 to the control 6 Drive shaft

2 Multi-function valves 7 to the control piston
3 Charge pump 8 to the control piston
4 Charge pressure relief valve A Connection A
5 Charge pressure relief valve B Connection B
The multi-function valve consists of:
l the no-stroke pressure controller
l
the high pressure relief valve
288 BOMAG 008 918 12

l the boost check valve
l and the bypass function
Fig. 5 Multi-function valves

Pumps of series 90 are equipped with so-called multi-function valves, which activate a pressure override and a
pressure relief valve, one after the other.
The multi-function valve contains a no-stroke pressure controller and a high pressure relief valve. When the pr-
adjusted pressure value is reached, the no-stroke pressure controller will return the pump very quickly back to-
wards neutral, thereby limiting the system pressure. In case of a unusually sudden pressure increase the high
pressure relief valve will immediately limit the system pressure by opening the system flow to the low pressure
side of the hydraulic circuit. The no-stroke pressure controller serves as pre-control unit for the piston of the high
pressure relief valve. The high pressure relief valve is designed for responding to pressures approx. 35 bar
above the nominal value of the no-stroke pressure.
Boost check valves The boost check valves are cone valves inside the multi-function valve. It enables flow
from the charge pump into the low pressure side of the working circuit, if the system pressure drops below a
certain value. With this feature pressure losses caused leakages or other factors can be compensated. Since
the variable displacement pump is able to work to either direction, two boost check valves are needed.
Bypass function The bypass function is also integrated in the multi-function valves and can be manually oper-
ated.when the vehicle (or the mechanical function) is to be moved, without the pump running.
Adjusting (opening) the bypass function
Caution
!
When working on the bypass valves switch off the drive and keep the high pressure circuit pressureless.
The bypass valves must be open on both multi-function valves to be able to achieve the bypass function.
Fig. 6
l Attach an open end spanner to the medium size hexagon of the multi-function valve and attach an open end
spanner to the large hexagon to prevent the valve body from turning. Turn the medium size hexagon for three
008 918 12 BOMAG 289

turns in anti-clockwise direction to open the bypass valve. Do not turn more than 3-1/2 turns, because oth-
erwise pressure fluid will run out.
l Before moving the vehicle set the control lever for the mechanical displacement control on the pump to full
forward. Hold the control lever in this position throughout the bypass function.
! Caution
"Towing" only at very low speed and only over short distances.

Pumps of series 90 are equipped with a charge pressure relief valve that can be adjusted from outside. Charge
pressure is adjusted by loosening the counter nut and turning the setscrew accordingly with a large screwdriver
or a 1/2" open end spanner.
Turning the setscrew clockwise increases the value, turning anti-clockwise reduces the value (by approx. 3.9
bar per revolution). The counter nut needs to be tightened with 52 Nm.
Fig. 7
The charge pressure relief valve has the function of maintaining the charge pressure at a specified value. A cone
valve reduces the charge pressure if this value is exceeded. This nominal value is measured against case pres-
sure and adjusted at 1500 rpm. This nominal setting assumes that the pump is running in idle position (zero
flow); the charge pressureb is slightly lower in forward or reverse.
290 BOMAG 008 918 12

Connections
Fig. 8
1 Pressure test port M2 system pressure, B 8 Suction port S

2 Leak oil connection L1 9 System pressure, port B
3 Pressure test port M4 control pressure 10 Speed transducer (option)
4 Pressure test port M5 control pressure 11 Charge pressure port
5 Leak oil connection L2 12 Charge pressure test port, M3
6 Pressure test port M1 system pressure, A 13 Control pressure port, X3
7 System pressure, port A
008 918 12 BOMAG 291

10.4 Vibration pumps 42R041 & 42R055
Variable displacement pumps, 42R041 / 42R055

Caution
!
The variable displacement axial piston pump must be filled with pressure fluid and purged during start-
up and operation. This must also be considered for longer periods of rest, because the system may run
empty through the hydraulic lines.
The variable displacement axial piston pump generates, controls and regulates a volumetric pressure fluid flow.
It has been designed for mobile applications, e.g. in construction equipment.
The 42R 041 is a variable displacement axial piston pump in swash plate design for hydrostatic drives in closed
circuits. The volumetric flow is proportional to the drive speed and the displacement.
EZ, electric two-point control, with control solenoid
Fig. 9
1 Control 4 Attachment plate

2 Servo piston 5 Spool valve
3 Swash plate bearing 6 Charge pump
292 BOMAG 008 918 12

Vibration pumps 42R041 & 42R055 10.4
Hydraulic diagram
Charge pump
Pump drive
High pressure limitation
4/3 way valve
Fig. 10
When operating a 4/3-way solenoid valve on the pump control pilot oil from the charge circuit is guided to one
of the two control piston sides. The swash plate inside the pump will swash to the corresponding side and the
pump will deliver oil to the vibration motor. The vibration motor starts and rotates the vibrator shaft inside the
drum.
When altering the position of the swash plate through the neutral position to the opposite side, the oil flow will
change its direction and the vibration motor will change its sense of rotation.
Since the end stops for the swash plate are set to different swashing angles to both directions, the angle for the
piston stroke is also different to both sides. This angle influences the length of the piston stroke and thereby the
actual displacement of the pump.
l
Large angle = high displacement = high vibrator shaft speed (frequency)
l
Small angle = low displacement = slow vibrator shaft speed (frequency)
High pressure relief valves (Fig. 10)
1 From the charge pump 3 High pressure relief valve with integrated
boost check valve
2 Closed circuit
Pressure peaks occurring during very fast swashing processes, as well as the maximum pressures are safe-
guarded by superordinate high pressure relief valves, which open when the adjusted value is exceeded and re-
008 918 12 BOMAG 293

lieve oil into the low pressure side. The fluid quantity always remains constant in the closed hydraulic circuit.
Leakages in pump and motor are compensated by the charge pump.
The boost check valves are integrated in the high pressure relief valves. These valves open to the low pressure
side and allow cool and filtered oil flow from the charge oil circuit to flow into the closed hydraulic circuit, in order
to compensate leaks and flushing quantities.
Charge pump
The charge pump is needed to supply the system with cool hydraulic fluid, to maintain a positive pressure in the
working circuit, to ensure a certain pressure level, to operate the control system and to compensate internal leak-
ages.
The charge pump is a fixed displacement Gerotor-type pump, integrated in the variable displacement pump and
driven by the pump shaft.
294 BOMAG 008 918 12

Axial piston swash plate principle / pump 10.5
Swash plate principle, pump
10.5 Axial piston swash plate principle / pump
Fig. 11
The swash plate pump is a positive displacement machine with oil displacing pistons arranged axially to the drive
shaft. The pistons are thereby supported by the swash plate.
Axial piston units based on the swash plate principle with fixed or variable displacement can be used as hydraulic
pumps or hydraulic motors. In pump mode the mechanical energy is converted to hydrostatic energy, when used
in motor mode the hydrostatic energy is converted to mechanical energy. When used as a pump, the flow volume
is proportional to the drive speed and the swashing angle. The available (pump) torque increases with the pres-
sure drop between high and low pressure side.
Variable displacement pumps and motors can be change their displacement, i.e. the pump delivery rate or motor
throughput, by simply changing the angle of the swash plate.
Fig. 12
008 918 12 BOMAG 295

10.5 Axial piston swash plate principle / pump
1 Drive shaft 8 Through drive

2 Piston 9 Valve plate
3 Piston area 10 Top dead centre TDC
4 Piston stroke 11 Bottom dead centre BTC
5 Slipping disc 12 Control slots in suction side of swash plate (for
sense of rotation shown)
6 Adjusting angle 13 Control slot on pressure side
7 Cylinder
Driven by the engine, the drive shaft rotates and drives the cylinder via a splined connection. The cylinder rotates
with the drive shaft and drives the 9 pistons. The pistons rest with their slipper pads on the sliding face of the
swashing cradle and perform an axial movement. The slipper pads are held on the sliding face and are positively
guided by a retaining device. During a complete rotation of the cylinder block each piston moves through the
bottom and top dead centre back to its initial position. From dead centre to dead centre is performs a full piston
stroke. During this process the flow volume determined by the stroke is drawn in through the control slots in the
valve plate or pumped out. During the suction stroke the hydraulic fluid is drawn into the increasing piston cham-
ber, i.e. it is actually pressed in. On the opposite side the oil is pressed out of the piston bores into the hydraulic
system during the compression stroke.
296 BOMAG 008 918 12

Troubleshooting axial piston pumps 10.6
10.6 Troubleshooting axial piston pumps
The following table should be of help when performing troubleshooting This table is by no means complete.
In practice you may encounter problems that have not been listed here.
Procedure
l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and
changing of settings can lead to a situation in which the original cause of a fault can no longer be detected.
l Get an overview over the function of the product in connection with the overall system.
l
Try to clarify whether the product was able to deliver the required function within the overall system before the
fault occurred.
l Develop a clear understanding of the troubleshooting process. If necessary ask the direct operator or machine
driver.
Try to detect changes to the overall system, the product is installed in:
l Have conditions or area of application of the product been changed?
l Were changes (e.g. changeovers) or repairs made to the overall system (machine/plant, electrics, control) or
to the product? If yes: What kind?
l Has the product or the machine been operated as intended?
l
How does the fault occur?
Fault Possible cause Remedy

Unusual noises Insufficient suction conditions, e.g.Machine or system manufacturer
air in the suction line, inadequate di-
(e.g. optimize feed conditions, use
ameter of the suction line, excessivesuitable pressure fluid).
viscosity of the pressure fluid, ex- Completely purge the axial piston
treme suction height, too low suctionunit, fill the suction line with pres-
pressure, foreign bodies in the suc- sure fluid.
tion line. Remove foreign bodies from inside
the suction line.
Inappropriate fastening of the axial Check the fastening of the axial pis-
piston unit. ton unit as specified by the machine
or plant manufacturer. Observe the
tightening torques.
Inappropriate fastening of attach- Fasten attachment parts as speci-
ment parts, e.g. coupling and hy- fied by the coupling or fittings manu-
draulic lines. facturer.
Pressure relief valves of the axial Purge the axial piston unit, check
piston unit (charge pressure, high the viscosity of the pressure fluid,
pressure, pressure override). consult the service department.
Mechanical damage to the axial pis- Replace the axial piston unit, con-
ton unit. sult the service department.
008 918 12 BOMAG 297

10.6 Troubleshooting axial piston pumps

No or insufficient volumetric flow Faulty mechanical drive (e.g. defec- Check and repair the drive.
tive coupling).
Drive speed too low. Consult the service department.
Insufficient suction conditions, e.g. Completely purge the axial piston
air in the suction line, inadequate di- unit, fill the suction line with pres-
ameter of the suction line, excessive sure fluid.
viscosity of the pressure fluid, ex- Remove foreign bodies from inside
treme suction height, too low suction the suction line.
pressure, foreign bodies in the suc-
tion line.
Pressure fluid not within the optimal Use appropriate pressure fluid.
viscosity range.
External control and setting facilities Check the external control.
defective.
Pilot or control pressure too low. Check pilot and control pressure,
consult the service department.
Functional disturbance in the control Consult the service department.
facility or the regulator on the axial
piston unit.
Wear of the axial piston unit. Replace the axial piston unit.
Mechanical damage to the axial pis- Replace the axial piston unit.
ton unit.
298 BOMAG 008 918 12

Troubleshooting axial piston pumps 10.6
No or insufficient pressure Faulty mechanical drive (e.g. defec- Check and repair the drive.
tive coupling).
Poor drive power. Consult the service department.
tion line.
viscosity range.
defective.
Pilot or control pressure too low. Check pilot and control pressure.
piston unit.
Mechanical damage to the axial pis- Replace the axial piston unit.
ton unit.
Drive unit defective (e.g. hydraulic Check the drive unit, replace if nec-
motor or cylinder). essary.
Fluctuations in pressure/volumetric Axial piston unit not or insufficiently Completely purge the axial piston
flow purged. unit.
tion line.
Pressure fluid too hot. Excessive input temperature on axi- Check the system, e.g. malfunction
al piston unit. of the cooler, pressure fluid level in
tank too low.
Malfunction of the pressure control Consult the service department.
valves (e.g. high pressure relief
valve, pressure override, pressure
controller).
Malfunction of the flushing valve Consult the service department.
(not for nominal size 18).
008 918 12 BOMAG 299

10.7 Travel motor 51 C/D 110
Swash plate motor with variable displacement, series 51

10.7 Travel motor 51 C/D 110
Designs: C and D
Fig. 13
Product description
A plug-in fixed displacement motor converts the hydrostatic volumetric flow into mechanical rotary motion. It has
mainly been designed for installation into mechanical gear drives.
Function
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
an axial stroke, thereby causing a rotary motion of the output shaft.
Once the respective piston has passed its dead centre (max. extended position), it will change to the low pres-
sure 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.
Flushing valve
In a closed circuit the same pressure fluid keeps permanently circulating between pump and motor. This can
cause overheating of the pressure fluid.
The flushing valve has the function to support cooling of the oil circuit by flushing the motor and thus to prolong
the service life of the motor. If the hydraulic motor is operated under load, the flushing valve opens during clock-
wise and anti-clockwise rotation, whereby a defined flushing quantity is discharged through an orifice from the
low pressure side of the circuit. This flushed out amount of oil then flows through the case drain back to the tank,
normally through a cooler. Any pressure fluid removed from the closed circuit must be replaced by cool oil from
the charge pump. The flushing valve thereby ensures permanent renewal and cooling of the pressure fluid. The
flushing pressure relief valve has a fixed setting of 16 bar and has the function of securing the minimum charge
pressure.
Control
The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle between
cylinder block and output shaft.
300 BOMAG 008 918 12

Travel motor 51 C/D 110 10.7
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 piston
rod side (test port M4) is thereby permanently pressurized with the actual travel pressure. In 1st speed range
(solenoid de-energized) the piston side (pressure test port, M3) is connected with the tank. In the 2nd speed
range the solenoids are energized, the valve switches and the piston side is also pressurized with the actual
travel pressure. Due to the area differential between piston rod side and piston side and the force resulting from
this, the pilot control moves to Qmin position.
Fig. 14
1 Control piston 7 Taper roller bearing

2 4-way valve 8 SAE-flange
3 Proportional valve 9 Synchronizing joint
4 Minimum swashing angle setting 10 Speed sensor
5 Valve segment 11 Piston
6 Bearing plate 12 Flushing pressure relief valve
008 918 12 BOMAG 301

10.8 Trouble shooting, variable displacement axial piston motor
10.8 Trouble shooting, variable displacement axial piston motor

The following table should be of help when performing troubleshooting This table is by no means complete.
In practice you may encounter problems that have not been listed here.
Procedure
l Always proceed systematically, even under time pressure. Indiscriminate, ill-considered disassembly and
changing of settings can lead to a situation in which the original cause of a fault can no longer be detected.
l Get an overview over the function of the product in connection with the overall system.
l
Try to clarify whether the product was able to deliver the required function within the overall system before the
fault occurred.
l Develop a clear understanding of the troubleshooting process. If necessary ask the direct operator or machine
driver.
Try to detect changes to the overall system, the product is installed in:
l Have conditions or area of application of the product been changed?
l Were changes (e.g. changeovers) or repairs made to the overall system (machine/plant, electrics, control) or
to the product? If yes: What kind?
l Has the product or the machine been operated as intended?
l
How does the fault occur?

Unusual noises
Inappropriate fastening of the axial Check the fastening of the axial pis-
piston unit ton unit as specified by the machine
or plant manufacturer. Observe the
tightening torques!
Inappropriate fastening of attach- Fasten attachment parts as speci-
ment parts, e.g. coupling and hy- fied by the coupling or fittings manu-
draulic lines. facturer.
Mechanical damage to the axial pis- Replace the axial piston unit
ton unit.
Fluctuations in pressure/volumetric Axial piston unit not or insufficiently Completely purge the axial piston
flow purged. unit.
302 BOMAG 008 918 12

Trouble shooting, variable displacement axial piston motor 10.8
Operation data are not reached. Insufficient flow from hydraulic Check the function of the hydraulic
pump pump
Minimum displacement incorrectly Consult the service department.
set
defective.
Control pressure too low Check control pressure, consult the
service department.
piston unit.
viscosity range.
Wear of the axial piston unit Replace the axial piston unit
Mechanical damage to the axial pis- Replace the axial piston unit
ton unit.
Pressure fluid too hot. Excessive input temperature on axi- Check the system, e.g. malfunction
al piston unit. of the cooler, pressure fluid level in
tank too low.
Malfunction of the pressure control Consult the service department.
valves (e.g. high pressure relief
valve, pressure override, pressure
controller).
Failure of the flushing valve Consult the service department.
Wear of the axial piston unit Replace the axial piston unit
008 918 12 BOMAG 303

10.9 Vibration motor A10FM 45
Vibration motor
10.9 Vibration motor A10FM 45
The vibration motor is an axial piston motor with fixed displacement in swash plate design. Since the motor can
be subjected to pressure from both sides, it is most suitable for the use in closed hydraulic circuits.
The output speed of the motor depends on the oil quantity supplied by the vibration pump.
The output torque raises with increasing pressure difference between low and high pressure side in the closed
circuit.
Changing the flow direction of the oil will also change the sense of rotation of the vibration motor.
When switching the vibration on the motor must first start to move the resting exciter shaft. This resistance caus-
es a hydraulic starting pressure, which is limited by the pressure override. Once the exciter shaft has reached
its final speed, the pressure will drop to 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
Soft ground = Low operating pressure
Fig. 15 Cross-sectional drawing
1 Flushing valve block 6 Drive shaft

2 Flushing valve 7 Swash plate
3 Working pistons with slipper pads 8 Retaining plate
4 Roller bearing for output shaft 9 Pre-tensioning spring
5 Radial seal 10 Flushing pressure relief valve
The vibration motor is equipped with an integrated flushing valve. When switching the vibration on a pressure
difference will appear between the two sides of the closed circuit. The higher pressure moves the valve spool of
the flushing valve against the neutral setting spring, so that oil can flow out of the low pressure side.
The flushing valve is fitted with a downstream 13 bar pressure relief valve. This valve makes sure that only a
certain quantity of hydraulic oil is flushed out of the low pressure side.
This oil flows back to the hydraulic tank. The flushed out oil is immediately replaced with fresh and filtered oil
through the corresponding boost check valve.
304 BOMAG 008 918 12

Vibration motor 90M 055 10.10
Vibration motor
10.10 Vibration motor 90M 055
The vibration motor is an axial piston motor with fixed displacement in swash plate design. Since the motor can
be subjected to pressure from both sides, it is most suitable for the use in closed hydraulic circuits.
The output speed of the motor depends on the oil quantity supplied by the vibration pump.
The output torque raises with increasing pressure difference between low and high pressure side in the closed
circuit.
Changing the flow direction of the oil will also change the sense of rotation of the vibration motor.
When switching the vibration on the motor must first start to move the resting exciter shaft. This resistance caus-
es a hydraulic starting pressure, which is limited by the pressure override. Once the exciter shaft has reached
its final speed, the pressure will drop to 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
Soft ground = Low operating pressure
Fig. 16 Cross-sectional drawing
1 Shuttle valve 6 Swash plate

2 Valve plate 7 Cylinder block
3 Piston 8 End housing
4 Anti-friction bearings 9 Shuttle valve
5 Drive shaft
Shuttle valve and flushing pressure relief valve

The flushing function consists of a shuttle valve and a flushing pressure relief valve. The shuttle valve connects
the low pressure side of the closed working circuit with the flushing pressure relief valve in the motor housing.
The flushing pressure relief valve regulates the charge pressure value, as soon as a pressure differential occurs
in the main circuit. A sping holds the shuttle valve in closed position, so that in case of a pressure reversal no
pressure fluid will exit the high pressure side.
008 918 12 BOMAG 305

10.10 Vibration motor 90M 055
Connections
Fig. 17
1 Pressure test port M3 flushing pressure 5 Speed sensor

2 Pressure test port M1 system pressure, A 6 Leak oil connection L2
3 Pressure test port M2 system pressure, B 7 System connection, B
4 Leak oil connection L1 8 System connection, A
306 BOMAG 008 918 12

Axial piston swash plate principle / motor 10.11
Swash plate principle, motor
10.11 Axial piston swash plate principle / motor
Fig. 18
The swash plate pump is a positive displacement machine with oil displacing pistons arranged axially to the drive
shaft. The pistons are thereby supported by the swash plate.
Axial piston units based on the swash plate principle with fixed or variable displacement can be used as hydraulic
pumps or hydraulic motors. In pump mode the mechanical energy is converted to hydrostatic energy, when used
in motor mode the hydrostatic energy is converted to mechanical energy. Variable displacement motors can
change their displacement, i.e. the pump delivery rate or motor throughput, by simply changing the angle of the
swash plate.
If the unit is used as motor, the output speed is proportional to the supplied volume of fluid. The available (motor)
torque increases with the pressure drop between high and low pressure side.
Fig. 19
008 918 12 BOMAG 307

10.11 Axial piston swash plate principle / motor
1 Drive shaft 8 Through drive

2 Piston 9 Valve plate
3 Piston area 10 Top dead centre TDC
4 Piston stroke 11 Bottom dead centre BTC
5 Slipping disc 12 Control slots in suction side of swash plate (for
sense of rotation shown)
6 Adjusting angle 13 Control slot on pressure side
7 Cylinder
The motor function is a reversal of the pump function. In this case the hydraulic fluid the hydraulic system directs
the oil flow to the hydraulic motor. The medium flows through control slots in the valve plate to the cylinder bores.
4 or 5 cylinder bores are opposed to the kidney shaped control slots in the pressure side. The other control slot
is in this case connected with the rest of the cylinder bores, which in turn are connected with the return flow side
or are partly covered by the connecting web between the kidney shaped control slots. By loading the piston it
slides down the slanted swash plate and drives the cylinder that guides it. The cylinder with the 9 pistons rotates
with the drive shaft, whereby the piston perform a stroke-like movement. The hydraulic pressure generates the
torque on the cylinder and thus the rotation of the drive shaft. The supplied fluid quantity determines the output
speed.
308 BOMAG 008 918 12

External gear pumps 10.12
External gear pumps
10.12 External gear pumps
External gear pumps mainly consist of the friction bearing mounted gear pair and the housing with front and rear
covers. The drive shaft, which is sealed with a radial seal, protrudes from the front cover. The bearing forces are
absorbed by friction bearings. These have been designed for high pressures and have excellent antifriction prop-
erties - particularly at low speeds. The gears have 12 teeth each. This keeps flow pulses and noise emissions
at a low level.
Axial seal Outer pressure field Inner pressure field Radial seal
Sealing zone
Cover Flange Compensation forces
Fig. 20 Axial compensation of gear pump
Internal sealing of the pressure chambers is achieved by flow volume dependent forces. This results in an ex-
cellent rate of efficiency. On the rear side the moveable bearing bushings are pressurized and thus tightly
pressed against the gears. The pressurized pressure fields are thereby limited by special seals. Sealing around
the circumference of the gears to the housing is assured by small gaps, which appears between gears and hous-
ing in dependence on the pressure.
Function
Fig. 21
The increasing volume caused by a tooth exiting a tooth gap results in a vacuum in the suction chamber. The
pressure fluid is transported into the pressure chamber. There the meshing of teeth and tooth gaps displaces
the pressure fluid into the upper supply line.
008 918 12 BOMAG 309

10.12 External gear pumps
Fig. 22
1 Cover 6 Gear (driven)

2 Seals and gaskets 7 Shaft
3 Housing 8 Flange
4 Gear (driving) 9 Bearing plate
5 Displacement chamber 10 Bearing plate
310 BOMAG 008 918 12

Travel circuit 10.13
Travel system
10.13 Travel circuit
The travel circuit is a closed hydraulic circuit.
Fig. 1
1 Cooler 8 Drive axle with brake

2 Steering valve 9 Rear travel motor, with speed range selector
Y31
3 Steering/charge pump 10 Travel gear with brake discs
4 Travel pump 11 Front travel motor, with speed range selector
Y30
5 Vibration pump 12 Return flow manifold with thermal element
6 Charge oil filter with differential pressure switch, 13 Hydraulic oil tank
B21
7 Brake valve, Y04
008 918 12 BOMAG 311

Travel pump and vibration pump are mounted together to a tandem unit which is driven by the flywheel side of
the engine via an elastic coupling. The travel pump has the function of supplying the travel circuit with hydraulic
oil.
Travel gear with travel motor, drum drive

The drive motor is a swash plate controlled axial piston motor of series 51C110 with variable displacement.
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.
Fig. 2 Reduction gear CR 31

1 Travel motor
2 Taper roller bearing
3 Spur wheel
4 Ring gear
5 Planet gear
6 Sun gear
7 Planet carrier
8 Brake discs
9 Mechanical seal
10 Brake piston
Travel motor rear, axle motor

The drive motor is a swash plate controlled axial piston motor of series 51D110 with variable displacement.
312 BOMAG 008 918 12

Fig. 3 Drive axle

1 Drive axle
2 Travel motor
Charge circuit
The gear pump driven by the auxiliary drive of the engine serves as steering pump and also as charge pump,
because the oil flow from steering valve is flowing to the charge port on travel and vibration pump. Furthermore,
the vibration pump has an integrated charge pump, both charge oil flows are united before the charge pressure
filter.
The charge circuit provides the oil for the charge system and the control functions in the closed circuits for travel
and vibration drive, as well as to release the parking brakes.
The charge circuit is equipped with a 12µ fine filter with bypass valve. These open at a pressure differential
(pressure difference between filter inlet and filter outlet) of Δp = 3.5 bar. This pressure differential depends on
the filter contamination and the viscosity of the hydraulic oil.
The differential pressure switch (B21) switches when a differential pressure of Δ p 2.5 bar is reached. The
fault information will therefore already be available before the bypass valve opens.
Return flows
All return flows pass through the return flow manifold with temperature controlled valve (thermostat). This ther-
mostat guides the oil flow directly back to the hydraulic oil tank, until the operating temperature is reached. At
an oil temperature of 55 °C the valve starts to switch over and at 70 °C the total amount of oil will flow through
the hydraulic oil cooler.
008 918 12 BOMAG 313

Option, cabin with heating
Fig. 4
314 BOMAG 008 918 12

1 Cooler 8 Drive axle with brake

2 Steering valve 9 Rear travel motor, with speed range selector
Y31
3 Steering/charge pump 10 Travel gear with brake discs
4 Travel pump 11 Front travel motor, with speed range selector
Y30
5 Vibration pump 12 Return flow manifold with thermal element
6 Charge oil filter with differential pressure switch, 13 Hydraulic oil tank
B21
7 Brake valve, Y04 14 Silencer, it is always subjected to hydraulic oil
flow and has the function of eliminating any vi-
brations and noises.
Brake control
During operation the closed hydrostatic travel circuit has the function of a service brake.
When the travel lever is returned towards neutral position, the displacement of the travel motor is adjusted to-
wards zero accordingly and the machine is hydraulically braked.
To avoid creeping movements of the machine, the machine is additionally equipped with multi-disc parking
brakes in the axle. These close in neutral position of the travel lever and when the engine is stopped.
The parking brakes are electrically operated by proximity switches (B13) on the travel lever via relay (K48) and
the 3/2-way solenoid valve (Y04). In de-energized state the charge oil supply to the brake pistons is interrupted,
allowing the hydraulic oil to return to the tank via the 3/2-way valve. When moving the travel lever out of neutral
position, the connection to the tank is interrupted and charge oil is directed to the brake piston. This hydraulic
pressure works against the spring force applied to the brake piston by the brake springs and relieves the brake
discs.
Travel lever
Fig. 5
B13 Initiator for brake Y04 Brake valve

B14 Initiator for reverse detection
008 918 12 BOMAG 315

10.14 Adjust the parking brake
10.14Adjust the parking brake
! Caution
Have adjustment work on the brakes only carried out by a specialist! Always adjust both sides.
l Secure the machine with wheel chocks against rolling.
l Start the diesel engine to relieve the brake.
Fig. 6
l
Disengage the travel lever (Fig. 6) to the left, but do not move to position "I" or "II".
The parking brake is released
Fig. 7
l Unscrew locking plate 2 (Fig. 7).
l
Turn the square (1) in anti-clockwise direction against the stop.
316 BOMAG 008 918 12

Adjust the parking brake 10.14
Fig. 8
l In order to adjust the brake clearance turn the square 1 (Fig. 8) three turns back in clockwise direction.
l Fasten the locking plate again.
l Pull the plug off the brake solenoid valve and perform the drive test.
The machine must be braked.
008 918 12 BOMAG 317

10.15 Stopping the machine, operating the parking brake
10.15Stopping the machine, operat- 10.16Towing in case of an engine

ing the parking brake failure
Danger
!
Danger of accident! Danger of injury!

Before releasing the parking brake secure the ma-
chine against unintended rolling by using appro-
priate means (e.g. metal wheel chocks).
When using towing ropes tow the machine only
uphill.
When towing downhill you must use a rigid towing
device.
The machine cannot be steered.
Use a towing vehicle with sufficient traction and
Fig. 9
braking power for the unbraked towed load.
l Return the travel lever (Fig. 9) slowly to "neutral"-
Do not touch hot engine parts.
position and engage it to the right in braking posi-
tion.
The machine is automatically braked by the hydrostat- Caution
!
ic drive and the parking brake is applied. Tow the machine only after releasing the parking
brake.
Towing speed 1 km/h, max. towing distance 500
m.
l
Always secure the machine against unintended roll-
ing.
Fig. 10
The parking brake warning lamp (k) (Fig. 10) lights up.
i Note
The parking brake also closes automatically when
shutting the engine down. Fig. 11
l Attach chains (Fig. 11) or towing ropes to the lifting
hooks.
l
Open the engine compartment hood and secure it.
318 BOMAG 008 918 12

Towing in case of an engine failure 10.16
Fig. 12 Fig. 14
l Back out the two high pressure relief valves (1) on l Turn both screws (Fig. 14) for releasing the drum
the travel pump (Fig. 12) for approx. 3 turns. brake evenly in clockwise direction, until the drum
can turn freely.
Caution
!
Do not back out more than 3 turns!

After towing
Caution
!
Before detaching the tow bar block the machine

with chocks to prevent unintended rolling.
Fig. 13
l To release the brake turn counter nuts (1) (Fig. 13)
approx. 8 mm back.
l
Turn the brake releasing screws (2) completely in
Fig. 15
against the stop.
l Tighten the two high pressure relief valves on the
travel pump (Fig. 15) again, tightening torque: 70
! Caution Nm.
From this stop turn the screw in for maximum an-
other turn to release the brake!
Turn the screws in evenly on both sides.
l Turn the screws in alternately for ¼ turn at a time.
l Repeat this measure on the opposite wheel side.
008 918 12 BOMAG 319

10.16 Towing in case of an engine failure
i Note
If necessary replace the sealing ring under the coun-
ter nut if it is leaking.
For this purpose completely unscrew the brake re-
leasing screw, replace the seal ring and lubricate the
screw with silicone grease.
Reinstall the screw with a new seal ring and adjust the
protrusion as described above.
Fig. 16
l Turn both screws for releasing the drum brake (Fig.
16) anti-clockwise against the stop.
l Turn all brake releasing screws of the axle evenly
back out, until they are light moving again.
Fig. 17
l Turn the brake releasing screws (Fig. 17) back in
again, until they abut against the brake piston.
Fig. 18
l Unscrew the brake releasing screws (Fig. 18) for
two turns and tighten the counter nuts.
l Repeat this adjustment procedure on the opposite
wheel side.
320 BOMAG 008 918 12

Vibration circuit 10.17
Vibration circuit
10.17 Vibration circuit
The vibration circuit is a closed hydraulic circuit, it consists mainly of the vibration pump with the integrated safety
elements and the vibration motors.
Travel pump and vibration pump are mounted together to a tandem unit which is driven by the flywheel side of
the engine via an elastic coupling. The vibration pump has the function of supplying the vibration circuit with hy-
draulic oil.
When changing the swashing angle in the vibration pump through the neutral position to the opposite side, the
flow direction of the oil and the sense of rotation of the vibration motor will change.
Since the displacement of the vibration pump is different to the two flow directions, the speeds of the vibration
motor are also different.
high amplitude
low amplitude
Fig. 1
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.
The eccentric weights on the vibrator shaft are fitted with additional change-over weights. Depending on the
sense of rotation of the vibrator shaft these change-over weights add to or subtract from the basic weights.
l Basic weight + change-over weight = high amplitude
l Basic weight - change-over weight = low amplitude
008 918 12 BOMAG 321

Fig. 2
1 Drum shell 8 Change-over weight

2 Vibration bearings 9 Coupling vib. motor – exciter shaft
3 Basic weight 10 Travel bearings
4 Vibration housing 11 Travel bearing housing
5 Cooling fan 12 Rubber buffer
6 Exciter shaft 13 Vibration motor
7 Elastic coupling between shafts 14 Flanged bearing housing
The vibration motor output shaft is joined with the exciter shafts in the drum via a Bowex coupling. Rotation of
the exciter shaft with the bolted on eccentric weights causes the vibration of the elastically suspended drums.
322 BOMAG 008 918 12

Fig. 3
1 Cooler 6 Charge circuit filter

2 Steering valve 7 Vibration motor
3 Steering/charge pump 8 Return flow manifold with thermal element
4 Travel pump 9 Hydraulic oil tank
5 Vibration pump, Y07 high amplitude, Y08 low ampli-
tude
Vibration motor
The vibration motor is a fixed displacement axial piston motor type A10FM 45.
008 918 12 BOMAG 323

Fig. 4
1 High pressure port high amplitude 4 Flushing spool

2 High pressure port, low amplitude 5 Flushing valve
3 Leak oil and flushing port
Charge circuit
The gear pump driven by the auxiliary drive of the engine serves as steering pump and also as charge pump,
because the oil flow from steering valve is flowing to the charge port on travel and vibration pump. Furthermore,
the vibration pump has an integrated charge pump, both charge oil flows are united before the charge pressure
filter.
The charge circuit provides the oil for the charge system and the control functions in the closed circuits for travel
and vibration drive, as well as to release the parking brakes and to change the travel speed ranges.
The charge circuit is equipped with a 12µ fine filter with bypass valve. These open at a pressure differential
(pressure difference between filter inlet and filter outlet) of Δp = 3.5 bar. This pressure differential depends on
the filter contamination and the viscosity of the hydraulic oil.
The differential pressure switch (B21) switches when a differential pressure of Δ p 2.5 bar is reached. The
fault information will therefore already be available before the bypass valve opens.
Return flows
All return flows pass through the return flow manifold with temperature controlled valve (thermostat). This ther-
mostat guides the oil flow directly back to the hydraulic oil tank, until the operating temperature is reached. At
an oil temperature of 55 °C the valve starts to switch over and at 70 °C the total amount of oil will flow through
the hydraulic oil cooler.
324 BOMAG 008 918 12

Fig. 5
1 Cooler 6 Charge circuit filter

2 Steering valve 7 Vibration motor
3 Steering/charge pump 8 Return flow manifold with thermal element
4 Travel pump 9 Hydraulic oil tank
5 Vibration pump, Y07 high amplitude, Y08 low ampli- 10 Silencer, it is always subjected to hydraulic oil
tude flow and has the function of eliminating any vi-
008 918 12 BOMAG 325

10.18 Steering circuit
BW211, one steering cylinder

Fig. 1
1 Steering valve 4 Hydraulic oil tank

2 Steering and charge pump with pressure test port 5 Steering cylinder
3 Charge circuit filter
326 BOMAG 008 918 12

Steering circuit 10.18
Fig. 2

3 Charge circuit filter 6 Silencer, it is always subjected to hydraulic oil
008 918 12 BOMAG 327

BW 212/213/214/216/218/219, two steering cylinders
Fig. 1

3 Charge circuit filter
328 BOMAG 008 918 12

Fig. 2

3 Charge circuit filter 6 Silencer, it is always subjected to hydraulic oil
Articulated joint
Front and rear frames of the single drum rollers are connected by an oscillating articulated joint. This ensures
that drum and wheels are at all times in contact with the ground, even when driving extreme curves.
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 bear-
ings 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.
008 918 12 BOMAG 329

Articulated joint
Steering cylinder
Fig. 3
When turning the steering wheel the steering cylinders will extend or retract. The piston rods swivel the front
console around the vertical bolts. This articulates the machine and results in a steering movement.
Steering valve
The steering valve consists mainly of:
l the distributor valve
l the rating pump
l the steering pressure relief valve
l
the shock valves
330 BOMAG 008 918 12

Fig. 4 Steering valve
1 Neutral setting springs 6 Ring gear

2 Housing 7 Gear
3 Inner spool 8 Check valve
4 Outer spool 9 Pressure relief valve
5 Universal shaft
When turning the steering wheel the distributor valve guides the oil flow to the corresponding steering cylinder
sides. 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 valve contains also a pressure relief valve. This valve limits the steering pressure to 175 bar. Since
the oil is available for the charge circuit after it as left the steering unit, the charge pressure must be added to
this value. The maximum steering pressure is therefore approx. 200 bar.
Suddenly occurring pressure peaks, which may be caused by e.g. external influences like driving against a curb
stone, are compensated by two shock valves, which are integrated in the steering valve. Each of these shock
valves is fitted with an additional anti-cavitation valve. These anti-cavitation valves protect the system against
cavitation which could be caused by the reaction of the shock valves.
A check valve inside the steering unit makes sure that the hydraulic oil cannot flow to the steering pump if forces
are introduced from outside. In such a case the steering cylinders would act as pumps and press the oil back to
the pump.
i Note
This steering system is a dynamic steering system, i.e. a small quantity of oil (approx. 1 - 2 l/min) will always flow
via the LS-line.
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 cylin-
ders or to the boost check valves for travel and vibration circuits.
008 918 12 BOMAG 331

10.19 Check the hydraulic oil level
10.19Check the hydraulic oil level 10.20Changing hydraulic oil and

breather filter
! Caution
In hydraulic systems filled with Panolin HLP i Note
Synth. 46 always use the same oil to top up. With See also the notes on the hydraulic system in the
other ester based oils consult the lubrication oil chapter "General notes on maintenance".
service of the respective oil manufacturer.
! Danger
Danger of scalding!
When draining off hot hydraulic oil!
! Caution
The hydraulic oil must also be changed after ma-
jor repairs in the hydraulic system.
Perform the oil change when the hydraulic oil is
warm.
Replace the hydraulic oil filter elements with every
hydraulic oil change.
Fig. 5
Change the filter only after the hydraulic oil
l
Check the hydraulic oil level in the inspection glass change and after the test run.
(Fig. 5).
Clean the area round hydraulic oil tank, filler
Normal level opening and breather filter.
approx. 3 cm below the top edge of the inspection Do not start the engine after draining the hydraulic
glass. oil.
Do not use any detergents to clean the system.
Minimum level
Use only lint-free cleaning cloths.
Middle of inspection glass.
For quality and quantity of oil refer to the "table of
fuels and lubricants".
! Caution
When changing from mineral oil based hydraulic
If, during the daily inspection of the oil level the oil to an ester based biologically degradable oil,
hydraulic oil level is found to have dropped, check you should consult the lubrication oil service of
all lines, hoses and components for leaks. the oil manufacturer for details.
l
If necessary fill in hydraulic oil through the filler
neck. Environment
For quality and quantity of oil refer to the table of Catch running out hydraulic oil and dispose of en-
fuels and lubricants. vironmentally.
332 BOMAG 008 918 12

Replace hydraulic oil filter 10.21
10.21Replace hydraulic oil filter
! Danger
Danger of scalding!
By hot oil when unscrewing the filter.
! Caution
If the filter has to be changed together with the hy-
draulic oil, the filter must only be changed after
the oil change and after the test run.
Fig. 6 Do not use the oil in the filter bowl again.

l Unscrew the plug (Fig. 6) and drain off all hydraulic
oil. Environment
l Check the seal ring, replace if necessary and turn Catch running out oil, dispose of oil and filter ele-
the plug tightly back in. ment environmentally.
i Note
Apart from the normal oil change intervals, the filter el-
ement must also be changed after major repairs in the
hydraulic system.
Fig. 7
l Remove the filler cap (Fig. 7).
l
Fill in new hydraulic oil through the screen.
i Note Fig. 8
We recommend to use the BOMAG filling and filtering l
Remove filter bowl (4) (Fig. 8) with filter element (3).
unit with fine filter to fill the system. This ensures finest
filtration of the hydraulic oil, prolongs the lifetime of the
l Examine the surface of the filter element thoroughly
hydraulic oil filter and protects the hydraulic system. for any visible dirt.
l Check the oil level in the inspection glass.
! Caution
Nominal value: Visible dirt may be an early sign for the failure of
approx. 3 cm below the upper edge of the inspection system components and indicate the possible fail-
glass ure of components. In this case determine the
cause and replace or repair the defective compo-
nents, if necessary. Negligence may cause de-
i Note
struction to the entire hydraulic system.
The breather filter for the hydraulic oil tank is integrat-
ed in the filler cap. You should therefore replace the Do not clean or reuse the filter element.
complete filler cap. l Take the old filter element (3) out, clean the filter
l Close the tank with a new cover. bowl and thread.
l
Reassemble the filter bowl with a new filter element
and new O-rings (1, 2).
l
After a short test run check the filter for leaks.
008 918 12 BOMAG 333

10.22 Changing the bypass filter
10.22Changing the bypass filter*
! Danger
Danger of scalding!
Danger of scalding by hot oil when unscrewing
the oil filter.
! Caution
If the filter has to be changed together with the hy-
draulic oil, the filter must only be changed after
the oil change and after the test run.
Replace the filter element at the latest after one
year
Environment
Dispose of the old filter element environmentally.
Fig. 9
l Open the engine hood (Fig. 9) completely and se-
cure it.
Fig. 10
l Unscrew the fastening screws (Fig. 10) and take off
the cover.
l
Replace the filter element, attach the cover and fas-
ten it with the screw.
334 BOMAG 008 918 12

11 Tests and adjustments
008 918 12 BOMAG 335

11.1 Special tools, tests and adjustments

1. Vibration reed frequency meter
1000 - 4000 rpm
17 - 67 Hz
Fig. 1
2. Sirometer (frequency meter)
800 - 50.000 rpm
14 - 750 Hz
Fig. 2
3. Anti-freeze tester, quick and accurate measuring,
sturdy plastic housing, automatic temperature
correction, no after-dripping, instructions for use
on unit, reading down to -40 °C. Material: Plastic,
Temperature range: down to -40 °C
Fig. 3
4. Digital rpm-meter for petrol engines
Fig. 4
336 BOMAG 008 918 12

Special tools, tests and adjustments 11.1
5. Digital rpm-meter for petrol engines
Fig. 5
6. Digital rpm-meter, optical/mechanical, universal
use
Fig. 6
7. Infrared manual thermometer, -18 to 275°C
Fig. 7
8. Hydraulic test case, large
i Note
4 X 600 bar pressure gauges
4 X 60 bar pressure gauges
8 pressure test hoses
Fig. 8
008 918 12 BOMAG 337

9. Hydraulic test case, small
i Note
2X 60 bar pressure gauge
2X 600 bar pressure gauges
4 pressure test hoses
Fig. 9
10. Pressure test hoses
1000 mm BOMAG part-no.: 079 930 02
2500 mm BOMAG part-no.: 079 930 03
Fig. 10
11. Pressure gauge
60 bar BOMAG part-no.: 059 721 07
600 bar BOMAG part-no.: 059 721 04
Fig. 11
12. Adapter for pressure test hose
Fig. 12
338 BOMAG 008 918 12

Special tools, tests and adjustments 11.1
13. Gear pump testing device
Fig. 13
14. Vacuum pump for hydraulic oil tank
BOMAG part-no.: 007 610 04 (12 Volt)
BOMAG part-no.: 007 610 24 (24 Volt)
Fig. 14
008 918 12 BOMAG 339

11.2 Adjusting the solenoid for engine speed control
11.2 Adjusting the solenoid for engine

speed control
15. Remove screw 3 (Fig. 1).
16. Switch on the ignition.
17. Switch on the solenoid (2) (move to full load posi-
tion).
i Note
When switched on, the plunger of the solenoid is
pulled in against the stop and the integrated limit
switch deactivates the pickup winding. The cur-
rent flow is reduced from approx. 70 A to approx.
3.5 A.
18. Push the throttle lever (1) to the right.
Fig. 1
i Note
There must be a gap of max. 0.5 mm between
stop screw (5) and throttle lever (1). Insert a dou-
ble folded piece of paper to check.
19. Keep adjusting the linkage (4), until the screw (3)
can be easily installed.
20. Retighten the screw (3).
340 BOMAG 008 918 12

Checking the rotation speeds 11.3
11.3 Checking the rotation speeds
Special tools
Vibration reed frequency meter, RPM-meter for
diesel engines.
! Caution
Perform measurements at operating tempera-
ture of the hydraulic oil (50 °C).
1. Drive the machine with both drums on an elastic
base (rubber buffers) (Fig. 1).
2. Block the wheels with suitable chocks.
Fig. 1
Check the engine speed
i Note
If necessary, the engine speed may also be
checked with the vibration Reed frequency meter.
1. Connect the RPM-meter to the injection line (Fig.
2).
2. Run the engine with maximum speed.
3. Apply the brake.
4. Measure the rotation speeds.
Nominal value idle speed:

Low idle speed, see technical data.
High idle speed, see technical data.
5. Switch the vibration on .
Nominal value nominal speed:

Fig. 2
See technical data.
Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting for the engine.
008 918 12 BOMAG 341

11.3 Checking the rotation speeds
Checking the exciter shaft speed

1. Switch the vibration on at max. engine speed.
2. Apply the brake.
3. Measure the speed of the vibrator shaft, rest the
tester on your thumb (Fig. 3).
Nominal value:
See technical data.
Evaluation of test
If the nominal value is not reached, perform trou-
ble shooting in the vibration circuit.
Fig. 3
342 BOMAG 008 918 12

Checking / adjusting the neutral positions of the travel pump 11.4
11.4 Checking / adjusting the neutral posi-
tions of the travel pump
Special tools
Hydraulic test case
! Caution
1. Block drums and wheels with suitable chocks
(Fig. 1).
Fig. 1
2. Unhook the travel cable (Fig. 2) from the pump.
Fig. 2
3. Pull the plug (Fig. 3) off the brake solenoid valve
to close the brake.
Fig. 3
008 918 12 BOMAG 343

11.4 Checking / adjusting the neutral positions of the travel pump
4. Connect 600 bar pressure gauges to high pres-

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

chanical neutral position (Fig. 7), until the pres-
sures on both pressure gauges are identical.
Fig. 7
344 BOMAG 008 918 12

Pressure tests in the travel circuit 11.5
11.5 Pressure tests in the travel circuit
Special tools
Hydraulic test case
! Caution
1. Block drums and wheels with suitable chocks
(Fig. 1).
Fig. 1
2. Pull the plug (Fig. 3) off the brake solenoid valve
to close the brake.
Fig. 2
3. Connect 600 bar pressure gauges to the high
pressure test ports for "forward travel" and "re-
verse travel" and a 60 bar pressure gauge to the
charge pressure test port (Fig. 2).
5. Read charge and high pressure gauges.
Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = charge pressure at high
Fig. 3 idle
Evaluation of test
If the nominal value is not reached, check the
steering/charge pump.
008 918 12 BOMAG 345

11.5 Pressure tests in the travel circuit
Measurement with quickly operated travel le-

ver
6. Move the travel lever (Fig. 4) quickly forward,
read the pressure gauge.
Nominal value
see technical data of travel pump:
Charge pressure gauge = charge pressure at
high idle
High pressure gauge = pressure override
Evaluation of test
Fig. 4
If the specified high pressure is not reached,
check the travel pump.
If the charge pressure drops considerably during
the high pressure test, check the components in-
dividually.
346 BOMAG 008 918 12

Checking / adjusting the vibrator shaft speeds 11.6
11.6 Checking / adjusting the vibrator shaft
speeds
Special tools
Vibration reed frequency meter
! Caution
1. Drive the machine on an elastic base (rubber
buffers) (Fig. 1).
2. Apply the parking brake and block the wheels ad-
ditionally with suitable chocks.
4. Switch on vibration high frequency / low ampli-
tude or low frequency / high amplitude.
Fig. 1
5. Measure the speed (Fig. 2), rest the tester on
your thumb.
Nominal value
high amplitude/
low frequency = see technical data
low amplitude/
high frequency = see technical data
Evaluation of test
In case of deviations exceeding 10% determine
the cause, perform trouble shooting for engine /
vibration circuit and check vibration motor.
Fig. 2
6. Adjust the speed on the corresponding adjust-
ment screw (Fig. 2).
i Note
Turning the adjustment screw in reduces the
speed, turning the screw out increases the
speed.
Fig. 3
008 918 12 BOMAG 347

11.7 Pressure measurements in the vibration circuit
11.7 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.
Fig. 1
4. Connect a 60 bar pressure gauge (Fig. 2) to the
charge pressure test port.
5. Connect a 600 bar pressure gauge each to the
high pressure test ports for "high amplitude" and
"low amplitude".
7. Switch on vibration with high or low frequency.
Nominal value
Charge pressure = charge pressure at high idle
(see technical data of travel pump).
Start-up pressure = vibration pump start-up pres-
Fig. 2 sure (see technical data of vibration pump).
Operating pressure = vibration pump operating
pressure (see technical data of vibration pump).
Evaluation of test
If the charge pressure drops, check the compo-
nents individually.
If the starting pressure is not reached, check the
vibration pump.
If the starting pressure is only reached for one fre-
quency, check the high pressure relief valves.
348 BOMAG 008 918 12

Check the leakage rate of the vibration motor 11.8
11.8 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.
2. Apply the brake.
Fig. 1
3. Block the flushing valve (Fig. 2) with washers.
Fig. 2
4. Disconnect the leak oil hose (Fig. 3), connect a
measuring hose and hold it into a measuring
beaker.
6. Switch the vibration on and measure the running
out leak oil during one timed minute.
Nominal value
max. 1.5 litre/min
Evaluation of test
If the permissible leak oil rate is exceeded, re-
place the vibration motor.
Fig. 3
008 918 12 BOMAG 349

11.9 Pressure test in steering circuit

Special tools
Hydraulic test case, gear pump testing equipment
! Caution
ture of the hydraulic oil (approx. 50 °C).
Measurement 1
1. Connect a 600 bar pressure gauge to the steering
pressure test port (Fig. 1).
2. Start the engine and run it at idle speed.
! Danger
Danger of crushing, do not access the articu-
lation area of the machine!
3. Turn the steering against an end stop.
4. Read the pressure gauge.
Nominal value
Fig. 1
see technical data, max. steering pressure of
Evaluation of test 1
If the nominal value is reached, check the steer-
ing cylinder.
Measurement 2
5. Disconnect the hydraulic hoses from ports L and
R (Fig. 2) (machines with one steering cylinder)
on the steering cylinder and close them with
plugs.
Fig. 2
6. Disconnect the hydraulic hoses from ports L and
R (Fig. 3) (machines with two steering cylinder)
on the steering cylinders and close them with
plugs.
7. Start the engine and run it at idle speed.
8. Turn the steering wheel.
9. Read the pressure gauge.
Nominal value
see technical data for steering/charge pump.
Fig. 3
350 BOMAG 008 918 12

Pressure test in steering circuit 11.9
If the nominal value is reached, replace the steer-
ing cylinder.
If the nominal value is not reached, check the
10. Reconnect the hydraulic hoses to the steering
cylinders.
Measurement 3
11. Actuate the emergency stop switch.
Fig. 4
12. Close the pump outlet port (Fig. 5) with the gear
pump test equipment.
13. Crank the engine with the starter
Nominal value
see technical data for steering/charge pump.
If the nominal value is reached, replace the steer-
ing valve.
If the nominal value is not reached, replace the
Fig. 5
008 918 12 BOMAG 351

352 BOMAG 008 918 12

12 Flushing and bleeding
008 918 12 BOMAG 353

12.1 Special tools for flushing

i Note
The following list informs about special tools for
flushing. You should choose the corresponding
tool for the work to be carried out.
14. Filling and filtering unit
Fig. 1
15. Flushing filter (S connection)

16. Filter element 1μ

17. Flushing hose 20S - 25S (2 pieces)

18. Screw socket R1“ - 25S (2 pieces)
Fig. 2
19. Flushing filter (L connection)

20. Filter element

21. Flushing hose 15L (2 pieces)

22. Screw socket R3/4“ -- 15L (2 pieces)
Fig. 3
23. SAE-flange 1“ - 20S

24. O-ring
BOMAG part-no. 062 203 30
Fig. 4
354 BOMAG 008 918 12

Special tools for flushing 12.1
25. Flanged plate 1“ - 25S

26. O-ring
BOMAG part-no. 062 202 22
Fig. 5
27. Reducing fitting 18L - 15L
Fig. 6
28. Reducing fitting 25S - 20S
Fig. 7
29. Reducing fitting 20S - 16S
Fig. 8
008 918 12 BOMAG 355

30. Connecting socket 15L
Fig. 9
31. Connecting socket 18L
Fig. 10
32. Connecting socket 16S
Fig. 11
33. Connecting fitting 20S
Fig. 12
356 BOMAG 008 918 12

Special tools for flushing 12.1
34. Connecting fitting 25S
Fig. 13
35. Angular fitting 18L
Fig. 14
36. Elbow fitting 16L
Fig. 15
37. Elbow 20S
Fig. 16
008 918 12 BOMAG 357

38. Elbow 25S
Fig. 17
39. Pipe connection 16S - 16S
Fig. 18
40. Connecting hose 15L
Fig. 19
358 BOMAG 008 918 12

Flushing - general 12.2
12.2 Flushing - general Solid particles in the circuit will very quickly
cause damage to machine components.
Changing a component
! Caution
Always flush the complete oil circuit after
you have replaced a component.
Fig. 1 Chips (abrasion) in the oil

Effect of contamination l Open and clean all components in the oil
circuit, replace if necessary.
Coarse particles (> 15 µm)
Sudden failure of components. l Clean all high pressure hoses in the oil cir-
cuit, replace if necessary.
Fine particle contamination (5 – 15 µm)
l If abrasion is found in the travel circuit you
Wear of components, internal leaks, inaccurate
should also flush the vibration circuit.
controlling behaviour, blockage of valves.
l If abrasion is found in the vibration circuit
Extra fine particle contamination (< 2 – 5 you should also flush the travel circuit.
µm)
Silting of oil, accelerated aging of oil, corrosion.
Water in oil
Increased wear, accelerated aging of oil.
008 918 12 BOMAG 359

12.2 Flushing - general
Before flushing Bleeding

Change the filter element
Fig. 3
Fig. 1
l Always bleed closed hydraulic circuits if
lines had been removed or connected.
Clean the hydraulic tank
Servicing the flushing filter kit
Fig. 4
Fig. 2
l Replace the filter element of the flushing fil-
ter when the red control pin of the contami-
!Caution nation indicator is pressed out during the
Change the oil in case of excessive contam- filtering process.
ination, oil discoloration or if the oil change l Clean hoses and connections and store the
interval is almost due. flushing kit in a clean and protected envi-
l Filter the tank content with the filling and fil- ronment.
tering unit and pump it into an oil container.
l Mark all hoses and disconnect them from
the hydraulic oil tank.
l Clean the oil tank thoroughly from inside, if
necessary remove the tank cover.
l Reconnect all hoses.
l Fill the hydraulic oil tank again with the fill-
ing and filtering unit.
360 BOMAG 008 918 12

Flushing schematic travel circuit (distribution travel pump) 12.3
008 918 12 BOMAG 361

12.3 Flushing schematic travel circuit (distribution travel pump)
1 Elbow union (tool) 13 High pressure hose (A, drum drive motor for-
ward)
2 Connecting union (tool)
14 High pressure hose (B, axle motor reverse)
3 Drum drive motor
15 High pressure hose (A, axle motor forward)
4 Axle motor
16 High pressure hose (B, axle motor reverse)
5 Screw socket R1 - 25S (tool)
17 High pressure port (B, drum drive motor reverse)
6 Flushing hose 25S - 20S (tool)
8 Flushing filter with filter element 1μ (tool)
9 Elbow union (tool)
10 Reducing fitting (tool)
11 Travel pump
12 High pressure hose (B, drum drive motor reverse)
362 BOMAG 008 918 12

Flushing the travel circuit (travel pump distribution) 12.4
12.4 Flushing the travel circuit (travel
pump distribution)
Flushing the drum drive

Replacing the hydraulic oil filter element
Cleaning the hydraulic oil tank
i Note
Observe the chapter "Flushing - General"
Installing the flushing filter
! Caution
Before the installation of the filters check hos-
es and connections for cleanliness.
The flushing filter must be installed in the low
pressure side in the return flow to the pump,
so that only cleaned oil will enter the travel
pump in forward travel.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
Fig. 1
1. Disconnect the high pressure hose 12 (see chap-
ter "Flushing schematic - travel circuit") from the
travel pump (high pressure port 17) and connect
it with the flushing hose (7) (flushing filter inlet
"IN").
2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port 17) on the travel
pump.
Disconnect the drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
cuit by joining the high pressure hoses (12 and
13) on the drum drive motor together.
Fig. 2
008 918 12 BOMAG 363

12.4 Flushing the travel circuit (travel pump distribution)
Bleeding the travel circuit
i Note
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 3
Flushing the hoses
4. Block drums and wheels with suitable chocks.
Fig. 4
i Note
Keep circulating the complete tank content with
the filling and filtering unit throughout the entire
flushing process.
Fig. 5
! Caution
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
5. Start the engine and shift the travel lever to travel
direction forward.
6. Perform the flushing process at various engine
speeds for approx. 10 minutes.
7. Shut down the engine.
8. Reconnect the hydraulic hoses (12 and 13) to the
drum drive motor.
Fig. 6
364 BOMAG 008 918 12

Flushing the drum drive motor
! Danger
Danger of accident!
The drum must rotate freely.
9. Jack up the front of the machine, so that the drum
can rotate freely.
10. Secure the rear wheels with chocks.
11. Pre-select the slow speed range.
Fig. 7
i Note
flushing process.
Fig. 8
! Caution
12. Start the engine, run it with maximum speed and
shift the travel lever to travel direction forward.
13. Run the flushing procedure for approx. 10 min-
utes. During this process keep changing the
pump flow by shifting the travel lever several
times between full and halve forward travel.
Fig. 9 15. Remove the flushing filter and reconnect the high
pressure lines.
008 918 12 BOMAG 365

Flushing the axle drive

"IN").
17. Connect the flushing hose (19) (flushing filter out-
let "OUT") to the (high pressure port 16) on the
travel pump.
Fig. 10
Disconnecting the axle motor
18. Take the axle drive motor out of the hydraulic cir-
15) on the axle drive motor together.
Fig. 11
i Note
Fig. 12
366 BOMAG 008 918 12

Flushing the hoses
Fig. 13
i Note
flushing process.
Fig. 14
! Caution
direction forward.
axle drive motor.
Fig. 15
Flushing the axle motor
!Danger
Danger of accident!
Both wheels must be off the ground. The
wheels must be able to rotate freely.
24. Jack up the rear of the machine, so that the
wheels can rotate freely.
25. Secure the drum with wheel chocks.
Fig. 16
008 918 12 BOMAG 367

i Note
flushing process.
Fig. 17
! Caution
pressure lines.

31. Bleed the travel circuit (see corresponding chap-
ter).
Keep circulating the tank content.

32. After completing the bleeding process circulate
the tank content with the filtering unit for another
15 minutes.
Function test
33. Check the hydraulic oil level in the tank, fill up if
necessary.
34. Check all connections for leaks with the engine
running (visual inspection).
35. Perform a test drive, load the travel system in for-
ward and reverse, e.g. by driving uphill or starting
on a gradient.
36. Check all ports and connections for leak tightness
(visual inspection).
Fig. 19
368 BOMAG 008 918 12

Flushing schematic travel circuit (distribution axle motor) 12.5
008 918 12 BOMAG 369

12.5 Flushing schematic travel circuit (distribution axle motor)
370 BOMAG 008 918 12

008 918 12 BOMAG 371

12.5 Flushing schematic travel circuit (distribution axle motor)
372 BOMAG 008 918 12

1 Elbow union (tool) 13 High pressure hose (drum drive motor forward)
2 Connecting union (tool) 14 High pressure hose (B, axle motor reverse)
3 Drum drive motor 15 High pressure hose (A, axle motor forward)
4 Axle motor 16 High pressure hose (B, axle motor reverse)
5 Screw socket R1 - 25S (tool) 17 not used
6 not used 18 Flushing hose 25S - 20S (tool)
7 not used 19 Flushing hose 25S - 20S (tool)
8 Flushing filter with filter element 1μ (tool)
9 not used
10 Reducing fitting (tool)
11 Travel pump
12 High pressure hose (drum drive motor reverse)
008 918 12 BOMAG 373

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

distribution)
Flushing the drum drive

i Note
! Caution
so that only cleaned oil will enter the travel
pump in forward travel.
With the connection shown in the illustration
the travel pump must therefore be actuated to
forward direction.
Fig. 1
"IN").
2. Connect the flushing hose (18) (flushing filter out-
let "OUT") to the (high pressure port 16) on the
travel pump.
Disconnect the drum drive motor
3. Take the drum drive motor out of the hydraulic cir-
13) on the drum drive motor together.
Fig. 2
374 BOMAG 008 918 12

Flushing the travel circuit (axle motor distribution) 12.6
i Note
Fig. 3
Flushing the hoses
i Note
flushing process.
Fig. 4
Fig. 5
! Caution
direction forward.
drum drive motor.
Fig. 6
008 918 12 BOMAG 375

Flushing the drum drive motor
! Danger
Danger of accident!
The drum must rotate freely.
9. Jack up the front of the machine, so that the drum
can rotate freely.
10. Secure the rear wheels with chocks.
Fig. 7
i Note
flushing process.
Fig. 8
! Caution
Fig. 9
376 BOMAG 008 918 12

Flushing the travel circuit (axle motor distribution) 12.6
Flushing the axle motor
!Danger
Danger of accident!
Both wheels must be off the ground. The
wheels must be able to rotate freely.
15. Jack up the rear of the machine, so that the
wheels can rotate freely.
16. Secure the drum with wheel chocks.
Fig. 10
i Note
flushing process.
Fig. 11
! Caution
pressure lines.

22. Bleed the travel circuit (see corresponding chap-
ter).

15 minutes.
008 918 12 BOMAG 377

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
378 BOMAG 008 918 12

Flushing schematic for vibration drive 12.7
1 Elbow union (tool) 7 Flushing hose 25S - 20S (tool)

2 Connecting union (tool) 8 Flushing filter with filter element 1μ (tool)
3 Vibration motor 9 SAE flange (tool)
4 Vibration pump 10 High pressure hose (B, high frequency)
5 Screw socket R1 - 25S (tool) 11 High pressure hose (A, low frequency)
008 918 12 BOMAG 379

12.8 Flushing the vibration circuit

i Note
! Caution
so that only cleaned oil will enter the vibration
pump in high frequency.
For the connection schematic shown here the
vibration must always be filtered with "high
frequency / low amplitude".
Fig. 1
ter "Flushing schematic - vibration circuit") from
the vibration pump (4) and connect it with the
flushing hose (7) (flushing filter inlet "IN").
2. Connect the flushing hose (6) (flushing filter outlet
"OUT") to the (high pressure port A) on the vibra-
tion pump.
Disconnect the vibration motor
3. Take the vibration motor out of the hydraulic cir-
11) on the vibration motor together.
Fig. 2
380 BOMAG 008 918 12

Flushing the vibration circuit 12.8
Bleeding the vibration circuit
i Note
Bleeding the vibration circuit, see chapter "Bleed-
ing the vibration circuit".
Fig. 3
Flushing the hoses
Fig. 4
i Note
flushing process.
Fig. 5
! Caution
Use only high frequency, as otherwise the
flushing filter will be subjected to oil flow from
the wrong direction.
5. Switch on vibration with high frequency.
7. Flush the circuit for approx. 10 minutes, thereby
switch the vibration on and off at intervals of ap-
prox. 30 seconds.
Fig. 6 vibration motor.
008 918 12 BOMAG 381

Flushing the vibration motor

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

15 minutes.
382 BOMAG 008 918 12

Flushing the vibration circuit 12.8
Function test
necessary.
18. Test drive.
Fig. 10
008 918 12 BOMAG 383

12.9 Bleeding the travel circuit
12.9 Bleeding the travel circuit
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
! Danger
The engine should not start.
Fig. 1
4. Hold the open ends of the pressure test hoses
(Fig. 2) into a container.
5. Operate the starter motor for approx. 30 seconds.
Wait one minute and repeat this procedure, until
oil starts to run out from the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 2
7. Unlock the emergency stop switch
Fig. 3
384 BOMAG 008 918 12

Bleeding the travel circuit 12.9
8. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Pause for approx. 30 seconds and keep repeat-
ing this procedure, until the gauge shows a con-
stant charge pressure reading.
Fig. 4
! Caution
With the flushing filter installed shift the travel
lever only to travel direction forward, as oth-
erwise the flushing filter will be subjected to
oil flow from the wrong direction.
!Danger
Run the engine with idle speed.
10. Start the engine.
11. Shift the travel lever (Fig. 5) approx. 1/3 to for-
ward direction.
Fig. 5 12. After approx. 1 to 2 minutes shut down the engine
for a minute.
i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
008 918 12 BOMAG 385

12.10 Bleeding the vibration circuit
12.10Bleeding the vibration circuit
Environment
Catch hydraulic oil and dispose of environ-
mentally.
1. Install a pressure test hose to the charge pres-
sure test port.
2. Install a pressure test hose each to the high pres-
sure test ports.
Fig. 1
4. Hold the open ends of the pressure test hoses
(Fig. 2) into a container.
5. Crank the engine approx. 10 seconds with the
starter motor. Wait one minute and keep repeat-
ing this procedure, until oil starts to run out from
the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 2
7. Unlock the emergency stop switch
Fig. 3
386 BOMAG 008 918 12

Bleeding the vibration circuit 12.10
8. Connect a 60 bar pressure gauge to the charge
pressure test port (Fig. 4) and run the engine
max. 15 seconds at idle speed.
9. Wait for approx. 30 seconds and repeat the pro-
cedure, until the pressure gauge shows a con-
stant charge pressure.
Fig. 4
! Caution
With the flushing filter installed use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-
tion.
10. For bleeding switch on vibration with high fre-
quency (Fig. 5).
11. Start the engine.
12. After running the engine 1 to 2 minutes pause for
approx. one minute.
Fig. 5 i Note
This waiting time is necessary to allow air bub-
bles to escape through the leak oil return line.
13. After a waiting time of approx. 1 minute keep re-
peating this procedure, until the indicated charge
pressure drops directly to zero when shutting
down the engine.
008 918 12 BOMAG 387

12.10 Bleeding the vibration circuit
388 BOMAG 008 918 12

13 Air conditioning system
008 918 12 BOMAG 389

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

conditioning system one must first become familiar
with the physical basics of such a system.
The four well known physical conditions of water apply
also for the refrigerant in the air conditioning system.
1. gaseous (invisible)
2. vaporous
3. liquid
4. solid
Fig. 2
Heat always flows from the warmer to the colder mat-
ter. Any matter consists of a mass of moving mole-
cules. The rapidly moving molecules or a warmer
matter dissipate part of their energy to the slower
moving molecules with less heat. The movement of
the molecules in the warmer matter becomes slower
and the molecules in the cooler matter are accelerat-
ed. This process continued, until all molecules in the
two matters move with identical speed. The matters
have then reached an identical temperature and the
transfer of heat stops.
Fig. 1
If the water in a container is heated up (absorption of
heat), the rising steam is visible. If the steam is heated
up further, due to the absorption of heat, the visible
steam will turn into invisible gas. This process is re-
versible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into
water and finally into ice.
390 BOMAG 008 918 12

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

In the pressure - temperature diagram for the refriger-
ant the drawn in closed curve shows the cycle of the
refrigerant. This cycle permanently continues in direc-
tion of the arrow.
The characters A, B, C, D stand for:
Fig. 3 Steam pressure curve A - compression
Steam pressure curve for refrigerant R134a B- condensation
The steam pressure curve is a means for explaining C- relaxation
the operation principle of an air conditioning system. D- evaporation.
A- liquid
B- gaseous
The diagram shows the evaporation curve of R134a.
The diagram for example shows, that R134a is liquid
at 0°C and a pressure of 5 bar, but becomes gaseous
at 40°C and 5 bar.
For better understanding one must also be aware of
the following:
1. A gas heats up when being compressed (e.g. air
pump, turbo charger, ...).
2. When relieving gas it will cool down (e.g. white frost
forms on the valve when relieving air pressure from a
car tire).
3. Condensing gas dissipates a lot of heat energy.
008 918 12 BOMAG 391

13.1 Physical basics
Excerpt from the wet steam table * R134a

* This table is used for the determination of evaporation and con-
densation temperature.
Saturation temperature Overpressure (pressure gauge Absolute pressure (pamb = 1 bar
reading Pe in bar) P in bar)
-20 0,33 1,33
-10 1,01 2,01
0 1,93 2,93
10 3,15 4,15
20 4,72 5,72
392 BOMAG 008 918 12

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

- 26.5 °C Physical properties of R134a:
The steam pressure curves of R134a and other refrig-
erants are partly very similar, making a clear differen-
Solidification point: tiation solely by pressure impossible. With R 134a the
compressor is lubricated by special synthetic refriger-
-101.6 °C
ation oils, e.g. PAG-oils (polyalkylene glycol oils).
Critical temperature:
Behaviour with metals:
100,6 °C
In pure condition refrigerant R134a is chemically sta-
ble and does not attack iron and aluminium. However,
contamination of the refrigerant, e.g. with chlorine
Critical pressure:
compounds, leads to aggressiveness against certain
40.56 bar (absolute) metals and plastics. This can cause clogging, leaks or
deposits on the pistons of the compressor.
Critical point:
Critical point (critical temperature and critical pres- Critical temperature / critical pressure:
sure) means that above this point there is no separat- Up to a gas pressure of 39.5 bar overpressure (this
ing interface between liquid and gas. Above its critical corresponds with a temperature of 101 °C) the refrig-
point any substance is gaseous. At temperatures be- erant R134a remains chemically stable, above this
low the critical point all refrigerant types in pressure temperature the refrigerant decomposes (see com-
containers have a liquid and a gaseous phase, i.e. a bustibility).
gas cushion is above the liquid. As long as gas is in
the container, besides the liquid, the pressure de-
pends on the ambient temperature. Water content:
In liquid refrigerant water can only be dissolved in very
low quantities. In contrast to this refrigerant steam
mixes with water steam at any ratio. If the dryer in the
008 918 12 BOMAG 393

13.3 Compressor oil / refrigeration oil
liquid container has absorbed approx. 8 gr. of water, 13.3 Compressor oil / refrigeration
the refrigerant circuit transports possibly existing wa-
ter in form of droplets. This water flows to the nozzle oil
of the expansion valve and turns to ice. The air condi- The compressor oil lubricates the movable parts in the
tioning system stops cooling. Water destroys the air compressor, seals e.g. the gap between piston and
conditioning system, because under high pressures cylinder inside the compressor to prevent refrigerant
and temperatures and in connection with other con- loss and prevents other seals in the system from dry-
taminants it forms acids. ing up.
Part of the compressor oil dissolves in the refrigerant
Inflammability: until saturation is reached, so that a gas mixture of re-
frigerant, water steam, compressor oil and contrast
Refrigerant is not inflammable. On the contrary, it has agent circulates through the system.
fire inhibiting or fire extinguishing properties. Refriger-
ant is decomposed by flames or glowing surfaces. Ul- Compressor oil (the oil quantity should be 10 % of the
traviolet light also cracks refrigerant (caused by refrigerant weight) mixes with the refrigerant and cir-
electric welding). This results in toxic fission products, culates permanently through the system.
these must not be inhaled. However, irritation of the In connection with R134a- air conditioning systems
mucous membranes is an early and in-time warning. special synthetic compressor oils, e.g. polyalkylene
glycol (PAG) oils, are used. This is necessary, be-
cause e.g. mineral oil does not mix with R134a. Apart
Filling factor: from this, the materials in the R134a air conditioning
In a container there must be a steam space above the system may be attacked when the mixture is flowing
liquid space. The liquid expands with increasing tem- through the refrigerant circuit under high pressure and
perature. The steam filled space becomes smaller. at high temperatures or if the lubrication film in the
From a certain time on the container will be filled with compressor tears off. The use of non-permitted oils
just liquid. After this only a minor temperature in- can cause damage to the air conditioning system, you
crease is enough to generate very high pressures in should therefore only used the approved oils.
the container, because the liquid would like to expand,
but there is no more room. The related forces are high
enough to cause the container to burst. In order to Properties of compressor oil / refrigeration oil:
avoid overfilling of a container the pressure gas direc- The most important properties are high solvency in
tive clearly specifies how many kilograms of refriger- connection with refrigerants, good lubrication charac-
ant may be filled into the container per litre volume. teristics, that they are free of acids and their low water
Multiplied with the internal volume this "filling factor" content. For this purpose only certain oils can be
determines the permissible filling capacity For refrig- used. PAG-oils suitable for use with refrigerant R134a
erants used in motor vehicles it is 1.15 kg/l. are highly hygroscopic and will not mix with other oil.
As a protection against the invasion of moisture drums
must immediately be closed again after they had been
opened. Compressor oil ages under the effect of
Environmental aspects moisture and acids, becomes dark, viscous and ag-
The contribution of R134a to the greenhouse effect is gressive against metals.
by factor 10 smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for
newly produced construction equipment were succes-
sively converted to refrigerant R134a. This refrigerant
does not contain any chlorine and is thus harmless for
the ozone layer. Until approx. 1992 air conditioning
systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decompo-
sition potential and also a potential to amplify the
greenhouse effect. Conversion programs for existing
old systems with the ozone damaging R12 are in ef-
fect. For reasons of protecting the environment refrig-
erant must not be discharged into the atmosphere.
394 BOMAG 008 918 12

Working principle of the air conditioning system 13.4
13.4 Working principle of the air 13.5 Monitoring devices
conditioning system
All air conditioning systems are based on the same
principle. They extract heat from the surrounding en- Pressure switch
vironment. Everybody knows the effect: if a sweating
The pressure switch (8) is used as monitoring feature
body is exposed to wind it will cool down, because
for too high and too low pressures. The switching con-
heat is extracted. For this purpose a refrigerant circu-
tacts (4 and 5) effect the magnetic clutch of the com-
lates in a closed circuit inside the vehicle. This refrig-
pressor via a relay (6).
erant thereby continuously changes its physical state
between liquid and gaseous. If the system pressure increases excessively, e.g. be-
cause of a excessively soiled condenser, a failed fan
or a defective expansion valve, the high pressure con-
tact (5) will cut off the electric power supply to the
magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off
pressure by the set differential pressure, the magnetic
clutch of the compressor is switched on again.
The low pressure contact (4) interrupts the electric
power supply to the magnetic clutch when the set
pressure is fallen short of (possible causes: lack of re-
frigerant, defective expansion valve, too low heat
load, defective evaporator fan, ...). Since the refriger-
ant R134a has an evaporation temperature of 0 °C at
an overpressure of 2 bar, the low pressure contact (4)
Fig. 1 Principle sketch of an air conditioning system
is set to approx. 1.5 bar to avoid icing. The switch on
An engine driven compressor (1) draws in gaseous re- pressure is 0.5 to 2 bar higher than the shut-off pres-
frigerant from the evaporator (5) and compresses it. sure (depending on system, see description of com-
During this process the temperature of the refrigerant ponents.)
increases tremendously.
Thermostat
The refrigerant vapour is then pumped to the con-
denser (2). This condenser is arranged directly in front A frost protection thermostat (3) protects the evapora-
of the vehicle radiator, so that a sufficient air flow is as- tor against icing. Similar to the pressure switch, the
sured. In the condenser (2) the gas is cooled down thermostat activates or deactivates the magnetic
and consequently liquefied. clutch for the compressor. Depending on the design,
the feeler of the temperature control is mounted be-
In the dryer / liquid container (3) the refrigerant is then
tween the fins of the evaporator or attached to the
collected and freed of moisture and contaminants.
evaporator outlet (suction side). With fixed tempera-
The expansion valve (4) regulates the flow rate from ture controls the control switches the compressor off
the dryer / liquid container (3) back to the evaporator at about 1 °C and back on again at about 2.5°C to 5.5
(5) and the circuit starts again. °C (depending on system, see description of compo-
nents.)
With adjustable temperature regulators the switching
point can be changed so that the compressor is al-
ready shut down at higher temperatures. This enables
regulation of the air temperature.
008 918 12 BOMAG 395

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

l 1 Switch
l 2 Fuse
l 3 Thermostat
l 4 Low pressure switch contact Fig. 1
l 5 High pressure switch contact The compressor is mounted to the engine and has the
duty to build up the refrigerant pressure required for
l
6 Relay
the function of the system. Coupling and decoupling is
l
7 Connection for magnetic clutch accomplished by an electromagnetically controlled
l
8 Pressure switch mechanical clutch, which is integrated in the V-belt
pulley of the compressor.
Compressor data
Displacement: 155 cm²
Weight: 6.9 kg
max. rpm: 6000
Sense of rotation: clockwise
Refrigerant: R134a
Oil quantity (scope of delivery): 207 gr
Oil: PAG SP-20 (H14-003-404)
! 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.
396 BOMAG 008 918 12

Description of components 13.6
Reason of oil loss Amount of oil lost Condenser
Loss when emptying approx. 15 gr
Defective A/C hose approx. 30 gr
Hose change approx. 15 gr
Replacement of condens- approx. 30 gr
er
Replacement of evapora- approx. 30 gr
tor
Replacement of liquid con- approx. 30 gr
tainer
Replacement of expan- approx. 15 gr
sion valve
! Caution
Please bear in mind, that the new compressor is
delivered with a filling of 207 gr. compressor oil. Fig. 1
To avoid excessive oil in the A/C-system and thus The condenser is located in front of the the radiator for
a poor cooling effect, the oil level in the A/C-sys- the machine. It emits heat energy from the system into
tem must be adjusted accordingly. the surrounding air and liquefies the gaseous refriger-
The quantity depends on the amount of oil that ant.
may have been lost in connection with the possi-
ble replacement of other components.
i Note
The compressor oil quantity must be 10% of the The fins must be free of dirt and damage.
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system re- ! Caution
quires a compressor oil / refrigerant oil filling of
100 gr. When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil lost by ex-
Procedure: changing the components, must be replaced with
Drain and measure the compressor oil from the fresh oil.
old compressor.
Drain the compressor oil from the new compres-
sor and only fill in the exact quantity that had been
drained out of the old compressor. The compres-
sor oil from the new compressor can be used for
this purpose.
i Note
Topping up compressor oil / refrigeration oil is possi-
ble on a pressureless compressor directly into the oil
pan, in a pressureless refrigeration system directly
into the pressure side, but it is also possible to draw it
into the pressure side of the refrigeration system dur-
ing the evacuation process.
008 918 12 BOMAG 397

Dryer / filter / fluid container / inspection Pressure relief valve

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

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

the reason for air entering into the system and since
The arrow marks on the filter/dryer must point in air cannot be condensed, one will not be able to get
flow direction, i.e. towards the expansion valve. rid of these bubbles by topping up refrigerant. In this
Filter/dryer cannot be treated for further use! case the air conditioning system needs to be evacuat-
ed and refilled.
398 BOMAG 008 918 12

i Note Expansion valve
Air in the system is characterized by high pressures
and temperatures.
On R134a refrigeration systems from KONVEKTA the
inspection glasses are equipped with moisture indica-
tors. In addition to the float, the dryer/collector/inspec-
tion glass combination has an indicator pearl
integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection
glass and should only be checked after approx. 5 min-
utes continuous operation, because the refrigerant
must first evenly distribute all over the system.
! Danger
In case of mechanical damage or corrosion on

this pressure container this collector unit must be
replaced, to avoid bursting and further damage. Fig. 1
The expansion valve is mounted inside the HKL-mod-
ule in the cabin. The expansion valve always allows a
small amount of the high pressure liquefied refrigerant
to flow into the evaporator, which has a much lower
pressure. This lower pressure causes these liquid re-
frigerant to expand and to evaporate to gaseous state.
The heat required for this evaporation process is tak-
en from the ambient air through the lamellas and sup-
plied to the refrigerant. This is the so-called cooling
effect.
The thermostatic expansion valve operates with an
external pressure compensation. This type of expan-
sion valve works with high accuracy, because it uses
pressure and temperature at the evaporator outlet and
adjusts and overheating of approx. 7 K. The already
installed expansion valves and the ones delivered as
spare parts have this overheating value pre-set. In or-
der to prevent a loss in performance or compressor
damage you should only use original expansion
valves, because adjusting expansion valves takes a
lot of time and care.
i Note
In case of dirt in the refrigerant system you should also
check or clean the screen at the expansion valve in-
let.+
008 918 12 BOMAG 399

Evaporator Thermostat
Thermostat with fixed setting
Fig. 1
The evaporator is mounted inside the HKL-module in
Fig. 1
the cabin. It consists of a heat exchanger (inside air -
refrigerant), with refrigerant flowing to a pipe system The feeler of a defroster thermostat to switch off the
with cooling flanges. magnetic clutch in case of icing up or to switch the
clutch back on after defrosting, is mounted on the
As with the condenser, correct operation of all fans evaporator.
and cleanliness of the fins must be assured.
With fixed temperature controls the control switches
Air conditioning systems have a circulation air filter the compressor off at about +1 °C and back on again
mounted in the air flow in front of the evaporator, at about +2.5°C to +5.5 °C.
which should be cleaned or changed by the operator
after each third trip, depending on the amount of dirt. Adjustable thermostat
A condensation water filter is mounted in the air flow With adjustable temperature regulators the switching
after the evaporator. This filter has the function to col- point can be changed so that the compressor is al-
lect the water that has condensed from the air in the ready shut down at higher temperatures. This enables
evaporator block and to discharge this water into the regulation of the air temperature.
water pan With a defective condensation water filter
condensation water may flow into the inside of the ve-
hicle.
! Caution
or condenser, any compressor oil lost by ex-
changing the components, must be replaced with
fresh oil.
Fig. 2 adjustable temperature controller
i Note
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
will be switched on.
400 BOMAG 008 918 12

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

GH 134 NW8 min. 50 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm
008 918 12 BOMAG 401

13.7 Measuring the compressor oil level
13.7 Measuring the compressor oil 13.8 Checking the magnetic clutch
level l Measure the voltage.
!Caution i Note
The compressor oil level must be checked after Nominal value = vehicle voltage
replacing a system component or if a leak in the l
Check the magnetic coil locking ring for secure fit.
system is suspected. Use only compressor oil / re-
frigeration oil PAG SP-20 (H14-003-404). l
Check the current consumption.
l Run the compressor for 10 minutes at engine idle
speed.
l remove the refrigerant from the air conditioning sys-
tem.
Fig. 1
Fig. 1 i Note
l
Turn the compressor, as shown in (Fig. 1), if neces- at 12 Volt vehicle voltage approx. 3.5 Amp.
sary remove V-belt and hoses.
at 24 Volt vehicle voltage approx. 1.75 Amp.
l
Remove the oil plug.
Overcurrent indicates a short circuit inside the mag-
netic coil.
i Note No current indicates an interrupted electric circuit.
The oil level must reach the bottom edge of the bore,
top up or drain off oil if necessary.
l
Close the oil plug again.
!Caution
The contact area must be clean and should be free
of damage.
Tightening torque 15 to 25 Nm
l Refill the air conditioning system.
Fig. 2 Measuring the air gap

l Measure the air gap on the magnetic clutch be-
tween V-belt pulley (2) and thrust plate (1).
402 BOMAG 008 918 12

Inspection and maintenance work 13.9
i Note 13.9 Inspection and maintenance
The gap should be 0.4 to 0.8 mm. work
l
Take off the drive V-belt and rotate the V-belt pulley l Visual inspection of the complete system for dam-
by hand while the magnetic clutch is disengaged. age.
l Check the compressor mounting bracket on the ve-
i Note hicle engine for tight fit and damage.
In case of excessive flatness faults or deviations the l Check the condition, alignment and tightness of the
magnetic clutch needs to be replaced. V-belt.
l
Check the routing of refrigerant hoses and cables in
Cross-section of magnetic clutch
the area of the vehicle engine and transmission, as
Fig. 3 shows a cross-section of the magnetic clutch. If well as on the chassis for chafing and rectify any de-
the coil (7) is not supplied with operating voltage, tected faults. Ensure sufficient clearance to hot
there is no contact between the front plate of the parts, such as the exhaust; install a protective
clutch (1) and the V-belt pulley (2). A spring presses shield, if necessary.
the front plate away from the belt pulley. The V-belt l Check the routing of hoses and hoses on the at-
pulley rotates with the bearing (3) in idle speed, the
tachment box or in the cabin.
compressor does not work. When the coil is supplied
with operating voltage (12 or 24 V), a magnetic field is l Check all hose and screw fittings for leaks.
generated and pulls the front plate of the clutch. Both l Check the fastening of the condenser unit.
front plate and compressor shaft (8) are then driven by
the V-belt pulley, the compressor works. l
Clean the condenser fins, replace the condenser
block if damaged fins are found.
l
Check the fastening of the evaporator unit.
l
Check the function of evaporator and condenser
fans.
l
Check the electric control panel. If discolorations on
conductors are found, these should be replaced
and possibly also the corresponding relays.
l
Switch on the cooling system and check the refrig-
erant level.
l
Filter/dryer and filter/dryer/fluid container combina-
tions must always be replaced after opening the re-
frigerant circuit. If these are in service for more than
1 year, there is a risk that they may be clogged by
excessive absorption of moisture! The filter/dryer
should be replaced in regular intervals.
l Measure the temperature on the evaporator: Meas-
ure the intake air temperature - Measure the blow
Fig. 3 Cross-section of magnetic clutch out air temperature - The temperature difference
should be at least 8-10 K.
l
Measuring the pressure in the refrigerant circuit
008 918 12 BOMAG 403

13.10 Checking, replacing the refrigerant compressor V-belt
13.10Checking, replacing the refrig- l Press the compressor in direction of arrow, until the
correct V-belt tension is reached.
erant compressor V-belt* l Retighten all fastening screws.
Danger
! Changing the V-belt
Danger of injury! l Slightly slacken the fastening screws 1, 2 and 3.
Work on the V-belt must only be performed with l Press the compressor against the direction of arrow
the engine shut down. completely against the engine.
Wear safety goggles. l Take the old V-belt off.
l Fit the new V-belt to the V-belt pulleys.
Check the V-belt
l Tension the V-belt as previously described.
Caution
!
Check the V-belt tension after a running time of 30

minutes.
Fig. 4
l
Inspect the entire circumference of the V-belt (Fig.
4) visually for damage and cracks. Replace dam-
aged or cracked V-belts.
l Check with thumb pressure whether the V-belt can
be depressed more than 10 to 15 mm (0.4 – 0.6
inches) between the V-belt pulleys, retighten if nec-
essary.
Tighten the V-belt.
Fig. 5
l
Slightly slacken fastening screws 1, 2 and 3 (Fig.
5).
404 BOMAG 008 918 12

Air conditioning service (old design) 13.11
13.11Air conditioning* service (old
design)
Clean 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.
Fig. 7
If, during operation of the air conditioning system, l Switch the air conditioning (Fig. 7) on.
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. 8
l Choose a cooling temperature with the rotary switch
for cabin heater (Fig. 8) in the blue section.
l
Open the air outlet nozzles.
l
Check, whether the out flowing air is noticeably
cooler.
i Note
The adjusted temperature must be below the actual
temperature inside the cabin, so that the compressor
l Open the hood.
Fig. 6
l
Unscrew the condenser fastening screws (Fig. 6)
and fold the condenser forward.
l
Clean the condenser fins on front and back with
compressed air or cold water .
Checking the refrigerant level

l
Start the engine.
008 918 12 BOMAG 405

13.11 Air conditioning service (old design)
Checking the moisture level of the drying

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

ice department every year before the operating
season.
Checking the condition of the drier/col-

lector unit
Fig. 10 !Caution
l
If the white float (Fig. 10) inside the inspection glass According to the regulation for pressure reser-
of the drier/collector unit floats at the bottom, inform voirs all pressure reservoirs must be repeatedly
the service department. inspected by a specialist. In this sense repeated
inspections are external examinations, normally
on pressure reservoirs in operation. In connection
i Note
with this inspection the drier/collector unit must
The refrigerant level is not correct.
be visually examined twice every year. During
l Refrigerant must be filled up, if necessary check the these inspections special attention must be paid
air conditioning system for leaks. 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!
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.
406 BOMAG 008 918 12

Service the air conditioning 13.12
13.12Service the air conditioning*
Clean the condenser
! 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. 12
l Check the drier/collector unit (Fig. 12) for mechani-
! Caution
cal damage or rust.
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.
Fig. 13
l Unscrew the condenser fastening screws (Fig. 6)
and fold the condenser forward.
l
Clean the condenser fins on front and back with
compressed air or cold water .
Checking the refrigerant level

l
Start the engine.
008 918 12 BOMAG 407

13.12 Service the air conditioning
Fig. 14 Fig. 16
l Turn the rotary switch for the cab ventilator (Fig. 14) l Check whether the white float (Fig. 16) inside the in-
to position "1". spection glass of the drier/collector unit floats right
at the top.
i Note
The refrigerant level is correct.
Fig. 15
l Choose a cooling temperature with the rotary switch
for the air conditioning system (Fig. 15) in the blue
section.
l
Open the air outlet nozzles. Fig. 17
l
Check, whether the out flowing air is noticeably l
If the white float (Fig. 17) inside the inspection glass
cooler. of the drier/collector unit floats at the bottom, inform
the service department.
i Note
The adjusted temperature must be below the actual i Note
temperature inside the cabin, so that the compressor The refrigerant level is not correct.
l Refrigerant must be filled up, if necessary check the
air conditioning system for leaks.
408 BOMAG 008 918 12

Service the air conditioning 13.12
Checking the moisture level of the drying
agent
Fig. 19
l Check the drier/collector unit (Fig. 19) for mechani-
cal damage or rust.
Fig. 18
l Check the moisture indication pearl (Fig. 18) inside
the inspection glass of the drier/collector unit.
orange = Drying agent o.k.
colourless= moisture level of drying agent too high.
l Inform the service department. Replace drier/col-
lector unit, check air conditioning system.
Caution
!
Have the drier/collector unit replaced by the serv-

ice department every year before the operating
season.
Checking the condition of the drier/col-

lector unit
!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!
this drier/collector unit this unit must be replaced,
to avoid bursting and further damage.
008 918 12 BOMAG 409

13.13 Drying and evacuation
13.13Drying and evacuation 13.14Emptying in case of repair

Evacuation of air conditioning systems using R-type For repair work the air conditioning systems must very
refrigerants not only has the purpose of emptying the often be emptied of all refrigerant.
system of all air before filling in refrigerant, but also to Especially with expensive refrigerants and larger
verify the leak tightness over a longer lifetime in the amounts of oil it may be necessary to keep the refrig-
achieved vacuum. However, the most important factor erant for later use.
in this work step is the drying of the system.
For later use these refrigerants must be drawn out
Any water residues in the refrigerant circuit will com- with suitable equipment and intermediately stored in
bine with the refrigerant, which will lead to the previ- collecting containers.
ously described consequential damage.
Vacuum pumps with a capacity of more than 100 l/min
Environment
and a final pressure of less than 30 micron, i.e. 0.039
mbar should be used to evacuate the refrigeration Contaminated refrigerant must be disposed of en-
system. vironmentally
The refrigerant compressor is not suitable for the pur- Releasing refrigerant into the atmosphere is pro-
pose of evacuation, because it is not able to achieve hibited (see restrictive injunction concerning
a sufficient final vacuum and, apart from this, may be CFC, day of enforcement 01. 08. 1991, § 8)
mechanically damaged because of a lack of lubrica-
tion when running empty during evacuation.
! Danger
It is common practice to evacuate the refrigeration For draining refrigeration systems you should not
system to a final vacuum of 1 Torr, i.e. 1.33 mbar. simply use any delivery containers, but only ap-
An exact time for evacuation and drying cannot be propriate pressure bottles, which must be special-
predicted. It can only be determined by means of a ly marked and should comply with the pressure
vacuum meter. However, if there is no vacuum meter gas directive.
at hand it is generally better to evacuate 1 hour longer
When transferring refrigerant you must make sure
than 1 hour too less.
that the bottle does not contain more than the per-
Function drying: mitted amount of refrigerant in litres and has suf-
ficient gas space for expansion (filling factor: 0,7).
Under normal ambient pressure (1.013 mbar) evapo-
rates absolute at 100° C. If the pressure is reduced, In order to reduce the evacuation period in case of
water will already evaporate, e.g. under a pressure of short repairs, you may fill the refrigerant circuit with
10 mbar, at an ambient temperature of almost 7°C, approx. 0.5 bar nitrogen when opening. This ensures
but the water will not evaporate all at once. Since it is that nitrogen will flow out of the refrigerant circuit while
very difficult to separate the steam from the vacuum in it is open and no air or moisture can enter. However,
the system, the evacuation process is supported by the necessity for vacuum generation and a dryer
the co-called vacuum breaking (filling the circuit with change remains.
dried nitrogen). With vacuum breaking the filled in
dried nitrogen absorbs the moisture in the refrigerant
circuit, which can then be easily discharged together
with the nitrogen.
410 BOMAG 008 918 12

Leak test 13.15
13.15Leak test
! Caution
The use of leak detection colouring matter is not
permitted, because its chemical composition is
unknown and its effect on compressor oil and rub-
ber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Before starting the evacuation process, the refrigerant
circuit is filled with nitrogen through a pressure reduc-
er valve (approx. 22 bar). After this all connections in
the air conditioning system are checked with the help
of a suitable leak detection spray. A leak is thereby in-
dicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air con-
ditioning system with refrigerant.
Leak test with electronic leak tester
Fig. 1 Electronic leak tester

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

Points susceptible for leakage are sprayed with a
soapy solution. Bubbles indicate the leak. The detec-
tion limit for R 134a is 250 g/year.
008 918 12 BOMAG 411

13.16 Filling instructions
13.16Filling 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.
412 BOMAG 008 918 12

Filling instructions 13.16
Fig. 1 10 Filter dryer

1 High pressure - gaseous 11 Fluid container
2 High pressure - liquid 12 Condenser
3 Low pressure - gaseous 13 Manual shut-off valve (not used)
4 Compressor 14 Pressure switch with high and low pressure con-
5 Compressor pressure switch (not used) tacts
6 not used 15 Defroster thermostat
7 Evaporator 16 Vacuum meter
8 Expansion valve 17 Low pressure gauge
9 Inspection glass 18 High pressure gauge
008 918 12 BOMAG 413

13.16 Filling instructions
19 Pressure reducing valve 16 Switch off the vacuum pump, watch the pressure
20 Vacuum pump gauges to see whether the vacuum is maintained.
21 Nitrogen bottle 17 Open the valve on the refrigerant bottle and open
the black and red hand wheels on the pressure
22 Refrigerant bottle
gauge bar. Fill refrigerant into the system, until a
23 Pressure gauge bar pressure equilibrium between suction and pres-
sure side is reached (reading of pressure gaug-
Filling instructions es).
1 Connect the service adapter with the blue hand 18 Close the red hand wheel.
wheel in the suction side. 19 Perform a leak test with the electronic leak detec-
2 Connect the service adapter with the red hand tor.
wheel in the pressure side (the hand wheels on 20 Start the engine and switch on the system.
the service adapters must be fully backed out - left 21 Open the blue hand wheel and continue filling in
hand stop) refrigerant until the inspection glass is free or air
3 Connect the blue suction hose below the blue bubbles (in fluid container/dryer combinations the
hand wheel on the pressure gauge bar to the blue white pearl should float in the upper third of the in-
service adapter. spection glass). Then close the refrigerant bottle.
4 Connect the red pressure hose below the red 22 Close the blue hand wheel on the pressure gauge
hand wheel on the pressure gauge bar to the red bar.
service adapter. 23 Preparing the test run: -Close windows and doors
5 Connect the yellow hose below the yellow hand -Fan on full speed stage -Mount measuring feel-
wheel on the manometer bar to the 2-stage vacu- ers to air discharge and air intake.
um pump. 24 Run the system for approx. 20 minutes with medi-
6 Connect the last hose below the black hand wheel um engine speed.
on the nitrogen bottle via the pressure reducing 25 The temperature difference between air discharge
valve. and air intake should be (depending on type of air
7 Check on the pressure gauge bar that all hand condition) 8-10°C. The ambient temperature
wheels are closed. thereby is approx. 20°C. (These data are only ref-
8 Turn the hand wheels on both service adapter erence values, which may be influenced by possi-
clockwise. This opens the valves (right hand ble insolation)
stop). 26 Switch off system and engine and check for leaks
9 Open the valve on the nitrogen bottle (only via again.
pressure reducer); pressure approx. 20 bar. 27 Turn out (left hand stop) and remove the hand
10 Open the black and red hand wheels on the pres- wheels on both service adapters.
sure gauge bar and fill nitrogen into the system, 28 Fit all valves with dust caps.
until a pressure of approx. 3.5 to 5.0 bar is indicat- 29 Perform a leak test.
ed on the suction side.
30 Mark the system with the corresponding type
11 Then open the blue hand wheel and raise the plates and information decals, such as type of oil
pressure in the suction side (max. 10 bar). Check and refrigerant.
for leaks with a leak detection fluid or soapsuds.
12 If the system is leak tight, release the nitrogen
from the system. For this purpose disconnect the
hose from the nitrogen bottle and open the red,
blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand
wheels on the pressure gauge bar. In case of a
leak no or only an insufficient vacuum will be
reached. In this case proceed as described under
point 9-12. Once the leak is sealed continue with
point 14.
15 Once a sufficient vacuum is reached, both pres-
sure gauges show -1, close all hand wheels on the
pressure gauge bar.
414 BOMAG 008 918 12

Trouble shooting in refrigerant circuit, basic principles 13.17
13.17Trouble shooting in refriger-
ant circuit, basic principles
Basic principles
Requirements
For trouble shooting two requirements must be ful-
filled:
l Expert knowledge
l technical equipment
Technical equipment
The most important aids for trouble shooting are pres-
sure gauges and thermometer. The refrigerant condi-
tions, like overheating and excessive cooling provide
important Information when searching for faults. Even
your own senses are important aids for trouble shoot-
ing. Bubbles in the sight glass, dirt and white frost can
be visibly perceived. If the compressor draws in wet
steam, this can be noticed by the suction line and it
may also be audibly detectable. An overloaded com- Fig. 2 Pressure gauge
pressor can even be smelled.
Example:
The following tools and auxiliary materials should be
A totally empty air conditioning system holds an at-
available for trouble shooting:
mospheric pressure of approx. Pamp = 1 bar.
l
Service station
Filling the system with refrigerant causes an excess
l
Pressure gauge pressure of Pe = 3 bar.
l
Thermometer
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
l
dry nitrogen
Evacuating the system down to Pe = -0.6 bar, creates
l
Refrigerant bottle for new refrigerant
a "vacuum" (negative excess pressure).
l
Container for old oil
l
Vacuum pump Pabs = Pamb + Pe = 1 bar +(- 0,6) bar = 0,4 bar
l
Hoses
l Scales
l Suction station
l Leak detector
The measuring equipment must be checked at regular
intervals. Calibration can only be made by an ap-
proved testing authority.
Pressure gauge
Most pressure gauges used in practice are (for cost
reasons) excess pressure gauges. These pressure
gauges measure the excess pressure in relation to the
ambient pressure (air pressure). In order to achieve
the absolute (actual) pressure the ambient pressure
must be added to the pressure gauge reading. The
absolute pressure is needed for the calculation and
determination of material data.
Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = excess pressure (pressure gauge reading)
008 918 12 BOMAG 415

13.17 Trouble shooting in refrigerant circuit, basic principles
Pressure gauge with saturation temperature scale If the suction condition of the compressor is directly on
the dew line, an e.g. incorrect evaporator load can
cause "wet suction". This can lead to two processes,
which are destructive for the compressor. The liquid
refrigerant washes off the lubricating film between pis-
ton and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in
the cylinder causes a direct energy transfer from pis-
ton to cylinder cover during compression. The valve
plate may then be damaged by so-called fluid strokes.
Apart from protecting the compressor against fluid,
overheating has further advantages. Since the fluid
proportions in the drawn in steam reduces the flow
rate of the compressor, it may be increased by a over-
heating. Overheating also improves the oil recircula-
tion.
Common overheating values

The optimal overheating value is approx. 5 - 8 Kelvin.
With this overheating the maximum system power is
reached. However, the thermostatic expansion valve
Fig. 3 Absolute pressure gauge is unable to regulate this value exactly. Depending on
design and operating conditions overheating fluctu-
Temperature scales on the pressure gauges always
ates within a range between 4 and 12 Kelvin. The in-
refer to the absolute pressures Pabs. Please note that
fluence of the ambient air on the suction line causes
it is not possible to measure a temperature directly
an additional overheating effect.
with a pressure gauge. The indicated temperatures
are just reference values. Only the saturation temper- Overheating is calculated as follows:
ature is assigned to the measured pressure.
Δ to2h = to2h - to
If the refrigerant is fluid, the temperature is below the
saturation temperature. Δ to2h, overheating at evaporator outlet in K
If the refrigerant is gaseous, the temperature is above to2h, temperature at evaporator outlet in °C
the saturation temperature. to, evaporation temperature in °C
Pressure gauges must indicate 0 bar when not con- „h“ represents "overheated"
nected to the system.
Low pressure gauges have a blue, high pressure Supercooling
gauges a red border.
Thermometer
It is the function of the expansion valve to reduce the
Normally digital thermometers with surface or contact refrigerant to a lower pressure level (evaporation
feelers are used. Especially for high temperature dif- pressure) after it has been liquefied. For an optimal
ferences excellent heat insulation of the measuring lo- function of the valve pure fluid must be applied to its
cation is of utmost importance. The sparing use of a inlet port.
heat conducting paste is highly recommended. If the
The refrigerant must "squeeze" (literally speaking)
measuring location is soiled, it needs to be cleaned
through a throttle gap inside the expansion valve.
and probably treated with a fine emery cloth. Only the
When comparing a certain mass of refrigerant in fluid
temperature of the feeler is measured. Due to missing
and in vaporous state (with constant pressure), the
heat insulation and insulating oxide layers on the line,
vaporous refrigerant requires a much higher volume.
temperature differences of a few degrees Kelvin be-
That's why the vaporous refrigerant needs a much
tween the measured and the actual values may arise.
longer time to "squeeze" through the throttle gap.
Vaporous refrigerant in front of the expansion valve
Overheating
reduces the flow rate and results in an undersupply of
the evaporator with refrigerant. Evaporation pressure
and evaporator power will drop.
Due to its design a refrigerant compressor can only
deliver gaseous or vaporous substances. Fluids are If the refrigeration system is operated with the "expan-
not compressible and must therefore not enter into the sion valve inlet" condition directly on the boiling curve,
compression chamber of the compressor. slightest fluctuations in operating condition may cause
416 BOMAG 008 918 12

Trouble shooting in refrigerant circuit, basic principles 13.17
a formation of bubbles in front of the expansion ele-
ment.
For this reason one shifts the condition "Expansion
Valve Inlet" away from the boiling curve into the fluid
area and refers to this condition as Supercooling. This
supercooling ensures a fluid supply in front of the ex-
pansion valve.
Common supercooling values

In systems with fluid container the supercooling at the
fluid container outlet is approx. Zero "0" Kelvin (as-
sumed that the system is filled with the correct refrig-
erant quantity). In this case the fluid container
provides the required fluid supply.
Supercooling is calculated as follows:
Δ tc2u = tc - tc2u
Δ tc2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
„u“ represents "supercooled"
008 918 12 BOMAG 417

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

1 Hot gas line (overheated steam)
2 Deheating (overheated steam)
3 Condenser / liquefier
4 Condensation (wet steam)
5 Fluid line (supercooled fluid)
6 Expansion valve
7 Injection line (wet steam)
8 Evaporation (wet steam)
9 Evaporator
10 Overheating (overheated steam)
11 Suction steam line (overheated steam)
12 Compressor
13 Supercooling (fluid)
14 Compression
15 Expansion
418 BOMAG 008 918 12

Trouble shooting, refrigerant circuit diagram 13.18
13.18Trouble shooting, refrigerant
circuit diagram
Fig. 1 Refrigerant circuit diagram 13 Compressor

1 Cold air 14 Condenser
2 Evaporator 15 Cooling air
3 Thermostat 16 Pressure gauge, low pressure
4 Warm air
5 Fan
6 Inspection glass
7 Expansion valve
8 Pressure gauge, high pressure
9 Pressure switch with high and low pressure con-
tacts
10 Dryer
11 Fluid container
12 Hot air
008 918 12 BOMAG 419

13.19 Trouble shooting procedure
13.19Trouble shooting procedure l Evaporator and heating (with highest fresh air fan
speed) do not draw leak air.
l The fresh air fan runs when the engine is running
Procedure
and the air conditioning system is set to max. cool-
Knowledge ing power.
Trouble shooting is not possible with exact knowledge
l Ambient temperature above 15 °C.
about the system design, the installed components l The thermostat is correctly installed and the switch-
and their function in the system trouble shooting is not ing temperatures are correct.
possible:
Visual inspection
With the appropriate experience some faults can be
visually detected or felt. Frequently occurring con-
denser soiling or formation of steam bubbles in the in-
spection glass can be quickly detected.
In case of unusual formation of hoarfrost on the evap-
orator the hoarfrost pattern provides useful informa-
tion. Hoarfrost only occurring at the inlet side is a clear
indication of insufficient refrigerant feed, which in turn
indicates an incorrectly working expansion valve or a
lack of refrigerant.. Complete hoarfrost covering indi-
cates load problems, i.e. no or insufficient air flow.
Even overheating can sometimes be detected with the
naked eye. At the end of the evaporator there should
be an area which is dry or at least drier at evaporator
temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a
local cooling can be felt or if condensation develops,
this is a clear indicator for an extreme pressure drop
in the line. Similar phenomena can be noticed in case
of blocked filters.
Unusually cold pressure lines indicate "wet" intake of
the compressor.
The oil level in the compressor sight glass provides in-
formation about the oil quantity and the oil recircula-
tion in the system. However, the oil level may also be
considerably influenced by condensing refrigerant.
Discoloration informs about the state of the oil.
Water in the system can simply be detected through
the inspection glass with moisture indicator.
i Note
The dangerous part of common rules is that they ap-
ply in most, but not in all cases. The refrigerant states
in the individual piping sections or components must
therefore be exactly determined by means of pressure
and temperature measurements.
Test prerequisites
l Cooler and condenser are clean, clean if neces-
sary.
l The ribbed belt for compressor and generator is
correctly tightened.
l All air ducts, covers and seals are OK and correctly
fitted. Flaps reach their end positions.
l The engine has operating temperature.
420 BOMAG 008 918 12

Trouble shooting procedure 13.19
Measuring points and measurements
Fig. 2 Flow diagram with measuring points to assess the filling quantity. In systems with fluid con-
l C, condenser measuring points tainer the inspection glass is most suitable to check
l E, expansion valve measuring points the minimum filling quantity. Supercooling is in this
case the between indicator for overfilling.
l O, evaporator measuring points
The hot gas temperature can be used to check wheth-
l V, compressor measuring points
er the compressor runs in the permissible operating
The flow diagram contains "Minimum Requirements" range.
which must be fulfilled to be able to check the system
or perform trouble shooting. Example: Measurement of overheating
Temperature and pressure at the evaporator outlet
l a) Which measuring equipment is required?
can be used to derive the overheating of the evapora- l b) Where to measure with which size?
tor. Overheating is a clear indicator for the evaporator l c) A pressure gauge connected to the evaporator
filling level. In case of excessive overheating the re- indicates "Peo2 = 1.7 bar". How high is the evapora-
frigerant quantity fed into the evaporator is too low, in tor pressure "Po" ?
case of insufficient overheating it is too high. In indi-
vidual cases one must then check if this situation is l
d) How high is the evaporator temperature "to" ?
caused by the expansion element or by insufficient fill- l e) A thermal sensor attached to the evaporator out-
ing. A differentiation is only possible if there is a clear let measures the temperature "to2h = +3 °C". How
indicator for the refrigerant filling quantity. high is the overheating „Δto2h“ ?
Pressure and temperature at the condenser outlet can l
f) Evaluation of the measured overheating.
be used to derive the supercooling. This can be used
008 918 12 BOMAG 421

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

l a) Pressure gauge, thermometer, steam table oil recirculation.
l b) Evaporation pressure "Peo2" and temperature The following list contains pressure values in a sys-
"to2h" are measured at the same point on the evap- tem, that can be expected at various ambient temper-
atures (measured at medium speeds).
orator outlet.
l c) Po = Peo2 + Pamb, "Evaporation pressure = Suction pressure (low pressure gauge)
pressure on evaporator + atmospheric pressure" =
Ambient temperature in °C Excess pressure in bar
1.7 bar + 1 bar = 2.7 bar.
25 approx. 2,0
l
d) "Pc" = 2,7 bar can then be used to derive an con- 30 approx. 2,5
densing temperature "to" of -2,2 °C from the steam 35 approx. 3
table for R134a. High pressure (high pressure gauge)
l e) Δto2h = to2h - to, „Overheating at evaporator out-
Ambient temperature in °C Excess pressure in bar
let = evaporator outlet temperature - evaporation
temperature" = 3 °C - (-2.2 °C) = 5.2 Kelvin. 25 approx. 8,0
35 approx. 13
l f) The determined overheating is within the usual
40 approx. 16
range of 4 - 12 Kelvin.
45 approx. 18
Example: Measuring supercooling
l a) Which measuring equipment is required?
l
b) Where to measure with which size?
l
c) A pressure gauge connected to the condenser in-
dicates "Pec2 = 15 bar". How high is the condensing
pressure "Pc" ?
l
d) How high is the condensing temperature "tc" ?
l
e) A thermal sensor attached to the condenser out-
let measures the temperature "tc2u = 58 °C". How
high is the supercooling "Δtc2u" ?
l
f) Evaluation of the measured supercooling.
Solution:
l
a) Pressure gauge, thermometer, steam table
l
b) Condensing pressure "Pec2" and temperature
"tc2u" are measured at the same point on the con-
denser.
l c) Pc = Pec2 + Pamb, "Evaporation pressure =
pressure on evaporator + atmospheric pressure" =
15 bar + 1 bar = 16 bar.
l d) "Pcc = 16 bar can then be used to derive an con-
densing temperature "tc" of 57.9 °C from the steam
table for R134a.
l e) Δtc2u = tc - tc2u, "Supercooling at condenser out-
let = condensing temperature - condenser outlet
temperature" = 57.9°C - 58 °C) = -0.1 Kelvin.
l f) The determined overheating is within the usual
range of approx. "0" Zero Kelvin.
Typical faults and possible causes

Most faults in the refrigerant side of the system can be
clearly assigned with the help a checklist. r Occur-
ring faults frequently have a similar appearance, but
different causes. An evaporator showing hoarfrost
may be quite normal. However, there may also
422 BOMAG 008 918 12

Values effecting the operating pressures tions, it is mandatory to know these dependencies.
Since the pressures occurring in a refrigeration sys- The following table contains some of these dependen-
tem are highly dependent on environmental condi- cies.
Measuring value Suction pressure High pressure
increases drops increases drops
Compressor speed increases X X
drops X X
Vehicle interior tempera- increases X X
ture drops X X
Ambient temperature increases X X
drops X X
Humidity increases X X
drops X X
008 918 12 BOMAG 423

Suction pressure too low (1), high pressure too

low to normal (2)
Fig. 3
Cause Possible effect Remedy

Lack of refrigerant no supercooling, bubbles in inspec- Check for leaks, refill
tion glass, high overheating, hoar-
frost on evaporator
Evaporator fins or air filter soiled Cooling power too low clean
Evaporator fan failed Low pressure shut off Repair the fan
Expansion valve defective Suction pressure gauge shows vac- Replace the valve
uum, because the valve has closed
Screen or nozzle in expansion valve high overheating clean
clogged
Filter dryer clogged Bubbles in inspection glass, high Change filter dryer
overheating, filter dryer cold
Heat power too low Frequent low pressure shut off, Check the control
thawing thermostat / rotary thermo-
stat switching too frequently
424 BOMAG 008 918 12

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

Condenser dirty high hot gas temperature, low cool- clean
ing power
Condenser fan failed high hot gas temperature, high pres- repair
sure shut down
overfilled high hot gas temperature, low su- Correct the filling capacity
percooling, low cooling power
Leak gas (air) high hot gas temperature, low renew filling
measured supercooling, low cooling
power
Restriction between compressor and high hot gas temperature, low cool- Check lines and valves
condenser ing power
008 918 12 BOMAG 425

Suction pressure too high (1), high pressure too

low to normal (2)
Fig. 5

Compressor defective Cooling power too low Replace the compressor
426 BOMAG 008 918 12

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

Expansion valve defective overheating too low, wet operation Replace the valve
of compressor
008 918 12 BOMAG 427

Other faults
Symptom Cause Possible effect Remedy

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

V-belt loose or excessively worn V-belt slips and generates noise Retention or renew the V-belt
Magnetic clutch loud Magnetic clutch runs until high pres- Repair or replace the magnetic
sure builds up, then the clutch starts clutch
to slip
Refrigerant compressor is loud Mounting bracket is loose, internal Repair the mounting bracket, re-
parts worn, low oil level in compres- place the compressor, renew the re-
sor frigeration oil
Fan is loud, fan motor excessively Replace the fan motor
worn
Whistling and rattling noise in opera- V-belt pulley and bearing worn Replace the bearing, check V-belt
tion, noticeable unevenness when pulley for wear
turning by hand
Rattling noise or vibration of high System overfilled Draw out refrigerant
pressure line, knocking noise in
compressor, ball in inspection glass
floating at the top
Expansion valve loud excessive moisture in system Replace the dryer
Hissing noise in evaporator housing, refrigerant level in system too low Perform a leak test, fill up the system
on expansion valve, turbidity in in-
spection glass or ball does not float
428 BOMAG 008 918 12

Inspection glass

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

The high pressure contact has System pressure exceeded, con- Clean the condenser, replace the
switched off the magnetic clutch denser excessively soiled, condens- expansion valve, check the con-
er fan defective, expansion valve denser fan
defective
The low pressure contact has System pressure fallen short of, re- Clean the evaporator, replace the
switched off the magnetic clutch frigerant level too low, expansion expansion valve, check the evapora-
valve defective, evaporator fan de- tor fan
fective, heat load too low, ambient
temperature below 1.5 °C
The thermostat has switched off the Ambient temperature below 1°C, Check the thermostat switching
magnetic clutch expansion valve defective, thermo- point, replace the expansion valve,
stat defective, air flow volume too clean the evaporator, check the
low evaporator fan
008 918 12 BOMAG 429

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

ture sure tion heat
of the fluid of the of the fluid of the of the fluid of the
steam steam steam
430 BOMAG 008 918 12

Steam table for R134a 13.20
008 918 12 BOMAG 431

432 BOMAG 008 918 12

Steam table for R134a 13.20
008 918 12 BOMAG 433

434 BOMAG 008 918 12

14 Cabin assembly
008 918 12 BOMAG 435

General safety regulations for assembly ! Caution
When installing the cabin to your machine you Paragraphs marked like this highlight possible
must strictly comply with the valid accident pre- dangers for machines or parts of the machine.
vention instructions or the country specific regu-
lations. However, dangers for persons and i Note
property may still arise, if:
Paragraphs marked like this contains technical infor-
l the lifting gear used has a too low bearing capacity mation and hints for optimal assembly.
l damaged or worn lifting tackle is used
l
unqualified personnel is entrusted with the installa- Environment
tion Paragraphs marked like this point out practices
l the safety instructions are not observed for safe and environmental disposal of fuels and
lubricants as well as replacement parts.
Each person involved in the installation of the
Strictly observe the national regulations for the
cabin must therefore read and comply with these
protection of the environment.
safety regulations. If necessary, the customer
must demand a written confirmation with signa-
ture. Information and safety stickers/decals on
Moreover, the following instructions and regulations
the cabin
must obviously also be complied with: Keep stickers/decals in good and legible condition
(see spare parts catalogue) and comply with their
l
applicable accident prevention instructions
meaning.
l
generally accepted safety and road traffic regula-
Replace damaged stickers/decals
tions
l
country specific safety regulations. It is the duty of Work on heating lines
the operator to be acquainted with these instruc-
tions and to apply these accordingly. This applies Before starting work on heating pipes relieve any
also for local regulations concerning different types pressure and let them cool down - danger of scalding!
of handling work. Should the recommendations in After completing work on the heating system of the
these instructions be different from the regulations machine check all connections and fittings for leaks.
valid in your country, you must comply with the
safety regulations valid in your country. Working on electric parts of the machine
Before starting to work on electric parts of the ma-
Changes and conversions to the cabin/ chine disconnect the battery and cover it with insulat-
machine ing material.
Unauthorized changes to the cabin are prohibited for Do not use fuses with higher ampere ratings and do
safety reasons. not repair fuses with a piece of wire. Fire hazard.
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 have an adverse effect
on the active and/or passive driving safety.
The manufacturer explicitly excludes any liability for
damage caused by the use of non-original parts or ac-
cessories.
Notes on safety in the assembly instruc-

tions
! Danger
Paragraphs marked like this highlight possible

dangers for persons.
436 BOMAG 008 918 12

Preparations 14.1
14.1 Preparations
! Danger
Danger of accident!
For transport purposes the driver's seat must be
tied down with cable straps thus to operate the
seat contact switch. Before resuming operation of
the machine these cable straps must strictly be re-
moved to ensure safe and reliable function of the
seat contact switch.
Check the 4 lifting eyes on the cabin roof for tight
fit. Fig. 8
Fasten the lifting gear to all four lifting eyes. l Fasten the lifting gear to the four lifting eyes 1 (Fig.
Use lifting gear (chains or ropes) of sufficient load 8).
bearing capacity. The minimum load bearing ca- l Loosen possible fastening on the transport pallet.
pacity of the crane must be 1000 kg.
l Slowly list the crane with a crane.
Do not stand or step under loads being lifted.
Danger
!
Danger of accident!
Fig. 7
l
Make sure that all fastening screws, washers, spac-
ers and nuts to fasten the cabin are available (Fig.
7).
l
Check whether rear rack, foot mat, step plate and
fastening kit are available.
008 918 12 BOMAG 437

14.2 Cabin assembly
14.2 Cabin assembly i Note

Mount the cabin immediately after sticking on the
! Danger
sealing tape, because the sealing tape will swell.
Danger of accident!
Use lifting gear (chains or ropes) of sufficient load
bearing capacity. The minimum load bearing ca-
pacity of the crane must be 1000 kg.
l Clean the operator's stand of dirt, oil and moisture.
Fig. 11
l Spray the sealing tape with soapsuds (Fig. 11), to
be able to slide the cabin on the operator's stand.
Fig. 9
l
Stick the supplied sealing tape 1 (Fig. 9) along the
edge of the operator's stand.
!Caution
Only unroll and stick the sealing tape on just be-
fore mounting the cab to the operator's stand. The
sealing tape will swell a few minutes after being
unrolled. In this case the cabin can no longer be
Fig. 12
mounted!
l Slowly lower the cabin vertically to the operator's
stand (Fig. 12).
Caution
!
The cabine must be lowered vertically onto the op-

erator's stand.
Fig. 10
l Stick the sealing tape 1 (Fig. 10) all around the op-
erator's stand.
l Do not run the sealing tape across the front recess
in the operator's stand (2), since this is the air inlet
for the cabin ventilation.
438 BOMAG 008 918 12

Cabin assembly 14.2
Fig. 13 Fig. 16
l Tighten the bottom fastening screw on the access
Caution
! side (Fig. 16) with 578 Nm.
Take care that none of the hoses and electric ca-
bles become squashed (Fig. 13).
l Run cables and hoses from inside the cabin through
the operator's stand to the outside.
Fig. 17
l Loosen both fastening screws (Fig. 17) at the rear
of the cabin again.
Fig. 14 i Note
l Turn both fastening screws (Fig. 14) at the rear of The cabin will now slide into final assembly position.
the cabin in handtight. l Tighten both fastening screws (Fig. 17) at the rear
of the cabin with 578 Nm.
Fig. 15
Fig. 18
i Note l
Tighten the rear lateral fastening screw on the left
If the bores do not match the cabin can be moved into hand side with 578 Nm (Fig. 18).
position by means of a crow bar (Fig. 15).
008 918 12 BOMAG 439

14.2 Cabin assembly
Fig. 19 Fig. 22
l Tighten the rear lateral fastening screw on the right l Tighten the front lateral fastening screw on the right
hand side with 578 Nm (Fig. 19). hand side with 578 Nm (Fig. 22).
Fig. 20 Fig. 23
l Tighten the rear inside fastening screw on the right l Tighten the front lateral fastening screw on the left
hand side with 578 Nm (Fig. 20). hand side with 578 Nm (Fig. 23).
Fig. 21 Fig. 24
l Turn nuts with washers onto both studs and tighten l Cover all lateral fastening screws with plastic caps
with 200 Nm (Fig. 21). (Fig. 24).
440 BOMAG 008 918 12

Cabin assembly 14.2
Fig. 25 Fig. 28
l Insert the foot mat 1 (Fig. 25). l Insert the rear rack and knock both plastic fasteners
carefully into the bores with a hammer (Fig. 28).
Fig. 26
Fig. 29
l Attach the step plate 1 (Fig. 26) and tighten the
three fastening screws (2). l Connect the feed 1 (Fig. 29) and the return flow (2)
for the air conditioning system with quick release
couplings.
l Connect the feed (4) and the return flow (3) of the
heating. (Observe the marks on the hoses).
i Note
Run the connecting lines for the heating parallel to
each other (do not cross).
i Note
Check the function of air conditioning and heating
within the scope of the function test.
Fig. 27 Observe identical hose diameters when connecting.
l Insert the dashboard and fasten it with four fasten-
ing screws (Fig. 27).
008 918 12 BOMAG 441

14.2 Cabin assembly
Danger
!
Before starting to work on electric parts of the ma-

chine disconnect the battery and cover it with in-
sulating material.
Fig. 30
l Plug on both connecting plugs for the washing wa-
ter pumps (Fig. 30).
Fig. 33
l Connect the plug connection of the air conditioning
system (Fig. 33).
Fig. 31
l Plug on the hoses for the washing water supply to
front and rear windscreens 1 (Fig. 31).
i Note
Check the function of the washing water system within
the scope of the function test.
Fig. 32
l
Insert the plug 1 (Fig. 32) into the socket (2).
l
Close the bayonet catch by turning the corrugated
cap nut in clockwise direction against the stop.
442 BOMAG 008 918 12

Final function tests and checks 14.3
14.3 Final function tests and
checks
Caution
!
Make sure that all screws have been tightened

with the specified torque.
i Note
After the cabin assembly the following tests must be
performed to assure that all cables and lines are cor-
rectly connected.
l Insert the ignition key and turn clockwise to position
"1".
l Operate the switches for headlights, direction indi-
cators and interior light to check their function.
l Operate the switches for front and rear windscreen
washer system and check their correct function.
i Note
If the function of the windscreen washer system is re-
versed, the two washing water hoses must be inter-
changed.
l
Start the engine.
l Switch the air conditioning on by the switch. After a
five minute operation the cabin must become no-
ticeably cooler.
l
Switch the air heater on by the switch. After a five
minute operation the cabin must become noticeably
warmer.
l
Function of the seat contact switch.
!Caution
The machine must not be operated if the seat con-
tact switch is not functioning correctly.
008 918 12 BOMAG 443

14.3 Final function tests and checks
444 BOMAG 008 918 12

15 Replacing the cab window panes
008 918 12 BOMAG 445

15.1 Assembly of window panes
Fig. 1
1 Glass panes
2 Fastening element
3 Fixing washer and spacer
4 Washer
5 Hexagon nut, self locking
6 Protective cap
446 BOMAG 008 918 12

Special tools, cabin windows 15.2
15.2 Special tools, cabin windows
1. Locking handle for fastening element
Fig. 1
2. Suction lifter
commercial
Fig. 2
3. Cutter
Commercial
Fig. 3
008 918 12 BOMAG 447

15.3 Auxiliary materials
15.3 Auxiliary materials

Safety gloves
4. Cutter
Commercial
Fig. 1
5. Window glass bonding agent
Fig. 2
6. Activator
Fig. 3
448 BOMAG 008 918 12

Auxiliary materials 15.3
7. Silicone sealant
Fig. 4
008 918 12 BOMAG 449

15.4 Removing and installing the window pane
15.4 Removing and installing the window

pane
Environment
Environmental damage
Dispose of glass splinters fro0m machine and
cabin or inside cabin in an environmentally
friendly way.
! Danger
Danger of cutting
Wear safety gloves.
1. Pull large glass rests off the bonding strip (Fig. 1).
Fig. 1
2. Clean the sealing surfaces from any adhesive
material (Fig. 2).
3. Use a cutter to remove adhesive residues with
glass rests.
4. Cover places without adhesive residues with an
activator.
Fig. 2
5. Insert the fastening element with washer into the
bore in the glass pane (Fig. 3).
Fig. 3
450 BOMAG 008 918 12

Removing and installing the window pane 15.4
6. Turn the fixing and spacer washer hand-tight onto
the thread of the fastening element (Fig. 4).
i Note
Do not overtighten the thread.
Fig. 4
7. Lay an approx. 1 cm high triangular bead of glass
pane bonding agent on the inside of the pane, ap-
prox. 1.5 cm away from the edge (Fig. 5).
i Note
Apply window pane bonding agent only to the
sides (sealing areas) which have contact with the
cabin.
Fig. 5
8. Attach the suction lifter to the outside of the pane
(Fig. 6).
9. Install the window pane so that the fastening ele-
ments fit into the bores of the fastening bars.
10. Press the glass pane against the sealing surface.
Fig. 6
11. Assemble the washer and the self-locking hexa-
gon nut.
12. Fasten the window pane to the fastening bar us-
ing a locking handle and a ring spanner (Fig. 7).
i Note
Only use the locking handle to counter.
13. Press the protective cap onto the hexagon nut.
Fig. 7
008 918 12 BOMAG 451

14. Remove the suction lifter (Fig. 8).
Fig. 8
15. Clean the joining edges on the window pane (Fig.
9).
i Note
The joint flanks must be solid, dry and free of dirt,
dust, grease, oil and other foreign substances.
16. Mask the upper and lower contact areas to the
cabin.
Fig. 9
17. Apply silicone sealant evenly and under pressure
first to the inside joint edge (Fig. 10).
Fig. 10
18. Then apply silicone sealant evenly and under
pressure to the outside joint edge (Fig. 11).
Fig. 11
452 BOMAG 008 918 12

Removing and installing the window pane 15.4
19. Then spray the joints from inside and outside with
water containing washing up liquid (Fig. 12).
Fig. 12
20. Treat the inside joint (Fig. 13)
Fig. 13
21. and the outside joint (Fig. 14) with a scraper or a
spattle.
i Note
Once the silicone sealing agent has cured it can
only be removed mechanically.
Fig. 14
008 918 12 BOMAG 453

454 BOMAG 008 918 12

16 Drum
008 918 12 BOMAG 455

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

ers
1. Disassembly device for side plate
Fig. 1
2. Assembly device for side plate
Fig. 2
3. Assembly device for coupling hub and flanged
hub
Fig. 3
456 BOMAG 008 918 12

Special tools, drum, single drum rollers 16.1
4. Pressing plate for cylinder roller bearing
Fig. 4
5. Pressing plate for travel bearing
Fig. 5
6. Pressing bushing for radial seal
Fig. 6
7. Lifting device for exciter unit
Fig. 7
008 918 12 BOMAG 457

16.2 Repair overview for drum
Fig. 1
458 BOMAG 008 918 12

Repair overview for drum 16.2
1 Rubber buffer 12 Rectangular rubber buffer
2 Vibration bearings 13 Side plate
3 Housing cover, basic weight 14 Travel bearings
4 Flange 15 Oil level inspection plug
5 Flanged housing 16 Oil drain plug
6 Coupling hub 17 Basic weight
7 Mechanical seal 18 Change-over weight
8 Flanged hub 19 Radial seal
9 Vibration motor 20 Vibrator shaft
10 Compensation plates 21 Fan
11 Spacer block 22 Drum shell
008 918 12 BOMAG 459

Fig. 2
460 BOMAG 008 918 12

Fig. 3
008 918 12 BOMAG 461

Fig. 4
462 BOMAG 008 918 12

Fig. 5
008 918 12 BOMAG 463

Fig. 6
464 BOMAG 008 918 12

Fig. 7
008 918 12 BOMAG 465

Fig. 8
466 BOMAG 008 918 12

Removing and installing the drum 16.3
16.3 Removing and installing the drum
i Note
After disassembling the side plate (vibration mo-
tor side) the drum can be lifted sideways out of
the frame (Fig. 1).
Fig. 1
i Note
However, the drum can also be removed without
having to disassemble the side plate, if it is lifted
up and out of the frame (Fig. 2).
Fig. 2
Removing the drum
i Note
The following section describes the procedure for
lifting the frame sideways out of the drum.
Environment
Environmental damage
Catch running out hydraulic oil and dispose
of environmentally.
8. Mark the hydraulic hoses (Fig. 3)on the travel mo-
tor and disconnect them from the ports.
9. Close all hydraulic hoses and motor ports with
suitable plugs.
Fig. 3
008 918 12 BOMAG 467

10. Mark the hydraulic hoses on the vibration motor

(Fig. 4) and disconnect them from the ports.
11. Close all hydraulic hoses and motor ports with
suitable plugs.
Fig. 4
! Danger
Danger of squashing! Do not stand or step
under loads being loaded.
Always secure the machine against unintend-
ed rolling!
12. Unscrew bolts 1 (Fig. 5) and nuts and remove the
front scraper (2).
13. Unscrew bolts (3) and nuts and remove the rear
scraper (4).
Fig. 5
14. Support the front cross-member safely with suita-
ble trestles or wooden blocks (Fig. 6).
Fig. 6
15. Support the rear cross-member safely with suita-
ble trestles or wooden blocks (Fig. 7).
Fig. 7
468 BOMAG 008 918 12

16. Disassemble bracket 1 (Fig. 8) for the hydraulic
hoses.
Fig. 8
17. Fasten the lifting gear to the side plate on the vi-
bration motor side.
18. Unscrew bolts 1 (Fig. 9) from the spacer blocks
on vibration and travel motors.
Fig. 9
!Danger
19. Force out plug 1 (Fig. 10) and unscrew the bolts
(2) from the front and rear cross-members.
20. Take off the side plate.
Fig. 10
21. Fasten the lifting tackle to the drum and lift the
drum carefully sideways out of the front frame
(Fig. 11).
!Danger
Fig. 11
008 918 12 BOMAG 469

22. Check all rubber buffers (Fig. 12), replace if nec-

essary (see corresponding chapter).
Fig. 12
23. Check rectangular rubber buffers (Fig. 13), re-
place if necessary.
Fig. 13
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. 14).
Fig. 14
i Note
Apply sliding lacquer OKS 240 to threads and
screw head contact face to ease assembly.
2. Attach the side plate, insert the bolts 2 (Fig. 15)
into rear and front cross-members and tighten
with 463 Nm.
3. Close the screw holes with plugs (1).
Fig. 15
470 BOMAG 008 918 12

4. Fasten the spacer blocks on travel and vibration
motor sides with bolts 1 (Fig. 16) and nuts to the
side plates.
Fig. 16
5. Connect hydraulic hoses to the connections on
travel motor and vibration motor according to the
marking (Fig. 17).
Fig. 17
6. Fasten bracket 1 (Fig. 18) for the hydraulic hoses.
Fig. 18
7. Assemble the front scraper 2 (Fig. 19), fasten
with bolts (1), washers and nuts.
8. Assemble the rear scraper (4), fasten with bolts
(3), washers and nuts.
i Note
Observe the adjustment measurement 30-35 mm
Fig. 19
008 918 12 BOMAG 471

! Caution
Before resuming operation of the machine:
Bleed the hydraulic system and check for
function and leaks.
Adjust the pretension of the rubber buffers.
9. On the vibration drive side measure the distance
"X" between spacer block and side plate (Fig. 20).
10. Calculate the thickness of the compensation
plates.
Nominal value:
Fig. 20
Distance "X" + 2 mm
i Note
Compensation plates of 2 and 5 mm thickness
are available.
11. Turn in screws into each welded nut (Fig. 21) and
provide sufficient space to insert the compensa-
tion plates.
Fig. 21
12. Insert the compensation plates (Fig. 22).
13. Turn in the fastening screws.
14. Unscrew the screws from the welded nuts.
15. Tighten the fastening screws.
Fig. 22
472 BOMAG 008 918 12

Repairing the drum 16.4
16.4 Repairing the drum
Removing the travel motor

! Danger
Do not stand or step under suspended loads.
1. Attach the lifting tackle to travel drive 3 (Fig. 3).
2. Unscrew all nuts (1) from the rubber buffers.
3. Take drive disc (2) with travel drive off the rubber
buffers and lay it down.
Fig. 1
4. Unscrew fastening screws 3 (Fig. 4) and take off
support legs (4).
5. Unscrew fastening screws 1 and take off drive
disc (2).
Fig. 2
Disassembling the exciter unit (travel

motor side)
1. Unscrew both socket head cap screws from the
flange (Fig. 3).
Fig. 3
008 918 12 BOMAG 473

2. Mount bracket 1 (Fig. 10) for the lifting device to

the flange.
3. Unscrew screws (2) from the flange.
i Note
Do not unscrew the thin drawn screws.
Fig. 4
4. Slide the lifting device over the bracket.
5. Force the exciter unit off with two forcing screws
(Fig. 5).
Fig. 5
! Danger
6. Pull the exciter unit out of the drum (Fig. 6).
7. Take the coupling element off the coupling half.
Fig. 6
474 BOMAG 008 918 12

Disassembling the exciter unit (travel
motor side)
1. Unscrew fastening screws 1 (Fig. 7) for the fan.
2. Loosen clamping screw (2).
3. Pull the coupling hub off the shaft.
Fig. 7
4. Unscrew all other fastening screws 1 (Fig. 8) from
the flange.
5. Press the flange off the flanged housing with forc-
ing screws (2).
Fig. 8
Environment
Environmental damage!
Catch running out oil and dispose of environ-
mentally.
6. Lift the flange off the flanged housing (Fig. 9).
7. Take the O-ring out of the groove in the flanged
housing.
Fig. 9
008 918 12 BOMAG 475

8. Unclip the circlip from the groove in the flange

(Fig. 10).
Fig. 10
9. Press the cylinder roller bearing with forcing
screws out of the flange (Fig. 11).
Fig. 11
10. Lift the exciter unit out of the flanged housing(Fig.
12).
Fig. 12
11. Knock the radial seal (Fig. 13) out of the flanged
housing.
Fig. 13
476 BOMAG 008 918 12

12. Unclip the circlip from the groove in the flanged
housing (Fig. 14).
Fig. 14
screws out of the flanged housing (Fig. 15).
Fig. 15
14. Extract inner ring 1 (Fig. 16) for the radial seal
and inner bearing races (2).
! Danger
Danger of burning!
Wear safety gloves.
i Note
If the rings are very tight, heat them up with a
torch.
Fig. 16
15. Unclip the circlip from the basic weight (Fig. 17).
Fig. 17
008 918 12 BOMAG 477

16. To change shaft 1 (Fig. 18) knock out dowel pins

(2 and 3) and press the shaft out of the basic
weight.
i Note
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).
Fig. 18
Disassembling the exciter unit (vibra-

tion motor side)
1. Unscrew fastening screw 1 (Fig. 19).
2. Take rectangular rubber buffer (2) with spacer
block (3) off the side plate.
iNote
Remove both rectangular rubber buffers.
Fig. 19
3. Unscrew fastening screws 1 (Fig. 20).
4. Force cover (2) together with the attached vibra-
tion motor off the side plate with forcing screws.
Fig. 20
478 BOMAG 008 918 12

5. To change the vibration motor loosen clamping
screw 1 (Fig. 21) and pull off coupling half (2).
Fig. 21
6. Unscrew nut 1 (Fig. 22), take off conical socket
(2) and conical disc (3).
7. Take the vibration motor off the cover.
Fig. 22
8. Remove the coupling element (Fig. 23).
Fig. 23
9. Fasten the lifting device.
! Caution
The four short fastening screws (2) must re-
main screwed in (the two others are not visi-
ble).
Fig. 24
008 918 12 BOMAG 479

11. Press the exciter unit out of the drum with forcing
screws (Fig. 25).
i Note
The second forcing screw is covered by the side
plate.
Fig. 25
!Caution
12. Pull the exciter unit out of the drum (Fig. 26).
Fig. 26
Removing, dismantling the side plate

1. Take off V-ring 1 (Fig. 27).
2. Unclip circlip (2).
Fig. 27
3. Attach the disassembly device to the side plate
(Fig. 28) and force off the side plate.
Fig. 28
480 BOMAG 008 918 12

4. Lift the side plate of the flanged hub (Fig. 29).
Fig. 29
5. Knock the grooved roller bearing out of the side
plate (Fig. 30) and take out the spacer ring.
Fig. 30
6. Unclip the circlip from the side plate (Fig. 31).
Fig. 31
7. Take the mechanical seal off the flanged hub
(Fig. 32).
Fig. 32
008 918 12 BOMAG 481

Dismantling the exciter unit (vibration

motor side)
1. Unscrew the fastening from the coupling hub.
2. Pull coupling hub (2) off the shaft using a pulling
device (Fig. 33).
Fig. 33
3. Loosen hose clamp 1 (Fig. 34).
4. Pull coupling hub (2) off the shaft.
Fig. 34
5. Unscrew all other fastening screws 1 (Fig. 35)
and press the flanged hub off the flanged housing
with forcing screws (2).
6. Take off the flanged hub.
7. Take the O-ring out of the groove in the flanged
housing.
Fig. 35
482 BOMAG 008 918 12

hub (Fig. 36).
Fig. 36
9. Knock the cylinder roller bearing out of the flang-
ed hub(Fig. 37).
Fig. 37
Environment
mentally.
10. Lift the exciter unit out of the flanged housing(Fig.
38).
Fig. 38
11. Knock the radial seal (Fig. 39) out of the flanged
housing.
Fig. 39
008 918 12 BOMAG 483


housing (Fig. 40).
Fig. 40
screws out of the flanged housing (Fig. 41).
Fig. 41
14. Extract inner rings 1 (Fig. 42) for the radial seals
and inner bearing races (2) from the shaft.
!Danger
Danger of burning!
Wear protective gloves.
i Note
If the rings are very tight, heat them up with a
torch.
Fig. 42
15. Unclip the circlip from the basic weight and re-
move the cover (Fig. 43).
i Note
The shafts cannot be pressed out. If damaged
they must be replaced with basic weight and cov-
er.
If necessary disassemble, assemble the change-
over weight (see corresponding chapter).
Fig. 43
484 BOMAG 008 918 12

Assembling the exciter unit (vibration
motor side)
! Caution
i Note
If the shafts are damaged they must be inserted
into the basic weight or the cover as follows.
! Danger
When working with liquid nitrogen protect
your face and wear gloves.
Do not place any unintended parts into liquid
Fig. 44 nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.
! Caution
Close the bores on the short shaft with a
screw.
1. Cool the shaft down in liquid nitrogen.
2. Slide the cooled down shaft with the bores
aligned into the basic weight until it bottoms (Fig.
44).
3. Secure shaft 1 (Fig. 45) with dowel pins (2 and 3).
! Caution
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.
i Note
Unscrew the screw from the shaft.
Fig. 45
! Caution
Close the bores on the short shaft with a
screw.
46).
Fig. 46
008 918 12 BOMAG 485

! Caution
i Note
Unscrew the screw from the shaft.
Fig. 47
7. Insert the fitting key into the keyway in the respec-
tive shaft (Fig. 48).
Fig. 48
8. Insert the circlip into the groove in the basic
weight and on the cover (Fig. 49).
Fig. 49
! Danger
Danger of burning!
Wear safety gloves.
9. Heat the inner bearing race up to approx. 100° C
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 50).
Fig. 50
486 BOMAG 008 918 12

! Danger
Danger of burning!
Wear safety gloves.
10. Heat the inner ring up to approx. 50° C and slide
it onto the short shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 51).
Fig. 51
!Danger
Danger of burning!
Wear safety gloves.
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 52).
Fig. 52
!Danger
Danger of burning!
Wear safety gloves.
it onto the longer shaft against the shoulder with
the wider chamfer facing towards the outside
(Fig. 53).
Fig. 53
13. Press cylinder roller bearing 1 (Fig. 54) with
pressing plate (2) into the flanged housing until it
bottoms.
Fig. 54
008 918 12 BOMAG 487

14. Insert the circlip into the groove in the flanged

housing (Fig. 55).
Fig. 55
15. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 56).
16. Fill approx. 1.2 l of oil SAE-15W/40 into the flang-
ed housing.
Fig. 56
!Caution
17. Insert the exciter unit with the longer shaft for-
ward into the flanged housing (Fig. 57).
Fig. 57
pressing plate (2) into the flanged hub until it bot-
toms.
Fig. 58
488 BOMAG 008 918 12

19. Insert the circlip into the groove in the flanged hub
(Fig. 59).
Fig. 59
20. Attach the flanged hub to the flanged housing
(Fig. 60).
! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
21. Unscrew eye bolts (1) and replace them with
short screws.
22. Turn short screws (2) into the tapped bores in the
flanged housing (four screws) and tighten them.
Fig. 60
23. Apply some grease to the sealing lip of radial seal
1 (Fig. 61).
24. Insert the radial seal into the flanged hub with the
sealing lip facing down and press it down against
the stop with pressing bushing (2).
Fig. 61
!Danger
Danger of burning!
Wear protective gloves.
25. Heat the coupling hub up to approx. 80 °C and
slide it onto the shaft against the stop (Fig. 62).
Fig. 62
008 918 12 BOMAG 489


1 (Fig. 63).
27. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).
Fig. 63
28. Cover the thread of screw 1 (Fig. 64) with a screw
retention agent (Loctite CVX strong, blue, 582).
29. Slide on the new U-seal ring (2), turn in and tight-
en the screws.
Fig. 64
! Danger
Danger of burning!
Wear safety gloves.
30. Heat coupling hub 1 (Fig. 65) with marking letter
“L“ up to approx. 80° C and slide it over the shaft
against the shoulder.
31. Turn in and tighten clamping screw (2).
Fig. 65
490 BOMAG 008 918 12

Assembling and installing the side
plate
1. Fill grooved ball bearing 1 (Fig. 66) on both sides
with grease.
2. Press the grooved ball bearing completely in us-
ing pressing plate (2).
Fig. 66
3. Insert the circlip into the groove in the side plate
(Fig. 67).
Fig. 67
4. Apply a thick coat of grease to the spacer ring on
both sides and insert it into the side plate (Fig.
68).
Fig. 68
008 918 12 BOMAG 491

5. Fill grooved ball bearing 1 (Fig. 69) on one sides

with grease.
6. Insert the grooved ball bearing with the grease
side forward and press it completely in with
pressing plate (2).
i Note
Grease the other side after installing the exciter
unit.
Fig. 69
7. Insert the oiled loop-ring into the mechanical seal
(Fig. 70).
8. Clean the sliding surfaces of the mechanical seal
and cover them with oil.
Fig. 70
9. Lay one half of the radial seal on the flanged hub
with the sliding surface pointing up (Fig. 71).
Fig. 71
10. Lay the second half of the mechanical seal down
with the sliding face pointing down (Fig. 72).
Fig. 72
492 BOMAG 008 918 12

11. Bolt the threaded section of the assembly device
to the flanged hub (Fig. 73).
Fig. 73
! Caution
under suspended loads.
12. Lay the side plate on the flanged hub (Fig. 74).
Fig. 74
13. Attach bushing 2 (Fig. 75) of the assembly device
and turn on nut (1).
Fig. 75
14. Pull the side plate with the assembly device onto
the flanged hub.
! Caution
During assembly make sure that the mechan-
ical seal slides correctly into the side plate
and the loop rings are not damaged (Fig. 76).
Fig. 76
008 918 12 BOMAG 493

15. Remove the assembly device.

16. Insert the circlip into the groove in the flanged hub
(Fig. 77).
Fig. 77
Assembling the exciter unit (travel

motor side)
!Danger
When working with liquid nitrogen protect
your face and wear gloves.
Do not place any unintended parts into liquid
nitrogen.
Observe the safety instructions for the han-
dling of liquid nitrogen.
! Caution
Fig. 78
78).
! Caution
Fig. 79
494 BOMAG 008 918 12

4. Insert the circlip into the groove in the basic
weight and on the cover (Fig. 80).
Fig. 80
! Danger
Danger of burning!
Wear safety gloves.
and press it onto the basic weight against the
shoulder with the larger outer diameter forward
(Fig. 81).
Fig. 81
! Danger
Danger of burning!
Wear safety gloves.
it onto the shaft against the shoulder with the wid-
er chamfer facing towards the outside (Fig. 82).
Fig. 82
! Danger
Danger of burning!
Wear safety gloves.
and press it onto the cover against the shoulder
with the larger outer diameter forward (Fig. 83).
Fig. 83
008 918 12 BOMAG 495


pressing plate (2) into the flanged housing until it
bottoms.
Fig. 84
9. Insert the circlip into the groove in the flanged
housing (Fig. 85).
Fig. 85
10. Fit the new radial seal with some grease into the
groove in the flanged housing (Fig. 86).
11. Fill approx. 1.2 l of oil SAE-15W/40 into the flang-
ed housing.
Fig. 86
! Caution
12. Insert the exciter unit into the flanged housing
(Fig. 87).
Fig. 87
496 BOMAG 008 918 12

pressing plate (2) into the flange until it bottoms.
Fig. 88
14. Insert the circlip into the groove in the flange (Fig.
89).
Fig. 89
15. Lift the flange onto the flanged housing and align
it the bores (Fig. 90).
! Caution
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
Fig. 90
16. Turn the screws into the tapped bores of the
flanged housing and tighten them (Fig. 91).
Fig. 91
008 918 12 BOMAG 497


1 (Fig. 92).
18. Slide the radial seal with the sealing lip forward
over the shaft and drive it completely into the
flanged housing, using a suitable tube (2).
Fig. 92
19. Cover the thread of screw 1 (Fig. 93) with a screw
retention agent (e.g. Loctite CVX strong, blue,
582).
20. Slide on the new U-seal ring (2), turn in and tight-
en the screws.
Fig. 93
21. Insert the fitting key into the keyway of the shaft
(Fig. 94).
Fig. 94
!Danger
Danger of burning!
Wear safety gloves.
22. Slide the fan with assembly disc over the shaft.
23. Heat coupling hub 1 (Fig. 95) with marking letter
“R“ up t approx. 80° C and slide it over the shaft
against the shoulder.
24. Turn in and tighten clamping screw (2).
25. Assemble the fan to the coupling hub.
Fig. 95
498 BOMAG 008 918 12

Assembling the exciter unit (travel
motor side)
1. Check coupling elements , replace if necessary.
2. Insert the coupling element into the coupling hub
(Fig. 96).
! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.
3. Fasten the lifting device to the exciter unit.
Fig. 96 ! Caution
4. Insert the vibrator unit into the drum (Fig. 97).
Fig. 97
i Note
Insert the exciter unit so that oil filler plug 1 (Fig.
98) is in line with bore (2) in the drum.
Fig. 98
008 918 12 BOMAG 499

5. Turn in and tighten screws 2 (Fig. 99).

6. Remove bracket (1) for the lifting device.
Fig. 99
7. Cover the thread of screws (Fig. 100) with a
screw retention agent (e.g. Loctite green 270).
8. Slide on the new U-seal ring, turn in and tighten
the screws.
Fig. 100
Installing the travel motor

1. Assemble drive disc 2 (Fig. 101) and support (4)
with screws (3).
Fig. 101
! Danger
2. Attach the drive disc 2 (Fig. 102) with the assem-
bled travel drive to the rubber buffers. Turn on
and tighten the nuts (1).
Fig. 102
500 BOMAG 008 918 12

Installing the exciter unit (vibration
motor side)
! Caution
Fitting and contact surface of the connection
between exciter unit and drum must be abso-
lutely dry and free of grease, oil, paint and
conserving agent.
! Danger
1. Fasten the lifting gear to the exciter unit and insert
it into the drum (Fig. 103).
Fig. 103
! Caution
Ensure correct engagement of coupling and
alignment of shaft (Fig. 104).
If the shafts are not correctly in line determine
the cause, if necessary measure the drum.
Fig. 104
2. Turn in and tighten screws 1 (Fig. 105).
3. Remove the lifting gear.
4. Fit cover (2) to the drum.
Fig. 105
008 918 12 BOMAG 501

5. Check the end float of the exciter shafts (Fig.

106).
Nominal value: 0.6...1.8 mm
Fig. 106
6. Attach disc 1 (Fig. 107), turn in and tighten the
fastening screws (2).
Fig. 107
7. Lay a new V-ring over the journal of the flanged
hub (Fig. 108).
8. Fill the grooved ball bearing with grease.
Fig. 108
9. Check coupling element , replace if necessary.
10. Insert the coupling element into the coupling hub
(Fig. 109).
Fig. 109
502 BOMAG 008 918 12

11. Fasten the vibration motor to the cover so that
sockets 1 (Fig. 110) and ventilation bore (2) are
opposite each other.
Fig. 110
12. Slide on coupling half 2 (Fig. 111) and secure with
clamping screw (1).
Fig. 111
13. Attach the cover with the installed vibration mo-
tor, turn in and tighten the screws (Fig. 112).
Fig. 112
14. Install rectangular rubber buffers 2 (Fig. 113) with
attached spacer block (3) and screws (1) to the
side plate.
i Note
Assemble both rectangular rubber buffers.
Fig. 113
008 918 12 BOMAG 503

16.5 Dismantling, assembling the change-over weights
16.5 Dismantling, assembling the change-

over weights
Dismantling the change-over weight

1. Unscrew all screws (Fig. 3).
Fig. 1
2. Force the cover off the basic weight with forcing
screws (Fig. 4).
Environment
mentally.
Fig. 2
3. Take the change-over weight out of the basic
weight (Fig. 5).
Fig. 3
504 BOMAG 008 918 12

Dismantling, assembling the change-over weights 16.5
4. Pull O-rings 1 and 2 (Fig. 4) out of the grooves.
Fig. 4
008 918 12 BOMAG 505

16.5 Dismantling, assembling the change-over weights
Assembling the change-over weights

!Caution
1. Install new O-rings 1 and 2 (Fig. 5) with grease.
Fig. 5
2. Insert the change-over weight into the basic
weight (Fig. 6).
Fig. 6
3. Fill silicon oil 47 V 1000 cst up to the upper edge
of the change-over weight (approx. 2,5 litres) into
the basic weight (Fig. 12).
Fig. 7
4. Attach the cover (Fig. 13), so that the raised are-
as are in line.
5. Turn in screws with screw retention agent (e.g.
Loctite blue 243) and tighten with 120 Nm.
6. Check the end float of the shaft.
i Note
There must be play.
Fig. 8
506 BOMAG 008 918 12

Changing the rubber buffers and adjusting the pretension 16.6
16.6 Changing the rubber buffers and ad-
justing the pretension
Relieve the rubber buffers
1. Lift the frame up by both sides, until rubber buff-
ers and rectangular buffers are relieved of any
load (Fig. 1).
2. Loosen all fastening screws.
Fig. 1
3. Turn one screw each into the welded nuts (Fig. 2)
on the spacer blocks.
Fig. 2
4. Remove the compensation shims (Fig. 3).
Fig. 3
008 918 12 BOMAG 507

16.6 Changing the rubber buffers and adjusting the pretension
5. Unscrew the screws (Fig. 4) from the welded

nuts.
Fig. 4
iNote
Check the rectangular rubber buffers, replace if
necessary.
Observe the assembly direction, arrow up.
Fig. 5
Changing the rubber buffers
6. Unscrew nut 1 (Fig. 3) and remove the washer.
7. Unscrew screws (2).
8. Take off rubber buffer (3).
9. Attach the new rubber buffer to the drive disc and
align the bores to the tapped bores in the drum.
10. Turn in and tighten the fastening screws.
11. Assemble the washer, turn on and tighten the nut.
Fig. 6
Adjusting the pre-load
12. Measure distance "X" between spacer piece and
side plate (Fig. 7).
13. Calculate the thickness of the compensation
plates.
Nominal value:
Distance "X" + 2 mm
Fig. 7
508 BOMAG 008 918 12

Changing the rubber buffers and adjusting the pretension 16.6
14. Turn in screws into each welded nut and provide
sufficient space to insert the compensation plates
(Fig. 8).
Fig. 8
15. Assemble the compensation shims (Fig. 9).
Fig. 9
16. Unscrew the screws (Fig. 10) from the welded
nuts.
Fig. 10
17. Tighten the fastening screws (Fig. 11).
18. Lower the frame again.
Fig. 11
008 918 12 BOMAG 509

16.6 Changing the rubber buffers and adjusting the pretension
510 BOMAG 008 918 12

17 Oscillating articulated joint
008 918 12 BOMAG 511

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

joint (BW177 to BW 216)
1. Pressing device for rocker bearings
Fig. 1
2. Pressing bushing for outer rocker bearing race
Fig. 2
3. Pressing bushing for inner rocker bearing race
Fig. 3
512 BOMAG 008 918 12

Special tools, oscillating articulated joint (BW177 to BW 216) 17.1
4. Guide pin
Fig. 4
5. Clamping device
Fig. 5
6. Disassembly device
Fig. 6
008 918 12 BOMAG 513

17.2 Repair overview oscillating articulated joint
514 BOMAG 008 918 12

Repair overview oscillating articulated joint 17.2
1 Housing 12 Cover
2 Seal ring 13 Cover
3 Cover 14 Intermediate ring
4 Self-aligning bearing 15 Self-aligning bearing
5 Bolt 16 Intermediate ring
6 Shim/supporting disc 17 Self-aligning bearing
7 Belleville springs 18 Carrier
8 Self-aligning bearing 19 Friction bearing
9 Console 20 V-ring
10 Belleville springs 21 Seal ring
11 Shim/supporting disc
008 918 12 BOMAG 515

17.2 Repair overview oscillating articulated joint
516 BOMAG 008 918 12

Repair overview oscillating articulated joint 17.2
008 918 12 BOMAG 517

17.3 Removing and installing the oscillating articulated joint
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.
Fig. 1
2. Support the rear frame near the oscillating articu-
lated joint (Fig. 2) on both sides safely with tres-
tles or wooden blocks.
Fig. 2
3. Fasten the lifting tackle to the front frame near the
oscillating articulated joint (Fig. 3).
Fig. 3
518 BOMAG 008 918 12

Removing and installing the oscillating articulated joint 17.3
axle holder (2).
5. Knock out bearing bolt (3).
6. Retract steering cylinder (4).
Fig. 4
!Danger
Danger of accident!
7. Support the oscillating articulated joint in the mid-
dle with a suitable jack or a similar device.
with disc (2).
Fig. 5
9. Unscrew nuts 3 (Fig. 6) and take off the clamping
washers (2).
10. Pull out the fastening screws (1).
11. Slightly raise the front frame and lower the oscil-
lating articulated joint to the ground.
12. Pull out the oscillating articulated joint.
Fig. 6
Note on assembly
13. Insert the bolt for the steering cylinder so that
groove (2) is in line with tapped bores (1).
Fig. 7
008 918 12 BOMAG 519

17.4 Dismantling the oscillating articulated joint
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.
Fig. 1
3. Take off the cover with Belleville springs, shim
and backing disc (Fig. 2).
4. Disassemble also the cover from the opposite
side.
i Note
No Belleville springs, shim and backing disc are
under this cover.
Fig. 2
5. Drive the console with a plastic hammer to one
side against the end stop (Fig. 3).
i Note
The outer race of the rocker bearing is thereby
stripped off.
Fig. 3
520 BOMAG 008 918 12

Dismantling the oscillating articulated joint 17.4
6. Force inner race 1 (Fig. 4) of the rocker bearing
off the bolt.
7. Take of supporting disc (2).
8. Drive the console to the opposite side and re-
move the rocker bearing in the same way.
Fig. 4
10. Press bolt (3) out of the console with forcing
screws (2).
i Note
Remove the bolt on the opposite side in the same
way.
Fig. 5
11. Lift console 1 (Fig. 6) off housing (2).
Fig. 6
12. Take the seal rings out of the console (Fig. 7).
Fig. 7
008 918 12 BOMAG 521

13. Remove the cover from the housing.

14. Take off shims 1 (Fig. 8), backing disc (2) and
Belleville springs (3).
Fig. 8
15. Unscrew bolts 1 (Fig. 9) and take off cover (2).
Fig. 9
16. Take the intermediate ring out of the housing
(Fig. 10).
Fig. 10
17. Place the plate 1 (Fig. 11) on the beam.
18. Attach the puller (2) to the housing (3) and sepa-
rate the carrier from the rocker bearings.
Fig. 11
522 BOMAG 008 918 12

Dismantling the oscillating articulated joint 17.4
19. Pull the housing off the beam (Fig. 12).
Fig. 12
20. Drive the outer race of the friction bearing out of
the housing (Fig. 13).
Fig. 13
21. Drive the friction bearing out of the housing (Fig.
14).
Fig. 14
22. Take seal ring 1 (Fig. 15) and V-ring (2) off the
beam.
Fig. 15
008 918 12 BOMAG 523

23. Check rocker bearings, if necessary press out of

the housing (Fig. 16).
Fig. 16
524 BOMAG 008 918 12

Assembling the oscillating articulated joint 17.5
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
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
! Caution
Do not use any grease.
Fig. 1
2. Slide the new V-ring on the beam against the stop
with the lip facing up (Fig. 2).
Fig. 2
3. Lay the seal ring into the beam (Fig. 3).
4. Fill the space between V-ring and seal ring with
multi-purpose grease.
Fig. 3
008 918 12 BOMAG 525

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

with the chamfered side pointing towards the out-
side (Fig. 4).
Fig. 4
6. Slide the housing over the beam (Fig. 5).
i Note
The journal on the housing must be centrally in
the recess of the beam.
Fig. 5
7. Press the seal ring carefully towards the inside,
until it sits in the recess of the housing (Fig. 6).
Fig. 6
8. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.
! Caution
9. Press the outer rocker bearing race 1 (Fig. 7) in
until it bottoms with the wider outer rim forward
using pressing sleeve (2).
Fig. 7
526 BOMAG 008 918 12

10. Press inner rocker bearing race 1 (Fig. 8) in until
it bottoms, using pressing sleeve (2).
Fig. 8
11. Insert the intermediate ring (Fig. 9).
Fig. 9
12. Press inner rocker bearing race 1 (Fig. 10) in until
it bottoms, using pressing sleeve (2).
Fig. 10
i Note
Apply sliding lacquer OKS 571 to mating surfaces
to ease assembly
! Caution
13. Press the outer rocker bearing race 1 (Fig. 11) in
until it bottoms with the wider outer rim pointing
up, using pressing sleeve (2).
Fig. 11
008 918 12 BOMAG 527

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

toms.
15. Attach cover (2) with the machined edge forward.
16. Turn in screws (3) and tighten crosswise.
Fig. 12
Determining the shim thickness
17. Determine the shim thickness, for this purpose
stand the cross-member on a wooden board with
an ∅ 18 mm bore.
! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
18. Slide the rod of the tensioning device in from un-
derneath, attach the plate, screw on the nut and
Fig. 13 tighten.
19. Measure the distance from housing edge to inter-
mediate ring (Fig. 13) and write it down, e.g. 4,7
mm.
i Note
From this measured value of 4.7 mm subtract the
fixed value of 4.0 mm to determine the shim thick-
ness.
Calculation example:
4,7 mm - 4,0 mm = 0,7 mm
measured value: 4,7 mm
fixed value: 4,0 mm
Shim thickness: 0,7 mm
20. Remove the tensioning device.
528 BOMAG 008 918 12

21. Insert shim 2 (Fig. 14) of appropriate thickness
and backing disc (1) into the cover.
Fig. 14
22. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 15).
Fig. 15
23. Assemble cover 2 (Fig. 16) with Belleville springs,
shim and backing disc.
Fig. 16
25. Press the new sealing rings into the respective
groove in the console (Fig. 17).
Fig. 17
008 918 12 BOMAG 529

26. Lift console 1 (Fig. 18) over the housing (2).
Fig. 18
27. Turn four guide pins into the housing bores (Fig.
19).
Fig. 19
i Note
Perform the following eight work steps on both
sides.
28. Slide the bolt over the guide pins (Fig. 20) and
drive in until it bottoms.
Fig. 20
! Caution
When driving in the bolt make sure that the
seal ring is not pressed out through the back
of the console (Fig. 21).
Fig. 21
530 BOMAG 008 918 12

29. Unscrew the guide pins .
30. Turn in the screws and tighten with 75 Nm (Fig.
22).
Fig. 22
31. Slide the backing discs over the bolt (Fig. 23).
Fig. 23
32. Drive the inner rocker bearing race on against the
end stop with the wider outer rim forward (Fig.
24).
Fig. 24
33. Spray the sliding surface of the outer rocker bear-
ing race with sliding agent OKS 571.
! Caution
34. Attach the outer rocker bearing race with the wid-
er outer rim facing towards the outside (Fig. 25)
and drive it in until it bottoms.
Fig. 25
008 918 12 BOMAG 531

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

console.
36. Turn in and tighten screws (2).
Fig. 26
Determining the shim thickness
37. Determine the shim thickness, for this purpose in-
sert rod 1 (Fig. 27) of the tensioning device from
underneath. Attach plate (2), screw on nut (3) and
tighten.
! Caution
Check the measurement with an axial pre-
load of 40kN. With threaded rod M12-8.8 tight-
ening torque 77Nm. With threaded rod M16-
8.8 tightening torque 90Nm.
Fig. 27
38. Measure the distance from outer rocker bearing
race to console surface (Fig. 28) and write it
down, e.g. 3.4 mm.
i Note
From this measured value of 3.4 mm subtract the
fixed value of 2.2 mm to determine the shim thick-
ness.
Calculation example:
3.4 mm - 2.2 mm = 1.2 mm
measured value: 3,4 mm
Fig. 28 fixed value: 2,2 mm
Shim thickness: 1.2 mm
39. Remove the tensioning device.
532 BOMAG 008 918 12

40. Insert shims 2 (Fig. 29) of appropriate thickness
and backing disc (1) into the cover.
Fig. 29
41. Lay the Belleville springs into the cover with the
curvature pointing down (Fig. 30).
Fig. 30
42. Assemble cover 1 (Fig. 31) with Belleville springs,
shims and supporting discs.
Fig. 31
44. Insert hexagon screw 1 (Fig. 32) so that the screw
head rests on the upper side of the console.
Fig. 32
008 918 12 BOMAG 533

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

with 120 Nm (Fig. 33).
Fig. 33
534 BOMAG 008 918 12

18 Suppliers documentation
008 918 12 BOMAG 535

536 BOMAG 008 918 12
18.1 Travel pump
008 918 12 BOMAG 537

18.1 Travel pump
Bild 34
538 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Service Manual
008 918 12 BOMAG 539

18.1 Travel pump
3ERIES!XIAL0ISTON#LOSED#IRCUIT0UMPS
Service Manual
2EVISIONS
HISTORY OF REVISIONS Table of Revisions

Date Page Changed Rev.
December 2011 69 4ORQUEVALUESCHANGEDFOR% !#

!PRIL 70 4ORQUEFOR''''""""CHANGED !"
TO.M;LBFsFT=
3EPTEMBER - &IRSTPRINTING REPLACES",. !!
¹3AUER $ANFOSS!LLRIGHTSRESERVED
3AUER $ANFOSSACCEPTSNORESPONSIBILITYFORPOSSIBLEERRORSINCATALOGSBROCHURESAND

OTHERPRINTEDMATERIAL3AUER $ANFOSSRESERVESTHERIGHTTOALTERITSPRODUCTSWITHOUT
PRIORNOTICE4HISALSOAPPLIESTOPRODUCTSALREADYORDEREDPROVIDEDTHATSUCHALTERATIONS
CANBEMADEWITHOUTAFFECTINGAGREEDSPECIlCATIONS!LLTRADEMARKSINTHISMATERIAL
AREPROPERTIESOFTHEIRRESPECTIVEOWNERS3AUER $ANFOSSTHE3AUER $ANFOSSLOGOTYPE
THE3AUER $ANFOSS3 ICON0,53»7HATREALLYMATTERSISINSIDE¸AND+NOW (OWIN
-OTION»ARETRADEMARKSOFTHE3AUER $ANFOSS'ROUP
2 520L0818s2EV!#sDecember 2011
540 BOMAG 008 918 12

Travel pump 18.1
Service Manual
#ONTENTS
INTRODUCTION /VERVIEW ........................................................................................................................................................... 6

7ARRANTY ............................................................................................................................................................ 6
'ENERALINSTRUCTIONS ...................................................................................................................................... 6
3AFETYPRECAUTIONS ......................................................................................................................................... 7
5NINTENDEDMACHINEMOVEMENT ....................................................................................................... 7
&LAMMABLECLEANINGSOLVENTS ............................................................................................................... 7
&LUIDUNDERPRESSURE ................................................................................................................................ 7
0ERSONALSAFETY ........................................................................................................................................... 7
3YMBOLSUSEDIN3AUER $ANFOSSLITERATURE.............................................................................................
$ESIGN ................................................................................................................................................................ 9
4HESYSTEMCIRCUIT.........................................................................................................................................10
OPERATION #HARGEPUMP .................................................................................................................................................12

#HARGERELIEFVALVE........................................................................................................................................12
-ULTI FUNCTIONVALVES ..................................................................................................................................12
0RESSURELIMITERANDHIGHPRESSURERELIEFVALVES ................................................................................
3YSTEMCHECKVALVES ....................................................................................................................................
"YPASSVALVES .................................................................................................................................................
3PEEDSENSORS ................................................................................................................................................
&ILTRATIONOPTIONS ..........................................................................................................................................
0RESSUREOVERRIDE0/2 nFRAMESIZEONLY...................................................................................
-ANUALDISPLACEMENTCONTROL-$# ....................................................................................................
.ON LINEAR-$# ............................................................................................................................................
3OLENOIDOVERRIDEVALVEFOR-$# ............................................................................................................
.EUTRALSTARTSWITCH.33 ..........................................................................................................................
(YDRAULICDISPLACEMENTCONTROL($# .................................................................................................
%LECTRICDISPLACEMENTCONTROL%$# ......................................................................................................
!UTOMOTIVECONTROL&"!))" ...................................................................................................................
0OSITION&.2 ELECTRICCONTROL .............................................................................................................
OPERATING /VERVIEW .........................................................................................................................................................16

PARAMETERS )NPUTSPEED ....................................................................................................................................................16
3YSTEMPRESSURE ............................................................................................................................................16
#HARGEPRESSURE ............................................................................................................................................17
#HARGEINLETPRESSURE ..................................................................................................................................17
#ASEPRESSURE .................................................................................................................................................17
4EMPERATUREANDVISCOSITY ........................................................................................................................
4EMPERATURE .............................................................................................................................................
6ISCOSITY......................................................................................................................................................
&LUIDANDlLTERRECOMMENDATIONS..........................................................................................................19
TECHNICAL /VERVIEW .........................................................................................................................................................20

SPECIFICATIONS &EATURESANDOPTIONS ..................................................................................................................................20
/PERATINGPARAMETERS ................................................................................................................................20
&LUIDSPECIlCATIONS ......................................................................................................................................20
520L0818s2EV!#sDecember 2011 3
008 918 12 BOMAG 541
18.1 Travel pump
Service Manual
#ONTENTS
INITIAL STARTUP 'ENERAL ............................................................................................................................................................21

PROCEDURES 3TART UPPROCEDURE ......................................................................................................................................21
PRESSURE 2EQUIREDTOOLS ...............................................................................................................................................

MEASUREMENTS 0ORTLOCATIONSANDGAUGEINSTALLATION ...................................................................................................
TROUBLESHOOTING /VERVIEW .........................................................................................................................................................26

.EUTRALDIFlCULTORIMPOSSIBLETOlND ...................................................................................................26
3YSTEMOPERATINGHOT .................................................................................................................................26
4RANSMISSIONOPERATESNORMALLYINONEDIRECTIONONLY ..................................................................27
3YSTEMWILLNOTOPERATEINEITHERDIRECTION.........................................................................................27
,OWMOTOROUTPUTTORQUE .........................................................................................................................
)MPROPERMOTOROUTPUTSPEED ................................................................................................................
3YSTEMNOISEORVIBRATION ..........................................................................................................................
3YSTEMRESPONSEISSLUGGISH .....................................................................................................................29
ADJUSTMENTS 3TANDARDPROCEDURESINSPECTIONSANDADJUSTMENTS ......................................................................

!DJUSTMENTS ...................................................................................................................................................
#HARGEPRESSURERELIEFVALVEADJUSTMENT .............................................................................................
-ULTI FUNCTIONVALVEPRESSUREADJUSTMENT ..........................................................................................
%NGAGINGTHEBYPASSFUNCTION.................................................................................................................
0RESSUREOVERRIDE0/2 VALVEPRESSUREADJUSTMENTOPTIONFORFRAMESIZE ..................
$ISPLACEMENTLIMITERADJUSTMENT...........................................................................................................
3TANDARDMANUALDISPLACEMENTCONTROL-$# ADJUSTMENT.........................................................
.ON LINEARMANUALDISPLACEMENTCONTROL-$# ..............................................................................
-$#NEUTRALSTARTSWITCH.33 ADJUSTMENTS .....................................................................................
.EUTRALSTARTSWITCHECCENTRICPLUGADJUSTMENTCONDITIONI .................................................
.33DEADBANDADJUSTMENTCONDITIONSIIIII .............................................................................
#HECKINGSWITCHCONTINUITY ......................................................................................................................
(YDRAULICDISPLACEMENTCONTROL($# ANDELECTRICDISPLACEMENTCONTROL%$#
ADJUSTMENT .....................................................................................................................................................
3PEEDSENSORADJUSTMENT..........................................................................................................................
542 BOMAG 008 918 12

Travel pump 18.1
Service Manual
#ONTENTS
MINOR REPAIR 3TANDARDPROCEDURES ..................................................................................................................................

3HAFTSEALANDSHAFTREPLACEMENT ...........................................................................................................
-ULTI FUNCTIONVALVECARTRIDGES ...............................................................................................................
-ULTI FUNCTIONVALVECARTRIDGES PRE..........................................................................................
0RESSUREOVERRIDEVALVEOPTIONFORFRAMESIZE .........................................................................
#HARGEPRESSURERELIEFVALVE .....................................................................................................................
!UXILIARYPAD ..................................................................................................................................................
#HARGEPUMP .................................................................................................................................................
!DDINGAN!UXILIARYPADTOAPUMPPREVIOUSLYWITHOUTONE .......................................................
)NTEGRALCHARGEPRESSURElLTERREPLACEMENT .......................................................................................
0UMPCONTROLCOVERPLATE ..........................................................................................................................60
$ISPLACEMENTCONTROLORIlCES ..................................................................................................................61
$ISPLACEMENTCONTROLORIlCECHECKVALVE ...........................................................................................61
$ISPLACEMENTCONTROLADAPTERPLATEEARLYPRODUCTIONPUMPSONLY ...............................61
-ANUALDISPLACEMENTCONTROL-$# ....................................................................................................62
3OLENOIDOVERRIDEVALVEFOR-$# ............................................................................................................
3OLENOIDOVERRIDEVALVEFOR-$#WITHPRESSURERELEASEDBRAKE .................................................
(YDRAULICANDELECTRICDISPLACEMENTCONTROLS ...................................................................................
0RESSURECONTROLPILOT0#0 FORELECTRICDISPLACEMENTCONTROL%$# ........................................66
0OSITION&.2 ELECTRICCONTROL .............................................................................................................67
$ISPLACEMENTCONTROLlLTERSCREENS .......................................................................................................
3PEEDSENSOR..................................................................................................................................................
TORQUE CHART &ASTENERSIZEANDTORQUECHART ................................................................................................................69

0LUGSIZEANDTORQUECHART ........................................................................................................................70
&ASTENERSANDPLUGS.....................................................................................................................................70
008 918 12 BOMAG 543
18.1 Travel pump
Service Manual
)NTRODUCTION
OVERVIEW 4HISMANUALINCLUDESINFORMATIONFORTHEINSTALLATIONMAINTENANCEANDMINORREPAIROF

3ERIESAXIALPISTONCLOSEDCIRCUITPUMPS)TINCLUDESADESCRIPTIONOFTHEUNITANDITS
INDIVIDUALCOMPONENTSTROUBLESHOOTINGINFORMATIONANDMINORREPAIRPROCEDURES
0ERFORMINGMINORREPAIRSREQUIRESYOUREMOVETHEUNITFROMTHEVEHICLEMACHINE
4HOROUGHLYCLEANTHEUNITBEFOREBEGINNINGMAINTENANCEORREPAIRACTIVITIES3INCEDIRT
ANDCONTAMINATIONARETHEGREATESTENEMIESOFANYTYPEOFHYDRAULICEQUIPMENTFOLLOW
CLEANLINESSREQUIREMENTSSTRICTLY4HISISESPECIALLYIMPORTANTWHENCHANGINGTHESYSTEM
lLTERANDWHENREMOVINGHOSESORPLUMBING
!WORLDWIDENETWORKOF3AUER $ANFOSS'LOBAL3ERVICE0ARTNERS'30S ISAVAILABLEFOR

MAJORREPAIRS3AUER $ANFOSSTRAINS'30SANDCERTIlESTHEIRFACILITIESONAREGULARBASIS
9OUCANLOCATEYOURNEAREST!3#USINGTHEDISTRIBUTORLOCATORATWWWSAUER DANFOSSCOM
#LICKONTHE Sales and ServiceLINK
WARRANTY 0ERFORMINGINSTALLATIONMAINTENANCEANDMINORREPAIRSACCORDINGTOTHEPROCEDURESIN

THISMANUALWILLNOTAFFECTYOURWARRANTY-AJORREPAIRSREQUIRINGTHEREMOVALOFAUNITS
REARORSIDECOVERVOIDSTHEWARRANTYUNLESSDONEBYA3AUER $ANFOSS!UTHORIZED3ERVICE
#ENTER
GENERAL INSTRUCTIONS &OLLOWTHESEGENERALPROCEDURESWHENREPAIRING3ERIESVARIABLEDISPLACEMENTCLOSED

CIRCUITPUMPS
w Remove the unit

0RIORTOPERFORMINGMAJORREPAIRSREMOVETHEUNITFROMTHEVEHICLEMACHINE#HOCK
THEWHEELSONTHEVEHICLEORLOCKTHEMECHANISMTOINHIBITMOVEMENT"EAWARETHAT
HYDRAULICmUIDMAYBEUNDERHIGHPRESSUREANDORHOT)NSPECTTHEOUTSIDEOFTHEPUMP
ANDlTTINGSFORDAMAGE#APHOSESAFTERREMOVALTOPREVENTCONTAMINATION
e Keep it clean
#LEANLINESSISAPRIMARYMEANSOFASSURINGSATISFACTORYPUMPLIFEONEITHERNEWOR
REPAIREDUNITS#LEANTHEOUTSIDEOFTHEPUMPTHOROUGHLYBEFOREDISASSEMBLY4AKECARE
TOAVOIDCONTAMINATIONOFTHESYSTEMPORTS#LEANINGPARTSBYUSINGACLEANSOLVENTWASH
ANDAIRDRYINGISUSUALLYADEQUATE
!SWITHANYPRECISIONEQUIPMENTKEEPALLPARTSFREEOFFOREIGNMATERIALSANDCHEMICALS
0ROTECTALLEXPOSEDSEALINGSURFACESANDOPENCAVITIESFROMDAMAGEANDFOREIGNMATERIAL
)FLEFTUNATTENDEDCOVERTHEPUMPWITHAPROTECTIVELAYEROFPLASTIC
d Replace all O-rings and gaskets

5SENEW/ RINGSANDGASKETSDURINGREASSEMBLY,IGHTLYLUBRICATEALL/ RINGSWITHCLEAN
PETROLEUMJELLYPRIORTOASSEMBLY
t Secure the unit

&ORREPAIRPLACETHEUNITINASTABLEPOSITIONWITHTHESHAFTPOINTINGDOWNWARD)TWILLBE
NECESSARYTOSECURETHEPUMPWHILEREMOVINGANDTORQUINGENDCOVERSCONTROLSAND
valves.
544 BOMAG 008 918 12

Travel pump 18.1
Service Manual
)NTRODUCTION
SAFETY PRECAUTIONS !LWAYSCONSIDERSAFETYPRECAUTIONSBEFOREBEGINNINGASERVICEPROCEDURE0ROTECT

YOURSELFANDOTHERSFROMINJURY4AKETHEFOLLOWINGGENERALPRECAUTIONSWHENEVERSERVICINGA
HYDRAULICSYSTEM
Unintended machine movement

W Warning
5NINTENDEDMOVEMENTOFTHEMACHINEORMECHANISMMAYCAUSEINJURYTOTHETECHNICIAN
ORBYSTANDERS4OPROTECTAGAINSTUNINTENDEDMOVEMENTSECURETHEMACHINEORDISABLE
DISCONNECTTHEMECHANISMWHILESERVICING
Flammable cleaning solvents

W Warning
3OMECLEANINGSOLVENTSAREmAMMABLE4OAVOIDPOSSIBLElREDONOTUSECLEANING
SOLVENTSINANAREAWHEREASOURCEOFIGNITIONMAYBEPRESENT
Fluid under pressure

W Warning
%SCAPINGHYDRAULICmUIDUNDERPRESSURECANHAVESUFlCIENTFORCETOPENETRATEYOURSKIN
CAUSINGSERIOUSINJURYANDORINFECTION4HISmUIDMAYALSOBEHOTENOUGHTOCAUSEBURNS
5SECAUTIONWHENDEALINGWITHHYDRAULICmUIDUNDERPRESSURE2ELIEVEPRESSUREINTHE
SYSTEMBEFOREREMOVINGHOSESlTTINGSGAUGESORCOMPONENTS.EVERUSEYOURHAND
ORANYOTHERBODYPARTTOCHECKFORLEAKSINAPRESSURIZEDLINE3EEKMEDICALATTENTION
IMMEDIATELYIFYOUARECUTBYHYDRAULICmUID
Personal safety
W Warning
0ROTECTYOURSELFFROMINJURY5SEPROPERSAFETYEQUIPMENTINCLUDINGSAFETYGLASSESATALL
TIMES
008 918 12 BOMAG 545
18.1 Travel pump
Service Manual
)NTRODUCTION
SYMBOLS USED IN  7!2.).'MAYRESULTININJURY  4IPHELPFULSUGGESTION

SAUER-DANFOSS
LITERATURE  #!54)/.MAYRESULTINDAMAGETO  ,UBRICATEWITHCLEANHYDRAULICmUID
PRODUCTORPROPERTY
 !PPLYGREASEPETROLEUMJELLY
 2EUSABLEPART
 !PPLYLOCKINGCOMPOUND
 .ON REUSABLEPARTUSEANEWPART
 )NSPECTFORWEARORDAMAGE
 .ON REMOVABLEITEM
 #LEANAREAORPART
 /PTIONnEITHERPARTMAYEXIST
 "ECAREFULNOTTOSCRATCHORDAMAGE
 3UPERSEDEDnPARTSARENOT
INTERCHANGEABLE  .OTECORRECTORIENTATION
 -EASUREMENTREQUIRED  -ARKORIENTATIONFORREINSTALLATION
 &LATNESSSPECIlCATION  4ORQUESPECIlCATION
 0ARALLELISMSPECIlCATION  0RESSINnPRESSlT
 %XTERNALHEXHEAD  0ULLOUTWITHTOOLnPRESSlT
 )NTERNALHEXHEAD  #OVERSPLINESWITHINSTALLATION
sleeve
 4ORXHEAD
 0RESSUREMEASUREMENTGAUGE
 / RINGBOSSPORT LOCATIONORSPECIlCATION
4HESYMBOLSABOVEAPPEARINTHEILLUSTRATIONSANDTEXTOFTHISMANUAL4HEYAREINTENDED
TOCOMMUNICATEHELPFULINFORMATIONATTHEPOINTWHEREITISMOSTUSEFULTOTHEREADER
)NMOSTINSTANCESTHEAPPEARANCEOFTHESYMBOLITSELFDENOTESITSMEANING4HELEGEND
ABOVEDElNESEACHSYMBOLANDEXPLAINSITSPURPOSE
546 BOMAG 008 918 12

Travel pump 18.1
Service Manual
)NTRODUCTION
DESIGN 3AUER $ANFOSS3ERIESCLOSEDCIRCUITPISTONPUMPSCONVERTINPUTTORQUEINTOHYDRAULIC

POWER4HEINPUTSHAFTTRANSMITSROTATIONALFORCETOTHECYLINDERBLOCK"EARINGSSUPPORT
THEINPUTSHAFTATTHEFRONTANDREAROFTHEPUMP4HESHAFTISSPLINEDINTOTHECYLINDER
BLOCK!LIP SEALATTHEFRONTENDOFTHEPUMPPREVENTSLEAKAGEWHERETHESHAFTEXITS
THEPUMPHOUSING4HESPINNINGCYLINDERBLOCKCONTAINSNINERECIPROCATINGPISTONS!
BALLJOINTATONEENDCONNECTSEACHPISTONTOABRASSSLIPPER&IXED CLEARANCEHOLD DOWN
BRACKETSKEEPTHESLIPPERSINCONTACTWITHTHESWASHPLATE4HERECIPROCATINGMOVEMENT
OFTHEPISTONSOCCURSASTHESLIPPERSSLIDEAGAINSTTHEINCLINEDSWASHPLATEDURINGROTATION
4HEVALVEPLATECONNECTSONEHALFOFTHECYLINDERBLOCKTOLOWPRESSUREANDTHEOTHER
HALFTOHIGHPRESSURE!SEACHPISTONCYCLESINANDOUTOFITSBOREmUIDISDRAWNFROMTHE
INLETANDDISPLACEDTOTHEOUTLETTHEREBYIMPARTINGHYDRAULICPOWERINTOTHESYSTEM!
SMALLAMOUNTOFmUIDmOWSFROMTHECYLINDERBLOCKVALVEPLATEANDSLIPPERSWASHPLATE
INTERFACESFORLUBRICATIONANDCOOLING#ASEDRAINPORTSRETURNTHISmUIDTOTHERESERVOIR
4HEANGLEOFTHESWASHPLATECONTROLSTHEVOLUMEOFmUIDDISPLACEDINTOTHESYSTEM4HE
SERVOPISTONFORCESTHESWASHPLATEINTOANINCLINEDPOSITION4HEPUMPCONTROLACTING
ONINPUTFROMTHEOPERATORBYMODULATINGPRESSUREBALANCEACROSSTHESERVOPISTONSETS
DISPLACEMENTINTHESYSTEMCIRCUIT
Cross section
Piston
Slipper
Displacement control
Slider block Servo arm
Servo piston
Feedback linkage
Cradle bearing
Bushing
Cylinder block Roller bearing
Shaft
Valve plate seal
Rear
bushing
Input shaft
Charge pump Swashplate Cradle guide P106 648E
008 918 12 BOMAG 547
18.1 Travel pump
Service Manual
)NTRODUCTION
THE SYSTEM CIRCUIT The basic closed circuit Basic closed circuit diagram
(YDRAULICLINESCONNECTTHEMAINPORTS
OFTHEPUMPTOTHEMAINPORTSOFTHE
MOTOR&LUIDmOWSINEITHERDIRECTION
FROMTHEPUMPTOTHEMOTORTHENBACK
Reservoir
TOTHEPUMPINTHISCLOSEDCIRCUIT%ITHER
OFTHEHYDRAULICLINESCANBEUNDERHIGH Input PV MF Output
PRESSURE)NPUMPINGMODETHEPOSITION
OFTHEPUMPSWASHPLATEDETERMINES
WHICHLINEISHIGHPRESSUREASWELLASTHE
DIRECTIONOFmUIDmOW
Flow (Bi-directional)
Case drain line
P104 120E
Case drain and heat exchanger

4HEPUMPANDMOTORREQUIRECASEDRAINLINESTOREMOVEHOTmUIDFROMTHESYSTEM
4HETOPMOSTPORTDRAINSTHEMOTORTOENSURETHECASEREMAINSFULLOFmUID&LUIDROUTES
THROUGHTHELOWERDRAINPORTONTHEPUMPANDOUTTHETOPMOSTPORTTOTHERESERVOIR
!HEATEXCHANGERWITHABYPASSVALVECOOLSTHECASEDRAINmUIDBEFOREITRETURNSTOTHE
reservoir.
System circuit diagram
Control handle Displacement control valve
Heat exchanger bypass valve
Reservoir
Orificed check
valve Vacuum gauge
Heat exchanger
Purge relief valve
Charge pressure relief valve P102 000
Reversible variable Servo control cylinder Multi-function valve Fixed displacement motor
displacement pump
To
pump
case
Servo
pressure
relief valves
Charge pump
Input shaft Output shaft
Multi-function valve Motor swashplate
Pump swashplate
Servo control cylinder Loop flushing valve
Pump Motor
Working loop (high pressure) Working loop (low pressure) Suction line Control fluid Case drain fluid
548 BOMAG 008 918 12

Travel pump 18.1
Service Manual
)NTRODUCTION
THE SYSTEM CIRCUIT

(continued)
Pump schematic
M3
X5
A
M1
M5
M4
M2
L1 S L2
P104 126E
008 918 12 BOMAG 549
18.1 Travel pump
Service Manual
/PERATION
CHARGE PUMP 4HECHARGEPUMPISNECESSARYTOSUPPLY Pump charge system

COOLmUIDTOTHESYSTEMTOMAINTAIN
Case
POSITIVEPRESSUREINTHEMAINSYSTEM drain Charge relief valve
line
LOOPTOPROVIDEPRESSURETOOPERATE System
check
THECONTROLSYSTEMANDTOMAKEUPFOR valves
INTERNALLEAKAGE#HARGEPRESSUREMUST Input PV PF
BEATITSSPECIlEDPRESSUREUNDERALL Charge
pump
CONDITIONSTOPREVENTDAMAGETOTHE
TRANSMISSION
4HECHARGEPUMPISAlXED
DISPLACEMENTGEROTORTYPEPUMPDRIVEN Inlet filter
OFFTHEMAINPUMPSHAFT4HECHARGE Tank P104 121E
RELIEFVALVELIMITSCHARGEPRESSURE
CHARGE RELIEF VALVE 4HECHARGERELIEFVALVEONTHEPUMP Charge pressure relief valve

MAINTAINSCHARGEPRESSUREATA
DESIGNATEDLEVEL!DIRECT ACTING
POPPETVALVERELIEVESmUIDWHENCHARGE
PRESSUREREACHESACERTAINLEVEL4HIS
LEVELISNOMINALLYSETREFERENCINGCASE
PRESSUREATRPM4HISNOMINAL
SETTINGASSUMESTHEPUMPISINNEUTRAL
ZEROmOW )NFORWARDORREVERSECHARGE
PRESSUREISLOWER4HEPUMPMODELCODE
SPECIlESTHECHARGERELIEFVALVESETTING
Charge pressure P106 157E
MULTI-FUNCTION VALVES 4HEMULTI FUNCTIONVALVEINCORPORATES Multi-function valve

THESYSTEMCHECKVALVETHEPRESSURE
LIMITERVALVETHEHIGHPRESSURERELIEF High pressure
Pressure limiter housing relief / check Check valve
VALVEANDTHEBYPASSVALVEINA Pressure limiter valve poppet poppet
REPLACEABLECARTRIDGE4HESEFUNCTIONS lock nut
AREDESCRIBEDSEPARATELY4HEREARETWO Pressure limiter

MULTI FUNCTIONVALVECARTRIDGESINEACH adjustment screw
3ERIESPUMPTOHANDLEFUNCTIONS
Bypass
INEITHERDIRECTION3EECORRESPONDING actuator Pressure limiter
Bypass
P104 122E
SECTIONSFORADJUSTMENTSANDREPAIRS valve poppet
3OMEMULTI FUNCTIONVALVESDONOTINCLUDEAPRESSURELIMITERVALVE
550 BOMAG 008 918 12

Travel pump 18.1
Service Manual
/PERATION
PRESSURE LIMITER AND 3ERIESPUMPSHAVEASEQUENCED Circuit diagram showing pressure

HIGH PRESSURE RELIEF PRESSURELIMITINGSYSTEMANDHIGH control mechanism
VALVES PRESSURERELIEFVALVES7HENTHESYSTEM
To control
PRESSUREREACHESTHEPRESETTHEPRESSURE
LIMITERSYSTEMRAPIDLYDE STROKESTHE Multi-function valve
PUMPTOLIMITSYSTEMPRESSURE&OR
UNUSUALLYRAPIDLOADAPPLICATIONTHE Servo piston Bypass
adjustment
HIGHPRESSURERELIEFVALVEIMMEDIATELY Port "A"
LIMITSSYSTEMPRESSUREBYCROSS PORTING Servo Pres.
Relief Valve
SYSTEMmOW4HEPRESSURELIMITERVALVE
Port "B"
ACTSASTHEPILOTFORTHEHIGHPRESSURE
Servo piston Charge
RELIEFVALVESPOOL4HEHIGHPRESSURE pressure
RELIEFVALVEISSEQUENCEDTOOPERATEAT relief valve
APPROXIMATELYBARPSI ABOVETHE Multi-function valve
LEVELTHATINITIATESTHEPRESSURELIMITER P104 123E
valve.
&ORSOMEAPPLICATIONSSUCHASDUALPATHVEHICLESTHEPRESSURELIMITERFUNCTIONMAYBE

DEFEATEDSOTHATONLYTHEHIGHPRESSURERELIEFVALVEFUNCTIONREMAINS
SYSTEM CHECK VALVES 4HESYSTEMCHECKVALVESALLOWPRESSURIZEDmOWFROMTHECHARGEPUMPTOENTERTHELOW

PRESSURESIDEOFTHELOOP4HISISNEEDEDASTHEPUMPGENERALLYLOSESSYSTEMPRESSURE
DUETOLUBRICATIONCOOLINGmOWANDOTHERFACTORS3INCETHEPUMPOPERATESINEITHER
DIRECTIONTHESYSTEMUSESTWOCHECKVALVESTODIRECTTHECHARGESUPPLYINTOTHELOW
PRESSURELINES4HESYSTEMCHECKVALVESAREPARTOFTHEMULTI FUNCTIONVALVEASSEMBLY
BYPASS VALVES 9OUCANOPERATETHEBYPASSVALVESTOMOVETHEVEHICLEORMECHANICALFUNCTIONWHENTHE

PUMPISNOTRUNNING-ANUALLYRESETTINGTHEVALVEPOSITIONOPENSTHEVALVE4HEBYPASS
VALVESAREBUILTINTOTHEMULTI FUNCTIONVALVES
SPEED SENSORS !NOPTIONALSPEEDSENSORCANPROVIDEUNITSPEEDINFORMATION4HESENSORREADSA

MAGNETICRINGONTHEUNITSCYLINDERBLOCK3EETHECORRESPONDINGSECTIONTOLOCATE
INSTALLANDADJUSTTHESPEEDSENSOR
008 918 12 BOMAG 551
18.1 Travel pump
Service Manual
/PERATION
FILTRATION OPTIONS 3ERIESPUMPSMAYHAVEEITHERSUCTION Suction filtration

ORCHARGEPRESSURElLTRATIONTOlLTERTHE Hydraulic fluid reservoir Manometer
mUIDENTERINGTHECIRCUIT
Charge pump
Filter
Suction filtration – option S

4HESUCTIONlLTERISINTHECIRCUITBETWEEN
THERESERVOIRANDTHEINLETTOTHECHARGE Adjustable
To low charge pressure relief valve
PUMPASSHOWNBELOW4HEUSEOFAlLTER loop and
P102 003E
CONTAMINATIONMONITORISRECOMMENDED control To pump case
Charge pressure filtration – option R, Charge pressure filtration

T, P, and L Screen
4HEPRESSURElLTERCANBEMOUNTED
ONTHEPUMPORREMOTELYFOREASEOF Hydraulic fluid reservoir
Adjustable
SERVICING9OUWILLTYPICALLYlNDA charge pressure
relief valve
MMESHSCREENINTHERESERVOIROR
Charge pump
THECHARGEINLET4HISSYSTEMREQUIRESA
lLTERCAPABLEOFWITHSTANDINGCHARGE Filter
To low To pump case
PRESSUREREFERENCETOATMOSPHERE ADD pressure
CASEPRESSURE side and
P102 004E
control
PRESSURE OVERRIDE 4HE0RESSURE/VER2IDEVALVE0/2 POR-Valve (180 frame size only)

(POR) – 180 FRAME SIZE MODULATESCONTROLPRESSURETOMAINTAIN To control
ONLY APUMPDISPLACEMENTWHICHPRODUCESA
SYSTEMPRESSURELEVELLESSTHANOREQUAL
TOTHE0/2SETTING&ORUNUSUALLYRAPID Multi-function valve
LOADAPPLICATIONTHEHIGHPRESSURERELIEF Pressure

Bypass
VALVEFUNCTIONOFTHEMULTI FUNCTION override control valve
adjustment
VALVESISAVAILABLETOALSOLIMITTHE Port "A"
pressure level. Shuttle

valve
Port "B"
4HEPRESSUREOVERRIDECONSISTSOFATHREE
WAYNORMALLYOPENVALVEWHICHOPERATES
INSERIESWITHTHEPUMPDISPLACEMENT Multi-function valve
Charge pressure
CONTROL#ONTROLSUPPLYPRESSURENORMALLY relief valve
PORTSTHROUGHTHE0/2VALVETOTHE P104 124E
DISPLACEMENTCONTROLVALVE)FTHESYSTEM
DEMANDSAPRESSUREABOVETHEOVERRIDE
SETTINGTHE0/2VALVEOVERRIDESTHE
CONTROLBYREDUCINGTHEPRESSURETOTHEDISPLACEMENTCONTROL!STHECONTROLPRESSURE
REDUCESTHEINTERNALFORCESROTATINGTHESWASHPLATEOVERCOMETHEFORCEOFTHESERVO
PISTONSANDDECREASESTHEPUMPSDISPLACEMENT
552 BOMAG 008 918 12

Travel pump 18.1
Service Manual
/PERATION
MANUAL DISPLACEMENT 4HEMANUALDISPLACEMENTCONTROLCONVERTSAMECHANICALINPUTSIGNALTOAHYDRAULIC

CONTROL (MDC) SIGNALUSINGASPRING CENTEREDFOUR WAYSERVOVALVE4HISVALVEPORTSHYDRAULICPRESSURE
TOEITHERSIDEOFADUAL ACTINGSERVOPISTON4HESERVOPISTONROTATESTHECRADLE
SWASHPLATETHROUGHANANGULARROTATIONOF¼²VARYINGTHEPUMPSDISPLACEMENTFROM
FULLINONEDIRECTIONTOFULLINTHEOPPOSITEDIRECTION4HEANGULARPOSITIONOFTHEPUMP
SWASHPLATEISPROPORTIONALTOTHEROTATIONOFTHECONTROLINPUTSHAFT
NON-LINEAR MDC 4HENON LINEARMANUALDISPLACEMENTCONTROLOPERATESINTHESAMEMANNEREXCEPTTHATIT

ISDESIGNEDSOTHECHANGEINTHEANGULARPOSITIONOFTHEPUMPSWASHPLATEPROGRESSIVELY
INCREASESASTHECONTROLINPUTSHAFTISROTATEDTOWARDITSMAXIMUMDISPLACEMENTPOSITION
SOLENOID OVERRIDE !SOLENOIDOVERRIDEVALVEOPTIONISAVAILABLEFORTHE-$#4HISSAFETYFEATURERETURNSTHE

VALVE FOR MDC SWASHPLATETOZERODISPLACEMENT)TISAVAILABLEINNORMALLYOPENACTIVATETOALLOW OR
NORMALLYCLOSEDACTIVATETODISALLOW OPTIONS
NEUTRAL START SWITCH 4HENEUTRALSTARTSWITCHISANOPTIONALFEATUREAVAILABLEWITHTHE-$#7HENCONNECTED

(NSS) PROPERLYWITHTHEVEHICLESELECTRICALSYSTEMTHENEUTRALSTARTSWITCHENSURESTHATTHE
PRIMEMOVERCANSTARTONLYWHENTHECONTROLISINNEUTRALPOSITION
HYDRAULIC 4HEHYDRAULICDISPLACEMENTCONTROLUSESAHYDRAULICINPUTSIGNALTOOPERATEASPRING
DISPLACEMENT CENTEREDFOUR WAYSERVOVALVE4HISVALVEPORTSHYDRAULICPRESSURETOEITHERSIDEOFA
CONTROL (HDC) DUAL ACTINGSERVOPISTON4HESERVOPISTONROTATESTHECRADLESWASHPLATETHROUGHAN
ANGULARROTATIONOF¼²THUSVARYINGTHEPUMPSDISPLACEMENTFROMFULLDISPLACEMENTIN
ONEDIRECTIONTOFULLDISPLACEMENTINTHEOPPOSITEDIRECTION4HEANGULARPOSITIONOFTHE
PUMPSWASHPLATEISPROPORTIONALTOINPUTPRESSURE
ELECTRIC DISPLACEMENT 4HEELECTRICDISPLACEMENTCONTROLUSESA0RESSURE#ONTROL0ILOT0#0 VALVETOMODULATE

CONTROL (EDC) PRESSUREBALANCEACROSSTHESPRING CENTEREDFOUR WAYSERVOVALVE4HE0#0VALVE
CONVERTSA$#ELECTRICALINPUTSIGNALTOAHYDRAULICSIGNAL4HESERVOVALVEPORTSHYDRAULIC
PRESSURETOEITHERSIDEOFADUAL ACTINGSERVOPISTON4HESERVOPISTONROTATESTHE
SWASHPLATETHROUGHANANGULARROTATIONOF¼²VARYINGTHEPUMPSDISPLACEMENT4HE
ANGULARPOSITIONOFTHESWASHPLATEISPROPORTIONALTOTHE%$#INPUT
AUTOMOTIVE CONTROL 4HEAUTOMOTIVECONTROLALLOWSTHEOPERATORTODRIVEAVEHICLESIMILARTOANAUTOMOBILE

(FBA II B) WITHANAUTOMATICTRANSMISSION4HEAUTOMOTIVECONTROLINCLUDESATHREE POSITION
ELECTRICCONTROLTOPROVIDEDIRECTIONCONTROL
3-POSITION (FNR) 4HISCONTROLUTILIZESAOR6DCELECTRICALLYOPERATEDSPOOLVALVETOPORTPRESSURETO

ELECTRIC CONTROL EITHERSIDEOFTHEPUMPSERVOPISTON%NERGIZINGONEOFTHESOLENOIDSCAUSESTHEPUMP
TOGOTOITSMAXIMUMDISPLACEMENTINTHECORRESPONDINGDIRECTION!LLFUNCTIONSOFTHE
THREE POSITION&.2 ELECTRICCONTROLAREPRESETATTHEFACTORY
008 918 12 BOMAG 553
18.1 Travel pump
Service Manual
/PERATINGPARAMETERS
OVERVIEW 4HISSECTIONDElNESTHEOPERATINGPARAMETERSANDLIMITATIONSFOR3ERIESPUMPSWITH
REGARDTOINPUTSPEEDSANDPRESSURES&ORACTUALPARAMETERSREFERTOTHEOPERATING
PARAMETERSFOREACHDISPLACEMENT
INPUT SPEED Minimum speedISTHELOWESTINPUTSPEEDRECOMMENDEDDURINGENGINEIDLECONDITION

/PERATINGBELOWMINIMUMSPEEDLIMITSTHEPUMPSABILITYTOMAINTAINADEQUATEmOWFOR
LUBRICATIONANDPOWERTRANSMISSION
Continuous speedISTHEHIGHESTINPUTSPEEDRECOMMENDEDATFULLPOWERCONDITION
/PERATINGATORBELOWTHISSPEEDSHOULDYIELDSATISFACTORYPRODUCTLIFE
Maximum speedISTHEHIGHESTOPERATINGSPEEDPERMITTED%XCEEDINGMAXIMUMSPEED
REDUCESPRODUCTLIFEANDCANCAUSELOSSOFHYDROSTATICPOWERANDBRAKINGCAPACITY.EVER
EXCEEDTHEMAXIMUMSPEEDLIMITUNDERANYOPERATINGCONDITIONS
7HENDETERMININGSPEEDLIMITSFORAPARTICULARAPPLICATIONSEE3AUER $ANFOSS
PUBLICATIONBLN-9884 Pressure and speed limits.
W7ARNING
Unintended vehicle or machine movement hazard
%XCEEDINGMAXIMUMSPEEDMAYCAUSEALOSSOFHYDROSTATICDRIVELINEPOWERANDBRAKING
CAPACITY9OUMUSTPROVIDEABRAKINGSYSTEMREDUNDANTTOTHEHYDROSTATICTRANSMISSION
SUFlCIENTTOSTOPANDHOLDTHEVEHICLEORMACHINEINTHEEVENTOFHYDROSTATICDRIVEPOWER
loss.
SYSTEM PRESSURE System pressureISTHEDIFFERENTIALPRESSUREBETWEENSYSTEMPORTS!AND")TISTHE

DOMINANTOPERATINGVARIABLEAFFECTINGHYDRAULICUNITLIFE(IGHSYSTEMPRESSUREWHICH
RESULTSFROMHIGHLOADREDUCESEXPECTEDLIFE3YSTEMPRESSUREMUSTREMAINATORBELOW
CONTINUOUSPRESSUREDURINGNORMALOPERATIONTOACHIEVEEXPECTEDLIFE
Continuous pressureISTHEAVERAGEREGULARLYOCCURRINGOPERATINGPRESSURE/PERATING

ATORBELOWTHISPRESSURESHOULDYIELDSATISFACTORYPRODUCTLIFE
Maximum pressureISTHEHIGHESTINTERMITTENTPRESSUREALLOWED-AXIMUMMACHINE
LOADSHOULDNEVEREXCEEDTHISPRESSURE&ORALLAPPLICATIONSTHELOADSHOULDMOVEBELOW
THISPRESSURE
!LLPRESSURELIMITSAREDIFFERENTIALPRESSURESREFERENCEDTOLOWLOOPCHARGE PRESSURE
3UBTRACTLOWLOOPPRESSUREFROMGAUGEREADINGSTOCOMPUTETHEDIFFERENTIAL
554 BOMAG 008 918 12

Travel pump 18.1
Service Manual
/PERATINGPARAMETERS
CHARGE PRESSURE !NINTERNALCHARGERELIEFVALVEREGULATESCHARGEPRESSURE4HECHARGEPUMPSUPPLIESTHE

CONTROLWITHPRESSURETOOPERATETHESWASHPLATEANDTOMAINTAINAMINIMUMPRESSUREIN
THELOWSIDEOFTHETRANSMISSIONLOOP
Minimum charge pressureISTHELOWESTPRESSUREALLOWEDTOMAINTAINASAFEWORKING

CONDITIONINTHELOWSIDEOFTHELOOP-INIMUMCONTROLPRESSUREREQUIREMENTSAREA
FUNCTIONOFSPEEDPRESSUREANDSWASHPLATEANGLEANDMAYBEHIGHERTHANTHEMINIMUM
CHARGEPRESSURESHOWNINTHEOPERATINGPARAMETERSTABLE
Maximum charge pressureISTHEHIGHESTCHARGEPRESSUREALLOWEDBYTHECHARGERELIEF

ADJUSTMENTANDPROVIDESNORMALCOMPONENTLIFE9OUCANUSEELEVATEDCHARGEPRESSURE
ASASECONDARYMEANSTOREDUCETHESWASHPLATERESPONSETIME
4HECHARGEPRESSURESETTINGINTHEORDERCODEISTHESETPRESSUREOFTHECHARGERELIEF
VALVEWITHTHEPUMPINNEUTRALOPERATINGATMIN-1RPM ANDWITHAmUIDVISCOSITY
OFMM2SEC353 4HECHARGEPRESSURESETTINGISREFERENCEDTOCASEPRESSURE
#HARGEPRESSUREISTHEDIFFERENTIALPRESSUREABOVECASEPRESSURE
CHARGE INLET PRESSURE !TNORMALOPERATINGTEMPERATURECHARGEINLETPRESSUREMUSTNOTFALLBELOWrated charge

inlet pressure.
Minimum charge inlet pressureISONLYALLOWEDATCOLDSTARTCONDITIONS)NSOME

APPLICATIONSITMAYBENECESSARYTOWARMUPTHEmUIDBYRUNNINGTHEENGINEATLIMITED
SPEEDUNTILTHESYSTEMmUIDTEMPERATUREREACHESANACCEPTABLELEVEL
5NDERNORMALOPERATINGCONDITIONSDONOTEXCEEDTHErated case pressure$URINGCOLD

CASE PRESSURE STARTMAINTAINTHECASEPRESSUREBELOWMAXIMUMINTERMITTENTCASEPRESSURE
C#AUTION
Possible component damage or leakage
/PERATIONWITHCASEPRESSUREINEXCESSOFSTATEDLIMITSMAYDAMAGESEALSGASKETSANDOR
HOUSINGSCAUSINGEXTERNALLEAKAGE0ERFORMANCEMAYALSOBEAFFECTEDSINCECHARGEAND
SYSTEMPRESSUREAREADDITIVETOCASEPRESSURE
008 918 12 BOMAG 555
18.1 Travel pump
Service Manual
/PERATINGPARAMETERS
TEMPERATURE AND Temperature

VISCOSITY 4HEHIGHTEMPERATURELIMITSAPPLYATTHEHOTTESTPOINTINTHETRANSMISSIONLOOPWHICH
ISNORMALLYTHEMOTORCASEDRAIN-AINTAINSYSTEMTEMPERATUREBELOWTHEQUOTEDrated
temperature.
.EVEREXCEEDTHEmaximum intermittent temperature.
#OLDOILWILLGENERALLYNOTAFFECTTHEDURABILITYOFTHETRANSMISSIONCOMPONENTSBUTIT
MAYAFFECTTHEABILITYOFOILTOmOWANDTRANSMITPOWERTHEREFORETEMPERATURESSHOULD
REMAIN²#;²&=ABOVETHEPOURPOINTOFTHEHYDRAULICmUID
4HEminimum temperatureRELATESTOTHEPHYSICALPROPERTIESOFCOMPONENTMATERIALS
3IZEHEATEXCHANGERSTOKEEPTHEmUIDWITHINTHESELIMITS4ESTHEATEXCHANGERSTOVERIFY
THATTHESETEMPERATURELIMITSARENOTEXCEEDED
Viscosity
&ORMAXIMUMEFlCIENCYANDBEARINGLIFEENSURETHEmUIDVISCOSITYREMAINSINTHE
recommended range.
Minimum viscositySHOULDBEENCOUNTEREDONLYDURINGBRIEFOCCASIONSOFMAXIMUM
AMBIENTTEMPERATUREANDSEVEREDUTYCYCLEOPERATION
Maximum viscositySHOULDBEENCOUNTEREDONLYATCOLDSTART
556 BOMAG 008 918 12

Travel pump 18.1
Service Manual
/PERATINGPARAMETERS
FLUID AND FILTER 4OENSUREOPTIMUMPUMPLIFEPERFORMREGULARMAINTENANCEOFTHEmUIDANDlLTER

RECOMMENDATIONS #ONTAMINATEDmUIDISTHEMAINCAUSEOFUNITFAILURE-AINTAINmUIDCLEANLINESSWHEN
SERVICING
#HECKTHERESERVOIRDAILYFORPROPERmUIDLEVELTHEPRESENCEOFWATERANDRANCIDmUID

ODOR&LUIDCONTAMINATEDBYWATERMAYAPPEARCLOUDYORMILKYORFREEWATERMAY
SETTLEINTHEBOTTOMOFTHERESERVOIR2ANCIDODORINDICATESTHEmUIDHASBEENEXPOSED
TOEXCESSIVEHEAT#HANGETHEmUIDIMMEDIATELYIFTHESECONDITIONSOCCUR#ORRECTTHE
PROBLEMIMMEDIATELY
)NSPECTVEHICLEFORLEAKSDAILY
Fluid and filter change interval
#HANGETHEmUIDANDlLTERPERTHE Reservoir type Max oil change interval
VEHICLEMACHINEMANUFACTURERS 3EALED HOURS
RECOMMENDATIONSORATTHEINTERVALS "REATHER HOURS
SHOWNINTHETABLE#HANGEmUIDAFTER
lRSTHOURS
C#AUTION
(IGHTEMPERATURESANDPRESSURESRESULTINACCELERATEDmUIDAGING#HANGEmUIDMORE
FREQUENTLYIFOPERATINGUNDEREXTREMECONDITIONS
#HANGETHEmUIDMOREFREQUENTLYIFITBECOMESCONTAMINATEDWITHFOREIGNMATTERDIRT
WATERGREASEETC ORIFTHEmUIDISSUBJECTEDTOTEMPERATURELEVELSGREATERTHANTHE
RECOMMENDEDMAXIMUM
$ISPOSEOFUSEDHYDRAULICmUIDPROPERLY.EVERREUSEHYDRAULICmUID
#HANGElLTERSWHENEVERTHEmUIDISCHANGEDORWHENTHElLTERINDICATORINDICATESAlLTER
CHANGE2EPLACEALLmUIDLOSTDURINGlLTERCHANGE
&ORDETAILEDlLTRATIONINFORMATIONSEE3AUER $ANFOSSPUBLICATION520L0463 Fluids

and Filtration&ORINFORMATIONONBIODEGRADABLEmUIDSSEE3AUER $ANFOSSPUBLICATION
520L0465 Biodegradable Hydraulic Fluids.
008 918 12 BOMAG 557
18.1 Travel pump
Service Manual
4ECHNICALSPECIlCATIONS
OVERVIEW 3PECIlCATIONSANDOPERATINGPARAMETERSFORPUMPSAPPEARHEREFORREFERENCE
FEATURES AND OPTIONS Model Series 90 Pumps

Mount 3!%"3!%#AND%3!%*
Pump type !XIALPISTONTYPE
Rotation "IDIRECTIONAL
Installation position $ISCRETIONARY(OUSINGMUSTALWAYSBElLLEDWITHHYDRAULICmUID$ONOTINSTALLWITH
CONTROLONBOTTOM
Input shafts 3PLINED
Control options -$#WITHOPTIONS %$#($#&.2
OPERATING Parameter Unit Pressure

PARAMETERS 2ATED ;=
bar
3YSTEMPRESSURE -AXIMUM ;=
;PSI=
-INIMUMLOWLOOP ;=
Minimum bar ;=
#HARGEPRESSURE
-AXIMUM ;PSI= ;=
2ATED BARABSOLUTE ;=
#HARGEINLETPRESSURE
-INIMUMCOLDSTART ;IN(GVACUUM= ;=
2ATED bar ;=
#ASEPRESSURE
-AXIMUM ;PSI= ;=
Frame size
Parameter Unit
042 055 075 100 130 180 250
Displacement cm³ 100
MAXIMUM ;INÃ= ;= ;= ;= ;= ;= ;= ;=
Minimum speed min-1 RPM
Rated speed min-1 RPM 2600
Maximum speed min-1 RPM
Maximum attainable speed at
min-1 RPM
maximum displacement
.sMBAR
Theoretical torque at maximum 0.67 1.19 2.07
;LBFsIN
displacement ;= ;= ;= ;= ;= ;= ;=
PSI=
kg
Weight BASEUNITONLY
;LB= ;= ;= ;= ;= ;= ;= ;=
FLUID SPECIFICATIONS Parameter Unit Minimum Continuous Maximum

6ISCOSITY mm2SECC3T 7 12-60 1600
;353= ;= ; = ;=
2ATINGSANDDATAAREBASED 4EMPERATURE ²#;²&= ; = ;= ;=
ONOPERATIONWITHPREMIUM #LEANLINESS )3/#LASSORBETTER
PETROLEUM BASEDHYDRAULIC &ILTRATIONEFlCIENCY SUCTIONlLTRATION 10
mUIDSCONTAININGOXIDATION CHARGElLTRATION 10
ANDFOAMINHIBITORS
558 BOMAG 008 918 12

Travel pump 18.1
Service Manual
)NITIALSTART UPPROCEDURE
GENERAL &OLLOWTHISPROCEDUREWHENSTARTING UPANEWPUMPINSTALLATIONORWHENRESTARTINGAN

INSTALLATIONINWHICHTHEPUMPWASREMOVED
W 7ARNING
0RIORTOINSTALLINGTHEPUMPINSPECTFORSHIPPINGDAMAGE
START-UP PROCEDURE %NSURETHATTHEHYDRAULICmUIDANDSYSTEMCOMPONENTSRESERVOIRHOSESVALVES

lTTINGSANDHEATEXCHANGER ARECLEANANDFREEOFCONTAMINATION
)NSTALLNEWSYSTEMlLTERELEMENTS IFNECESSARY#HECKTHATINLETLINElTTINGSARE

PROPERLYTIGHTENEDANDTHEREARENOAIRLEAKS
)NSTALLTHEPUMP)NSTALLABAR;PSI=GAUGEINTHECHARGEPRESSUREGAUGEPORT
-
&ILLTHEHOUSINGBYADDINGlLTEREDmUIDINTHEUPPERCASEDRAINPORT/PENTHECASE
PLUGINTHETOPOFTHECONTROLTOASSISTWITHAIRBLEED
&ILLTHERESERVOIRWITHHYDRAULICmUIDOFTHERECOMMENDEDTYPEANDVISCOSITY5SEA
MICRONlLLERlLTER&ILLINLETLINEFROMRESERVOIRTOPUMP
$ISCONNECTTHEPUMPCONTROLINPUTSIGNAL
!FTERSTART UPTHEmUIDLEVELINTHERESERVOIRMAYDROPDUETOlLLINGOFTHESYSTEM
COMPONENTS#HECKTHELEVELINTHERESERVOIRTOMAINTAINAFULLmUIDLEVELTHROUGHOUTTHE
START UPPROCEDURE
C #AUTION
$AMAGETOHYDRAULICCOMPONENTSMAYOCCURFROMFAILURETOMAINTAINmUIDSUPPLY
5SEACOMMONMETHODTODISABLETHEENGINETOPREVENTTHEENGINEFROMSTARTING
#RANKTHESTARTERFORSEVERALSECONDS$ONOTTOEXCEEDTHEENGINEMANUFACTURERS
RECOMMENDATION7AITSECONDSANDTHENCRANKTHEENGINEASECONDTIME
4HISOPERATIONHELPSREMOVEAIRFROMTHESYSTEMLINES2ElLLTHERESERVOIRTO
RECOMMENDEDFULLmUIDLEVEL
008 918 12 BOMAG 559
18.1 Travel pump
Service Manual
)NITIALSTART UPPROCEDURE
START-UP PROCEDURE 7HENCHARGEPRESSUREREACHESBAR;PSI=ENABLEANDSTARTENGINE,ETTHE

(continued) ENGINERUNFORAMINIMUMOFSECONDSATLOWIDLETOALLOWTHEAIRTOWORKITSELFOUT
OFTHESYSTEM#HECKFORLEAKSATALLLINECONNECTIONSANDLISTENFORCAVITATION#HECK
FORPROPERmUIDLEVELINRESERVOIR
C#AUTION
!IRENTRAPMENTINmUIDUNDERHIGHPRESSUREMAYDAMAGEHYDRAULICCOMPONENTS
C#AUTION
$ONOTRUNATMAXIMUMPRESSUREUNTILSYSTEMISFREEOFAIRANDmUIDHASBEENTHOROUGHLY
lLTERED
7HENADEQUATECHARGEPRESSUREISESTABLISHEDASSHOWNINMODELCODE INCREASE

ENGINESPEEDTONORMALOPERATINGRPMTOFURTHERPURGERESIDUALAIRFROMTHESYSTEM
3HUTOFFTHEENGINE#ONNECTTHEPUMPCONTROLSIGNAL3TARTTHEENGINECHECKINGTO

BECERTAINTHEPUMPREMAINSINNEUTRAL2UNTHEENGINEATNORMALOPERATINGSPEED
ANDCAREFULLYCHECKFORFORWARDANDREVERSECONTROLOPERATION
#ONTINUETOCYCLEBETWEENFORWARDANDREVERSEFORATLEASTlVEMINUTESTOBLEEDALL
AIRANDmUSHSYSTEMCONTAMINANTSOUTOFLOOP
.ORMALCHARGEPRESSUREmUCTUATIONMAYOCCURDURINGFORWARDANDREVERSEOPERATION
#HECKTHATTHERESERVOIRISFULL2EMOVECHARGEPRESSUREGAUGE4HEPUMPISNOW
READYFOROPERATION
560 BOMAG 008 918 12

Travel pump 18.1
Service Manual
0RESSUREMEASUREMENT
REQUIRED TOOLS 9OUCANPERFORMTHESERVICEPROCEDURESDESCRIBEDINTHISMANUALUSINGCOMMON

MECHANICSTOOLS3PECIALTOOLSIFREQUIREDARESHOWN5SECALIBRATEDPRESSUREGAUGESTO
ENSUREACCURACY5SESNUBBERSTOPROTECTPRESSUREGAUGES
PORT LOCATIONS AND 4HEFOLLOWINGSECTIONSLISTTHEPORTSFOREACHTYPEOFHYDRAULICUNIT4HElTTINGSIZEAND

GAUGE INSTALLATION RECOMMENDEDPRESSUREGAUGEAREALSOSPECIlED
4HEFOLLOWINGTABLEANDDRAWINGSSHOWTHEPORTLOCATIONSANDGAUGESIZESNEEDED
Port information
Port identifier Pressure obtained Gauge size Port size
M1, M2 3YSTEMPRESSURE BAR;PSI=
M3 (M6) #HARGEPRESSURE BAR;PSI=
M4, M5 Servo pressure BAR;PSI=
L1, L2 #ASEPRESSURE BAR;PSI=

X1, X2 ($#%$#CONTROLPRESSURE BAR;PSI= OR
X3 %XTERNALCONTROLPRESSURE BAR;PSI=
S #HARGEPUMPINLET 6ACUUMGAUGE
4EEINTOINLETLINE

3!% SPLITmANGE
008 918 12 BOMAG 561
18.1 Travel pump
Service Manual
0RESSUREMEASUREMENT
PORT LOCATIONS AND

GAUGE INSTALLATION
(continued)
Pump with side port end cap and manual displacement control
Case drain Servo / displacement

port L1 cylinder pressure
gauge port M4
Servo / displacement
System pressure cylinder pressure
port B gauge port M5
External control pressure
System pressure supply port X3
gauge port M2
Speed sensor
Charge inlet pressure

(vacuum)
System pressure
gauge port M1
Carge pump
inlet port S System pressure
port A Case drain port L2 Charge pressure
gauge port M3 P106 158E
562 BOMAG 008 918 12

Travel pump 18.1
Service Manual
0RESSUREMEASUREMENT
PORT LOCATIONS AND

GAUGE INSTALLATION
(continued)
Pump with twin port end cap and manual displacement control
cylinder pressure
gauge port M4
Case drain
port L1
cylinder pressure
gauge port M5
System pressure
gauge port M2
System pressure
port B
Charge pump inlet

port S
System pressure
port A
System pressure
gauge port M1
Case drain port L2
P106 160E
Pump with side port end cap and remote pressure filtration Pump with side port end cap and integral pressure
filtration
Charge pressure
gauge port M6 Port E
(before the filter) (from filter)
Port D
(to filter)
Charge pressure
gauge port M3
Charge pressure (back side-after
gauge port M3 the filter)
(after the filter)
P106 163E
008 918 12 BOMAG 563
18.1 Travel pump
Service Manual
4ROUBLESHOOTING
OVERVIEW 4HISSECTIONPROVIDESGENERALSTEPSTOFOLLOWIFCERTAINUNDESIRABLESYSTEMCONDITIONS
OCCUR&OLLOWTHESTEPSINASECTIONUNTILYOUSOLVETHEPROBLEM3OMEOFTHEITEMS
ARESYSTEMSPECIlC&ORAREASCOVEREDINTHISMANUALWEREFERENCETHESECTION!LWAYS
OBSERVETHESAFETYPRECAUTIONSLISTEDINTHEIntroductionSECTIONPAGE ANDTHOSE
RELATINGTOYOURSPECIlCEQUIPMENT
NEUTRAL DIFFICULT OR
IMPOSSIBLE TO FIND
Item Description Action

)NPUTTOPUMPCONTROL )NPUTTOCONTROLMODULEISOPERATINGIMPROPERLY #HECKCONTROLINPUTANDREPAIRORREPLACEASNECESSARY
0UMPDISPLACEMENTCONTROL #ONTROLLINAGESARENOTSECURECONTROLORIlCESARE !DJUSTREPAIRORREPLACECONTROLMODULEASNECESSARY
BLOCKED
-ULTIFUNCTIONVALVE -ULTIFUNCTIONVALVEISLEAKING 3WAPMULTIFUNCTIONVALVES)FSYSTEMCHANGESDIRECTION
REPLACEDEFECTIVEVALVE
SYSTEM OPERATING HOT

Oil level in reservoir )NSUFlCIENTHYDRAULICmUIDWILLNOTMEETCOOLING &ILLRESERVOIRTOPROPERLEVEL
DEMANDSOFSYSTEM
(EATEXCHANGER (EATEXCHANGERISNOTSUFlCIENTLYCOOLINGTHE #HECKAIRmOWANDINPUTAIRTEMPERATUREFORHEAT
SYSTEM EXCHANGER#LEANREPAIRORREPLACEHEATEXCHANGER
#HARGEPRESSURE ,OWCHARGEPRESSUREWILLOVERWORKSYSTEM -EASURECHARGEPRESSURE)NSPECTANDADJUSTORREPLACE
CHARGERELIEFVALVEORREPAIRLEAKYCHARGEPUMP
#HARGEPUMPINLETVACUUM (IGHINLETVACUUMWILLOVERWORKSYSTEM!DIRTY #HECKCHARGEINLETVACUUM)FHIGHINSPECTINLETlLTERAND
lLTERWILLINCREASETHEINLETVACUUM)NADEQUATELINE REPLACEASNECESSARY#HECKFORADEQUATELINESIZELENGTH
SIZEWILLRESTRICTmOW OROTHERRESTRICTIONS
3YSTEMRELIEFPRESSURESETTINGS )FTHESYSTEMRELIEFSETTINGSARETOOLOWTHERELIEF 6ERIFYSETTINGSOFPRESSURELIMITERSANDHIGHPRESSURE
VALVESWILLBEOVERWORKED RELIEFVALVESANDADJUSTORREPLACEMULTI FUNCTIONVALVES
ASNECESSARY
&ORINTERNALLEAKAGEINMOTOR ,EAKAGEWILLREDUCELOWSIDESYSTEMPRESSUREAND -ONITORMOTORCASEmOWWITHOUTLOOPmUSHINGINTHE
OVERWORKTHESYSTEM CIRCUITUSEDEFEATSPOOL )FmOWISEXCESSIVEREPLACE
MOTOR
3YSTEMPRESSURE (IGHSYSTEMPRESSUREWILLOVERHEATSYSTEM -EASURESYSTEMPRESSURE)FPRESSUREISHIGHREDUCELOADS
564 BOMAG 008 918 12

Travel pump 18.1
Service Manual
4ROUBLESHOOTING
TRANSMISSION
OPERATES NORMALLY IN
ONE DIRECTION ONLY

)NPUTTOPUMPCONTROL )NPUTTOCONTROLMODULEISOPERATINGIMPROPERLY #HECKCONTROLINPUTANDREPAIRORREPLACEASNECESSARY
0UMPDISPLACEMENTCONTROL #ONTROLLINKAGESARENOTSECURECONTROLORIlCESARE 2EPAIRORREPLACECONTROLMODULEASNECESSARY
BLOCKED
3YSTEMPRESSURELIMITERSHIGH )NTERCHANGINGTHEMULTI FUNCTIONVALVESWILLSHOW )NTERCHANGEMULTI FUNCTIONVALVES)FTHEPROBLEM
PRESSURERELIEFVALVESORSYSTEM IFTHEPROBLEMISRELATEDTOTHEVALVEFUNCTIONS CHANGESDIRECTIONREPAIRORREPLACETHEVALVEONTHESIDE
CHECKVALVES CONTAINEDINTHEMULTI FUNCTIONVALVES THATDOESNOTOPERATE
#HARGEPRESSURE )FCHARGEPRESSUREDECAYSINONEDIRECTIONTHELOOP -EASURECHARGEPRESSUREINFORWARDANDREVERSE)F
mUSHINGVALVEMAYBESTICKINGINONEDIRECTION PRESSUREDECAYSINONEDIRECTIONINSPECTANDREPAIRTHE
MOTORLOOPmUSHINGVALVE
SYSTEM WILL NOT

OPERATE IN EITHER
DIRECTION

Oil level in reservoir )NSUFlCIENTHYDRAULICmUIDTOSUPPLYSYSTEMLOOP &ILLRESERVOIRTOPROPERLEVEL
)NPUTTOPUMPCONTROL )NPUTTOCONTROLMODULEISOPERATINGIMPROPERLY #HECKCONTROLINPUTANDREPAIRREPLACEASNECESSARY
0UMPDISPLACEMENTCONTROL #ONTROLLINKAGEISNOTSECURECONTROLORIlCESARE 2EPAIRORREPLACECONTROLMODULEASNECESSARY
BLOCKEDETC
"YPASSVALVES OPEN )FBYPASSVALVES AREOPENTHESYSTEMLOOPWILLBE #LOSEBYPASSVALVES2EPLACEMULTI FUNCTIONVALVEIF
DEPRESSURIZED DEFECTIVE
#HARGEPRESSUREWITHPUMPIN ,OWCHARGEPRESSUREISINSUFlCIENTTORECHARGE -EASURECHARGEPRESSUREWITHTHEPUMPINNEUTRAL)F
NEUTRAL SYSTEMLOOP PRESSUREISLOWGOTOPump charge relief valveOTHERWISE
CONTINUEWITHCharge pressure with pump in stroke.
#HARGEPRESSUREWITHPUMPIN ,OWCHARGEPRESSUREWITHTHEPUMPINSTROKE -EASURECHARGEPRESSUREWITHPUMPINSTROKE)FPRESSURE
STROKE INDICATESAMOTORCHARGERELIEFVALVEORSYSTEM ISLOWADJUSTORREPLACEMOTORCHARGERELIEFVALVE
PRESSURERELIEFVALVEMAYBEIMPROPERLYSET OTHERWISEGOTOCharge pumps.
0UMPCHARGERELIEFVALVE !PUMPCHARGERELIEFVALVETHATISLEAKYORSETTOOLOW !DJUSTORREPLACEPUMPCHARGERELIEFVALVEASNECESSARY
WILLDEPRESSURIZETHESYSTEM
#HARGEPUMPINLETlLTER !CLOGGEDlLTERWILLUNDERSUPPLYSYSTEMLOOP )NSPECTlLTERANDREPLACEIFNECESSARY
#HARGEPUMPS !MALFUNCTIONINGCHARGEPUMPWILLPROVIDE 2EPAIRORREPLACETHECHARGEPUMP
INSUFlCIENTCHARGEmOW
0UMPDISPLACEMENTCONTROL #ONTROLLINKAGESARENOTSECURECONTROLORIlCESARE 2EPAIRORREPLACECONTROLMODULEASNECESSARY
BLOCKED
3YSTEMPRESSURE ,OWSYSTEMPRESSUREWILLNOTPROVIDEPOWER -EASURESYSTEMPRESSURE#ONTINUETONEXTSTEP
NECESSARYTOMOVELOAD
3YSTEMMULTI FUNCTIONVALVES $EFECTIVEMULTI FUNCTIONVALVESWILLCAUSESYSTEMTO 2EPAIRORREPLACEMULTI FUNCTIONVALVES
PRESSURETOBELOW
008 918 12 BOMAG 565
18.1 Travel pump
Service Manual
4ROUBLESHOOTING
LOW MOTOR OUTPUT

TORQUE

3YSTEMPRESSUREATMOTOR ,OWSYSTEMPRESSUREATTHEMOTORWILLREDUCETORQUE -EASURESYSTEMPRESSUREATMOTOR)FPRESSURELIMITER
SETTINGISLOWINCREASESETTING
6ARIABLEMOTORSTUCKAT -INIMUMMOTORDISPLACEMENTYIELDSLOWOUTPUT #HECKCONTROLSUPPLYPRESSUREORREPAIRDISPLACEMENT
MINIMUMDISPLACEMENT TORQUE CONTROL#HECKMOTORCONTROLORIlCES
)NTERNALLEAKAGE )NTERNALLEAKAGEWILLREDUCESYSTEMPRESSURE #HECKFORLEAKING/ RINGSGASKETSANDOTHERlTTINGS
2EPAIRUNITASREQUIREDORREPLACELEAKINGUNIT
IMPROPER MOTOR
OUTPUT SPEED

Oil level in reservoir )NSUFlCIENTHYDRAULICmUIDWILLREDUCEMOTORSPEED &ILLOILTOPROPERLEVEL
0UMPOUTPUTmOW )NCORRECTOUTmOWWILLAFFECTOUTPUTSPEED)NCORRECT -EASUREPUMPOUTPUTANDCHECKFORPROPERPUMPSPEED
OUTPUTmOWINDICATESTHESWASHPLATEISOUTOF %NSURETHEPUMPISINFULLSTROKE
POSITION
6ARIABLEMOTORDISPLACEMENT )FVARIABLEMOTORDISPLACEMENTCONTROLISNOT 3EEIFVARIABLEMOTORDISPLACEMENTCONTROLISRESPONDING
CONTROL FUNCTIONINGCORRECTLYVARIABLEMOTORSWASHPLATEMAY )FNOTREPAIRORREPLACECONTROL
BEINWRONGPOSITION
)NTERNALLEAKAGE )NTERNALLEAKAGEWILLREDUCESYSTEMPRESSURE #HECKFORLEAKING/ RINGSGASKETSANDOTHERlTTINGS
2EPAIRUNITASREQUIREDORREPLACELEAKYUNIT
SYSTEM NOISE OR
VIBRATION

Oil in reservoir )NSUFlCIENTHYDRAULICmUIDWILLLEADTOCAVITATION &ILLRESERVOIRTOPROPERLEVEL
!IRINSYSTEM !IRBUBBLESWILLLEADTOCAVITATION ,OOKFORFOAMINRESERVOIR#HECKFORLEAKSONINLETSIDE
SYSTEMLOOPANDREPAIR!FTERWARDSLETRESERVOIRSETTLE
UNTILFOAMDISSIPATES2UNSYSTEMATLOWSPEEDTOMOVE
SYSTEMmUIDTORESERVOIR2EPEAT
0UMPINLETVACUUM (IGHINLETVACUUMCAUSESNOISE!DIRTYlLTERWILL )NSPECTANDREPLACElLTERASNECESSARY#HECKFORPROPER
INCREASETHEINLETVACUUM SUCTIONLINESIZE
3HAFTCOUPLINGS !LOOSESHAFTCOUPLINGWILLCAUSEEXCESSIVENOISE 2EPLACELOOSESHAFTCOUPLINGORREPLACEPUMPORMOTOR
3HAFTALIGNMENT -ISALIGNEDSHAFTSCAUSENOISE !LIGNSHAFTS
566 BOMAG 008 918 12

Travel pump 18.1
Service Manual
4ROUBLESHOOTING
SYSTEM RESPONSE IS
SLUGGISH

Oil level in reservoir )NSUFlCIENTHYDRAULICmUIDCAUSESSLUGGISHRESPONSE &ILLRESERVOIRTOPROPERLEVEL
-ULTI FUNCTIONVALVESPRESSURE )NCORRECTPRESSURESETTINGSAFFECTSSYSTEMREACTION !DJUSTORREPLACEMULTI FUNCTIONVALVES
SETTINGS TIME
0UMPINLETVACUUM (IGHPUMPINLETVACUUMREDUCESSYSTEMPRESSURE -EASURECHARGEINLETVACUUM)FHIGHREPLACEINLETlLTER
0RIMEMOVERSPEED ,OWENGINESPEEDREDUCESSYSTEMPERFORMANCE !DJUSTENGINESPEED
#HARGEANDCONTROLPRESSURES )NCORRECTCHARGEORCONTROLPRESSURESAFFECTSSYSTEM -EASURECHARGEANDCONTROLPRESSURESANDCORRECTIF
performance. NECESSARY
3YSTEMINTERNALLEAKAGE )NTERNALLEAKAGEREDUCESSYSTEMPRESSURE #HECKFORLEAKAGEIN/ RINGSGASKETSANDOTHERlTTINGS
008 918 12 BOMAG 567
18.1 Travel pump
Service Manual
!DJUSTMENTS
STANDARD
PROCEDURES, "EFOREWORKINGONTHEPUMPCLEANTHEOUTSIDEOFTHEPUMP
INSPECTIONS, AND
ADJUSTMENTS
CCaution
#ONTAMINATIONCANDAMAGEINTERNALCOMPONENTSANDVOIDYOURWARRANTY4AKE
PRECAUTIONSTOENSURESYSTEMCLEANLINESSWHENREMOVINGANDREINSTALLINGSYSTEMLINES
7ITHTHEPRIMEMOVEROFFTHOROUGHLYCLEANTHEOUTSIDEOFTHEPUMP
)FREMOVINGTHEPUMPTAGEACHHYDRAULICLINECONNECTEDTOTHEPUMP)FHYDRAULIC

LINESAREDISCONNECTEDPLUGEACHOPENPORTWITHACLEANPLUGTOENSURETHATDIRTAND
CONTAMINATIONDONOTGETINTOTHEPUMP
%NSURETHESURROUNDINGAREASARECLEANANDFREEOFCONTAMINANTS
)NSPECTTHESYSTEMFORCONTAMINATION
6ISUALLYINSPECTTHEHYDRAULICmUIDFORSIGNSOFSYSTEMCONTAMINATIONmUID

DISCOLORATIONFOAMINTHEmUIDSLUDGEORSMALLMETALPARTICLES
)FTHEREARESIGNSOFCONTAMINATIONINTHEHYDRAULICmUIDREPLACEALLlLTERSDRAINAND

mUSHTHEHYDRAULICSYSTEMANDlLLWITHTHECORRECTlLTEREDHYDRAULICmUID
&LUSHTHELINESBEFOREREPLACINGTHEHYDRAULICmUID
568 BOMAG 008 918 12

Travel pump 18.1
Service Manual
!DJUSTMENTS
ADJUSTMENTS 4HISSECTIONOFFERSINSTRUCTIONONINSPECTIONANDADJUSTMENTOFPUMPCOMPONENTS2EAD
THROUGHTHEENTIRERELATEDSECTIONBEFOREBEGINNINGASERVICEACTIVITY2EFERTOPressure
measurementsPAGESANDFORLOCATIONOFGAUGEPORTSANDSUGGESTEDGAUGE
SIZES
CHARGE PRESSURE 4HEFOLLOWINGPROCEDUREEXPLAINSHOWTOCHECKANDADJUSTTHECHARGEPRESSURERELIEF

RELIEF VALVE valve.
ADJUSTMENT
)NSTALLABAR;PSI=PRESSUREGAUGEINTHEPUMPCHARGEPRESSUREGAUGEPORT
W Warning - )NSTALLABAR;PSI=GAUGETOMEASURECASEPRESSURETEEINTO,OR,OR
4HEFOLLOWINGPROCEDURE USESERVOGAUGEPORT-OR- /PERATETHESYSTEMWITHTHEPUMPINNEUTRALZERO
MAYREQUIRETHEVEHICLE DISPLACEMENT WHENMEASURINGPUMPCHARGEPRESSURE
MACHINETOBEDISABLED
WHEELSRAISEDOFFTHE 4HETABLESHOWSTHEACCEPTABLEPUMPCHARGEPRESSURERANGEFORSOMECHARGERELIEF
GROUNDWORKFUNCTION VALVESETTINGS4HESEPRESSURESASSUMEMINÂRPM ANDARESERVOIRTEMPERATURE
DISCONNECTEDETC INORDER OF²#;²&=ANDAREREFERENCEDTOCASEPRESSURE
TOPREVENTINJURYTOTHE
TECHNICIANANDBYSTANDERS
4AKENECESSARYSAFETY Charge pressure relief valve
Case drain port L1
PRECAUTIONSBEFOREMOVING
THEVEHICLEMACHINE M4 G )(*!
K90 B 1 1/16-12
Adjusting screw t .% $.t]
K10 M5
Lock nut
.% $.t]
Charge pressure gauge port M3

G )(*!
B

t .%$.t]
(()'()!++$ P106 162E
,ISTEDPRESSURESASSUMEAPUMPSPEED Charge pressure ranges

OFMIN-1RPM !THIGHERPUMP Model code Measured charge pressure*
INPUTSPEEDSWITHHIGHERCHARGEmOWS nBAR
20
THECHARGEPRESSUREWILLRISEOVERTHE ;nPSI=
RATEDSETTING nBAR

;nPSI=
nBAR

;nPSI=

4HISISTHEACTUALCHARGEPRESSUREPORTGAUGE
READINGMINUSTHECASEPRESSUREPORTGAUGE
READING
008 918 12 BOMAG 569
18.1 Travel pump
Service Manual
!DJUSTMENTS
CHARGE PRESSURE %ARLIERPRODUCTION3ERIESPUMPSHAVEASHIMADJUSTABLECHARGEPRESSURERELIEF

RELIEF VALVE VALVE3HIMKITSAREAVAILABLEFROM3AUER $ANFOSS2EMOVETHEPLUGUSINGAINHEX
ADJUSTMENT WRENCHANDEXCHANGESHIMSBEHINDTHESPRINGTOADJUSTCHARGEPRESSURE4ORQUE
(continued) PLUGTO.sM;LBFsFT=
,ATERPRODUCTION3ERIESPUMPSHAVEANEXTERNALSCREW ADJUSTABLECHARGE

PRESSURERELIEFVALVE,OOSENLOCKNUT+ ANDTURNTHEADJUSTINGSCREW+ USINGA
SCREWDRIVERORINHEXWRENCHTOADJUSTCHARGEPRESSURESETTING
Lock nut wrench size

Frame size Wrench size
n INCH
n INCH
#LOCKWISEROTATIONOFTHEPLUGINCREASESTHESETTINGANDCOUNTERCLOCKWISEROTATION
DECREASESTHESETTINGATARATEOFAPPROXIMATELYBAR;PSI=PERTURN 4ORQUE
LOCKNUTTO.sM;LBFsFT=
/NCEYOUACHIEVETHEDESIREDCHARGEPRESSURESETTINGREMOVETHEGAUGESANDPLUG

THEPORTS
570 BOMAG 008 918 12

Travel pump 18.1
Service Manual
!DJUSTMENTS
MULTI-FUNCTION VALVE 9OUACCOMPLISHADJUSTMENTOFTHEPRESSURELIMITERSETTINGANDTHEHIGHPRESSURERELIEF

PRESSURE ADJUSTMENT VALVE(026 SETTINGSIMULTANEOUSLY4HE(026SETTINGISAUTOMATICALLYSETAPPROXIMATELY
BAR;PSI=ABOVETHEPRESSURELIMITERSETTING
W7ARNING ,OCKTHEMOTOROUTPUTSHAFTBYLOCKINGTHEVEHICLESBRAKESORRIGIDLYlXINGTHEWORK
4AKENECESSARYPRECAUTIONS FUNCTIONSOITCANNOTROTATEORCAPTHESYSTEMPORTSW
THATTHEMOTORSHAFT
REMAINSSTATIONARYDURING
THEADJUSTMENTPROCEDURE
Multi-function valve adjustment
Charge pressure gauge port M3

G 0 - 50 bar [0 - 1000 psi]
B 9/16-18
t 1%$1t]
I Adjusting screw
h Lo#&-,+%$$* /&-,
tLock nut torque ((*'(*!,,$
System pressure gauge port M2

G 0 - 1000 bar [0 - 10000 psi]
B 9/16-18
t 1%$1t]
System pressure gauge port M1
G 0 - 1000 bar [0 - 10000 psi]
B 9/16-18
t 1%$1t]
P106 168E
)NSTALLTWOBARORPSI PRESSUREGAUGESINTHEHIGHPRESSUREGAUGE

PORTS-AND- )NSTALLABARORPSI PRESSUREGAUGEINTHEPUMPCHARGE
PRESSUREGAUGEPORT-
3TARTTHEPRIMEMOVERANDOPERATEATNORMALSPEED
,OOSENLOCKINGNUT
)NSERTANINTERNALHEXWRENCHINTOTHEPRESSUREADJUSTINGSCREW
!PLASTICDUSTPLUGISINSTALLEDINTHEADJUSTINGSCREW
008 918 12 BOMAG 571
18.1 Travel pump
Service Manual
!DJUSTMENTS
MULTI-FUNCTION VALVE 4HEMODELCODESHOWSTHEFACTORYPRESETPRESSURELIMITERSETTING)TISREFERENCEDTO

PRESSURE ADJUSTMENT CHARGEPRESSURESOTHEPRESSURELIMITERSETTINGISTHEDIFFERENCEBETWEENTHEHIGH
(continued) ANDLOWPRESSURESIDESOFTHESYSTEMLOOP!CTIVATEORMOVETHECONTROLINPUTSO
THATPRESSUREINCREASESINTHEHIGHPRESSURESIDEOFTHECLOSEDCIRCUITTOTHEPRESSURE
LIMITERPRESSURESETTING4HEPRESSURELIMITERSETTINGISREACHEDWHENTHEPRESSURE
STOPSINCREASINGANDREMAINSSTEADYATAGIVENPRESSURELEVELASSHOWNONTHE
GAUGES
2ETURNTHEPUMPTOITSNEUTRALZEROmOW POSITIONANDADJUSTTHEPRESSURELIMITER

SETTINGBYROTATINGTHEPRESSUREADJUSTINGSCREWWITHANINTERNALHEXWRENCH
#LOCKWISEROTATIONOFTHEPRESSUREADJUSTMENTSCREWINCREASESTHEPRESSURESETTING
ANDCOUNTERCLOCKWISEROTATIONDECREASESTHEPRESSURESETTING%ACHCOMPLETE
ROTATIONOFTHEPRESSUREADJUSTINGSCREWCHANGESTHEPRESSUREASSHOWNINTHE
FOLLOWINGTABLE
Pressure limiter adjustment data

Frame size Lock nut wrench size and torque Adjusting Approximate pressure change
screw size per revolution of adjusting screw
EARLY MM.sM;LBFsIN= MM BAR;PSI=
MM.sM;LBFsFT= MM BAR;PSI=
EARLY MM.sM;LBFsFT= MM BAR;PSI=
MM.sM;LBFsFT= MM BAR;PSI=
4OVERIFYTHEACTUALPRESSURESETTINGACTUATEORMOVETHECONTROLINPUTSOTHATTHE

PUMPAGAINDEVELOPSPRESSUREINTHEHIGHPRESSURECIRCUITTOTHENEWLYADJUSTED
PRESSURELIMITERPRESSURESETTINGTHENREADTHEHIGHPRESSUREGAUGE!LLOWTHEPUMP
TORETURNTOITSNEUTRALPOSITION4HEPRESSUREINTHEHIGHPRESSURECIRCUITSHOULD
RETURNTOTHECHARGEPRESSURESETTING
7HILEHOLDINGTHEPRESSUREADJUSTINGSCREWSTATIONARYTIGHTENTHEPRESSUREADJUSTING

SCREWLOCKNUT4ORQUEASSHOWNINTHETABLE
$ONOTOVERTORQUE
3HUTDOWNTHEPRIMEMOVERREMOVETHEGAUGESANDINSTALLTHEGAUGEPORTPLUGS

2EPLACETHEPLASTICDUSTPLUGSIFUSED
5SETHESAMEPROCEDUREFORSETTINGTHEPRESSURELIMITOFTHEOTHERMULTI FUNCTIONVALVE
-OVEORACTIVATETHECONTROLINPUTSIGNALINTHEOPPOSITEDIRECTIONSOTHATHIGHPRESSURE
DEVELOPSINTHEOPPOSITESIDEOFTHECLOSEDCIRCUIT
572 BOMAG 008 918 12

Travel pump 18.1
Service Manual
!DJUSTMENTS
ENGAGING THE BYPASS 4HEMULTI FUNCTIONVALVECARTRIDGESPERFORMTHEBYPASSFUNCTION3HUTDOWNTHEPRIME

FUNCTION MOVERWHENENGAGINGTHEBYPASSFUNCTION/PENBOTHTHEBYPASSVALVESTOENGAGETHE
BYPASSFUNCTION
C#AUTION LOOSENTHEBYPASSACTUATORTHREE Bypass actuator wrench size

$AMAGETOTHEPUMPAND TURNS2EFERTOTABLEFORWRENCHSIZE Frame size Wrench size
MOTORCANRESULTFROM NEWERn INCH
ROTATINGTHESECOMPONENTS $ONOTROTATEMORETHAN n INCH
WITHOUTCHARGEmOWFOR REVOLUTIONSASADDITIONALROTATIONWILL
LUBRICATION"YPASSVALVES PERMITEXTERNALLEAKAGE Multi-Function Valve with Bypass
AREINTENDEDFORMOVING Function Engaged
AMACHINEORVEHICLEFOR &ORUNITSWITHAN-$# TYPECONTROL Opening bypass valve
allows flow to circuit
VERYSHORTDISTANCESATVERY PRIORTOMOVINGTHEVEHICLEOR Bypass through multi-function valves
SLOWSPEEDS4HEYARENOT OTHERWISECAUSINGTHEMOTORSHAFT actuator
TOWVALVES TOTURNMOVETHECONTROLHANDLEOF

THEMANUALDISPLACEMENTCONTROL
ONTHEPUMPTOTHEMAXIMUMFULL
FORWARDPOSITION(OLDTHEHANDLE
INTHISPOSITIONDURINGBYPASSVALVE
OPERATION
P104 144E
4OCLOSETHEBYPASSVALVETIGHTENTHE

BYPASSACTUATOR3EETABLEPROVIDED Bypass actuator torque
FORPROPERTORQUE Frame size Torque
NEWERn .sM;LBFsFT=
n .sM;LBFsFT=
008 918 12 BOMAG 573
18.1 Travel pump
Service Manual
!DJUSTMENTS
PRESSURE OVERRIDE 0RESSUREOVERRIDEVALVEOPERATIONIS Pressure override valve for 180 frame size
(POR) VALVE PRESSURE EXPLAINEDINTHEOperation section
ADJUSTMENT (OPTION PAGE Pressure override valve Adjusting screw
FOR 180 FRAME SIZE) Lock nut
)NSTALLTWOBAR;PSI=
PRESSUREGAUGESINTHEHIGHPRESSURE
GAUGEPORTS-AND- )NSTALLA
BAR;PSI=PRESSUREGAUGEIN
W Warning THEPUMPCHARGEPRESSUREGAUGE
5NINTENDEDMOVEMENTOF PORT-
THEMACHINEORMECHANISM
MAYCAUSEINJURYTOTHE 3TARTTHEPRIMEMOVERANDOPERATEAT
TECHNICIANORBYSTANDERS NORMALSPEED
4OPROTECTAGAINST P104 145E
UNINTENDEDMOVEMENT 7ITHTHEPUMPOPERATINGAT

SECURETHEMACHINE APPROXIMATELYDISPLACEMENT
ORDISABLEDISCONNECT LOADTHEWORKFUNCTIONANDNOTETHEPRESSUREASTHE0/2VALVEOPERATESPUMP
THEMECHANISMWHILE DISPLACEMENTREDUCESTOZERO
SERVICING
!DJUSTTHEPRESSUREOVERRIDESETTINGBYLOOSENINGTHELOCKNUTWITHAINCHHEX
WRENCHANDTURNINGTHEADJUSTMENTSCREWWITHAINCHINTERNALHEXWRENCH
3ETTHE0/2SETTINGTOATLEASTBAR;PSI=BELOWTHEHIGHPRESSURERELIEFVALVE
SETTINGOFTHEMULTI FUNCTIONVALVES
4ORQUETHELOCKNUTTO.sM;LBFsFT=
3HUTDOWNTHEPRIMEMOVERANDREMOVETHEGAUGESANDINSTALLTHEGAUGEPORT
PLUGS
574 BOMAG 008 918 12

Travel pump 18.1
Service Manual
!DJUSTMENTS
DISPLACEMENT LIMITER 9OUCANLIMITTHEMAXIMUMDISPLACEMENTINEITHERDIRECTION

ADJUSTMENT
,OOSENTHELOCKNUT& WHILE Displacement limiter adjustment
HOLDINGTHEADJUSTINGSCREW&
STEADY
2OTATETHEADJUSTINGSCREWSOME
C#AUTION AMOUNTUSINGINFORMATIONINTHE
4AKECAREINADJUSTING FOLLOWINGTABLE C2OTATINGTHE
DISPLACEMENTLIMITERSTO ADJUSTINGSCREWCLOCKWISEDECREASES
AVOIDUNDESIRABLEmOWOR THEMAXIMUMDISPLACEMENTOFTHE
SPEEDCONDITIONS2E PUMPWHILEROTATINGTHEADJUSTING
TORQUELOCKNUT& SCREWCOUNTERCLOCKWISEINCREASES
AFTEREVERYADJUSTMENTTO THEMAXIMUMDISPLACEMENT
PREVENTANUNEXPECTED
F213
CHANGEINOPERATING /NETURNOFTHEADJUSTINGSCREW IAdjusting screw
CONDITIONSANDTOPREVENT CHANGESTHEMAXIMUMDISPLACEMENT
EXTERNALLEAKAGEDURING ASSHOWNINTABLEBELOW F212
Lock nut
UNITOPERATION
Lock nut torque
!FTERESTABLISHINGTHEDESIRED
MAXIMUMDISPLACEMENTSETTING
TORQUETHELOCKNUTTOTHETORQUE P106 164E
SHOWNINTABLEBELOW
Frame size Lock nut wrench size and torque Adjusting Approximate displacement change
screw size per revolution of adjusting screw
MM.sM;LBFsFT= MM CMÃREV ;INÃREV=
MM.sM;LBFsFT= MM CMÃREV ;INÃREV=
MM.sM;LBFsFT= MM CMÃREV;INÃREV=
100 MM.sM;LBFsFT= MM CMÃREV;INÃREV=
MM.sM;LBFsFT= 6 mm CMÃREV;INÃREV=
MM.sM;LBFsFT= 6 mm CMÃREV;INÃREV=
STANDARD MANUAL 4HEREARENOADJUSTABLEELEMENTSINTHEMANUALDISPLACEMENTCONTROL#ENTERINGSPRINGS

DISPLACEMENT ANDWASHERSONEACHENDOFTHECONTROLSPOOLHOLDITINITSNEUTRALPOSITION3INCETHERE
CONTROL (MDC) ISNOCENTERINGSPRINGONTHECONTROLINPUTSHAFTTHESHAFTAUTOMATICALLYASSUMESTHE
ADJUSTMENT APPROPRIATEPOSITIONWHENTHECONTROLISINSTALLEDONTHEPUMP
008 918 12 BOMAG 575
18.1 Travel pump
Service Manual
!DJUSTMENTS
NON-LINEAR MANUAL !CENTERINGSPRINGLOCATEDONTHECONTROLINPUTSHAFTLOCATESTHECONTROLSHAFTINITS

DISPLACEMENT NEUTRALPOSITION!BIASSPRINGONTHECONTROLSPOOLMAINTAINSAFORCEONTHESPOOLAND
CONTROL (MDC) THECONTROLLINKAGETOELIMINATEFREE PLAYINTHELINKAGE
.EUTRALADJUSTMENTISTHEONLYADJUSTMENTTHATCANBEMADEONTHENONLINEARMANUAL
DISPLACEMENTCONTROL!LLOTHERFUNCTIONSAREPRESETATTHEFACTORY0ERFORMNEUTRAL
ADJUSTMENTONATESTSTANDORONTHEVEHICLEMACHINEWITHTHEPRIMEMOVEROPERATING
W Warning
MDC neutral adjustment

Servo pressure gauge port M5
0 - 50 bar [0 - 1000 psi]
Servo pressure gauge port M4 9/16-18
$ $t]
G 0 - 50 bar [0 - 1000 psi]
B 9/16-18 M72
t $ $t] I
M90

$$t]
P106 165E
)NSTALLABAR;PSI=GAUGEINEACHOFTHETWOSERVOCYLINDERGAUGEPORTS-
AND- $ISCONNECTTHEEXTERNALCONTROLLINKAGEFROMTHECONTROLHANDLEANDMAKE
CERTAINTHECONTROLSHAFTISINITSNEUTRALPOSITION3TARTTHEPRIMEMOVERANDOPERATE
ATNORMALSPEED
,OOSENTHELOCKNUT- ONTHENEUTRALADJUSTINGSCREW- WITHAMMHEX

WRENCH
5SINGAMMINTERNALHEXWRENCHROTATETHENEUTRALADJUSTINGSCREWCLOCKWISEUNTIL

THEPRESSUREINCREASESONONEOFTHEPRESSUREGAUGES.OTETHEANGULARPOSITIONOF
THEWRENCH4HENROTATETHEADJUSTINGSCREWCOUNTERCLOCKWISEUNTILTHEPRESSURE
INCREASESBYANEQUALAMOUNTONTHEOTHERGAUGE.OTETHEANGULARPOSITIONOFTHE
WRENCH
2OTATETHEADJUSTINGSCREWCLOCKWISEHALFTHEDISTANCEBETWEENTHELOCATIONSNOTED
ABOVE4HEGAUGESSHOULDREADTHESAMEPRESSUREINDICATINGTHATTHECONTROLISINITS
NEUTRALPOSITION
576 BOMAG 008 918 12

Travel pump 18.1
Service Manual
!DJUSTMENTS
NON-LINEAR MANUAL (OLDTHEADJUSTINGSCREWSTATIONARYANDTIGHTENTHELOCKNUTTO.sM;LBFsFT=

DISPLACEMENT $ONOTOVERTORQUETHENUT
CONTROL (MDC)
(continued) /NCETHENEUTRALPOSITIONISSETSTOPTHEPRIMEMOVERREMOVETHEGAUGESANDINSTALL
THEGAUGEPORTPLUGS2ECONNECTTHEEXTERNALCONTROLLINKAGE
MDC NEUTRAL 4HE.EUTRAL3TART3WITCH.33 PROVIDES MDC with neutral start switch

START SWITCH (NSS) AMEANSTOPREVENTTHESYSTEMPRIME
A A
ADJUSTMENTS MOVERFROMSTARTINGWHILETHEPUMP
CONTROLHANDLEISIN STROKE7HENTHE
Control shaft Switch cam
CONTROLINPUTSHAFTISINITSNEUTRAL
POSITIONTHESWITCHPINENGAGESASLOTON
THEECCENTRICCAMATTACHEDTOTHECONTROL Switch lock nut
SHAFT4HISALLOWSTHESPRINGLOADED Neutral start switch
.33TOCLOSECOMPLETINGTHEELECTRICAL
Eccentric plug
STARTINGCIRCUITFORTHEPRIMEMOVER
Switch pin
7HENTHECONTROLINPUTSHAFTISNOTINITS
Special lock nut
NEUTRALPOSITIONTHEECCENTRICCAMOPENS for eccentric plug
THE.33SWITCH
4HENEUTRALSTARTSWITCHISTHREADEDINTO View at section A-A

THESPECIALLOCKNUTFORTHEECCENTRIC
PLUG4URNINGTHE.33CLOCKWISE#7
MOVESTHE.33CLOSERTOTHESWITCH
CAMONTHECONTROLSHAFTANDNARROWS
THE.33DEADBAND4URNINGTHE.33
Orifice check valve seat
COUNTERCLOCKWISE##7 MOVESTHE Control spool assembly
.33FARTHERFROMTHESWITCHCAMON Control link assembly
THECONTROLSHAFTWIDENINGTHE.33 View A-A P104 146E
DEADBAND4HESWITCHPINISLOCATEDINAN
ECCENTRICPLUGWHICHISTURNEDTOMOVE
THECENTEROFTHE.33DEADBAND
008 918 12 BOMAG 577
18.1 Travel pump
Service Manual
!DJUSTMENTS
MDC NEUTRAL !DJUSTTHE.EUTRAL3TART3WITCHTOMEET Neutral start switch adjustment

START SWITCH (NSS) THEFOLLOWINGTHREEREQUIREMENTS requirements
ADJUSTMENTS NSS deadband Control shaft
(continued) I 4HEDISTANCEYOUCANMOVETHE (switch closed, ON) (free-play)
CONTROLHANDLEWITHOUTOPENING Control deadband
(neutral)
THE.33ISTHENSS deadband4HE
DISTANCEYOUCANMOVETHECONTROL Total control
HANDLEWITHOUTMOVINGTHECONTROL shaft rotation
SPOOLENOUGHTOPORTHYDRAULIC
mUIDTOTHEPUMPDISPLACEMENT Control shaft
CONTROLCYLINDERSISTHEcontrol
deadband4HESEDEADBANDSMUST
BECONCENTRIC
3INCEYOUCANNOTADJUSTTHEPOSITION
OFTHECONTROLDEADBANDYOUMUST
ADJUSTTHEPOSITIONOFTHE.33
DEADBANDTOMATCHIT
II 4HE.33DEADBANDMUSTBEWIDE
ENOUGHSOTHE.33WILLNOTOPEN
WITHINTHELOOSEAREAOFCONTROL
HANDLEMOVEMENTCAUSEDBYNORMAL P104 147E
OPERATINGCLEARANCESINTHECONTROL
LINKAGECONTROLSHAFTFREE PLAY
"YSETTINGTHE.33TOOPENOUTSIDETHISAREATHECONTROLSPOOLSPRINGSORCONTROL
SHAFTCENTERINGSPRINGCANALWAYSRETURNTHEHANDLETONEUTRALANDRE CLOSETHE.33
III 4HE.33DEADBANDMUSTBENARROWENOUGHSOTHE.33WILLOPENBEFORETHEUNIT
BUILDSBAR;PSI=DIFFERENTIALSYSTEMPRESSUREINEITHERDIRECTION
578 BOMAG 008 918 12

Travel pump 18.1
Service Manual
!DJUSTMENTS
MDC NEUTRAL Neutral start switch eccentric plug Eccentric plug adjustment tool
START SWITCH (NSS) adjustment (condition i)
12.7 9.14
ADJUSTMENTS #ENTERTHE.33DEADBANDANDTHE [0.5] [0.36]
(continued) CONTROLDEADBANDINRELATIONTOEACH
OTHER3INCEYOUCANNOTADJUSTTHE
POSITIONOFTHECONTROLDEADBANDYOU
MUSTADJUSTTHEPOSITIONOFTHE.33 3.175 1.52
[0.125] [0.06]
DEADBANDTOMATCHIT4HESWITCHPIN 25.4
ISLOCATEDINANECCENTRICPLUGWHICH [1.0]
YOUTURNTOMOVETHECENTEROFTHE.33
P104 149E
DEADBAND%NSURETHE-$#ISINSTALLED
ONTHEPUMPANDINITSNEUTRALPOSITION
WHENADJUSTINGTHENEUTRALSTARTSWITCH NSS with eccentric plug
ECCENTRICPLUG4HEACCOMPANYING
DRAWINGPROVIDESDIMENSIONSFORAN
ECCENTRICPLUGADJUSTMENTTOOL
(OLDTHESWITCHANDECCENTRICPLUG
FROMTURNINGANDUSEA INCH
WRENCHTOLOOSENTHELOCKNUT B
W 7ARNING 2EMOVETHENEUTRALSTARTSWITCHW Switch

Eccentric plug lock nut
$ONOTSTARTTHEPRIME Switch pin
B
MOVERWHILETHENEUTRAL .OTETHESLOTSONTHEECCENTRICPLUG Special lock nut
STARTSWITCHISREMOVED FORTHEADJUSTMENTTOOL(OLDTHE for eccentric plug Neutral start switch
FROMTHECONTROL#ASE ECCENTRICPLUGINPLACEWITHTHE
PRESSUREWILLFORCETHEPIN ADJUSTMENTTOOLANDLOOSENTHELOCK Special lock nut
for eccentric plug
OUTOFTHEECCENTRICPLUG NUTWITHA INCHWRENCH
Eccentric plug
CAUSINGOILLOSS Control
mounting
0OSITIONTHEECCENTRICPLUGSOTHE surface Switch pin
SWITCHPINISOFFSETTOWARDTHE
View B-B
CONTROLMOUNTINGSURFACE4HISWILL (switch and lock nut removed)
PROVIDETHEBESTCONTACTBETWEEN P104 150E
THEPINANDTHECAMONTHECONTROL
SHAFT
008 918 12 BOMAG 579
18.1 Travel pump
Service Manual
!DJUSTMENTS
MDC NEUTRAL (OLDTHECONTROLSHAFTINITSNEUTRAL Eccentric plug adjustment

START SWITCH (NSS) POSITIONINTHECENTEROFTHECONTROL Switch pin Eccentric plug
ADJUSTMENTS SHAFTFREE PLAYAREA ,OCATETHE
(continued) SWITCHPININTHESLOTOFTHESWITCH
CAMBYTURNINGTHEECCENTRICPLUG
WHILECHECKINGTHEPINPOSITION
DEPTH INTHEPLUG7HENTHEPIN 90° 90°
ENGAGESTHECAMSLOTTHEPINWILLBE
ATITSMAXIMUMDEPTHINTHEPLUG Control mounting Eccentric plug
adjustment range
(ANDTIGHTENTHEPLUGLOCKNUTTO surface
P104 151E
HOLDTHEECCENTRICPLUGINPOSITION
4URNTHECONTROLSHAFTANEQUAL
AMOUNTINEITHERDIRECTIONFROM
NEUTRAL4HESWITCHPINSHOULDMOVEOUTOFTHEECCENTRICPLUGANEQUALDISTANCE
WHENTHECONTROLSHAFTISTURNED4URNTHEECCENTRICPLUGTOCENTERTHESWITCHPIN
WITHTHECAMSLOT/NLYASMALLAMOUNTOFADJUSTMENTINEITHERDIRECTIONISNEEDEDTO
CENTERTHEPIN
7HILEHOLDINGTHEECCENTRICPLUGINPLACETIGHTENTHEECCENTRICPLUGLOCKNUTTO

.sM;LBFsFT=2EINSTALLANDADJUSTTHESWITCHASOUTLINEDINTHEPREVIOUSSECTION
4HEECCENTRICPLUGNORMALLYREQUIRESBETWEEN AND TURNSTOINSTALLINTOTHE

CONTROLHOUSING
C#AUTION
$ONOTTURNTHEECCENTRICPLUGINTOOROUTOFTHEHOUSINGBEYONDSPECIlCATIONS
/NCETHESWITCHISCORRECTLYADJUSTEDHOLDTHESWITCHINPLACEANDTIGHTENTHELOCK

NUTTO.sM;LBFsFT=TORQUE
NSS deadband adjustment (conditions ii & iii)

4HE.33DEADBANDMUSTBEWIDEENOUGHSOTHE.33WILLNOTOPENWITHINTHECONTROL
SHAFTFREE PLAYAREAANDITMUSTBENARROWENOUGHSOTHE.33WILLOPENBEFORETHEUNIT
BUILDSBARPSI DIFFERENTIALSYSTEMPRESSUREINEITHERDIRECTION
)NSTALLTWOBAR;PSI=PRESSUREGAUGESINTHESYSTEMPRESSUREGAUGEPORTS
-AND-
5SINGTWO INCHWRENCHESHOLDTHENEUTRALSTARTSWITCHFROMTURNINGAND

LOOSENTHELOCKNUT
$ISCONNECTTHEEXTERNALCONTROLLINKAGEANDMAKECERTAINTHECONTROLSHAFTISINITS
NEUTRALPOSITION
!TTACHACONTINUITYCHECKERTOTHETERMINALSOFTHESWITCH7ITHTHECONTROLSHAFTIN
ITSNEUTRALPOSITIONTURNTHESWITCHCLOCKWISE#7 UNTILTHESWITCHOPENSTHENTURN
THESWITCHCOUNTERCLOCKWISE##7 UNTILITCLOSES4URNTHESWITCHCOUNTERCLOCKWISE
##7 ANADDITIONALTURN² AFTERTHESWITCHCLOSES
580 BOMAG 008 918 12

Travel pump 18.1
Service Manual
!DJUSTMENTS
MDC NEUTRAL (OLDTHESWITCHINPLACEANDTIGHTEN Neutral start switch

START SWITCH (NSS) THELOCKNUTTO.sMLBFsFT
ADJUSTMENTS TORQUE
(continued)
7ITHTHECONTINUITYCHECKERATTACHED
TOTHESWITCHROTATETHECONTROL Control shaft
HANDLEORTHECONTROLSHAFT INEACH
DIRECTIONTOASSURETHESWITCHOPENS
WHENTHECONTROLISNOTINTHENEUTRAL Switch lock nut
POSITION Neutral start switch

Switch cam
)FTHESWITCHCLOSESINNEUTRALAND
SATISFACTORILYOPENSINEACHDIRECTION Switch pin 1-1/8 in
PROCEEDTOCHECKTHESWITCHWITH
##t)
THEPRIMEMOVERRUNNING4HESWITCH P104 148E
MUSTOPENBEFORETHEUNITBUILDS
BAR;PSI=DIFFERENTIALSYSTEM
PRESSUREINEITHERDIRECTION
)FTHESWITCHOPENSAFTERTHEUNITBUILDSSYSTEMPRESSUREINEITHERDIRECTIONLOOSEN
THESWITCHLOCKNUTANDTURNTHESWITCHCLOCKWISE#7 TURN² 4IGHTENTHE
SWITCHLOCKNUTANDRECHECKTHESWITCHOPERATION2EPEATTHISPROCEDUREIFNECESSARY
)FTHESWITCHDOESNOTOPENWITHANEQUALMOVEMENTOFTHECONTROLHANDLEINEACH
DIRECTIONTURNOFFPRIMEMOVERREMOVETHEPRESSUREGAUGESANDCONTINUEWITHTHE
NEXTSECTION
)FNEUTRALSTARTSWITCHOPERATIONISSATISFACTORYTURNOFFTHEPRIMEMOVERREMOVETHE

PRESSUREGAUGESANDRECONNECTTHEEXTERNALCONTROLLINKAGE
008 918 12 BOMAG 581
18.1 Travel pump
Service Manual
!DJUSTMENTS
CHECKING SWITCH 2ECHECKSWITCHCONTINUITYTODETERMINEWHETHERADDITIONALADJUSTMENTOFTHEECCENTRIC

CONTINUITY PLUGISNECESSARYW
W 7ARNING )NSTALLABAR;PSI=GAUGEINEACHOFTHETWOSERVOCYLINDERGAUGEPORTS-

4HEFOLLOWINGPROCEDURE AND- !TTACHACONTINUITYCHECKERTOTHETERMINALSOFTHENEUTRALSTARTSWITCH
MAYREQUIRETHEVEHICLE
MACHINETOBEDISABLED
WHEELSRAISEDOFFTHE Checking switch continuity
GROUNDWORKFUNCTION
DISCONNECTEDETC WHILE
PERFORMINGTHEPROCEDURE G 0 - 50 bar [0 - 1000 psi]
INORDERTOPREVENTINJURY
Servo pressure gauge port M4 B 9/16-18
TOTHETECHNICIANAND G 0 - 50 bar [0 - 1000 psi] t ""t]
BYSTANDERS4AKENECESSARY B 9/16-18
SAFETYPRECAUTIONSBEFORE t ""t]
MOVINGTHEVEHICLE
MACHINE
P106 166E
%NERGIZETHESTARTERCIRCUITANDSTARTTHEPRIMEMOVER
7HILEOPERATINGATNORMALSPEEDANDWITHTHEPUMPINITSNEUTRALZEROmOW
POSITIONNOTETHEPRESSUREREADINGONTHEGAUGES.OTETHISREADINGASTHEBASE
pressure.
3LOWLYMOVETHECONTROLHANDLEINONEDIRECTIONWHILEOBSERVINGTHEPRESSURE
GAUGESANDTHECONTINUITYCHECKER4HESWITCHMUSTOPENBEFORETHEPRESSUREON
EITHERGAUGEINCREASESMORETHANBAR;PSI=FROMTHEBASEPRESSUREOBTAINEDAT
NEUTRAL
3LOWLYMOVETHECONTROLHANDLEINTHEOPPOSITEDIRECTION!GAIN4HESWITCHMUST

OPENBEFORETHEGAUGEPRESSUREINCREASESMORETHANBAR;PSI=FROMBASE
pressure.
6ERIFYCONTINUITYAGAINWHENTHECONTROLISRETURNEDTONEUTRAL
)FTHESWITCHDOESNOTOPENATBASEPRESSUREPLUSTOBAR;TOPSI=INEITHER
DIRECTIONSTOPTHEPRIMEMOVERANDREADJUSTTHEECCENTRICPLUGASDESCRIBEDINTHE
PREVIOUSSECTION)FTHEPRESSUREDIFFERENCEISEQUALINEACHDIRECTIONBUTGREATER
THANBAR;PSI=LOOSENTHESWITCHLOCKNUTANDTURNTHESWITCHCLOCKWISE
TURN² TOINCREASETHESENSITIVITY2ETIGHTENTHELOCKNUTANDRECHECKPRESSURE
DIFFERENCESANDCONTINUITY
!FTERVERIFYINGPROPERCONTROLANDSWITCHOPERATIONSTOPTHEPRIMEMOVER2EMOVE

THECONTINUITYCHECKERANDPRESSUREGAUGES2EINSTALLTHESERVOPRESSUREPORTPLUGS
ANDRECONNECTTHEELECTRICALLEADSFROMTHEMACHINESTARTERCIRCUITTOTHE.33)NSTALL
ANDADJUSTTHEEXTERNALCONTROLLINKAGEIFNECESSARY
582 BOMAG 008 918 12

Travel pump 18.1
Service Manual
!DJUSTMENTS
HYDRAULIC 4HENEUTRALADJUSTMENTISTHEONLYADJUSTMENTTHATCANBEMADEONHYDRAULICAND
DISPLACEMENT ELECTRICDISPLACEMENTCONTROLS!LLOTHERFUNCTIONSAREPRESETATTHEFACTORY
CONTROL (HDC) AND
ELECTRIC DISPLACEMENT -AKETHISADJUSTMENTONATESTSTANDORONTHEVEHICLEMACHINEWITHTHEPRIMEMOVER
CONTROL (EDC) OPERATINGW
ADJUSTMENT
HDC and EDC neutral adjustment

W 7ARNING
4HEFOLLOWINGPROCEDURE
MAYREQUIRETHEVEHICLE G 0 - 50 bar [0 - 1000 psi]
MACHINETOBEDISABLED
Servo pressure gauge port M4 B 9/16-20
WHEELSRAISEDOFFTHE G 0 - 50 bar [0 - 1000 psi] t ##t]
GROUNDWORKFUNCTION B 9/16-20 M72
DISCONNECTEDETC WHILE t ##t] I
PERFORMINGTHEPROCEDURE
INORDERTOPREVENTINJURY
TOTHETECHNICIANAND
BYSTANDERS4AKENECESSARY
SAFETYPRECAUTIONSBEFORE
MOVINGTHEVEHICLE
MACHINE M90
h
t # #t] or
##t]
P106 167E
)NSTALLABAR;PSI=GAUGEINEACHOFTHETWODISPLACEMENTCONTROLCYLINDER
GAUGEPORTS-AND- $ISCONNECTTHEEXTERNALCONTROLINPUTHYDRAULICOR
ELECTRONIC FROMTHECONTROL3TARTTHEPRIMEMOVERANDOPERATEATNORMALSPEED
,OOSENTHELOCKNUT- WITHAMMORMMHEXWRENCH
5SINGAMMORMMINTERNALHEXWRENCHROTATETHEADJUSTINGSCREW-

CLOCKWISEUNTILTHEPRESSUREINCREASESINONEOFTHEPRESSUREGAUGES.OTETHE
ANGULARPOSITIONOFTHEWRENCH2OTATETHENEUTRALADJUSTINGSCREWCOUNTERCLOCKWISE
UNTILTHEPRESSUREINCREASESBYANEQUALAMOUNTONTHEOTHERGAUGE!GAINNOTETHE
ANGULARPOSITIONOFTHEWRENCH
2OTATETHEADJUSTINGSCREWCLOCKWISEHALFTHEDISTANCEBETWEENTHELOCATIONSNOTED
ABOVE4HEGAUGESSHOULDREADTHESAMEPRESSURECASEPRESSURE INDICATINGTHATTHE
CONTROLISINITSNEUTRALPOSITION
(OLDTHENEUTRALADJUSTINGSCREWSTATIONARY4IGHTENTHENEUTRALADJUSTINGSCREW
LOCKNUTTO.sM;LBFsIN=FORTHEMMSCREWOR.sM;LBFsIN=FORTHEMM
SCREW$ONOTOVERTORQUETHENUT
/NCETHENEUTRALPOSITIONISSETSTOPTHEPRIMEMOVERREMOVETHEGAUGESANDINSTALL

THEGAUGEPORTPLUGS2ECONNECTTHEEXTERNALCONTROLINPUT
008 918 12 BOMAG 583
18.1 Travel pump
Service Manual
!DJUSTMENTS
SPEED SENSOR 7HENINSTALLINGORADJUSTINGTHESPEEDSENSORONAPUMPITMUSTBESETATASPECIlC

ADJUSTMENT DISTANCEFROMTHESPEEDRINGONTHEUNITSCYLINDER4OLOCATETHEPOSITIONOFTHESPEED
SENSORONTHEUNITORDESCRIPTIONSEETHECORRESPONDINGSECTION
,OOSENTHESENSORLOCKNUTWITHAN Cross section view of speed sensor in

INCHHEXWRENCH variable pump
4URNTHESENSORCLOCKWISE#7 BY

HANDUNTILITCONTACTSTHESPEEDRING
Gap
4URNTHESENSORCOUNTERCLOCKWISE
##7 TURN² TOESTABLISHTHE
Speed sensor
NOMINALGAPOFMM;INCH= Magnetic speed ring
Cylinder block
4HENTURNTHESENSORCLOCKWISE#7 P104 152E
UNTILTHEWRENCHmATSONSENSORBODY
AREPOSITIONEDATA²ANGLETOTHE Positioning speed sensor relative to
PUMPSHAFTCENTERLINE pump shaft
Shaft centerline
1/2 inch wrench flats
-OSTOPEN ENDWRENCHESHAVEA²
HANDLEOFFSET 22° 22°
4HElNALSENSORPOSITIONSHOULDBE Speed sensor with Speed sensor with

BETWEEN² ANDTURN² packard connector turck connector
COUNTERCLOCKWISE##7 FROMTHE Shaft centerline

POINTWHERETHESENSORCONTACTSTHE
SPEEDRING
22° 22°
(OLDSENSORINPOSITIONWITHA
Speed sensor with Speed sensor with
INCHHEXWRENCHWHILETIGHTENING packard connector turck connector
THELOCKNUTTO.sM;LBFsFT=
P104 155E
584 BOMAG 008 918 12

Travel pump 18.1
Service Manual
Minor repair
STANDARD PROCEDURES Removing the pump

"EFOREWORKINGONTHEPUMPCLEANTHEOUTSIDEOFTHEPUMP)FTHEPUMPHASANAUXILIARY
PUMPATTACHEDREMOVEBOTHPUMPSASASINGLEUNIT4AGANDCAPALLHYDRAULICLINESAS
THEYAREDISCONNECTEDANDPLUGALLOPENPORTSTOENSURETHATCONTAMINATIONDOESNOT
ENTERTHESYSTEM
CCaution
#ONTAMINATIONCANDAMAGEINTERNALCOMPONENTSANDVOIDYOURWARRANTY4AKE
PRECAUTIONSTOENSURESYSTEMCLEANLINESSWHENREMOVINGANDREINSTALLINGSYSTEMLINES
Disassembly
7ITHTHEPRIMEMOVEROFFTHOROUGHLYCLEANTHEOUTSIDEOFTHEPUMP
2. 4AGCAPANDDISCONNECTEACHHYDRAULICLINECONNECTEDTOTHEPUMP!SHYDRAULIC

LINESAREDISCONNECTEDPLUGEACHOPENPORTTOENSURETHATDIRTANDCONTAMINATION
DONOTENTERTHESYSTEM
2EMOVETHEPUMPANDITSAUXILIARYPUMPIFAPPLICABLE ASASINGLEUNIT
Inspection
%NSURETHEWORKSURFACEANDSURROUNDINGAREAARECLEANANDFREEOFCONTAMINANTS
)NSPECTTHESYSTEMFORCONTAMINATION
,OOKATTHEHYDRAULICmUIDFORSIGNSOFSYSTEMCONTAMINATIONmUIDDISCOLORATION

FOAMSLUDGEORSMALLMETALPARTICLES
Reassembly
"EFOREREPLACINGTHEPUMPONTHEMACHINEREPLACEALLlLTERSANDDRAINANDlLLTHE
HYDRAULICSYSTEMWITHTHECORRECTHYDRAULICmUID
&LUSHTHELINESBEFOREREPLACINGTHEHYDRAULICmUID
008 918 12 BOMAG 585
18.1 Travel pump
Service Manual
Minor repair
SHAFT SEAL AND SHAFT 9OUCANREPLACETHESHAFTANDSEALWITHOUTMAJORDISASSEMBLYOFTHEUNIT#LEANPUMP

REPLACEMENT ANDSURROUNDINGAREATHOROUGHLY$ISCONNECTANDREMOVETHEPUMPFROMTHEUNITAND
CLEANITTHOROUGHLYBEFORESTARTINGREPAIRS-ARKALLCONNECTIONSFORLATERREASSEMBLY
Shaft removal
0OSITIONTHEPUMPWITHTHESHAFTFACINGUP
)FTHEUNITISPOSITIONEDHORIZONTALLYORMOVEDORJARREDWHILETHESHAFTISOUTTHECYLINDER

BLOCKCOULDMOVEOUTOFPLACEMAKINGSHAFTINSTALLATIONDIFlCULT
2EMOVETHETHREEORFOURSCREWS, HOLDINGTHERETAINERPLATE, ANDSEAL

CARRIER, TOTHEHOUSINGUSINGAMMHEXWRENCHUNIT AMMINTERNAL
HEXWRENCHTHROUGHUNITS ORAMMINTERNALHEXWRENCHTHROUGH
UNITS 2EMOVETHERETAINERPLATE
#ERTAINEARLIERPRODUCTIONUNITSUSEA Shaft assembly

ONEPIECERETAINERPLATEANDSEALCARRIER
L70
!FTERREMOVINGTHESCREWSTHE L60

SPRINGFORCEONTHESHAFTMAYMOVE
THESEALCARRIEROUTOFITSBOREBY
L30
APPROXIMATELYMM;INCH=)F
THESEALCARRIERDOESNOTMOVEFROM L40
ITSBOREPRYITFROMITSBOREANDOR
LIGHTLYTAPTHEENDOFTHESHAFTWITHA L50
SOFTMALLET L20
2EMOVETHE/ RING, FROMTHE

SEALCARRIERANDDISCARD L10
0LACESEALCARRIERANDSEALINANARBOR L100

PRESSANDPRESSOUTTHESEAL,
2EMOVESHAFT, ANDROLLER

BEARINGASSEMBLY, FROM
PUMP9OUCANTRANSFERTHEBEARING
ASSEMBLYTOTHENEWSHAFT
5SINGSNAP RINGPLIERSREMOVETHE

RETAININGRING, THATSECURESTHE
ROLLERBEARINGASSEMBLY2EMOVETHE
ROLLERBEARINGASSEMBLY
P106 181E
586 BOMAG 008 918 12

Travel pump 18.1
Service Manual
Minor repair
SHAFT SEAL AND SHAFT Inspection

REPLACEMENT )NSPECTTHESEALCARRIERTHENEWSEALANDTHE/ RINGFORANYDAMAGEORNICKS
(continued)
)NSPECTTHESHAFTANDBEARINGFORRUSTWEARORCONTAMINATION3PINTHEBEARINGIN
YOURHANDFEELINGFORROUGHNESS2EPLACEIFNECESSARY
Reassembly
5SINGTHEARBORPRESSPRESSTHENEWSEAL, INTOSEALCARRIER, "ECAREFULNOTTO
DAMAGETHESEAL
)FTHESHAFTISNOTBEINGREPLACEDPROCEEDTOSTEP
0LACEROLLERBEARINGASSEMBLYONNEWSHAFTANDSECUREWITHTHERETAININGRING
)NSTALLANINSTALLATIONSLEEVEORWRAPSPLINEORKEYEDENDOFSHAFTWITHPLASTIClLMTO
PREVENTDAMAGETOTHESEALINGLIPONTHESEALDURINGINSTALLATION
,UBRICATEANDINSTALLANEW/ RING, ONTHESEALCARRIER,UBRICATETHESEALWITH

CLEANPETROLEUMJELLY
!SSEMBLETHESEALCARRIERANDSEALOVERTHESHAFTANDINTOTHEHOUSINGBORE)NSTALL
THERETAINERPLATEIFUSED
)NSTALLTHESCREWSANDTORQUETOTHE Shaft retainer screw torque

APPROPRIATEVALUEINTHETABLETOTHE Frame size Torque
RIGHT n .sM;LBFsFT=
n .sM;LBFsFT=
4ORQUETHESCREWSINASEQUENCED n .sM;LBFsFT=
PATTERNTHENRECHECK
008 918 12 BOMAG 587
18.1 Travel pump
Service Manual
Minor repair
MULTI-FUNCTION VALVE Multi-function valve removal / installation

CARTRIDGES
/LDERMULTIFUNCTION
VALVESPRE CONTAIN
DIFFERENTCOMPONENTS
See multifunction valves P2B1
- Pre 1988PAGE FOR
DISASSEMBLYINSTRUCTIONS
P13
P06
P2A1
P106 180E
Removal Multi-function valve wrench size

2EMOVEMULTI FUNCTIONVALVES0! Frame size Wrench size
AND0" USINGHEXWRENCHLISTEDIN n INCH
TABLE n INCH
2EMOVEANDDISCARD/ RINGS0AND0
2ELIEVESPRINGPRESSUREBYREMOVINGBYPASSACTUATOR0 USINGA WRENCH4O

RETAINPRESSURESETTINGDONOTSEPARATEADJUSTINGSCREW0 ANDLOCKNUT0 FROM
BYPASSACTUATOR0
2EMOVEANDDISCARD/ RING0
-ULTI FUNCTIONVALVESARESOLDASCOMPLETEUNITSONLY9OUMAYPURCHASE/ RINGS

SEPARATELY
4HEPOPPETSEATSECTIONISPRESSEDOVERALIP0LACETHECARTRIDGEINAVISEANDPRYTHE
POPPETSEAT0 OFFWITHANAPPROPRIATETOOL-AINTAINSUFlCIENTCONTROLTOPREVENT
THEINTERNALCOMPONENTSFROMmYINGLOOSE$ONOTDAMAGEPARTSDURINGDISASSEMBLY
2EMOVEINTERNALPARTS0000000AND0
588 BOMAG 008 918 12

Travel pump 18.1
Service Manual
Minor repair
MULTI-FUNCTION VALVE Multi-function valve

CARTRIDGES
(continued) P04
P03
P01
P02
P05
P06
P07
P08
P17
P16
P15
P14
P09
P11
P13
P12
E101 531E
Inspection
#LEANANDINSPECTALLDISASSEMBLEDPARTS
Reassembly
,UBRICATEANDINSTALLINTERNALCOMPONENTS00000000AND
0
0LACETHECARTRIDGEINAVISEANDPRESSONTHEPOPPETSEAT0
,UBRICATEANDINSTALLNEW/ RINGS000
)NSTALLBYPASSACTUATOR0 WITHPRESSURELIMITERVALVE0 4ORQUETO.sM

;LBFsFT=
C#AUTION
)FPRESSURELIMITER0 WASREMOVEDFROMBYPASSACTUATOR0 ADJUSTPRESSURELIMITER
TOMODELCODESPECIlCATIONS
C#AUTION )NSTALLCARTRIDGESANDTORQUEASSHOWNINTHETABLEC

$ONOTOVERTORQUETHE
MULTI FUNCTIONVALVE
CARTRIDGES Multi-function valve torque
Frame size Torque
n .sM;LBFsFT=
n .sM;LBFsFT=
008 918 12 BOMAG 589
18.1 Travel pump
Service Manual
Minor repair
MULTI-FUNCTION VALVE Removal Multi-function valve wrench size

CARTRIDGES - PRE 1988 2EMOVEMULTI FUNCTIONVALVESUSING Frame size Wrench size
HEXWRENCHLISTEDINTABLE n INCH
n INCH
)TISNOTNECESSARYTOREMOVETHEBYPASSFUNCTION0 EXCEPTFORCLEANING7RENCH

SIZEIS
-ULTI FUNCTIONVALVESARESOLDASCOMPLETEUNITSONLY/ RINGSMAYBEPURCHASED

SEPARATELY
4ORETAINPRESSURESETTINGDONOTDISASSEMBLEBYPASSFUNCTION0
2EMOVERETAININGRING0 WITHASNAPRINGPLIERS
2EMOVEPOPPETSEAT0
Inspection
#LEANANDINSPECTALLDISASSEMBLEDPARTS
Multi-function valve - pre 1988
P14
P19
P12
P06
P21
P15
P14
P09
P11
P13 P22
P1
E101 532E
590 BOMAG 008 918 12

Travel pump 18.1
Service Manual
Minor repair
MULTI-FUNCTION VALVE Reassembly

CARTRIDGES - PRE 1988 ,UBRICATEANDINSTALLINTERNALCOMPONENTS00000AND0
(continued)
)NSTALLPOPPETSEAT0
)NSTALLRETAININGRING0
)FPREVIOUSLYREMOVEDLUBRICATEANDINSTALL/ RING0
)FPREVIOUSLYREMOVEDREASSEMBLEANDINSTALLBYPASSACTUATOR0 4ORQUETO

.sM;LBFsFT=
C#AUTION
)FPRESSURELIMITERWASREMOVEDFROMBYPASSACTUATOR0 ADJUSTPRESSURELIMITERTO
MODELCODESPECIlCATIONS
C#AUTION )NSTALLCARTRIDGESANDTORQUEASSHOWNINTHETABLEBELOWC

$ONOTOVERTORQUETHE
MULTI FUNCTIONVALVE
CARTRIDGES Multi-function valve torque
Frame size Torque
n .sM;LBFsFT=
n .sM;LBFsFT=
PRESSURE OVERRIDE Removal Pressure override valve components

VALVE (OPTION FOR 180 2EMOVETHEFOURSCREWSATTACHING
FRAME SIZE) THEPRESSUREOVERRIDEVALVETOTHE
Screws
PUMPENDCAPWITHAMMINTERNAL
HEXWRENCH2EMOVEANDDISCARDTHE Pressure override
/ RINGS valve
Inspection
O-rings
#LEANANDINSPECTVALVEFORDAMAGE
TOPARTS
Reassembly
)NSTALLNEW/ RINGS)NSTALLTHEVALVE
ONTOTHEPUMPENDCAPANDTORQUE
THESCREWSTO.sM;LBFsFT=
E101 079E
008 918 12 BOMAG 591
18.1 Travel pump
Service Manual
Minor repair
CHARGE PRESSURE 4HECHARGEPRESSURERELIEFVALVEISSHIMADJUSTABLEEARLYMODELS ORSCREWADJUSTABLE

RELIEF VALVE LATEMODELS 3CREWADJUSTABLECHARGERELIEFVALVEISSHOWN
Removal
2EMOVETHESHIMADJUSTABLECHARGERELIEFVALVEPLUGWITHAINCHHEXWRENCH
"EFOREREMOVINGTHESCREWADJUSTABLERELIEFVALVEPLUGMARKTHEPLUG+ LOCKNUT

+ ANDHOUSINGTOAPPROXIMATELYMAINTAINTHEORIGINALADJUSTMENTWHENASSEM
BLING2EMOVETHESCREWADJUSTABLECHARGERELIEFVALVEPLUGBYLOOSENINGTHELOCK
NUTWITHAHEXWRENCHCORRESPONDINGTOTHETABLE
5NSCREWTHEPLUGUSINGALARGE Lock nut wrench size

SCREWDRIVERORINCHHEXWRENCH Frame size Wrench size
2EMOVEANDDISCARDTHE/ RING+ n INCH
n INCH
2EMOVETHESPRING+ ANDRELIEF
VALVEPOPPET+
Inspection
)NSPECTTHEPOPPET+ ANDMATING
K90
SEATINTHEENDCAPFORDAMAGEOR h Lock nut
FOREIGNMATERIAL t Lock nut torque
7HENINSPECTINGSHIMADJUSTABLE K10
VALVESDONOTALTERTHESHIMSOR h1/2 in
INTERCHANGEPARTS dK50 K
Reassembly K70
)NSTALLTHEPOPPET+ ANDSPRING
K80
+ &ORSHIMADJUSTABLEVALVES
INSTALLTHESHIMSANDPLUGTORQUE
TO.sM;LBFsFT=&ORSCREW
ADJUSTABLEVALVESINSTALLTHEPLUG See appropriate table
WITHITSLOCKNUTALIGNINGTHEMARKS
MADEATDISASSEMBLYANDTORQUETHE
LOCKNUTTO.sM;LBFsFT=
#HECKTHECHARGEPRESSUREAND
ADJUSTIFNECESSARY2EFERTOCharge
pressure adjustmentsPAGE
P106 169E
592 BOMAG 008 918 12

Travel pump 18.1
Service Manual
Minor repair
AUXILIARY PAD Removal

2EMOVETHEFOURENDCAPSCREWS* 2EMOVEANDDISCARDSPECIALWASHERS* .
C#AUTION Aux. pad screw wrench size

/NEARLIERPRODUCTIONFRAMESIZE Frame size Wrench sizes
PUMPSWITHTWINPORTSSECURETHEEND nEARLY MMINTERNALHEX
CAPTOTHEPUMPHOUSINGWITHACLAMPTO LATE MMINTERNALHEX
AVOIDGASKETDAMAGE MMHEX
n MMHEX
2EMOVETHEAUXILIARYPAD* AND n MMINTERNALHEX
DISCARDTHE/ RINGS*AND* n MMINTERNALHEX
Inspection
)NSPECTTHEAUXILIARYPADFORDAMAGEANDREPLACEIFNECESSARY
4AKECARETOASSURETHESURFACESARECLEANANDFREEOFANYFOREIGNMATERIALORPAINT
PRIORTOINSTALLINGTHEAUXILIARYPAD
C#AUTION
$ONOTALLOWTHEFORCEOFTHECYLINDERBLOCKSPRINGANDSWASHPLATELEVELERSPRINGSTO
SEPARATETHEENDCAPFROMTHEPUMPHOUSING'ASKETDAMAGEANDEXTERNALLEAKAGEMAY
RESULT
Auxiliary pad components (typical)
J50
J80
Endcap screw J70
Screw torque
J60
See appropriate table for wrench size and torque
E101 084E
Inspection
)NSPECTTHEAUXILIARYPADCOMPONENTSFORWEARORDAMAGEANDREPLACEIFANYIS
FOUND
4AKECARETOENSURETHESURFACESARECLEANANDFREEOFANYFOREIGNMATERIALORPAINT
PRIORTOINSTALLINGTHEAUXILIARYPAD
Reassembly
,UBRICATEANDINSTALL/ RING* ONENDCAPPILOT
)NSTALLTHEAUXILIARYMOUNTINGPAD End cap screw torque

* ONREAROFENDCAP Frame size Torque
.sM;LBFsFT=
)NSTALLFOURLARGESCREWS* .sM;LBFsFT=
4ORQUEENDCAPSCREWSINA ANDNEWWASHERS* THROUGH .sM;LBFsFT=
CRISS CROSSPATTERN THEMOUNTINGPADANDENDCAP n .sM;LBFsFT=
INTOTHEHOUSING4ORQUEPERTHE n .sM;LBFsFT=
ACCOMPANYINGTABLE
008 918 12 BOMAG 593
18.1 Travel pump
Service Manual
Minor repair
CHARGE PUMP 4HEFOLLOWINGPROCEDURESHOWSHOWTOREMOVEANDINSTALLACHARGEPUMP
Removal
&ORPUMPSWITHANAUXILIARYMOUNTINGPADREFERTOTHEAuxiliary PadINSTRUCTIONS
PAGE
C#AUTION
/NEARLIERPRODUCTIONFRAMESIZEPUMPSWITHTWINPORTSSECURETHEENDCAPTOTHE
PUMPHOUSINGWITHACLAMPTOAVOIDGASKETDAMAGE
2EMOVETHESIXSCREWS( HOLDINGTHECHARGEPUMPCOVERRETAINER(
2EMOVETHERETAINER( ANDTHE Retainer screw wrench size

CHARGEPUMPCOVER* 2EMOVE Frame size Wrench size
ANDDISCARD/ RING* .OTETHE n 10 mm
ORIENTATIONOFTHEGEROTORASSEMBLY n MM
(
Current charge pump configuration
H40
H05
H60
H50
H31
J50
J15
J30
H70
E101 082E
H80
2EFERTOAPPROPRIATESauer-Danfoss Series 90 service parts manualFOREARLIERCHARGEPUMP

CONlGURATIONS
2EMOVETHECHARGEPUMPCOUPLING( ANDCHARGEPUMPDRIVEKEY(
2EMOVETHECHARGEPUMPGEROTORASSEMBLY(
594 BOMAG 008 918 12

Travel pump 18.1
Service Manual
Minor repair
CHARGE PUMP 2EMOVETHEALIGNMENTPIN(

(continued)
2EMOVETHEINNERPORTPLATE(
Inspection
)NSPECTALLPARTSFORABNORMALWEARORDAMAGEANDREPLACEIFNECESSARY
)FINSTALLINGADIFFERENTDISPLACEMENTCHARGEPUMPTHEGEROTORASSEMBLYGEROTOROUTER

ECCENTRICRINGANDINNERPORTPLATEEARLYANDLATEPRODUCTIONPUMPS OROUTERSPACER
PLATES INTERMEDIATEPRODUCTIONPUMPS MUSTBEREPLACEDTOGETHER)FDIFFERENT
THICKNESSPORTPLATESAREUSEDINANEARLYPRODUCTIONCHARGEPUMPASSEMBLYTHETHICKER
PLATEISTHEINNERPORTPLATEINSTALLEDNEXTTOTHEPUMPENDCAP
$IFFERENTPRODUCTIONCHARGEPUMPASSEMBLIESINCLUDEADIFFERENTQUANTITYTYPEOFPORT
PLATESANDSPACERPLATES
Reassembly
"ESURETOINSTALLTHECHARGEPUMPINTHE Orienting alignment pin
PROPERORIENTATION)FUNSUREOFCHARGE
Discharge Gerotor Discharge
PUMPROTATIONREFERTOTHEMODELCODE assembly
Alignment pin
4HEORIENTATIONOFTHEGEROTORASSEMBLY
Inlet Inlet
OUTERECCENTRICRINGANDTHELOCATION
Alignment pin
OFTHEALIGNMENTPININTHEENDCAP
Gerotor assembly
DETERMINETHECHARGEPUMPROTATION
Left hand rotation Right hand rotation
(outside looking into pump) (outside looking into pump)
$ONOTMIXCHARGEPUMPPARTSFROM P104 160E
DIFFERENTPRODUCTIONPERIODS!LWAYS
INSTALLASACOMPLETEASSEMBLY
)NSTALLTHEINNERPORTPLATE( ANDTHEGEROTORASSEMBLYOUTERRING
)NSTALLTHEALIGNMENTPIN( TOPROPERLYORIENTTHEPORTPLATESANDOUTERECCENTRIC

RINGFORCORRESPONDINGPUMPROTATION
0RIORTOINSTALLATIONLUBRICATETHE)$/$ANDSIDEFACESOFTHEGEROTORASSEMBLY
)NSTALLTHEGEROTORASSEMBLY(
)NSTALLTHEOUTERPORTPLATEEARLYPRODUCTIONANDINTERMEDIATEPRODUCTIONPUMPS
ONLY
)NSTALLTHESPACERPLATEIFPRESENTINTERMEDIATEPRODUCTIONPUMPS
)NSTALLTHECHARGEPUMPDRIVEKEY( INTOTHECHARGEPUMPCOUPLING( AND

RETAINWITHPETROLEUMJELLY
008 918 12 BOMAG 595
18.1 Travel pump
Service Manual
Minor repair
CHARGE PUMP )NTERMEDIATEPRODUCTIONCMÃANDCMÃPUMPSUSETHESAMECHARGEPUMP

(continued) COUPLING4WOKEYWAYSAREPROVIDEDINTHECOUPLINGFORTHECHARGEPUMPSUSEDINTHESE
UNITS4HEREARKEYWAYWITHIDENTIlERGROOVE ISUSEDINCMÃPUMPS4HEFRONTKEYWAY
CLOSESTTOTHEINTERNALLYSPLINEDENDOFTHESHAFT ISUSEDINCMÃPUMPS
)NSTALLTHECHARGEPUMPCOUPLING4HEINTERNALLYSPLINEDENDOFTHECOUPLINGMUST
ENGAGETHEMAINPUMPSHAFT
4HEOUTSIDEDIAMETEROFTHEINTERNALLYSPLINEDENDOFSOMEEARLYPRODUCTIONCHARGE
PUMPCOUPLINGSWERECHAMFERED%ARLYPRODUCTIONENDCAPSMAYNOTBEMACHINEDTO
ACCEPTANON CHAMFEREDCOUPLING!LWAYSUSEACHAMFEREDCHARGEPUMPCOUPLINGIN
PUMPSWITHTHEEARLYENDCAP
&ORPUMPSWITHANAUXILIARYMOUNTINGPADINSTALLTHEAUXILIARYDRIVECOUPLING
&ORPUMPSWITHNOAUXILIARYPADINSTALLANEW/ RING* ONTOCHARGEPUMPCOVER

)FANAUXILIARYPADISINSTALLEDAN/ RINGISNOTUSEDONTHECOVER
#AREFULLYREMOVETHEALIGNMENTPINFROMTHECHARGEPUMPPARTS)NSTALLTHEPININITS
HOLEINTHECHARGEPUMPCOVER* SEEPREVIOUSPAGEFORCORRECTORIENTATION AND
RETAINWITHPETROLEUMJELLY)NSTALLTHECOVERWITHALIGNMENTPIN INTOTHEENDCAP
ANDALIGNEDCHARGEPUMPPARTS4AKECARENOTTODAMAGETHECOVER/ RINGIFUSED
C#AUTION
)NORDERTOAVOIDLOSSOFCHARGEPRESSUREINPUMPSWITHANAUXILIARYMOUNTINGPAD
ALWAYSINSTALLTHECHARGEPUMPCOVERWITHTHEPADDRAINHOLELOCATEDONTHESAMESIDE
OFTHEENDCAPASTHECHARGEINLETPORT2EFERTOTHESECTION“Auxiliary Pad Installation” for
DETAILS
)NSTALLTHECHARGEPUMPCOVER Retainer screw torque

RETAINER( ANDTHESIXINTERNAL Frame size Torque
HEXSCREWS( 4ORQUETHESCREWS n .sM;LBFsFT=
PERTHETABLEATTHERIGHT n .sM;LBFsFT=
&ORPUMPSWITHAUXILIARYMOUNTINGPADSINSTALLTHE/ RINGANDAUXILIARYMOUNTING

PADADAPTORONTOTHEENDCAP2EFERTOTHECORRESPONDINGSECTIONFORINSTRUCTIONSON
AUXILIARYPADINSTALLATION
ADDING AN AUXILIARY )FINSTALLINGANAUXILIARYPADKITONAPUMPTHATWASPREVIOUSLYWITHOUTONECAREFULLY

PAD TO A PUMP REMOVETHEALIGNMENTPINFROMTHECHARGEPUMPPARTS
PREVIOUSLY WITHOUT
ONE )NSTALLTHEPININITSHOLEINTHENEWCHARGEPUMPCOVERWITHHOLEFORTHEAUXILIARY
COUPLING ANDRETAINWITHPETROLEUMJELLY
)NSTALLTHENEWCHARGEPUMPCOVERWITHALIGNMENTPININTOTHEENDCAPANDTHE
ALIGNEDCHARGEPUMPPARTS
,UBRICATEANDINSTALL/ RING)NSTALLAUXILIARYPAD2EFERTOPREVIOUSSECTIONSAuxiliary

padPAGEANDCharge pumpPAGEFORINSTRUCTIONS
596 BOMAG 008 918 12

Travel pump 18.1
Service Manual
Minor repair
INTEGRAL CHARGE Removal Lock nut wrench size and torque

PRESSURE FILTER 2EMOVETHElLTERCANISTER. FROM Frame size Wrench size Torque
REPLACEMENT THElLTERHEAD. ASDESCRIBEDON n INCH .sM;LBFsFT=
THECANISTER n INCH .sM;LBFsFT=
n INCH .sM;LBFsFT=
(OLDTHElLTERHEADINPLACEAND
LOOSENTHELOCKNUT. USINGTHEWRENCHSIZECORRESPONDINGTOPUMPFRAMESIZE
2OTATETHElLTERHEADCOUNTERCLOCKWISETOREMOVEITFROMTHEHOUSING2EMOVEAND
DISCARDTHE/ RING.
2EMOVETHEHYDRAULICTUBE. FROMITSBOREINTHEENDCAP
Inspection
)NSPECTTHElLTERHEADANDLOCKNUTSEALINGSURFACES)FYOUlNDANYNICKSORSCRATCHES
REPLACETHEDAMAGEDCOMPONENTS
Reassembly
)NSTALLTHEHYDRAULICTUBE. INTOITSBOREINTHEENDCAP)NSTALLTHElLTERHEAD.
INTOTHEPORTUSINGANEW/ RING. 4HEHYDRAULICTUBESHOULDGOINWITHLOWFORCE
!FTERROTATINGTHElLTERHEADCLOCKWISESOTHATTHETHREADSENGAGEWITHTHETHREADS
C#AUTION INTHEENDCAPCONTINUETOROTATEITCLOCKWISEBETWEENANDREVOLUTIONS0OSITION
&AILURETOINSTALLTHElLTER HEADASDESIREDC
MANIFOLDORlLTERHEAD
TOASUFlCIENTDEPTHIN 7HILEHOLDINGTHElLTERHEADINTHEDESIREDPOSITIONTIGHTENTHESWIVELLOCKNUT
THEENDCAPWILLRESULTIN . ANDTORQUEASSHOWNINTABLE
INSUFlCIENTENGAGEMENT
OFTHETUBEINTHEEND )NSTALLANEWlLTERCANISTER. PERTHEINSTRUCTIONSONTHElLTERCANISTER
CAPBORE4HISMAYALLOW
UNlLTEREDOILTOBYPASSTHE
lLTERANDENTERTHECHARGE Integral charge pressure filter
SYSTEM
N25 N20
N15 Fi"!#"
#""! #
N36A
N36
11/16 in

$
$t]
N40
N10
N35A
N35
11/16 in

$
$t] P106 182E
008 918 12 BOMAG 597
18.1 Travel pump
Service Manual
Minor repair
PUMP CONTROL COVER Removal

PLATE 4HOROUGHLYCLEANEXTERNALSURFACESPRIORTOREMOVALOFCOVERPLATE
5SINGAMMINTERNALHEXWRENCHREMOVETHESIXCOVERPLATEMOUNTINGSCREWS

- 2EMOVETHECOVERPLATE- ANDGASKET- FROMHOUSING$ISCARDTHE
GASKET
C#AUTION
0ROTECTEXPOSEDSURFACESANDCAVITIESFROMDAMAGEANDFOREIGNMATERIAL
Reassembly
)NSTALLANEWGASKETONTHEHOUSING)NSTALLTHECOVERPLATEANDINSTALLTHESCREWS
4ORQUETHESCREWSTO.sM;LBFsFT=
)NSTALLASEALINGWASHERUNDERTHEHEADOFANYMOUNTINGSCREWSTHATAREINSTALLEDINTO
THROUGHHOLESINTHEHOUSING
Pump controls cover plate
M90 (x6)
h 5 mm

$$!]
M1
Seal washer
location (42, 180, 250 cc)
M11
d
P106 184E
598 BOMAG 008 918 12

Travel pump 18.1
Service Manual
Minor repair
DISPLACEMENT 2EMOVETHECONTROLASSEMBLYAS Underside of an HDC/EDC module showing

CONTROL ORIFICES DESCRIBEDINTHEINSTRUCTIONSFORTHE orifice locations
SPECIlCDISPLACEMENTCONTROL A
B
TA P
/RIlCEPLUGSMAYBELOCATEDIN TB
THECONTROLASSEMBLYATTHEPUMP
HOUSINGFACE2EMOVETHEORIlCE
PLUGSONEATATIMETOAVOIDMIXING
THEMUP WITHAMMINTERNALHEX
WRENCH.OTETHELOCATIONOFEACH Orifice plugs
PLUGDONOTINTERCHANGEPLUGS Orifice check valve
#LEANREINSTALLANDTORQUETHEORIlCE E101 085E
PLUGSTO.sM;LBFsFT=
!SSEMBLETHECONTROLONTOTHEPUMP2EFERTOTHEINSTRUCTIONSFORTHESPECIlCCONTROL
DISPLACEMENT 2EMOVETHECONTROLASSEMBLYAS Underside of an MDC module showing

CONTROL ORIFICE DESCRIBEDINTHEINSTRUCTIONSFORTHE orifice locations
CHECK VALVE SPECIlCDISPLACEMENTCONTROL
TA A B TB
4HEORIlCECHECKVALVEISLOCATEDIN P
THECONTROLASSEMBLYATTHESURFACE
OFTHEPUMPHOUSINGFACE2EMOVE
THESPRINGRETAINERANDSPRINGFROM
Orifice plugs
THEORIlCECHECKVALVECAVITYAND
THENREMOVETHEORIlCECHECKVALVE
Orifice check valve
#LEANANDINSTALLTHEORIlCECHECK E101 086E
VALVEINTHECAVITYANDTHENINSTALL
THESPRINGANDSPRINGRETAINERTOHOLDTHEORIlCECHECKVALVEINPOSITION
!SSEMBLETHECONTROLONTOTHEPUMP2EFERTOTHEINSTRUCTIONSFORTHESPECIlCCONTROL
DISPLACEMENT $ONOTREMOVETHEADAPTERPLATEUNLESS Displacement control adapter plate (early

CONTROL ADAPTER LEAKAGEISEVIDENT4HEMOUNTINGSCREWS production 130 cm³ pumps only)
PLATE (EARLY WITHSEALINGCOMPOUNDAREDIFlCULTTO Adapter plate
screws
PRODUCTION 130 remove.
PUMPS ONLY) 6 mm
4HESCREWSFASTENINGTHECONTROLADAPTER

PLATETOTHEHOUSINGHAVESEALING

COMPOUNDONTHETHREADS9OUMAY O-rings Adapter plate
REMOVETHEMWITHAMMINTERNALHEX
WRENCHIFNECESSARY2EMOVEANDDISCARD
THE/ RINGSANDSEALS Seal
7HENINSTALLINGTHEADAPTERPLATE
REPLACESCREWSWITHSEALINGCOMPOUND
ANDENSURETHENEW/ RINGSANDSEALARE
E101 087E
INTHEPROPERPOSITION4ORQUETHESCREWS
TO.sM;LBFsFT=
008 918 12 BOMAG 599
18.1 Travel pump
Service Manual
Minor repair
MANUAL DISPLACEMENT Removal

CONTROL (MDC) 4HOROUGHLYCLEANEXTERNALSURFACESPRIORTOREMOVALOFCONTROL
5SINGAMMINTERNALHEXWRENCHREMOVETHESIXCONTROLMOUNTINGSCREWS-

2EMOVETHECONTROL- WITHORIlCECHECKVALVE4 ANDSPRING4 ANDCONTROL
GASKET- FROMTHEHOUSING$ISCARDTHEGASKET
)FNECESSARYREMOVETHECONTROLHANDLE- BYREMOVINGTHELOCKINGNUT- AND

WASHER-
C#AUTION
Reassembly
)NSTALLANEWGASKET- )NSPECTCONTROLTOASSURETHATTHECONTROLORIlCECHECK
VALVEANDSPRINGAREINTHEIRPROPERPOSITIONINTHECONTROL
)NSTALLTHECONTROL%NGAGETHEPINONTHECONTROLLINKAGEINTOTHEMATINGHOLEINTHE
LINKATTACHEDTOTHESWASHPLATE
7ITHTHECONTROLINPOSITIONMOVECONTROLLEVERBOTHDIRECTIONSTOCHECKPROPER

ENGAGEMENTOFCONTROLLINKAGEPIN)FPROPERLYASSEMBLEDLEVERWILLRETURNTO
CENTER)FLEVERDOESNOTRETURNTOCENTERREMOVETHECONTROLANDREPEATTHEABOVE
PROCEDURE
MDC removal/installation
M72
S40 M71 h 8 mm
h 1-1/8 in M70 *" !*']

*"
!*']
M90 (x6)
I 5 mm
*"
!*']
M11
Seal washer d
location (42, 180, 250 cc)
T
T30 T40
P106 185E
600 BOMAG 008 918 12

Travel pump 18.1
Service Manual
Minor repair
MANUAL DISPLACEMENT )FREMOVEDINSTALLTHECONTROLHANDLE- ANDLOCKINGNUT- WITHWASHER-

CONTROL (MDC) (OLDTHEPOSITIONOFTHEHANDLEANDTORQUETHELOCKINGNUTTO.sM;LBFsFT=USING
(continued) ANMMHEXWRENCH
!LIGNTHECONTROLGASKETANDINSTALLTHESCREWS4ORQUETHESCREWSTO.sM
;LBFsFT=
W 7ARNING )NSTALLASEALINGWASHERUNDERTHEHEADOFMOUNTINGSCREWSTHATAREINSTALLEDINTO
4HENEUTRALSTARTSWITCH THROUGHHOLESINTHEHOUSING
NEUTRALMUSTBEREADJUSTED
AFTERREASSEMBLINGTHE
-$#MODULE )FTHECONTROLISEQUIPPEDWITHANEUTRALSTARTSWITCHREFERTOMDC Neutral start switch
adjustmentINSTRUCTIONSPAGE
SOLENOID OVERRIDE Removal

VALVE FOR MDC 4HOROUGHLYCLEANEXTERNALSURFACESPRIORTOREMOVALOFVALVE
2EMOVETHESOLENOIDFROMTHEVALVEBYREMOVINGTHENUTWITHAINCHHEX
WRENCH2EMOVETHESOLENOIDVALVE- FROMTHEMANIFOLD- WITHAINCH
HEXWRENCH
5SINGAMMINTERNALHEXWRENCHREMOVETHETWOSCREWS- ANDREMOVE

SOLENOIDMANIFOLD- FROMHOUSING2EMOVEANDDISCARDTHEGASKET-
Reassembly
4ORQUEVALVE- TO.sM;LBFsFT=4ORQUESOLENOIDNUTTO.sM;LBFsFT=
$ONOTOVERTORQUETHESOLENOIDNUT
)NSTALLANEWGASKETONTHECONTROLHOUSING)NSTALLTHEMANIFOLDONTOTHECONTROL
HOUSINGALIGNTHEGASKETANDINSTALLTHESCREWS4ORQUETHESCREWSTO.sM
;LBFsFT=
Solenoid override valve removal/installation
M90 (x6)
5 mm M77

] M76A
M76C
M76B
M76
M78 (x2)
5 mm
M75
]
P106 186E
008 918 12 BOMAG 601
18.1 Travel pump
Service Manual
Minor repair

VALVE FOR MDC WITH 4HOROUGHLYCLEANEXTERNALSURFACESPRIORTOREMOVALOFVALVE
PRESSURE RELEASED
BRAKE 5SINGAMMINTERNALHEXWRENCHREMOVETHEFOURSOLENOIDVALVEMOUNTINGSCREWS
- 2EMOVETHESOLENOIDVALVE- WITH/ RINGS FROMTHEADAPTERPLATE$ISCARD
THE/ RINGS
5SINGAMMINTERNALHEXWRENCHREMOVETHEFOURADAPTERPLATEMOUNTINGSCREWS

- 2EMOVETHEADAPTERPLATEAND/ RINGS--AND- FROMTHECONTROL
HOUSING$ISCARDTHE/ RINGS
Reassembly
5SINGPETROLEUMJELLYTORETAINTHEMINSTALLNEW/ RINGS--- ONTHE
ADAPTERPLATE0LACETHEADAPTERPLATEINTOPOSITIONANDINSTALLTHESCREWS-
4ORQUETHESCREWSTO.sM;LBFsFT=
5SINGPETROLEUMJELLYTORETAINTHEMINSTALLNEW/ RINGSONTOTHESOLENOIDVALVE

ASSEMBLY- ANDINSTALLTHESOLENOIDVALVEONTOTHEADAPTERPLATE)NSTALLTHE
SCREWS- ANDTORQUETO.sM;LBFsFT=
M98 (x4)
4 mm
M9
t]
M95
M96
M97 M92 (x4)
4 mm
t]
P106 192E
602 BOMAG 008 918 12

Travel pump 18.1
Service Manual
Minor repair
HYDRAULIC AND Removal

ELECTRIC DISPLACEMENT 4HOROUGHLYCLEANEXTERNALSURFACESPRIORTOREMOVALOFCONTROL
CONTROLS
5SINGAMMINTERNALHEXWRENCHREMOVETHESIXCONTROLMOUNTINGSCREWS-
GASKET- FROMHOUSING$ISCARDTHEGASKET
C#AUTION
Reassembly
)NSTALLANEWGASKET- 6ERIFYTHECONTROLORIlCECHECKVALVEANDSPRING4 AREIN
THEIRPROPERPOSITIONINTHECONTROL
0OSITIONTHECONTROLONTHEHOUSING)NSERTTHECONTROLLINKAGEPININTOTHE
SWASHPLATELINK.
Hydraulic/Electric displacement control

M90 (x6)
I 5 mm

]
M1
M11
d
T30
T40
P106 187E
008 918 12 BOMAG 603
18.1 Travel pump
Service Manual
Minor repair
7ITHTHECONTROLINPOSITIONMOVECONTROLASSEMBLYLEFTANDRIGHTTOCHECK

ENGAGEMENTOFPININTHELINK0ROPERENGAGEMENTISINDICATEDBYANINCREASING
RESISTANCEASTHECONTROLISMOVEDAWAYFROMCENTERPOSITION.ON ENGAGEMENTOF
PINISINDICATEDBYLACKOFSPRINGFORCE)NCASEOFNON ENGAGEMENTREMOVECONTROL
ANDREPEATTHEABOVEPROCEDURE
;LBFsFT=
PRESSURE CONTROL Removal

PILOT (PCP) FOR 4HOROUGHLYCLEANEXTERNALSURFACESOFCONTROL
ELECTRIC DISPLACEMENT
CONTROL (EDC) 5SINGAMMINTERNALHEXWRENCHREMOVETHEFOURSCREWS- ANDREMOVETHE
0#0-
Inspection
#HECKSURFACESFORNICKSORDAMAGE#LEANINTERNALSCREENS
Reassembly
)NSTALLNEW/ RINGS-AND- IN0#0(OUSING0LACE0#0AGAINST%$#HOUSING
ANDINSTALLTHESCREWS- 4ORQUETO.sM;LBFsFT=
$ONOTREMOVEBLACKPLASTICCOVERFROMTHEALUMINUMPLATE4HISISNOTASERVICEABLEITEM
ANDWILLVOIDTHEPRODUCTWARRANTY
PCP removal/installation M90 (x6)

5 mm
''$]
Seal washer
location
(42, 180, 250 cc)
M97
M96 (x3)
M98 (x4)
M9
4 mm

'
't] P106 194E
604 BOMAG 008 918 12

Travel pump 18.1
Service Manual
Minor repair
3-POSITION (FNR) Removal

ELECTRIC CONTROL 4HOROUGHLYCLEANEXTERNALSURFACESPRIORTOREMOVALOFCONTROL
5SINGAMMINTERNALHEXWRENCHREMOVETHEFOURSOLENOIDVALVEMOUNTINGSCREWS

7 2EMOVETHESOLENOIDVALVE7 WITH/ RINGS7! ANDORIlCE FROM
THEADAPTERPLATE
5SINGAMMINTERNALHEXWRENCHREMOVETHESIXADAPTERPLATEMOUNTINGSCREWS

C#AUTION - 2EMOVETHEADAPTERPLATEANDGASKET- FROMTHEHOUSING$ISCARDTHE
0ROTECTEXPOSEDSURFACES GASKETC
ANDCAVITIESFROMDAMAGE
ANDFOREIGNMATERIAL Inspection
)NSPECTTHEORIlCEINSTALLEDBETWEENTHEVALVEANDADAPTERPLATE4HISORIlCEmust be
INSTALLEDINTHECASEDRAINPASSAGEFORPROPERPRESSURELIMITEROPERATION
Reassembly
)NSTALLASEALINGWASHER )NSTALLANEWGASKET- ONTHEHOUSING0LACETHEADAPTERPLATEINTOPOSITIONAND
UNDERTHEHEADOFANY INSTALLTHESCREWS- C4ORQUETHESCREWSTO.sM;LBFsFT=
MOUNTINGSCREWSTHAT
AREINSTALLEDINTOTHROUGH )NSTALLNEW/ RINGS7! ANDTHEORIlCEONTOTHESOLENOIDVALVEASSEMBLYAND
HOLESINTHEHOUSING INSTALLTHESOLENOIDVALVEONTOTHEADAPTERPLATE)NSTALLSCREWS7 4ORQUETO
.sM;LBFsFT=
FNR removal/installation
W702 (x4)
I 5 mm

*"
!*t]
W701A
M90 (x6) d
I 5 mm
*"!*'] T80
T70
T50 M900
M1
Seal washer
location (42, 180, 250 cc)
T
M11 T30
T40
d
P106 185E
008 918 12 BOMAG 605
18.1 Travel pump
Service Manual
Minor repair
DISPLACEMENT )FTHEPUMPISEQUIPPEDWITHCONTROL Filter screen installation

CONTROL FILTER lLTERSCREENSINTHEPUMPHOUSINGLATE B90
SCREENS PRODUCTION PRESSTHEMINTOPOSITION
WITHTHEROUNDEDEDGEOFTHElLTER P106 690E
SCREENSFACINGTHECONTROL UNTILTHEYARE
mUSHTOMM;INCH=BELOWTHE
SURFACEOFTHEHOUSING
SPEED SENSOR Removal

,OOSENTHELOCKNUTUSINGAINHEXWRENCH
5NSCREWTHESPEEDSENSOR" FROMTHEPUMPHOUSING2EMOVEANDDISCARDTHE

/ RING"!
Reassembly
)NSTALLANEW/ RINGBEFOREREINSTALLINGTHESENSOR
2EINSTALLTHESPEEDSENSORWITHLOCKNUTAND/ RING INTOTHEHOUSING!DJUSTTHE

GAPBETWEENTHESENSORANDTHEMAGNETICSPEEDRINGASINSTRUCTEDINSpeed sensor
adjustmentPAGE ANDTORQUETHESENSORLOCKNUTTO.sM;LBFsFT=
)FASPEEDSENSORISNOTINSTALLEDUSEAININTERNALHEXWRENCHTOTORQUETHE

HOUSINGPLUG" TO.sM;LBFsFT=
Typical location of speed sensor

B83 O-ring plug
]
B83A
B83 B83A
]
E101 095E
606 BOMAG 008 918 12

Travel pump 18.1
Service Manual
4ORQUECHART
FASTENER SIZE AND Item Fastener Frame size Wrench size Torque
TORQUE CHART B83 3PEEDSENSORLOCKNUT INHEX .sM;LBFsFT=
E60 3IDECOVERSCREW MMHEX .sM;LBFsFT=
"LINDHOLES MMHEX .sM;LBFsFT=
MMHEX .sM;LBFsFT=
4HRUHOLES MMHEX .sM;LBFsFT=
MMHEX .sM;LBFsFT=
& 3ERVOCYLINDERSCREW MMHEX .sM;LBFsFT=
F211 MMHEX .sM;LBFsFT=
' %NDCAPSCREW MMINTERNALHEX .sM;LBFsFT=
G97 MMINTERNALHEX .sM;LBFsFT=
MMHEX .sM;LBFsFT=
MMHEX .sM;LBFsFT=
H80 #HARGEPUMPRETAININGSCREW MMHEX .sM;LBFsFT=
MMHEX .sM;LBFsFT=
J80 %NDCAPSCREW MMINTERNALHEX .sM;LBFsFT=
EARLY MMINTERNALHEX .sM;LBFsFT=
LATE MMINTERNALHEX .sM;LBFsFT=
MMHEX .sM;LBFsFT=
MMHEX .sM;LBFsFT=
MMINTERNALHEX .sM;LBFsFT=
K10 #HARGEPRESSUREVALVEPLUG INHEX .!
K90 #HARGEPRESSURELOCKNUT INHEX .sM;LBFsFT=
INHEX .sM;LBFsFT=
L70 3HAFTRETAININGSCREW MMHEX .sM;LBFsFT=
M72 -$#HANDLENUT MM .sM;LBFsFT=
M78 $E STROKEVALVEMANIFOLDSCREW MMINTERNALHEX .sM;LBFsFT=
M85 %CCENTRICPLUGLOCKNUT INHEX .sM;LBFsFT=
M88 .EUTRALSTARTSWITCHLOCKNUT INHEX .sM;LBFsFT=
M90 #ONTROLMOUNTINGSCREW MMINTERNALHEX .sM;LBFsFT=
M92 3OLENOIDVALVEMOUNTINGSCREW MMINTERNALHEX .sM;LBFsFT=
M98 0#0MOUNTINGSCREW MMINTERNALHEX .sM;LBFsFT=
N10 &ILTERREDUCERASSEMBLY INHEX .sM;LBFsFT=
INHEX .sM;LBFsFT=
INHEX .sM;LBFsFT=
N37 &ILTERPLUGASSEMBLY ININTERNALHEX .sM;LBFsFT=
0" -ULTI FUNCTIONVALVE INHEX .sM;LBFsFT=
P2A1 INHEX .sM;LBFsFT=
008 918 12 BOMAG 607
18.1 Travel pump
Service Manual
4ORQUECHART
PLUG SIZE AND TORQUE )FANYPLUGSORlTTINGSAREREMOVEDFROMTHEPUMPDURINGSERVICINGINSTALLANDTORQUEAS

CHART INDICATEDINTHEACCOMPANYINGTABLEC
!LWAYSINSTALLNEW/ RINGSBEFOREREINSTALLINGTHEPLUGSORlTTINGS
C#AUTION
4ORQUEPLUGSORlTTINGS Item O-ring plug Wrench size Torque
INSTALLEDINTOALUMINUM B70, B72 INTERNALHEXWRENCH .sM;LBFsFT=
HOUSINGSTOTHELOWER B71 INTERNALHEXWRENCH .sM;LBFsFT=
VALUESSPECIlEDFOR B80 INTERNALHEXWRENCH .sM;LBFsFT=
INTERNALHEXPLUGSOFTHE B82, B83 INTERNALHEXWRENCH .sM;LBFsFT=
SAMESIZE G18 INTERNALHEXWRENCH .sM;LBFsFT=
G45-G50 INCHHEXWRENCH .sM;LBFsFT=
G52-G54 INTERNALHEXWRENCH .sM;LBFsFT=
H90 (not shown) INTERNALHEXWRENCH .sM;LBFsFT=
N35, N36 (not shown) INCHHEXWRENCH .sM;LBFsFT=
N37 INTERNALHEXWRENCH .sM;LBFsFT=
FASTENERS AND PLUGS
Fastener and plug locations

B70, B72 O-ring plug
9/16-18
J80 Auxilliary pad / G90 End cap screw
end cap screw M90 Control bolt
H80 Charge pump

retaining screw L70 Shaft seal
retaining screw
G53, G54 O-ring plug

9/16-18
K10 Charge pressure

relief valve plug M88 Neutral start switch
lock nut
M85 Eccentric plug
K90 Charge pressure lock nut
relief valve lock nut
B80 O-ring plug
1-1/16-12 P2B1 Multi-function valve
G97 End cap screw B71 O-ring plug

B82 O-ring plug
9/16-18
9/16-18
B83 Speed sensor /
G50 O-ring plug O-ring plug
9/16-18 9/16-18
G49 O-ring plug

9/16-18
G48 O-ring plug

9/16-18
N37 Filter plug assembly

F111 / F211 Servo cylinder screw E60 Side cover screw N10 Filter reducer assembly
P106 189E
P2A1 Multi-function valve
608 BOMAG 008 918 12

Travel pump 18.1
Service Manual
.OTES
008 918 12 BOMAG 609
18.1 Travel pump
Products we offer: Sauer-Danfoss is a global manufacturer and supplier of high-

quality hydraulic and electronic components. We specialize in
Bent Axis Motors providing state-of-the-art technology and solutions that excel in
the harsh operating conditions of the mobile off-highway market.
Closed Circuit Axial Piston Pumps
Building on our extensive applications expertise, we work closely
and Motors
with our customers to ensure exceptional performance for a broad
Displays range of off-highway vehicles.
Electrohydraulic Power Steering
We help OEMs around the world speed up system development,
Electrohydraulics reduce costs and bring vehicles to market faster.
Sauer-Danfoss – Your Strongest Partner in Mobile Hydraulics.
Hydraulic Power Steering
Integrated Systems
Joysticks and Control Handles
Go to www.sauer-danfoss.com for further product information.
Microcontrollers and Software
Open Circuit Axial Piston Pumps
Orbital Motors Wherever off-highway vehicles are at work, so is Sauer-Danfoss.
PLUS+1™ GUIDE
We offer expert worldwide support for our customers, ensuring
Proportional Valves the best possible solutions for outstanding performance. And with
an extensive network of Global Service Partners, we also provide
Sensors
comprehensive global service for all of our components.
Steering
Transit Mixer Drives
Please contact the Sauer-Danfoss representative nearest you.
Local address:
Members of the Sauer-Danfoss Group:
Comatrol
www.comatrol.com
Schwarzmüller-Inverter
www.schwarzmueller-inverter.com
Sauer-Danfoss (US) Company Sauer-Danfoss ApS
2800 East 13th Street DK-6430 Nordborg, Denmark
Ames, IA 50010, USA Phone: +45 7488 4444
Turolla
Phone: +1 515 239 6000 Fax: +45 7488 4400
www.turollaocg.com Fax: +1 515 239 6618
Hydro-Gear Sauer-Danfoss GmbH & Co. OHG Sauer-Danfoss-Daikin LTD.

www.hydro-gear.com Postfach 2460, D-24531 Neumünster Shin-Osaka TERASAKI 3rd Bldg. 6F
Krokamp 35, D-24539 Neumünster, Germany 1-5-28 Nishimiyahara, Yodogawa-ku
Phone: +49 4321 871 0 Osaka 532-0004, Japan
Sauer-Danfoss-Daikin Fax: +49 4321 871 122 Phone: +81 6 6395 6066
Fax: +81 6 6395 8585
www.sauer-danfoss-daikin.com
520L0818s2EV!#sDecember 2011
www.sauer-danfoss.com
610 BOMAG 008 918 12
Travel pump 18.1
Series 90 Pumps
Repair Instructions
008 918 12 BOMAG 611

18.1 Travel pump
Series 90 Pumps
Repair Instructions
2EVISIONS

!PRIL 79 4ORQUEFOR''''""""CHANGED !"
TO.M;LBFsFT=
$EC &IRSTPRINTING !!
3AUER $ANFOSSACCEPTSNORESPONSIBILITYFORPOSSIBLEERRORSINCATALOGSBROCHURESANDOTHERPRINTEDMATERIAL

3AUER $ANFOSSRESERVESTHERIGHTTOALTERITSPRODUCTSWITHOUTPRIORNOTICE4HISALSOAPPLIESTOPRODUCTS
ALREADYORDEREDPROVIDEDTHATSUCHALTERATIONSARENTINCONmICTWITHAGREEDSPECIlCATIONS!LLTRADEMARKSIN
THISMATERIALAREPROPERTIESOFTHEIRRESPECTIVEOWNERS3AUER $ANFOSSANDTHE3AUER $ANFOSSLOGOTYPEARE
TRADEMARKSOFTHE3AUER $ANFOSS'ROUP
&RONTCOVERILLUSTRATIONS&&&
2 11019577s2EV!"s!PRIL
612 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
Contents
INTRODUCTION /VERVIEW
'ENERALINSTRUCTIONS
3AFETYPRECAUTIONS
5NINTENDEDMACHINEMOVEMENT
&LAMMABLECLEANINGSOLVENTS
&LUIDUNDERPRESSURE
0ERSONALSAFETY
3YMBOLSUSEDIN3AUER $ANFOSSLITERATURE 7
DISASSEMBLY 3HAFT
-ULTI FUNCTIONVALVECARTRIDGES 9
-ULTI FUNCTIONVALVECARTRIDGES PRE
#HARGEPRESSURERELIEFVALVE
0RESSUREOVERRIDEVALVEOPTIONFORFRAMESIZE
!UXILIARYPAD
#HARGEPUMP
)NTEGRALCHARGEPRESSURElLTERREPLACEMENT
0UMPCONTROLCOVERPLATE
-ANUALDISPLACEMENTCONTROL-$# 7
3OLENOIDOVERRIDEVALVEFOR-$#
3OLENOIDOVERRIDEVALVEFOR-$#WITHPRESSURERELEASEDBRAKE9
(YDRAULICANDELECTRICDISPLACEMENTCONTROLS0
0RESSURECONTROLPILOT0#0 FORELECTRICDISPLACEMENTCONTROL%$#
0OSITION&.2 ELECTRICCONTROL
$ISPLACEMENTCONTROLORIlCES%$#($#CONTROL
$ISPLACEMENTCONTROLORIlCECHECKVALVE-$#CONTROL
$ISPLACEMENTCONTROLADAPTERPLATEEARLYPRODUCTIONPUMPSONLY
$ISPLACEMENTCONTROLlLTERSCREENS
3PEEDSENSOR
3ERVORELIEFVALVES
%NDCAP9
6ALVEPLATE0
3IDECOVER0
3IDECOVERDISASSEMBLY
#YLINDERBLOCK
#YLINDERBLOCK
3ERVOCYLINDERS
3WASHPLATE
0ISTONASSEMBLY
3WASHPLATE
INSPECTION /VERVIEW7
3HAFTASSEMBLY7
0ISTONSANDSLIPPERS7
#YLINDERBLOCK
%NDCAPJOURNALBEARING
6ALVEPLATE
-ULTI FUNCTIONVALVECARTRIDGES9
#HARGEPRESSURERELIEFVALVE0
#HARGEPUMP0
11019577s2EV!"s!PRIL 3
008 918 12 BOMAG 613
18.1 Travel pump
Series 90 Pumps
Repair Instructions
Contents
INSPECTION (YDRAULICANDELECTRICDISPLACEMENTCONTROLS
(CONTINUED) )NTEGRALCHARGEPRESSURElLTER
3WASHPLATE
3ERVOPISTON
#YLINDERBLOCK
ASSEMBLY #YLINDERBLOCK
3ERVOPISTON2INGS
3ERVOARM
3WASHPLATEGUIDE
2OLLPINANDmATWASHER
0ISTONASSEMBLY7
&IXED CLEARANCEHOLD DOWNBEARING
"EARINGCAGE0
(OUSING
3ERVOCYLINDERSCREWS
$ISPLACEMENTLIMITER
"EARINGCAGELOCATORLINK
6ERIFYPROPERASSEMBLY
3WASHPLATELEVELER
)NSTALLINGLEVELERANDSIDECOVER
3ETTINGLEVELER NEUTRALPOSITION
#YLINDERBLOCKINSTALLATION7
0OSITIONINGTHESIDECOVER7
%NDCAPINSTALLATION
0REPARINGFORENDCAPINSTALLATION
%NDCAPPARTS9
%NDCAPINSTALLATION9
3PEEDSENSOR0
-ULTI FUNCTIONVALVECARTRIDGES PRE
0RESSUREOVERRIDEVALVEOPTIONFORFRAMESIZE
#HARGEPRESSURERELIEFVALVE
#HARGEPUMP
!UXILIARYPAD
$ISPLACEMENTCONTROLlLTERSCREENS
)NTEGRALCHARGEPRESSURElLTERREPLACEMENT
0UMPCONTROLCOVERPLATE7
$ISPLACEMENTCONTROLADAPTERPLATEEARLYPRODUCTIONPUMPSONLY 7
(YDRAULICANDELECTRICDISPLACEMENTCONTROLS
-ANUALDISPLACEMENTCONTROL-$# 9
3OLENOIDOVERRIDEVALVEFOR-$#70
3OLENOIDOVERRIDEVALVEFOR-$#WITHPRESSURERELEASEDBRAKE7
0RESSURECONTROLPILOT0#0 FORELECTRICDISPLACEMENTCONTROL%$# 7
0OSITION&.2 ELECTRICCONTROL7
-ULTI FUNCTIONVALVECARTRIDGES7
)NSTALLINGSHAFTANDBEARING7
&INALASSEMBLYANDTESTING77
&ASTENERSIZEANDTORQUECHART7
0LUGSIZEANDTORQUECHART79
&ASTENERSANDPLUGS79
4 11019577s2EV!"s!PRIL
614 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
)NTRODUCTION
OVERVIEW 4HISMANUALDETAILSMAJORREPAIRPROCEDURESFOR3ERIESPUMPS4HESEINCLUDETHE
COMPLETEDISASSEMBLYINSPECTIONANDREASSEMBLYOFTHEUNIT7HEREREWORKOFWORN
ORDAMAGEDCOMPONENTSISPOSSIBLESPECIlCATIONSAPPEARTOENSURETHESEPARTSMEET
FACTORYTOLERANCES/NLY3AUER $ANFOSS'LOBAL3ERVICE0ARTNERS'30S AREAUTHORIZEDTO
PERFORMMAJORREPAIRS3AUER $ANFOSSTRAINS'LOBAL3ERVICE0ARTNERSANDCERTIlESTHEIR
FACILITIESONAREGULARBASIS
W 7ARNING
5SEOFCOMPONENTSTHATDONOTCOMPLYWITHREWORKSPECIlCATIONSMAYRESULTINLOSSOF
PERFORMANCEWHICHMAYCONSTITUTEASAFETYHAZARD$ONOTREUSECOMPONENTSTHATDONT
COMPLYTOGIVENSPECIlCATIONSREPLACEWITHGENUINE3AUER $ANFOSSSERVICEPARTS
-INORREPAIRPROCEDURESADJUSTMENTSANDTROUBLESHOOTINGINFORMATIONAPPEARINTHE

Series 90 Pumps Service Manual520L0818-INORREPAIRSINCLUDESERVICEOPERATIONSYOU
CANPERFORMWITHOUTREMOVINGTHEUNITSENDCAP2EMOVALOFTHEENDCAPVOIDSYOUR
WARRANTY
&OLLOWTHESEGENERALPROCEDURESWHENREPAIRING3ERIESPUMPS
GENERAL INSTRUCTIONS
w Remove the unit
HYDRAULICmUIDMAYBEUNDERHIGHPRESSUREANDORHOT)NSPECTTHEOUTSIDEOFTHE
PUMPANDlTTINGSFORDAMAGE#APHOSESANDPLUGPORTSAFTERREMOVALTOPREVENT
CONTAMINATION
e Keep it clean
TOAVOIDCONTAMINATIONOFTHESYSTEMPORTS#LEANINGPARTSINACLEANSOLVENTWASHAND
AIRDRYINGISUSUALLYADEQUATE
l Lubricate moving parts

$URINGASSEMBLYCOATALLMOVINGPARTSWITHCLEANHYDRAULICmUID4HISASSURESTHATTHESE
PARTSARELUBRICATEDDURINGSTART UP

3AUER $ANFOSSRECOMMENDSTHATYOUREPLACEALL/ RINGSSEALSANDGASKETS,IGHTLY
LUBRICATEALL/ RINGSWITHCLEANPETROLEUMJELLYPRIORTOASSEMBLY
t Secure the unit

&ORMAJORREPAIRPLACETHEUNITINASTABLEPOSITIONWITHTHESHAFTPOINTINGDOWNWARD)T
ISNECESSARYTOSECURETHEPUMPWHILEREMOVINGANDTORQUINGTHEENDCAPBOLTS
11019577s2EV!"s!PRIL 5
008 918 12 BOMAG 615
18.1 Travel pump
Series 90 Pumps
Repair Instructions
)NTRODUCTION

HYDRAULICSYSTEM

W Warning
ORBYSTANDERS4OPROTECTAGAINSTUNINTENDEDMOVEMENTSECURETHEMACHINEOR
DISABLEDISCONNECTTHEMECHANISMWHILESERVICING

W Warning

W Warning
Personal safety
W Warning
TIMES
6 11019577s2EV!"s!PRIL
616 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
)NTRODUCTION

SAUER-DANFOSS
LITERATURE  #!54)/.MAYRESULTINDAMAGETO  ,UBRICATEWITHHYDRAULICmUID
PRODUCTORPROPERTY
 2EUSABLEPART
 #LEANAREAORPART
SLEEVE
 4ORXHEAD
11019577s2EV!"s!PRIL 7
008 918 12 BOMAG 617
18.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SHAFT Shaft and bearing Removing the shaft and bearing assembly
0OSITIONPUMPWITHTHESHAFT
POINTINGUP L70
.UMBEROFSCREWSANDWRENCHSIZEVARIES L60
BYMODEL
L30
2EMOVETHETHREEORFOURSCREWS
L40
, HOLDINGTHERETAINERPLATE,
ANDSEALCARRIER, TOTHEHOUSING L50
USINGAMMHEXWRENCH
L20
UNIT AMMINTERNALHEXWRENCH
THROUGHUNITS ORAMM
INTERNALHEXWRENCHTHROUGH L10
UNITS 2EMOVETHERETAINERPLATE
0RYTHESEALCARRIER, FROMITS L100

BORE9OUMAYTAPLIGHTLYONTHEEND
OFTHESHAFTWITHASOFTMALLETTO
FACILITATEREMOVAL
2EMOVETHE/ RING, FROMTHE

SEALCARRIERANDDISCARD
0LACESEALCARRIERINANARBORPRESS
ANDPRESSOUTTHESEAL, $ISCARD
SEAL
P106 181E
,IFTTHESHAFTANDBEARINGASSEMBLY
OUTOFTHEPUMP
2EMOVETHESNAPRING,
2EMOVETHEBEARINGWASHERAND
ROLLERASSEMBLY,
0RESSTHEINNERBEARINGRACEOFFTHE
SHAFT,
8 11019577s2EV!"s!PRIL
618 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
MULTI-FUNCTION VALVE Multi-function valve removal

CARTRIDGES
/LDERMULTIFUNCTION
VALVESPRE CONTAIN
DIFFERENTCOMPONENTS P2B1
See multifunction valves
- Pre 1988PAGE0 FOR
DISASSEMBLYINSTRUCTIONS
P13
P06
P2A1
E101 537E
Removal Multi-function valve wrench size

2EMOVEMULTI FUNCTIONVALVES0!AND Frame size Wrench size
0" USINGHEXWRENCHLISTEDINTABLE n INCH
n INCH
11019577s2EV!"s!PRIL 9
008 918 12 BOMAG 619
18.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
MULTI-FUNCTION VALVE Disassembly

CARTRIDGE (continued) 2EMOVEANDDISCARD/ RINGS0AND0
2ELIEVESPRINGPRESSUREBYREMOVINGBYPASSACTUATOR0 USINGA WRENCH4O

RETAINPRESSURESETTINGDONOTSEPARATEADJUSTINGSCREW0 ANDLOCKNUT0 FROM
BYPASSACTUATOR0
2EMOVEANDDISCARD/ RING0
-ULTI FUNCTIONVALVESARESOLDASCOMPLETEUNITSONLY9OUMAYPURCHASE/ RINGS

SEPARATELY
4HEPOPPETSEATSECTIONISPRESSEDOVERALIP0LACETHECARTRIDGEINAVISEANDPRYTHE
POPPETSEAT0 OFFWITHANAPPROPRIATETOOL-AINTAINSUFlCIENTCONTROLTOPREVENT
THEINTERNALCOMPONENTSFROMmYINGLOOSE$ONOTDAMAGEPARTSDURINGDISASSEMBLY
P04
P03
P01
P02
P05
P06
P07
P08
P17
P16
P15
P14
P09
P11
P13
P12
E101 531E
10 11019577s2EV!"s!PRIL
620 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
MULTI-FUNCTION VALVE Removal Multi-function valve wrench size

CARTRIDGES - PRE 1988 2EMOVEMULTI FUNCTIONVALVESUSINGHEX Frame size Wrench size
WRENCHLISTEDINTABLE n INCH
n INCH
Disassembly
)TISNOTNECESSARYTOREMOVETHEBYPASSACTUATOR0 EXCEPTFORCLEANING7RENCH

SIZEIS
-ULTI FUNCTIONVALVESARESOLDASCOMPLETEUNITSONLY/ RINGSMAYBEPURCHASED

SEPARATELY
4ORETAINPRESSURESETTINGDONOTDISASSEMBLEBYPASSACTUATOR0
2EMOVERETAININGRING0 WITHASNAPRINGPLIERS
2EMOVEPOPPETSEAT0
P14
P19
P12
P06
P21
P15
P14
P11 P22
P09
P1
P13
E101 532E
11019577s2EV!"s!PRIL 11
008 918 12 BOMAG 621
18.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
CHARGE PRESSURE 4HECHARGEPRESSURERELIEFVALVEIS Charge pressure relief valve

RELIEF VALVE SHIMADJUSTABLEEARLYMODELS OR
SCREWADJUSTABLELATEMODELS 3CREW +
h ,OCKNUT
ADJUSTABLECHARGERELIEFVALVEISSHOWN
Removal +
2EMOVETHESHIMADJUSTABLECHARGE hIN
RELIEFVALVEPLUGWITHAINCHHEX d+ +
WRENCH2ETAINSHIMS
+
"EFOREREMOVINGTHESCREW
ADJUSTABLERELIEFVALVEPLUGMARK +
THEPLUG+ LOCKNUT+ AND
HOUSINGTOAPPROXIMATELYMAINTAIN
THEORIGINALADJUSTMENTWHENASSEM
3EETABLEFOr
BLING2EMOVETHESCREWADJUSTABLE WRENCHSIZe
CHARGERELIEFVALVEPLUGBYLOOSENING
THELOCKNUTWITHAHEXWRENCH
CORRESPONDINGTOTHETABLE
5NSCREWTHEPLUGUSINGALARGE
SCREWDRIVERORINCHHEXWRENCH
2EMOVEANDDISCARDTHE/ RING+
2EMOVETHESPRING+ ANDRELIEF

VALVEPOPPET+
Lock nut wrench size

n INCH %%
n INCH
PRESSURE OVERRIDE Removal Pressure override valve components

VALVE (OPTION FOR 180 2EMOVEFOURSCREWSATTACHING
Screws
FRAME SIZE) THEPRESSUREOVERRIDEVALVETOTHE
ENDCAPWITHAMMINTERNALHEX Pressure override
WRENCH valve
2EMOVEANDDISCARDTHE/ RINGS

O-rings
E101 079E
12 11019577s2EV!"s!PRIL
622 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
AUXILIARY PAD Removal

2EMOVEFOURENDCAPSCREWS* 2EMOVEANDDISCARDSEALWASHERS*
2EMOVETHEAUXILIARYPAD* ANDDISCARDTHE/ RING*
Auxiliary pad components (typical)
J50
J80
Endcap screw J70
J60
See table for wrench size and torque
E101 084E
Auxiliary pad screw wrench size

Frame size Wrench sizes
nEARLY MMINTERNALHEX
LATE MMINTERNALHEX
MMHEX
n MMHEX
n MMINTERNALHEX
n MMINTERNALHEX
11019577s2EV!"s!PRIL 13
008 918 12 BOMAG 623
18.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
CHARGE PUMP Removal

&ORPUMPSWITHANAUXILIARYMOUNTINGPADREFERTOTHEAuxiliary Pad instructions
PAGE
2EMOVEANDDISCARDSIXSCREWS( FROMTHECHARGEPUMPCOVERRETAINER(
2EMOVERETAINER( ANDTHE Retainer screw wrench size

CHARGEPUMPCOVER* 2EMOVE Frame size Wrench size
ANDDISCARD/ RING* .OTETHE n MM
ORIENTATIONOFTHEGEROTORASSEMBLY n MM
(
Current charge pump configuration
H40
H05
H60
H50
H31
J15
J50
J30
H70
E101 539E
H80
2EFERTOAPPROPRIATESauer-Danfoss Series 90 service parts manualFOREARLIERCHARGEPUMP

CONlGURATIONS
2EMOVECHARGEPUMPCOUPLING( ANDCHARGEPUMPDRIVEKEY(
2EMOVETHECHARGEPUMPGEROTORASSEMBLY(
2EMOVETHEALIGNMENTPIN(
2EMOVETHEVALVEPLATE(
14 11019577s2EV!"s!PRIL
624 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
INTEGRAL CHARGE Removal Lock nut wrench size and torque

PRESSURE FILTER 2EMOVElLTERCANISTER. FROMTHE Frame size Wrench size Torque
REPLACEMENT lLTERHEAD. ASDESCRIBEDONTHE n INCH .sM;LBFsFT=
CANISTER n INCH .sM;LBFsFT=
n INCH .sM;LBFsFT=
(OLDlLTERHEADINPLACEANDLOOSENTHELOCKNUT. USINGTHEWRENCHSIZEINTHE

TABLE
2OTATElLTERHEADCOUNTERCLOCKWISETOREMOVEITFROMTHEHOUSING2EMOVEAND
DISCARDTHE/ RING.
2EMOVEHYDRAULICTUBE. FROMITSBOREINTHEENDCAP
Integral charge pressure filter
N25 N20
N15 Filter manifold lock nut
N36A
N36
11/16 in
N40
N10
N35A
N35
11/16 in
P106 182E
11019577s2EV!"s!PRIL 15
008 918 12 BOMAG 625
18.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
PUMP CONTROL COVER Removal

PLATE 4HOROUGHLYCLEANEXTERNALSURFACESPRIORTOREMOVINGCOVERPLATE
5SINGAMMINTERNALHEXWRENCHREMOVESIXCOVERPLATEMOUNTINGSCREWS-

2EMOVETHECOVERPLATE- ANDGASKET- FROMHOUSING$ISCARDTHEGASKET
CCaution
Pump controls cover plate

M90 X
MM
t .sM;LBFsFT=
-
3EALWASHER
LOCATIONCC
-
d
0%
16 11019577s2EV!"s!PRIL
626 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
MANUAL DISPLACEMENT Removal

CONTROL (MDC) 4HOROUGHLYCLEANEXTERNALSURFACESPRIORTOREMOVINGCONTROL
5SINGAMMINTERNALHEXWRENCHREMOVESIXCONTROLMOUNTINGSCREWS-

GASKET- FROMTHEHOUSING$ISCARDTHEGASKET
)FNECESSARYREMOVETHECONTROLHANDLE- BYREMOVINGTHELOCKINGNUT- AND

WASHER-
CCaution
MDC removal/installation
-
3 - h MM
h IN M70
-X
I MM
-
3EALWASHER d
LOCATIONCC
4
4 4
0%
11019577s2EV!"s!PRIL 17
008 918 12 BOMAG 627
18.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

VALVE FOR MDC 4HOROUGHLYCLEANEXTERNALSURFACESPRIORTOREMOVINGVALVE
2EMOVETHESOLENOIDFROMTHEVALVEBYREMOVINGTHECOIL NUTWITHAINCHHEX

WRENCH2EMOVETHESOLENOIDVALVE- FROMTHEMANIFOLD- WITHAINCH
HEXWRENCH2EMOVETHE/ RINGS-!" ANDBACKUPRING-# DISCARD
5SINGAMMINTERNALHEXWRENCHREMOVETWOSCREWS- ANDREMOVESOLENOID

MANIFOLD- FROMHOUSING2EMOVEANDDISCARDTHEGASKET-
Seal washer
location
(42, 180, 250 cc)
M77
M76A
M76C
M76B
M76
M78 (x2)
5 mm
M75
P106 186E
18 11019577s2EV!"s!PRIL
628 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY

VALVE FOR MDC WITH 4HOROUGHLYCLEANEXTERNALSURFACESPRIORTOREMOVINGVALVE
PRESSURE RELEASED
BRAKE 5SINGAMMINTERNALHEXWRENCHREMOVETHEFOURSOLENOIDVALVEMOUNTINGSCREWS
- 2EMOVETHESOLENOIDVALVE- WITH/ RINGS FROMTHEADAPTERPLATE$ISCARD
THE/ RINGS
5SINGAMMINTERNALHEXWRENCHREMOVETHEFOURADAPTERPLATEMOUNTINGSCREWS

- 2EMOVETHEADAPTERPLATEAND/ RINGS--AND- FROMTHECONTROL
HOUSING$ISCARDTHE/ RINGS
M98 (x4)
4 mm
M9
M95
M96
M97 M92 (x4)
4 mm
P106 192E
11019577s2EV!"s!PRIL 19
008 918 12 BOMAG 629
18.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
HYDRAULIC AND Removal

ELECTRIC DISPLACEMENT 4HOROUGHLYCLEANEXTERNALSURFACESPRIORTOREMOVINGCONTROL
CONTROLS
5SINGAMMINTERNALHEXWRENCHREMOVESIXCONTROLMOUNTINGSCREWS-
$ISCARDSEALWASHERIFPRESENT2EMOVECONTROL- WITHORIlCECHECKVALVE4
ANDSPRING4 ANDCONTROLGASKET- FROMHOUSING$ISCARDTHEGASKET
CCaution

-X
I MM
-
-
d
4
4
0%
20 11019577s2EV!"s!PRIL
630 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
PRESSURE CONTROL Removal

PILOT (PCP) FOR 4HOROUGHLYCLEANEXTERNALSURFACESOFCONTROL
ELECTRIC DISPLACEMENT
CONTROL (EDC) 5SINGAMMINTERNALHEXWRENCHREMOVEFOURSCREWS- ANDREMOVETHE0#0
- 2EMOVEANDDISCARDTHE/ RINGS--
$ONOTDISASSEMBLETHE
0#0- )TISAVAILABLE PCP removal/installation
ONLYASACOMPLETEUNIT
M97
M96 (x3)
M98 (x4)
M9
4 mm
P106 194E
11019577s2EV!"s!PRIL 21
008 918 12 BOMAG 631
18.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
3-POSITION (FNR) Removal

ELECTRIC CONTROL 4HOROUGHLYCLEANEXTERNALSURFACESPRIORTOREMOVALOFCONTROL
5SINGAMMINTERNALHEXWRENCHREMOVEFOURSOLENOIDVALVEMOUNTINGSCREWS

7 2EMOVETHESOLENOIDVALVE7 WITH/ RINGS7! ANDORIlCEFROM
THEADAPTERPLATE
5SINGAMMINTERNALHEXWRENCHREMOVETHESIXADAPTERPLATEMOUNTINGSCREWS

CCaution - 2EMOVETHEADAPTERPLATEANDGASKET- FROMTHEHOUSING$ISCARDTHE
0ROTECTEXPOSEDSURFACES GASKETC
ANDCAVITIESFROMDAMAGE
ANDFOREIGNMATERIAL )FNECESSARYREMOVEANDCLEANTHETHREEORIlCES444 USINGAMM
INTERNALHEXWRENCHANDAMMINTERNALHEXWRENCH
$ONOTDISASSEMBLETHE FNR removal/installation

&.2CONTROL)TISAVAILABLE 7X
I MM
ASACOMPLETEUNITONLY
7!
-X d
I MM
4
4
4
-
3EALWASHER
LOCATIONCC
4
- 4
4
d
0%
22 11019577s2EV!"s!PRIL
632 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
DISPLACEMENT 2EMOVETHECONTROLASSEMBLYAS Underside of an HDC/EDC module showing

CONTROL ORIFICES DESCRIBEDINTHEINSTRUCTIONSFORTHE orifice locations
(EDC/HDC CONTROL) SPECIlCDISPLACEMENTCONTROL A
B
TA P
9OUMAYlNDORIlCEPLUGSINTHE TB
CONTROLASSEMBLYATTHEPUMP
HOUSINGFACE4OAVOIDMIXINGTHEM
UPREMOVECLEANANDREPLACE
ORIlCEPLUGSINDIVIDUALLY5SEAMM
INTERNALHEXWRENCHTOREMOVETHE Orifice plugs
PLUGS.OTETHELOCATIONOFEACHPLUG Orifice check valve
DONOTINTERCHANGEPLUGS#LEAN E101 085E
REINSTALLANDTORQUETHEORIlCEPLUGS
TO.sM;LBFsFT=
DISPLACEMENT 2EMOVETHECONTROLASSEMBLYAS Underside of an MDC module showing

CONTROL ORIFICE DESCRIBEDINTHEINSTRUCTIONSFORTHE orifice locations
CHECK VALVE (MDC SPECIlCDISPLACEMENTCONTROL
CONTROL) TA A B TB
4HEORIlCECHECKVALVEISINTHE P
CONTROLASSEMBLYATTHESURFACEOF
THEPUMPHOUSINGFACE2EMOVETHE
SPRINGRETAINERANDSPRINGFROMTHE
Orifice plugs
ORIlCECHECKVALVECAVITYANDTHEN
REMOVETHEORIlCECHECKVALVE
Orifice check valve
#LEANANDINSTALLTHEORIlCECHECK E101 086E
VALVEINTHECAVITYANDTHENINSTALL
THESPRINGANDSPRINGRETAINER
TOHOLDTHEORIlCECHECKVALVEIN
POSITION
DISPLACEMENT $ONOTREMOVETHEADAPTERPLATEUNLESS Displacement control adapter plate (early

CONTROL ADAPTER LEAKAGEISEVIDENT4HEMOUNTINGSCREWS production 130 cm³ pumps only)
PLATE (EARLY WITHSEALINGCOMPOUNDAREDIFlCULTTO Adapter plate
PRODUCTION 130 REMOVE screws
PUMPS ONLY)
4HESCREWSFASTENINGTHECONTROLADAPTER 6 mm
PLATETOTHEHOUSINGHAVESEALING
t]
COMPOUNDONTHETHREADS9OUMAY O-rings
REMOVETHEMWITHAMMINTERNALHEX Adapter plate
WRENCHIFNECESSARY2EMOVEANDDISCARD
THE/ RINGSANDSEALS Seal
E101 087E
11019577s2EV!"s!PRIL 23
008 918 12 BOMAG 633
18.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
DISPLACEMENT )FYOUREMOVETHESCREENSREPLACEWITH Filter screen installation

CONTROL FILTER NEWSCREENS0RESSTHEMINTOPOSITION B90
SCREENS WITHTHEROUNDEDEDGEOFTHESCREEN
FACINGTHECONTROLUNTILTHEYAREmUSHTO P106 690E
MM;INCH=BELOWTHESURFACEOF
THEHOUSING
SPEED SENSOR Removal

,OOSENTHELOCKNUTUSINGANINHEXWRENCH
5NSCREWSPEEDSENSOR" FROMTHEPUMPHOUSING2EMOVEANDDISCARDTHE/ RING

"!
Typical location of speed sensor

B83 O-ring plug
ft]
B83A
B83 B83A

t]
E101 095E
24 11019577s2EV!"s!PRIL
634 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SERVO RELIEF VALVES #ERTAINFRAMESIZEPUMPSWITHTWINPORTENDCAPSMAYHAVETHESERVORELIEFVALVESAND

ROTATIONPLUGSINAREMOVABLEROTATIONBLOCK
5SINGAMMINTERNALHEXWRENCHREMOVETHEROTATIONBLOCKSCREWS
2EMOVETHEBLOCK
2EMOVETHEGASKET
3OMEPUMPSHAVEAPRESSURE LIMITERFUNCTION
2EMOVETHESERVORELIEFVALVESFROMTHEENDCAPORROTATIONBLOCK 5SEA

SCREWDRIVER
Servo relief valve removal
Veiw 'C'
View 'C'
View 'C'
P80
P802
P70
P702
With Pressure Limiters Without Pressure Limiters
P106 729E
Servo relief passage plugs
3OMEPUMPSHAVEPRESSURELIMITERVALVESANDORRELIEFVALVES
.OTETHEPOSITIONOFTHEROTATIONPIPEPLUGS
5SINGAINCHINTERNALHEXWRENCHREMOVETHESERVORELIEFPASSAGEPLUGS FROMTHE

ENDCAPORROTATIONBLOCK
5SINGAINCHINTERNALHEXWRENCHREMOVETHEPIPEPLUGSFROMTHEENDCAPOR
ROTATIONBLOCK
#LEANPASSAGESWITHASUITABLESOLVENT
3EETHEILLUSTRATIONSONTHEFOLLOWINGPAGESFORPROPERPLUGANDVALVELOCATIONSON
VARIOUSPUMPS
11019577s2EV!"s!PRIL 25
008 918 12 BOMAG 635
18.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SERVO RELIEF VALVES Installing servo relief valves

(continued) )NSTALLSERVORELIEFVALVESORRELIEFVALVEPASSAGEPLUGSINTOTHEENDCAPORROTATION
BLOCK
)NSTALLSERVORELIEFVALVESINTHEENDCAPORROTATIONBLOCKOFPUMPSWITHPRESSURE
LIMITERFUNCTIONSORRELIEFVALVES
)NSTALLTHEROTATIONPIPEPLUGSINTOTHEENDCAPORROTATIONBLOCKW
W7ARNING
-AKESURETHEPRESSURELIMITERLOGICPLUGSAREINTHECORRECTPORTSFORPUMPROTATION
5NCONTROLLABLEMACHINEMOVEMENTRESULTSFROMIMPROPERPLUGINSTALLATION6ERIFYCORRECT
PRESSURELIMITERFUNCTION4ESTTHEPUMPBEFOREINSTALLINGINMACHINE!LSOTESTITBEFORE
RELEASINGTHEMACHINEFROMREPAIR
4ORQUETHESERVORELIEFVALVESORRELIEFVALVEPASSAGEPLUGSTO.sM;LBFsFT=
4ORQUETHEROTATIONPIPEPLUGSTO.sM;LBFsFT=
)NSTALLROTATIONBLOCKGASKETANDSCREWSIFUSED
4ORQUETHEROTATIONBLOCKSCREWSTO.sM;LBFsFT=
Specifications
Pressure limiter Pump rotation Holes with Holes with servo Holes with Open holes
Port A Port B pipe plugs relief valves O-ring plugs
9ES 9ES 2IGHT#7 .ONE
9ES 9ES ,EFT##7 .ONE
.O .O %ITHER .ONE
9ES .O 2IGHT#7 .ONE
9ES .O ,EFT##7 .ONE
9ES 9ES 2IGHT#7 WITH .ONE
AUTOMOTIVECONTROL
9ES 9ES ,EFT##7 WITH .ONE
AUTOMOTIVECONTROL
030 twin ported end cap (early units) 030 Twin ported end cap
3 4
7 6
5 6
5
3 4
7
1 1
2
2
0 0
26 11019577s2EV!"s!PRIL
636 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SERVO RELIEF VALVES 042 twin ported end cap (early units) 042 twin ported end cap
(continued)
6 3 6
2 2
3
5
5 1 4 1
7 4 7
0
0
055 side ported end cap 055 twin ported end cap
6 6
2 2
4 5 4
1 1
7 7
5 3 3
0 0
075 side and twin ported end cap 075 twin ported end cap rotation block
6 1 2
4 2
1
5 4 3
5
7 3
0
6 7
0
11019577s2EV!"s!PRIL 27
008 918 12 BOMAG 637
18.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SERVO RELIEF VALVES 100 side ported end cap 100 twin ported end cap
(continued)
6 6 2
2
4 7 1 5 7
3
3
1
5 4
0
0
130 twin ported end cap 180 twin ported end cap rotation block
4 3
1 2
5
5 4
3
6 1 2 6
7
0
0
250 twin port end cap
5 4
3 6
7
2 1
0
28 11019577s2EV!"s!PRIL
638 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
ENDCAP 0LACETHEPUMPONTHEWORKSURFACEWITHENDCAP' FACINGUP
.UMBEROFSCREWSANDWRENCHSIZEVARIESBYMODEL
5SINGAORMMINTERNALHEXWRENCHORAMMHEXWRENCHREMOVETHEOR

SCREWS'' FASTENINGTHEENDCAPTOTHEPUMPHOUSING
4HESCREW' RETAINSASPACER' A (J80) Screw removal

LIFTINGBRACKET' ANDAWASHER' Pump size Wrench size
CC MMINTERNALHEX
2EMOVESCREWS* IFPRESENT CC MMHEX
2EFERTOTHETABLEScrew removalFOR CCANDCC MMHEX
WRENCHSIZES CC MMINTERNALHEX
CCANDCC MMINTERNALHEX
2EMOVEENDCAP' FROMHOUSING
4HEALIGNMENTPINSANDVALVEPLATEWILLUSUALLYREMAINWITHTHEHOUSING
2EMOVEANDDISCARDENDCAPGASKET'
2EMOVETHEHARDENEDSHIMS% FROMTHEENDCAPPOCKETS
Removing the end cap and gasket

G97
G95
G94
J80
G93
G90
G04
E24
E101 101
11019577s2EV!"s!PRIL 29
008 918 12 BOMAG 639
18.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
VALVEPLATE Valveplate and springs Removing internal parts

2EMOVEVALVEPLATE# NOTING
DIRECTIONOFARROWSONVALVEPLATE
2EMOVETHELONGSPRINGS% FROM

THESWASHPLATELEVELER D95
3OMEUNITSHAVEDUALSWASHPLATELEVELER B50 (2X)

SPRINGSANINNERSPRINGNESTEDINSIDE
EACHOFTHESTANDARDSPRINGS
B10
2EMOVETHESHORTSWASHPLATEHOLD
DOWNSPRING$IFPRESENT E82
E101 102
Arrows C80
2EMOVETHETWOALIGNMENTPINS
"
SIDECOVER -ARKTHEORIENTATIONOFTHESIDE Removing the side cover

COVER% TOTHEHOUSING
3TRAIGHTENTHELOCKINGTABSUSEDON
EARLIERPRODUCTIONUNITS
2EMOVETHESIDECOVERSCREWS
% 2EFERTOTABLEBELOW FORWRENCH
SIZES
2EMOVESIDECOVERASSEMBLYFROM
PUMPHOUSING
Side cover screw removal

B10
Pump size Wrench size
CC MMHEX
CCTHROUGHCC MMHEX
CCTHROUGHCC MMHEX
E101 103
E60
30 11019577s2EV!"s!PRIL
640 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SIDECOVER Side cover components Leveler disassembly

DISASSEMBLY 2EMOVESPACERWASHERSIFUSED ON
E30
THELEVELERSPRINGSEATS%
E30
3OMEUNITSWITHDUALSWASHPLATELEVELER
SPRINGSHAVESPACERWASHERSONTHE
LEVELERSPRINGSEATS
E22
2EMOVESPRINGSEATS% FROM
SWASHPLATELEVELER%
3OMELEVELERSDONOTHAVEREMOVABLE
Spacer
SPRINGSEATS Washer
2EMOVETHESEALINGNUTS% AND

GUIDEPOSTS% HOLDINGTHELEVELER
% TOTHESIDECOVER% 2EFERTO
TABLEBELOWFORWRENCHSIZES E90
Sealing nut removal

Pump size Wrench sizes
CCANDCC MMOPENEND
MMHEX

CCTHROUGHCC INCHOPENEND
MMHEX
CCTHROUGHCC MMOPENEND
MMHEX
E101 104
.OTETHEORIENTATIONSOFTHELEVELER
% ANDSIDECOVER% E40
2EMOVELEVELER% FROMSIDECOVER

% Cylinder block removal
2EMOVETHEINSERTASSEMBLY%
2EMOVEANDDISCARDSIDECOVER/ C12

RING%
CYLINDER BLOCK 2EMOVETHECYLINDERBLOCK# FROM

THEHOUSING
4HESWASHPLATEANDPISTONASSEMBLY
REMAINSINTHEHOUSINGC4AKECARETO
PREVENTPISTONSFROMBEINGSCRATCHED
WHILETHECYLINDERBLOCKISOUTOFTHE
HOUSING4HEPISTONSARENOTSELECTIVELY
lTTEDHOWEVERUNITSWITHHIGHHOURLY
USAGEMAYDEVELOPWEARPATTERNS
.UMBERTHEPISTONSANDBORESFORRE E101 131
ASSEMBLYIFTHEYARETOBEREUSED
11019577s2EV!"s!PRIL 31
008 918 12 BOMAG 641
18.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
CYLINDER BLOCK -OSTREPAIRSDONOTREQUIREBLOCKSPRING Cylinder block disassembly

REMOVAL0ERFORMTHISPROCEDUREONLY
IFYOUSUSPECTPROBLEMSWITHTHEBLOCK
SPRING C16
W7ARNING
2ISKOFPERSONALINJURY
C15
#OMPRESSINGTHEBLOCK 5SINGAPRESSAPPLYPRESSUREON
SPRINGREQUIRESTO THEBLOCKSPRINGWASHER# TO
.;TOLBF =5SEA COMPRESSTHEBLOCKSPRING#
PRESSSUFlCIENTTOMAINTAIN #OMPRESSTHESPRINGENOUGHTO C14
THISFORCEWITHREASONABLE SAFELYREMOVETHESPIRALRETAINING
EFFORT%NSURETHESPRINGIS RING# 7HILEMAINTAINING
SECUREBEFOREATTEMPTING PRESSUREUNWINDTHESPIRALRETAINING
TOREMOVETHESPIRAL RING#AREFULLYRELEASETHEPRESSURE C13
RETAININGRING2ELEASETHE ANDREMOVETHEOUTERBLOCKSPRING
PRESSURESLOWLYAFTERTHE WASHERBLOCKSPRINGANDINNER
RETAININGRINGISREMOVED BLOCKSPRINGWASHER# FROMTHE
CYLINDERBLOCKW
C12
E101-113
32 11019577s2EV!"s!PRIL
642 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SERVO CYLINDERS -ARKTHESERVOCYLINDERS&& ANDHOUSING" 4HISHELPSTOIDENTIFYEACH

SERVOCYLINDER&& WITHITSRESPECTIVESIDEOFTHEHOUSING"
.UMBEROFSCREWSANDWRENCHSIZEVARIESBYMODEL
5SINGAMMORMMHEXWRENCHREMOVETHEORSCREWS&&

RETAININGEACHSERVOCYLINDER&& TOTHEHOUSING"
A &OREARLYPRODUCTIONUNITSCAREFULLYPRYEACHCYLINDER&& FROMTHE

HOUSING" BYUSINGASCREWDRIVERINTHENOTCHESINTHECYLINDER
4HESERVOPISTONWILL
REMAININTHEHOUSING B &ORLATERPRODUCTIONUNITSINSTALLANMMORMMSCREWINTHETHREADED
&ORLATERPRODUCTIONUNITS HOLEINTHECENTEROFEACHCYLINDER&& ANDPULLTHECYLINDERSFROMTHE
WITHDISPLACEMENTLIMITERS HOUSING"
REMOVETHENUT
&& ANDLIMITER
SCREW&& FROM Servo cylinder removal
EACHSERVOCYLINDER
F112 F113
&& ANDINSTALLAN
MMORMMSCREWIN
ITSPLACEASAPULLERSCREW F40
F50
F40
F50
B10
F40
F50
F40
F50
F212
F213 E101 105E
11019577s2EV!"s!PRIL 33
008 918 12 BOMAG 643
18.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SWASHPLATE 2EMOVETHESWASHPLATEBEARINGCAGELINKPIN$ FROMTHEHOUSINGTHROUGHTHE

CONTROLOPENING
CMÃDISPLACEMENT 2EMOVETHEBEARINGCAGELOCATORLINK$ FROMTHESWASHPLATETHROUGHTHECONTROL

PUMPSUSEASCREWASTHE OPENING
LINKPIN2EMOVEITWITHA
MMINTERNALHEXWRENCHIF CCANDCCPUMPSHAVESCREW TYPELINKPINS/NEISATTHECONTROLOPENING4HE
NECESSARY OTHERISATTHESIDECOVEROPENING
2EMOVETHESWASHPLATE$ ANDPISTONASSEMBLY# THROUGHTHEHOUSINGSIDE

COVEROPENING
5NITSWITHANAUTOMOTIVE
CONTROLHAVEATHREADED $ISENGAGETHESERVOARM$ FROMTHESLIDERBLOCK& INTHESERVOPISTONASYOU
HOLEINONEENDOFTHE REMOVETHEASSEMBLY
SERVOPISTON4HISISFORTHE
CENTERINGASSISTSPRING 2EMOVETHESERVOPISTONANDSLIDERBLOCK& FROMHOUSING
ASSEMBLY&ORTHESEUNITS
NOTETHEORIENTATIONOF 2EMOVETHECRADLEBEARINGCAGEANDRACESWITHLOCATINGPINS
THESERVOPISTONINTHE
HOUSING 4HEBEARINGRACELOCATINGPINSAREALOOSElT
Disassembling the swashplate

Locating Pin
Servo piston
F20
D10
D95 D85 Bearing race
D80 Bearing cage

C20
D10
D50
D80
D85
C20
D50 E101 106E
34 11019577s2EV!"s!PRIL
644 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
PISTON ASSEMBLY 5SINGAMMORMMHEXWRENCHREMOVETHESCREWSC70 ANDSPACERS#

HOLDINGTHETWOSLIPPERGUIDEHOLDDOWNBEARINGS# TOTHESWASHPLATE$
$ISCARDSCREWS# 2EPLACEWITHNEWSCREWSWHENPUMPISASSEMBLED
2EMOVETHEHOLDDOWNBEARINGS# ANDSPACERS#
2EMOVETHESLIPPERGUIDE# ANDPISTONS# FROMTHESWASHPLATE$
2EMOVETHEPISTONASSEMBLIES# FROMTHESLIPPERGUIDE#
Removing the piston/slipper assembly
C20
C30
C50
D50
C40
C20
C30
C50
D50
C40
E101 107E
11019577s2EV!"s!PRIL 35
008 918 12 BOMAG 645
18.1 Travel pump
Series 90 Pumps
Repair Instructions
$ISASSEMBLY
SWASHPLATE 2EMOVEGUIDE$ ANDFEEDBACKLINK- BYREMOVINGSPECIALLOCKINGSCREW$

$ISCARDLOCKINGSCREW3EETABLESwashplate componentsBELOWFORWRENCHSIZES
2EMOVESERVOARM$ FROMSWASHPLATE$ BYREMOVINGLOCKINGSCREW$

$ISCARDLOCKINGSCREW3EETABLESwashplate componentsBELOWFORWRENCHSIZES
#LEANTHETHREADEDHOLESFORTHEHOLDDOWNSCREWSINSWASHPLATE$ OFALLOLD

LOCKINGCOMPOUND5SEA-8OR-8THREADTAP FORTHISPROCEDURE
#LEANTHETHREADEDHOLESFORTHELOCKINGSCREWS$$ INSWASHPLATE$ OFALL

OLDLOCKINGCOMPOUND5SEATHREADTAPGIVENINTHETABLEBELOW FORTHISPROCEDURE
Swashplate components
Pump size D55 wrench size D55 thread size D65 wrench size D65 thread size
CCANDCC MMHEX - MMINTERNALHEX -
Removing the swashplate guide and servo arm
M14
M14
D10
D10
D50 D50
E101 191E
36 11019577s2EV!"s!PRIL
646 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
Inspection
OVERVIEW #LEANALLPARTSINASUITABLESOLVENT2EPLACE/ RINGSGASKETSSHAFTSEAL)NSPECTALLPARTS

FORDAMAGENICKSORUNUSUALWEARPATTERNS2EPLACEALLPARTSWITHUNUSUALOREXCESSIVE
WEARORDISCOLORATIONWHICHINDICATESEXCESSIVEHEAT
SHAFT ASSEMBLY Inspection

)NSPECTTHESEALCARRIERFORANYDAMAGEORNICKS)NSPECTTHESHAFTANDBEARINGFORRUST
WEARORCONTAMINATION3PINTHEBEARINGINYOURHANDFEELINGFORROUGHNESS2EPLACEIF
NECESSARY
Shaft assembly
Shaft
Bearing
Seal Carrier
E101 541E
PISTONS AND SLIPPERS )NSPECTTHEPISTONSFORDAMAGEAND Inspect pistons

DISCOLORATION$ISCOLOREDPISTONSMAY
INDICATEEXCESSIVEHEATDONOTREUSE
Slipper
)NSPECTTHERUNNINGSURFACEOFTHE
SLIPPERS2EPLACEANYPISTONASSEMBLIES
WITHSCOREDORROUNDEDSLIPPEREDGES
-EASURETHESLIPPERFOOTTHICKNESS
2EPLACEANYPISTONASSEMBLIESWITH P104 109E
WORNSLIPPERS#HECKTHESLIPPERAXIAL
END PLAY2EPLACEANYPISTONASSEMBLIES
WITHEXCESSIVEEND PLAY2EFERTO2EWORK
3PECIlCATIONS,FORCOMPONENT
REWORKGUIDELINES
11019577s2EV!"s!PRIL 37
008 918 12 BOMAG 647
18.1 Travel pump
Series 90 Pumps
Repair Instructions
Inspection
CYLINDER BLOCK %XAMINETHERUNNINGFACEOFTHECYLINDER Inspect cylinder block

BLOCK4HESURFACESHOULDBESMOOTHAND
FREEOFNICKSANDBURRS2EMOVEANYBURRS
%NSURETHATNOSCRATCHESORGROOVESEXIST
Cylinder
THESEMAYDRASTICALLYREDUCEOUTPUT block
mOWANDLIFEOFPUMP2EFERTO2EWORK
3PECIlCATIONS,FORCOMPONENT A
REWORKGUIDELINES
flat to 0.0026 mm check for burrs

[0.000100 in]
P106 692E
ENDCAP JOURNAL )NSPECTTHEENDCAPVALVEPLATEAND End cap and journal bearing

BEARING SEALINGSURFACESFORNICKSANDSCRATCHES
#HECKSURFACEmATNESS2EFERTO2EWORK
3PECIlCATIONS,FORCOMPONENT
REWORKGUIDELINES)FANYOFTHEBASE
W7ARNING METALISVISIBLETHROUGHTHEPLASTIC
$ONOTDAMAGETHEVALVE BEARINGMATERIALREPLACETHEENDCAP
PLATESURFACEOFTHEEND JOURNALBEARING' 5SEASUITABLE
CAPWHENREMOVINGTHE PULLERTOREMOVETHEBEARINGW0RESSTHE
BEARING JOURNALBEARINGINTOTHEENDCAP'
USINGAPRESSPIN-AKESUREBEARINGIS
mUSHTOMM;INCHES=BELOW
THEVALVEPLATESURFACEOFTHEENDCAP
'
2EPLACEENDCAP)FJOURNALBEARINGSPINS
INTHEENDCAP
E101 108
VALVEPLATE )NSPECTVALVEPLATEFORWEARANDSCRATCHES3CRATCHESDEEPENOUGHFORYOUTOFEELWITH
YOURlNGERNAILORAPENCIL TIPARENOTACCEPTABLE$ONOTATTEMPTTOREWORK3ERIES
VALVEPLATESREPLACEIFDAMAGED
38 11019577s2EV!"s!PRIL
648 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
Inspection
MULTI-FUNCTION VALVE Inspection

CARTRIDGES #LEANANDINSPECTALLPARTS#ARTRIDGEISAVAILABLEASCOMPLETEUNITONLY
/ RINGSAREAVAILABLESEPARATELY
P04
P03
P01
P02
P05
P06
P07
P08
P17
P16
P15
P14
P09
P11
P13
P12
E101 531E

P14
P19
P12
P06
P21
P15
P14
P11 P22
P09
P1
P13
E101 532E
11019577s2EV!"s!PRIL 39
008 918 12 BOMAG 649
18.1 Travel pump
Series 90 Pumps
Repair Instructions
Inspection
CHARGE PRESSURE Inspection

RELIEF VALVE )NSPECTTHEPOPPET+ ANDMATINGSEATINTHEENDCAPFORDAMAGEORFOREIGNMATERIAL
7HENINSPECTINGSHIMADJUSTABLEVALVESDONOTALTERTHESHIMSORINTERCHANGEPARTS
,OCKNUt
"ODY
/ RING
3PRING
Seat
%%
CHARGE PUMP Inspection

)NSPECTALLPARTSFORWEARORDAMAGEANDREPLACEIFNECESSARY#HECKGEROTORASSEMBLY
ANDVALVEPLATEFORPITTINGFROMCAVITATION
Charge pump
H40
H05
H60
H50
H31
J50
J15
J30
H70
E101 542E
H80
40 11019577s2EV!"s!PRIL
650 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
Inspection
INTEGRAL CHARGE Inspection

PRESSURE FILTER )NSPECTTHElLTERHEADANDLOCKNUTSEALINGSURFACES)FYOUlNDANYNICKSORSCRATCHES
REPLACEDAMAGEDCOMPONENTS
Integral charge pressure filter manifold
N25 N20
N15
N36A
N36
N10
N35A
N35
11/16 in
E101 543E
HYDRAULIC AND Inspection

ELECTRIC DISPLACEMENT )NSPECTMACHINEDSURFACESONCONTROLANDPUMPFORNICKSANDSCRATCHES2EPLACECONTROL
CONTROLS IFYOUlNDDAMAGETOMACHINEDSURFACES
Hydraulic/Electric displacement controls
%%
11019577s2EV!"s!PRIL 41
008 918 12 BOMAG 651
18.1 Travel pump
Series 90 Pumps
Repair Instructions
Inspection
SWASHPLATE )NSPECTRUNNINGSURFACEFORWEARORSCRATCHES)NSPECTHOLDDOWNSCREWHOLESFOR
DAMAGE)FSCREWHOLESAREDAMAGEDREPLACESWASHPLATE)NSPECTFORWEARINLEVELERPAD
AREASEXCESSIVEWEARMAYAFFECTPUMPNEUTRAL)FYOUlNDDAMAGEREPLACESWASHPLATE
)NSPECTSWASHPLATEGUIDE$ FORWEAR2EPLACEIFNECESSARY2EFERTO2EWORK
3PECIlCATIONS,FORCOMPONENTREWORKGUIDELINES
Swashplate and guide inspection
D50
Hold down
screw holes
Running surface
Leveler pad areas E101 548E
42 11019577s2EV!"s!PRIL
652 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
Inspection
SERVO PISTON )NSPECTTHESERVOPISTONFORWEAR2EMOVEANDDISCARDSEALRINGS& ANDEXPANDER

/ RINGS& 2EPLACESERVOPISTONIFNECESSARY2EPLACE/ RINGSANDSEALRINGSBEFORE
REASSEMBLY
Servo piston inspection
Servo piston
E101 112E
CYLINDER BLOCK 6ISUALLYINSPECTTHECYLINDERBLOCK Cylinder block inspection

SPRINGANDWASHERSFORINDICATIONSOF
WEARORDAMAGE2EPLACEIFWEARCRACKS C16
OROTHERDAMAGEISPRESENT
C15
C14
C13
C12
E101-113
11019577s2EV!"s!PRIL 43
008 918 12 BOMAG 653
18.1 Travel pump
Series 90 Pumps
Repair Instructions
Inspection
CYLINDER BLOCK #OATALLPARTSWITHCLEANHYDRAULIC Cylinder block assembly

mUIDPRIORTOREASSEMBLY
W7ARNING C16
2ISKOFPERSONALINJURY )NSTALLTHEINNERBLOCKSPRINGWASHER
#OMPRESSINGTHEBLOCK # BLOCKSPRING# ANDOUTER
SPRINGREQUIRESTO WASHER# INTOTHECYLINDER C15
.;TOLBF =5SEA BLOCK5SINGAPRESSCOMPRESSTHE
PRESSSUFlCIENTTOMAINTAIN BLOCKSPRINGENOUGHTOEXPOSETHE
THISFORCEWITHREASONABLE RETAININGRINGGROOVE7INDTHESPIRAL
C14
EFFORT%NSURETHESPRINGIS RETAININGRING# INTOTHEGROOVE
SECUREBEFOREATTEMPTING INTHECYLINDERBLOCKW
TOREMOVETHESPIRAL
RETAININGRING2ELEASETHE 2ELEASEPRESSUREONSPRING6ISUALLY C13
PRESSURESLOWLYAFTERTHE CHECKTHATSPIRALRETAININGRINGIS
RETAININGRINGISREMOVED PROPERLYPOSITIONEDINITSGROOVE
C12
E101-113
SERVO PISTON RINGS )NSTALLNEWEXPANDER/ RINGS& INTOTHESEALGROOVESINTHESERVOPISTON)NSTALL

THESEALRINGS& INTHEGROOVESOVERTHEEXPANDER/ RINGS& C
C Caution !LLOWTHEASSEMBLYTOSETFORATLEASTMINUTES4HISALLOWSTHESEALRINGS& TO

$ONOTSTRETCHTHE RETURNTOTHEIRORIGINALUNSTRETCHEDSIZE
SEALRINGSANYMORE
THANNECESSARYDURING Servo piston assembly
INSTALLATION
Servo piston
P106 730E
44 11019577s2EV!"s!PRIL
654 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
SERVO ARM )NSTALLTHESERVOARM$
!LIGNPRESSlTDESIGNSERVOARMSWITHTHESWASHPLATESSLOTANDTHREADEDHOLESWHILE
INSTALLING0RESSCOMPLETELYINTOTHESWASHPLATESLOT
)NSTALLNEWLOCKINGSCREW$ WITHPRE APPLIEDLOCKINGCOMPOUNDINTOSWASHPLATE
4ORQUELOCKINGSCREW$ 3EETABLEBELOWFORWRENCHSIZESANDTORQUES
Servo arm specifications

Pump size Wrench size (for D55) 4ORQUE.sM;LBFsFT=
CCTHROUGHCC MMHEX ;=
CC MMHEX ;=
CC MMHEX ;=
CCCC MMHEX ;=
Servo arm installation
D10 D10
D50 D50
E101 110
11019577s2EV!"s!PRIL 45
008 918 12 BOMAG 655
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
SWASHPLATE GUIDE !SSEMBLETHESWASHPLATEGUIDE$ ANDFEEDBACKLINK- TOTHESWASHPLATE

)NSTALLNEWLOCKINGSCREW$ WITHPRE APPLIEDLOCKINGCOMPOUNDUSINGANINTERNAL
HEXWRENCH
4ORQUETHESCREWTOSPECIlCATIONSINTHETABLEBELOW
7HENINSTALLINGTHEGUIDEONTOTHECCSWASHPLATEHOLDTHESTRAIGHTSIDESOFTHE
GUIDEPERPENDICULARTOTHESLIPPERSURFACEOFTHESWASHPLATE$ WHILETIGHTENING
SCREW
Special locking screw specifications
Pump size D65 wrench sizes 4ORQUE.sM;LBFsFT=
CCANDCC MMINTERNALHEX ;=
CCTHROUGHCC MMINTERNALHEX ;=
CC MMINTERNALHEX ;=
CCANDCC MMINTERNALHEX ;=
Attaching swashplate guide

D65
M14
M14
D60
D50
D50
E101 111
Roll pin and flat washer

)NSTALLTHEHEADEDROLLPIN$ ANDmATWASHER$ IFREMOVED&ORPROPERDISTANCE
(BETWEENTHEWASHER$ ANDTHESIDEOFTHESWASHPLATEFOLLOWTHETABLESRoll pin
specifications (A)AND(B) BELOW
Roll pin specifications (A) Pin and washer positions

Pump frame size Distance, H: + 0.1, -0.25 mm
; INCHES=
CC MM;INCHES= Swashplate
NOWASHER D75
Roll pin specifications (B)

D70
Pump frame size Distance, H: ± 0.25 mm
;¼INCHES=
Distance H
CC MM;INCHES= P104 188E
CCTHROUGHCC MM;INCHES=
CC MM;INCHES=
CCANDCC ;=
;=

0INATSIDECOVERPOSITION

0INATCONTROLPOSITION
46 11019577s2EV!"s!PRIL
656 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
PISTON ASSEMBLY Piston assembly

!SSEMBLETHEPISTONASSEMBLIES# INTOTHESLIPPERGUIDE#
C Caution ,UBRICATETHESLIPPERANDSWASHPLATERUNNINGSURFACES

-OSTPARTSHAVECRITICAL
HIGHTOLERANCESURFACES #ENTERTHEPISTONS# ANDGUIDE# ONTHESWASHPLATE
4AKECARENOTTODAMAGE
THESESURFACESDURING
ASSEMBLY0ROTECTEXPOSED Piston assembly
SURFACESOPENINGSAND
PORTSFROMDAMAGEAND
FOREIGNMATERIAL
D10
C20
D50
C20
D50
E101 114
11019577s2EV!"s!PRIL 47
008 918 12 BOMAG 657
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
PISTON ASSEMBLY Fixed-clearance hold-down bearing

(continued)
3OMEEARLYPRODUCTIONPUMPSUSEASPRING LOADEDHOLD DOWNMECHANISM3ERVICEPARTS
FORTHESPRING LOADEDHOLD DOWNMECHANISMARENOLONGERAVAILABLE4HElXED CLEARANCE
HOLD DOWNBEARINGMUSTBEINSTALLEDIFHOLD DOWNPARTSREQUIREREPLACEMENTONTHESE
EARLYPUMPS2EFERTOTHEAPPROPRIATEService Parts ManualFORMOREINFORMATION
!SSEMBLEONE HALFOFTHElXED CLEARANCESLIPPERGUIDEHOLD DOWNBEARINGS#
0OSITIONSPACERS# OVERTHETHREADEDHOLESINTHESWASHPLATE$
C Caution )NSTALLONESLIPPERGUIDEHOLDDOWNBEARING# ANDSPACERS# C

0OSITIONTHESPLITBETWEEN
THE#SLIPPERGUIDE )NSTALLNEWSCREWSC70 THROUGHTHESLIPPERGUIDEHOLDDOWNBEARING# AND
BEARINGPLATESINLINEWITH SPACERS# C
THE$SWASHPLATEARM
,OCATETHEBEARINGSURFACE C Caution
OFTHE#BEARINGPLATES !LWAYSUSENEWSCREWSWITHPROPERLOCKINGCOMPOUND
NEXTTOTHE#SLIPPER
GUIDE 3TARTTHESCREWSC70 INTOTHESWASHPLATE$ DONOTTORQUE
0OSITIONSLIPPERGUIDEWITHPISTONSUNDERlRSTHOLDDOWNBEARING
!SSEMBLESECONDSLIPPERGUIDEHOLDDOWNBEARINGWITHSCREWSANDSPACERSONTOTHE
SWASHPLATE3TARTTHESCREWSDONOTTORQUE
,UBRICATESLIPPERGUIDEANDHOLDDOWNBEARINGS
Hold-down bearing installation

D50
D10
C30
C20
C40
C50
E101 115
48 11019577s2EV!"s!PRIL
658 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
PISTON ASSEMBLY Alternate hold-down bearing installation

(continued) D50
D10
C30
C20
C40
D50
C50
P106 542E
4ORQUETHESLIPPERGUIDEHOLD DOWN Torque settings

SCREWSC70 TOTHESPECIlCATIONSIN Pump size 4ORQUE.sM;LBFsFT=
Torque settings CCTHROUGHCC ;=
CCTHROUGHCC ;=
%NSURETHESLIPPERGUIDE# ANDPISTONSLIPPERS# SLIDEFREELYONTHESWASHPLATE

AFTERALLBOLTSARETORQUED
11019577s2EV!"s!PRIL 49
008 918 12 BOMAG 659
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
BEARING CAGE .EWPARTSHAVELOCKINGPIN" INTEGRALTOBEARINGRACE&OROLDERPUMPSLOCKINGPINS

ARESEPARATEFROMRACES4HELOCATINGPINSASSUREPROPERASSEMBLY
2ETAINTHERACESINPOSITIONWITHPETROLEUMJELLY
)NSTALLTHEBEARINGRACESINTOTHEHOUSINGPOSITIONINGTHERACESONTHELOCATINGPINS

"
!SSEMBLEANDLUBRICATETHEBEARINGCAGE
)NSTALLTHEBEARINGCAGEONTHEBEARINGRACES
Bearing assembly
Bearing race
New parts have locking pin (B20) integral

to bearing race. For older pumps, locking
pins are separate from races. B20
B20
P106 513E
50 11019577s2EV!"s!PRIL
660 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
HOUSING 2EFERTOTHEILLUSTRATIONHousing installations, NEXTPAGEFORTHENEXTSTEPS
0OSITIONTHESERVOPISTON& INTHEHOUSING
&ORUNITSWITHAN ,UBRICATEANDINSTALLTHEBRONZESLIDERBLOCK& ONTOTHESERVOPISTON

AUTOMOTIVECONTROL
THESERVOPISTONHASA #AREFULLYLOWERTHESWASHPLATEASSEMBLYINTOTHEHOUSINGTHROUGHTHEENDCAP
THREADEDHOLEONITS OPENING0ROTECTTHEPISTONSFROMBEINGSCRATCHED
MACHINEDEND0UTTHISEND
ONTHESIDEOFTHEHOUSING (OLDTHESWASHPLATEASSEMBLYAPPROXIMATELYMM;³INCH=ABOVETHECRADLE
WHERETHECENTERINGASSIST BEARINGS
SPRINGSLEEVEISLOCATED
0OSITIONTHEFEEDBACKLINK$ INTHECONTROLOPENING
,OWERTHESWASHPLATEASSEMBLYONTOTHECRADLEBEARINGS
C Caution 0OSITIONTHESERVOPISTONONTHESLIDERBLOCK& 4HEPARTSSHOULDSLIDEFREELY

"ESURETOASSEMBLETHE
CORRECTSERVOCYLINDERON ,UBRICATEINSIDETHESERVOCYLINDERS(OLDTHESERVOPISTONINPLACEANDINSTALLTHE
EACHSIDEOFTHEHOUSING SERVOCYLINDERSC
&ORUNITSWITHANAUTOMOTIVECONTROLTHEREISASPECIALSERVOCYLINDERONTHECENTERING
ASSISTSPRINGSIDEOFTHEHOUSING
)FPREVIOUSLYREMOVEDINSTALLNEWSCREENS" 5SEPROPERINSTALLATIONTOOL
11019577s2EV!"s!PRIL 51
008 918 12 BOMAG 661
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
HOUSING (continued) Servo cylinder screws

)NSTALLTHESERVOCYLINDERS& COMPLETELYINTOTHEHOUSINGBORES
C Caution .UMBEROFSCREWSANDWRENCHSIZESVARYBYMODEL
)FTHESERVOCYLINDERSARE
NOTSEATEDCOMPLETELYINTO )NSTALLTHEORSCREWS&& Servo cylinder screw torques
THEBORESTIGHTENINGOF INEACHSERVOCYLINDERC Pump size F111/F211
THESCREWSCANDAMAGETHE .sM;LBFsFT=
/ RINGS 4ORQUETOSPECIlCATIONSINServo CC ;=
cylinder screw torques CC ;=
CC ;=
&ORUNITSWITHANAUTOMOTIVECONTROL CC ;=
INSTALLTHESERVOCYLINDERSCREWSONTOTHE CC ;=
HOUSINGSCENTERINGASSISTSPRINGSIDE CC ;=
CCANDCC ;=
)FPREVIOUSLYREMOVEDREPLACE
SCREENS" WITHNEWSCREENS
Housing installations
F20
F10
F111
Swashplate assembly F112

O
D14
F111 F113
F213 B60
O
F212
F211
F211 E101 118E
52 11019577s2EV!"s!PRIL
662 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
HOUSING (continued) Displacement limiter.

)NSTALLDISPLACMENTLIMITERS&& INTOSERVOCYLINDERSTOLOCATIONMARKED
DURRINGDISASSEMBLY7RENCHSIZESARESHOWNINTABLEBELOW
)NSTALLNEWSEALLOCKNUTS&& ONTODISPLACEMENTLIMITERS4ORQUESEAL

LOCKNUTSWHILEHOLDINGDISPLACEMENTLIMITER7RENCHSIZESANDTORQUEVALUESARE
SHOWNINTABLEBELOW2EFERTOTHESeries 90 Pumps Service Manual 520L0818FOR
DISPLACEMENTLIMITERADJUSTMENTINFORMATION
Displacment limiter and seal lock nut wrench sizes and torques
Pump size F113 F213 F112/F212 F112/F212
wrench size wrench 4ORQUE.sM;LBFsFT=
CC CC MM MM ;=
CC MM MM ;=
CCANDCC MM MM ;=
Housing installations
F20
Servo piston
F111
Swashplate assembly F112

O
D14
F113
F111
F213
B60
O
F211
F212
F211
E101 118E
11019577s2EV!"s!PRIL 53
008 918 12 BOMAG 663
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
BEARING CAGE LOCATOR !LIGNTHESWASHPLATESBEARINGCAGESLOTWITHTHEHEADEDSPRINGPIN!LIGNWITHTHE

LINK HOUSINGSPINHOLE3EEILLUSTRATIONLocator link positionFORCORRECTORIENTATION
(OOKTHECAGELOCATORLINK$ OVERTHESPRINGPINBETWEENTHEWASHERANDTHE

SWASHPLATE
2OTATETHELINK$ INTOTHEBEARINGCAGESLOT
FRAMESIZEPUMPSDONOTHAVEAWASHERONTHESPRINGPIN
!LIGNTHELOCATORLINK$ HOLEWITHTHEHOUSINGHOLE
)NSTALLTHELINKPIN$ THROUGHTHELOCATORLINK$ ANDINTOTHEHOUSING
ANDPUMPSUSEAmATHEADSCREWASTHELINKPIN3TEPSANDREFERTOTHESE

C Caution PUMPS
!LWAYSUSEANEWSCREW
WITHPROPERLOCKING )NSTALLANEWSCREWWITHLOCKINGCOMPOUND THROUGHTHELOCATORLINK$ ANDINTO
COMPOUND THEHOUSINGC
C Caution 4IGHTENTHESCREWINTOTHEHOUSING$OTHISUNTILTHEHEADOFTHESCREWISATAHEIGHTOF

$O./4TORQUETHISSCREW TOMM;TOINCHES=FROMTHEPUMPHOUSINGSMACHINEDSURFACEC
AGAINSTTHE$LOCATOR
LINK4HELINKMUSTROTATE Locator link position
FREELY Finished Assembly
Housing pin hole
D80
D85
Bearing cage slot

Headed spring
pin washer
E101 120E
54 11019577s2EV!"s!PRIL
664 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
VERIFY PROPER 0USHTHESWASHPLATEASSEMBLYTOWARDTHECONTROLSIDEOFTHEHOUSINGUNTILTHE

ASSEMBLY SWASHPLATEGUIDECONTACTSTHEBEARINGRACE
#HECKFORCLEARANCEBETWEENTHESERVOARMANDTHESLIDERBLOCK
%NSURESWASHPLATEASSEMBLYMOVESFREELYONBEARINGS
2OTATESWASHPLATEONBEARINGSTOCHECKFORCONTROLLINKMOVEMENTANDPROPER
LOCATORLINKPOSITION
SWASHPLATE LEVELER 0LACEINSERTS% ONTOSIDECOVER Attach leveler to side cover

%
E30
0OSITIONTHESWASHPLATELEVELER%
ONTHESIDECOVERINSERTS%
.OTETHEORIENTATIONOFTHELEVELER
% ANDTHESIDECOVER%
)NSTALLTHEGUIDEPOSTS%
E22
ANDSEALINGNUTS% 3EEGuide
post/sealing nut installationTABLE
FORWRENCHSIZESANDTORQUE
SPECIlCATIONS E90
)NSTALLTHELEVELERSPRINGSEATS% IF

NECESSARY
3OMEPUMPSDONOTHAVEREMOVABLE
SWASHPLATELEVELERSPRINGSEATS%
E40
E101 121
Guide post/sealing nut installation

Pump size Wrench sizes 4ORQUE.sM;LBFsFT=
CCANDCC MMOPENEND ;=
MMHEX
CCTHROUGHCC
INCHOPENEND ;=
MMHEX
CCTHROUGHCC MMOPENEND ;=
MMHEX
11019577s2EV!"s!PRIL 55
008 918 12 BOMAG 665
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
INSTALLING LEVELER ,UBRICATEANDINSTALLANEWSIDECOVER/ RING%

AND SIDE COVER
)NSTALLTHESIDECOVERASSEMBLYC
C Caution )NSTALLSIDECOVERSCREWS% WITHOUTLOCKINGCOMPOUNDATOCLOCKAND

3LIDESWASHPLATELEVELER OCLOCKLOCATIONS4IGHTENONLYTOHALFTORQUE
% TOWARDTHECASEDRAIN
PORT4HISALLOWSTHELEVELER 4HISHOLDSTHE%COVERWHILECHECKINGTHEZEROANGLEPOSITIONOFTHESWASHPLATE
% TOCLEARTHESIDEOF
THESWASHPLATEDURINGSIDE Setting leveler - neutral position
COVERINSTALLATION )FREUSINGORIGINALPARTSROTATETHESIDECOVER% TOALIGNTHEMARKSONTHECOVER
ANDHOUSINGADDEDDURINGDISASSEMBLY )FUSINGNEWSWASHPLATELEVELERPARTS
ALIGNMENTMARKSMAYNOTBEACCURATE
!PPLYAFORCEOFTO.;TOLBF =TOTHESWASHPLATELEVELER% 4HISENSURES

BOTHARMSAREINCONTACTWITHTHESWASHPLATE#LAMPAmATPLATONTOTHEPUMP
HOUSINGASSHOWNIN Leveling swashplateDRAWINGBELOW
%NSURETHESWASHPLATEISONITSBEARINGS
-EASUREWITHADEPTHMICROMETERTOlNDTHEDISTANCEFROMTHEENDCAPFACEOFTHE
HOUSINGTOTHEOUTEREDGEOFTHESWASHPLATESURFACE
W7ARNING
4HESEMEASUREMENTSMUST 4AKEASECONDMEASUREMENTATAPOINT²FROMTHElRSTPOINTOFMEASUREMENTAT
NOTVARYBYMORETHAN THEOPPOSITEEDGEOFSWASHPLATESURFACE W
MM;INCHES=
Side cover and O-ring installations

Slide towards this end
Blind housing screw when installing
torques and Through
8AND9AREMEASUREMENTS housing screw torques
Case drain
FROMTHETOPOFTHE port
SWASHPLATETOTHEENDOF
THEHOUSING$IFFERENCE
BETWEEN8AND9MUSTBE E20
LESSTHAN
MM;IN=
Leveling swashplate E10

22-44 N [5-10 lb]
Y X
B10
E101 122E
P106 516E
56 11019577s2EV!"s!PRIL
666 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
INSTALLING LEVELER Positioning the side cover

AND SIDE COVER 2OTATETHESIDECOVER% WHICHWILLALSOROTATETHELEVELERANDSWASHPLATEUNTIL
(continued) THEMEASUREDDEPTHONEACHSIDEOFTHESWASHPLATEISWITHINMM;IN=
)NSTALLTHEREMAININGSCREWS% WITHPRE APPLIEDLOCKINGCOMPOUND

W7ARNING
4HESEMEASUREMENTSMUST 4ORQUETHESESCREWSTOTHESPECIlCATIONSINBlind housing screw torques ANDThrough
NOTVARYBYMORETHAN housing screw torques.
MM;INCHES=
2EPLACETHESCREWS% USEDINITIALLYTOHOLDTHESIDECOVERONWHILESETTING
NEUTRALWITHNEWSCREWSTHATHAVELOCKINGCOMPOUND
4ORQUETHESESCREWSTOTHESPECIlCATIONSINBlind housing screw torques.
Through housing screw torques Blind housing screw torques

Pump size 4ORQUE.sM;LBFsFT= Pump size 4ORQUE.sM;LBFsFT=
CCANDCC ;= CCANDCC ;=
CCTHROUGHCC ;= CCTHROUGHCC ;=
CCTHROUGHCC ;= CCTHROUGHCC ;=
CYLINDER BLOCK 0OSITIONPISTONSUSINGATWISTING Installing cylinder block

INSTALLATION MOTIONSOTHATTHEYALLLEANINA
Turn cylinder block
CLOCKWISEDIRECTION counterclockwise when
placing on pistons.
3ETCYLINDERBLOCK# ONTOPISTONS O
SOEACHBLOCKBORESITSONTOPOFA
PISTON
C12
0REVENTTHEPISTONSSLIPPERSFROM
TURNINGBYCAREFULLYPLACING a
SCREWDRIVERBETWEENTHESLIPPER
RETAINERANDSWASHPLATE$ONOT
SCRATCHSWASHPLATEORSLIPPERS
Lean pistons clockwise.
4URNTHECYLINDERBLOCK
COUNTERCLOCKWISE
4HISMAKESTHEPISTONSSTANDUPSTRAIGHT O
ANDlTINTOTHEBLOCKBORES
,OWERTHEBLOCKONTOTHEPISTONS
2ELUBRICATEPISTONBORESANDCYLINDER
BLOCK
E101 130E
11019577s2EV!"s!PRIL 57
008 918 12 BOMAG 667
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
END CAP INSTALLATION Preparing for end cap installation Installing the valve plate
)NSTALLTHEENDCAPALIGNMENTPINS
" INTOTHEHOUSING
,UBRICATETHERUNNINGSURFACEOFTHE B50

CYLINDERBLOCK
B50
)NSTALLTHEVALVEPLATE# ONTHE

ALIGNMENTPINS
.OTETHEDIRECTIONOFTHEARROWCUT
OUTSINTHEVALVEPLATE
7HENVIEWINGFROMTHEENDCAPSIDE E101 123E
OFVALVEPLATETHEARROWSMUSTPOINTIN
THEOPPOSITEDIRECTIONOFPUMPROTATION Installing the springs
&OREXAMPLEARIGHTHANDCLOCKWISE
ROTATIONPUMPMUSTHAVETHEARROWS
POINTINGINTHECOUNTERCLOCKWISE
DIRECTION E80
D95
)NSTALLTHELONGSPRINGS%
WITHINNERSPRINGSIFUSED ONTHE
SWASHPLATELEVELERSPRINGSEATS
)FUSEDINSTALLTHESHORTSPRING$

ONTHESERVOARMBRACKET
3OMEMODELSAREBUILTWITHANALTERNATE
SERVOARMWHICHDOESNOTREQUIRESPRING
$
E101 124
0LACENEWENDCAPGASKET' Installing the gasket

C Caution ONTHEHOUSINGINTHEORIENTATION
$ONOTBENDORDAMAGE SHOWNLOCATEDBYTHEALIGNMENT
THEENDCAPGASKETDURING PINS C
INSTALLATION
G30 C
E101 125E
58 11019577s2EV!"s!PRIL
668 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
END CAP INSTALLATION End cap parts Installations into end cap
(continued) ,UBRICATETHEENDCAPJOURNAL
BEARING' 0RESSBEARINGINTO
HOUSINGIFNECESSARY
)NSTALLTHEHARDENEDSHIMS%
INTHEENDCAPPOCKETSFORTHE
SWASHPLATELEVELERSPRINGS
2ETAINTHESHIMSUSINGPETROLEUMJELLY End cap
4HESHIMPOCKETSAREDIFFERENTDEPTHIN
ENDCAP
E24
E101 126E
End cap installation Fastening end cap to housing

,OWERTHEENDCAPONTOHOUSING
WHILEPOSITIONINGTHESPRINGSINTHEIR
ENDCAPPOCKETS
G95
)NSTALLTHELARGEENDCAPSCREWS G94
* G93
7HENPROPERLYINSTALLED
THEENDCAPENGAGES 4IGHTENTHELARGEENDCAPSCREWS
THEALIGNMENTPINS4HE * EVENLY3EELarge end cap screw
SPRINGSHOLDTHEENDCAP torques
TOMM;TOINCH=
AWAYFROMTHEHOUSING .UMBEROFSCREWSANDWRENCHSIZEVARIES
BYMODEL
E101 127E
)NSTALLTHEORSMALLERSCREWS
'' HOLDINGTHEENDCAPTO Torque 6 mm internal hex
THEHOUSING #"'#$)t]
Torque 8 mm internal hex
#"'#$)t]
4HEREISALIFTINGBRACKET' SPACER
' ANDWASHER' ONTHEENDCAP See Large endcap screw
SCREW' torques for appropriate J80
torque values.
4ORQUETHEMMINTERNALHEXSCREWS
'' TO.sM;LBFsFT= Large end cap screw torques
Pump size 4ORQUE.sM;LBFsFT=
4ORQUETHEMMINTERNALHEXSCREWS CC ;=
'' TO.sM;LBFsFT= CC ;=
CC ;=
CC ;=
CC ;=
CC ;=
CCANDCC ;=
11019577s2EV!"s!PRIL 59
008 918 12 BOMAG 669
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
SPEED SENSOR Assembly

)NSTALLANEW/ RING"! ONTOTHESENSOR"
5SINGANWRENCHINSTALLTHESPEEDSENSORWITHLOCKNUTAND/ RING INTO

THEHOUSING!DJUSTTHEGAPBETWEENTHESENSORANDTHEMAGNETICSPEEDRINGAS
INSTRUCTEDIN Speed sensor adjustment in Series 90 Pumps Service Manual 520L0818
!FTERADJUSTMENT TORQUETHESENSORLOCKNUTTO.sM;LBFsFT=
)FASPEEDSENSORISNOTINSTALLEDUSEAININTERNALHEXWRENCHTOTORQUETHE

HOUSINGPLUG" TO.sM;LBFsFT=
Speed sensor
B83 O-ring plug
ft]
B83A
B83 B83A

t]
E101 095E
60 11019577s2EV!"s!PRIL
670 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
MULTI-FUNCTION VALVE Multi-function valve - pre 1988

CARTRIDGES - PRE 1988
P14
P19
P12
P06
P21
P15
P14
P11 P22
P09
P1
P13
E101 532E
Assembly
,UBRICATEANDINSTALLINTERNALCOMPONENTS00000AND0
)NSTALLPOPPETSEAT0
)NSTALLRETAININGRING0
,UBRICATEANDINSTALL/ RING0
)FPREVIOUSLYREMOVEDREASSEMBLEANDINSTALLBYPASSACTUATOR0 4ORQUETO

.sM;LBFsFT=
CCaution
)FPRESSURELIMITERWASREMOVEDFROMBYPASSACTUATOR0 ADJUSTPRESSURELIMITERTO
MODELCODESPECIlCATIONS
)NSTALLCARTRIDGESANDTORQUEASSHOWNINTHETABLEBELOWC
Multi-function valve wrench size Multi-function valve torque

Frame size Wrench size Frame size Torque
n INCH n .sM;LBFsFT=
11019577s2EV!"s!PRIL 61
008 918 12 BOMAG 671
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
PRESSURE OVERRIDE Assembly Pressure override valve components

VALVE (OPTION FOR 180 )NSTALLNEW/ RINGS
FRAME SIZE)
Screws
)NSTALLTHEVALVEONTOTHEPUMPEND
CAPANDTORQUETHESCREWSTO.sM Pressure override
;LBFsFT= valve
O-rings
E101 079E
CHARGE PRESSURE Assembly Lock nut wrench size

RELIEF VALVE )NSTALLTHEPOPPET+ ANDSPRING Frame size Wrench size
+ n INCH
n INCH
&ORSHIMADJUSTABLEVALVESINSTALL
THESHIMSANDPLUGTORQUETO
.sM;LBFsFT=&ORSCREWADJUSTABLE Charge pressure relief valve
VALVESINSTALLTHEPLUGWITHITSLOCK
NUTALIGNINGTHEMARKSMADEAT
+
DISASSEMBLYANDTORQUETHELOCKNUT h ,OCKNUT
TO.sM;LBFsFT= t ,OCKNUTTORQUE
#HECKTHECHARGEPRESSUREAND +

ADJUSTIFNECESSARY hIN
d+ +
+
+
3EEAPPROPRIATETABLE
62 11019577s2EV!"s!PRIL
672 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
CHARGE PUMP Current charge pump configuration
H40
H05
H60
H50
H31
J50
J15
J30
H70
E101 082E
H80
Retainer screw wrench size

n MM
n MM
Assembly
"ESURETOINSTALLTHECHARGEPUMPINTHEPROPERORIENTATION)FUNSUREOFCHARGEPUMP
ROTATIONREFERTOTHEMODELCODE
4HEORIENTATIONOFTHEGEROTORASSEMBLYOUTERECCENTRICRINGANDTHELOCATIONOFTHE
ALIGNMENTPININTHEENDCAPDETERMINETHECHARGEPUMPROTATION$ONOTMIXCHARGE
PUMPPARTSFROMDIFFERENTPRODUCTIONPERIODS!LWAYSINSTALLASACOMPLETEASSEMBLY
)NSTALLTHEVALVEPLATE( ANDTHEGEROTORASSEMBLYOUTERRING
)NSTALLTHEALIGNMENTPIN( TOPROPERLYORIENTTHEVALVEPLATEANDOUTERECCENTRIC

RINGFORCORRESPONDINGPUMPROTATION
0RIORTOINSTALLATIONLUBRICATETHE)$/$ANDSIDEFACESOFTHEGEROTORASSEMBLY
)NSTALLTHEGEROTORASSEMBLY(
)NSTALLTHEOUTERPLATEEARLYPRODUCTIONANDINTERMEDIATEPRODUCTIONPUMPSONLY
NOTSHOWN
11019577s2EV!"s!PRIL 63
008 918 12 BOMAG 673
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
CHARGE PUMP )NTERMEDIATEPRODUCTIONCMÃANDCMÃPUMPSUSETHESAMECHARGEPUMP

(continued) COUPLING4WOKEYWAYSAREPROVIDEDINTHECOUPLINGFORTHECHARGEPUMPSUSEDINTHESE
UNITS4HEREARKEYWAYWITHIDENTIlERGROOVE ISUSEDINCMÃPUMPS4HEFRONTKEYWAY
CLOSESTTOTHEINTERNALLYSPLINEDENDOFTHESHAFT ISUSEDINCMÃPUMPS
)NSTALLTHECHARGEPUMPCOUPLING4HEINTERNALLYSPLINEDENDOFTHECOUPLINGMUST
ENGAGETHEMAINPUMPSHAFT&ORPUMPSWITHANAUXILIARYMOUNTINGPADINSTALLTHE
AUXILIARYDRIVECOUPLINGINSTEAD
4HEOUTSIDEDIAMETEROFTHEINTERNALLYSPLINEDENDOFSOMEEARLYPRODUCTIONCHARGE
PUMPCOUPLINGSWASCHAMFERED%ARLYPRODUCTIONENDCAPSMAYNOTBEMACHINEDTO
ACCEPTANON CHAMFEREDCOUPLING!LWAYSUSEACHAMFEREDCHARGEPUMPCOUPLINGIN
PUMPSWITHTHEEARLYENDCAP
&ORPUMPSWITHNOAUXILIARYPADINSTALLANEW/ RING* ONTOCHARGEPUMPCOVER

)FANAUXILIARYPADISINSTALLEDAN/ RINGISNOTUSEDONTHECOVER
#AREFULLYREMOVETHEALIGNMENTPINFROMTHECHARGEPUMPPARTS)NSTALLTHEPININITS
HOLEINTHECHARGEPUMPCOVER* SEEPREVIOUSPAGEFORCORRECTORIENTATION AND
RETAINWITHPETROLEUMJELLY)NSTALLTHECOVERWITHALIGNMENTPIN INTOTHEENDCAP
ANDALIGNEDCHARGEPUMPPARTS4AKECARENOTTODAMAGETHECOVER/ RINGIFUSED
CCaution
)NORDERTOAVOIDLOSSOFCHARGEPRESSUREINPUMPSWITHANAUXILIARYMOUNTINGPAD
ALWAYSINSTALLTHECHARGEPUMPCOVERSOTHEPADDRAINHOLEISLOCATEDONTHESAMESIDEOF
THEENDCAPASTHECHARGEINLETPORT
)NSTALLTHECHARGEPUMPCOVER Retainer screw torque

RETAINER( ANDTHESIXINTERNAL Frame size Torque
HEXSCREWS( 4ORQUETHESCREWS n .sM;LBFsFT=
PERTHETABLEATTHERIGHT n .sM;LBFsFT=
&ORPUMPSWITHAUXILIARYMOUNTINGPADSINSTALLTHE/ RINGANDAUXILIARYMOUNTING

PADADAPTORONTOTHEENDCAP
64 11019577s2EV!"s!PRIL
674 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
AUXILIARY PAD Auxiliary pad components (typical)
J50
J80
Endcap screw J70
J60
See table for wrench size and torque
E101 084E
Assembly
,UBRICATEANDINSTALL/ RING* ONENDCAPPILOT
)NSTALLTHEAUXILIARYMOUNTINGPAD* ONREAROFENDCAP
4ORQUEAUXPADSCREWSINA )NSTALLFOURLARGESCREWS* ANDNEWWASHERS* THROUGHTHEMOUNTINGPADAND

CRISS CROSSPATTERN ENDCAPINTOTHEHOUSING4ORQUEPERTHEACCOMPANYINGTABLE
Aux. pad screw wrench size Aux pad screw torque

Frame size Wrench sizes Frame size Torque
nEARLY MMINTERNALHEX .sM;LBFsFT=
MMHEX .sM;LBFsFT=
n MMHEX n .sM;LBFsFT=
n MMINTERNALHEX n .sM;LBFsFT=
n MMINTERNALHEX
DISPLACEMENT )FTHEPUMPISEQUIPPEDWITHCONTROL Filter screen installation

CONTROL FILTER lLTERSCREENSINTHEPUMPHOUSINGLATE B90
SCREENS PRODUCTION PRESSTHEMINTOPOSITION
WITHTHEROUNDEDEDGEOFTHElLTER P106 690E
SCREENSFACINGTHECONTROL UNTILTHEYARE
mUSHTOMM;INCH=BELOWTHE
SURFACEOFTHEHOUSING
11019577s2EV!"s!PRIL 65
008 918 12 BOMAG 675
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
INTEGRAL CHARGE Assembly

PRESSURE FILTER )NSTALLTHEHYDRAULICTUBE. INTOITSBOREINTHEENDCAP)NSTALLTHElLTERHEAD.
REPLACEMENT INTOTHEPORTUSINGANEW/ RING. 4HEHYDRAULICTUBESHOULDGOINWITHLOWFORCE
!FTERROTATINGTHElLTERHEADCLOCKWISESOTHATTHETHREADSENGAGEWITHTHETHREADS
CCaution INTHEENDCAPCONTINUETOROTATEITCLOCKWISEBETWEENANDREVOLUTIONS0OSITION
&AILURETOINSTALLTHElLTER HEADASDESIREDC
MANIFOLDORlLTERHEAD
TOASUFlCIENTDEPTHIN 7HILEHOLDINGTHElLTERHEADINTHEDESIREDPOSITIONTIGHTENTHESWIVELLOCKNUT
THEENDCAPWILLRESULTIN . ANDTORQUEASSHOWNINTABLE
INSUFlCIENTENGAGEMENT
OFTHETUBEINTHEEND )NSTALLANEWlLTERCANISTER. PERTHEINSTRUCTIONSONTHElLTERCANISTER
CAPBORE4HISMAYALLOW
UNlLTEREDOILTOBYPASSTHE
lLTERANDENTERTHECHARGE Integral charge pressure filter
SYSTEM
N25 N20
N15 Filter manifold lock nut
N36A
N36
11/16 in
N40
N10
N35A
N35
11/16 in
P106 182E
Lock nut wrench size and torque

Frame size Wrench size Torque
n INCH .sM;LBFsFT=
n INCH .sM;LBFsFT=
n INCH .sM;LBFsFT=
66 11019577s2EV!"s!PRIL
676 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
PUMP CONTROL COVER Assembly

PLATE )NSTALLANEWGASKETONTHEHOUSING)NSTALLTHECOVERPLATE
)NSTALLSCREWS- USINGAMMINTERNALHEXWRENCH4ORQUETHESCREWSTO.sM

;LBFsFT=
Pump controls cover plate M90 X

MM
t .sM;LBFsFT=
-
3EALWASHER
LOCATIONCC
-
d
0%
DISPLACEMENT )NSTALLNEW/ RINGSUSINGPETROLEUM Displacement control adapter plate (early

CONTROL ADAPTER JELLYTORETAINTHEM production 130 cm³ pumps only)
PLATE (EARLY Adapter plate
PRODUCTION 130 )NSTALLADAPTERPLATE screws
PUMPS ONLY)
)NSTALLSCREWSUSINGAMMINTERNAL 6 mm
HEXWRENCH4ORQUETO.sM
;LBFsFT= t]
O-rings
Adapter plate
Seal
E101 087E
11019577s2EV!"s!PRIL 67
008 918 12 BOMAG 677
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
HYDRAULIC AND Assembly

ELECTRIC DISPLACEMENT )NSTALLANEWGASKET- 6ERIFYTHECONTROLORIlCECHECKVALVEANDSPRING4 AREIN
CONTROLS THEIRPROPERPOSITIONINTHECONTROL
0OSITIONTHECONTROL- ONTHEHOUSING)NSERTTHECONTROLLINKAGEPININTOTHE

SWASHPLATELINK

-X
I MM
-
-
d
4
4
0%
68 11019577s2EV!"s!PRIL
678 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
MANUAL DISPLACEMENT Assembly

CONTROL (MDC) )NSTALLANEWGASKET- )NSPECTCONTROLTOASSURETHATTHECONTROLORIlCECHECK
VALVEANDSPRINGAREINTHEIRPROPERPOSITIONINTHECONTROL
)NSTALLTHECONTROL%NGAGETHEPINONTHECONTROLLINKAGEINTOTHEMATINGHOLEINTHE
LINKATTACHEDTOTHESWASHPLATE
)FREMOVEDINSTALLTHECONTROLHANDLE- ANDLOCKINGNUT- WITHWASHER-

(OLDTHEPOSITIONOFTHEHANDLEANDTORQUETHELOCKINGNUTTO.sM;LBFsFT=
USINGANMMHEXWRENCH
MDC installation -

3 - h MM
h IN M70
-X
I MM
-
3EALWASHER d
LOCATIONCC
4
4 4
0%
7ITHTHECONTROLINPOSITIONMOVECONTROLLEVERBOTHDIRECTIONSTOCHECKPROPER

ENGAGEMENTOFCONTROLLINKAGEPIN)FPROPERLYASSEMBLEDLEVERWILLRETURNTO
CENTER)FLEVERDOESNOTRETURNTOCENTERREMOVETHECONTROLANDREPEATTHEABOVE
PROCEDURE
;LBFsFT=
W 7ARNING
2ISKOFIMPROPERMACHINE )NSTALLASEALINGWASHERUNDERTHEHEADOFMOUNTINGSCREWSINTHELOCATIONSHOWN
START UP)FEQUIPPEDWITH
.EUTRAL3TART3WITCH.33 )FTHECONTROLISEQUIPPEDWITHANEUTRALSTARTSWITCHREFERTOMDC Neutral start switch
PERFORM.33ADJUSTMENT adjustmentINSTRUCTIONSINTHESeries 90 Pumps Service Manual 520L0818
PROCEDUREINSERVICE
11019577s2EV!"s!PRIL 69
008 918 12 BOMAG 679
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
SOLENOID OVERRIDE Solenoid override valve installationSeal washer

VALVE FOR MDC location
(42, 180, 250 cc)
M77
M76A
M76C
M76B
M76
M78 (x2)
5 mm
M75
P106 186E
Assembly
)NSTALLANEWGASKET- ONTHECONTROLHOUSING)NSTALLTHEMANIFOLD- ONTO
THECONTROLHOUSINGALIGNTHEGASKETANDINSTALLTHESCREWS- 4ORQUETHESCREWS
TO.sM;LBFsFT=
5SINGAMMWRENCHTORQUEVALVE- TO.sM;LBFsFT=)FSOLENOIDWAS

REMOVEDTORQUESOLENOIDNUTTO.sM;LBFsFT=$ONOTOVERTORQUETHESOLENOID
NUT
70 11019577s2EV!"s!PRIL
680 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
SOLENOID OVERRIDE Assembly

VALVE FOR MDC WITH 5SINGPETROLEUMJELLYTORETAINTHEMINSTALLNEW/ RINGS--- ONTHE
PRESSURE RELEASED ADAPTERPLATE0LACETHEADAPTERPLATEINTOPOSITIONANDUSINGAMMINTERNALHEX
BRAKE INSTALLTHESCREWS- 4ORQUETHESCREWSTO.sM;LBFsFT=
5SINGPETROLEUMJELLYTORETAINTHEMINSTALLNEW/ RINGSONTOTHESOLENOIDVALVE

ASSEMBLY- ANDINSTALLTHESOLENOIDVALVEONTOTHEADAPTERPLATE5SINGAMM
INTERNALHEXINSTALLTHESCREWS- ANDTORQUETO.sM;LBFsFT=
Solenoid override valve installation
M98 (x4)
4 mm
M9
M95
M96
M97 M92 (x4)
4 mm
P106 192E
11019577s2EV!"s!PRIL 71
008 918 12 BOMAG 681
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
PRESSURE CONTROL Assembly

PILOT (PCP) FOR 5SINGPETROLEUMJELLYTORETAINTHEMINSTALLNEW/ RINGS-AND- IN0#0
ELECTRIC DISPLACEMENT (OUSING
CONTROL (EDC)
0LACE0#0AGAINST%$#HOUSINGANDUSINGAMMINTERNALHEXINSTALLTHESCREWS
- 4ORQUETO.sM;LBFsFT=
$ONOTREMOVEBLACKPLASTICCOVERFROMTHEALUMINUMPLATE4HISISNOTASERVICEABLEITEM
ANDREMOVALVOIDSTHEPRODUCTWARRANTY
PCP installation
M97
M96 (x3)
M98 (x4)
M9
4 mm
P106 194E
72 11019577s2EV!"s!PRIL
682 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
3-POSITION (FNR) Assembly

ELECTRIC CONTROL )NSTALLANEWGASKET- ONTHEHOUSING0LACETHEADAPTERPLATEINTOPOSITIONAND
USINGAMMINTERNALHEXINSTALLTHESCREWS- )NSTALLASEALINGWASHERUNDERTHE
HEADOFMOUNTINGSCREWSTHATAREINSTALLEDINTOTHROUGHHOLESINTHEHOUSING4ORQUE
THESCREWSTO.sM;LBFsFT=
)NSTALLORIlCES4AND4 INTOADAPTERPLATEUSINGAORMM

INTERNALHEXWRENCH)NSTALLORIlCE4 INTOADAPTERPLATEUSINGAORMM
INTERNALHEXWRENCH4ORQUE-THREADSTO.sM;LBSsLFT=-THREADSTO.sM
;LBSsLFT=AND-THREADSTO.sM;LBSsLFT=
5SINGPETROLEUMJELLYTORETAINTHEMINSTALLNEW/ RINGS7! ONTOTHESOLENOID

VALVEASSEMBLYANDINSTALLTHESOLENOIDVALVEONTOTHEADAPTERPLATE5SINGAMM
INTERNALHEXINSTALLSCREWS7 4ORQUETO.sM;LBFsFT=
FNR installation
7X
I MM
7!
-X d
I MM
4
4
4
-
3EALWASHER
LOCATIONCC
4
- 4
4
d
0%
11019577s2EV!"s!PRIL 73
008 918 12 BOMAG 683
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
MULTI-FUNCTION VALVE Multi-function valve installation

CARTRIDGES
P2B1
P13
P06
P2A1
P106 180E
P04
P03
P01
P02
P05
P06
P07
P08
P17
P16
P15
P14
P09
P11
P13
P12
E101 531E
74 11019577s2EV!"s!PRIL
684 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
Assembly
,UBRICATEANDINSTALLINTERNALCOMPONENTS00000000AND
0
0LACETHECARTRIDGEINAVISEANDPRESSONTHEPOPPETSEAT0
)NSTALLBYPASSACTUATOR0 WITHPRESSURELIMITERVALVE0 4ORQUETO.sM

;LBFsFT=
CCaution
)FPRESSURELIMITER0 WASREMOVEDFROMBYPASSACTUATOR0 ADJUSTPRESSURELIMITER
TOMODELCODESPECIlCATIONS
CCaution
$ONOTOVERTORQUETHE )NSTALLCARTRIDGESANDTORQUEASSHOWNINTHETABLEC
MULTI FUNCTIONVALVE
CARTRIDGES Multi-function valve wrench size Multi-function valve torque
Frame size Wrench size Frame size Torque
11019577s2EV!"s!PRIL 75
008 918 12 BOMAG 685
18.1 Travel pump
Series 90 Pumps
Repair Instructions
!SSEMBLY
INSTALLING SHAFT AND Shaft and bearing installation

BEARING 0OSITIONTHEPUMPONITSENDCAP
0RESSTHEROLLERBEARING, ONTOTHEINPUTSHAFT, &ORUNITSWITHA PIECE

BEARINGPRESSTHEINNERRACEONTOTHESHAFTTHENINSTALLTHEOUTERRACECAGEASSEMBLY
ANDSPECIALWASHERC
5SINGSUITABLERETAINING RINGPLIERSINSTALLTHEBEARINGRETAININGRING,
C Caution
$ONOTDAMAGETHESEALINGSURFACEINTHEHOUSINGDURINGSHAFTBEARINGINSTALLATION
,UBRICATEANDINSTALLSHAFTANDBEARINGASSEMBLYTHROUGHFRONTOFHOUSINGALIGNING

THESHAFTSPLINEWITHTHECYLINDERBLOCKSPLINE)FPUMPISEQUIPPEDWITHAUXILIARY
PADALIGNCHARGEPUMPSHAFTWITHAUXILIARYPADCOUPLING
#ONTINUETOLOWERTHESHAFTINTOTHEUNITWHILEALIGNINGTHEENDOFTHESHAFTWITHEND
CAPJOURNALBEARING
)FNECESSARYCOATTHE ,UBRICATEANDPRESSSEAL, IN Installing the shaft and bearing assembly
OUTSIDEDIAMETEROFTHE CARRIER,
L70
SEALLIGHTLYWITHASEALANT (see table)
SUCHAS,OCTITE4-(IGH ,UBRICATEANDINSTALL/ RING, IN
0ERFORMANCE3EALANT CARRIER, L60
PRIORTOINSTALLA
TION4HISAIDSINPREVENTING ,UBRICATEANDPRESSSEALCARRIERINTO L30
LEAKSCAUSEDBYDAMAGE ITSBOREINTHEHOUSING
L40
TOTHESEALBOREINTHESEAL
CARRIER )NSTALLRETAINERPLATE, ANDBOLTS L50
, 7RENCHSIZESANDTORQUEVALUES
L20
FORRETAINERPLATEBOLTSARESHOWNIN
TABLEBELOW
L10
L70 wrench sizes and torques

Pump size Wrench size 4ORQUE.sM;LBFsFT= L100
CC MMHEX .sM;LBFsFT=
CC MM .sM;LBFsFT=
INTERNALHEX
CC MM .sM;LBFsFT=
INTERNALHEX
E101 534E
76 11019577s2EV!"s!PRIL
686 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
!SSEMBLY
FINAL ASSEMBLY AND Final assembly and testing procedures

TESTING 2OTATETHEPUMPSHAFTWITHATORQUEWRENCHTOASSURECORRECTASSEMBLY4HETABLETorque
to turn shaft at 0° (with seal assembly installed) shows TORQUESNECESSARYTOTURNTHE
SHAFTAFTERBREAK AWAY
Torque to turn shaft at 0° (with seal assembly installed)

Pump size -INIMUMTORQUE.sM;LBFsFT= -AXIMUMTORQUE.sM;LBFsFT=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
CC ;= ;=
W7ARNING
4ESTTHEPUMPBEFOREPUTTINGITINTOSERVICE6ERIFYCORRECTPRESSURELIMITERANDCONTROL
FUNCTION)MPROPERFUNCTIONOFTHESESYSTEMSCANRESULTINUNCONTROLLABLEMOVEMENTOF
THEVEHICLEMACHINE
11019577s2EV!"s!PRIL 77
008 918 12 BOMAG 687
18.1 Travel pump
Series 90 Pumps
Repair Instructions
4ORQUE#HART
FASTENER SIZE AND Item Fastener Frame size Wrench size Torque
TORQUE CHART B83 3PEEDSENSORLOCKNUT INHEX .sM;LBFsFT=
"LINDHOLES MMHEX .sM;LBFsFT=
MMHEX .sM;LBFsFT=
4HRUHOLES MMHEX .sM;LBFsFT=
MMHEX .sM;LBFsFT=
F111/ 3ERVOCYLINDERSCREW MMHEX .sM;LBFsFT=
F211 MMHEX .sM;LBFsFT=
G90/ %NDCAPSCREW MMINTERNALHEX .sM;LBFsFT=
G97 MMINTERNALHEX .sM;LBFsFT=
MMHEX .sM;LBFsFT=
MMHEX .sM;LBFsFT=
H80 #HARGEPUMPRETAININGSCREW MMHEX .sM;LBFsFT=
MMHEX .sM;LBFsFT=
J80 %NDCAPSCREW MMINTERNALHEX .sM;LBFsFT=
EARLY MMINTERNALHEX .sM;LBFsFT=
MMHEX .sM;LBFsFT=
MMHEX .sM;LBFsFT=
K10 #HARGEPRESSUREVALVEPLUG INHEX .!
K90 #HARGEPRESSURELOCKNUT INHEX .sM;LBFsFT=
INHEX .sM;LBFsFT=
L70 3HAFTRETAININGSCREW MMHEX .sM;LBFsFT=
M72 -$#HANDLENUT MM .sM;LBFsFT=
M78 $E STROKEVALVEMANIFOLDSCREW MMINTERNALHEX .sM;LBFsFT=
M85 %CCENTRICPLUGLOCKNUT INHEX .sM;LBFsFT=
M88 .EUTRALSTARTSWITCHLOCKNUT INHEX .sM;LBFsFT=
M90 #ONTROLMOUNTINGSCREW MMINTERNALHEX .sM;LBFsFT=
M92 3OLENOIDVALVEMOUNTINGSCREW MMINTERNALHEX .sM;LBFsFT=
M98 0#0MOUNTINGSCREW MMINTERNALHEX .sM;LBFsFT=
N10 &ILTERREDUCERASSEMBLY INHEX .sM;LBFsFT=
INHEX .sM;LBFsFT=
INHEX .sM;LBFsFT=
N37 &ILTERPLUGASSEMBLY ININTERNALHEX .sM;LBFsFT=
P2B1/ -ULTI FUNCTIONVALVE INHEX .sM;LBFsFT=
P2A1 INHEX .sM;LBFsFT=
78 11019577s2EV!"s!PRIL
688 BOMAG 008 918 12

Travel pump 18.1
Series 90 Pumps
Repair Instructions
4ORQUE#HART
PLUG SIZE AND TORQUE )FANYPLUGSORlTTINGSAREREMOVEDFROMTHEPUMPDURINGSERVICINGINSTALLANDTORQUEAS

CHART INDICATEDINTHEACCOMPANYINGTABLEC
!LWAYSINSTALLNEW/ RINGSBEFOREREINSTALLINGTHEPLUGSORlTTINGS
CCaution
4ORQUEPLUGSORlTTINGS Item O-ring plug Wrench size Torque
INSTALLEDINTOALUMINUM B70, B72 INTERNALHEXWRENCH .sM;LBFsFT=
HOUSINGSTOTHELOWER B71 INTERNALHEXWRENCH .sM;LBFsFT=
VALUESSPECIlEDFOR B80 INTERNALHEXWRENCH .sM;LBFsFT=
INTERNALHEXPLUGSOFTHE B82, B83 INTERNALHEXWRENCH .sM;LBFsFT=
SAMESIZE G18 INTERNALHEXWRENCH .sM;LBFsFT=
G45-G50 INCHHEXWRENCH .sM;LBFsFT=
G52-G54 INTERNALHEXWRENCH .sM;LBFsFT=
H90 (not shown) INTERNALHEXWRENCH .sM;LBFsFT=
N35, N36 (not shown) INCHHEXWRENCH .sM;LBFsFT=
N37 INTERNALHEXWRENCH .sM;LBFsFT=
FASTENERS AND PLUGS
Fastener and plug locations
B70, B72 O-ring plug

9/16-18
J80 Auxilliary pad / G90 End cap screw
end cap screw M90 Control bolt
H80 Charge pump

retaining screw L70 Shaft seal
retaining screw
G53, G54 O-ring plug

9/16-18
K10 Charge pressure

relief valve plug M88 Neutral start switch
lock nut
M85 Eccentric plug
K90 Charge pressure lock nut
relief valve lock nut
B80 O-ring plug
1-1/16-12 P2B1 Multi-function valve
G97 End cap screw B71 O-ring plug

B82 O-ring plug
9/16-18
9/16-18
B83 Speed sensor /
G50 O-ring plug O-ring plug
9/16-18 9/16-18
G49 O-ring plug

9/16-18
G48 O-ring plug

9/16-18
N37 Filter plug assembly

F111 / F211 Servo cylinder screw E60 Side cover screw N10 Filter reducer assembly
P106 189E
P2A1 Multi-function valve
11019577s2EV!"s!PRIL 79
008 918 12 BOMAG 689
18.1 Travel pump
OUR PRODUCTS Sauer-Danfoss Mobile Power and Control Systems

– Market Leaders Worldwide
(YDROSTATICTRANSMISSIONS
3AUER $ANFOSSISACOMPREHENSIVESUPPLIERPROVIDINGCOMPLETE
(YDRAULICPOWERSTEERING
SYSTEMSTOTHEGLOBALMOBILEMARKET
%LECTRICPOWERSTEERING
3AUER $ANFOSSSERVESMARKETSSUCHASAGRICULTURECONSTRUCTIONROAD
%LECTROHYDRAULICPOWERSTEERING
BUILDINGMATERIALHANDLINGMUNICIPALFORESTRYTURFCAREANDMANY
#LOSEDANDOPENCIRCUITAXIALPISTON OTHERS
PUMPSANDMOTORS
'EARPUMPSANDMOTORS 7EOFFEROURCUSTOMERSOPTIMUMSOLUTIONSFORTHEIRNEEDSAND
DEVELOPNEWPRODUCTSANDSYSTEMSINCLOSECOOPERATIONAND
"ENTAXISMOTORS PARTNERSHIPWITHTHEM
/RBITALMOTORS
3AUER $ANFOSSSPECIALIZESININTEGRATINGAFULLRANGEOFSYSTEM
4RANSITMIXERDRIVES COMPONENTSTOPROVIDEVEHICLEDESIGNERSWITHTHEMOSTADVANCED
0LANETARYCOMPACTGEARS TOTALSYSTEMDESIGN
0ROPORTIONALVALVES 3AUER $ANFOSSPROVIDESCOMPREHENSIVEWORLDWIDESERVICEFORITS

$IRECTIONALSPOOLVALVES PRODUCTSTHROUGHANEXTENSIVENETWORKOF'LOBAL3ERVICE0ARTNERS
STRATEGICALLYLOCATEDINALLPARTSOFTHEWORLD
#ARTRIDGEVALVES
(YDRAULICINTEGRATEDCIRCUITS
,OCALADDRESS
(YDROSTATICTRANSAXLES
)NTEGRATEDSYSTEMS
&ANDRIVESYSTEMS
%LECTROHYDRAULICS
-ICROCONTROLLERSANDSOFTWARE
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$ISPLAYS %ASTTH3TREET $+ .ORDBORG$ENMARK
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WWWSAUER DANFOSSCOM
11019577s2EV!"s!PRIL
690 BOMAG 008 918 12

18.2 Vibration pump
008 918 12 BOMAG 691

18.2 Vibration pump
692 BOMAG 008 918 12

Vibration pump 18.2
Series 42
Axial Piston Closed
Circuit Pumps
Service Manual
008 918 12 BOMAG 693

18.2 Vibration pump
Series 42 Axial Piston Closed Circuit Pumps
Service Manual
2EVISIONS
History of Revisions Table of Revisions

.OVEMBER last NEWBACKPAGE #"

$ECEMBER all Major update CA
*ULY all Major update "!

2 520L0638 s2EVISION#"s.OVEMBER
694 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
4ABLEOF#ONTENTS
Introduction /VERVIEW 5
7ARRANTY 5
'ENERALINSTRUCTIONS 5
3AFETYPRECAUTIONS 6
3YMBOLSUSEDIN3AUER $ANFOSSLITERATURE
1998 Model Release /VERVIEW 8

$ESCRIPTIONOFCHANGE 8
Functional description 'ENERALDESCRIPTIONANDCROSS SECTIONALVIEW

4HESYSTEMCIRCUIT
0UMPFEATURES
Filtration options2
$ISPLACEMENTLIMITERS3
#HARGECHECKHIGHPRESSURERELIEFVALVES3
"YPASSVALVES3
!UXILIARYMOUNTINGPADS4
Control options -ANUALDISPLACEMENTCONTROL-$# 5

%LECTRICALDISPLACEMENTCONTROL%$# 5
(IGHCURRENTELECTRICALDISPLACEMENTCONTROL(# %$# 6
.ON FEEDBACKPROPORTIONALHYDRAULIC.&0( control6
.ON FEEDBACKPROPORTIONALELECTRIC.&0% control
&ORWARD .EUTRAL 2EVERSE&.2 THREE POSITIONELECTRICCONTROL
Technical specifications 3PECIlCATIONS8
Pressure measurement 2EQUIREDTOOLS

0ORTLOCATIONSANDPRESSUREGAUGEINSTALLATION
0ORTSANDPRESSUREGAUGES
Initial start-up procedure 'ENERAL2

3TART UPPROCEDURE2
Fluid and filter 2ECOMMENDATIONS22

maintenance
Troubleshooting 3YSTEMOPERATINGHOT23
3YSTEMRESPONSEISSLUGGISH24
3YSTEMWILLNOTOPERATEINEITHERDIRECTION25
3YSTEMWILLNOTOPERATEINONEDIRECTION26
.EUTRALDIFlCULTORIMPOSSIBLETOlND26
520L0638 s2EVISION#"s.OVEMBER 3
008 918 12 BOMAG 695
18.2 Vibration pump
Service Manual
Adjustments $ISPLACEMENTLIMITERADJUSTMENT2
Pump neutral adjustment28
#ONTROLNEUTRALADJUSTMENTFOR-$#AND%$#(# %$#2
Minor repair Standard procedures3

3IZEANDTORQUEFORPLUGSANDlTTINGS3
#HARGERELIEFVALVE32
Optional speed sensor34
-$#-ODULE35
(# %$#AND%$#-ODULES3
-$#%$#3POOLLINKAGEANDNEUTRALADJUSTMENTSCREW3
-$#.EUTRALSTARTBACKUPALARMSWITCH4
-$#3OLENOIDOVERRIDEVALVE43
&.2.&0%AND.&0(#ONTROLSBOLT ONVALVES 44
&.2.&0%AND.&0(#ONTROLSINTEGRALVALVES 45
3YSTEM#HECK2ELIEF3#2 VALVESHIGHPRESSURERELIEFCHARGECHECKANDBYPASSVALVES 46
Filtration adapters4
!UXILIARYPADCHARGEPUMPCOVER4
#HARGEPUMP5
3ERVOPISTONCOVERSAND.&0(CONTROLORIlCE54
,OOPmUSHINGANDLOOPmUSHINGRELIEFVALVE56
3HAFTSEALROLLERBEARINGANDSHAFTREPLACEMENT58
Appendix A - torques 4ORQUETABLE6
Appendix B - 0RE BLOCKPOINTCHANGE62

Specification tags 0OST BLOCKPOINTCHANGE62
Appendix C - 0RE BLOCKPOINTCHANGENOMENCLATURE63

nomenclature 0OST BLOCKPOINTCHANGENOMENCLATURE64
696 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
Introduction
Overview 4HISMANUALINCLUDESINFORMATIONFORTHEINSTALLATIONMAINTENANCEANDMINORREPAIROF

3ERIESAXIALPISTONCLOSEDCIRCUITPUMPS)TINCLUDESADESCRIPTIONOFTHEUNITANDITS
INDIVIDUALCOMPONENTSTROUBLESHOOTINGINFORMATIONANDMINORREPAIRPROCEDURES
0ERFORMINGMINORREPAIRSREQUIRESYOUTOREMOVETHEUNITFROMTHEVEHICLEMACHINE
4HOROUGHLYCLEANTHEUNITBEFOREBEGINNINGMAINTENANCEORREPAIRACTIVITIES3INCEDIRT
ANDCONTAMINATIONARETHEGREATESTENEMIESOFANYTYPEOFHYDRAULICEQUIPMENTFOLLOW
CLEANLINESSREQUIREMENTSSTRICTLY4HISISESPECIALLYIMPORTANTWHENCHANGINGTHESYSTEM
lLTERANDWHENREMOVINGHOSESORPLUMBING
!WORLDWIDENETWORKOF3AUER $ANFOSS!UTHORIZED3ERVICE#ENTERS!3#S ISAVAILABLEFOR

MAJORREPAIRS3AUER $ANFOSSTRAINSANDCERTIlES!3#SONAREGULARBASIS9OUCANLOCATE
YOURNEAREST!3#USINGTHEDISTRIBUTORLOCATORATWWWSAUER DANFOSSCOM#LICKONTHE
Sales and ServiceLINK
Warranty 0ERFORMINGINSTALLATIONMAINTENANCEANDMINORREPAIRSACCORDINGTOTHEPROCEDURESIN

THISMANUALDOESNOTAFFECTYOURWARRANTY-AJORREPAIRSREQUIRINGTHEREMOVALOFAUNITS
REARCOVERORFRONTmANGEVOIDSTHEWARRANTYUNLESSDONEBYA3AUER $ANFOSSGLOBAL
SERVICEPARTNER
General instructions &OLLOWTHESEGENERALPROCEDURESWHENREPAIRING3ERIESVARIABLEDISPLACEMENTCLOSED

CIRCUITPUMPS
w Remove the unit

0RIORTOPERFORMINGMINORREPAIRSREMOVETHEUNITFROMTHEVEHICLEMACHINE#HOCK
e Keep it clean
TOAVOIDCONTAMINATIONOFTHESYSTEMPORTS#LEANINGPARTSWITHACLEANSOLVENTWASH
!SWITHANYPRECISIONEQUIPMENTYOUMUSTKEEPALLPARTSFREEOFFOREIGNMATERIALAND
CHEMICALS0ROTECTALLEXPOSEDSEALINGSURFACESANDOPENCAVITIESFROMDAMAGEAND
FOREIGNMATERIAL)FLEFTUNATTENDEDCOVERTHEPUMPWITHAPROTECTIVELAYEROFPLASTIC

3AUER $ANFOSSRECOMMENDSREPLACINGALL/ RINGSGASKETSANDSEALSWHENSERVICING
,IGHTLYLUBRICATEALL/ RINGSWITHCLEANPETROLEUMJELLYPRIORTOASSEMBLY
t Secure the unit

&ORREPAIRPLACETHEUNITINASTABLEPOSITIONWITHTHESHAFTPOINTINGDOWNWARD)TISNECESSARY
TOSECURETHEPUMPWHILEREMOVINGANDTORQUINGENDCOVERSCONTROLSANDVALVES
008 918 12 BOMAG 697
18.2 Vibration pump
Service Manual
Introduction
Safety precautions !LWAYSCONSIDERSAFETYPRECAUTIONSBEFOREBEGINNINGASERVICEPROCEDURE0ROTECT

HYDRAULICSYSTEM

W Warning

W Warning

W Warning
Personal safety
W Warning
TIMES
698 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
Introduction
Symbols used in Sauer-  7!2.).'MAYRESULTININJURY  4IPHELPFULSUGGESTION

Danfoss literature
 #!54)/.MAYRESULTINDAMAGETO  ,UBRICATEWITHHYDRAULICmUID
PRODUCTORPROPERTY
 2EUSABLEPART
 Clean area or part
 Superseded – parts are not
sleeve
 4ORXHEAD
008 918 12 BOMAG 699
18.2 Vibration pump
Service Manual
-ODEL2ELEASE
Overview 0ARTSMAYORMAYNOTBEINTERCHANGEABLEBETWEENPRE ANDPOST MODEL

YEARPUMPS-ANYPARTSINCLUDINGTHEHOUSINGASSEMBLYAREUNIQUETOTHEMODELYEAR
CHANGE
Description of change Housing

4HEPORTCOVERFORTHECONTROLSPOOL&/"OPTION CM3ONLY CHANGEDFROMAmATPLATE
WITHTWOSCREWSTOAN3!%/ RINGBOSSPLUG4HESCREWHOLESFORTHESERVOCOVERSAND
FOUROFTHESIXSCREWHOLESFORTHESIDECOVERAREDEEPERTOACCEPTAMMLONGERSCREW
4HETWOHOLESNEXTTOTHECHARGEPUMPCOVERSTAYEDTHESAMELENGTH
Charge pump
4HEGEROTORDRIVEPINCHANGEDTOAPARALLELKEY!RETAININGRINGWASADDEDTOTHECHARGE
PUMPSHAFTTOLOCATETHEGEROTOR4HEOUTERSTEPONTHEGEROTORCOVERWASELIMINATED
ANDTHELOCATINGPINSLOTDEPTHINCREASED
Auxiliary flange shipping cover

4HECOVERCHANGEDTOAmATCOVERPLATEWITHASPECIALSEALRINGNOTTOBEUSEDTOSEALAN
AUXILIARYPUMP UNDERTHECOVER!PADONLY
Charge relief valve

4HERELIEFVALVECHANGEDFROMANON ADJUSTABLETOANADJUSTABLERELIEFVALVE4HISCHANGE
REQUIRESAUPGRADEHOUSING
Spool - loop flushing

4HESPOOLCHANGEDTOBECOMECOMMONBETWEENTHEANDCM3PUMPS4HIS
CHANGEREQUIRESAUPGRADEHOUSING
700 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
&UNCTIONAL$ESCRIPTION
Overview 4HISSECTIONDESCRIBESTHEOPERATIONOFPUMPSANDTHEIRSERVICEABLEFEATURES)TISAUSEFUL
REFERENCEFORREADERSUNFAMILIARWITHTHEFUNCTIONOFTHISSPECIlCPUMP
General description and 4HE3ERIESPUMPSARESERVOCONTROLLEDAXIALPISTONPUMPSDESIGNEDFORCLOSED

cross-sectional view CIRCUITAPPLICATIONS4HEINPUTSHAFTTURNSTHEPUMPCYLINDERBLOCKCONTAININGNINE
RECIPROCATINGPISTONSTHATAREHELDTOTHESWASHPLATEWITHABLOCKSPRING%ACHPISTONHAS
ABRASSSLIPPERCONNECTEDTOONEENDBYABALLJOINT4HERECIPROCATINGMOVEMENTOCCURS
ASTHESLIPPERSSLIDEALONGTHEINCLINEDSWASHPLATEDURINGROTATION!SEACHPISTONCYCLES
INANDOUTOFITSBOREmUIDISDRAWNFROMTHEINLETANDDISPLACEDTOTHEOUTLETTHEREBY
IMPARTINGHYDRAULICPOWERTOTHESYSTEM6IATHEVALVEPLATEONEHALFOFTHECYLINDER
BLOCKISCONNECTEDTOLOWPRESSUREANDTHEOTHERTOHIGHPRESSURE#LEARANCESALLOWA
SMALLAMOUNTOFmUIDTOmOWFROMTHECYLINDERBLOCKVALVEPLATEANDSLIPPERSWASHPLATE
INTERFACESFORLUBRICATIONANDCOOLING#ASEDRAINPORTSRETURNTHISmUIDTOTHERESERVOIR
4HEANGLEOFTHESWASHPLATECONTROLSTHEVOLUMEOFmUIDDISPLACEDINTOTHESYSTEM
4HESERVOPISTONFORCESTHESWASHPLATEINTOANINCLINEDPOSITIONINTOSTROKE )NTERNAL
MOMENTSANDCENTERINGSPRINGSWITHINTHESERVOPISTONRETURNTHESWASHPLATETOTHE
NEUTRALPOSITIONOUTOFSTROKE
Cross section
Slipper
Swashplate
Piston
Cylinder block
Roller bearing Charge pump

Valve plate
0%
008 918 12 BOMAG 701
18.2 Vibration pump
Service Manual
The system circuit System circuit diagram

Servo control cylinder
Displacement control valve
Heat exchanger Reservoir

bypass
Filter
Fixed
Control Heat displacement
handle exchanger motor
Cylinder Cylinder
block block
assembly Charge relief assembly
valve
Output
Charge shaft
pump
Input
shaft Variable Suction flow
displacement Check valves Charge pressure
pump with high pressure Servo pressure
relief valves High pressure
Case flow
0%
Closed circuit operation
(YDRAULICLINESCONNECTTHEMAINPORTS Charge pump
OFTHEPUMPTOTHEMAINPORTSOFTHE O-ring
MOTOR&LUIDmOWSINEITHERDIRECTION
FROMTHEPUMPTOTHEMOTORANDBACK
%ITHEROFTHEHYDRAULICLINESCANBEUNDER Gerotor cover
HIGHPRESSURE4HEPOSITIONOFPUMP
SWASHPLATEDETERMINESWHICHLINEISHIGH
PRESSUREASWELLASTHEDIRECTIONOFmOW
Seal
Case drain and heat exchanger
"OTHTHEPUMPANDMOTORMUSTDRAIN Coupling
mUID!CASEDRAINLINEACHIEVESTHIS4HE Square key
LINECONNECTSTOTHEPUMPORMOTOR
ATTHETOP MOSTDRAINPORTINORDERTO Gerotor set
MAINTAINANADEQUATEmUIDLEVELINTHE
COMPONENTS&LUIDCOOLINGDEMANDSMAY
REQUIREAHEATEXCHANGERWITHABYPASS Retainer
VALVETOCOOLTHECASEDRAINmUIDBEFOREIT ring Orientation
pin
RETURNSTOTHERESERVOIR
Pump features Charge pump

4HECHARGEPUMPISNECESSARYTOSUPPLY
mUIDTOMAINTAINPOSITIVEPRESSUREINTHE
SYSTEMLOOPTOPROVIDEPRESSURETOOPERATE
THECONTROLSYSTEMANDTOMAKEUPFOR
INTERNALLEAKAGEANDLOOPmUSHINGmOW4O
PREVENTDAMAGETOTHETRANSMISSIONTHE
P108 065E
PUMPMUSTMAINTAINTHESPECIlEDCHARGE
PRESSUREUNDERALLCONDITIONSOFOPERATION
702 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
Pump features 4HECHARGEPUMPISAlXED DISPLACEMENTGEROTORTYPEPUMP4HEMAINPUMPDRIVES

(continued) THECHARGEPUMPOFFTHEMAINSHAFT!SPRINGANDPOPPETSTYLERELIEFVALVELIMITSCHARGE
PRESSURE
4HESTANDARDCHARGEPUMPISSATISFACTORYFORMOSTAPPLICATIONSHOWEVEROTHER
DISPLACEMENTSAREAVAILABLE!GEARPUMPMOUNTEDTOTHEAUXILIARYPADMAYAUGMENT
CHARGEmOWIFADDITIONALVOLUMEISREQUIRED
Charge relief valve

4HECHARGERELIEFVALVEMAINTAINSCHARGEPRESSUREATADESIGNATEDLEVEL4HECHARGERELIEF
VALVEISADIRECTACTINGPOPPETVALVEWHICHOPENSANDDISCHARGESmUIDTOTHEPUMPCASE
WHENPRESSUREREACHESTHATLEVEL)TISNOMINALLYSETWITHTHEPUMPRUNNINGATRPM
)NFORWARDORREVERSECHARGEPRESSUREISSLIGHTLYLOWERTHANWHENINNEUTRALPOSITION4HE
MODELCODEOFTHEPUMPSPECIlESTHECHARGERELIEFVALVESETTING
Loop flushing valve

!LOOPmUSHINGVALVEDUMPSmOWFROMTHELOWSIDEOFTHEMAINLOOPREMOVINGHEATAND
CONTAMINANTS0UMPSEQUIPPEDWITHANINTEGRALLOOPmUSHINGVALVEALSOINCLUDEALOOP
mUSHINGRELIEFVALVE4HELOOPmUSHINGRELIEFVALVEPOPPETINCLUDESANORIlCETHATCONTROLS
mUSHINGmOWUNDERMOSTCONDITIONS!COMBINATIONOFORIlCESIZEANDCHARGEPRESSURE
RELIEFSETTINGPRODUCESASPECIlCmUSHINGmOW
Charge relief, loop flushing relief, and loop flushing valve
Charge relief
valve
Loop flushing
relief valve
Loop flushing
spool
Loop flushing
defeat spool
P108 095E
008 918 12 BOMAG 703
18.2 Vibration pump
Service Manual
Filtration options 3ERIESPUMPSMAYBEEQUIPPEDWITHPROVISIONSFOREITHERSUCTIONORCHARGEPRESSURE

lLTRATIONTOlLTERTHEmUIDENTERINGTHECIRCUIT
Suction filtration
4HESUCTIONlLTERISINTHECIRCUITBETWEENTHERESERVOIRANDTHEINLETTOTHECHARGEPUMP
Charge pressure filtration Suction filtration

4HEPRESSURElLTERISREMOTELYMOUNTED Filter
INTHECIRCUITAFTERTHECHARGEPUMP
Reservoir
9OUMAYUSEPARTIALORFULLmOWPRESSURE
lLTRATIONCIRCUITSWITH3ERIESPUMPS Strainer
7ITHOUTAlLTERADAPTERSUCTIONlLTRATION To low pressure
side of loop and Charge
ISTHEONLYOPTION servo control pump
Charge
relief
valve
Filtration adapters
To pump case P001603
Partial flow pressure filtration

Reservoir
Strainer
Filter
Partial flow
pressure
filtration
Charge pump
To low pressure
side of loop and
servo control
Charge
Full flow Full flow relief valve
pressure suction
filtration
filtration To pump case 0%
Full flow pressure filtration

Reservoir
Strainer
Filter
with bypass
To low pressure
side of loop and Charge
servo control pump
Charge
P108 066E relief
pump
To pump case P001605E
704 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
Displacement limiters 3ERIESPUMPSAREAVAILABLEWITH Displacement limiters

MECHANICALDISPLACEMENTLIMITERSINTHE $ISPLACEMENTLIMITER
SERVOCOVERS4HEDISPLACEMENTLIMITERS FACtoRYSETFORMAXIMUMDISPLACEMENT
CANLIMITDISPLACEMENTOFTHEPUMP
TOANYVALUEFROMMAXIMUMTOZEROIN
EITHERDIRECTION
Servo control
Charge check / high !LLSERIESPUMPSHAVEACOMBINATION cYLINDER
pressure relief valves CHARGECHECKHIGHPRESSURERELIEFVALVE $ISPLACEMENTLIMITER
4HECHARGECHECKFUNCTIONALLOWS SETFORREDUCEDMAXIMUMDISPLACEMENT
PRESSURIZEDmOWFROMTHECHARGEPUMP 0%
TOENTERTHELOWPRESSURESIDEOFTHELOOP
4HISmOWISNECESSARYTOREPLENISHmUID High pressure relief valve
DISCHARGEDTOTHEPUMPMOTORCASEFOR
LUBRICATIONANDCOOLINGREQUIREMENTS High pressure
3INCETHEPUMPCANOPERATEINEITHER side of working loop
DIRECTIONITUSESTWOCHARGECHECKVALVES
TODIRECTTHECHARGESUPPLYINTOTHELOW
PRESSURESIDE
(IGHPRESSURERELIEFVALVESAREAVAILABLE Charge check and

high pressure
INARANGEOFSETTINGSASSHOWNINTHE relief valve
MODELCODE4HEMODELCODEMAYSPECIFY 0%
INDIVIDUALPRESSURESETTINGS4HEHIGH
PRESSURERELIEFVALVESETTINGSAREREFERENCEDTOCHARGEPRESSUREANDARESETATLMIN;53
GALMIN=OFmOW
Bypass valves /PTIONALBYPASSPLUNGERSAREAVAILABLE Charge check and high pressure relief

FORUSEWHENITISNECESSARYTOMOVETHE valves with bypass
VEHICLEORMECHANICALFUNCTIONANDTHE To/from other
bypass valve
PRIMEMOVERISNOTRUNNING
To/from
working loop
C#!54)/. 4OGETHERTHESEVALVESCONNECTBOTH
"YPASSVALVESAREFOR SIDESOFTHEMAINHYDRAULICCIRCUIT
MOVINGAMACHINEOR ALLOWINGmUIDTOCIRCULATEWITHOUT
VEHICLEFORVERYSHORT ROTATINGTHEPUMPANDPRIMEMOVER
DISTANCESATVERYSLOW
SPEEDS4HEYARENOTTOW 4HEBYPASSFUNCTIONISINTEGRALTOTHE Charge check and
Bypass high pressure
VALVES)FPRESSUREBUILDS CHARGECHECKHIGHPRESSURERELIEFVALVE relief valve
plunger
WITHINTHESYSTEMTHE ASSEMBLY$EPRESSINGTHEPLUNGERIN P100394E
VALVESMAYCLOSECAUSING THEPLUGOFTHEVALVEASSEMBLYOPENS
DAMAGETOTHEPUMPAND THEVALVE4HEVALVEREMAINSOPENUNTILTHEPRIMEMOVERRESTARTSORPRESSUREBUILDSIN
MOTORORPRIMEMOVER THESYSTEMANDCAUSESTHEVALVETHECLOSE9OUMUSTDEPRESSTHEPLUNGERSINBOTHOFTHE
-OVETHEVEHICLEMACHINE CHECKRELIEFVALVEASSEMBLIESFORPROPERBYPASSOPERATIONC
ATNOMORETHANOF
TOPSPEEDFORNOMORE
THANTHREEMINUTES
008 918 12 BOMAG 705
18.2 Vibration pump
Service Manual
Auxiliary mounting pads 3!%!AND3!%"AUXILIARYMOUNTINGmANGESAREAVAILABLEONALL3ERIESPUMPSANDARE

INTEGRALTOTHECHARGEPUMPCOVER4HISmANGEALLOWSMOUNTINGOFAUXILIARYHYDRAULIC
PUMPSANDMOUNTINGOFADDITIONAL3ERIESPUMPSTOMAKETANDEMPUMPS4HEPADS
ALLOWFULLTHROUGH TORQUECAPABILITY
Auxiliary mounting pads
Charge pump cover
O-ring
U085
U035 (x8)
Cover plate
Pad seal
P108 096E
706 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
Control Options
Manual displacement 4HE-ANUAL$ISPLACEMENT#ONTROL-$# USESAMECHANICALINPUTTOOPERATETHECONTROLSPOOL

control (MDC) INTHEPUMP!CAMCONNECTSTHEINPUTHANDLETOTHECONTROLSPOOLALLOWINGMANIPULATIONOF
THEOPERATINGCURVEUSINGDIFFERENTCAMPROlLES4HECONTROLSPOOLMODULATESTHEPRESSURE
BALANCEACROSSTHEPUMPSSERVOPISTON4HEANGLEOFTHESWASHPLATEISPROPORTIONALTOTHE
ANGULARPOSITIONOFTHECONTROLINPUT!MECHANICALFEEDBACKLINKAGEMOVESTHECONTROLSPOOL
TOWARDNEUTRALASTHESWASHPLATEANGLEREACHESTHECOMMANDEDPOSITION-ECHANICALFEEDBACK
ALLOWSTHEPUMPTOHOLDVERYACCURATELYAT
THECOMMANDEDDISPLACEMENT#ENTERING MDC on series 42 pump
SPRINGSANDINTERNALMOMENTSRETURN
THESWASHPLATETONEUTRALPOSITIONINTHE
ABSENCEOFCONTROLINPUT
Solenoid override valve

!SOLENOIDOVERRIDEVALVEISAVAILABLEFORTHE
MANUALDISPLACEMENTCONTROL4HISSAFETY
FEATURESHUNTSTHESERVOPISTONALLOWINGTHE
PUMPTORETURNTONEUTRALWHENACTIVATED
.ORMALLYOPENORNORMALLYCLOSEDOPTIONS
AREAVAILABLE
0
Neutral start switch (NSS)

4HE.EUTRAL3TART3WITCH.33 ISANOPTIONALCAM OPERATEDBALL TYPEMICROSWITCH7HEN
CONNECTEDPROPERLYTOTHEVEHICLESELECTRICALSYSTEMTHE.33ENSURESTHATTHEPRIME
MOVERWILLSTARTONLYWHENTHECONTROLINPUTSHAFTISINTHENEUTRALPOSITION
Back-up alarm switch (BAS)

4HE"ACK UP!LARM3WITCH"!3 ISAVAILABLEFORTHE-$#ANDWORKSINASSOCIATIONWITH
THE.337HENCONNECTEDPROPERLYTOTHEVEHICLESELECTRICALSYSTEMTHE"!3CANSOUND
ANALARMWHENTHECONTROLCOMMANDSTHEVEHICLEINTOREVERSE/NECAMANDSWITCH
ASSEMBLYCONTROLSBOTHFUNCTIONS2EPOSITIONINGTHECAMACCOMMODATESBOTHCLOCKWISE
ANDCOUNTERCLOCKWISECONTROLHANDLEROTATIONTOREVERSEDIRECTION
Electrical displacement 4HE%LECTRICAL$ISPLACEMENT#ONTROL%$# ISATWO STAGECONTROLUSINGA$#INPUTCURRENTTO

control (EDC) CONTROLPUMPDISPLACEMENT3TAGEONETHE0RESSURE#ONTROL0ILOT0#0 VALVEUSESTHE$#INPUT
TOOPERATEATORQUEMOTORWHICHDRIVESAmAPPERVALVE4HEmAPINTHE0#0BLOCKSAPORTIONOF
mOWFROMONEORTHEOTHEROFTWONOZZLES4HETWONOZZLESMODULATEPRESSUREBALANCEACROSSA
SENSINGPISTONINTHECONTROL4HECONTROLPISTONISCONNECTEDTOTHECONTROLSPOOLINTHEPUMP
BYAPINANDLINKAGE4HECONTROLSPOOL
MODULATESTHEDIFFERENTIALPRESSUREACROSS EDC on series 42 pump
THEPUMPSSERVOPISTONTHISISSTAGETWO
4HEANGLEOFTHESWASHPLATEISPROPORTIONAL
TOTHEINPUTCURRENT!MECHANICALFEEDBACK
LINKAGEMOVESTHECONTROLSPOOLTOWARD
NEUTRALASTHESWASHPLATEANGLEREACHESTHE
COMMANDEDPOSITION-ECHANICALFEEDBACK
ALLOWSTHEPUMPTOHOLDVERYACCURATELYAT
THECOMMANDEDDISPLACEMENT#ENTERING
ABSENCEOFCONTROLINPUT
0
008 918 12 BOMAG 707
18.2 Vibration pump
Service Manual
Control Options
High current electrical 4HE(IGH#URRENT%LECTRICAL$ISPLACEMENT#ONTROL(# %$# ISATWO STAGECONTROLUSINGA

displacement control $#INPUTCURRENTWITH0ULSE7ITH-ODULATION07- TOCONTROLPUMPDISPLACEMENT3TAGE
(HC-EDC) ONEUSESTWO0ROPORTIONAL0RESSURE2EDUCING6ALVES0026 TOPROVIDEREDUCINGPRESSURE
PROPORTIONALTOTHEINPUTCURRENT4HEPRESSUREFROMEACH0026ISPROVIDEDTOEACHENDOFTHE
SENSINGPISTONINTHECONTROLTHISISSTAGEONE4HESENSINGPISTONISCONNECTEDTOTHECONTROL
SPOOLINTHEPUMPBYAPINANDLINKAGE4HE
CONTROLSPOOLMODULATESTHEDIFFERENTIAL HC-EDC on series 42 pump
PRESSUREACROSSTHEPUMPSSERVOPISTONTHIS
ISSTAGETWO4HEANGLEOFTHESWASHPLATEIS
PROPORTIONALTOTHEINPUTCURRENT
!MECHANICALFEEDBACKLINKAGEMOVES
THECONTROLSPOOLTOWARDNEUTRALASTHE
SWASHPLATEANGLEREACHESTHECOMMANDED
POSITION-ECHANICALFEEDBACKALLOWS
THEPUMPTOHOLDVERYACCURATELYATTHE
COMMANDEDDISPLACEMENT#ENTERING
ABSENCEOFCONTROLINPUT P108 111E
Non-feedback 4HE.ON &EEDBACK0ROPORTIONAL NFPH control on series 42 pump

proportional hydraulic (YDRAULIC.&0( CONTROLISAHYDRAULIC
(NFPH) control DISPLACEMENTCONTROL%XTERNALVALVING
SUPPLIESANINPUTPRESSUREDIRECTLYTOTHE
PUMPSERVOPISTONVIACONTROLPORTS8
AND8TOCONTROLPUMPDISPLACEMENT
0UMPDISPLACEMENTISPROPORTIONALTOTHE
PRESSUREDIFFERENCEACROSSTHESERVOPISTON
(OWEVERBECAUSETHISCONTROLDOESNOTUSE
MECHANICALFEEDBACKDISPLACEMENTALSO
DEPENDSUPONINPUTSPEEDANDSYSTEM
PRESSURE4HISCHARACTERISTICPROVIDES
APOWERLIMITINGFUNCTIONBYREDUCING
DISPLACEMENTASSYSTEMPRESSUREINCREASES 0
708 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
Control Options
Non-feedback 4HE.ON &EEDBACK0ROPORTIONAL%LECTRIC.&0% CONTROLISANELECTRICCONTROL!07-INPUT

proportional electric SIGNALTOONEOFTWOSOLENOIDSONTHECONTROLVALVEPORTSCHARGEPRESSURETOONESIDEOFTHE
(NFPE) control SERVOPISTON
0UMPDISPLACEMENTISPROPORTIONALTOTHESIGNALCURRENT(OWEVERBECAUSETHISCONTROL
DOESNOTUSEMECHANICALFEEDBACKDISPLACEMENTALSODEPENDSONINPUTSPEEDAND
SYSTEMPRESSURE4HISCHARACTERISTICPROVIDESAPOWERLIMITINGFUNCTIONBYREDUCING
DISPLACEMENTASSYSTEMPRESSUREINCREASES
NFPE control on series 42 pump (28/32cc) NFPE control on series 42 pump (41/51cc)
P100 415
P108 112E
Forward-Neutral-Reverse 4HE&ORWARD .EUTRAL 2EVERSE&.2 ISATHREE POSITIONCONTROL)TUSESAOR6DC

(FNR) three-position ELECTRICALLYOPERATEDSPOOLVALVETOPORTPRESSURETOEITHERSIDEOFTHESERVOPISTON
electric control %NERGIZINGONEOFTHETWOSOLENOIDSWILLCAUSETHEPUMPTOGOTOITSMAXIMUM
DISPLACEMENTINTHECORRESPONDINGDIRECTION4HE&.2CONTROLDOESNOTUSEMECHANICAL
FEEDBACK
!LLFUNCTIONSOFTHETHREEPOSITION&.2 ELECTRICCONTROLAREPRESETATTHEFACTORY
FNR control on series 42 pump (28/32cc) FNR control on series 42 pump (41/51cc)
P108 112E
0
008 918 12 BOMAG 709
18.2 Vibration pump
Service Manual
4ECHNICAL3PECIlCATIONS
Specifications General specifications

Product line Series 42 pumps
Pump type )N LINEAXIALPISTONPOSITIVEDISPLACEMENTVARIABLEPUMPSINCLUDINGCRADLE
SWASHPLATEANDSERVOCONTROL
Direction of input rotation #LOCKWISEORCOUNTERCLOCKWISEAVAILABLE
Installation position 0UMPINSTALLATIONRECOMMENDEDWITHTHECONTROLATTHETOPORSIDE#ONSULT
3AUER $ANFOSSFORNON CONFORMANCEGUIDELINES(OUSINGMUSTALWAYSBElLLED
WITHHYDRAULICmUID
Filtration configuration 3UCTIONORCHARGEPRESSURElLTRATION
Other system )NDEPENDENTBRAKINGSYSTEMSUITABLERESERVOIRANDHEATEXCHANGER
requirements
Hardware specifications
Model 28 32 41 51
Pump configuration 3INGLEPUMP 3INGLEPUMP 3INGLEPUMP 3INGLEPUMP
Displacement ;= ;= ;= ;=
3 3
cm /rev [in /rev]
Mass kg [lbm] ;= ;= ;= ;=
Case pressure
Rated pressure bar [psi] ;=
Maximum pressure (cold start) bar [psi] ;=
Speed limits
Frame size cm3 28 32 41 51
Minimum speed min¯¹ (rpm)
Rated speed at maximum displacement min¯¹ (rpm)
Maximum speed at maximum displacement min¯¹ (rpm)
System pressure
Rated pressure bar [psi] ;= ;= ;= ;=
Maximum pressure bar [psi] ;= ;= ;= ;=
Theoretical flow
Theoretical flow at rated speed l/min [US gal/min] ;= ;= ;= ;=
Inlet pressure
Rated pressure (absolute) bar [in Hg vacuum] ;=
Minimum pressure (absolute) (cold start) ;=
bar [in Hg vacuum]
710 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
Pressure Measurement
Required tools 9OUCANPERFORMTHESERVICEPROCEDURESINTHISMANUALUSINGCOMMONMECHANICSHAND

TOOLS#ALIBRATEGAUGESFREQUENTLYTOENSUREACCURACY5SESNUBBERSTOPROTECTPRESSURE
GAUGES
Port locations and !PUMPWITHAMANUALDISPLACEMENTCONTROL-$# ANDNOlLTRATIONADAPTERISSHOWN

pressure gauge 7ITHNON FEEDBACKCONTROLSTHEPOSITIONSOFTHECASEDRAINSMAYVARY7ITHAlLTRATION
installation ADAPTERTHEPORTINGINTHElLTRATIONOPTIONSAREAVARIES
Ports and pressure 0ROPERSERVICEANDDIAGNOSISMAYREQUIREPRESSUREMEASUREMENTATVARIOUSPOINTSIN

gauges THEHYDRAULICCIRCUIT4HE3ERIESPUMPHASSEVERALLOCATIONSATWHICHTOTAKETHESE
MEASUREMENTS4HEFOLLOWINGILLUSTRATIONSHOWSTHELOCATIONSOFTHEVARIOUSGAUGEPORTS
4HETABLESHOWSTHERECOMMENDEDGAUGESIZEANDTHElTTINGSIZEFOREACHPORT2EFERTO
THISINFORMATIONWHENINSTALLINGPRESSUREGAUGES
Gauge ports
Gauge Pressure measured Recommended gauge O-ring boss
port size 28/32 cc 41 / 51 cc
-- 3YSTEMPRESSUREFORPORTS!AND" BAR;PSI=
M3 #HARGEPRESSURE BAR;PSI=

-- Servo pressure BAR;PSI=

,, Case pressure BAR;PSI=
S #HARGEPUMPINLETPRESSURE BAR;IN(GVACUUM=

3OMEOLDERMODELSMAYUSEA / RINGlTTING
28/32 cm3 base unit with MDC and no filtration adapter

Servo pressure
gauge port M5
System pressure
gauge port M2 Charge pressure
Servo pressure
gauge port M3
gauge port M4
System (charge pressure
pressure supply for no
port B charge pump
option)
System
pressure
port A Case drain
Charge pump
port L1
inlet port S
Case Drain
System pressure Port L2
gauge port M1
LEFT SIDE VIEW RIGHT SIDE VIEW P108 067E
008 918 12 BOMAG 711
18.2 Vibration pump
Service Manual
Pressure Measurement
Ports and pressure 41/51 cm3 base unit with MDC and no filtration adapter
gauges (continued)
System pressure Servo pressure
gauge port M2 gauge port M5 Charge pressure
gauge port M3
System Servo pressure
pressure gauge port M4
port B
Case drain
System port L2
pressure
port A
Case drain Charge pump
port L1 inlet port S
System pressure
gauge port M1 P108 068E
LEFT SIDE VIEW RIGHT SIDE VIEW
Filtration adapters (28/32 cm3, and 41/51 cm3 models)

Outlet to
filter, port D
Charge pressure Charge pressure

gauge, port M3 gauge, port M3
Inlet from
filter, port E
P108 084E
712 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
)NITIAL3TART 5P0ROCEDURE
General &OLLOWTHISPROCEDUREWHENSTARTING UPANEW3ERIESINSTALLATIONORWHENRESTARTING

ANINSTALLATIONINWHICHTHEPUMPHASBEENREMOVED
WARNING
0RIORTOINSTALLINGTHEPUMPINSPECTFORDAMAGEINCURREDDURINGSHIPPING-AKECERTAIN
ALLSYSTEMCOMPONENTSRESERVOIRHOSESVALVESlTTINGSHEATEXCHANGERETC ARECLEAN
PRIORTOlLLINGWITHmUID
Start-up procedure #ONNECTTHEPUMPTOTHEPRIMEMOVER%NSURETHATPUMPSHAFTISPROPERLYALIGNED

WITHTHESHAFTOFTHEPRIMEMOVER 
 CAUTION
)NCORRECTSHAFTALIGNMENT &ILLTHERESERVOIRWITHRECOMMENDEDHYDRAULICmUID!LWAYSlLTERmUIDTHROUGHA
MAYRESULTINDAMAGE MICRONABSOLUTElLTERPOURINGINTOTHERESERVOIR.EVERREUSEHYDRAULICmUID
TODRIVESHAFTBEARINGS
ORSEALWHICHCANCAUSE &ILLTHEMAINPUMPHOUSINGWITHCLEANHYDRAULICmUID0OURlLTEREDOILDIRECTLYINTO
EXTERNALOILLEAKAGE THEUPPERMOSTCASEDRAINPORT
&ILLTHEINLETLINELEADINGFROMTHEPUMPTOTHERESERVOIR#HECKTHEINLETLINEFOR
PROPERLYTIGHTENEDlTTINGSANDBECERTAINITISFREEOFRESTRICTIONSANDAIRLEAKS
4OENSURETHEPUMPSTAYSlLLEDWITHOILINSTALLTHECASEDRAINLINEINTHEUPPERMOST

CASEDRAINPORT
)NSTALLAGAUGEATPORT-TOMONITORSYSTEMPRESSUREDURINGSTARTUP
&OLLOWRECOMMENDATIONSINTHEVEHICLEMACHINEOPERATORSMANUALFORPRIMEMOVER
STARTUPPROCEDURES
7HILEWATCHINGTHEPRESSUREGAUGEAT-JOGTHEPRIMEMOVERORRUNATTHELOWEST

POSSIBLESPEEDUNTILSYSTEMPRESSUREBUILDSTONORMALLEVELSMINIMUMBAR;
PSI= /NCESYSTEMPRESSUREISESTABLISHEDINCREASETOFULLOPERATINGSPEED)FTHE
PUMPDOESNOTMAINTAINSYSTEMPRESSURESHUTDOWNTHEPRIMEMOVERDETERMINE
CAUSEANDTAKECORRECTIVEACTION2EFERTOTroubleshootingPAGE2
/PERATETHEHYDRAULICSYSTEMFORATLEASTlFTEENMINUTESUNDERLIGHTLOADCONDITIONS
#HECKANDADJUSTCONTROLSETTINGSASNECESSARYAFTERINSTALLATION2EFERTOAdjustments
PAGE2.
3HUTDOWNTHEPRIMEMOVERANDREMOVETHEPRESSUREGAUGE2EPLACEPLUGATPORT-
#HECKTHEmUIDLEVELINTHERESERVOIRADDCLEANlLTEREDmUIDIFNECESSARY
4HEPUMPISNOWREADYFOROPERATION
008 918 12 BOMAG 713
18.2 Vibration pump
Service Manual
Fluid and Filter Maintenance
Recommendations 4OENSUREOPTIMUMLIFEOF3ERIESPRODUCTSPERFORMREGULARMAINTENANCEOFTHEmUID

ANDlLTER#ONTAMINATEDmUIDISTHEMAINCAUSEOFUNITFAILURE4AKECARETOMAINTAINmUID
CLEANLINESSWHENSERVICING

ODOR7ATERINTHEmUIDMAYBENOTEDBYACLOUDYORMILKYAPPEARANCEORFREEWATER
INTHEBOTTOMOFTHERESERVOIR2ANCIDODORINDICATESTHEmUIDHASBEENEXPOSEDTO
EXCESSIVEHEAT#HANGETHEmUIDIMMEDIATELYIFTHESECONDITIONSOCCUR#ORRECTTHE
PROBLEMIMMEDIATELY
#HANGETHEmUIDANDlLTERPERTHE Fluid and filter change intervals

VEHICLEMACHINEMANUFACTURERS Sealed reservoir HOURS
RECOMMENDATIONSORATTHESEINTERVALS "REATHERRESERVOIR HOURS
WATERGREASEETC ORIFTHEmUIDISSUBJECTEDTOTEMPERATURELEVELSGREATERTHATTHE
RECOMMENDEDMAXIMUM
$ISPOSEOFUSEDHYDRAULICmUIDPROPERLY.EVERREUSEHYDRAULICmUID
#HANGElLTERSWHENEVERTHEmUIDISCHANGEDORWHENTHElLTERINDICATORSHOWSTHATITIS
NECESSARYTOCHANGETHElLTER2EPLACEALLmUIDLOSTDURINGlLTERCHANGE
714 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
4ROUBLESHOOTING
Overview 4HISSECTIONPROVIDESGENERALSTEPSTOFOLLOWIFYOUOBSERVECERTAINUNDESIRABLESYSTEM
CONDITIONS3OMEOFTHEITEMSARESYSTEMSPECIlC!LWAYSOBSERVETHESAFETYPRECAUTIONS
LISTEDINTHEINTRODUCTIONOFTHISMANUAL)FSTANDARDTROUBLESHOOTINGPROCEDURESDONOT
REMEDYTHEPROBLEMCONTACTA3AUER $ANFOSS'LOBAL3ERVICE0ARTNER
System operating hot Item Description Action

Oil level in reservoir )NSUFlCIENTHYDRAULICmUIDWILL &ILLTHERESERVOIRTOTHEPROPERLEVEL
NOTMEETTHECOOLINGDEMANDSOF WITHCLEANHYDRAULICOIL
SYSTEM
(EATEXCHANGERIFEQUIPPED 4HEHEATEXCHANGERISNOT #HECKTHEAIRmOWANDINPUTAIR
SUFlCIENTLYCOOLINGTHESYSTEM TEMPERATUREFORTHEHEATEXCHANGER
#LEANREPAIRORREPLACETHEHEAT
EXCHANGERASNECESSARY
"YPASSVALVE !PARTIALLYACTIVATEDBYPASSVALVE 6ERIFYTHATTHEBYPASSVALVEISFULLY
MAYRESULTINHEATGENERATIONWITHIN CLOSEDANDTHATTHEVALVEISSEATING
THESYSTEM PROPERLY2EPAIRORREPLACEITAS
NECESSARY
3#23YSTEM#HECK2ELIEF !PARTIALLYACTIVATED3#2VALVEOR 6ERIFYTHATTHE3#2VALVEISSEATING
6ALVES 3#2VALVESWITHRELIEFSETTINGSTOO PROPERLYANDISATTHECORRECTRELIEF
LOWMAYRESULTINHEATGENERATION SETTING2EPAIRORREPLACEITAS
WITHINTHESYSTEM NECESSARY
/ILlLTERS #LOGGEDOILlLTERSMAYRESULTINAN )NSPECTTHEOILlLTERSANDVERIFYTHAT
INSUFlCIENTSUPPLYOFCOOLOILTOTHE THEYARESTILLOPERABLE2EPLACETHEM
SYSTEM IFNECESSARY
-ACHINELOAD %XCESSIVELOADSOREXTREMEDUTY 6ERIFYTHATTHEMACHINEISOPERATING
CYCLESCOULDRESULTINTHEPUMPAND WITHINTHEPARAMETERSFORWHICHIT
ORMOTOROPERATINGATSPEEDSAND WASDESIGNED)FNECESSARYREDUCE
PRESSURESBEYONDSYSTEMDESIGN THELOADONTHEMACHINE
LIMITATIONS
008 918 12 BOMAG 715
18.2 Vibration pump
Service Manual
4ROUBLESHOOTING
System response is Item Description Action

sluggish 2ESERVOIROILLEVEL 4HEREISANINSUFlCIENTAMOUNT &ILLTHERESERVOIRTOTHEPROPERLEVEL
OFHYDRAULICmUIDRESULTINGINAN WITHCLEANHYDRAULICmUID
INADEQUATESUPPLYFORTHESYSTEM
LOOP
)NPUTCONTROLSIGNAL 4HEPUMPISRECEIVINGAFAULTY 6ERIFYTHATTHEINPUTSIGNALISCORRECT
LINKAGECURRENTORPRESSURE CONTROLSIGNAL-$# BINDINGOR ANDIDENTICALINBOTHDIRECTIONS
BROKENLINKAGE%$# FAULTYOR
INADEQUATEELECTRICALSIGNAL($#
BLOCKEDORINCORRECTLYORIlCED
CONTROLLINES
Pump control !DAMAGEDPUMPCONTROLORCONTROL 6ERIFYTHATTHEPUMPSCONTROLIS
SPOOLWILLNOTCORRECTLYTRANSMITTHE OPERATINGPROPERLYANDTHATTHE
CONTROLINPUTSIGNALTOTHEPUMP CONTROLSPOOLISNOTDAMAGEDOR
WORNANDMOVESFREELYWITHINITS
BORE#LEANREPAIRORREPLACEITAS
NECESSARY
"YPASSVALVE !PARTIALLYACTIVATEDBYPASSVALVE 6ERIFYTHATTHEBYPASSVALVEIS
WILLCAUSECROSSPORTLEAKAGE CLOSEDANDTHATTHEVALVEISSEATING
PROPERLY#LEANREPAIRORREPLACEIT
ASNECESSARY
3#2SYSTEMCHECKRELIEF /NEORBOTHOFTHE3#2VALVESMAY 6ERIFYTHATTHE3#2VALVESOPERATE
valves BEBINDINGWITHINTHEIRBORES FREELY2EPAIRORREPLACETHEMAS
NECESSARY
#HARGEPRESSUREINNEUTRAL 4HEISLOWCHARGEPRESSURERESULTING )NSPECTTHECHARGEPUMPFOR
FROMADAMAGEDCHARGEPUMPOR DAMAGEANDVERIFYTHECHARGE
LOWCHARGEPRESSURERELIEFVALVE PRESSURERELIEFVALVESETTING2EPAIR
SETTING ORREPLACEITASNECESSARY
#HARGEPRESSUREINSTROKE 4HEREISLOWCHARGEPRESSURE 2EPAIRORREPLACETHECOMPONENT
RESULTINGFROMINTERNALLEAKAGE ORCOMPONENTSWITHINTHESYSTEM
WITHINTHESYSTEM CAUSINGTHEINTERNALLEAKAGE
Servo pressure 4HEREISINSUFlCIENTPRESSURE #HECKSERVOPRESSURESATPORT-
DIFFERENTIALACROSSTHESERVOPISTON AND-TOVERIFYSUFlCIENTPRESSURE
DELTA6ERIFYTHATTHESERVOSUPPLY
ANDDRAINPATHSAREUNOBSTRUCTED
ANDTHATANYORIlCESAREOFTHE
CORRECTSIZEANDFREEOFDEBRIS#LEAN
REPAIRORREPLACEASNECESSARY
#HARGEPUMP 4HECHARGEPUMPHASBEEN 6ERIFYTHATTHECHARGEPUMPISIN
DAMAGEDORINSTALLEDWITHTHE GOODWORKINGORDERANDTHATITIS
INCORRECTROTATIONALORIENTATION CORRECTLYINSTALLED2EPAIRORREPLACE
ITASNECESSARY
716 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
4ROUBLESHOOTING
System will not operate Item Description Action

in either direction Oil level in reservoir 4HEREISINSUFlCIENTHYDRAULICmUID &ILLTHERESERVOIRTOTHEPROPERLEVEL
TOSUPPLYTHESYSTEMLOOP WITHCLEANHYDRAULICOIL
)NPUTCONTROLSIGNAL 4HEPUMPISRECEIVINGAFAULTY 6ERIFYTHATTHEINPUTSIGNALISCORRECT
LINKAGECURRENTORPRESSURE CONTROLSIGNAL-$# BINDINGOR ANDIDENTICALINBOTHDIRECTIONS
BROKENLINKAGE%$# FAULTYOR !DJUSTCLEANREPAIRORREPLACETHE
INADEQUATEELECTRICALSIGNAL($# INPUTDEVICEASNECESSARY
CONTROLLINES
/ILlLTERS #LOGGEDOILlLTERSMAYRESULTIN )NSPECTTHEOILlLTERSANDVERIFYTHAT
ANINSUFlCIENTSUPPLYOFOILTOTHE THEYARESTILLSERVICEABLE2EPLACE
SYSTEM THEMASNECESSARY
"YPASSVALVE !PARTIALLYACTIVATEDBYPASSVALVE 6ERIFYTHATTHEBYPASSVALVESARE
MAYRESULTINACROSSPORTLEAKAGE CLOSEDANDTHATTHEVALVESARE
SEATINGPROPERLY#LEANREPAIROR
REPLACETHEMASNECESSARY
#HARGEPRESSURE #HARGEPRESSUREMAYBEINSUFlCIENT )NSPECTTHECHARGEPUMPFOR
INNEUTRAL TORECHARGETHESYSTEMLOOP DAMAGEANDVERIFYTHATTHECHARGE
PRESSURERELIEFVALVEISATTHEPROPER
SETTING2EPAIRORREPLACEITAS
NECESSARY
#HARGEPRESSURE 4HEREISLOWCHARGEPRESSURE 2EPAIRORREPLACETHECOMPONENT
INSTROKE RESULTINGFROMINTERNALLEAKAGE ORCOMPONENTSWITHINTHESYSTEM
WITHINTHESYSTEM CAUSINGTHEINTERNALLEAKAGE
Servo pressure 4HEREISANINSUFlCIENTPRESSURE #HECKSERVOPRESSURESTOVERIFY
DIFFERENTIALACROSSTHESERVOPISTON SUFlCIENTPRESSUREDELTA6ERIFYTHAT
THESERVOSUPPLYANDDRAINPATHSARE
UNOBSTRUCTEDANDTHATANYORIlCES
AREOFTHECORRECTSIZEANDFREEOF
DEBRIS#LEANREPAIRORREPLACETHEM
ASNECESSARY
#HARGEPUMP 4HECHARGEPUMPISDAMAGEDOR 6ERIFYTHATTHECHARGEPUMPISIN
HASBEENINSTALLEDWITHTHEINCORRECT GOODWORKINGORDERANDTHATITIS
ROTATIONALORIENTATION CORRECTLYINSTALLED2EPAIRORREPLACE
ITASNECESSARY
3#2SYSTEMCHECKRELIEF 4HE3#2VALVESAREMALFUNCTIONING 6ERIFYTHATTHE3#2VALVESARE
valves ORIMPROPERLYSET OPERATINGANDPROPERLYSET2EPAIROR
REPLACETHEMASNECESSARY
$ISPLACEMENTLIMITERS $ISPLACEMENTLIMITERSMAYBE 6ERIFYTHATTHEDISPLACEMENTLIMITERS
IMPROPERLYADJUSTEDSUCHTHATTHE AREADJUSTEDTOTHEPROPERSETTING
SERVOPISTONISLOCKEDINPLACE
008 918 12 BOMAG 717
18.2 Vibration pump
Service Manual
4ROUBLESHOOTING
System will not operate Item Description Action

in one direction )NPUTCONTROLSIGNALLINKAGE 4HEPUMPISRECEIVINGAFAULTY 6ERIFYTHATTHEINPUTSIGNALISCORRECT
CURRENTORPRESSURE CONTROLSIGNAL-$# BINDINGOR ANDIDENTICALINBOTHDIRECTIONS
BROKENLINKAGE%$# FAULTYOR !DJUSTCLEANREPAIRORREPLACETHE
INADEQUATEELECTRICALSIGNAL($# CONTROLMODULEASNECESSARY
CONTROLLINES
3#23YSTEM#HECK2ELIEF 4HE3#2VALVESAREMALFUNCTIONING 6ERIFYTHATTHE3#2VALVESARE
valves ORIMPROPERLYSET OPERATINGPROPERLY2EPAIRORREPLACE
THEMASNECESSARY
Pump control !DAMAGEDORBIASEDPUMP 6ERIFYTHATTHEPUMPSCONTROLIS
CONTROLMAYBESENDINGASIGNAL FUNCTIONINGPROPERLY2EPAIROR
COMMANDINGTHEPUMPTOSTROKE REPLACEITASNECESSARY
ONLYINONEDIRECTION
Servo pressure 4HEDRAINORSUPPLYPATHTOONESIDE 6ERIFYTHATTHESERVOSUPPLYAND
OFTHESERVOPISTONMAYBEBLOCKED DRAINPATHSAREUNOBSTRUCTEDAND
THATANYORIlCESAREOFTHECORRECT
SIZEANDFREEOFDEBRIS#LEANOR
REPAIRTHEMASNECESSARY
$ISPLACEMENTLIMITERSIF 4HEDISPLACEMENTLIMITERSMAYBE 6ERIFYTHATTHEDISPLACEMENTLIMITERS
EQUIPPED IMPROPERLYADJUSTEDSUCHTHATTHE AREADJUSTEDPROPERLY
SERVOPISTONISPREVENTEDFROM
MOVINGINONEDIRECTION
Neutral difficult or Item $ESCRIPTION Action

impossible to find )NPUTCONTROLSIGNALLINKAGE 4HEPUMPISRECEIVINGAFAULTY 6ERIFYTHATTHEINPUTSIGNALISCORRECT
CURRENTORPRESSURE CONTROLSIGNAL-$# BINDINGOR ANDIDENTICALINBOTHDIRECTIONS
BROKENLINKAGE%$# FAULTYOR !DJUSTCLEANREPAIRORREPLACE
INADEQUATEELECTRICALSIGNAL($# CONTROLMODULEASNECESSARY
CONTROLLINES
3YSTEMPRESSURE 7ITHNOINPUTSIGNALTOTHECONTROL 2EADJUSTPUMPNEUTRALSETTING2EFER
APRESSUREDELTAMAYEXISTBETWEEN to adjustment procedure on PAGE
THETWOSIDESOFTHEWORKINGLOOP
Servo pressure 7ITHNOINPUTSIGNALTOTHECONTROL 2EADJUSTTHECONTROLNEUTRALSETTING
APRESSUREDELTAMAYEXISTACROSSTHE 2EFERTOADJUSTMENTPROCEDUREON
SERVOPISTON PAGE
0#0PRESSURE%$#SONLY 7ITHNOINPUTSIGNALTOTHECONTROLA 2EPLACETHE%$#
PRESSUREDIFFERENCEMAYEXISTACROSS
THECONTROLSPOOL
718 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
Adjustments
Overview 4HISSECTIONOFFERSINSTRUCTIONONHOWTOPERFORMADJUSTMENTSTOTHE3ERIESPUMP
2EADTHROUGHTHEENTIREPROCEDUREBEFOREBEGINNINGANYSERVICEACTIVITY
Displacement limiter -OUNTTHEPUMPONATESTSTANDCAPABLE Displacement limiters

L025
adjustment OFMEASURINGSYSTEMmOWFROMTHE!AND Displacement
"PORTS limiter seal
lock nut
L020 13 mm
,OOSENTHEDISPLACEMENTLIMITERSEAL Displacement
.%
LOCKNUT, BUTDONOTREMOVEIT limiter

$!.!+
4 mm
L001
3TARTTHEPRIMEMOVERANDPLACE Servo
THEPUMPINTOFULLSTROKEINONE piston
DIRECTION.OTETHESYSTEMOUTPUT cover
7!2.).' mOWFROMEITHERTHE!OR"SYSTEM
4HESEALNUTLOCKNUT PORT
MUSTBERETORQUEDAFTER
EVERYADJUSTMENTANDTHE !DJUSTTHEDISPLACEMENTLIMITER
LIMITERSCREWMUSTHAVE ADJUSTMENTSCREW, UNTILTHE
FULLTHREADENGAGEMENT DESIREDOUTPUTmOWISREACHED
INTHESERVOPISTONCOVER 4URNINGTHEDISPLACEMENTLIMITER
to prevent unexpected ADJUSTMENTSCREWCLOCKWISE
CHANGESINOPERATING DECREASESTHEMAXIMUMOUTPUTmOW
conditions and to prevent SETTING4URNINGTHEDISPLACEMENT
EXTERNALLEAKAGEDURING LIMITERADJUSTMENTSCREWCOUNTER
UNITOPERATION CLOCKWISEINCREASESTHEMAXIMUM RIGHT SIDE VIEW (M4)
M020
OUTPUTmOWSETTING Displacement
limiter M025
4HEPUMPACHIEVESOVERALLMAXIMUM 4 mm Displacement
limiter seal
mOWWHENTHEDISPLACEMENTLIMITERDOES lock nut
NOTCONTACTTHESERVOPISTONWHILETHE 13 mm
UNITISINFULLSTROKE .%
M001

$!.!+
Servo
piston
/NEFULLTURNOFTHEDISPLACEMENTLIMITER cover
ADJUSTMENTSCREWRESULTSINAPPROXIMATE
mOWOUTPUTCHANGESPERTHETABLE
/NCEYOUACHIEVETHEPROPEROUTPUT
mOWTORQUETHEDISPLACEMENT
Displacement limiter LIMITERSEALLOCKNUT, TO.sM
adjustment ;LBFsFT=WHILEHOLDINGTHEPOSITION
Size Displacement change OFTHEADJUSTMENTSCREW,
per turn
28 cm3 CM3REV;IN3REV= )FREQUIREDREPEATTHISPROCEDURE
32 cm3 CM3REV;IN3REV= USINGTHEOPPOSITEDISPLACEMENT
CM3 CM3REV;IN3REV= LIMITERTOSETTHEOUTPUTmOWINTHE LEFT SIDE VIEW (M5)
CM3 CM3REV;IN3REV= OTHERDIRECTION P108 077E
008 918 12 BOMAG 719
18.2 Vibration pump
Service Manual
Adjustments
Pump neutral adjustment :EROOUTPUTmOWFROMTHEPUMPDElNESTHENEUTRALCONDITION4OATTAINZEROOUTPUT

mOWTHEPUMPMUSTACHIEVEBOTHMECHANICALNEUTRALANDCONTROLNEUTRALCONDITIONS
-ECHANICALNEUTRALISTHECONDITIONWHENTHESWASHPLATEISATZEROANGLEWITHOUTANY
7!2.).' SIGNALINPUTFROMTHECONTROL3ETMECHANICALNEUTRALPRIORTOSETTINGCONTROLNEUTRAL
4OPREVENTINJURYDISABLE
THEMACHINERAISE $ISABLETHECONTROLINPUTTOTHE Pump neutral adjustment screw
WHEELSOFFTHEGROUNDOR PUMPBYEQUALIZINGTHEPRESSURESON T060
DISCONNECTTHEMECHANISM BOTHENDSOFTHEPUMPSERVOPISTON Pump mechanical
4OACCOMPLISHTHISCONNECTAN neutral adjustment
seal lock nut
3!% HOSEBETWEENSERVOGAUGE See table
PORTS-AND- See table
)NSTALLPRESSUREGAUGESINGAUGE T015

PORTS-AND-TOMEASURESYSTEM Pump neutral
PRESSURE adjustment screw
See table
See table
3TARTTHEPRIMEMOVERANDRUNAT
NORMALOPERATINGSPEED %%
MDC Shown
,OOSENTHEPUMPNEUTRAL
ADJUSTMENTSEALLOCKNUT4 IN Neutral adjustment gauge port readings
THECENTEROFTHESERVOCOVERONTHE M1 / M2
RIGHTSIDEOFTHEPUMP M1 / M2
4URNTHEADJUSTMENTSCREW4
CLOCKWISEUNTILONEOFTHEGAUGES
REGISTERSANINCREASEINSYSTEM M1 / M2
PRESSURE-ARKTHEPOSITIONOFTHE
ADJUSTMENTSCREW4URNTHESCREW
COUNTERCLOCKWISEUNTILTHEOTHER
GAUGEREGISTERSANINCREASEIN 0
SYSTEMPRESSURE-ARKTHEPOSITION
OFTHEADJUSTMENTSCREW4URNTHEADJUSTMENTSCREWCLOCKWISETOAPOSITIONHALFWAY
BETWEENTHEMARKS4HESYSTEMPRESSUREGAUGESSHOULDINDICATEEQUALPRESSURES
7HILEHOLDINGTHEADJUSTMENTSCREWINPOSITIONTORQUETHESEALLOCKNUT4

4ORQUECM3MODELSWITHAN-$#%$#ORAN(# %$#TO .sM;
LBFsFT=4ORQUEALLCM3MODELSANDCM3MODELSWITH.&0CONTROLSTO
.sM;LBFsFT=
3TOPTHEPRIMEMOVERANDREMOVETHEHOSEBETWEENGAUGEPORTS-AND-
2EMOVETHEPRESSUREGAUGESINGAUGEPORTS-AND-2EINSTALLTHEPLUGSINTHE
GAUGEPORTS
0ROCEEDTOTHECONTROLNEUTRALADJUSTMENTSECTIONONTHENEXTPAGE
Frame size cm3 28/32 41/51

Control MDC/EDC/HC-EDC NFP MDC/EDC/HC-EDC NFP
Lock nut mm
Servo adjust screw mm [in] 5
,OCKNUTTORQUE.sM;LBFsFT= ;= ;= ;= ;=
720 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
Adjustments
Control neutral #ONTROLNEUTRALADJUSTMENTALIGNSTHE Control neutral adjustment screw

adjustment for MDC and PUMPSWASHPLATEANDTHECONTROLSPOOL D014
neutral
EDC/HC-EDC SOTHATAZEROANGLECONTROLSETTING adjustment screw
PROVIDESAZERODEGREESWASHPLATE 5 mm
SETTING0ERFORMTHISADJUSTMENT
7!2.).' WHENEVERYOUADJUSTORMOVEANYPART
4HEFOLLOWINGPROCEDURE OFTHECONTROLORSWASHPLATEMECHANISM
REQUIRESTHEVEHICLE ORAFTERYOUADJUSTTHEPUMPNEUTRAL
MACHINETOBEDISABLED SETTING
WHEELSRAISEDOFFTHE
GROUNDWORKFUNCTION 
DISCONNECTEDETC WHILE $ISCONNECTTHEEXTERNALCONTROL
D015
PERFORMINGTHEPROCEDURE LINKAGEFOR-$# ORCONTROLSIGNAL neutral
INORDERTOPREVENTINJURY INPUTFOR%$#AND(# %$# FROMTHE adjustment lock nut
TOTHETECHNICIANAND PUMP 17 mm

BYSTANDERS HC-EDC Shown
P108 080E
)NSTALLPRESSUREGAUGESINTHESERVO
GAUGEPORTS-AND-TOMEASURE
PRESSUREONTHEPUMPSERVOPISTON
Equalization of pressure gauges using
3TARTTHEPRIMEMOVERANDRUNAT pump neutral adjustment screw
NORMALOPERATINGSPEED M3 / M4
,OOSENTHECONTROLNEUTRAL
ADJUSTMENTSEALLOCKNUT$
M3 / M4
4URNTHEADJUSTMENTSCREW$
CLOCKWISEUNTILONEOFTHEGAUGES
REGISTERSANINCREASEINPRESSUREON
THESERVOPISTON-ARKTHEPOSITIONOF
THEADJUSTMENTSCREW
4URNTHESCREWCOUNTERCLOCKWISE M3 / M4
UNTILTHEOTHERGAUGEREGISTERSAN
P101 270E
INCREASEINPRESSUREONTHESERVO
PISTON-ARKTHEPOSITIONOFTHE
ADJUSTMENTSCREW
4URNTHEADJUSTMENTSCREWCLOCKWISESOTHATITISMIDWAYBETWEENTHEMARKS
!DJUSTMENTSCREWMOVEMENTPRODUCESCONSTANTCHANGEFORBOTHDIRECTIONSSOBOTH
THEPRESSUREGAUGESSHOULDINDICATENEARLYEQUALPRESSURES
7HILEHOLDINGTHEADJUSTMENTSCREW$ INPOSITIONTORQUETHESEALLOCKNUT

$ TO.sM;LBFsFT=
3TOPTHEPRIMEMOVERANDREMOVETHEPRESSUREGAUGES2EMOVETHEPLUGSINTHE
GAUGEPORTS
#ONNECTTHEEXTERNALCONTROLLINKAGEFOR-$# ORCONTROLSIGNALINPUTFOR%$#AND

(# %$# TOTHEPUMP2ECONNECTTHEWORKFUNCTION
008 918 12 BOMAG 721
18.2 Vibration pump
Service Manual
-INOR2EPAIR
Standard procedures Remove the pump

0RIORTOPERFORMINGCERTAINMINORREPAIRSONTHE3ERIESPUMPITMAYBENECESSARYTO
REMOVETHEPUMPFROMTHEMACHINE#HOCKTHEVEHICLETOPROHIBITMOVEMENT"EAWARE
THATHYDRAULICmUIDMAYBEUNDERHIGHPRESSUREANDMAYBEHOT)NSPECTTHEOUTSIDEOF
THEPUMPANDlTTINGSFORDAMAGE
Keep it clean
#LEANLINESSISAPRIMARYMEANSOFASSURINGSATISFACTORYPUMPLIFEONEITHERNEWORREPAIRED
UNITS#LEANTHEOUTSIDEOFTHEPUMPTHOROUGHLYBEFOREDISASSEMBLY4AKECARETOAVOID
CONTAMINATIONOFTHESYSTEMPORTS#LEANPARTSUSINGACLEANSOLVENTWASHANDAIRDRY
Inspect for system contamination

)NSPECTTHEPUMPFORSYSTEMCONTAMINATION)FYOUlNDCONTAMINATIONFULLYDISASSEMBLE
CLEANANDINSPECTALLCOMPONENTSOFTHEPUMPUSING11007277 Series 42 Axial Piston
Closed Circuit Pumps Repair ManualINCONJUNCTIONWITHTHISMANUAL
Replace the O-rings and gaskets Pump face orientations

3AUER $ANFOSSRECOMMENDSYOUREPLACE Left face
ALL/ RINGSANDGASKETS,IGHTLYLUBRICATE
/ RINGSWITHCLEANPETROLEUMJELLYPRIOR
TOASSEMBLY Front face Top face
Lubricate all moving parts

$URINGREASSEMBLYCOATALLMOVING
PARTSWITHAlLMOFCLEANHYDRAULIC
OIL4HISWILLHELPTOLUBRICATETHESE
PARTSDURINGSTART UP&ORmUIDQUALITY
REQUIREMENTSREFERTOBULLETIN520L0463
Bottom face
Hydraulic Fluids and Lubricants, Technical
Rear face
Information.
Right face P108 079E
722 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
-INOR2EPAIR
Size and torque for plugs 0LUGANDlTTINGSIZESAPPEARHERE Case drain plug

and fittings 2EPLACE/ RINGSANDLUBRICATEWITH F091 28/32 cm3 41/51 cm3
PETROLEUMJELLYWHENEVERAPLUGIS )NTERNALHEX IN IN
REMOVED4ORQUEEACHASINDICATED 4ORQUE .sM .sM
;LBFsFT= ;LBFsFT=
Size and torque for plugs and fittings
Servo gauge
port M4
L010
11
/16 in
+!
+'
Charge pressure Charge pump

gauge port M3 inlet port S
F091 (position varies,
(see table) Case drain refer to Filtration
port L1 options)
Servo gauge
port M5
M010
11
/16 in
+!
+'
Case drain
port L2
F091
(see table)
N002
11
/16 in
+!
+'
F093
System 11
System ports gauge ports /16 in
A and B M1 and M2 +! +'
P108 097E
008 918 12 BOMAG 723
18.2 Vibration pump
Service Manual
-INOR2EPAIR
Charge relief valve 9OUMAYREMOVETHECHARGERELIEFVALVEFORCLEANINGANDINSTALLATIONOFNEW/ RINGS9OU

MAYCHANGETHEPRESSURESETTINGHOWEVERNOTETHATTHESETTINGWILLVARYFORDIFFERENT
CHARGEmOWSDEPENDINGONCHARGEPUMPSIZEANDPUMPSPEED4HEFACTORYSETTINGISSET
RELATIVETOASPECIlCCHARGEmOWAT²&ANDMIN RPM INPUTSPEED4HEACTUAL
CHARGEPRESSUREVARIESATDIFFERENTSPEEDS
Shim adjustable style (pre-blockpoint change)

/NUNITSMANUFACTUREDPRIORTOTHEBLOCKPOINTCHANGEYOUADJUSTTHECHARGE
PRESSURERELIEFVALVEBYCHANGINGTHENUMBERORSIZEOFSHIMSLOCATEDBEHINDTHECHARGE
PRESSURERELIEFVALVESPRING
2EMOVETHESHIMADJUSTABLECHARGERELIEFVALVEPLUG' FROMTHEPUMPHOUSING

2EMOVEANDDISCARDTHE/ RING'! FROMTHEPLUG
2EMOVESHIMS' SPRING' Adjustable charge relief valve components

ANDPOPPET' FROMHOUSING
G040
)NSPECTTHEPOPPETANDMATINGSEAT Shim adjustable
charge relief valve plug
INTHEHOUSINGFORDAMAGEORFOREIGN 1 in
MATERIAL 54-136 [40-100]
G040A
)NSTALLANEW/ RING'! ON G041
O-Ring
Shims
THECHARGERELIEFVALVEPLUG'
2EINSTALLTHEPOPPET' SPRING
' ANDSHIMS' INTOTHE G043 G042
Poppet Spring
PUMPHOUSING4OCONlRMTHE
CHARGERELIEFVALVESETTINGMEASURE
THECHARGEPRESSUREATPORT-4HE
CHARGEPRESSURELEVELSOFFWHENIT
REACHESTHERELIEFSETTING
)NSTALLPLUG' 4ORQUETO

.M LBFsFT
E100 016E
Pressure change per shim

Approximate pressure change Shim thickness
BAR;PSI= MM;IN=
724 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
Adjustments
Charge relief valve

(continued) Externally adjustable style
4HEBLOCKPOINTCHANGEDISCONTINUEDTHEUSEOFTHESHIMADJUSTABLECHARGERELIEF
VALVEANDMADETHEEXTERNALLYADJUSTABLECHARGERELIEFVALVESTANDARD4HECHARGE
PRESSURECHANGESBYAPPROXIMATELYBARPSI PERQUARTERTURNOFTHEADJUSTABLE
CHARGERELIEFVALVEPLUGTHISAPPLIESTOBOTHEXTERNALANDINTERNALHEXSTYLEPLUGS
-ARKTHEADJUSTABLECHARGERELIEFVALVEPLUG4 LOCKNUT4 ANDTHEPUMP

HOUSINGPRIORTOREMOVINGTHECHARGERELIEFVALVEINORDERTOAPPROXIMATELYDUPLICATE
THECHARGEPRESSURERELIEFVALVESORIGINALSETTINGUPONREASSEMBLY
,OOSENTHELOCKNUT4 ANDUNSCREWTHEADJUSTABLECHARGERELIEFVALVEPLUG

4
Externally adjustable charge relief valve
2EMOVEANDDISCARDTHE/ RING components
4! FROMTHEADJUSTABLECHARGE T041
RELIEFVALVEPLUG4 Lock nut
1 1/16 in
28 cc: .m
2EMOVETHESPRING4 AND $.+
POPPET4 FROMTHEHOUSING 41 cc: .m
$.+
)NSPECTTHEPOPPET4 ANDSEAT T039A

WITHINTHEHOUSINGFORDAMAGE O-ring
ORFOREIGNMATERIAL2EPLACEAS T039
NECESSARY T039 Anti-stall
Adjustable adjustable charge
charge relief T042 relief valve plug
)NSTALLTHEPOPPET4 ANDSPRING valve plug Spring 8.5 mm
4 INTOTHEHOUSING ½ in T043
Poppet
)NSTALLANEW/ RING4! ONTOTHE
ADJUSTABLECHARGERELIEFVALVEPLUG
4
)NSTALLTHEADJUSTABLECHARGERELIEF
VALVEPLUG4 ANDTHELOCKNUT
4 INTOTHEHOUSINGALIGNINGTHE
MARKSMADEPRIORTODISASSEMBLY
/NCM3MODELSTORQUETHE

LOCKNUT4 TO.sM;LBFsFT=
ANDONCM3MODELSTORQUETHE
P108 128E
LOCKNUT4 TO.sM;LBFsFT=
4HISMAYCAUSEMISALIGNMENTOFTHE
ORIGINALPOSITIONMARKSMADEEARLIER
#ONlRMTHECHARGERELIEFVALVESETTINGBYMEASURINGCHARGEPRESSUREATTHECHARGE
PRESSUREGAUGEPORT- 4HECHARGEPRESSUREREADINGSHOULDLEVELOFFWHENTHE
RELIEFSETTINGISREACHED
008 918 12 BOMAG 725
18.2 Vibration pump
Service Manual
-INOR2EPAIR
Optional speed sensor 7HENINSTALLINGORADJUSTINGTHESPEED Speed sensor replacement

SENSORONAPUMPYOUMUSTSETITTOA
SPECIlCDISTANCEFROMTHESPEEDRINGON
THECYLINDERBLOCK N002
1-1/16 in N002 O-ring plug
11/16 in
Removal t]
t]
,OOSENTHELOCKNUTUSINGA IN
HEXWRENCH N002A
N002A
5NTHREADTHESPEEDSENSOR.
FROMTHEPUMPHOUSING2EMOVEAND
DISCARDTHE/ RING.!
Reassembly
!LWAYSINSTALLANEW/ RINGBEFORE
REINSTALLINGTHESENSOR
2EINSTALLTHESPEEDSENSORWITHLOCK
P108 081E
NUTAND/ RING INTOTHEHOUSING
4URNTHESENSORCLOCKWISE#7 BY
HANDUNTILITCONTACTSTHESPEEDRING Cross section view of speed sensor in
variable pump
4URNTHESENSORCOUNTERCLOCKWISE
##7 TURN² TOESTABLISHTHE
NOMINALGAPOFMM;INCH=
Gap
4HENTURNTHESENSORCLOCKWISE#7
UNTILTHEWRENCHmATSONSENSORBODY
Speed sensor
AREPOSITIONEDATA²ANGLETOTHE Magnetic speed ring
PUMPSHAFTCENTERLINE Cylinder block
P104 152E
-OSTADJUSTABLEWRENCHESHAVEA²
HANDLEOFFSET Positioning speed sensor relative to
pump shaft
4HElNALSENSORPOSITIONSHOULDBE Shaft centerline
BETWEEN² ANDTURN²
COUNTERCLOCKWISE##7 FROMTHE 22° 22°
POINTWHERETHESENSORCONTACTSTHE
SPEEDRING Speed sensor with Speed sensor with
packard connector turck connector
(OLDSENSORINPOSITIONWITHA Shaft centerline

INCHHEXWRENCHWHILETIGHTENING
THELOCKNUTTO.sM;LBFsFT=
22° 22°
Speed sensor with Speed sensor with

packard connector turck connector
P104 155E
726 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
-INOR2EPAIR
MDC Module Removal

4HEMANUALDISPLACEMENTCONTROL-$# ACTUATESTHECONTROLSPOOLTHROUGHACONNECTION
TOTHESUMMINGLINKPIN4HEFOLLOWINGPROCEDUREDESCRIBESHOWTOREMOVEANDINSTALLTHE
CONTROL#ONTROLSPOOLANDLINKAGEREMOVALISEXPLAINEDONPAGESAND4
#LEANEXTERNALSURFACESOFTHEPUMP
)FNECESSARYREMOVETHE-$#HANDLE Link pin into cam slot
$ ANDDISCONNECT.33WIRING
$
"EINGCAREFULNOTTOLOSETHE
BACKLASHSPRING$ REMOVETHE
CONTROLSPOOLPLUGS$AND$
2EMOVETHESEVEN CONTROLBOLTS

$ THATSECURETHECONTROLTOTHE
PUMPHOUSING2EMOVETHECONTROL
$ ANDGASKET% FROMTHE
Summing link
PUMP$ISCARDTHEGASKET pin (D011)
MUST enter
the slot in the
%NSURETHATTHEHOUSINGANDCONTROL control cam
SURFACESARECLEANANDFREEOFGASKET
MATERIAL)FNECESSARYCLEANTHE
SURFACESWITHSOLVENT
Installation %%
0LACEANEWGASKET% ONTHE
control module MDC module assembly
D019
D003 D016
4HECONTROLGASKETACTSASREGULATING 3
/16 in D017
ORIlCES#HECKTHE0ARTS-ANUALCM3
,ORCM3, AND
D070
YOURORDERCODETOCONlRMYOUHAVETHE D002
CORRECTCONTROLGASKET
D040A
T-30
D040
&OREXACTPOSITIONINGPLACE

THE-$#ALIGNMENTTOOLSEE
DIMENSIONEDDIAGRAMNEXTPAGE E001
D032A
7!2.).' OVERTHEEXPOSEDSUMMINGLINK
D91
5NINTENDEDVEHICLE PIN)F-$#ALIGNMENTTOOLISNOT
MACHINEMOVEMENT AVAILABLESKIPTOMDC alignment
D032
HAZARD-$#MUSTBE without tool STEPSA A 7/8 in
ALIGNEDTOTHEHOUSING
WITHININCH 3LIDETHE-$#$ OVERTHETOOL

)NACCURATEALIGNMENT WHILEENGAGINGTHETOOLWITHTHESLOT
D035A
MAYCAUSENEUTRALTO INTHE-$#CAMANDALLOWITTOPASS
BEOFFCENTERORMAKEIT THROUGHTHEHOLEONTHEFRONTOFTHE
IMPOSSIBLETOSET -$#HOUSING
D035
5/16 in P108 087E
)NSTALLTHECONTROLSCREWS$ AND
TORQUETO .sM; LBFsFT=

008 918 12 BOMAG 727
18.2 Vibration pump
Service Manual
-INOR2EPAIR
MDC Module (continued) 2EMOVETHEALIGNMENTTOOLANDINSTALLPLUG$ TORQUETO.sM;LBFsFT=
2EPLACETHESPRING$ ANDSPOOLPLUGS$AND$
!DJUSTCONTROLNEUTRALSEEPAGE MDC cam
MDC alignment without tool.

)FTHE-$#ALIGNMENTTOOLISNOT
AVAILABLEITISPOSSIBLETOLOCATETHE Point of
contact
APPROXIMATEPOSITIONOFTHEPINBY Summing
CREATINGANIMAGINARYCIRCLEATTHE link pin Imaginary circle
CORRECTLOCATIONASINDICATEDINTHE
ILLUSTRATION4HEPOINTATWHICHTHE
MDC cam
IMAGINARYCIRCLECONTACTSTHESLOTINTHE
CAMISTHESUGGESTEDCONTACTPOINTOF 0%
THESUMMINGLINKPIN7HENENGAGING
THEPININTHECAMSLOTYOUMAYNEEDTO MDC alignment tool
USEAmATTOOLSUCHASASCREWDRIVERTO 16 mm
POSITIONTHELINKAGE 6 mm Ø [0.63 in]
[0.236 in]
6.97 mm -0.05 Ø
&ORPROPERCONTROLOPERATIONTHE [0.2744 in -0.002]
SUMMINGLINKMUSTENGAGETHESLOTON 20 mm 5.06 mm +0.05 Ø
THECONTROLMODULE&OREXACTPLACEMENT [0.79 in] [0.1992 in +0.002]
USETHEALIGNMENTTOOLSHOWN ~ 100 mm
[3.94 in] 0%
A )NSTALLANDHAND TIGHTENTHESEVEN MACHINED FROM MILD STEEL

CONTROLRETAININGSCREWSANDTHEN
BACKOFFEACHSCREWONETURN Torque patterns (MDC, EDC and HC-EDC)
TORQUE BOLTS IN ORDER INDICATED
A !DJUSTTHECONTROLPOSITIONSOTHAT
THESUMMINGLINKPINISALIGNEDAS 4 3 6
DESCRIBEDABOVEANDTORQUEBOLTS
$ TO.sM;LBFsFT=
1
A 2EPLACETHECOVERPLUG$ AND
TORQUETO.sM;LBFsFT= 7
2 5
#ONTINUEABOVETOSTEP
8 Torque this bolt
first & last
P108 082E
728 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
-INOR2EPAIR
HC-EDC and EDC Module 4HE(IGH#URRENT%LECTRIC$ISPLACEMENT#ONTROL(# %$# ANDTHE%LECTRIC$ISPLACEMENT

#ONTROL%$# ACTUATETHECONTROLSPOOLVIAACONNECTIONTOTHESUMMINGLINKPIN4HE
FOLLOWINGPROCEDUREDESCRIBESHOWTOREMOVEANDREPLACETHECONTROLHOUSING
Removal
#LEANTHEEXTERNALSURFACESOFTHEPUMP)FNECESSARYREMOVECONTROLINPUT
"EINGCAREFULNOTTOLOSETHEBACKLASHSPRING$ REMOVETHECONTROLSPOOLPLUGS

$AND$
2EMOVETHESEVEN CONTROLBOLTS$$ .OTETHEPOSITIONOFTHEDIFFERENT

LENGTHSCREWS2EMOVETHECONTROLANDCONTROLGASKET% FROMTHEPUMP
EDC module assembly
D082

&&
D081

&& T-30
.&
T-30
% . ,
.&
% . ,
#'
.&

% . ,
E001 D032
D032A
(%
'
#')(+#,#('
-&&#'!
%#'$)#'
',r
,""(%#',"
(',*(%+%#*
D035A %($
D035

#'
.&

% . , P108 085E
008 918 12 BOMAG 729
18.2 Vibration pump
Service Manual
-INOR2EPAIR
HC-EDC and EDC Module Replacement

(continued) #LEANTHESEALINGSURFACESOFTHECONTROLANDTHEPUMPHOUSING0LACEANEWGASKET
% INPOSITIONONTHEHOUSING
7!2.).'
&AILURETOPROPERLYENGAGE 4HECONTROLORIlCESAREPARTOFTHECONTROLGASKET2EFERTOTHEAPPROPRIATE3ERVICE0ARTS
THESUMMINGLINKPINWITH ,ISTTODETERMINETHECORRECTGASKET
CONTROLSLIDERBLOCKWILL
result in incorrect control Torque patterns (MDC, EDC and HC-EDC)
OPERATIONWHICHMAYLEAD (OLDTHESUMMINGLINKPIN$ TORQUE BOLTS IN ORDER INDICATED
TOLOSSOFCONTROLOFTHE INPOSITIONWHILEINSTALLINGTHE
VEHICLEMACHINE CONTROL4HELINKPIN-534ENGAGE 4 3 6
THEHOLEINTHECONTROLSLIDERBLOCK
SEEDIAGRAMONPREVIOUSPAGE
1
,AYTHESERVOPISTONSIDEOFTHECONTROL
7
DOWNlRSTTHENWATCHTHELINKPIN
2 5
ENGAGEFROMTHECHARGEPUMPSIDEOF
THEPUMP
8 Torque this bolt
first & last
)NSTALLTHECONTROLBOLTS$$ P108 082E
TORQUETO.sM;LBFsFT=
2EPLACETHESPRING$ )NSTALLNEW

/ RINGSONCONTROLSPOOLPLUGS$
AND$ )NSTALLPLUGSANDTORQUE
TO.sM;LBFsFT=
!DJUSTTHENEUTRALPOSITIONOFTHE
CONTROLASSHOWNONPAGE
730 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
-INOR2EPAIR
MDC/EDC Spool, linkage, 9OUMAYREMOVETHECONTROLSPOOLCONTROLLINKAGEANDCONTROLNEUTRALADJUSTMENTSCREW

and neutral adjustment FORCLEANINGANDTOCHANGETHE/ RINGSORTHESEALLOCKNUT
screw
Removal
#LEANTHEEXTERNALSURFACESOFTHEPUMP
2EMOVETHE-$#%$#OR(# %$#MODULEANDTHECONTROLGASKETFROMTHEPUMP

HOUSING$ISCARDGASKET3EEPAGESTHROUGH3FORCONTROLREMOVALPROCEDURE
2EMOVETHESUMMINGLINK$ .OTETHEMANNERINWHICHTHEPARTSAREASSEMBLED

ANDTHEWAYTHESUMMINGLINKENGAGESTHECONTROLSPOOL$
2EMOVETHESUMMINGLINKBYSLIDINGITOFFTHEFEEDBACKLINK
MDC/EDC/HC-EDC spool and linkage
D011
D010 D015

D012 D014
D013 D032
D91 7/8 in

D90
D090
D035
5
/16 in

F034
F035
P036
T-30

P108 086E
008 918 12 BOMAG 731
18.2 Vibration pump
Service Manual
-INOR2EPAIR
MDC / EDC Spool, linkage, 5SINGAMMINTERNALHEXWRENCHREMOVETHESUMMINGLINKPIVOTPIN$

and neutral adjustment 3LIDETHEFEEDBACKLINK$ TOWARDSTHESERVOPISTONTODISENGAGETHENEUTRAL
screw (continued) ADJUSTMENTLINK$ 9OUCANNOWREMOVEALLLINKAGES
2EMOVETHETWOBOREPLUGS$AND$ .OTETHEORIENTATIONOFTHECONTROL

SPOOL$ ANDWHICHSIDEOFTHEPUMPTHESPRING$ ISLOCATEDSPRINGISONTHE
OPPOSITESIDEFROMTHElLTERADAPTER 2EMOVESPRINGANDSPOOL
0RIORTOTHEBLOCKPOINTCHANGETHEFULL FEATUREDCM3HOUSINGFORTHE3ERIES

PUMPUSEDACONTROLSPOOLCOVER& GASKET& ANDTWOSCREWS& INSTEADOF
ABOREPLUGONTHECONTROLSPOOLSNON SPRINGSIDE$ISCARDTHECONTROLGASKET& AND
THOROUGHLYCLEANTHEMATINGSURFACE
2EMOVETHECONTROLNEUTRALADJUSTMENTSEALNUT$ ANDSCREW$
Installation
)NSTALLTHECONTROLNEUTRALADJUSTMENTSCREW$ ANDSEALLOCKNUT$ $ONOT
TIGHTENTHENUT
,UBRICATEANDINSTALLTHECONTROLSPOOL$ ANDSPRING$ NOTINGPROPER

ORIENTATION)NSTALLTHETWOSIDEBOREPLUGSANDTORQUETO.sM;LBFsFT=
2EPLACETHESUMMINGLINKFEEDBACKLINKANDNEUTRALADJUSTMENTLINK
&IRSTCOMBINETHECENTERPINOFTHEFEEDBACKLINK$ WITHTHEMATINGBOREOFTHE
NEUTRALADJUSTMENTLINK$ )NSERTTHEENDOFTHEFEEDBACKLINKINTOTHESERVO
PISTONSLOT-ATETHENEUTRALADJUSTMENTLINKWITHTHECONTROLNEUTRALADJUSTMENT
SCREW$ )NSERTTHELINKAGEPIVOTSCREW$ ANDTORQUETO.sM;LBFsFT=
)NSTALLTHESUMMINGLINK$ )TMAYBENECESSARYTOROTATETHECONTROLSPOOLSO
THATTHESUMMINGLINKFORKENGAGESTHEmATSONTHECONTROLSPOOL
)NSTALLTHE-$#%$#OR(# %$#ACCORDINGTOPROCEDURESONPAGESTHROUGH
Servo piston linkage and control spool Feedback link (D012) must
enter slot in servo piston
D010
D091
4 mm Internal hex nut
Backlash spring
Fork on summing link

(D011) must engage flats
on control spool (D090
D090
Control
spool Slot in neutral adjust link
(D013) must engage groove
in adjusting screw (D014) %%
Internal parts shown with housing removed
732 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
-INOR2EPAIR
MDC Neutral start / 4HE.EUTRAL3TART3WITCH.33 PREVENTSTHEENGINEANDPUMPFROMSTARTINGWHENTHE

backup alarm switch PUMPCONTROLHANDLEISNOTINNEUTRAL4HE.33SHOULDBEWIREDINSERIESWITHTHEENGINE
STARTINGCIRCUIT4HESWITCHCONTACTISCLOSEDATTHECONTROLHANDLESNEUTRALPOSITIONAND
OPENSWHENTHECONTROLHANDLEISROTATED²TO²FROMNEUTRAL
4HE"ACKUP!LARM3WITCH"!3 CLOSESWHENTHECONTROLHANDLEISINAREVERSEPOSITION
4HISSWITCHISNORMALLYWIREDINSERIESWITHABACKUPALARM4HESWITCHCONTACTISOPEN
UNTILTHECONTROLHANDLEISROTATED²TO²INTHEREVERSEDIRECTION
7!2.).' Top view of NSS showing NSS cam positions

4HECONTROLHANDLES
neutral position must
CONFORMTOTHEPUMPS
NEUTRALPOSITIONFOR
THE.33"!3TOWORK
EFFECTIVELY3EEPAGEFOR
control neutral adjustment
Control Control Control
Yoke cam Yoke cam Yoke cam
NSS cam NSS cam
I. NSS ONLY II. NSS WITH BAS III. NSS WITH BAS
(CW = REVERSE) (CCW = REVERSE)
0%
9OUCANCONlGURETHE.33"!3ASSEMBLYFORTHREEDIFFERENTSETTINGS
) .33ONLY
)) .33WITH"!3FORUNITSWHERECLOCKWISE#7 HANDLEROTATIONRESULTSINREVERSE
MOTION
))) .33WITH"!3FORUNITSWHERECOUNTERCLOCKWISE##7 HANDLEROTATIONRESULTSIN
REVERSEMOTION
4HESETTINGMUSTBEINACCORDANCEWITHTHECONlGURATIONOFTHEUNIT3EETHEMODEL
CODEIFUNCERTAINOFTHETYPEOF.33SETTINGTHEMACHINEISEQUIPPEDWITH
!DJUSTMENTISNORMALLYNOTREQUIREDUNLESSTHEFUNCTIONOFTHE.33ISCHANGEDBETWEEN
)))OR)))
!DJUSTMENTOFTHE.33OR.33AND
"!3REQUIRESASPECIALALIGNMENTTOOL Alignment tool
$IMENSIONSAPPEARATRIGHT4HETOOL 0.04 x 45°
9/16 -18 UNF 2A thread
R 0.125 Ø 0.236 -0.03
POSITIONSTHECAMPRECISELYRELATIVETO chamfer
Knurl
THECONTROLHOUSING
35.0
1.250
0.306 0.354
2.000
Material: 0.75 Ø x 3 ETD150 0%
(All dimensions in inches)
008 918 12 BOMAG 733
18.2 Vibration pump
Service Manual
-INOR2EPAIR
MDC Neutral start / 2EMOVETHE-$#MODULEFROMTHE Side view of NSS and NSS cavity
backup alarm switch PUMPHOUSING 23.3 mm D039
(continued) D038
5SINGAINHEXWRENCHREMOVE 8 mm
THE.33"!3$ m
1 mm D037

5SINGASCREWDRIVERTOPRYITOUT
REMOVEANDDISCARDTHE.33COVER
$ "ECAREFULNOTTODAMAGETHE
D040
INTERNALHARDWARE 7
/8 in

m
5SINGANMMHEXSOCKETREMOVE
THENUT$ 0%
0RYTHECAM$ OFFTHESHAFT Apply locking pliers here.
/NTHEUNDERSIDEOFTHE-$#
MODULEGENTLYCLAMPAPAIROF
LOCKINGPLIERSAROUNDTHESPRING
CONTACTSOFTHECONTROLCAM"E
CAREFULNOTTODAMAGETHESPRING
WIRES4HEPLIERSHOLDTHENUBONTHE
CONTROLCAMTOTHEPINUNDERNEATH
4HISHOLDSTHECONTROLCAMINNEUTRAL
POSITION
3ETTHE.33CAM$ INTHE 0

PROPERORIENTATION)))OR))) 3EETHE
ILLUSTRATIONONPREVIOUSPAGE NSS assembly on MDC
4HREADTHEALIGNMENTTOOLINTOTHE D040

(with weatherpack
.33CAVITYTOHOLDTHECAMINPLACE connector)
D040
)NSTALLTHENUT$ ONTOTHECAM (with screw
terminals)
ANDTORQUETO.sM;LBFsFT=
5SINGANAPPROPRIATEPRESSPRESS

ANEWCOVER$ INTOTHECAM
NSS Cavity
CAVITY5SEATOOLWITHADIAMETEROF
MM;IN=0RESSTHENEWCOVER
SOTHATITSITSMM;IN=BELOWTHE
CASTSURFACEASILLUSTRATEDABOVE
2EMOVETHEALIGNMENTTOOLAND
LOCKINGPLIERS
D037
,UBRICATEANDINSTALLANEW/ RINGON D038
THE.33$ ANDINSTALLTHE.33TO D039 P108 088E
THE-$#4ORQUETO.sM;LBFsFT=
2EINSTALLTHE-$#MODULEONTOTHE
PUMPHOUSINGASSHOWNONPAGESAND3
734 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
-INOR2EPAIR
MDC Solenoid override 4HESOLENOIDOVERRIDEVALVEISASAFETY Solenoid override assembly

valve FEATURETHATSHUNTSBOTHENDSOFTHE D056B
SERVOCONTROLPISTONWHENTHESOLENOIDIS 3
/4 in
DE ENERGIZED4HEPUMPWILLSTROKEONLY "
D056 "!
WHENTHEVEHICLECONTROLSENERGIZETHE
SOLENOID
D056C
4HESOLENOIDOVERRIDEWITHBRAKERELEASE D054
OPTIONALLOWSHYDRAULICCONTROLOFA
SPRING APPLIEDHYDRAULICALLY RELEASED
BRAKE7HENDE ENERGIZEDTHEBRAKE D056 D056D
DRAINSTHROUGHPORT8
D056A
Removal D056F
5SINGAINCHWRENCHREMOVETHE
COILNUT$" FROMTHEVALVESTEM D056G
2EMOVETHECOIL$ ANDWASHER

D053
$#
P108 099E
5SINGSNAP RINGPLIERSREMOVETHE
RETAININGRING$ ATTHEBASEOF
THESOLENOID
2EMOVETHEVALVESTEM$$
PLUNGER$' SPRING$& AND
SPOOL$
2EMOVETHE/ RING$! FROMTHE

STEMANDDISCARDIT
Installation
,UBRICATEANDINSTALLANEW/ RING
$! ONTHEVALVESTEM$$ Po ! X7
0LACETHESPRING$& ANDTHEPLUNGER$' INSIDEOFTHESTEM
!TTACHTHESPOOL$ TOTHEPLUNGER$'
)NSERTTHESOLENOIDSPOOLASSEMBLYINTOTHESOLENOIDOVERRIDECAVITY
5SINGSNAP RINGPLIERSINSTALLTHERETAININGRING$
)NSTALLTHEWASHER$# ONTOTHEVALVESTEM
)NSTALLTHECOIL$ ANDCOILNUT$" ANDTORQUETO.sM;LBFsFT=$ONOT

OVERTORQUECOILNUT
008 918 12 BOMAG 735
18.2 Vibration pump
Service Manual
-INOR2EPAIR
FNR, NFPE, and NFPH 4HE&.2.&0%AND.&0(ARENON FEEDBACKTYPECONTROLS4HE&.2AND.&0%CONTROLS

Controls (bolt-on valves) CONSISTOFEXTERNALSOLENOID ACTUATEDSPOOLVALVESMOUNTEDONTHEPUMPHOUSING4HE
PUMPRECEIVESHYDRAULICINPUTFOR.&0(THROUGHPORTSONTHEPUMPSCONTROLSURFACE
n3!%/ RINGBOSSPORT 4HESEPORTSCONNECTDIRECTLYTOTHESERVOPISTON
9OUMAYREMOVETHE&.2AND.&0%CONTROLSTOCLEANTHEPORTSANDREPLACETHE/ RINGS
HOWEVERTHECONTROLSARENOTSERVICEABLE4HEGASKET% CONTAINSCONTROLORIlCES
/RIlCEPLUGSFOR.&0(PUMPSAREBENEATHTHESERVOCOVERS
Removal of FNR and NFPE modules (bolt-on valves)

#LEANTHEPUMPANDCONTROLHOUSINGS
2EMOVETHEFOUR SCREWS$ RETAININGTHEMODULETOTHEHOUSINGANDREMOVE

THEMODULE$ FROMTHEPUMPHOUSING
2EMOVEANDDISCARDTHEFOUR/ RINGS$! %XAMINETHEPORTSFORCLEANLINESS
Installation of FNR and NFPE modules (bolt-on valves)

#LEANTHESEALINGSURFACES)NSTALLNEWGASKET%
5SINGPETROLEUMJELLYTORETAINTHEMINSTALLNEW/ RINGS$! INTHEBOTTOMOF

THECONTROL
2EPLACETHEBOLTS$ ANDTORQUETO.sM;LBFsFT=

NEUTRALADJUSTBOLTSIDE
FNR and NFPE assembly (bolt-on valves) D081

4 mm
Bolt torque patterns

Torque bolts in order indicated
D004
2 3
4 1
D004A
2 3
4 1
P101 580E
E074 41/51cc
Frame Size
P108 100E
736 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
-INOR2EPAIR
FNR, NFPE, and NFPH 4HE&.2AND.&0%ARENON FEEDBACKTYPECONTROLS4HE&.2AND.&0%CONTROLSCONSISTOF

Controls (integral valves) SOLENOID ACTUATEDSPOOLVALVESMOUNTEDONTHEPUMPHOUSING
9OUMAYREMOVETHEVALVESTOCLEANTHEPORTSANDREPLACETHE/ RINGSHOWEVERTHE

VALVESARENOTSERVICEABLE
Removal of FNR and NFPE modules (integral valve style)

#LEANTHEPUMPANDCONTROLHOUSINGS
2EMOVETHECOILNUTS$ ANDCOILS$ $ISCARD/ RINGS$AND$ FROM

.&0%COILS
2EMOVEVALVEACTUATERSTEMS$ ANDDISCARD/ RINGS
%XAMINETHEPORTSFORCLEANLINESS
Installation of FNR and NFPE modules (integral valve style)

#LEANTHEVALVESANDPORTS
)NSTALLNEW/ RINGSONVALVEACTUATORSTEMS$
)NSTALLACTUATORSTEMS$ ANDTORQUETO.sM;LBFsFT=
)NSTALLCOIL$ 5SENEW/ RINGS$AND$ WITH.&0%COILS
4ORQUECOILNUTPERILLUSTRATION
FNR and NFPE assembly (integral valves)
D060 7/8 inch

"
"
D061 D062
D099 3/4 inch
includes
"
D063
and D064 "
D063
D061
D060 D064 D062

3/4 inch
"
1 inch "
"
" P108 123E
008 918 12 BOMAG 737
18.2 Vibration pump
Service Manual
-INOR2EPAIR
System Check Relief 4HE3YSTEM#HECK2ELIEFVALVEASSEMBLY System check relief valve components

(SCR) valves (high PERFORMSTHECHARGECHECKHIGHPRESSURE K007
pressure relief, charge RELIEFANDLOOPBYPASSFUNCTIONS9OU 1 inch WITH
%" BYPASS
check, and bypass valves) MAYREMOVETHISASSEMBLYFORCLEANING
ANDREPLACEMENTOF/ RINGS4HEMODEL !%$
WITHOUT
CODESPECIlESWHICHCONlGURATIONOF BYPASS
3#2VALVESYOURPUMPUSES K007 K008
5
/16 mm K009
K008 K010
5SINGAINCHWRENCHORA %"
K009
INCHINTERNALHEXWRENCHREMOVE !%$ ]
K010
THEVALVESEATPLUGS+ FROMTHE
J005
PUMPHOUSING2EMOVEANDDISCARD
THE/ RINGSANDBACKUPRINGS+
+AND+
H005
2EMOVETHECHECKPOPPETRELIEF
VALVEASSEMBLIES(* FROMTHE
P108 089E
PUMPHOUSING
)NSPECTTHEVALVESANDMATINGSEATS
INTHEVALVESEATPLUGS+ FOR
DAMAGEORFOREIGNMATERIAL
4HE3#2VALVES(* ARENON
SERVICEABLEREPLACEASACOMPLETEUNIT
)NSTALLNEWOUTER/ RING+

BACKUPRING+ ANDINNER/ RING
+ ONEACHVALVESEATPLUG
6ERIFYTHATTHECONICALSPRINGSARE
PROPERLYRETAINEDONTHECHECK
POPPETSRELIEFVALVES(* )NSTALLTHECHECKPOPPETRELIEFVALVEASSEMBLIES
INTOTHEPUMPHOUSING%NSURETHATTHEVALVEASSEMBLYMOVESFREELYINITSBORE
5SINGAINCHWRENCHORAINCHINTERNALHEXWRENCHINSTALLTHEVALVESEATPLUGS

ORVALVESEATBYPASSPLUGSINTOTHEPUMPHOUSINGANDTORQUETO.sM;LBFsFT=
738 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
-INOR2EPAIR
Filtration adapters Filter-related pump hardware

&ILTRATIONSYSTEMSFOR3ERIESPUMPINCLUDEFULLmOWSUCTIONlLTRATIONPRESSURE
lLTRATIONANDPARTIALmOWPRESSURElLTRATION3AUER $ANFOSSPROVIDESAlLTRATIONADAPTER
FOREACHCONlGURATION)FlLTRATIONISPROVIDEDELSEWHEREINTHEHYDRAULICCIRCUITTHE
PUMPMAYNOTHAVEAlLTRATIONADAPTER
Housing with filtration adapter
0UMPSHOUSINGSWITHOUTlLTRATION R043
ADAPTERSHAVEANUNUSEDANDPLUGGED Pre 1998: 7/8 in
CONSTRUCTIONBORENEXTTOTHECHARGE !
#
RELIEFVALVE7HENTHESEPUMPSUSE #!
SUCTIONlLTRATIONTHEFACTORYPLUGS
EXTERNALCHARGEINLET
R042 (x7)
0UMPHOUSINGSWITHlLTRATIONADAPTERS

R040
HAVEANAPPROPRIATEADAPTERANDGASKET T30
4HEPOSITIONOFTHE-GAUGEPORT #
#!
VARRIESDEPENDINGONlLTRATIONTYPE
R041
0UMPSMANUFACTUREDAFTERHAVE
lLTERADAPTERSCREWSTHATAREMM
;IN=LONGERTHANTHESCREWSUSEDON P108 090E
PRE PUMPS4HELONGERSCREWSARE
ONLYCOMPATIBLEWITHPOST PUMPS
Removal
#LEANTHEEXTERIOROFTHEPUMP
2EMOVEANYHOSESORPIPINGFROM
THElLTERADAPTER
5SINGA44ORXDRIVERORMM
INTERNALHEXREMOVETHESIXSCREWS Housing without filtration adapter
2 SECURINGTHElLTERADAPTERTO
THEHOUSING
G004
2EMOVETHElLTERADAPTER2
2EMOVETHEGASKET2 AND

DISCARD4HOROUGHLYCLEANALLMATING
SURFACES
R045
5/8 in
P108 091E

Suction Filtration Only
008 918 12 BOMAG 739
18.2 Vibration pump
Service Manual
-INOR2EPAIR
Filtration adapters Replacement

(continued) )NSTALLANEWGASKET2 ANDPLACETHElLTERADAPTER2 ONTHEHOUSING
5SINGA44ORXDRIVERORMMINTERNALHEXINSTALLBOLTS2 ANDTORQUETO

.sM;LBFsFT=
Bolt torque patterns

TORQUE BOLTS IN THE ORDER INDICATED
3
6
5
1
2
8
4 Torque this bolt 7
first and last
0
740 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
-INOR2EPAIR
Auxiliary pad/charge 5SETHEFOLLOWINGPROCEDURETOINSTALLANEWGASKET5 ORTOCHANGETHEAUXILIARYPAD

pump cover OPTION0ADSAREAVAILABLEFOR3!%!AND3!%"AUXILIARYPUMPSORFOROPTIONSWITHNO
AUXILIARYPAD
4HECHARGEPUMPCOVERINTEGRATESTHEAUXILIARYMOUNTINGPAD7HENNOAUXILIARYPUMP
ISPRESENTONAN3!%!OR3!%"STYLEPADTHEPADINCLUDESASHIPPINGPLATE5 AND
/ RING5
Removal of charge pump cover/auxiliary pad

/RIENTTHEPUMPSOTHATTHECHARGEPUMPCOVERORPAD5 ISFACINGUP
)FPRESENTREMOVETHEAUXILIARYPUMPORCOVER5 BYREMOVINGTHETWOSCREWS

5 $ISCARDTHE/ RING5
2EMOVESCREWS5 RETAININGTHECHARGEPUMPCOVERPAD2EMOVETHECHARGE

PUMPCOVERPAD5 ANDGASKET5 9OUMAYREUSETHEGASKET#LEANALL
MATINGSURFACES
2EMOVEANDDISCARDCHARGEPUMPSEAL' ,EAVEALIGNMENTPINSINTHEHOUSING
Auxiliary pad options
U040
No pad charge
U035 (x8) pump cover
6 mm

-$
#-)]
(x8)
U090
9 U035 G023
/16 in

-$
#-)] U080
U085
U030
U040
U035 SAE-A pad
U090
3
/4 in (x8)
-$

#-)]
U040
SAE-B pad
U080 P108 103E
U085
008 918 12 BOMAG 741
18.2 Vibration pump
Service Manual
-INOR2EPAIR
Auxiliary psd/charge Bolt torque patterns

pump cover Installation
TORQUE BOLTS IN ORDER INDICATED
(continued) )NSPECTTHECHARGEPUMPCOVERPAD
GASKET5 ANDMATINGSURFACES
)FUNDAMAGEDYOUMAYREUSETHE
6 2 4 8
GASKET2EPLACETHEGASKETIFYOU
SUSPECTLEAKAGE)NSTALLTHEGASKET
)NSTALLANEWCHARGEPUMPCOVERPAD
SEAL'
)NSTALLTHECHARGEPUMPCOVER
PAD5 5SINGAMMINTERNAL
HEXTORQUETHESIXORSEVENBOLTS
3 1
5 TO.sM;LBFsFT=USINGTHE
PATTERNATTHERIGHT 7 5
9
2EPLACETHE/ RING5 AND Torque this bolt first and last.
COVERPLATE5 ORAUXILIARY
PUMP)NSTALLANDTORQUETHETWO
MOUNTINGSCREWS5 &OR3!%!
PADSTORQUETHEMOUNTINGSCREWS 6 2 4 8
TO.sM;LBFsFT=&OR3!%"PADS
TORQUETHEMOUNTINGSCREWSTO
.sM;LBFsFT=
4HETHREADEDSCREWHOLESINTHEAUXILIARY
PUMPMOUNTINGPADINEARLYPRODUCTION
PUMPSWITHTHE3!%!PADOPTIONGO
CLEARTHROUGHTHECHARGEPUMPCOVER
5SE-XINTERNALHEXSET SCREWSTO 3 1
PLUGANYHOLESNOTUSEDTOATTACHTHE
COVERPLATEORAUXILIARYPUMP)NSTALL 7 5
HANDTIGHTTOPREVENTTHEENTRANCEOF 9
FOREIGNMATERIALINTOTHEPUMP Torque this bolt first and last
P108 083E
742 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
-INOR2EPAIR
Charge pump 9OUMAYDISASSEMBLETHECHARGEPUMPTOINSPECTCLEANORTOCHANGETHEAUXILIARYSHAFT

DRIVECOUPLING5 0OSTPUMPSCONTAINANUMBEROFNON INTERCHANGEABLEPARTS
WITHINTHECHARGEPUMPSYSTEM
s 0RE PUMPSHAVEAGEROTORDRIVECOUPLINGWITHADRIVEPINFORTHEGEROTOR
ELEMENTWHILEPOSTRELEASEPUMPSWILLCONTAINACOUPLINGWITHAPARALLELDRIVE
KEY4HISCHANGEALSORESULTSINACHANGETOTHEGEROTORSET7HENSERVICINGTHE
GEROTORTHESETWOELEMENTSMUSTBEPLACEDINCOMBINATION!SERVICEKITISAVAILABLE
FORPRE CHARGEPUMPS2EFERTOSERVICEBULLETIN
s 0OSTRELEASEPUMPSALSOCONTAINACOUPLINGWITHARETAININGRINGTOPOSITIVELY
LOCATETHECOUPLINGINTHEASSEMBLY4HISCHANGEELIMINATEDTHENEEDFORACOUPLING
SPACER
s 4HEOUTERSTEPONTHEGEROTORCOVER Charge pump components

HASBEENREMOVEDONTHEPOST G023
RELEASEPUMPS
G020
Disassembly
2EMOVEALIGNMENTPINS5
G015
2EMOVETHEGEROTORCOVERASSEMBLY
' 2EMOVEANDDISCARD U015
GEROTORCOVER/ RING' EARLY Use feeler
gauge
PRODUCTION3!%!PADMODELSMAY G005
CONTAINTWOORTHREESEALSONLYTHE Keyway
INNER'SEALISREQUIRED G010
2EMOVETHEDRIVECOUPLING5 G006

U025
ANDGEROTORGEARSET' 2EMOVE U025
G065
RETAININGRING'
2EMOVETHEGEROTORDRIVEPINORKEY
' 2EMOVETHEGEROTORCOVER
LOCATINGPIN'
)NSPECTTHEGEROTORASSEMBLY'
%NSURETHEUPPERANDLOWERSURFACES
OFTHEGEROTORAREFREEOFNICKSAND
GROOVES4HEMATINGSURFACESOF
THEINNERANDOUTERGEARSSHOULD
lTSNUGLYANDCREATEATIGHTSEAL
)NSPECTTHEKEYWAYFORMAJORWEAR)T P108 092E
ISNORMALTOlNDASMALLIMPRESSION
FROMTHEDRIVEPIN' -EASURE
GEROTORTIPCLEARANCEFORWEAR
ILLUSTRATEDABOVE 3EATTHEGEROTORASSEMBLYINTOTHEGEROTORCOVERANDALIGNTHE
ASSEMBLYSOTHATONEOFTHETIPSOFTHEINNERGEARFULLYENGAGESAVALLEYINTHEOUTER
GEAR5SINGAFEELERGAUGEMEASURETHECLEARANCEOFTHEOPPOSITETIP#LEARANCE
SHOULDBEMM;INCH=ORLESS 2EPLACETHEGEROTORIFNECESSARY4HE
GEROTORASSEMBLYISMACHINEDASAMATCHEDPAIR
008 918 12 BOMAG 743
18.2 Vibration pump
Service Manual
-INOR2EPAIR
Charge pump )NSPECTTHEDRIVEPINORKEY' TOENSURETHATTHEEDGESARENOTROUNDEDAND

(continued) THATTHEDRIVECOUPLINGSINTERNALSPLINESARESTRAIGHTANDFREEOFDAMAGEONBOTH
ENDS#HECKFORWEARONTHETOPANDBOTTOMSURFACES2EPLACETHEDRIVEPINORKEYIF
WORN
)NSPECTTHEGEROTORCOVER' )TSHOULDBEFREEOFNICKSANDSCRATCHES4HEDRIVE

COUPLINGJOURNALBEARING' ISONTHEINSIDEDIAMETEROFTHESMALLBOREOFTHE
ALUMINUMGEROTORCOVER4HEDRIVECOUPLINGSHOULDlTTHEJOURNALBEARINGWITH
ARELATIVELYCLOSElT)FTHECOUPLINGHASWORNTHROUGHTHEBEARINGANDINTOTHE
ALUMINUMGEROTORCOVERREPLACETHEGEROTORCOVERANDDRIVECOUPLING)FTHElTIS
EXCESSIVELYLOOSEANDTHEDRIVECOUPLINGHASNOTWORNINTOTHEGEROTORCOVERREMOVE
THEOLDJOURNALBEARINGFROMTHEGEROTORCOVERANDPRESSANEWJOURNALBEARINGINTO
THECOVERFROMTHECAVITYSIDE0RESSTHEBEARINGTOADEPTHOFMM;IN=
FROMTHEBOTTOMCAVITYSIDE OFTHEGEROTORCOVER
Assembly
)NSTALLTHETWOCHARGEPUMPCOVERPADALIGNMENTPINS5
)NSTALLTHEGEROTORCOVERLOCATINGPIN
' Charge pump orientation looking inside of
gerotor pump cover
)NSTALLTHECM3SPACERNOTSHOWN G020
IFPREVIOUSLYREMOVED3PACERSEXIST
12.88 mm
ONTHEOLDERCM3MODELS G015 [0.507 in]
)NSTALLTHEDRIVEPINORKEY'
INTOTHEDRIVECOUPLING5SE
PETROLEUMJELLYTOHOLDITINPLACE
,UBRICATEANDINSTALLTHEGEROTOR
SET' ONTOTHEDRIVECOUPLING CW CCW
5 !LIGNTHENOTCHINTHEINNER 0%
GEARWITHTHEDRIVEPINORKEY'
)FPRESENTINSTALLTHERETAININGRING' ONTOTHEDRIVECOUPLING
7ITHTHESMALLERENDOFTHEDRIVECOUPLING5 FACINGUPINSTALLTHEDRIVECOUPLING

ANDGEROTORONTOTHESHAFT
$IFFERENTDRIVECOUPLINGSAREUSEDWITHDIFFERENTCHARGEPUMPCOVERS
0LACETHEGEROTORCOVERASSEMBLY'' OVERTHEGEROTORASSEMBLYANDROTATE

UNTILTHECOVERENGAGESTHEORIENTATIONPIN4HECOVERlTSmAT
,UBRICATETHENEWGEROTORCOVER/ RING' WITHPETROLEUMJELLYANDPLACEITON

THEGEROTORCOVER' %ARLYPRODUCTION!PADMODELSMAYCONTAINTWOORTHREE
SEALS
)NSTALLTHECHARGEPUMPCOVERGASKETCHARGEPUMPCOVERANDAUXILIARYPUMP
744 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
-INOR2EPAIR
Charge pump Units without integral charge pump

(continued) 6ARIABLEPUMPSWITHOUTANINTEGRALCHARGEPUMPHAVEASPACER' INTHELOCATION
WHERETHEGEROTORASSEMBLYGOES!PLUG. BLOCKSTHECHARGEPUMPINLETPORT
0UMPSWITHOUTANINTEGRALCHARGEPUMPTHATARENOTMACHINEDTOACCEPTAlLTRATION
ADAPTERCONTAINACHARGEPUMPDEFEATPLUG2 INTHEGEROTORCAVITYOUTLET!N/ RING
2! HOLDSTHISPLUGINPLACE,ATERMODELSHAVEAN-THREADINTHEEXPOSEDENDOF
THEPLUGFOREASIERREMOVAL2EPLACETHE/ RINGWHENREMOVINGTHEPLUG
0UMPSWITHOUTANINTEGRALCHARGEPUMPTHATAREMACHINEDTOACCEPTAlLTRATIONADAPTER
DONOTCONTAINACHARGEPUMPDEFEATPLUG0UMPSINTHISCONlGURATIONUSEAFULL mOW
PRESSURElLTRATIONADAPTERWITHASTEEL/ RINGPLUG2 INTHECHARGEmOWOUTLETPORT
4HESUCTIONlLTRATIONADAPTERDOESNOTSUITTHISCONlGURATIONNEITHERDOESTHEPARTIAL
mOWPRESSURElLTRATIONADAPTER)TBYPASSESTHECHARGERELIEFVALVE
No charge pump option components

G023
G020
R020
U015
R020A
G010
Charge inlet
G006
G004
Charge inlet
To filter
G004
R086
P108 093E
Housing with filtration adapter Housing without filtration adapter
008 918 12 BOMAG 745
18.2 Vibration pump
Service Manual
-INOR2EPAIR
Servo piston covers and 9OUCANREMOVETHESERVOPISTONCOVERSTOCHANGETHEGASKETORTOINSPECTCHANGETHE

NFPH control orifice .&0(CONTROLORIlCES
Disassembly
2EMOVELOCKNUT4 FROMTHERIGHTSIDESERVOCOVER
5SINGA4 4ORXDRIVERORMMINTERNALHEXREMOVETHESERVOCOVERBOLTS-

0OSTRELEASEPUMPSHAVECOVERBOLTSTHATAREMM;IN=LONGERTHANPRE
PUMPS4HELONGERBOLTSAREONLYCOMPATIBLEWITHPOST PUMPHOUSING
2EMOVETHESERVOPISTONCOVERS,-
4OREMOVETHERIGHTSIDESERVOCOVERTURNTHENEUTRALADJUSTMENTSCREW4
CLOCKWISEINWARD FARENOUGHFORTHESERVOCOVERTOCLEARTHENEARBYCASEDRAINPORT
4HENPULLTHECOVERAWAYFROMTHEHOUSINGANDTURNTHECOVERCOUNTERCLOCKWISETO
REMOVEITFROMTHEADJUSTMENTSCREW
2EMOVETHEGASKETS,- #LEANGASKETSURFACES
.&0(CONTROLORIlCEPLUGS%AND% ARELOCATEDBENEATHTHESERVOCOVERS)F

NECESSARYREMOVEANDCLEANTHEORIlCES
Servo piston cover components

L005
5 mm M005
T060 T30 5 mm
$ #(' *" T30
&'! !*' *"
L001 !*'
L005
T060 (non-feedback
5 mm M001
$ #(' $#'%$!&$#!)
&'! T30
*" M002 E052
L001 !*' E051
NFPH orifice
NFPH orifice
L002 3 mm
3 mm
*"
*" !*'
!*'
T015
P108 104E
Frame size cm3

Control -$#%$#(# %$# .&0%.&0( -$#%$#(# %$# .&0%.&0(
,OCKNUT MM MM MM MM
3ERVOADJUSTSCREW 5 mm MM MM MM
746 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
-INOR2EPAIR
Servo piston covers and Assembly Bolt torque patterns

NFPH control orifice 2EPLACETHE.&0(CONTROLORIlCEPLUGS TORQUE BOLTS IN ORDER INDICATED
(continued) %% IFTHEYWEREREMOVED
2 3
)NSTALLNEWGASKETS,-
7!2.).' /NTHERIGHTSIDETHREADTHESERVO

5NINTENDEDVEHICLE PISTONCOVER, ONTOTHENEUTRAL
MOVEMENTHAZARD ADJUSTMENTSCREW4HENWHILE
4 1
7HENYOUREMOVETHE HOLDINGTHECOVERTURNTHENEUTRAL
RIGHTSIDESERVOPISTON ADJUSTMENTSCREW4 COUNTER
COVERYOUMUSTSETNEUTRAL CLOCKWISETORUNTHECOVERDOWNTHE
ANDCONTROLNEUTRAL2EFER SCREWTHREADS  6
Torque this
to PAGESAND bolt first and
5SINGA44ORXDRIVERORMM 5
last
INTERNALHEXINSTALLTHESERVOPISTON
COVERSCREWS,- 4ORQUE 0
TO.sM;LBFsFT=INTHEPATTERN
SHOWN
)NSTALLANEWSEALLOCKNUT4 ONTOTHENEUTRALADJUSTMENTSCREW4 $ONOT

TORQUEATTHISTIME
0ERFORMPUMPNEUTRALADJUSTMENTANDCONTROLNEUTRALADJUSTMENTPROCEDURES2EFER
to PAGESAND
2EMOVALOFTHESERVOCOVERSMAYCHANGETHEPOSITIONOFTHEDISPLACEMENTLIMITERS
READJUSTIFNECESSARY
008 918 12 BOMAG 747
18.2 Vibration pump
Service Manual
-INOR2EPAIR
Loop flushing and loop 4HELOOPmUSHINGFUNCTIONCONSISTSOFTHE Loop flushing valve and loop flushing
flushing relief valve LOOPmUSHINGSHUTTLEVALVEANDTHELOOP defeat components
mUSHINGRELIEFVALVE9OUMAYREMOVETHE Q050
11
ASSEMBLIESFORCLEANINGANDINSTALLATION /16 in
OFNEW/ RINGS9OUMAYEXCHANGE

THERELIEFVALVEPOPPETFORONEWITHA Q060
5
DIFFERENTmOWRATING4AKENOTICETHOUGH /8 in

PREMODELSCONTAINEDRELIEFSHIMS

DONOTCHANGETHESESHIMSUNLESS3AUER
Q050A
$ANFOSSSPECIlCALLYINSTRUCTSYOUTODO
SO9OUMAYALSODEFEATTHELOOPmUSHING Q050A
Q060A
FUNCTIONBYINSTALLINGADEFEATSPOOL
Q051 Q051
Q061
3ERIESPUMPSBUILTPRIORTO
USEUNIQUELOOPmUSHINGSPOOLS0OST
Q062
RELEASEPUMPSUSEACOMMON
LOOPmUSHINGSPOOL4HEYARENOT
INTERCHANGEABLE P108 105E
Loop flushing valve

2EMOVETHELOOPmUSHINGPLUG
1 $ISCARDTHE/ RING1!
2EMOVETHELOOPmUSHINGSPOOL
ASSEMBLY1 FROMTHEHOUSING
)NSPECTTHEPARTSFORDAMAGEOR
FOREIGNMATERIAL%NSURETHEWASHER
SECURELYRETAINSTHECENTERINGSPRING
)NSTALLTHELOOPmUSHINGVALVESPOOLASSEMBLY1 INTOITSBORE)NSTALLANEW

/ RING1! ONTHELOOPmUSHINGPLUG1 TORQUETO.sM;LBFsFT=
Loop flushing relief valve
4WOSTYLESOFLOOPmUSHINGRELIEFVALVEPLUGSEXIST4HESTYLEOFPLUGISDEPENDSONTHE
CHARGEPRESSURESPECIlCATION)FTHECHARGEPRESSUREISGREATERTHANOREQUALTOBAR
;PSI=THEPLUGHASTWOIDENTIlCATIONGROOVES)FTHECHARGEPRESSUREISLESSTHAN
BAR;PSI=THEPLUGHASASINGLEIDENTIlCATIONGROOVE
2EMOVETHELOOPmUSHINGRELIEFVALVEPLUG1 $ISCARDTHE/ RING1!
2EMOVETHESPRING1 ANDPOPPET1 FROMTHEHOUSING
$ONOTALTERTHESHIMSBETWEENTHESPRINGANDPLUGORINTERCHANGEPARTSWITH

ANOTHERVALVE)NSPECTTHEPOPPETANDMATINGSEATINTHEHOUSINGFORDAMAGEOR
FOREIGNMATERIAL)NSPECTTHEORIlCEINTHEVALVEPOPPET
)NSTALLANEW/ RING1! ONTHEPLUG1 )NSTALLTHEPOPPET1 SPRING

1 SHIMSANDPLUGINTOTHEPUMPHOUSINGTORQUETO.sM;LBFsFT=
748 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
-INOR2EPAIR
Loop flushing valve Defeating loop flushing

(continued) 2EMOVETHELOOPmUSHINGPLUG1 $ISCARDTHE/ RING1!
2EMOVETHELOOPmUSHINGSPOOLASSEMBLY1 FROMTHEPUMPHOUSING
)NSTALLTHEDEFEATSPOOL1 INTOTHESPOOLBOREWITHTAPPEDENDFACING

OUTWARDS)NSTALLTHESTANDARDPLUGWITH/ RINGINTOTHEHOUSINGANDTORQUETO
.sM;LBFsFT=
2EMOVETHELOOPmUSHINGRELIEFPLUG1 $ISCARDTHE/ RING1!
2EMOVETHELOOPmUSHINGRELIEFVALVECOMPONENTS11
)NSTALLTHELOOPmUSHINGRELIEFPLUG1 WITHANEW/ RING1! INTOTHE

HOUSINGANDTORQUETO.sM;LBFsFT=
008 918 12 BOMAG 749
18.2 Vibration pump
Service Manual
-INOR2EPAIR
Shaft seal, roller bearing, 3ERIESPUMPSUSEALIPTYPESHAFTSEAL9OUCANREPLACETHESEALANDORSHAFTWITHOUT

and shaft replacement MAJORDISASSEMBLY
Seal removal
0OSITIONTHEPUMPWITHTHESHAFTFACINGUP
)FTHEUNITISPOSITIONEDHORIZONTALLYWHENTHESHAFTISREMOVEDTHECYLINDERBLOCKCOULD
MOVEOUTOFPLACEMAKINGSHAFTINSTALLATIONDIFlCULT
2EMOVETHECASEDRAINPLUG& TORELIEVEANYVACUUMTHATMAYBEPRESENT
2EMOVETHESPIRALRETAININGRING& 5SINGASCREWDRIVERPRYTHEENDOFTHERING

FREEANDUNWINDTHEREMAINDEROFTHERINGOUTOFTHEGROOVE
2EMOVETHESEALCARRIERASSEMBLY# ,OOSENITFROMTHEUNITBYPRYINGONTHE

RAISEDSURFACEOFTHESEALCARRIERWITHASCREWDRIVER
2EMOVEANDDISCARD/ RING#
0RYORPRESSLIPSEAL# FROMTHESEALCARRIER# USECAUTIONTOAVOID

DAMAGINGTHESEALCARRIER$ISCARD
THESEAL Shaft seal components
)NSPECTTHESEALCARRIER# FOR

DAMAGE
F096
0RESSTHENEWSEAL# INTO
THESHAFTBEARINGSIDEOFTHESEAL
CARRIER"ECAREFULTOONLYPRESSON C020
THEOUTSIDEDIAMETEROFTHELIPSEAL
/RIENTTHESEALASSHOWNINTHE
ILLUSTRATION"ECAREFULNOTTODAMAGE C017
THESEAL
see table
Installation of shaft seal
C017 F091
C018
Seal carrier shown

C020 with the inside
facing up P108 069E
Case Drain Plug

Press seal to bottom of the carrier Frame Size CM3 CM3
E100 020E
)NTERNAL(EX IN IN
4ORQUE .sM .sM
;LBFsFT= ;LBFsFT=
750 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
-INOR2EPAIR
Shaft seal, roller bearing, Shaft removal

and shaft replacement 'RIPTHESHAFTASSEMBLYBYTHE Shaft seal, roller bearing, and shaft
(continued) SPLINESORKEYEDENDANDREMOVE replacement
FROMTHEPUMP
C002
)NSPECTTHESHAFTFORDAMAGE%NSURE
THESHAFTANDSPLINESARESTRAIGHT
ANDFREEOFDAMAGEORHEAVYWEAR C003
)NSPECTTHESURFACEWHERETHEREAR
SHAFTBEARINGCONTACTSTHESHAFT)F
SPALLINGISPRESENTREPLACETHESHAFT
ANDREARSHAFTBEARING
C001
2EPLACEMENTOFSHAFTREARBEARINGIS
AMAJORREPAIRANDVIOLATESTHEUNITS
WARRANTYPOLICYUNLESSPERFORMEDBYAN
AUTHORIZED3AUER $ANFOSS'LOBAL3ERVICE
0ARTNER
)FNECESSARYCLEANTHESEALING
AREAWITHANONABRASIVEMATERIAL
,UBRICATETHESHAFTWITHALIGHT
COATINGOFHYDRAULICmUID
)NSPECTTHESHAFTBEARING#
FORDAMAGEANDROTATETOENSURE
SMOOTHNESS)FYOUSUSPECT
CONTAMINATIONORDAMAGECLEANWITH
SOLVENTANDLUBRICATEWITHHYDRAULIC
mUID2EPLACEIFNECESSARY P108 107E
)FYOUARENOTREPLACINGTHESHAFTOR
BEARINGPROCEEDWITHREASSEMBLY
Shaft bearing replacement

2EMOVETHERETAININGRING#
USINGSNAPRINGPLIERS
/BSERVETHEORIENTATIONOFTHE
CHAMFERONTHEBEARING0RESSTHE
BEARINGOFFOFTHESHAFT
6ERIFYTHECHAMFERONTHEBEARINGIS
FACINGTOWARDTHEPUMP0RESSTHE
NEWBEARINGONTOTHESHAFT0RESS
ONLYONTHEINNERRACEOFTHEROLLER
BEARING
5SINGSNAP RINGPLIERSINSTALLTHE

RETAININGRING#
008 918 12 BOMAG 751
18.2 Vibration pump
Service Manual
-INOR2EPAIR
Shaft seal, roller bearing, Reassembly Shaft seal, roller bearing, and shaft
and shaft replacement %NSURETHATTHECYLINDERKITANDREAR replacement
(continued) BEARINGAREALIGNED)NSERTTHESHAFT
ASSEMBLYINTOTHEPUMP)TMAYBE
NECESSARYTOGRIPTHESPLINEDENDOF
THESHAFTANDTWISTTOALIGNITWITH
THEBLOCKSPLINESANDPROPERLYSEATIT
INTOTHEREARBEARING F096
,UBRICATEANEW/ RING# WITH

PETROLEUMJELLYANDSEATITINTOTHE C020
HOUSINGONTOPOFTHEBEARING
#OVERTHEENDOFTHESHAFTWITHAN C017

ASSEMBLYSLEEVE,UBRICATESHAFTSEAL
WITHPETROLEUMJELLY
see table
3LIDETHESEALCARRIERASSEMBLYOVER
THESHAFTANDINTOTHEHOUSING0RESS
F091
THESEALCARRIERAGAINSTTHE/ RING
)TMAYBENECESSARYTOUSEALARGE
SOCKETTOPRESSTHESEALCARRIERDOWN
COMPLETELY
7INDTHESPIRALRETAININGRING&
INTOTHEGROOVEINTHEHOUSING
P108 069E
752 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
!PPENDIX! 4ORQUES
Torque table Sequence Part Description Tool Type Tool Size Torque
Number .sM;LBFsFT=
$ -$#BOLTS 4ORXWRENCH)NTERNALHEX 4 MM ;=
$ #OVERPLUG )NTERNALHEXWRENCH 3
in ;=
$ ,INKAGEPIVOTSCREW )NTERNALHEXWRENCH 4 mm ;=
$ -$#%$#(# %$#NEUTRAL %XTERNALHEXWRENCH MM ;=
ADJUSTMENTSEALLOCKNUT
$ #ONTROLSPOOLBOREPLUG %XTERNALHEXWRENCH IN ;=
$ #ONTROLSPOOLBOREPLUG )NTERNALHEXWRENCH IN ;=
$ Control nut %XTERNALHEXWRENCH 8 mm ;=

$ .EUTRALSTARTSWITCH %XTERNALHEXWRENCH 8 in ;=
$! 2ETAININGNUT %XTERNALHEXWRENCH 3
4 in ;=
$ &.2.&0%BOLTS )NTERNALHEXWRENCH 4 mm ;=
$$ %$#(# %$#BOLTS 4ORXWRENCH)NTERNALHEX 4 MM ;=
% .&0(ORIlCE )NTERNALHEXWRENCH 3 mm ;=

& #ASEDRAINPLUGCM3 )NTERNALHEXWRENCH in ;=
& #ASEDRAINPLUGCM3 )NTERNALHEXWRENCH 5
8 in ;=

& 3YSTEMGAUGEPORTS-AND- %XTERNALHEXWRENCH in ;=
PLUGS
' 3HIMADJUSTABLECHARGERELIEF %XTERNALHEXWRENCH IN ;=
VALVEPLUG
+ 6ALVESEATPLUG %XTERNALHEXWRENCH IN ;=
WITHBYPASS
+ 6ALVESEATPLUG )NTERNALHEXWRENCH in
5
;=
WITHOUTBYPASS
,- 3ERVOPISTONCOVERBOLTS 4ORXWRENCH)NTERNALHEX 4 MM ;=

,- 3ERVOGAUGEPLUG %XTERNALHEXWRENCH in ;=
,- $ISPLACEMENTLIMITERSEALLOCK %XTERNALHEXWRENCH MM ;=
nut

. 0ORT.PLUG %XTERNALHEXWRENCH in ;=
0 #ONTROLSPOOLCOVERSCREWS 4ORXWRENCH)NTERNALHEX 4 MM ;=
PRE BLOCKPOINTCHANGE

1" ,OOPmUSHINGPLUG )NTERNALHEXWRENCH 4 in ;=
PRE BLOCKPOINTCHANGE

1" ,OOPmUSHINGPLUG %XTERNALHEXWRENCH in ;=
POST BLOCKPOINTCHANGE
1" ,OOPmUSHINGRELIEFVALVEPLUG %XTERNALHEXWRENCH 5
8 in ;=
2 &ILTRATIONADAPTERBOLTS 4ORXWRENCH)NTERNALHEX 4 MM ;=
4 ,OCKNUTCM3 %XTERNALHEXWRENCH in ;=
4 ,OCKNUTCM3 %XTERNALHEXWRENCH in ;=
4 0UMPMECHANICALNEUTRAL %XTERNALHEXWRENCH MM ;=
cm3-$#%$#(# %$#
4 0UMPMECHANICALNEUTRAL %XTERNALHEXWRENCH MM ;=
cm3.&0CONTROLANDCM3
ALLCONTROLS
5 #HARGEPUMPCOVERBOLTS 4ORXWRENCH)NTERNALHEX 4 MM ;=

5 !UXILIARYPUMPSCREWS %XTERNALHEXWRENCH in ;=
3!% !PAD
5 !UXILIARYPUMPSCREWS %XTERNALHEXWRENCH 4 in
3
;=
3!% "PAD
008 918 12 BOMAG 753
18.2 Vibration pump
Service Manual
!PPENDIX" 3PECIlCATION4AGS
Pre-block point change

Ames, Iowa, U.S.A. Neumünster, Germany
Model Code
42L28 - C - ANN1 - 01 -
ANA - 2CNB - NN - NN - N - Model code
N - N - NNN - NNN
Model No. Ident Nr
4282051
A 97 23 67890
Serial No. Fabr Nr
MADE IN U.S.A.
3ERIALNO
{ X XX XX
NUMBER
XXXXX
,OCATION 9EAR 7EEK 3EQUENCE
Post-block point change Name plate (USA)
Model
number
Model-No./Ident-No.
Model Model Code ,#!..!.!
code #.".......
......
Serial
number
Serial-No. !
A=Ames, IA
Made in USA
P100438E Place of manufacture

Specifications
tag
Name plate (Japan)
0
Model
DAIKIN
Model-No./Ident-No.
number
428 XXXX
Model Model Code ,#!..!.!
code #.".......
......
Serial
number
Serial-No. 98888
Y=Osaka, Japan
J=Osaka, Japan
Made in Japan
P108 106E Place of manufacture
754 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
!PPENDIX# .OMENCLATURE
Pre-block point change s 3ERIES

nomenclature
s 2OTATION
s &RAME3IZE
s )NPUT3HAFT
s #ONTROL
s #ONTROL2ESPONSE
s (OUSING
s #HARGE0UMP
s 3YSTEM2ELIEF 0ORT!
s 3YSTEM2ELIEF 0ORT"
s "YPASS6ALVE
s $ISPLACEMENT,IMITERS 3IDE
s 3PECIAL(ARDWARE
s 3PECIAL&EATURES
008 918 12 BOMAG 755
18.2 Vibration pump
Service Manual
!PPENDIX# .OMENCLATURE
Post-block point change s 3ERIES

nomenclature
s 2OTATION
s &RAME3IZE
s )NPUT3HAFT
s #ONTROL
s #ONTROL2ESPONSE
s (OUSING
s ,OOP&LUSHING
s &ILTRATION
s #HARGE0UMP
s #HARGE2ELIEF3ETTING
s 3PECIAL$RIVE&EATURES
s !UXILIARY-OUNTING0AD
s 3YSTEM2ELIEF 0ORT!
s 3YSTEM2ELIEF 0ORT"
s "YPASS6ALVE
s 3PECIAL(ARDWARE
s 3PECIAL&EATURES
756 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
.OTES
008 918 12 BOMAG 757
18.2 Vibration pump
Service Manual
.OTES
758 BOMAG 008 918 12
Vibration pump 18.2
Service Manual
.OTES
008 918 12 BOMAG 759
18.2 Vibration pump
Products we offer: Sauer-Danfoss is a global manufacturer and supplier of high-

quality hydraulic and electronic components. We specialize in
• Bent Axis Motors providing state-of-the-art technology and solutions that excel in
the harsh operating conditions of the mobile off-highway market.
• Closed Circuit Axial Piston Pumps
Building on our extensive applications expertise, we work closely
and Motors
with our customers to ensure exceptional performance for a broad
• Displays range of off-highway vehicles.
• Electrohydraulic Power Steering
We help OEMs around the world speed up system development,
• Electrohydraulics reduce costs and bring vehicles to market faster.
Sauer-Danfoss – Your Strongest Partner in Mobile Hydraulics.
• Hydraulic Power Steering
• Integrated Systems
• Joysticks and Control Handles
Go to www.sauer-danfoss.com for further product information.
• Microcontrollers and Software
• Open Circuit Axial Piston Pumps
• Orbital Motors Wherever off-highway vehicles are at work, so is Sauer-Danfoss.
• PLUS+1™ GUIDE
We offer expert worldwide support for our customers, ensuring
• Proportional Valves the best possible solutions for outstanding performance. And with
an extensive network of Global Service Partners, we also provide
• Sensors
comprehensive global service for all of our components.
• Steering
• Transit Mixer Drives
Please contact the Sauer-Danfoss representative nearest you.
Local address:
Members of the Sauer-Danfoss Group:
Comatrol
www.comatrol.com
Schwarzmüller-Inverter
www.schwarzmueller-inverter.com
Sauer-Danfoss (US) Company Sauer-Danfoss ApS
2800 East 13th Street DK-6430 Nordborg, Denmark
Ames, IA 50010, USA Phone: +45 7488 4444
Turolla
Phone: +1 515 239 6000 Fax: +45 7488 4400
www.turollaocg.com Fax: +1 515 239 6618
Hydro-Gear Sauer-Danfoss GmbH & Co. OHG Sauer-Danfoss-Daikin LTD.

www.hydro-gear.com Postfach 2460, D-24531 Neumünster Shin-Osaka TERASAKI 3rd Bldg. 6F
Krokamp 35, D-24539 Neumünster, Germany 1-5-28 Nishimiyahara, Yodogawa-ku
Phone: +49 4321 871 0 Osaka 532-0004, Japan
Sauer-Danfoss-Daikin Fax: +49 4321 871 122 Phone: +81 6 6395 6066
Fax: +81 6 6395 8585
www.sauer-danfoss-daikin.com
www.sauer-danfoss.com
520L0638 s2EVISION#"s.OVEMBER
760 BOMAG 008 918 12
18.3 Travel motor
008 918 12 BOMAG 761

18.3 Travel motor
762 BOMAG 008 918 12

Travel motor 18.3
Series 51 and 51-1

Bent Axis Motors
Service Manual
008 918 12 BOMAG 763

18.3 Travel motor
Series 51 and 51-1 Motors
Service Manual
2EVISIONS

November 2009 14 correction to defeated loop flushing information AE

November 2009 19 11009442 is correct number for Series 51 two position AD
controls manual
April 2009 5 remove list of manuals AC
&EBRUARY 34 &RAMESIZE -INIMUMDISPLACEMENTRANGETOCCM AB
$ECEMBER - First edition AA

2 11008567s2EV!%s.OVEMBER
764 BOMAG 008 918 12

Travel motor 18.3
Service Manual
Contents
INTRODUCTION /VERVIEW 5
/RDERINGREPLACEMENTPARTSANDSERVICE 5
3AFETYPRECAUTIONS
5NINTENDEDMACHINEMOVEMENT
&LAMMABLECLEANINGSOLVENTS
&LUIDUNDERPRESSURE
0ERSONALSAFETY
(AZARDOUSMATERIAL
+EEPITCLEAN 8
)NSPECTFORSYSTEMCONTAMINATION 8
2EPLACETHE/ RINGSANDGASKETS 8
,UBRICATEALLMOVINGPARTS 8
4ORQUINGPROCEDURE 8
6ARIABLEDISPLACEMENTMOTORS
3ERIES MOTORS1
Closed circuit11
/PENCIRCUIT11
3HAFTS1
OPERATION ,OOPmUSHING13
$ISPLACEMENTLIMITERS15
-OUNTINGCONlGURATIONS1
3PEEDSENSORS1
Controls18
4WO POSITIONCONTROLS18
/VERVIEW18
0RESSURE COMPENSATORCONTROLS1
0ROPORTIONALCONTROLS
TECHNICAL 'ENERALSPECIlCATIONS1
SPECIFICATIONS 4ECHNICALDATA1
&LUIDSPECIlCATIONS
PRESSURE 2EQUIREDTOOLS3
MEASUREMENTS 0ORTLOCATIONSANDGAUGEINSTALLATION3
FLUID AND FILTER &LUIDANDlLTERRECOMMENDATIONS5

MAINTENANCE (AZARDOUSMATERIAL5
INITIAL STARTUP 0ROCEDURE

PROCEDURES
11008567s2EV!%s.OVEMBER 3
008 918 12 BOMAG 765
18.3 Travel motor
Service Manual
Contents
TROUBLESHOOTING 3LUGGISHSYSTEM8
3YSTEMOPERATINGHOT8
%XCESSIVENOISEORVIBRATION
-OTOROPERATESNORMALLYINONEDIRECTIONONLY
)MPROPEROUTPUTSPEED
,OWOUTPUTTORQUE3
ADJUSTMENTS /VERVIEW31
#HARGEPRESSURERELIEFVALVE31
-EASURINGCHARGEPRESSURE31
!DJUSTINGCHARGEPRESSURE3
-INIMUMDISPLACEMENTLIMITER33
!DJUSTINGMINIMUMDISPLACEMENT33
-AXIMUMDISPLACEMENTLIMITER35
3ERIESMOTORS35
3ERIES MOTORS35
MINOR REPAIR )NSTALLATIONANDADJUSTMENT3

$).AND3!%mANGEUNITS3
#ARTRIDGEUNITS38
3HAFTSEALREPLACEMENT3
3!%AND$).mANGEDMOTORS3
#ARTRIDGEmANGEDMOTORS41
,OOPmUSHINGSHUTTLEVALVE4
#HARGERELIEFVALVE44
/VERVIEW44
0OPPETSTYLEOLDERPRODUCTION 44
/RIlCEDSTYLE45
$EFEATPLUG4
-AXIMUMANGLESTOP 3ERIESMOTORS4
-AXIMUMANGLESTOP 3ERIES MOTORS48
-INIMUMANGLEADJUSTMENTSCREW5
7AYVALVEANDTHRESHOLDSPRINGS5
4HRESHOLDADJUSTMENTSCREWANDSPRINGSDISASSEMBLY54
REPAIR PARTS (OUSINGPLUGSANDSPEEDSENSORS

&LANGEANDSHAFTSEAL1
%NDCAP
3ERIESRAMPANDTHRESHOLD4
3ERIES %NDCAP
766 BOMAG 008 918 12

Travel motor 18.3
Service Manual
Introduction
OVERVIEW 4HECOMPLETESERVICEANDREPAIRINFORMATIONFOR3ERIESAND3ERIES MOTORSIS

INAMODULARFORMAT3ERVICEINFORMATIONMODULESAREAVAILABLEFORTHEBASICMOTOR
COMPONENTSFOREACHFAMILYOFMOTORCONTROLSANDFORMAJORREPAIRPROCEDURES%ACH
MODULECONTAINSINFORMATIONONTHEFUNCTIONADJUSTMENTANDREPAIROFEACHGROUP
OFCOMPONENTSORCONTROLS4HEREPAIRINSTRUCTIONSMODULEFOCUSESONMAJORREPAIR
PROCEDURES
&UNCTIONALDESCRIPTIONTECHNICALSPECIlCATIONSADJUSTMENTPROCEDURESMINORREPAIR

PROCEDURESANDEXPLODEDVIEWCOMMONPARTSDRAWINGSFORTHEBASIC3ERIESAND
3ERIES MOTORCOMPONENTSCOMPRISETHISMANUAL)TDISCUSSESTHOSEMINORREPAIRS
YOUCANPERFORMWITHOUTREMOVINGTHEMOTORSENDCAP4HESEREPAIRSWILLNOTAFFECTTHE
UNITSWARRANTY
-AJORREPAIRSREQUIREREMOVINGTHEMOTORSENDCAP4HISMANUALDOESNOTDESCRIBE
-AJORREPAIRSPERFORMED THEM/NLY3AUER $ANFOSS!UTHORIZED3ERVICE#ENTERSANDORORIGINALEQUIPMENT
BYPERSONSOTHERTHANA MANUFACTURERSTRAINEDBY3AUER $ANFOSSSHOULDPERFORMTHESEREPAIRS
3AUER $ANFOSS!UTHORIZED
Service Center or trained &ORINFORMATIONONCONTROLTYPESSEEPAGES
/%-PERSONNELMAYVOID
THEUNITSWARRANTY
ORDERING /RDERGENUINE3AUER $ANFOSSREPLACEMENTPARTSTOENSURETHEBESTPERFORMANCE&OR

REPLACEMENT PARTS lists of available service parts and service kits for Series 51 unitsSEE520L0765THROUGH
AND SERVICE 520L0770
3AUER $ANFOSSPROVIDESACOMPLETEREPAIRANDPARTSSERVICEFORALLPRODUCTS#ONTACTANY
3AUER $ANFOSS!UTHORIZED3ERVICE#ENTERFORDETAILS#HECKOURWEBSITEATHTTPWWW
SAUER DANFOSSCOMTOSEEALISTOF3AUER $ANFOSS!UTHORIZED3ERVICE#ENTERLOCATIONS
008 918 12 BOMAG 767
18.3 Travel motor
Service Manual
Introduction

HYDRAULICSYSTEM

W Warning

W Warning

W Warning
Personal safety
W Warning
TIMES
Hazardous material
W Warning
(YDRAULICmUIDCONTAINSHAZARDOUSMATERIAL!VOIDPROLONGEDCONTACTWITHHYDRAULIC
mUID!LWAYSDISPOSEOFUSEDHYDRAULICmUIDACMÃORDINGTOSTATEANDFEDERAL
ENVIRONMENTALREGULATIONS
768 BOMAG 008 918 12

Travel motor 18.3
Service Manual
Introduction

SAUER-DANFOSS
PRODUCTORPROPERTY
 2EUSABLEPART
 #LEANAREAORPART
sleeve
 4ORXHEAD
008 918 12 BOMAG 769
18.3 Travel motor
Service Manual
Introduction
GENERAL INSTRUCTIONS Keep it clean

 9OUCANCOMPLETEMANYREPAIRSORADJUSTMENTSWITHOUTREMOVINGTHEUNITFROMTHE
MACHINEifTHEUNITISACCESSIBLEANDYOUCANTHOROUGHLYCLEANITBEFOREBEGINNINGANY
PROCEDURES
#LEANLINESSISAPRIMARYMEANSOFASSURINGSATISFACTORYMOTORLIFEONEITHERNEWOR
REPAIREDUNITSClean the outside of the motor thoroughly before disassembly.4AKECARETO
AVOIDCONTAMINATIONOFTHESYSTEMPORTS#LEANINGPARTSWITHACLEANSOLVENTWASHAND
AIRDRYINGISUSUALLYADEQUATE
#APALLHOSESAFTERREMOVALANDPLUGALLOPENPORTS#OVERANYUNATTENDEDPARTSWITHA
PROTECTIVELAYEROFPLASTIC
Inspect for system contamination

 )NSPECTTHEMOTORFORSIGNSOFSYSTEMCONTAMINATION)FYOUlNDCONTAMINATIONFULLY
DISASSEMBLECLEANANDINSPECTALLCOMPONENTSOFTHEMOTOR
Replace the O-rings and gaskets

  2EPLACEALL/ RINGSANDGASKETS$ISCARDTHEMONLYAFTERYOUMAKECERTAIN
THATYOUHAVETHECORRECTREPLACEMENTPARTS,IGHTLYLUBRICATEALL/ RINGSWITHCLEAN
PETROLEUMJELLYBEFOREASSEMBLY
Lubricate all moving parts

 $URINGREASSEMBLYCOATALLMOVINGPARTSWITHAlLMOFCLEANHYDRAULICOIL4HISHELPS
LUBRICATETHESURFACESDURINGSTART UP
&ORmUIDQUALITYREQUIREMENTSREFERTO520L0463 Hydraulic Fluids and Lubricants,

Technical Information
Torque procedure
$URINGREASSEMBLYCROSSTORQUEALLRETAININGSCREWSTOTHEGIVENVALUE$ONOT
OVERTORQUE
770 BOMAG 008 918 12

Travel motor 18.3
Service Manual
Introduction
VARIABLE 3ERIESAND3ERIES VARIABLEDISPLACEMENTMOTORSFEATUREABENT AXISROTATING

DISPLACEMENT MOTORS GROUPTHATPROVIDESHIGHSTARTINGTORQUEANDHIGHSPEED4HEBALLENDOFEACHPISTON
RUNSINABUSHINGPRESSEDINTOTHEDRIVESHAFT4HISPERMITSTHETRANSFEROFHYDRAULIC
POWERDIRECTLYINTOROTARYMOTIONATTHEDRIVESHAFT4HEPRESSUREBALANCEDSPHERICAL
PISTONRINGSMAINTAINCONTACTWITHTHECYLINDERBLOCKBORESPROVIDINGHIGHVOLUMETRIC
EFlCIENCYANDLOWFRICTION!CONSTANTVELOCITYJOINTSYNCHRONIZINGSHAFT KEEPSTHE
ROTATIONOFTHECYLINDERBLOCKSYNCHRONIZEDWITHTHEMOTOROUTPUTSHAFT
!SERVOPISTONCHANGESTHEANGLEOFTHEROTATINGGROUPANDVARYSTHEDISPLACEMENTOF
THEMOTOR$ECREASINGDISPLACEMENTINCREASESSPEED)NCREASINGDISPLACEMENTDECREASES
SPEED
3EVERALHYDRAULICANDELECTROHYDRAULICCONTROLSAREAVAILABLE
4HE WAYSPOOLVALVESHIFTSTHESERVOSUPPLYPRESSURETOCHANGETHEMOTOR
DISPLACEMENT4HESERVOSUPPLYPRESSURECANBEEXTERNALORINTERNAL
Series 51 motor cross section

-INIMUMDISPLACEMENt ValvESEGMENt
liter 3PEEDPICKUPRING
"EARING
(YDRAULICPROPORtional PLATE
control 4APEREDROLLERBEARINGS
WAY
valve
3!% &LANGE
3PEEDSENSOR 3YNCHRONIZINGSHAFt
0ISTON
Servo
PISTON #HARGEPRESSURERELIEFValve 0%
008 918 12 BOMAG 771
18.3 Travel motor
Service Manual
Introduction
SERIES 51-1 MOTORS 3ERIES MOTORSFEATURESIMPLIlEDENDCAPANDCONTROLCOMPONENTS4HESERVOPISTON

INTHE3ERIES HASADIFFERENTIALAREAOFTO4HECONNECTINGJOINTISDESIGNEDTO
DECREASETHEOVERALLLENGTHOFTHEMOTOR
4HE3ERIES CONTROLFEEDSSERVOPRESSUREDIRECTLYTOTHESERVOPISTON,OWSYSTEM
LOOPPRESSUREFORTWO POSITIONCONTROLSANDHIGHSYSTEMLOOPPRESSUREFORPRESSURE
COMPENSATINGCONTROLSACTUATESTHESERVOPISTON
2OTATINGHARDWAREANDHOUSINGCOMPONENTSARECOMMONBETWEEN3ERIESAND3ERIES

Series 51-1 motor cross section

-INIMUM ValvESEGMENt
DISPLACEMENTLIMITER
"EARINGPLATE 3PEEDPICKUPRING
4APEREDROLLERBEARINGS
$). FLANGE
3YNCHRONIZINGSHAFt
3PEEDSENSOR
ServOPISTON
0ISTON
%LECTROHYDRAULICTWO POSITIONCONTROl
#HARGEPRESSURERELIEFValve 0%
772 BOMAG 008 918 12

Travel motor 18.3
Service Manual
Introduction
CLOSED CIRCUIT )NACLOSEDCIRCUITHYDRAULICLINESCONNECTTHEMAINPORTSOFTHEPUMPTOTHEMAINPORTS

OFTHEMOTOR&LUIDmOWSINEITHERDIRECTIONFROMTHEPUMPTOTHEMOTORANDBACKTOTHE
PUMP%ITHEROFTHEHYDRAULICLINESCANBEUNDERHIGHPRESSURE
Case
drain
line
/UTPUT
)NPUT 06 MV
2ESERvoir FlOW"I DIRECTIONAL

0%
4HEDIRECTIONANDSPEEDOFTHEmUIDmOWANDMOTOROUTPUTSHAFTROTATION DEPENDS
ONTHEPOSITIONOFTHEPUMPSWASHPLATE4HEPUMPmOWANDMOTORDISPLACEMENT
DETERMINESMOTOROUTPUTSHAFTSPEED4HEMACHINELOADDETERMINESTHESYSTEM
PRESSURE
OPEN CIRCUIT !HYDRAULICLINECONNECTSTHEOUTLETPORTOFTHEPUMPTOADIRECTIONALVALVEINANOPEN

CIRCUIT4HEMAINPORTSOFTHEMOTORCONNECTTOTHEWORKINGPORTSOFTHISVALVE7HENTHE
DIRECTIONALVALVEISACTUATEDmUIDmOWSlRSTFROMTHEPUMPTOTHEVALVE4HEDIRECTIONAL
VALVETHENDIRECTSTHEmUIDTOTHEMOTORINEITHERDIRECTION
FlOW FlOW
5NIDIRECTIONAL "I DIRECTIONAL
$)2%#4)/.!,VA,6%
)NPUT 05-0 MV /UTPUT
Case
drain
line
2ESERvoir
0%
4HEDIRECTIONOFmUIDmOWANDMOTOROUTPUTSHAFTROTATION DEPENDSONTHEPOSITION
OFTHEDIRECTIONALVALVE4HEMOTOROUTPUTSPEEDDEPENDSON PUMPOUTPUTVOLUME
THERESTRICTIONOFTHEVALVEOPENINGAND MOTORDISPLACEMENT4HEMACHINELOAD
DETERMINESTHESYSTEMPRESSURE4HEDIRECTIONALVALVEROUTESmUIDRETURNINGFROMTHE
MOTORTOTHERESERVOIR!DDITIONALCOMPONENTSMAYBENECESSARYTOPROVIDEDYNAMIC
BREAKINGANDTODEALWITHOVERRUNNINGLOADS
008 918 12 BOMAG 773
18.3 Travel motor
Service Manual
Introduction
SHAFTS -ANYSHAFTCONlGURATIONSAREAVAILABLEON3ERIESAND3ERIES MOTORS4HESETABLES

SHOWSHAFTSTHATMAYBEONEACHMOTORmANGECONlGURATION
Series 51-1 shaft options

Frame size 60 80 110
Order Cart/ Cart/ Cart/
Shaft description Flange SAE SAE SAE
code DIN DIN DIN
S1 TOOTHPITCH 34$ — 34$ — — —
# TOOTHPITCH /04 — — — — —
# TOOTHPITCH — — /04 — — —
C8 TOOTHPITCH — — — — — —
F1 TOOTHPITCH — — — — 34$ —
D1 7XXXXGPER$). — 34$ — — /04
$ 7XXXXGPER$). — /04 — 34$ — —
D3 7XXXXGPER$). — — — /04 — 34$
D4 7XXXXGPER$). — — — — — /04
Series 51 shaft options
Frame size 80 110 160 250

Order Shaft Cart/ Cart/ Cart/
Flange SAE SAE SAE SAE
code description DIN DIN DIN
S1 TOOTHPITCH 34$ — — — — — —
# TOOTHPITCH /04 — — — — — —
C8 TOOTHPITCH — — /04 — /04 — —
F1 TOOTHPITCH — — 34$ — 34$ — —
& TOOTH PITCH — — — — — — 34$
$ 7XXXXGPER$). — 34$ — — — — —
D3 7XXXXGPER$). — /04 — — — — —
D4 7XXXXGPER$). — — — 34$ — — —
D5 7XXXXGPER$). — — — — — 34$ —
774 BOMAG 008 918 12

Travel motor 18.3
Service Manual
/PERATION
LOOP FLUSHING 3ERIESAND MOTORSAREDESIGNEDTOACCOMMODATEALOOPmUSHINGFUNCTION

)NSTALLATIONSTHATREQUIREADDITIONALmUIDREMOVALFROMTHEMAINHYDRAULICCIRCUITBECAUSE
OFTRANSMISSIONCOOLINGREQUIREMENTSUSEALOOPmUSHINGFUNCTION4HELOOPmUSHING
FUNCTIONCONSISTSOFASHUTTLEVALVEANDAPOPPETSTYLERELIEFVALVEORANORIlCEDRELIEF
VALVECARTRIDGE
4HEshuttle valve ACTSASARESOLVERDIRECTINGmUIDONLYFROMTHELOWPRESSURESIDEOFTHE

LOOPTOTHEMOTORRELIEFVALVE4HESHUTTLEVALVEISSPRINGCENTEREDTOTHECLOSEDPOSITION
TOPREVENTHIGHPRESSUREmUIDLOSSFROMTHECIRCUITWHENREVERSINGDIRECTIONS
Loop flushing cross-section showing orificed relief valve
/RIFICED
RELIEFValve 3HUTTLEValve
0%
4HEpoppet style relief valveREGULATESTHECHARGEPRESSURELEVELINTHESYSTEMCIRCUIT

WHENTHEREISAPRESSUREDIFFERENTIALINTHEMAINLOOP7HENYOUUSETHISVALVETHE
PRESSURESETTINGOFTHEMOTORMUSTBELESSTHANTHEPUMPSCHARGEPRESSURESETTING4HE
PRESSURESETTINGOFTHISVALVEISCRITICALTOACHIEVINGTHEPROPERLOOPmUSHINGmOWRATE
Loop flushing cross-section showing poppet style relief valve

0OPPETSTYLE
RELIEFVALVe
3HUTTLEValve
0%
008 918 12 BOMAG 775
18.3 Travel motor
Service Manual
/PERATION
LOOP FLUSHING 4HEorificed relief cartridgeCONTROLSmUSHINGmOWUNDERMOSTCONDITIONS!

(continued) COMBINATIONOFORIlCESIZEANDCHARGEPRESSUREWILLPRODUCEASPECIlCmUSHINGmOW9OU
MAYEXCHANGETHEORIlCEDRELIEFCARTRIDGEFORONEWITHADIFFERENTmOWRATING
Loop flushing cross-section showing defeated relief valve

/RIFICED
RELIEF
valve
3HUTTLE
valve
0
!PLUGISINSTALLEDINTHERELIEFVALVECAVITYTODEFEATTHELOOPmUSHINGFUNCTION
Defeated loop flushing
Defeat
plug
Shuttle spool
P101 265E
776 BOMAG 008 918 12

Travel motor 18.3
Service Manual
/PERATION
DISPLACEMENT LIMITERS 3ERIESAND3ERIES MOTORSINCORPORATEMECHANICALDISPLACEMENTLIMITERS9OUCAN

SETASPECIlCDISPLACEMENTRANGEBYLIMITINGTHETRAVELOFTHEVALVESEGMENTROTATING
GROUP
Displacement limiters Series 51

4AMPERRESISTANT
caP
WAY
valve MINIMUM
DISPLACEMENT
LIMITER
ValvESEGMENt
3PACER
ServOPISTON
-AXIMUM
DISPLACEMENT
LIMITER 0%
4HEmaximum displacement OFTHEMOTORISSETBYASCREWANDSPACERSINSTALLEDON

THEENDOFTHESERVOPISTON4HE minimum displacementOFTHEMOTORISSETBYAN
ADJUSTABLESTOPINTHEMOTORHOUSING
Displacement limiters Series 51-1

4AMPER
resistant caP
MINIMUM
DISPLACEMENTLIMITER
ValvESEGMENt
Servo
PISTON
-AXIMUMDISPLACEMENT
3PACER
0%
See Adjustments,PAGES FORAVAILABLESETTINGRANGES

008 918 12 BOMAG 777
18.3 Travel motor
Service Manual
/PERATION
MOUNTING 3ERIESAND3ERIES MOTORSAREAVAILABLEINTHREEMOUNTINGCONlGURATIONS4HEY

CONFIGURATIONS AREDESIGNATEDBYTHELETTERS6#OR$FOLLOWINGTHENUMBERINTHEMODELCODE4HE
DESIGNATIONSREPRESENT
• 6 3!%#$OR%MOUNTINGmANGE
• # #ARTRIDGESTYLEMOUNTING
• $ $).)3/MOUNTINGmANGE
SAE configuration
P101 197
Cartridge configuration
P101 198
DIN configuration
P101 199
778 BOMAG 008 918 12

Travel motor 18.3
Service Manual
/PERATION
SPEED SENSORS 3ERIESAND3ERIES MOTORSAREAVAILABLEWITHANOPTIONALSPEEDSENSORFORDIRECT

MEASUREMENTOFMOTOROUTPUTSPEED4HESENSORMAYALSOBEUSEDTOSENSETHEDIRECTION
OFMOTORROTATION
Speed sensor with Packard connector

0ACKARDWEATHER PACK
PINTOWERCONNECtor
2Ed
A
3UPPLYVOLTAGE
7HITe
B SPEEDSIGNAL
BlacK
C GROUNDCOMMON
'REEn
D direction
$EUTZCONNECtor
0%
!SPECIALMAGNETICSPEEDRINGISPRESSEDONTOTHEOUTSIDEDIAMETEROFTHESHAFT!(ALL
EFFECTSENSORISINSTALLEDINTHEMOTORHOUSING4HESENSORACMÃEPTSSUPPLYVOLTAGEAND
OUTPUTSADIGITALPULSESIGNALINRESPONSETOTHESPEEDOFTHERING
Speed sensor location cartridge motors
3PEED
sensor Conical end
0ISTON
"EARING
-AGNETICRING
0% PRESSEDONTOTHESHAFT
4HEOUTPUTCHANGESITSHIGHLOWSTATEASTHENORTHANDSOUTHPOLESOFTHEPERMANENTLY
MAGNETIZEDSPEEDRINGPASSBYTHEFACEOFTHESENSOR4HEDIGITALSIGNALISGENERATEDAT
FREQUENCIESSUITABLEFORMICROPROCESSOR BASEDCONTROLS
Speed sensor location SAE / DIN flange motors
4HE3!%AND$).mANGEMOTORSUSEA
mATENDSPEEDSENSOR#ARTRIDGEmANGE
0ISTON MOTORSUSEACONICALENDSPEEDSENSOR
-AGNETICRING
3PEEDSENSOR
0%
008 918 12 BOMAG 779
18.3 Travel motor
Service Manual
/PERATION
CONTROLS Overview
4HEREARETHREEBASICCATEGORIESOFCONTROLSAVAILABLEFOR3ERIESAND3ERIES
• 4WO POSITIONCONTROLS
• 0RESSURE COMPENSATORCONTROLS
• 0ROPORTIONALCONTROLS3ERIESONLY
TWO-POSITION 4WO POSITIONCONTROLSSHIFTTHEMOTORTO Two-position control

CONTROLS ONLYTWODISCRETEPOSITIONS
• MAXIMUMDISPLACEMENT
• MINIMUMDISPLACEMENT
#ONTROLINPUTMAYBEEITHERBYHYDRAULIC
ORELECTRICALSIGNAL4OCHANGEMOTOR
DISPLACEMENTTHECONTROLROUTESPILOT
G36
PRESSURETOONEENDOFTHESERVOPISTON
G42
WHILEDRAININGTHEOTHER3ERIES G38
CONTROLSMAYDIRECTPILOTPRESSURETO
G42
BOTHENDSOFTHESERVOSIMULTANEOUSLY G38
ALLOWINGTHEDIFFERENTIALAREAOFTHE M16
PISTONTOSTROKETHEMOTORTOMINIMUM M16A
ANGLE
M18
M18A
3OMETWO POSITIONCONTROLSAREAVAILABLE M18 M10
WITHAPressure COMPENSATOROverRide M18A M12
PCOR FEATURE M1
4HE0#/2FEATUREALLOWSNORMAL
M18
POSITIONCONTROLWHILECAUSINGTHE M18A M16A
MOTORTOINCREASEDISPLACEMENTWHEN M16
SYSTEMPRESSUREREACHESASETLEVEL M22
DUETOLOAD4HEPRESSURECOMPENSATOR P101 268
PORTIONOFTHECONTROLOVERRIDESTHE
MINIMUMDISPLACEMENTPOSITIONCOMMANDEDBYTHECONTROLINPUTSIGNAL0#/2CONTROLS
AREAVAILABLEWITHBRAKEPRESSUREDEFEATTOPREVENTTHEPRESSURECOMPENSATORFROM
OPERATINGDURINGDYNAMICBRAKING
#OMPLETEFUNCTIONALDESCRIPTIONMAINTENANCEANDREPAIRPROCEDURESFOR POSITION

CONTROLSARECOVEREDINDETAILINTHESESUPPLEMENTSTOTHISMANUAL
• Series 51 Hydraulic and Electrohydraulic Two-position Controls

4YPES.(:% %& &' '3
• Series 51-1 Controls Service Instructions

4YPES.% % %" " "4444!4(
780 BOMAG 008 918 12

Travel motor 18.3
Service Manual
/PERATION
PRESSURE- 0RESSURECOMPENSATOR0# CONTROLS

COMPENSATOR ALLOWTHEMOTORTOMATCHITS
CONTROLS DISPLACEMENTTOTHESYSTEMLOAD5SUALLY
THISMEANSTHATTHEMOTORDEFAULTSTO
MINIMUMDISPLACEMENTWHILEALLOWING
THEMOTORTOINCREASEDISPLACEMENT
WHENSYSTEMPRESSUREREACHESASETLEVEL
DUETOLOAD4HISPERMITSTHEMOTORTO
REGULATESYSTEMPRESSUREBYMODULATING
THEDISPLACEMENTANGLEOFTHEROTATING
GROUP!SDISPLACEMENTINCREASESSO
DOESAVAILABLETORQUEWHILEOUTPUT
SPEEDDECREASESANDSYSTEMPRESSURE
REMAINSNEARLYCONSTANTATTHE0#SETTING
0#CONTROLSAREAVAILABLEWITHABRAKE 0%
Pressure DEFEATBPD FEATURE4HE"0$
FEATUREDEFEATSTHEOPERATIONOFTHE0#
DURINGDYNAMICBREAKINGWHENTHE
MOTORISRUNNINGASAPUMP
!SHUTTLESPOOLUPSTREAMOFTHE0#VALVEDIRECTSONLYACMÃELERATIONSYSTEMPRESSURETO
THE0#$URINGDYNAMICDECELERATIONTHEDYNAMICBREAKINGPRESSUREISBLOCKEDFROM
THE0#4HEMOTORREMAINSATMINIMUMDISPLACEMENTLIMITINGRAPIDANDUNCONTROLLED
PRESSURESORENGINEOVER SPEEDINGWHILETHEVEHICLEMACHINEISSLOWINGDOWN(YDRAULIC
ORELECTRICACTUATIONISAVAILABLE0#ONONESYSTEM PRESSURESIDEISALSOANOPTION
#OMPLETEFUNCTIONALDESCRIPTIONMAINTENANCEANDREPAIRPROCEDURESFORPRESSURE

COMPENSATORCONTROLSARECOVEREDINDETAILINTHESUPPLEMENTTOTHISMANUAL
• Series 51 Two Position Controls Service Manual

4YPES444(4!0#0$
008 918 12 BOMAG 781
18.3 Travel motor
Service Manual
/PERATION
PROPORTIONAL Proportional control 0ROPORTIONALCONTROLSALLOWTHEMOTOR

CONTROLS TOOPERATEINANINlNITELYVARIABLE
DISPLACEMENTPOSITIONBASEDONA
HYDRAULICORELECTRICALINPUTSIGNAL
0ROPORTIONALCONTROLSAREAVAILABLEON
3ERIESMOTORS3ERIES MOTORSARE
TWO POSITIONONLY0ROPORTIONALCONTROLS
AREALSOAVAILABLEWITHA0#/2FEATURE
4HE0#/2FEATUREALLOWSNORMAL
PROPORTIONALCONTROLWHILECAUSINGTHE
MOTORTOINCREASEDISPLACEMENTWHEN
SYSTEMPRESSUREREACHESASETLEVEL
DUETOLOAD4HEPRESSURECOMPENSATOR
PORTIONOFTHECONTROLoverridesANY
POSITIONLESSTHANMAXIMUMAS
COMMANDEDBYTHECONTROLINPUTSIGNAL
0#/2CONTROLSAREAVAILABLEWITH"0$
TOPREVENTTHEPRESSURECOMPENSATOR
FROMOPERATINGDURINGDYNAMICBRAKING
3UPPLEMENTSTOTHISMANUALDETAIL
FUNCTIONALDESCRIPTIONMAINTENANCE
ANDREPAIRPROCEDURESFORPROPORTIONAL
P001826
CONTROLS3UPPLEMENTSINCLUDE
• Series 51 Single Input Hydraulic Proportional Controls

4YPES(:(!("(%(3((***++
• Series 51 Dual Input Hydraulic Proportional Controls

4YPES(0(#*!
• Series 51 Electrohydraulic Proportional Controls

4YPES%0%1%2%3, ,,!$$
782 BOMAG 008 918 12

Travel motor 18.3
Service Manual
GENERAL -OSTSPECIlCATIONSFOR3ERIESAND MOTORSARELISTEDONTHESEPAGES&OR

SPECIFICATIONS DElNITIONSOFTHEVARIOUSSPECIlCATIONSSEE520L0440 Series 51 Technical Information
Manual
.OTALLHARDWAREOPTIONSAREAVAILABLEFORALLCONlGURATIONS#ONSULTTHESeries 51 Model
Code Supplement or price bookFORMOREINFORMATION
"ASICREQUIREMENTS
• -OTORTYPE !XIALPISTONMOTORWITHVARIABLEDISPLACEMENTBENT
AXISDESIGN
• $IRECTIONOFROTATION #LOCKWISEANDCOUNTER CLOCKWISEBI DIRECTIONAL
• )NSTALLATIONPOSITION $ISCRETIONARYTHEHOUSINGMUSTALWAYSBElLLEDWITH
HYDRAULICmUID
• /THERSYSTEMREQUIREMENTS )NDEPENDENTBRAKINGSYSTEMCIRCUITOVERPRESSURE

PROTECTIONSUITABLERESERVOIR
4ECHNICALDATAINCLUDESDIMENSIONANDFRAMESIZEFORDISPLACEMENTCASEANDSYSTEM
PRESSURESPEEDANDTORQUE4HESETABLESILLUSTRATEEACHFACET
TECHNICAL DATA
Frame size
Dimension 60 80 110 160 250
3
-AXIMUMDISPLACEMENT 6GMAX CM
[in3] ;= ;= ;= ;= ;=
-INIMUMDISPLACEMENT 6GMIN CM3
[in3] ;= ;= ;= ;= ;=
2ATEDmOW 1 LMIN
;GALMIN= ;= ;= [81] ;= [145]
-AXIMUMCORNERPOWER 0CORNER K7
MAX ;HP= ;= ;= ;= ;= ;=
7EIGHTWITHCONTROL(Z M KG 44
LB ;= ;= ;= ;= ;
-ASSMOMENTOFINERTIAOFTHEINTERNAL KGsM
ROTATINGPARTS SLUGsFT ;= ;= ;= ;= ;=
4YPEOFMOUNTING &OUR BOLTmANGE3!%OR$).mANGECONlGURATION
4WO BOLTmANGECARTRIDGEMOTORCONlGURATION
0IPECONNECTIONS -AINPRESSUREPORTS3!%mANGE
2EMAININGPORTS3!%STRAIGHT THREAD/ RINGBOSS
Controls 4WO POSITIONPROPORTIONAL3ERIES HYDRAULICORELECTRICPRESSURECOMPENSATORWWOOVERRIDE
WWOBRAKEPRESSUREDEFEAT
$ISPLACEMENTLIMITER !LL3ERIESMOTORSINCORPORATEMECHANICALMINIMUMANDMAXIMUMDISPLACEMENTLIMITERS
3HAFTCONlGURATION 3PLINED!.3)OR$).SHAFT
008 918 12 BOMAG 783
18.3 Travel motor
Service Manual
TECHNICAL DATA Case pressure System pressure range

(continued)
bar psi bar psi
2ATEDPRESSURE 3 44 -AXIMUMDELTAPRESSURE
-AXIMUMPRESSURECOLDSTART 5 -INIMUMLOWPRESSURESIDE 145
-INIMUMPRESSURE 1 15
Speed limits
Frame size
-1
Speed min [rpm] 060 080 110 160 250
ATMAXIMUMDISPLACEMENT
2ATEDSPEED
ATMINIMUMDISPLACEMENT
ATMAXIMUMDISPLACEMENT
-AXIMUMSPEED1
ATMINIMUMDISPLACEMENT
1
#ONTACTYOUR3AUER $ANFOSSREPRESENTATIVEFORMAXIMUMSPEEDATDISPLACEMENTSBETWEENMAXIMUMAND
MINIMUMDISPLACEMENT
Theoretical torque
Frame size
Displacement condition 060 080 110 160 250
ATMAXIMUM .sMBAR
DISPLACEMENT ;LBFsINPSI= 583
ATMINIMUM .sMBAR
DISPLACEMENT ;LBFsINPSI= 313
FLUID SPECIFICATIONS Temperature range1 Viscosity

Calefaction °C °F mm2/s SUS
)NTERMITTENTCOLDSTART -INIMUMINTERMITTENT
Continuous 2ECOMMENDEDOPERATING
RANGE
)NTERMITTENT 115
1 -AXIMUMCOLDSTART
!TTHEHOTTESTPOINTUSUALLYTHECASEDRAINPORT
Fluid cleanliness
Cleanliness level and βx-ratio
2EQUIREDmUIDCLEANLINESSLEVEL )3/#LASS
2ECOMMENDEDβx RATIOFORSUCTIONlLTRATION B35-45"≥
2ECOMMENDEDβx RATIOFORCHARGEPRESSURElLTRATION B "≥
2ECOMMENDEDINLETSCREENSIZEFORCHARGEPRESSURElLTRATION μM μM
784 BOMAG 008 918 12

Travel motor 18.3
Service Manual
0RESSUREMEASUREMENTS
REQUIRED TOOLS 9OUCANPERFORMSERVICEPROCEDURESDESCRIBEDINTHISMANUALUSINGCOMMONMECHANICS

HANDTOOLS3PECIALTOOLSIFREQUIREDARESHOWN#ALIBRATEPRESSUREGAUGESFREQUENTLYTO
ENSUREACMÃURACY5SESNUBBERSTOPROTECTPRESSUREGAUGES
PORT LOCATIONS AND Series 51 motors

GAUGE INSTALLATION
Servo pressure supply Side port
for minimum angle or servo Y
pressure minimum angle
Guage port M3
System pressure B
M3
Main ports A+B Gauge port M2
Case drain L1
Y
side port
W
M1
Servo supply
M5
pressure
Guage port M5
System pressure A
Alternate position Gauge port M1
case drain L2 Control pressure
Guage port M7
Gauge information W
Servo pressure supply for
3YSTEMPRESSURE BAR;PSI= maximum angle or
M1
PORTA / RINGlTTING servo pressure maximum angle
Guage port M4
3YSTEMPRESSURE BAR;PSI=
-
PORTB / RINGlTTING
0%A
3ERVOPRESSURE BAR;PSI=

M3
MINIMUMANGLE / RINGlTTING
3ERVOSUPPLY BAR;PSI=
M4 PRESSURE
MAXIMUMANGLE / RINGlTTING
3ERVOSUPPLY BAR;PSI= Axial port Y

M5
PRESSURE / RINGlTTING
System pressure A+B
Guage port M1+M2 Main
port B
M3
Axial port W
M4
M5
Main
port A P107 757E
008 918 12 BOMAG 785
18.3 Travel motor
Service Manual
0RESSUREMEASUREMENTS
PORT LOCATIONS AND Series 51-1 motors

GAUGE INSTALLATION
Y
(continued)
3IDEPOrt
,OOPFLUSHING
SHUTTLEValve
X
#HARGEPRESSURe
RELIEFValve
7
M4
#ASEDRAIN,
3YSEMPRESSUREB
Y B A 'AUGEPOrt-
-AINPORTS!"
3YSTEMPRESSUREA 7
'UAGEPOrt M1
Alternate
POSITION
CASEDRAIN,
Gauge information 'UAGEPOrt M4

ServOPRESSURe
3YSTEMPRESSURE BAR;PSI= 0% MAXIMUMANGLE
M1
PORTA / RINGlTTING
3YSTEMPRESSURE BAR;PSI=

-
PORTB / RINGlTTING
BAR;PSI=
3ERVOPRESSURE BAR;PSI=
M3 MINIMUMANGLE GAUGEFOR POSITION
ONCONTROL control
/ RINGlTTING
BAR;PSI=
BAR;PSI= Y
3ERVOSUPPLY !XIALPOrt
M4 PRESSURE GAUGEFOR POSITION
MAXIMUMANGLE control
/ RINGlTTING
7
X
M4
B A
Main
POrt B
-AINPOrt A
3YSTEMPRESSURE!"
'UAGEPOrt-- 0%
786 BOMAG 008 918 12

Travel motor 18.3
Service Manual
&LUIDANDlLTERMAINTENANCE
FLUID AND FILTER 4OENSUREOPTIMUMLIFEPERFORMREGULARMAINTENANCEOFTHEmUIDANDlLTER

RECOMMENDATIONS #ONTAMINATEDmUIDISTHEMAINCAUSEOFUNITFAILURE4AKECARETOMAINTAINmUID
CLEANLINESSWHENSERVICING)NSPECTVEHICLEFORLEAKSDAILY

ODOR&LUIDCONTAMINATEDBYWATERMAYAPPEARCLOUDYORMILKYORFREEWATERMAYSETTLE
INTHEBOTTOMOFTHERESERVOIR2ANCIDODORINDICATESEXCESSIVEHEAT#HANGETHEmUID
IMMEDIATELYIFTHESECONDITIONSOCMÃUR#ORRECTTHEPROBLEMIMMEDIATELY
#HANGETHEmUIDANDlLTERPERTHE Fluid and filter change interval

VEHICLEMACHINEMANUFACTURERS Reservoir type Max. oil change interval
RECOMMENDATIONSORATTHESEINTERVALS Sealed HOURS
&IRSTmUIDCHANGERECOMMENDEDAT "REATHER HOURS
HOURS
(IGHTEMPERATURESANDPRESSURESRESULTINACMÃELERATEDmUIDAGING-OREFREQUENTmUID
CHANGESMAYBEREQUIRED
WATERGREASEETC ORIFTHEmUIDISSUBJECTEDTOTEMPERATURELEVELSGREATERTHATTHE
RECOMMENDEDMAXIMUM$ISPOSEOFUSEDHYDRAULICmUIDPROPERLY.EVERREUSEHYDRAULIC
mUID
#HANGElLTERSWHENEVERTHEmUIDISCHANGEDORWHENTHElLTERINDICATORSHOWSTHATITIS
NECESSARYTOCHANGETHElLTER2EPLACEALLmUIDLOSTDURINGlLTERCHANGE
Hazardous material
W Warning
(YDRAULICmUIDCONTAINSHAZARDOUSMATERIAL!VOIDCONTACTWITHHYDRAULICmUID!LWAYS
DISPOSEOFUSEDHYDRAULICmUIDACMÃORDINGTOSTATEANDFEDERALENVIRONMENTAL
REGULATIONS
008 918 12 BOMAG 787
18.3 Travel motor
Service Manual
)NITIALSTARTUPPROCEDURES
PROCEDURE !LWAYSFOLLOWTHISPROCEDUREWHENSTARTING UPANEW3ERIESOR3ERIES INSTALLATION

ORWHENRESTARTINGANINSTALLATIONINWHICHEITHERTHEPUMPORMOTORHASBEENREMOVED
7!2.).' "EFOREINSTALLINGTHEMOTORANDORPUMPINSPECTTHEUNITSFORDAMAGEINCURRED

4HISSERVICEPROCEDURE DURINGSHIPPINGANDHANDLING
MAYREQUIREDISABLING
THEVEHICLEMACHINE -AKECERTAINALLSYSTEMCOMPONENTSRESERVOIRHOSESVALVESlTTINGSHEATEXCHANGER
RAISINGTHEWHEELSOFFTHE ANDSOFORTH ARECLEANBEFORElLLINGWITHmUID
GROUNDDISCONNECTING
WORKFUNCTIONANDSO &ILLTHERESERVOIRWITHRECOMMENDEDHYDRAULICmUID&ILTERUSINGAMICRON
FORTH WHILEPERFORMING NOMINALNOBYPASS lLTERINTOTHERESERVOIR5SINGCONTAMINATEDmUIDMAYDAMAGE
TOPREVENTINJURYTOTHE COMPONENTSWHICHMAYRESULTINUNEXPECTEDVEHICLEMACHINEMOVEMENT
TECHNICIANANDBYSTANDERS
4AKETHENECESSARYSAFETY &ILLTHEINLETLINELEADINGFROMTHERESERVOIRTOTHEPUMP
PRECAUTIONS
#HECKINLETLINEFORPROPERLYTIGHTENEDlTTINGS
-AKESURETHEINLETLINEISFREEOFRESTRICTIONSANDAIRLEAKS
&ILLTHEMOTORANDORPUMPHOUSINGWITHCLEANHYDRAULICmUIDBEFORESTARTUP&ILLBY
POURINGlLTEREDOILINTOTHEUPPERCASEDRAINPORT
 Caution
.EVERSTARTTHEPRIMEMOVERUNLESSTHEMOTORANDPUMPARE filled completelyWITH
CLEANHYDRAULICmUID
)NSTALLA BAR; PSI=PRESSUREGAUGEINTHECHARGEPRESSUREGAUGEPORTOF

THEPUMPTOMONITORTHECHARGEPRESSUREDURINGSTART UP
$ISCONNECTANYEXTERNALCONTROLINPUTSIGNALLINKAGEFOR-$#HYDRAULICLINESFOR

($#ORELECTRICALCONNECTIONSFOR%$# FROMTHEPUMPCONTROLUNTILAFTERINITIALSTART
UP4HISENSURESTHATTHEPUMPREMAINSINITSNEUTRALPOSITION
5SEACOMMONMETHODTODISABLETHEPRIMEMOVER*OGSLOWLYROTATE PRIMEMOVER

UNTILCHARGEPRESSURESTARTSTORISE
7!2.).' %NABLEPRIMEMOVER3TARTTHEPRIMEMOVERANDRUNATTHELOWESTPOSSIBLESPEED

$ONOTSTARTTHEPRIME UNTILCHARGEPRESSUREISESTABLISHED
MOVERUNLESSTHEPUMPIS
INNEUTRALPOSITIONSWASH )FNECESSARYBLEEDEXCESSAIRFROMTHEHIGHPRESSURELINESTHROUGHTHEHIGHPRESSURE
PLATEAT²ANGLE 4AKE SYSTEMGAUGEPORT
NECESSARYPRECAUTIONS
TOPREVENTMACHINE /NCECHARGEPRESSUREISESTABLISHEDINCREASESPEEDTONORMALOPERATINGSPEED
MOVEMENTINCASEPUMPIS
ACTUATEDINSTROKEDURING #HARGEPRESSURESHOULDBEASINDICATEDINTHEPUMPMODELCODE)FCHARGEPRESSUREIS
INITIALSTART UP LOWSHUTDOWNANDDETERMINECAUSE3EE TroubleshootingPAGES
 Caution
,OWCHARGEPRESSUREMAYAFFECTTHEOPERATORSABILITYTOCONTROLTHEMACHINE
788 BOMAG 008 918 12

Travel motor 18.3
Service Manual
)NITIALSTARTUPPROCEDURES
PROCEDURE (continued) 3HUTDOWNTHEPRIMEMOVER
#ONNECTTHEEXTERNALCONTROLINPUTSIGNAL
2ECONNECTTHEMACHINEFUNCTIONIFDISCONNECTEDEARLIER
3TARTTHEPRIMEMOVERCHECKINGTOENSURETHEPUMPREMAINSINNEUTRAL
#HECKFORFORWARDANDREVERSEMACHINEOPERATIONWITHTHEPRIMEMOVERATNORMAL

OPERATINGSPEED
#HARGEPRESSUREMAYDECREASESLIGHTLYDURINGFORWARDORREVERSEOPERATION
#ONTINUETOCYCLESLOWLYBETWEENFORWARDANDREVERSEFORATLEASTlVEMINUTES
3HUTDOWNPRIMEMOVER
2EMOVEGAUGES
0LUGTHEGAUGEPORTS
#HECKRESERVOIRLEVEL
!DDlLTEREDmUIDTOTHERESERVOIRIFNEEDED
4HEMOTORTRANSMISSIONISNOWREADYFOROPERATION
008 918 12 BOMAG 789
18.3 Travel motor
Service Manual
4ROUBLESHOOTING
SLUGGISH SYSTEM
Check Cause Corrective action

#ONTROLORIlCES "LOCKEDORRESTRICTEDORIlCEWILLCAUSESLUGGISH 2EMOVEINSPECTANDCLEANALLORIlCES%NSURETHE
RESPONSE/RIlCESINSTALLEDTOTHEWRONG APPROPRIATEORIlCESAREINSTALLED
LOCATIONSWILLCAUSE0#/2CONTROLTOBESLUGGISH
4HRESHOLDSETTINGPROPORTIONAL )NAPPROPRIATELYHIGHTHRESHOLDSETTINGWILLSHIFT #HECKTHRESHOLDSETTING!DJUSTIFNECESSARY
CONTROLS THEMOTORATTHEWRONGTIME
#ONTROLSPOOLORPISTON !STICKY WAYSPOOLORCONTROLPISTONWILLCAUSE #LEANANDINSPECTTHE WAYVALVESPOOLANDCONTROL
SLUGGISHRESPONSE PISTON2EPLACEIFNECESSARY
0RESSURECOMPENSATORSETTING )NAPPROPRIATELYLOWPRESSURECOMPENSATING #HECKPRESSURECOMPENSATORSETTING!DJUSTIF
SETTINGWILLSHIFTMOTORTOMAXIMUM NECESSARY
DISPLACEMENTATLOWERPRESSURE
#ONTROLINPUTSIGNAL !NIMPROPERORERRATICINPUTSIGNALTOTHECONTROL #HECKINPUTSIGNALORELECTRICCURRENTANDCORRECTIF
MAYCAUSESLUGGISHRESPONSE NECESSARY
#HARGEPRESSURE )NAPPROPRIATELYLOWPRESSURESETTINGATLOOP -EASURECHANGEPRESSUREINFORWARDANDREVERSE
mUSHINGRELIEFVALVEMAYCAUSEIMPROPERSUPPLY !DJUSTLOOPmUSHINGRELIEFVALVEIFNECESSARY
PRESSURETOMOTORCONTROL
3YSTEMPRESSURE )NAPPROPRIATELYLOWSYSTEMPRESSURESETTINGMAY -EASURESYSTEMPRESSURE!DJUSTPUMPPRESSURE
CAUSESLUGGISHRESPONSE LIMITERORSYSTEMRELIEFVALVEIFNECESSARY
)NTERNALLEAKAGE %XCESSIVELEAKAGEWILLCAUSELOWERCHARGE )NSTALLLOOPmUSHINGDEFEATOPTIONANDMONITORCASE
PRESSUREANDAFFECTPERFORMANCE mOW)FCASEmOWISEXCESSIVEMOTORMAYREQUIRE
MAJORREPAIR#ONTACTYOUR3AUER $ANFOSSSERVICE
PROVIDER
SYSTEM OPERATING HOT

Oil level )NSUFlCIENTHYDRAULICmUIDWILLCAUSEOVERHEATING &ILLRESERVOIRTOPROPERLEVEL
(EATEXCHANGER "LOCKEDHEATEXCHANGERORLOWAIRmOWWILLNOT #HECKTEMPERATUREUPSTREAMANDDOWNSTREAM
SUFlCIENTLYCOOLTHESYSTEM OFHEATEXCHANGER#LEANREPAIRORREPLACEHEAT
EXCHANGERIFNECESSARY
,OOPmUSHINGCHARGEPRESSURE )NAPPROPRIATELYHIGHLOOPmUSHINGRELIEFVALVE -ONITORCASEDRAINmOW)FLOWADJUSTLOOPmUSHING
SETTINGWILLREDUCEORPREVENTLOOPmUSHINGmOW RELIEFVALVESETTINGORREPLACEWITHORIlCEDTYPE
)MPROPERORIlCESIZEWILLNOTGIVEPROPERmOWFOR RELIEF
COOLINGPURPOSES
3YSTEMPRESSURE )FSYSTEMRELIEFVALVESETTINGSARETOOLOWEXCESS !DJUSTSYSTEMRELIEFVALVESETTINGS
HEATWILLBEGENERATED
!IRINSYSTEM %NTRAINEDAIRGENERATESHEATUNDERPRESSUREAND ,OOKFORFOAMORBUBBLESINRESERVOIR#HECKFOR
causes cavitation LEAKSONINLETSIDEOFCHARGEPUMP
)NTERNALLEAKAGE %XCESSIVEINTERNALLEAKAGEWILLOVERHEATTHE )NSTALLLOOPmUSHINGDEFEATOPTIONANDMONITORCASE
SYSTEM mOW)FCASEmOWISEXCESSIVEMOTORMAYREQUIRE
MAJORREPAIR#ONTACTYOUR3AUER $ANFOSSSERVICE
PROVIDER
790 BOMAG 008 918 12

Travel motor 18.3
Service Manual
4ROUBLESHOOTING
EXCESSIVE NOISE OR
VIBRATION
Oil level in reservoir )NSUFlCIENTHYDRAULICmUIDWILLCAUSECAVITATION &ILLRESERVOIRTOPROPERLEVEL
!IRINSYSTEM !IRBUBBLESMAYLEADTOCAVITATION ,OOKFORFOAMORBUBBLESINRESERVOIR#HECKFOR
LEAKSONINLETSIDEOFCHARGEPUMP
3HAFTCOUPLING ,OOSESHAFTCOUPLINGCREATESEXCESSNOISE 2EPLACELOOSESHAFTCOUPLING2EPLACEORREPAIR
MOTORIFSHAFTSPLINESAREWORNEXCESSIVELY
3HAFTALIGNMENT -ISALIGNEDSHAFTSCREATEEXCESSIVENOISEAND #ORRECTSHAFTMISALIGNMENT
DAMAGEMOTOR
MOTOR OPERATES
NORMALLY IN ONE
DIRECTION ONLY
#HARGEPRESSURE )FCHARGEPRESSUREISLOWINONEDIRECTIONTHE -EASURECHARGEPRESSUREINFORWARDANDREVERSE)F
LOOPmUSHINGSHUTTLESPOOLMAYBESTICKINGTO PRESSUREDROPSINONEDIRECTIONINSPECTANDREPAIR
ONESIDE LOOPmUSHINGSHUTTLESPOOL
Motor control )FCONTROLSHIFTSMOTORTOMINIMUMDISPLACEMENT -EASUREMAXIMUMANDMINIMUMSERVOPRESSURES
INONEDIRECTIONMOTORMAYNOTHAVEENOUGH TOCHECKCONTROLOPERATION2EPAIRCONTROLORCORRECT
TORQUETOOPERATE INPUTSIGNALIFNECESSARY
0RESSURECOMPENSATORCONTROL )FPRESSURECOMPENSATOROPERATESINONE #HECKBRAKEPRESSUREDEFEATSPOOL)TMAYBE
DIRECTIONONLYTHEMOTORWILLSTAYATMINIMUM STICKINGORRECEIVINGANIMPROPERSIGNAL2EPAIR
DISPLACEMENTINTHEOTHERDIRECTION SPOOLORCORRECTINPUTSIGNAL
IMPROPER OUTPUT
SPEED
Oil level in reservoir )NSUFlCIENTHYDRAULICmUIDWILLREDUCESYSTEM &ILLRESERVOIRTOPROPERLEVEL
EFlCIENCY
4HRESHOLDSETTING )MPROPERTHRESHOLDSETTINGWILLCAUSEMOTORTO #HECKTHRESHOLDSETTING2EFERTOCONTROLSERVICE
HAVEWRONGDISPLACEMENTFORGIVENSIGNAL MANUALFORADJUSTMENTPROCEDURE
0RESSURECOMPENSATORSETTING )MPROPERPRESSURECOMPENSATORSETTINGSHIFTS #HECKPRESSURECOMPENSATORSETTING!DJUSTIF
MOTORDISPLACEMENTATWRONGPRESSURE NECESSARY
#ONTROLSPOOLORPISTON 0RESSURECOMPENSATORPISTONORSPOOLSTICKING #HECKPRESSURECOMPENSATORPISTONORSPOOL2EPAIR
HOLDSMOTORATWRONGDISPLACEMENT ORREPLACEIFNEEDED
#ONTROLORIlCES "LOCKEDORRESTRICTEDORIlCECAUSESMOTORTOSHIFT 2EMOVEINSPECTANDCLEANALLORIlCES
IMPROPERLY
#ONTROLPISTON 3TICKYCONTROLPISTONCAUSESMOTORTOSHIFT #HECKCONTROLPISTONFORPROPEROPERATION2EPAIRIF
IMPROPERLY NECESSARY
#ONTROLINPUTSIGNAL )MPROPERINPUTSIGNALCAUSESMOTORTOSHIFT #ORRECTCONTROLINPUTSIGNAL
IMPROPERLY
)NTERNALLEAKAGE %XCESSINTERNALLEAKAGECAUSESLOWERCHARGE )NSTALLLOOPmUSHINGDEFEATOPTIONANDMONITORCASE
PRESSUREANDAFFECTSSYSTEMPERFORMANCE mOW)FCASEmOWISEXCESSIVEMOTORMAYREQUIRE
INCLUDINGOUTPUTSPEED MAJORREPAIR#ONTACTYOUR3AUER $ANFOSS3ERVICE
0ROVIDER
008 918 12 BOMAG 791
18.3 Travel motor
Service Manual
4ROUBLESHOOTING
LOW OUTPUT TORQUE

3YSTEMPRESSURE ,OWSYSTEMPRESSUREATMOTORREDUCESOUTPUT -EASURESYSTEMPRESSUREATTHEMOTOR)FTHE
TORQUE PRESSURELIMITERORRELIEFVALVESETTINGISLOW
INCREASESETTINGTOTHEPROPERLEVEL
#HARGEPRESSURE ,OWLOOPmUSHINGRELIEFVALVESETTINGMAYCAUSE -EASURECHARGEPRESSUREINFORWARDANDREVERSE
IMPROPERSUPPLYPRESSURETOMOTORCONTROL !DJUSTLOOPmUSHINGRELIEFVALVESETTINGIFNECESSARY
0RESSURECOMPENSATORSETTING (IGHPRESSURECOMPENSATORSETTINGCAUSES #HECKANDADJUSTPRESSURECOMPENSATORSETTING
IMPROPERMOTORDISPLACEMENTFORTORQUE
REQUIRED
#ONTROLORIlCES "LOCKEDORRESTRICTEDORIlCECAUSESMOTORTOSHIFT 2EMOVEINSPECTANDCLEANALLORIlCES
IMPROPERLY
0RESSURECOMPENSATORPISTONOR 3TICKINGPRESSURECOMPENSATORPISTONORSPOOL 2EMOVEANDINSPECTCONTROLSPOOLANDSENSING
SPOOL CAUSESCONTROLTOHOLDMOTORATMINIMUM PISTON2EPAIRORREPLACEIFNECESSARY
DISPLACEMENT
#ONTROLSPOOLORPISTON 3TICKING WAYSPOOLORCONTROLPISTONCAUSES 2EMOVEANDINSPECT WAYSPOOLANDCONTROL
MOTORTOSHIFTIMPROPERLY PISTON2EPAIRORREPLACEIFNECESSARY
4WOPOSITIONSOLENOID 4WOPOSITIONCONTROLNOTSHIFTINGMOTORTO )NSPECTSOLENOIDVALVEFORBENTSTEMORBADCOIL
MAXIMUMDISPLACEMENT 2EPAIRORREPLACEIFNECESSARY
#ONTROLINPUTSIGNAL )MPROPERCONTROLINPUTSIGNALCAUSESMOTORTO #ORRECTCONTROLINPUTSIGNAL
STAYATMINIMUMDISPLACEMENT
4HRESHOLDSETTING )MPROPERTHRESHOLDSETTINGCAUSESIMPROPER #HECKANDADJUSTTHRESHOLDSETTING
MOTORDISPLACEMENTFORTORQUEREQUIRED
)NTERNALLEAKAGE %XCESSINTERNALLEAKAGECAUSESCHARGEPRESSURE )NSTALLLOOPmUSHINGDEFEATOPTIONANDMONITORCASE
TODECAYREDUCINGOUTPUTTORQUE mOW)FCASEmOWISEXCESSIVEMOTORMAYREQUIRE
MAJORREPAIR#ONTACTYOUR3AUER $ANFOSS3ERVICE
0ROVIDER
792 BOMAG 008 918 12

Travel motor 18.3
Service Manual
!DJUSTMENTS
OVERVIEW !DJUSTCOMPONENTSOFTHE3ERIESAND3ERIES MOTORSPERFOLLOWINGPROCEDURES

WHERENECESSARYREFERTOPressure MeasurementPAGES 4FORGAUGEPORTLOCATIONS
ANDSIZES

3ETTHECHARGEPRESSURERELIEFVALVETOTHEMODELORDERCODESPECIlCATIONS)NMOST
7!2.).' APPLICATIONSTHEMOTORCHARGERELIEFVALVEISSETTOBAR;TOPSI=below the setting
4HISSERVICEPROCEDURE of the pump charge relief valveMEASUREDWITHTHEPUMPINITSNEUTRALORZERO ANGLE
MAYREQUIREDISABLINGTHE POSITION 4HISSETTINGASSUMESARESERVOIRTEMPERATUREOF²#;²&=#HARGEPRESSURE
VEHICLEMACHINERAISING ISREFERENCEDADDITIVE TOCASEPRESSURE
THEWHEELSOFFTHEGROUND
DISCONNECTINGTHEWORK Measuring charge pressure
FUNCTIONANDSOFORTH )NSTALLATOBAR;TOPSI= Series 51 charge pressure relief valve
WHILEPERFORMINGINORDER PRESSUREGAUGEINPORT-OR- Adjustment
TOPREVENTINJURYTOTHE USEWHICHEVERISATlowLOOP plug
TECHNICIANANDBYSTANDERS PRESSURE 1
1 /16
4AKETHENECESSARYSAFETY lock nut
PRECAUTIONS )NSTALLATOBAR;TOPSI=
GAUGEINPORT,OR,TOMEASURE
CASEPRESSURE
/PERATETHESYSTEMWITHTHEPRIME
MOVERATNORMALOPERATINGSPEED
P101 208E
ANDTHEPUMPATHALFSTROKEFORWARD
ORREVERSE
/LDER3ERIESAND3ERIES MOTORSMAYBEEQUIPPEDWITHANEXTERNALSCREW
ADJUSTABLECHARGEPRESSURERELIEFVALVENOTSHOWN
008 918 12 BOMAG 793
18.3 Travel motor
Service Manual
!DJUSTMENTS
OVERVIEW (continued) Adjusting charge pressure

,OOSENTHELOCKNUTUSINGA1HEXWRENCH
4URNTHEADJUSTMENTPLUGWITHALARGESCREWDRIVERORMMHEXWRENCH
7!2.).'
)NCORRECTCHARGEPRESSURE #LOCKWISEROTATIONOFTHEPLUGINCREASESTHESETTINGANDCOUNTERCLOCKWISEROTATION
SETTINGSMAYRESULTINTHE DECREASESTHESETTING4HECHARGEPRESSURESETTINGWILLBEREDUCEDORINCREASEDATARATE
INABILITYTOBUILDREQUIRED OFAPPROXIMATELYBAR;PSI=PERTURN
SYSTEMPRESSUREANDOR
INADEQUATELOOPmUSHING !FTERADJUSTINGTHEPLUGTORQUETHELOCKNUTTO.sM;LBFsFT=$ONOTOVERTORQUE
mOWS9OUMUSTMAINTAIN
THECORRECTCHARGEPRESSURE 2EMOVETHEGAUGES
UNDERALLOPERATION
CONDITIONSTOMAINTAIN 2EINSTALLTHEPORTPLUGS
PUMPPERFORMANCE
-OTORSWITHLOOPmUSHINGDEFEATEDOREQUIPPEDWITHANORIlCEDCHARGEPRESSURERELIEF
valve SEEcharge relief valve, orificed styleONPAGE DONOTREQUIREADJUSTMENT
Series 51-1 charge pressure relief valve

11/16 inch

t]
Adjustment plug
0%
794 BOMAG 008 918 12

Travel motor 18.3
Service Manual
!DJUSTMENTS
MINIMUM 4HEFACTORYSETSMINIMUMDISPLACEMENT!TAMPER RESISTANTCAPCOVERSTHEADJUSTMENT

DISPLACEMENT LIMITER SCREW
 Caution
4OAVOIDUNEXPECTEDCHANGESINOPERATINGCONDITIONSANDTOPREVENTEXTERNALLEAKAGE
TORQUETHELOCKNUT9 AFTEReveryADJUSTMENT
$ETECTCHANGESINMOTORDISPLACEMENTBYPROVIDINGACONSTANTmOWOFmUIDTOTHE
MOTORWHILEMAINTAININGTHEMOTORATMINIMUMDISPLACEMENTANDMONITORINGTHE
MOTOROUTPUTSHAFTSPEED!NINCREASEINDISPLACEMENTWILLRESULTINADECREASEINSHAFT
SPEEDWHILEADECREASEINDISPLACEMENTWILLRESULTINANINCREASEINSHAFTSPEED
7!2.).' Adjusting minimum displacement

!DJUSTMENTOFTHE 2EMOVETHETAMPERRESISTANTCAP1 FROMTHEADJUSTINGSCREW9 2EMOVING
MINIMUMDISPLACEMENT THETAMPERRESISTANTCAPDESTROYSTHELOCKINGDEVICE
LIMITERCANRESULTIN
UNDESIRABLEORUNSAFE $ISCARDTHECAP1 AFTERCOMPARINGITWITHANEWONETOMAKESURETHENEWONE
SPEEDCONDITIONS lTS
#ONSULTWITHTHE/RIGINAL
%QUIPMENT-ANUFACTURER Minimum displacement limiter
ORYOUR3AUER $ANFOSS Q120
REPRESENTATIVEBEFORE Tamper
CHANGINGTHEMINIMUM resistant
Y20
cap
DISPLACEMENTSETTING
!FTERADJUSTMENTVERIFY Y10
MINIMUMDISPLACEMENT
SETTINGBYUSINGAN
APPROPRIATETESTAPPARATUS
P101216E
(OLDADJUSTINGSCREW9 USINGAMMORMMINTERNALHEXWRENCH
,OOSENTHESEALINGLOCKNUT9 USINGA

• MMHEXWRENCHFORCMÃANDCMÃFRAMESIZEMOTORS
or
•MMHEXWRENCHFORCMÃCMÃANDCMÃFRAMESIZEMOTORS
008 918 12 BOMAG 795
18.3 Travel motor
Service Manual
!DJUSTMENTS
MINIMUM 4URNTHEADJUSTMENTSCREW9 FORTHEDESIREDDISPLACEMENTFOLLOWINGTHETABLE

DISPLACEMENT LIMITER WITHA
(continued) • MMHEXWRENCHFORCMÃANDCMÃFRAMESIZEMOTORS
or
• MMHEXWRENCHFORCMÃCMÃANDCMÃFRAMESIZEMOTORS
2OTATINGTHEADJUSTMENTSCREWCLOCKWISEINCREASESTHEMINIMUMDISPLACEMENTOFTHE
MOTORROTATINGTHEADJUSTMENTSCREWCOUNTERCLOCKWISEDECREASESIT
4HEMINIMUMDISPLACEMENTSETTINGCHANGESSEECHART FOREACHFULLREVOLUTIONOFTHE
ADJUSTMENTSCREW-AJORCHANGESINMINIMUMDISPLACEMENTSETTINGMAYREQUIREA
DIFFERENTSIZEADJUSTMENTSCREW
Adjustment screw and displacement

Approximate change in minimum
Frame Minimum displacement Screw size and length displacement per revolution of
size range cm³ [in3] mm [in] adjusting screw
cm³/rev [in3/rev]
; = -X;=
;=
; = -X;=
; = -X;=
;=
; = -X;=
; = -X;=
;=
; = -X;=
; = -X;=
;=
; = -X;=
; = -X;=
; = -X;= ;=
; = -X;=
C#AUTION !FTERADJUSTMENTTORQUETHELOCKNUTONTHEADJUSTMENTSCREWTO

$ONOTOVERTORQUELOCKNUT • .sM;LBFsFT=FORCMÃANDCMÃMOTORS
or
• .sM;LBFsFT=FORCMÃCMÃANDCMÃMOTORS
)NSTALLANEWTAMPER RESISTANTCAP
796 BOMAG 008 918 12

Travel motor 18.3
Service Manual
!DJUSTMENTS
MAXIMUM ,IMITTHEMAXIMUMDISPLACEMENTBYSETTINGTHESTROKEOFTHESERVOPISTON!STOPSCREW
DISPLACEMENT LIMITER ANDSPACERISONTHESERVOPISTONTOLIMITTHEMAXIMUMDISPLACEMENTOFTHEMOTORTO
LESSTHAN3PACERSAREAVAILABLEININCREMENTS
7!2.).' ,IMITTHEDISPLACEMENTBYUSINGSPACERSONTHEDISPLACEMENTSTOPSCREW7HEN
!DJUSTINGTHEMAXIMUM CHANGINGTHEMAXIMUMDISPLACEMENTYOUMAYNEEDADIFFERENTLENGTHSCREWTO
DISPLACEMENTLIMITERCAN ACCOMMODATETHEALTERNATESPACERS
RESULTINUNDESIRABLEOR
UNSAFESPEEDCONDITIONS $ETECTCHANGESINMOTORDISPLACEMENTBYPROVIDINGACONSTANTmOWOFmUIDTOTHE
#ONSULTWITHTHE/RIGINAL MOTORWHILEMAINTAININGTHEMOTORATMAXIMUMDISPLACEMENTANDMONITORINGTHE
%QUIPMENT-ANUFACTURER MOTOROUTPUTSHAFTSPEED
ORYOUR3AUER $ANFOSS
REPRESENTATIVEBEFORE !NINCREASEINDISPLACEMENTRESULTSINADECREASEINSHAFTSPEED!DECREASEIN
CHANGINGTHEMAXIMUM DISPLACEMENTRESULTSINANINCREASEINSHAFTSPEED
DISPLACEMENTSETTING
Series 51 motors Series 51 Maximum displacement limiter

2EMOVETHESCREWS' RETAINING G24 G24
THESERVOCOVER' USING F10* G24
• ANMMHEXWRENCHCMÃ
CMÃCMÃANDCMÃ F20* G24
G260
MOTORS
OR G36
• AMMHEXWRENCHCMÃ
G100
MOTORS
2EMOVETHESERVOCOVER' AND

/ RINGS' AND'
P101 223E
2EMOVETHEDISPLACEMENTLIMITER
SCREW& ANDSPACER& IFUSED
WITHAMMHEXWRENCHFORCMÃCMÃCMÃCMÃANDCMÃMOTORS
3AVEORIGINALSPACERREPLACINGEACHWITHTHEAPPROPRIATESPACERANDSCREWTO

ACHIEVETHEDESIREDMAXIMUMDISPLACEMENT3EETHEchart on the next page
Series 51-1 Maximum displacement limiter Series 51-1 motors

M16 2EMOVETHESCREWS-
RETAININGTHECONTROLASSEMBLYUSING
F10* M16 ANMMHEXWRENCH
F20*
2EMOVETHECONTROLASSEMBLY
Control
G36 2EMOVEINTERFACE' AND / RINGS
' ORSEALPLATE
or
G42
!DDAPPROPRIATESPACER&
ANDSCREWTOACHIEVETHEDESIRED
DISPLACEMENTSEEchart below
P101 222E
008 918 12 BOMAG 797
18.3 Travel motor
Service Manual
!DJUSTMENTS
MAXIMUM 5SINGALONGERSPACERDECREASESTHEMAXIMUMDISPLACEMENT5SINGASHORTERSPACER
DISPLACEMENT LIMITER INCREASESMAXIMUMDISPLACEMENT
(continued)
4ORQUEDISPLACEMENTLIMITERSCREW& TO
• .sM;LBFsFT=FORTHECMÃANDCMÃMOTORS
• .sM;LBFsFT=FORTHECMÃMOTOR
 Caution
$ONOTOVERTORQUESCREWS
Maximum displacement screw (F10) and spacer (F20)

% of full F10=screw
60 cm³ 80cm³ 110cm³ 160cm³ 250cm³
disp. F20=spacer
&. -X -X -X -X -X
&! &X -X -X -X -X

&! MM MM MM MM MM
&" -X -X -X -X -X

&" MM MM MM MM MM
&# -X -X -X -X -X
85
&# MM MM MM MM MM
&$ -X -X -X -X -X

&$ MM MM MM MM MM
&% M8 x 35 -X -X -X -X

&% MM MM MM MM MM
&& -X -X -X -X -X

&& MM MM MM MM MM
&' -X -X -X -X -X

&' MM MM MM MM MM
2EPLACEALL/ RINGSORSEALPLATE$ONOTDISCARDANY/ RINGUNTILYOUARECERTAINTHAT

YOUHAVETHECORRECTREPLACEMENT
)NSTALLTHE3ERIESMINIMUMANGLESERVOCOVEROR3ERIES CONTROL
)NSTALLTHESERVOCOVER' ORCONTROLSCREWS-
4ORQUETHESERVOCOVERCONTROLSCREWS- TO

• .sM;LBFsFT=FORCMÃCMÃCMÃANDCMÃMOTORSUSINGANMM
HEXWRENCH
• .sM;LBFsFT=FORCMÃMOTORUSINGAMMHEXWRENCH
 Caution
798 BOMAG 008 918 12

Travel motor 18.3
Service Manual
!DJUSTMENTS
SPEED SENSOR DIN and SAE flange units

INSTALLATION AND ,OOSENLOCKNUT
ADJUSTMENT
+EEPALLOLDPARTSUNTILYOURECEIVEANDINVENTORYNEWPARTS
Speed sensor installation

Speed sensor
4 pin turck
Air gap to be 1.52 [0.060] max.
(Approx. 1/2-1 turn of thread)
M12x1D6G thread
Keyway ref. Pin 1

16.2 power +
Pin 2
[0.64]
50.8 direction
[2.00]
61.2 Pin 4
[2.41]
Pin 3
Speed speed ground
ring
P101334E
12.7 [0.50]
flats
0USHTHE/ RINGTOWARDCONNECTORENDOFSENSORUNITSOTHATTHE/ RINGDOESNOT

CONTACTMOTORHOUSINGDURINGSTEP
Speed sensor with Turck connector Speed sensor with Packard connector
Shaft
centerline
1/2 inch
wrench flats
22°
22°
P101332Erev
Shaft
centerline 1/2 inch
wrench flats
22°
22°
008 918 12 BOMAG 799
18.3 Travel motor
Service Manual
!DJUSTMENTS
INSTALLATION 4HREADSENSOR#7 INTOMOTORHOUSINGBYHANDUNTILBOTTOMENDTOUCHESTHE

AND ADJUSTMENT SPEEDRING
(continued)
"ACKOUT##7 TURN
#ONTINUEBACKINGOUTUNTILTHEmATSARE²EITHERSIDEOFTHEMOTORSHAFTCENTERLINE
²TO²ISACMÃEPTABLE
(OLDSENSORWITHAINCHWRENCHTORQUETHELOCKNUTUSINGANINCHWRENCH

TO.sM;LBFsFT=
 Caution
$ONOTOVERTORQUELOCKNUT
Cartridge units
,OOSENLOCKNUT
0USH/ RINGTOWARDCONNECTORENDOFSENSORUNITSOTHATTHE/ RINGDOESNOTCONTACT

MOTORHOUSINGDURINGSTEP
4HREADSENSOR#7 INTOMOTORHOUSINGBYHANDUNTILBOTTOMENDTOUCHESTHESPEED

RING
"ACKOUT##7 TURNS
4URNINOROUTWHICHEVERISCLOSEST UNTILTHEORIENTATIONNOTCHIS²AWAYFROM

HOUSING
(OLDSENSORWITHAINCHWRENCHTORQUETHELOCKNUTUSINGANINCHWRENCH

TO.sM;LBFsFT=
 Caution
Cartridge model speed sensor
Orientation
NOTCH IN
;=
;=
FLATS
5.& !THREAD

3PEEDRING
Orientation !IRGAPTOBE
NOTCH MM;IN=
MAXAPPROXIMATE
3PEEDSENSOR TURNOFTHREAD 0%
800 BOMAG 008 918 12

Travel motor 18.3
Service Manual
-INORREPAIR
SHAFT SEAL SAE and DIN flanged motors

REPLACEMENT Disassembly
4HOROUGHLYCLEANALLEXTERNALSURFACESBEFOREDISASSEMBLY
Internal parts of the shaft seal

L70
L35
L40
L50
0
2EMOVETHESCREWS, RETAININGTHEmANGETOTHEMOTORHOUSINGUSINGA

• MMHEXWRENCHFORCMÃANDCMÃMOTORS
• MMHEXWRENCHFORCMÃMOTORS
2EMOVETHEmANGE, FROMTHEMOTORHOUSINGUSINGANAPPROPRIATEPULLER
0RESSOUTTHESHAFTSEAL, FROMTHEmANGEFRONTSIDE
Inspection
)NSPECTTHESHAFTSEALCAVITYINTHEmANGE
)NSPECTTHESEALINGAREAONTHESHAFTFORWEAR
Reassembly
/RIENTTHENEWSHAFTSEAL, WITHTHECUPPEDSIDEFACINGTOWARDSTHEMOTORSHAFT
BEARINGS
0RESSTHESHAFTSEAL, INTOTHEmANGEFROMTHEREARSIDE0RESSUNTILTHESHAFTSEAL

BOTTOMSOUTINTHECAVITY
2EMOVETHE/ RING,
$ISCARDTHE/ RINGAFTERMAKINGCERTAINTHATYOUHAVEACORRECTREPLACEMENT
008 918 12 BOMAG 801
18.3 Travel motor
Service Manual
-INORREPAIR
SHAFT SEAL ,UBRICATEWITHPETROLEUMJELLYANDINSTALLNEW/ RING, TOTHEGROOVEINTHE

REPLACEMENT mANGE
(continued)
)NSTALLTHEmANGE, TOTHEHOUSINGUSINGASEALPROTECTIONSLEEVEONTHESHAFT
)NSTALLTHESOCKETHEADCAPSCREWS,
4IGHTENTHESOCKETHEADCAPSCREWS, SLOWLYINACRISSCROSSPATTERNUNTILTHE

mANGEISPULLEDFULLYDOWNONTOTHEHOUSING
4ORQUETHECAPSCREWSUSINGACRISSCROSSPATTERNTO
• .sM;LBFsFT=FORCMÃANDCMÃMOTORSUSINGANMMWRENCH
• .sM;LBFsFT=FORCMÃMOTORSUSINGAMMWRENCH
 Caution
$ONOTOVERTORQUECAPSCREWS
2EMOVETHESHAFTPROTECTIONSLEEVE
802 BOMAG 008 918 12

Travel motor 18.3
Service Manual
-INORREPAIR
SHAFT SEAL Cartridge flanged motors

REPLACEMENT Disassembly
(continued) 4HOROUGHLYCLEANALLEXTERNALSURFACESBEFOREDISASSEMBLY
2EMOVETHESEALCARRIERSNAPRING, FROMTHEMOTORHOUSINGUSINGAPPROPRIATE

SNAPRINGPLIERS
#AREFULLYPULLTHESEALCARRIER, FROMTHEHOUSING
 Caution
$ONOTDAMAGETHEHOUSINGBOREORSHAFT
2EMOVETHE/ RING,# FROMTHEHOUSINGBORE
$ISCARDTHE/ RING,# AFTERINSPECTINGTHENEWONETOMAKECERTAINTHATITlTS
#AREFULLYPRESSTHESHAFTSEAL, FROMTHESEALCARRIER
$ISCARDTHESHAFTSEAL, FROMTHESEALCARRIER, AFTERMAKINGCERTAINTHATTHE

NEWONElTS
 Caution
$ONOTDAMAGETHESEALCARRIERDURINGREMOVAL
Inspection
)NSPECTTHESEALCARRIER, ANDHOUSINGBOREFORDAMAGE
)NSPECTTHESEALINGAREAONTHESHAFTFORWEAR
Common parts of a cartridge flanged motor L80
L75
L40
L50
L40
Shaft seal
L75 Seal carrier
P101225
008 918 12 BOMAG 803
18.3 Travel motor
Service Manual
-INORREPAIR
SHAFT SEAL Reassembl;y

REPLACEMENT /RIENTTHENEWSHAFTSEAL, SOTHECUPPEDSIDEFACESINWARD
(continued)
0RESSNEWSHAFTSEAL, INTOTHESEALCARRIER,
0RESSUNTILTHESHAFTSEALBOTTOMSOUTINTHECAVITY
5SINGPETROLEUMJELLYTOLUBRICATEINSTALLNEW/ RING, TOTHEGROOVEINTHE

HOUSINGBORE
5SINGASEALPROTECTIONSLEEVEONTHESHAFTPUSHTHESEALCARRIER, INTOTHE

HOUSINGBOREUNTILITCLEARSTHESNAPRINGGROOVE
)NSTALLSNAPRING, INTOTHEGROVEINTHEHOUSINGBOREUSINGTHEAPPROPRIATESNAP

RINGPLIERS
2EMOVETHESHAFTSEALPROTECTIONSLEEVE
LOOP FLUSHING Disassembly

SHUTTLE VALVE 4HOROUGHLYCLEANALLEXTERNALSURFACESBEFOREDISASSEMBLY
5SINGANINCHHEXWRENCHREMOVETHETWOHEXPLUGS' FROMTHEENDCAP
2EMOVETHE/ RINGS'! FROMTHEHEXPLUGS
Common parts of loop flushing shuttle valve
G20
G20A
K14
K16
K18
K16
G20A
G20
K14
P101226
Legend for G20

hUSEANINCHWRENCH
t.sM;LBFsFT=
804 BOMAG 008 918 12

Travel motor 18.3
Service Manual
-INORREPAIR
LOOP FLUSHING $ISCARDTHE/ RINGS'! AFTERINSPECTINGTHENEWONESTOMAKECERTAINTHEYlT

SHUTTLE VALVE
(continued) 2EMOVETHESPRINGS+ ANDSEATS+ ORSPRINGSEATASSEMBLYFROMTHECAVITY
2EMOVETHESPOOL+ FROMTHECAVITY
Inspection
)NSPECTTHESPOOL+ ANDCAVITYFORWEARORDAMAGE
#LEANTHESPOOLANDCAVITY
Reassembly
!AFTERMAKINGCERTAINTHATYOUHAVETHEEXACTREPLACEMENTPARTSREPLACEPARTSAS
NECESSARY
)NSTALLTHESPRINGSEAT+ ORSPRINGSEATASSEMBLYTOONEENDOFTHESPOOL
,UBRICATETHESPOOLWITHCLEANHYDRAULICOIL
3LIDETHELUBRICATEDSPOOLINTOTHECAVITY
)NSTALLTHEOTHERSPRINGSEAT+ ORSPRINGSEATASSEMBLYTOTHESPOOLFROMTHE

OPPOSITEEND
)NSTALLNEW/ RINGS'! TOTHEHEXPLUGS'
0LACETHE+SPRINGSINTOTHEHEXPLUGS
)NSTALLTHEHEXPLUGS
4ORQUETHEHEXPLUGSTO.sM;LBFsFT=USINGANHEXWRENCH
 Caution
$ONOTOVERTORQUEHEXPLUGS
008 918 12 BOMAG 805
18.3 Travel motor
Service Manual
-INORREPAIR
CHARGE RELIEF VALVE Overview

9OUMAYUSEONEOFTWOCHARGERELIEFVALVESON3ERIESAND3ERIES MOTORSEITHER
POPPETORORIlCED!LTERNATIVELYADEFEATPLUGMAYBLOCKTHECHARGERELIEFVALVECAVITY
Poppet style (older production)

Disassembly
,OOSENTHELOCKNUT+ USINGA1HEXWRENCH
5NSCREWTHEADJUSTMENTSCREW+ FROMTHECAVITYINTHEENDCAPUSINGASTANDARD

SCREWDRIVERORAMMWRENCH
2EMOVETHE/ RING+ FROMTHEADJUSTMENTSCREW
$ISCARDTHE/ RING+ AFTERINSPECTINGTHENEWONETOMAKECERTAINTHATITlTS
2EMOVETHESPRING+ ANDPOPPET+ FROMTHECAVITY
Inspection
)NSPECTTHEPARTSANDCAVITYFORWEARORDAMAGE
#LEANTHECAVITY
Reassembly
2EPLACEANYDAMAGEDORWORNPARTMAKINGCERTAINTHATYOUHAVETHEEXACT
REPLACEMENTPARTSBEFOREDISCARDINGTHEWORNPARTS
)NSTALLTHEPOPPET+ TOTHECAVITY

Poppet charge relief valve
)NSTALLTHESPRING+ TOTHEPOPPET K90
)NSTALLANEW/ RING+ TOTHE K10

ADJUSTMENTSCREW+
K70
)NSTALLTHEADJUSTMENTSCREWINTHE K80
CAVITY
K50
(ANDTIGHTENTHELOCKNUT+
#HECKANDADJUSTTHECHARGERELIEF
VALVETOTHEPROPERSETTING
P101 227
806 BOMAG 008 918 12

Travel motor 18.3
Service Manual
-INORREPAIR
CHARGE RELIEF VALVE Orificed style

(continued) Disassembly
2EMOVECARTRIDGE+ FROMTHECAVITYINTHEENDCAPUSINGAINCHHEXWRENCH
2EMOVE/ RING+ FROMTHECARTRIDGE
$ISCARD/ RINGAFTERINSPECTINGTHENEWONETOMAKECERTAINTHATITlTS
$ISASSEMBLECARTRIDGE+ USINGINCHANDINCHHEXWRENCHES
2EMOVEPLUG+
2EMOVE/ RING+! Orificed charge relief valve

K95
$ISCARDTHE/ RINGAFTERINSPECTING
THENEWONETOMAKECERTAINTHATIT K95A
lTS K70
K000
K80
2EMOVESPRING+ K10
2EMOVEPOPPET+
K50
Inspection
)NSPECTTHECAVITYANDPARTSFORWEAR
ORDAMAGE
P101 227
#LEANTHECAVITYANDPARTS
Reassembly
2EPLACEPARTSASNECESSARYAFTERINSPECTINGTHENEWONETOMAKECERTAINTHATEACH
lTS
$ISCARDREPLACEDPARTS
)NSTALL/ RINGS+ +! TOPLUGS+ +
2EASSEMBLETHECARTRIDGE
4ORQUEPLUG+ TO.sM;LBFsFT=USINGANHEXWRENCH
)NSTALLCARTRIDGEINTOTHECAVITY
4ORQUECARTRIDGETO.sM;LBFsFT=USINGAINCHHEXWRENCH
 Caution
$ONOTOVERTORQUECARTRIDGE
008 918 12 BOMAG 807
18.3 Travel motor
Service Manual
-INORREPAIR
CHARGE RELIEF VALVE Defeat plug

(continued) Disassembly
2EMOVEPLUG+ FROMTHECAVITYINTHEENDCAPUSINGAINCHWRENCH
2EMOVE/ RING+! FROMTHEPLUG
$ISCARD/ RING+! AFTERINSPECTINGTHENEWONETOMAKECERTAINTHATITlTS
Inspection
#LEANANDINSPECTTHECAVITY
Defeat plug
)NSPECTTHEPLUG+ K90
#LEANORREPLACETHEPLUGIF K90A

NECESSARY
Reassembly
)NSTALLANEW/ RINGTOTHEPLUG
)NSTALLTHEPLUGINTOTHECAVITY
P101 227
4ORQUEPLUG+ TO.sM;LBFsFT=USINGAINCHWRENCH
 Caution
$ONOTOVERTORQUEPLUG
808 BOMAG 008 918 12

Travel motor 18.3
Service Manual
-INORREPAIR
MAXIMUM ANGLE Disassembly

STOP - SERIES 51 4HOROUGHLYCLEANALLEXTERNALSURFACESBEFOREDISASSEMBLY
MOTORS
2EMOVETHESCREWS' RETAININGTHEMINIMUMANGLESERVOCOVERTOTHEENDCAP
USING
• ANMMHEXWRENCHFORCMÃCMÃCMÃANDCMÃMOTORS
• AMMHEXWRENCHFORCMÃMOTOR
2EMOVETHE/ RINGS'AND'
$ISCARDTHE/ RINGSAFTERINSPECTINGTHENEWONESTOMAKECERTAINTHATTHEYlT
2EMOVETHEMAXIMUMANGLESTOPSCREW& FROMTHESERVOPISTONENDUSING

• ANMMINTERNALHEXWRENCHFORCMÃMOTORS
• AMMINTERNALHEXWRENCHFORCMÃCMÃCMÃANDCMÃMOTORS
)FEQUIPPEDREMOVETHESPACER& FROMTHESERVOPISTONEND
Inspection
)NSPECTALLPARTSFORWEARORDAMAGE2EPLACEWORNORDAMAGEDPARTS
Legend
' for G24
IUSEANMMINTERNALHEXWRENCH
t.sM;LBFsFT=FORCMÃCMÃCMÃMOTORS
' for G24

IUSEAMMINTERNALHEXWRENCH
' t.sM;LBFsFT=FORCMÃMOTORS
'
for F10
IUSEANMMINTERNALHEXWRENCH
&

t.sM;LBFsFT=FORCMÃMOTORS
&
for F10
IUSEAMMINTERNALHEXWRENCH
t.sM;LBFsFT=FORCMÃCMÃCMÃCMÃ
' MOTORS
0
Reassembly
)NSTALLTHESTOPSCREWANDSPACERIFSOEQUIPPED TOTHESERVOPISTONEND
4ORQUETHESTOPSCREW& TO

• .sM;LBFsFT=FORACMÃMOTORUSINGANMMINTERNALHEXWRENCH
• .sM;LBFsFT=FORCMÃCMÃCMÃANDCMÃMOTORSUSINGA
MMINTERNALHEXWRENCH
008 918 12 BOMAG 809
18.3 Travel motor
Service Manual
-INORREPAIR
MAXIMUM ANGLE STOP - 5SINGPETROLEUMJELLYTORETAINTHEMINSTALLANEW/ RING'AND' TOTHEEND

SERIES 51 MOTORS CAP
(continued)
)NSTALLSERVOCOVERTO' THEENDCAP
)NSTALLTHESCREWSITEMS'
4ORQUETHESCREWS' TO

• .sM;LBFsFT=FORCMÃCMÃCMÃANDCMÃMOTORSUSINGANMM
INTERNALHEXWRENCH
•.sM;LBFsFT=FORCMÃMOTORSUSINGAMMINTERNALHEXWRENCH
 Caution
MAXIMUM ANGLE STOP - Disassembly

SERIES 51-1 MOTORS 2EMOVETHESCREWS- RETAININGTHECONTROLASSEMBLYUSINGANMMINTERNAL
HEXWRENCH
2EMOVETHECONTROLASSEMBLY
Series 51-1 maximum displacement limiter

M16 Legend
&
F10* IUSINGANMMINTERNALHEXWRENCH
M16 t.sM;LBFsFT=FORCMÃMOTORS
F20* &
IUSINGAMMINTERNALHEXWRENCH
Control t.sM;LBFsFT=FORCMÃANDCMÃMOTORS
G36
&
or IUSINGAMMINTERNALHEXWRENCH
G42 t.sM;LBFsFT=FORCMÃCMÃANDCMÃ
MOTORS
P101 222E
2EMOVEINTERFACE' AND/ RINGS' ORSEALPLATE
2EMOVETHESCREW& ANDSPACER& IFPRESENTUSING

sANMMINTERNALHEXWRENCHFORCMÃMOTORSAND
sAMMINTERNALHEXWRENCHFORCMÃANDCMÃMOTORS
810 BOMAG 008 918 12

Travel motor 18.3
Service Manual
-INORREPAIR
MAXIMUM ANGLE STOP - Inspection

SERIES 51-1 MOTORS )NSPECTFORANYCONTAMINANTS
(continued)
Reassembly
#LEANTHEENDCAPANDSERVOPISTONAREA
2EPLACETHESCREW& ANDSPACER& IFTHEYWEREPRESENT
4ORQUEDISPLACEMENTLIMITERSCREW& TO

• .sM;LBFsFT=FORTHECMÃANDCMÃMOTORSUSINGAMMHEXWRENCH
• .sM;LBFsFT=FORTHECMÃMOTORUSINGANMMHEXWRENCH
 Caution
$ONOTOVERTORQUESCREW
2EPLACEALL/ RINGS
$ISCARDALLPREVIOUSLYUSED/ RINGS$ONOTDISCARDANY/ RINGSUNTILYOUARECERTAIN

THATYOUHAVETHECORRECTREPLACEMENT
)NSTALLTHECONTROL
)NSTALLTHECONTROLSCREWS'
4ORQUETHECONTROLSCREWS- TO.sM;LBFsFT=USINGANMMHEXWRENCH
 Caution
$ONOTOVERTORQUESCREW
008 918 12 BOMAG 811
18.3 Travel motor
Service Manual
-INORREPAIR
MINIMUM ANGLE Disassembly

ADJUSTMENT SCREW 4HOROUGHLYCLEANALLEXTERNALSURFACESBEFOREDISASSEMBLY
2EMOVETHETAMPERRESISTANTCAP1 COVERINGTHEADJUSTMENTSCREW
$ISCARDTHECAP2EMOVINGTHECAPDESTROYSTHELOCKINGDEVICE
7!2.).' -EASURETHELENGTHOFTHESCREW9 TOASSURECORRECTREINSTALLATION

)MPROPERADJUSTMENT
OFTHEMINIMUM Minimum displacement limiter
DISPLACEMENTLIMITERCAN Q120
Tamper
RESULTINUNDESIRABLEOR resistant
UNSAFESPEEDCONDITIONS Y20
cap
#ONSULTWITHTHEORIGINAL
Y10
EQUIPMENTMANUFACTURER
ORYOUR3AUER $ANFOSS
REPRESENTATIVEBEFORE
CHANGINGTHEMINIMUM
DISPLACEMENTSETTING!FTER
ADJUSTMENTVERIFYTHE
MINIMUMDISPLACEMENT
SETTINGBYTESTINGUSINGAN
APPROPRIATETESTAPPARATUS
P101216E
,OOSENTHELOCKNUT9 ONTHEMINIMUMANGLEADJUSTMENTSCREWUSING

• AMMHEXWRENCHFORCMÃANDCMÃMOTORS
OR
• MMHEXWRENCHFORCMÃCMÃANDCMÃMOTORS
2EMOVETHEADJUSTMENTSCREW9
• USINGAMMHEXWRENCHFORCMÃANDCMÃFRAMESIZEMOTORS
OR
• MMHEXWRENCHFORCMÃCMÃANDCMÃMOTORS
Inspection
)NSPECTTHEADJUSTMENTSCREW
Reassembly
)NSTALLTHEADJUSTMENTSCREWTOTHEMOTORHOUSING
4URNTHEADJUSTMENTSCREWTHEAPPROPRIATENUMBEROFREVOLUTIONSTOSETTHE
APPROXIMATEDISPLACEMENTLIMITORPROPERLENGTH
812 BOMAG 008 918 12

Travel motor 18.3
Service Manual
-INORREPAIR
MINIMUM ANGLE #HECKTHEMINIMUMDISPLACEMENTANDRESETASREQUIRED

ADJUSTMENT SCREW
(continued) 6ERIFYMINIMUMDISPLACEMENTSETTINGBYTESTINGEITHERONANAPPROPRIATETEST
APPARATUSORINTHEVEHICLE
See Adjustments,ONPAGES 4
7HILEHOLDINGTHEADJUSTMENTSCREWTORQUETHESEALLOCKNUT9 TO

• .sM;LBFsFT=FORCMÃANDCMÃMOTORSUSINGAMMHEXWRENCH
OR
• .sM;LBFsFT=FORCMÃCMÃANDCMÃMOTORSUSINGAMMHEX
WRENCH
 Caution
008 918 12 BOMAG 813
18.3 Travel motor
Service Manual
-INORREPAIR
4-WAY VALVE AND 4-way valve disassembly

THRESHOLD SPRINGS 2EMOVESCREWS- FROMTHECONTROLUSING
• MMHEXWRENCHFORCMÃCMÃCMÃMOTORS
4-way valve and threshold springs expanded view

G110
U8**
(250)
T1** G110
T3**
G12 G30
T2**
G30 G36
U5**
G42
S10* S10 G90
(160, 250)
S20
S10*
G38
(060, 080
110) G38
G42
J30
M22
J10*
J20/S70
T7**
T8**
F32
F324
P101 240
814 BOMAG 008 918 12

Travel motor 18.3
Service Manual
-INORREPAIR
4-WAY VALVE AND 2EMOVETHECONTROLVALVEFROMTHEENDCAP

THRESHOLD SPRINGS
(continued) 2EMOVETHEINTERFACE/ RINGS''AND' ORSEALPLATE
$ISCARDTHE/ RINGSONLYAFTERMAKINGCERTAINYOUHAVETHECORRECTREPLACEMENTS
2EMOVETHEPLUGS'AND' COVERINGORIlCES44AND4USINGA

• ©INCHHEXWRENCHFOR'PLUGS
• 18INCHHEXWRENCHFOR'PLUGS
2EMOVETHE/ RINGS'!AND'! FROMPLUGS
$ISCARDTHE/ RINGSAFTERINSPECTINGTHENEWONETOMAKECERTAINTHATITlTS
2EMOVETHEORIlCES44AND4 USINGAMMHEXWRENCH
4AGTOEACHORIlCERECORDINGITSLOCATIONFORREASSEMBLY
2EMOVETHEFOUR WAYSPOOL& FROMTHE WAYVALVESLEEVE
Inspection
)NSPECTALLPARTSFORWEARORDAMAGE2EPLACEWORNORDAMAGEDPARTS
Reassembly
)NSTALLAMMSCREWINTOONEOFTHETHREADEDHOLESINTHESLEEVE
5SETHESCREWTOPULLTHESLEEVEOUTOFTHECAVITY
2EMOVETHE/ RINGS& FROMTHESLEEVE&
$ISCARDTHE/ RINGS& AFTERINSPECTINGTHENEWONESTOMAKECERTAINTHATTHEY

lT
2EMOVEORIlCES4AND4 FROMTHESLEEVE& USINGAMMINTERNALHEX

WRENCH
008 918 12 BOMAG 815
18.3 Travel motor
Service Manual
-INORREPAIR
4-WAY VALVE AND Threshold adjustment screw and springs disassembly

THRESHOLD SPRINGS 2EMOVETHRESHOLDSPRINGGUIDE* FROMTHECAVITY
(continued)
2EMOVETHETHRESHOLDSPRINGS 3
2EMOVETHETHRESHOLDSPRINGGUIDE*
Threshold springs
G12
G12A G30
G30A
T1 T3
T2
G30A
S10*
(160, 250)
S20
G30
J30
S10*
(060, 080
110)
J20
T7**
T8**
F32
F324
P101 240 0E!
)FPRESENTREMOVETHERAMPSPRINGS 3
4HEREARERAMPSPRINGSANDINTERMEDIATESPRINGGUIDESINCMÃANDCMÃMOTORS
2EMOVETHEINTERMEDIATERAMPSPRINGGUIDE3 IFPRESENT2EMOVETHEOTHER

SPRINGIFPRESENT
2EMOVETHEBOTTOMSPRINGGUIDE3
816 BOMAG 008 918 12

Travel motor 18.3
Service Manual
-INORREPAIR
4-WAY VALVE AND 4URNTHEMOTOROVERTOACCESSTHETHRESHOLDADJUSTMENTSCREW*

THRESHOLD SPRINGS
(continued) ,OOSENLOCKNUT* Adjustment screws and springs
Exploded view — common parts
,OOSENTHEMOUNTINGSLEEVE*
J70
HOLDINGTHETHRESHOLDADJUSTMENT
J60
SCREW* USINGAMMWRENCH J50
5NSCREWTHETHRESHOLDADJUSTMENT J90

SCREWASSEMBLY
J40
2EMOVETHE/ RING* FROM
THRESHOLDADJUSTMENTSCREW
$ISCARDTHE/ RINGAFTERINSPECTING

THENEWONETOMAKECERTAINTHATIT
lTS N1U5
U5**
Inspection G90
#LEANALLPARTS
S10* S10
S20
)NSPECTALLPARTS S20
JS10*
2EPLACEANYPARTASNECESSARY
DISCARDINGOLDORWORNPARTSONLY
AFTERMAKINGCERTAINYOUHAVETHE J30
CORRECTREPLACEMENTS J10*
J20/S70
Reassembly
T7**
)NSTALLNEW/ RING* ONTHRESHOLD
T8**
ADJUSTMENTSCREW
)NSTALLTHEMOUNTINGSLEEVE*
WITHTHETHRESHOLDADJUSTMENTSCREW
F324
F32
3LIDESCREW* THROUGHTHEHOLEINTHE
P101 231
FEEDBACKFORK
4ORQUETHEMOUNTINGSLEEVETO
.sM;LBFsFT=USINGAMM
WRENCH
4URNTHEMOTOROVERTOACCESSTHE WAYVALVECAVITY
5SINGAMAGNETICPROBECAREFULLYINSTALLTHERAMPSPRINGGUIDE3 IFPRESENT INTO

THECAVITY
3LIDEGUIDE3 INTOTHEENDOFTHETHRESHOLDADJUSTINGSCREW
008 918 12 BOMAG 817
18.3 Travel motor
Service Manual
-INORREPAIR
4-WAY VALVE AND )NSTALLTHERAMPSPRING3 INTOTHECAVITYSITTINGITPROPERLYONTHESPRINGGUIDE

THRESHOLD SPRINGS 3 )NSTALLTHEINTERMEDIATESPRINGGUIDEANDSECONDRAMPSPRING3 INTOTHE
(continued) CMÃANDCMÃUNITS
Ramp spring guide location
#AREFULLYINSTALLTHETHRESHOLDSPRING J70
GUIDE* ONTOTHEENDOFTHE J60
THRESHOLDADJUSTINGSCREW* USING J50
AMAGNETICPROBE
J90
4HEGUIDEMUSTSITINTHEHOLEINTHE
THRESHOLDADJUSTINGSCREW* J40
)NSTALLTHETHRESHOLDSPRING* ON

TOTHESPRINGGUIDE*
)NSTALLTHEREMAININGSPRINGGUIDE S10* S10

* ONTOTHEENDOFTHERAMP
THRESHOLDSPRING3 USINGA S20
MAGNETICPROBE S10*
J30
S10*
J20 P101 231
818 BOMAG 008 918 12

Travel motor 18.3
Service Manual
-INORREPAIR
4-WAY VALVE AND Assembling the 4-way valve

THRESHOLD SPRINGS 5SINGTHEDIAGRAMOFORIENTATIONTHATYOUPREPAREDWHENDISASSEMBLINGREASSEMBLETHE
(continued) WAYVALVEACCORDINGLYPUTTINGTHEPARTSINTHEMARKEDPLACESONTHE WAYVALVEIN
THATORDER
)NSTALLORIlCES4AND4 INAPPROPRIATECAVITIESINTHE WAYVALVESLEEVEUSINGA

MMHEXWRENCH
 Caution 4ORQUETHEORIlCESTO.sM;LBFsFT=

$ONOTOVERTORQUEORIlCES
Assembly orientation
' '
'!
'!
4
4
4
5
3
3 '!
'

' '
3 '
3

* '
'
*
'
*3
4
-
4
&
&
0
Legend for T7/T8
IUSEAMMHEX
WRENCH
FORCMÃCMÃCMÃCMÃCMÃMOTORS
t
t.sM;LBFsFT=
008 918 12 BOMAG 819
18.3 Travel motor
Service Manual
-INORREPAIR
4-WAY VALVE AND Assembling the 4-way valve (continued)

THRESHOLD SPRINGS )NSTALLNEW/ RINGS& ONTOTHE WAYVALVESLEEVE&
(continued)
,UBRICATETHESLEEVEAND/ RINGSWITHCLEANHYDRAULICOIL
Assembly orientation
' '
'!
'!
4
4
4
5
3
3 '!
'

' '
3 '
3

* '
'
*
'
*3
4
-
Legend for T1, T2, T3
4
IUSEAMMHEXWRENCH
FORCMÃCMÃCMÃCMÃ
tCMÃMOTORS
t
t.sM;LBFsFT=
&
&
0
0USHTHESLEEVE& INTOTHECAVITY
,UBRICATETHE WAYSPOOLWITHCLEANHYDRAULICOIL
)NSTALLTHE WAYSPOOLINTHECAVITYOFTHESLEEVE
)NSTALLORIlCES44AND4 INTHEAPPROPRIATECAVITIES
820 BOMAG 008 918 12

Travel motor 18.3
Service Manual
-INORREPAIR
4-WAY VALVE AND Assembling the 4-way valve (continued)

THRESHOLD SPRINGS 4ORQUETHE44AND4 ORIlCESTO.sM;LBFsFT=USINGAMMHEXWRENCH
(continued)
)NSTALLNEWRINGS'!AND'! ONTHECAVITYPLUGS'AND'
)NSTALLTHECAVITYPLUGSINTHEORIlCECAVITIES
4ORQUETHECAVITYPLUGS' TO.sM;LBFsFT=USINGA© INCHHEXWRENCH
4ORQUETHECAVITYPLUGS' TO.sM;LBFsFT=USINGA18 INCHWRENCH
5SINGPETROLEUMJELLYTORETAINITINSTALLANEWINTERFACE/ RING'
5SINGPETROLEUMJELLYTORETAINTHEMINSTALLNEWINTERFACE/ RINGS'AND'
)NSTALLTHEMOTORCONTROLANDORMULTIFUNCTIONBLOCK
)NSTALLTHESCREWS-
4ORQUETHESCREWS
• .sM;LBFsFT=USINGAMMINTERNALHEXWRENCHFORCMÃCMÃ
CMÃMOTORS
• .sM;LBFsFT=USINGAMMINTERNALHEXWRENCHFORCMÃANDCMÃ
MOTORS
 Caution
008 918 12 BOMAG 821
18.3 Travel motor
Our Products Sauer-Danfoss Mobile Power and Control Systems

/PENCIRCUITAXIALPISTONPUMPS
'EARPUMPSANDMOTORS SYSTEMSTOTHEGLOBALMOBILEMARKET
&ANDRIVESYSTEMS
#LOSEDCIRCUITAXIALPISTONPUMPS BUILDINGMATERIALHANDLINGMUNICIPALFORESTRYTURFCAREANDMANY
ANDMOTORS OTHERS
"ENTAXISMOTORS
7EOFFEROURCUSTOMERSOPTIMUMSOLUTIONSFORTHEIRNEEDSAND
(YDROSTATICTRANSMISSIONS DEVELOPNEWPRODUCTSANDSYSTEMSINCLOSECOOPERATIONAND
PARTNERSHIPWITHTHEM
4RANSITMIXERDRIVES
(YDROSTATICTRANSAXLES 3AUER $ANFOSSSPECIALIZESININTEGRATINGAFULLRANGEOFSYSTEM
COMPONENTSTOPROVIDEVEHICLEDESIGNERSWITHTHEMOSTADVANCED
%LECTROHYDRAULICS
TOTALSYSTEMDESIGN
)NTEGRATEDSYSTEMS
3AUER $ANFOSSPROVIDESCOMPREHENSIVEWORLDWIDESERVICEFORITS
PRODUCTSTHROUGHANEXTENSIVENETWORKOF'LOBAL3ERVICE0ARTNERS
0,53»'5)$% STRATEGICALLYLOCATEDINALLPARTSOFTHEWORLD
$ISPLAYS
*OYSTICKSANDCONTROLHANDLES ,OCALADDRESS
Sensors
/RBITALMOTORS
Inverters
(YDRAULICINTEGRATEDCIRCUITS()# 3AUER $ANFOSS53 #OMPANY 3AUER $ANFOSS!P3
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#ARTRIDGEVALVES !MES)!53! 0HONE
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11008567s2EV!%s.OVEMBER
822 BOMAG 008 918 12

Travel motor 18.3
Series 51 and 51-1

Bent Axis Motors
Repair Instructions
008 918 12 BOMAG 823

18.3 Travel motor
Series 51 and 51-1 Bent Axis Motors
Repair Instructions
2EVISIONS

*ANUARY - First edition AA

&RONTCOVERILLUSTRATIONS&0%
2 11009449s2EV!!s*ANUARY
824 BOMAG 008 918 12

Travel motor 18.3
Repair Instructions
Contents
INTRODUCTION /VERVIEW 4
3AFETYPRECAUTIONS 5
5NINTENDEDMACHINEMOVEMENT 5
&LAMMABLECLEANINGSOLVENTS 5
&LUIDUNDERPRESSURE 5
0ERSONALSAFETY 5
3ECTIONDIAGRAM 7
DISASSEMBLY %NDCAP
2OTATINGCOMPONENTS 9
3HAFTREMOVAL3!%OR$). 1
3HAFTREMOVAL#ARTRIDGE 11
%NDCAPDISASSEMBLY1
FRAME1
FRAME1
FRAME1
!LLFRAMESIZES1
%NDCAP14
INSPECTION 3HAFTASSEMBLY15
0ISTONRINGS1
"EARINGPLATEVALVESEGMENTANDCYLINDERBLOCK17
ASSEMBLY %NDCAPASSEMBLY1
!LLFRAMESIZES1
FRAME1
FRAME1
FRAMES
!LLFRAMESIZES1
3HAFTANDMOUNTINGmANGEASSEMBLY
3!%$).mANGE
#ARTRIDGEmANGE
#YLINDERBLOCKANDSYNCHRONIZINGSHAFT5
3YNCHRONIZINGSHAFTANDROLLERS5
#YLINDERBLOCK7
"EARINGPLATEANDVALVESEGMENT9
"EARINGPLATE9
%NDCAPINSTALLATION
11009449s2EV!!s*ANUARY 3
008 918 12 BOMAG 825
18.3 Travel motor
Repair Instructions
Introduction
OVERVIEW 4HISMANUALDETAILSREPAIRPROCEDURESFOR3ERIESBENTAXISMOTORS4HESEINCLUDETHE
COMPLETEDISASSEMBLYINSPECTIONANDREASSEMBLYOFTHEUNIT7HEREREWORKOFWORNOR
DAMAGEDCOMPONENTSISPOSSIBLESPECIlCATIONSAREGIVENTOENSURETHESEPARTSMEET
FACTORYTOLERANCES/NLY3AUER $ANFOSS'LOBAL3ERVICE0ARTNERSMAYPERFORMMAJOR
REPAIRS3AUER $ANFOSSTRAINS'LOBAL3ERVICE0ARTNERSTOPERFORMMAJORREPAIRSAND
CERTIlESTHEIRFACILITIESONAREGULARBASIS
W 7ARNING
5SEOFCOMPONENTSTHATDONOTCOMPLYWITHREWORKSPECIlCATIONSMAYRESULTINLOSSOF
PERFORMANCEWHICHMAYCONSTITUTEASAFETYHAZARD$ONOTREUSECOMPONENTSTHATDONT
COMPLYTOGIVENSPECIlCATIONSREPLACEWITHGENUINE3AUER $ANFOSSSERVICEPARTS
-INORREPAIRPROCEDURESADJUSTMENTSANDTROUBLESHOOTINGINFORMATIONAREGIVENINTHE

Series 51 and 51-1 Service Manual11008567-INORREPAIRSINCLUDESERVICEOPERATIONS
YOUCANPERFORMWITHOUTREMOVINGTHEUNITSENDCAP2EMOVALOFTHEENDCAPVOIDSYOUR
WARRANTY
GENERAL INSTRUCTIONS &OLLOWTHESEGENERALPROCEDURESWHENREPAIRING3ERIESBENTAXISVARIABLE

DISPLACEMENTCLOSEDCIRCUITMOTORS
w Remove the unit

e Keep it clean
TOAVOIDCONTAMINATIONOFTHESYSTEMPORTS#LEANINGPARTSWITHACLEANSOLVENTWASH
!SWITHANYPRECISIONEQUIPMENTYOUMUSTKEEPALLPARTSFREEOFFOREIGNMATERIALSAND
CHEMICALS0ROTECTALLEXPOSEDSEALINGSURFACESANDOPENCAVITIESFROMDAMAGEAND
FOREIGNMATERIAL)FLEFTUNATTENDEDCOVERTHEPUMPWITHAPROTECTIVELAYEROFPLASTIC
l Lubricate moving parts

$URINGASSEMBLYCOATALLMOVINGPARTSWITHCLEANHYDRAULICOIL4HISASSURESTHATTHESE
PARTSARELUBRICATEDDURINGSTART UP

3AUER $ANFOSSRECOMMENDSYOUREPLACEALL/ RINGSGASKETSANDSEALS,UBRICATE/ RINGS
WITHCLEANPETROLEUMJELLYPRIORTOASSEMBLY'REASEMUSTBESOLUBLEINHYDRAULICmUID
t Secure the unit

&ORMAJORREPAIRPLACETHEUNITINASTABLEPOSITIONWITHTHESHAFTPOINTINGDOWNWARD
3ECURETHEPUMPWHILEREMOVINGANDTORQUINGTHEENDCAPBOLTS
826 BOMAG 008 918 12

Travel motor 18.3
Repair Instructions
Introduction

YOURSELFANDOTHERSFROMINJURY4AKETHEFOLLOWINGGENERALPRECAUTIONSWHENEVERSERVICING
AHYDRAULICSYSTEM

W Warning

W Warning

W Warning
Personal safety
W Warning
TIMES
008 918 12 BOMAG 827
18.3 Travel motor
Repair Instructions
Introduction

SAUER-DANFOSS
PRODUCTORPROPERTY
 2EUSABLEPART
 #LEANAREAORPART
 Superseded – parts are not
SLEEVE
 4ORXHEAD
828 BOMAG 008 918 12

Travel motor 18.3
Repair Instructions
Introduction
SECTION DIAGRAM Series 51 bent axis variable motor
Multi-function
Pressure compensator Minimum displacement
block
override limiter
Control Valve segment

(hydraulic proportional) Motor output shaft
Bearing plate
Tapered roller bearings
4-way valve
and sleeve
Control
springs
Synchronizing
Piston
shaft and rollers
End cap Housing
Servo piston
Charge pressure
relief valve
Minimum angle
servo cover P104 085
008 918 12 BOMAG 829
18.3 Travel motor
Repair Instructions
$ISASSEMBLY
ENDCAP &OLLOWINGPROCEDURESINTHESeries 51 and 51-1 Service Manual110085672EMOVETHE

CONTROLANDMULTI FUNCTIONBLOCKIFINSTALLED 2EMOVETHE WAYVALVESPOOLANDSLEEVE
IFINSTALLED 2EMOVETHETHRESHOLDSPRINGSANDGUIDES2EMOVETHECONTROLSPRINGSIF
INSTALLED 2EMOVETHERAMPSPRINGSANDGUIDESIFINSTALLED 2EMOVETHEMINIMUMANGLE
SERVOCOVERFROMTHEMOTOR2EMOVETHELOOP mUSHINGVALVEANDCHARGERELIEFVALVE
2EMOVETHESCREWS'AND' RETAININGTHEENDCAPASSEMBLYTOTHEMOTOR

HOUSING
2EMOVETHEENDCAPASSEMBLY
2EMOVETHEGASKET' DISCARD
2EMOVETHEALIGNMENTPINS"
Endcap and rotating components

B05
C10
Note orientation of segment with end cap and housing
Note orientation of pins

C20
Note orientation of rollers with synchronizing shaft (recess faces the centerline of the shaft)
(later version rollers do not have recess and can be installed either way), and synchronizing
shaft with cylinder block and output shaft, small end into shaft and big end into block.
Note locations of longer and
C05 G32
shorter screws
060 and 080: 8mm

G34
110 and 160: 10mm
250: 12mm
End cap assembly

Q20
(side port configuration shown)
B50
G60
B50
P104 086
SAE flange version Cartridge version
830 BOMAG 008 918 12

Travel motor 18.3
Repair Instructions
$ISASSEMBLY
ROTATING COMPONENTS 2EMOVETHEVALVESEGMENT" ANDSETASIDE
2EMOVETHEBEARINGPLATE# ANDALIGNMENTPINS#
2EMOVETHECYLINDERBLOCK# ANDSETASIDE"ECAREFULNOTTOSCRATCHTHERUNNING

SURFACEOFTHEBLOCK
2EMOVETHESYNCHRONIZINGSHAFTASSEMBLY# WITHROLLERSANDPINS
Endcap and rotating components
B05
C10
Note orientation of segment with end cap and housing
Note orientation of pins

C20
Note orientation of rollers with synchronizing shaft (recess faces the centerline of the shaft)
(later version rollers do not have recess and can be installed either way), and synchronizing
shaft with cylinder block and output shaft, small end into shaft and big end into block.
Note locations of longer and
C05 G32
shorter screws
060 and 080: 8mm

G34
110 and 160: 10mm
250: 12mm
End cap assembly

Q20
(side port configuration shown)
B50
G60
B50
P104 086
SAE flange version Cartridge version
008 918 12 BOMAG 831
18.3 Travel motor
Repair Instructions
$ISASSEMBLY
SHAFT REMOVAL (SAE OR Shaft assembly SAE or DIN flange version 2EMOVESCREWS, RETAININGTHE
DIN) MOUNTINGmANGE, TOTHEMAIN
HOUSING"
2EMOVETHEMOUNTINGmANGEUSINGA
B10 SUITABLEPULLER
2EMOVETHE/ RING, DISCARD
2EMOVETHESHAFTSEAL, FROMTHE

mANGEDISCARD
0RESSSHAFTASSEMBLYOUTOFMAIN
HOUSINGTAKINGCARENOTTODAMAGE
THESHAFTANDSPEEDSENSORRINGIF
INSTALLED
Shaft assembly
C Caution
$ONOTDAMAGEPISTONSOCKETS
L50
L40
P104 087
L35
L70
060 and 080: 6mm
110: 8mm
160: 10mm
250: 12mm
832 BOMAG 008 918 12

Travel motor 18.3
Repair Instructions
$ISASSEMBLY
SHAFT REMOVAL 2EMOVERETAININGRING,

(CARTRIDGE)
2EMOVESEALCARRIER,
2EMOVESHAFTSEAL, DISCARD
2EMOVERETAININGRING, FORTHESHAFTSEALCARRIER, FROMTHEBEARING

HOUSING,
2EMOVETHESCREWS, RETAININGTHEBEARINGHOUSING, TOTHEMAINHOUSING

"
3EPARATETHEBEARINGHOUSINGFROMTHEMAINHOUSING"
2EMOVETHERETAININGRING, IFPRESENT
2EMOVESPACERRING,
2EMOVE/ RINGS,AND,ORGASKET, DISCARD
0RESSSHAFTASSEMBLYOUTOFBEARINGHOUSINGTAKINGCARETONOTDAMAGETHESHAFT

PISTONSOCKETSANDSPEEDSENSORRINGIFINSTALLED
Shaft assembly, cartridge version

Prior to
N94-42
L80
L35
N94-42
L85 thru L40
L90 N98-32 L50
L95 L80
B80
L35 L750
L95
L81
L70
L82
L35 060 and 080: 6mm

N98-33 110: 8mm
and beyond 160: 10mm
250: 12mm
L95
L81
L90
L85 P104 088

B10
008 918 12 BOMAG 833
18.3 Travel motor
Repair Instructions
$ISASSEMBLY
ENDCAP DISASSEMBLY 060 frame

2EMOVEENDCAPPLUG' 2EMOVE/ RING'! FROMPLUGDISCARD
2EMOVELOCKSCREWS& FROMSERVOPISTON&
2EMOVECONE POINTSETSCREWS& FROMSERVOPISTON
2EMOVEFEEDBACKFORK& THROUGHTHEHOLEINTHEENDCAP
2EMOVETHESETTINGLUG& FROMINSIDEOFENDCAP
End cap components
3 mm (060)
3 mm (060)
F30
F28 (060)
F26 F10
F11 F12
060: 3/8 inch
G80 080: 9/16 inch
G80A
F26
G10
F24 F28
(060)
F24
(080)
F10 F12
F11
End cap
(typical for 060 and 080 frame sizes)
F26 axial port style shown
F28
P104 089
5 mm (080)
080 frame
2EMOVEENDCAPPLUG'
2EMOVELOCKSCREW&
2EMOVECONE POINTSETSCREW&
2EMOVEFEEDBACKFORKSETTINGLUG& THROUGHHOLEINENDCAP
834 BOMAG 008 918 12

Travel motor 18.3
Repair Instructions
$ISASSEMBLY
ENDCAP DISASSEMBLY 110 - 250 frame

(continued) 2EMOVELOCKSCREW&
2EMOVECONE POINTSETSCREW&
2EMOVEFEEDBACKFORKSETTINGLUG& FROMINSIDEOFENDCAP
Disassembling the end cap
F10 F12
5 mm (110, 160, 250)
F11
F26
G10
F28
F24
(110, 160, 250)
P104 090
End cap
(typical for 110, 160, and 250 frame sizes)
side port style shown
All frame sizes

2EMOVESERVOPISTON& FROMENDCAP& GLIDERINGENDlRST
)NSPECTGLIDERING& FORDAMAGEORWEAR
2EMOVEGLIDERING& FROMSERVOPISTONIFYOUNEEDTOREPLACEIT
2EMOVE/ RING& FROMSERVOPISTONDISCARD
)NSPECTSERVOPISTONBOREINENDCAPFORDAMAGEORWEAR
008 918 12 BOMAG 835
18.3 Travel motor
Repair Instructions
$ISASSEMBLY
ENDCAP DISASSEMBLY 51-1 Endcap

(continued) 2EMOVESERVOPISTON& FROMENDCAP' GLIDERINGENDlRST
)NSPECTGLIDERING& FORDAMAGEORWEAR
2EMOVEGLIDERING& FROMSERVOPISTONIFYOUNEEDTOREPLACEIT
2EMOVE/ RING& FROMSERVOPISTONDISCARD
)NSPECTSERVOPISTONBOREINENDCAPFORDAMAGEORWEAR
Disassembling the end cap
F11
F10
F12 Servo piston
G10 End cap assembly
P106 541E
836 BOMAG 008 918 12

Travel motor 18.3
Repair Instructions
Inspection
SHAFT ASSEMBLY #HECKTHESEALAREAOFTHESHAFT, Shaft assembly

FORDAMAGEORWEAR
C Caution
4HEOPTIONALMAGNETIC #HECKTHEOUTPUTSPLINESFORDAMAGE
SPEEDSENSORRINGIS ORWEAR
PRESSEDONTOAMACHINED
SURFACEOFTHESHAFT4AKE )NSPECTSYNCHRONIZINGSHAFTRACEWAYS
CARENOTTODAMAGETHE FORWEAR
SENSORRING
)NSPECTSHAFTBEARINGSFORWEARAND L1
ROUGHNESS
#HECKTHATTHEBEARINGRETAININGNUT
ISlRMLYSTAKEDTOTHEOUTPUTSHAFT
ANDTHATNONOTICEABLELOOSENESSIS P104 091
PRESENTINTHEBEARINGS
#HECKTHEPISTONASSEMBLIES, FORDAMAGEORWEAR
"EARINGSANDPISTONSARENOTINDIVIDUALLYSERVICEABLE2EPLACETHEENTIRESHAFTASSEMBLYIF
ANYCOMPONENTSAREDAMAGEDORWORN
008 918 12 BOMAG 837
18.3 Travel motor
Repair Instructions
Inspection
PISTON RINGS 5SEASMALLPAIROFRETAININGRINGPLIERSTOSPREADANDREMOVETHEPISTONRINGS,

FROMTHEPISTONS$ISCARDTHERINGS
)NSTALLNEWPISTONRINGS, %NSURETHESPHERICALSURFACECONFORMSTOTHESHAPEOF

THEPISTON!RADIALIDENTIlCATIONMARKAPPEARSONTHEOUTERSIDEOFTHEPISTONRINGS
$ONOTLETTHEENDSOFEACHPISTONRINGOVERLAPEACHOTHER
Spherical piston rings

L230
Split line
Radial identification mark located

on this side of piston ring
The spherical surface of the piston ring must

conform to the spherical shape of the piston
P104 092
838 BOMAG 008 918 12

Travel motor 18.3
Repair Instructions
Inspection
BEARING PLATE, )NSPECTTHEBRONZESURFACEOFTHEBEARINGPLATE# FORDAMAGEANDEXCESSIVEWEAR

VALVE SEGMENT, AND 3EALINGSURFACEMUSTBEFREEFROMSCRATCHESANDNICKS4HELOCATINGPINHOLESMUST
CYLINDER BLOCK NOTBEWORN2EPLACEIFNECESSARY
Bearing plate Valve segment

C10 B05
P104 093
P106 350E
)NSPECTTHEVALVESEGMENT" FORDAMAGEORWEARONTHESEALINGSURFACES
)NSPECTTHESPINDLEFORWEAR
%NSURETHESPINDLEISLOCATEDCORRECTLYINTHEVALVESEGMENTBYMEASURINGDISTANCE
A)FTHISDIMENSIONISNOTWITHINTHERANGESHOWNINTHETABLEITINDICATESTHATTHE
SPINDLEHASMOVEDINTHEVALVESEGMENT2EPLACEIT
Valve segment Spindle location distance

Frame size Distance A MM;IN=
A
¼;¼=
¼;¼=
P104 094
¼;¼=
¼;¼=
¼;¼=
$ONOTLAPTHEVALVESEGMENTTOREMOVESCRATCHES4HEHARDTREATEDSURFACEISTHINAND
LAPPINGMAYREMOVETHISSURFACE2EMOVINGTHESPINDLELOOSENSITSTIGHTPRESSlTAND
ALLOWSITTOMOVE
)NSPECTCYLINDERBLOCKASSEMBLYFOR Cylinder block bearing

WEARORDAMAGE)FBEARINGISWORN
ORDAMAGEDREPLACETHECOMPLETE Bearing
BLOCKASSEMBLY4HEBEARINGISNOT
AVAILABLEASASEPARATEPART
4HEPISTONBORESMUSTBESMOOTH
4HEBEARINGPLATESURFACEMUSTBE
FREEFROMSCRATCHESORNICKS4HE P104 095
HOLESFORTHEBEARINGPLATELOCATING
PINSMUSTBEFREEFROMWEAR4HE
RACESFORTHESYNCHRONIZINGSHAFT
ROLLERSMUSTALSOBEFREEFROMWEAR
008 918 12 BOMAG 839
18.3 Travel motor
Repair Instructions
!SSEMBLY
ENDCAP ASSEMBLY All frame sizes

#AREFULLYINSTALLANEW/ RING& ANDGLIDERING& ONTHESERVOPISTON&
,UBRICATETHEGLIDERING
)NSTALLTHESERVOPISTONINTOTHEENDCAP'
4HEENDOFTHESERVOPISTONWITHTHEGLIDERINGISOPPOSITETHEMULTI FUNCTIONBLOCK
CONTROLMOUNTINGSURFACEOFTHEENDCAP
060 frame
)NSTALLTHESETTINGLUG& INTOTHESERVOPISTON& FROMINSIDEOFENDCAP
5SINGAMMINTERNALHEXWRENCHINSTALLTHECONE POINTSETSCREW& SOTHATITS

POINTENTERSTHEGROOVEINTHESETTINGLUGANDTORQUETO.sM;LBFsIN=
)NSTALLTHELOCKSCREW&
5SINGAMMHEXWRENCHTORQUETHELOCKSCREW& TO.sM;LBFsIN=
)NSTALLTHEFEEDBACKFORK& INTOTHESERVOPISTONTHROUGHTHEHOLEINTHEENDCAP
4HECONTACTPADSONTHEFORKMUSTFACETOWARDTHEMULTI FUNCTIONBLOCKCONTROLENDOF
THEENDCAP
5SINGAMMINTERNALHEXWRENCHINSTALLTHEOTHERCONE POINTSETSCREW& SOTHAT

ITSPOINTENTERSTHEGROOVEINTHEFEEDBACKFORK& $ONOTTIGHTENTHESETSCREW
YET3EEPAGEFORlNALASSEMBLYINSTRUCTIONS
,UBRICATEANDINSTALLANEW/ RING'! ONTHEENDCAPPLUG' )NSTALLTHEPLUG
5SINGAININTERNALHEXWRENCHTORQUETHEENDCAPPLUGTO.sM;LBFsFT=
080 frame
)NSTALLFEEDBACKFORKSETTINGLUG& INTOTHESERVOPISTONTHROUGHTHEHOLEINTHE
ENDCAP
4HEOFFSETOFTHEFORKMUSTBEFACINGAWAYFROMTHEMULTI FUNCTIONBLOCKCONTROLENDOF
THEENDCAP
)NSTALLTHECONE POINTSETSCREW& SOTHATITSPOINTENTERSTHEGROOVEINTHE

FEEDBACKFORK& SETTINGLUG& $ONOTTIGHTENTHESETSCREWYET3EEPAGE
FORlNALASSEMBLYINSTRUCTIONS
)NSTALLTHEENDCAPPLUG'
5SINGAININTERNALHEXWRENCHTORQUETHEENDCAPPLUG' TO.sM

;LBFsFT=
840 BOMAG 008 918 12

Travel motor 18.3
Repair Instructions
!SSEMBLY
ENDCAP ASSEMBLY
(continued) Setting lugs
$$ +(!*-!* /(+#!#+! $$

F11 0$
#0!%
F30
F26 (060) 0$#0!%
F10
F12
!%h
+#*!+%*!&%
Groove #&"&%*(&#
0$

#)0* G80
F24 F26
G80A
(060)
F28 G10
End cap (axial port style shown)
F24
+(!*-!* /(+#!#+! (080)
+#*!+%*!&%
#&"&%*(&#
Groove
F10
F11 F12
F26
$$
P104 096
008 918 12 BOMAG 841
18.3 Travel motor
Repair Instructions
!SSEMBLY
ENDCAP ASSEMBLY 110-250 frames

(continued) )NSTALLFEEDBACKFORK& SETTINGLUGINTOTHESERVOPISTONFROMINSIDEOFTHE
ENDCAP
4HEOFFSETOFTHEFORKMUSTBEAWAYFROMTHEMULTI FUNCTIONBLOCKCONTROLENDOFTHE
ENDCAP
)NSTALLTHECONE POINTSETSCREW& SOTHATITSPOINTENTERSTHEGROOVEINTHE

FEEDBACKFORK& SETTINGLUG$ONOTTIGHTENTHESETSCREWYET3EEPAGEFOR
lNALASSEMBLYINSTRUCTIONS
Cone-point screw and feedback fork
Lubricate with hydraulic fluid
F10
F11 F12
Multi-function
Groove block/control
F26
G10
F24
(110, 160, 250)
End cap (side port style shown)

typical for 110, 160, and 250 frame sizes P104 097
842 BOMAG 008 918 12

Travel motor 18.3
Repair Instructions
!SSEMBLY
ENDCAP ASSEMBLY All frame sizes

(continued) 0OSITIONFEEDBACKFORK& CC ORFEEDBACKFORKSETTINGLUGCC CC
PERPENDICULARTOTHESETTINGPISTONFORPROPERCONTROLSPRINGOPERATION
)NSERTAMM;IN=DIAMETERRODWITHTHEENDMACHINEDPERPENDICULARTOITS

AXISINTOTHEVALVESLEEVEBOREINTHEENDCAP!LIGNTHEFORKWHILETIGHTENINGTHE
CONE POINTSETSCREW&
5SINGAORMMINTERNALHEXWRENCHTORQUETHECONE POINTSETSCREWTO.sM

;LBFsIN=
)NSTALLANDTORQUETHELOCKSCREW& TO

• .sM;LBFsIN=USINGAMMINTERNALHEXWRENCHFORACCMOTOR
• .sM;LBFsFT=USINGAMMINTERNALHEXWRENCHFORTHECCTHROUGHCC
MOTORS
Cone-point set screws

3 mm

]
F28
F26
3 mm

060 frame size
F28
6 mm

]
F26
6 mm

080, 110, 160, 250, frame sizes
008 918 12 BOMAG 843
18.3 Travel motor
Repair Instructions
!SSEMBLY
SHAFT AND MOUNTING SAE/DIN flange

FLANGE ASSEMBLY 3UPPORTTHEMAINHOUSING" SOTHEBEARINGBOREISVERTICAL
0RESSSHAFTASSEMBLY, INTOMAINHOUSING
)NSTALLNEW/ RING, ONMOUNTINGmANGE,
)NSTALLNEWSEAL, INmANGE
#OVERTHESHAFTSPLINESWITHANINSTALLATIONSLEEVETOPROTECTTHESEALDURING
ASSEMBLY)NSTALLmANGEASSEMBLY,
)NSTALLSCREWS,
4ORQUESCREWS, TOVALUESHOWNINTHEDIAGRAM
SAE/DIN Flange version bearing bore and housing

#"" L70 ,"
!,(]
"" ,"
!,(]
"" ,"!,(]
""
,"!,(]

)& ('!! %+ (&'
L35
L50
L1
B10
B10
19°
$)' #')%%$&( #%&''

' * +

844 BOMAG 008 918 12

Travel motor 18.3
Repair Instructions
!SSEMBLY
SHAFT AND MOUNTING Cartridge flange

FLANGE ASSEMBLY )NSTALLTHEINNERRETAININGRING, FORTHESHAFTSEALCARRIERINTHEBEARINGHOUSING
(continued)
0RESSSHAFTASSEMBLYINTOBEARINGHOUSING,
C Caution )NSTALLSPACERRING, C

$ONOTDAMAGETHEPISTON
SOCKETSORSHAFTSEAL )NSTALLTHEENDOFTHESPACERWITHTHELARGERINSIDEDIAMETERNEXTTOTHEINNERSHAFT
SURFACE BEARINGCUP
)NSTALLRETAININGRING,
!LIGNENDSOFTHERETAININGRINGBETWEENTHETWOBOLTHOLESTOALLOWCLEARANCEFOR
SPEEDSENSOR
Speed sensors
speed sensor
Notch
Locking nut
Spacer ring
Sensor
Axial notch on speed sensor
Retaining-ring (L81)
P104 100
008 918 12 BOMAG 845
18.3 Travel motor
Repair Instructions
!SSEMBLY
SHAFT AND MOUNTING )NSTALL/ RINGS, AND, ORGASKET,

FLANGE ASSEMBLY
(continued) )NSTALLMAINHOUSING" %NSURESNAPRING, ENDSALIGNWITHSPEEDSENSORPORT
)NSTALLSCREWS,
4ORQUESCREWS
• .sM;LBFsFT=FORCCANDCC
• .sM;LBFsFT=FORCC
• .sM;LBFsFT=FORCC
Cartridge version bearing bore and housing
Before N94-42
N94-42
through L80
L35
N98-32
L85
O
L40
L90 L50
L95 L80
B80
L35 L750
L95
O
L81
N98-33
and beyond
L70
L82
060 and 080: 6mm
110: 8mm
L35 160: 10mm
250: 12mm
L95
P104 101
L81
L90
B10 L85
846 BOMAG 008 918 12

Travel motor 18.3
Repair Instructions
!SSEMBLY
CYLINDER BLOCK AND Synchronizing shaft and rollers

SYNCHRONIZING SHAFT 5SINGPETROLEUMJELLYTORETAINITINSTALLTHElRSTSYNCHRONIZINGSHAFTSUPPORTPIN
# INTOTHERECESSINTHECYLINDERBLOCK
5SINGPETROLEUMJELLYTORETAINTHEMINSTALLTHESYNCHRONIZINGSHAFTROLLERS# ON

THEJOURNALSOFTHESYNCHRONIZINGSHAFT#
0OSITIONTHERECESSONEACHROLLERTOFACETHECENTERLINEOFTHESYNCHRONIZINGSHAFT
-OTORSBUILTAFTERSERIALNUMBER. 88888HAVESYMMETRICALROLLERS
3EESERVICEBULLETINSB-2001-015
0OSITIONEACHROLLERWITHITSOUTSIDEEDGEmUSHWITHTHEENDOFTHESYNCHRONIZING
SHAFTJOURNAL
Cylinder block and sync-shaft
Cylinder
block
C40
C50
C60
Q20
C60 C50
C40
P104 102
008 918 12 BOMAG 847
18.3 Travel motor
Repair Instructions
!SSEMBLY
MOTOR ASSEMBLY Synchronizing shaft and rollers (continued)

(continued) )NSTALLTHESECOND#SYNCHRONIZINGSHAFTSUPPORTPININTOTHEMOTORSHAFT
ASSEMBLY
)NSTALLTHESYNCHRONIZINGSHAFTANDROLLERSINTOTHEMOTORSHAFT
4HECYLINDERBLOCKENDOFTHESHAFTISALARGERDIAMETERTHANTHEMOTORSHAFTENDONALL
FRAMESIZES4HEROLLERSMUSTENTERTHERACESINTHEMOTORSHAFTANDTHERECESSINTHEEND
OFTHESYNCHRONIZINGSHAFTMUSTENGAGETHESUPPORTPIN
4IPANDROTATETHESYNCHRONIZINGSHAFTINALLDIRECTIONSTOCHECKFORBINDING4HE
SYNCHRONIZINGSHAFTROLLERSMUSTMOVEFREELYINTHERACESINTHEMOTORSHAFT
Cylinder block and sync-shaft
Cylinder
block
C40
C50
C60
Q20
C60 C50
C40
P104 102
848 BOMAG 008 918 12

Travel motor 18.3
Repair Instructions
!SSEMBLY
CYLINDER BLOCK AND Cylinder block Pistons

SYNCHRONIZING SHAFT ,UBRICATETHEPISTONSANDSYNC SHAFT Position the motor shaft
(continued) ANDROLLERSWITHCLEANHYDRAULICOIL as shown prior to installing
the cylinder block
ANDROTATETHESHAFTTOTHEPOSITION
SHOWNINTHEILLUSTRATION
4IPTHEPISTONSCLOSESTTOTHE
MINIMUMANGLESTOPOUTTOWARDTHE
HOUSING
4IPTHEREMAININGPISTONSFORWARD
TOWARDTHELOWESTPARTOFTHEEND
CAPMOUNTINGSURFACE
4IPTHESYNCHRONIZINGSHAFTFORWARD
TOWARDTHELOWESTPARTOFTHEEND
CAPMOUNTINGSURFACE
P104 103
0OSITIONTHECYLINDERBLOCKSOONE (Cylinder block not installed)
SYNCHRONIZINGSHAFTROLLERRACEWAYIS
ALIGNEDBETWEENTWOPISTONS
)NSTALLTHECYLINDERBLOCKANDITSSUPPORTPIN# ONTOTHEPISTONSAND

SYNCHRONIZINGSHAFT
4HESYNCHRONIZINGSHAFTROLLERS# ENTERTHEIRRACESINTHEBLOCKWHILEEACHPISTON

ENTERSITSCORRESPONDINGBOREINTHEBLOCK
)NSERTABRASSRODTHROUGHTHECYLINDERBLOCKKIDNEYSTOGUIDETHEPISTONSINTO
POSITION
3TARTWITHTHEFOUR PISTONSCLOSESTTOTHELOWESTPARTOFTHEENDCAPMOUNTING

SURFACE
!FTERTHEPISTONSENTERTHEIRBORESTILTTHECYLINDERBLOCKSOTHESYNCHRONIZINGSHAFT

ROLLERS# ENTERTHEIRRACESINTHECYLINDERBLOCKANDTHENEXTTWOPISTONSENTER
THEIRBORE
4HESUPPORTPIN# ENTERSITSRECESSINTHESYNCHRONIZINGSHAFT#
,IFTTHECYLINDERBLOCKSLIGHTLY
'UIDETHEREMAININGPISTONSINTOTHEIRBORES
!FTERTHELASTPISTONISINPOSITIONCHECKTHEPOSITIONOFTHEROLLERSCLOSESTTOTHE

MINIMUMANGLESTOP
-AINTAINANINWARDFORCEONTHECYLINDERBLOCK
#AREFULLYPUSHITTOWARDTHEHIGHESTPARTOFTHEENDCAPMOUNTINGSURFACE
008 918 12 BOMAG 849
18.3 Travel motor
Repair Instructions
!SSEMBLY
CYLINDER BLOCK AND #HECKTHATALLOFTHESYNCHRONIZINGSHAFTROLLERSAREINPOSITION

SYNCHRONIZING SHAFT
(continued) )FTHECYLINDERBLOCKISPROPERLYINSTALLEDTHEREWILLBEVERYLITTLEROTATIONALFREE PLAY
BETWEENTHECYLINDERBLOCKANDTHEMOTORSHAFT
Lubricate the pistons and cylinder

Cylinder block block bores with hydraulic oil
Cylinder block
Pistons
P104 104
SAE flange version shown
cartridge version similar
850 BOMAG 008 918 12

Travel motor 18.3
Repair Instructions
!SSEMBLY
BEARING PLATE AND Bearing plate

VALVE SEGMENT )NSTALLTHEBEARINGPLATELOCATINGPINS# INTOTHECYLINDERBLOCK
)NSTALLTHELONGERENDOFEACHSHOULDEREDPININTOTHEBLOCK
)NSTALLTHEBEARINGPLATE# ONTHECYLINDERBLOCKWITHSTEELSIDEFACINGTHEBLOCK
,UBRICATETHEBRONZESIDEOFTHEPLATEWITHHYDRAULICOIL
)NSTALLTHEENDCAPALIGNMENTPINS" )NSTALLANEWGASKET'
,OCATETHECYLINDERBLOCKINTHEAPPROXIMATECENTEROFTHEHOUSINGOPENING
4IPTHEHOUSINGUNTILTHEENDCAPMOUNTINGSURFACEISLEVELTOHELPKEEPTHEBLOCK
CENTERED$ONOTALLOWPISTONSORSYNCHRONIZINGSHAFTROLLERSTOFALLOUTOFPOSITION
5SINGPETROLEUMJELLYINSTALLTHEVALVESEGMENT" INTOTHEENDCAPSOTHE

SEGMENTSPINDLEENGAGESTHESETTINGLUGINTHESERVOPISTON
/RIENTTHEVALVESEGMENTSOTHEHOLEATTHEEDGEISALIGNEDWITHTHELOOP mUSHING

VALVEDRAINHOLEINTHEENDCAP
,OCATETHEVALVESEGMENTANDSERVOPISTONINTHEAPPROXIMATECENTEROFTHEIRTRAVEL
G32
Bearing plate and valve segment
see page 30
G34
End cap
(typical side port
configuration shown)
B50 B05
C10
C20 G60
B50

P104 105
(cartridge version similar)
008 918 12 BOMAG 851
18.3 Travel motor
Repair Instructions
!SSEMBLY
ENDCAP INSTALLATION 2OTATETHEMOTORSHAFTANDCHECKFORPLAYBETWEENTHESHAFTANDCYLINDERBLOCK!NY

PLAYINDICATESTHATTHESYNCHRONIZINGSHAFTROLLERSARENOTINSTALLEDCORRECTLY
C Caution
$ONOTALLOWTHEPISTONSOR )NSTALLTHEENDCAPASSEMBLYANDVALVESEGMENTSOTHESPINDLEENGAGESTHEBEARING
SYNCHRONIZINGSHAFTROLLERS INTHECYLINDERBLOCKC
TOFALLOUTOFPOSITION
)NSTALLSCREWS' AND' TORETAINTHEENDCAPASSEMBLYTOTHEMOTOR
)NSTALLTHESCREWSINTHEIRPROPERLOCATIONSTOENSUREADEQUATETHREADENGAGEMENT4HE
INTERNALSPRINGINTHEMOTORSHAFT WILLHOLDTHEENDCAPAWAYFROMTHEHOUSINGASHORT
DISTANCE
C Caution 4IGHTENTHESCREWSBYHANDINA Endcap screw torque

$ONOTFORCETHEEND DOUBLE 8PATTERNWHILEROTATING Frame size Wrench size 4ORQUE.sM
CAPINTOPOSITIONONTHE THEMOTORSHAFTTOENSUREPROPER ;LBFsFT=
HOUSING)FNECESSARY POSITIONINGOFTHESYNCHRONIZING MM ;=
REASSEMBLETHE SHAFTROLLERS
MM ;=
COMPONENTSTOENSURE
PROPERALIGNMENT 7HENTHEENDCAPISINPOSITION MM ;=
TORQUETHESCREWSINADOUBLE 8 MM ;
PATTERNASSHOWNINTHETABLEC MM ;=
2ECHECKTHEENDCAPSCREWTORQUE
2EINSTALLTHEMINIMUMANGLESERVOCOVERCONTROLSPRINGSIFUSED WAYVALVESPOOL

ANDSLEEVEIFUSED ANDCONTROLANDMULTIFUNCTIONBLOCKIFUSED 2EFERTO Series 51
and 51-1 Service Manual, 11008567FORINSTRUCTIONS
Torquing pattern
G34 see table

Endcap assembly 2/10
3/11 5/13
with valve segment G32 7/15
6/14 8/16
1/9 4/12
Double-X pattern torquing sequence
(110 frame size with side port end cap shown)

cartridge version similar
P104 106
852 BOMAG 008 918 12

Travel motor 18.3
Repair Instructions
!SSEMBLY
ENDCAP INSTALLATION &OLLOWINGPROCEDURESINTHESeries 51 and 51-1 Service Manual11008567)NSTALLTHE

(continued) CONTROLANDMULTI FUNCTIONBLOCKIFINSTALLED )NSTALLTHE WAYVALVESPOOLANDSLEEVEIF
INSTALLED )NSTALLTHETHRESHOLDSPRINGSANDGUIDES)NSTALLTHECONTROLSPRINGSIFINSTALLED
)NSTALLTHERAMPSPRINGSANDGUIDESIFINSTALLED )NSTALLTHEMINIMUMANGLESERVOCOVER
FROMTHEMOTOR)NSTALLTHELOOP mUSHINGVALVEANDCHARGERELIEFVALVE
!FTERASSEMBLYTESTANDADJUSTTHEMOTORASNECESSARYBEFOREPLACINGTHEUNITBACKIN
SERVICE2EFERTOSeries 51 and 51-1 Service Manual11008567FORADJUSTMENTPROCEDURES
008 918 12 BOMAG 853
18.3 Travel motor
OUR PRODUCTS Sauer-Danfoss Mobile Power and Control Systems

#LOSEDANDOPENCIRCUITAXIALPISTON OTHERS
PUMPSANDMOTORS
"ENTAXISMOTORS PARTNERSHIPWITHTHEM
/RBITALMOTORS
4RANSITMIXERDRIVES COMPONENTSTOPROVIDEVEHICLEDESIGNERSWITHTHEMOSTADVANCED
0LANETARYCOMPACTGEARS TOTALSYSTEMDESIGN
0ROPORTIONALVALVES 3AUER $ANFOSSPROVIDESCOMPREHENSIVEWORLDWIDESERVICEFORITS

$IRECTIONALSPOOLVALVES PRODUCTSTHROUGHANEXTENSIVENETWORKOF'LOBAL3ERVICE0ARTNERS
#ARTRIDGEVALVES
,OCALADDRESS
)NTEGRATEDSYSTEMS
&ANDRIVESYSTEMS
%LECTROHYDRAULICS
%LECTRICMOTORSANDINVERTERS
*OYSTICKSANDCONTROLHANDLES 3AUER $ANFOSS53 #OMPANY 3AUER $ANFOSS!P3
%ASTTH3TREET $+ .ORDBORG$E.sMARK
$ISPLAYS !MES)!53! 0HONE
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+ROKAMP$ .EUMüNSTER'ERMANY )SOGAMI DORI#HUO KU
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WWWSAUER DANFOSSCOM
11009449s2EV!!s*ANUARY
854 BOMAG 008 918 12

18.4 Vibration motor
008 918 12 BOMAG 855

856 BOMAG 008 918 12

Vibration motor 18.4
A10FM
A10FE
RDE 92172-01-R/08.01
ersetzt / replaces 06.99
Reparaturanleitung - A10FM 28 - 60 Baureihe 5

A10FE 28 - 60 Baureihe 5
Repair instructions - A10FM 28 - 60 Series 5
A10FE 28 - 60 Series 5
008 918 12 BOMAG 857

RDE 92172-01-R/08.01
18.4
Hinweis / Inhalt
Vibration motor
Reparaturanleitung A10FM / A10FE
Notice / Contents Repair Instructions A10FM / A10FE
HINWEIS NOTICE
Bezeichnungen, Beschreibungen und Darstellungen Specifications, descriptions and illustrative material shown
entsprechen dem Informationsstand zum Zeitpunkt der herein were as accurate as known at the time this
Drucklegung dieser Unterlage. publication was approved for printing.
Änderungen können den Service am Produkt beein- BRUENINGHAUS HYDROMATIK reserves the right to
flussen, Verpflichtungen entstehen uns daraus nicht. discontinue models or options at any time or to change
Methoden und Vorrichtungen sind Empfehlungen, für specifications, materials, or design without notice and
deren Resultat wir keine Haftung übernehmen können. without incurring obligation.
BRUENINGHAUS HYDROMATIK- Baugruppen, mit Anga- Optional equipment and accessories may add cost to the
be der Fabrik-Nr. bestellt, sind die Basis guter Reparatu- basic unit, and some options are available only in
ren. combination with certain models or other options.
Einstell- und Prüfarbeiten sind bei Betriebstemperatur auf For the available combinations refer to the relevant data
dem Teststand vorzunehmen. sheet for the basic unit and the desired option.
Schutz von Personen und Eigentum ist durch Vor- Adjustment and tests have to be carried out on the test
kehrungen sicherzustellen. bench under operating temperatures.
Sachkenntnis, die Voraussetzung für jede Service-arbeit, Protection of personnel and property has to be guar-
vermitteln wir in unseren Schulungskursen. anteed by appropriate measures.
Expert knowledge, the precondition of any service work,
can be obtained in our training courses.
INHALT Seite/ CONTENTS

Page
A10FM / A10FE A10FM / A10FE
Schnittbild 3 Sectional view

Allgemeine Reparaturhinweise 4 General repair guidelines
Triebwelle abdichten 5-7 Sealing the drive shaft
Motor demontieren 8-14 Disassemble the motor
Überprüfungshinweise 15 Inspection hints
Motor montieren 16-19 Motor assembly
Spülventil demontieren 20 Disassembly of the flushing valve
Abstimmung- Lagerung / Hinweise 21 Bearing adjustment / Note
Werkzeuge / Hilfswerkzeuge / Tools / auxiliary tools /
Anziehdrehmomente 27 tightening torques
2 Brueninghaus Hydromatik
858 BOMAG 008 918 12
RDE 92172-01-R/08.01
Vibration motor
Schnittbild
18.4
Reparaturanleitung A10FM / A10 FE
Sectional view Repair Instructions A10FM / A10FE
A10FM
A10FE
Optional Option
Ausführung mit Spülventil Unit with flushing valve
für geschlossenen Kreislauf for closed circuit application
008 918 12 BOMAG Brueninghaus Hydromatik

859 3
RDE 92172-01-R/08.01
18.4
Allgemeine Reparaturhinweise
Vibration motor
General repair guidelines Repair Instructions A10FM / A10FE
Achtung!
Nachfolgend Hinweise bei allen Reparaturarbeiten
an Hydraulikaggregaten beachten!
Attention!
Observe the following guidelines when carrying out repairs
on hydraulic units!
Alle Öffnungen der Hydraulikaggregate verschließen.
Close off all openings of the hydraulic unit.
Alle Dichtungen erneuern.

Nur original BRUENINGHAUS HYDROMATIK
Ersatzteile verwenden.
Replace all of the seals.

Use only original BRUENINGHAUS HYDROMATIK
spare parts.
Alle Dicht- und Gleitflächen auf Verschleiß prüfen.

Achtung: Nacharbeiten an Dichtflächen z.B. durch
Schleifpapier kann die Oberfläche beschädigen.
Check all sealing and sliding surfaces for wear.

Attention: Re-work of the sliding surfaces by using, for
example abrasive paper, can damage the surface.
Hydraulikaggregate vor Inbetriebnahme mit

Hydrauliköl befüllen.
Fill the hydraulic unit with hydraulic oil

before commissioning.
860 BOMAG 008 918 12
RDE 92172-01-R/08.01
Vibration motor
Triebwelle abdichten
18.4
Sealing the drive shaft Repair Instructions A10FM / A10FE
2
1
2 1. Sicherungsring, 2. Wellendichtring
1
1. Circlip, 2. Shaft seal
3 (Paßfeder ausbauen bei Ausführung Paßfeder))

Triebwelle abkleben.
Sicherungsring ausbauen.
(Remove key, version with keyway)

Protect the drive shaft.
Remove the circlip.

861 5
RDE 92172-01-R/08.01
18.4
Vibration motor
4 Nach der Demontage des gelaufenen Wellendichtringes,

einfetten des neuen WDR.(Kontrolle der Laufflächen, Welle,
Gehäuse).
Change the shaft seal and check its sliding surface (drive shaft)
and housing, grease the sealing ring.
5 Welle mit Schutzhülse oder Klebeband versehen.
Use installation tool or plastic strip for assembling seal.
6 Mit geeignetem Rohr den WDR nur so tief montieren,

daß der Sicherungsring montierbar ist (zu tiefes Montieren
führt zum Ausfall: Berührung mit dem Wellenlager!).
Use a suitable pipe to mount the shaft seal ring, but don't
push it too deap. If the shaft ring touches the bearing ring
you will damage the seal ring.
7 Sicherungsring einsetzen.
Assemble the snap ring.
8 Sicherungsring ganz einrasten.
Assemble the snap ring in the correct position.
862 BOMAG 008 918 12
RDE 92172-01-R/08.01
Vibration motor
18.4
Hinweis! Note!
Die hier beschriebene Möglichkeit zum Wechsel der This discription showes how th change the drive shaft
Antriebswellen - Abdichtung stellt nicht die serienmäßi- sealing ring but it isn't the way of serial assembly.
ge Montage dar. Für sicheres Dichtungsverhalten ist eine The sealing ring is assembled together with the taper
Montage des Dichtringes zusammen mit dem Kegel- roller bearing from inside the motor housing normally to
rollenlager von innen her durch das Montagegehäuse get a secure sealing condition. If you decide to repair the
durchzuführen. Soll aus Gründen der Vereinfachung im motor in the shown way be very careful while handling
Reparaturfall die vorgehend beschriebene Vorgehens- so that the drive shaft wouldn't be damaged during
weise durchgeführt werden, so ist beim Ausbau der disassembly of the shaft sealing ring.
Dichtung besonders darauf zu achten, daß die Antriebs-
welle nicht beschädigt wird.

863 7
RDE 92172-01-R/08.01
18.4
Motor demontieren
Vibration motor
Disassemble the motor Repair Instructions A10FM / A10FE
A10FM
864 BOMAG 008 918 12
RDE 92172-01-R/08.01
Vibration motor
Motor demontieren
18.4
A10FE
10

865 9
RDE 92172-01-R/08.01
18.4
Motor demontieren
Vibration motor
11 Demontageposition
Lage der Anschlußplatte zum
Gehäuse kennzeichnen.
Disassembly position
Mark the location of the connection plate
on the housing.
12 Anschlußplattenbefestigung über Kreuz lösen.
Remove the connection plate fixing bolts crosswise.
13 Anschlußplatte abheben.
Verteilerplatte
kann herunterfallen - festhalten.
Verteilerplatte abheben.
Remove the connection plate.

Distributor plate
can drop down - hold tight.
Remove distributor plate.
866 BOMAG 008 918 12
RDE 92172-01-R/08.01
Vibration motor
Motor demontieren
18.4
14 Verteilerplatte abheben.
Remove control plate.
15 Lageraußenring mit Abziehvorrichtung ausbauen.

Dichtfläche Verteilerplatte nicht beschädigen.
Remove bearing outer ring with withdrawal tool.

Do not damage the sealing surface.
16 Abheben des Kegelrollenlagers (anschlußplattenseitig).

Entfernen der Abstimmscheibe.
Disassemble the taper roller bearing (near by port plate)

Remove the adjustment shim.

867 11
RDE 92172-01-R/08.01
18.4
Motor demontieren
Vibration motor
17 Triebwerk in horizontaler Lage herausziehen.
Remove the rotary group in a horizontal position.
18 Welle nach hinten herausziehen.
Remove the drive shaft to rear side.
19 Hubscheibe mit Sonderwerkzeug ausbauen (siehe Bild 20).
Remove swash plate with special tool (see picture 20).
20 Der Ausbau der Hubscheibe erfolgt mit einer Schleuder,

ein kleiner Haken - aus Rundmaterial Durchmesser 6 mm -
greift dabei unter die Hubscheibe.
Loosen the swash plate with a slide hammer ( a small

hook - diameter 6 mm - catches the end of the swash
plate at the bottom).
21 Lager mit Presse abziehen.
Press down bearing.
868 BOMAG 008 918 12
RDE 92172-01-R/08.01
Vibration motor
Motor demontieren
18.4
22 Abziehen des Lageraußenringes im Pumpengehäuse.

Zweckmäßige Unterlage benutzen, zur Vermeidung von
Gehäusebeschädigungen (s. a. Hinweis Abb.xx).
The external front bearing ring is pulled out of the pump

housing (tool and surface infos see picture xx, too).
23 Sicherungsring entfernen.
Disassemblecirclip and shaft seal.
24 Wellendichtring und Fixierscheibe entnehmen
Remove shaft seal ring and shim.

869 13
RDE 92172-01-R/08.01
18.4
Motor demontieren
Vibration motor
25 Feder mit Vorrichtung vorspannen.
Pre-tension the spring using a suitable device.
26 Sicherungsring demontieren.
Feder und Druckstifte ausbauen.
Remove circlip.
Remove spring and pressure pins.
27
870 BOMAG 008 918 12
RDE 92172-01-R/08.01
Vibration motor
Überprüfungshinweise
18.4
Inspection hints Repair Instructions A10FM / A10FE
28 Kontrolle!
Lauffläche (1) keine Kratzer, keine Metalleinlagerungen,
kein Axialspiel (2), (Kolben nur satzweise tauschen).
Check!
Check to see that there are no scratches or metal deposits
on the sliding surface (1), and that there is no axial play (2),
(pistons must only be replaced as a set).
29 Kontrolle!
Zylinderbohrungen (1), Verzahnungen (2).
Check!
Cylinder bores (1), splines (2).
30 Riefenfrei, keine Einlaufspuren
Free of grooves, no signs of wear.
31 Kontrolle!
Zylindergleitfläche riefenfrei, nicht eingelaufen, keine
Einlagerungen, Steuerplatte nicht riefig (nur satzweise
austauschen).
Check!
Cylinder sliding surface free of grooves, no wear, no
embedded foreign particles. That there are no scratches
on the control plate. (Only replace them as a set).
32 Kontrolle!
Auflagefläche - Steuerplatte ohne Beschädigung.
Check!
Mounting surface - control plate undamaged

871 15
RDE 92172-01-R/08.01
18.4
Motor montieren
Vibration motor
Motor assembly Repair Instructions A10FM / A10FE
33 Sicherungsring ins Gehäuse montieren.
Fit the circlip into the housing.
34 Wellendichtring und Fixierscheibe gegen

Sicherungsring einsetzen.
Assemble shaft seal ring and shim

against circlip.
35 Montage des Wellendichtringes 1 gegen den Sicherungsring 2,

3 anschließend Fixierscheibe 3 einlegen.
1 Assembly of the shaft seal 1 against the safety ring 2,

back up the shim 3 down to the seal ring.
36 Lageraußenring ins Gehäuse pressen.

Welle mit Lager vormontiert ins Gehäuse einstecken.
Wellendichtring nicht beschädigen.

Wellenverzahnung mit Klebeband umwickeln.
Press outer bearing ring into housing.

Shaft seal with pre-assembled bearing into housing.
Protect splines of the shaft with plastic strip

against damage of the seal lip.
872 BOMAG 008 918 12
RDE 92172-01-R/08.01
Vibration motor
Motor montieren
18.4
37 Hubscheibe montieren.
Assemble swash plate.
38 Mit Vorrichtung Druckstifte montieren.
Fit pressure pins using an assembly aid.
39 Feder mit Vorrichtung vorspannen.
Pre-tension the spring using a suitable device.
40
41 Kolben mit Rückzugeinrichtung montieren.

Hinweis:
Kolben, Gleitschuhe einölen.
Assemble piston with retaining plate.

Note:
Oil piston and slipper pad.

873 17
RDE 92172-01-R/08.01
18.4
Motor montieren
Vibration motor
42 Rotationsgruppe montieren!
Montagehilfe:
Mit O-Ring Kolben festhalten.
Fit rotary group!
Assembly aid:
Hold the pistons by using an O-ring.
43 Lager (1) in Anschlußplatte montieren.

4 Zylinderstift (2) einsetzen.
O-Ring (3) einsetzen.
Verteilerplatte (4) aufsetzen.
3
Montagehilfe:
Teile mit Fett fixieren.
1
Fit bearing (1) in connection plate.

2 Fit cyilindrical pin (2).
Fit O-ring (3).
Fit distributor plate (4).
Assembly:
Hold the components in place with grease.
874 BOMAG 008 918 12
RDE 92172-01-R/08.01
Vibration motor
Motor montieren
18.4
44 Verteilerplatte montieren.
Montagehilfe: Fett
Fit distributor plate.

Assembly aid: Grease
45 Anschlußplatte aufsetzen und mit Schrauben

über Kreuz anziehen.
Fit the connection plate and fix it with

the screws crosswise.
A10FM A10FE
46

875 19
RDE 92172-01-R/08.01
18.4
Spülventil demontieren
Vibration motor
Disassembly of the flushing valve Repair Instructions A10FM / A10FE
47 Beidseitig Schrauben 1 lösen und Federn mit Scheiben 2

entnehmen.
Loosen screws 1, take out springs and shims 2.
1
2
2
1
48 Spülschieber 3 vorsichtig zu einer Seite heausdrücken.
Take out spool carefully.
49 Verschlußschraube Speisedruckventil 4 lösen,

Feder und Einsatz entnehmen.
Loosen the screw of the boost valve and take out

the spring and the cartridge.
Montage in umgekehrter Reihenfolge!
Assembling by opposite steps!
876 BOMAG 008 918 12
RDE 92172-01-R/08.01
Vibration motor
Abstimmung- Lagerung / Hinweise
18.4
Bearing adjustment / Note Repair Instructions A10FM / A10FE
Montage - Abstimmung (Kegelrollenlager) / Taper roller bearing initial tension
AA10FM Baureihe 50
AA10FM Series 50
0 .... 0,05 mm
Pos. 12
Abstimmung der Triebwerkslagerung Adjustment of stopper min displacement

Die Vorspannung der Triebwerkslagerung muß im Cast iron housing must have initial tension of bearings:
Gußgehäuse von 0 bis 0,05 mm durch Abschleifen der 0 ...... 0,05 mm , grind Pos. 12 if necessary.
Abstimmscheibe Pos. 12 hergestellt werden.
Adjustment: Qmin- stopper
Einstellhinweis: Qmin-Anschlag With a given inflow and pressureless circulation adjust
Bei gegebenem Zusatzstrom wird bei drucklosem the stopper Qmin displacement so that the measured
Umlauf der Anschlag Qmin so eingestellt, daß die gemes- speed of the motors results in a displacement of 12 cm3
sene Drehzahl des Motors einem Schluckvolumen von (vgmin).
12 cm3 entspricht (vgmin). Increase of adjustment is possible to vgmax = 45 cm3
Eine kontinuierliche Verstellung bis vgmax = 45 cm3 ist Differential volume is appr. 3,1 cm3 (see page 3).
möglich - Volumenänderung pro Gewindestiftum-
Q inflow x 1000
drehung ca. 3,1 cm3 (s. a. Seite 3). Displacement vgmin =
Measurement speed
Q Zulauf x 1000
Schluckvolumen vgmin =
Meßdrehzahl
Achtung: Falsch eingestellte Qmin Anschläge können zu Attention: Wrong adjustments of stopper Qmin
überhöhten Drehzahlen bis hin zum Ausfall der Bauteile displacement increases the speed of the motor up to a
führen. possible failure of parts of the unit.

877 21
RDE 92172-01-R/08.01
18.4
Werkzeuge / Hilfswerkzeuge / Anziehdrehmomente
Vibration motor
Tools / auxiliary tools / tightening torques Repair Instructions A10FM / A10FE
49 Plastikhammer
Soft hammer
50 Schleuder
...
Anziehdrehmomente /
Tightening torques
Festigkeitsklassen 8,8; 10,9; 12,9

Bolt tensile strength grade:
M4 M5 M6 M8 M10 M12 M14 M16 M18 M20 M24 M30
8,8 2,3 5,0 8,5 21 41 72 115 176 240 350 600 1220
Ma 10,9 3,2 7,2 12 29 58 100 165 250 350 490 840 1670
12,9 4,1 8,5 14,5 35 70 121 195 300 410 590 990 2000
Ma (Nm) = max. Anziehdrehmoments (geölte Schrauben μ = 0,125)

Ma (Nm) = max. tightening torques (lubricated screws μ = 0,125)
51
878 BOMAG 008 918 12
008 918 12 BOMAG 879

880 BOMAG 008 918 12

008 918 12 BOMAG 881

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

S000 005E
Copyright 1987-1998, SAUER-SUNDSTRAND GmbH & Co. S90MVCTCD

S90PVMFCD
All rights reserved. Contents subject to change.
2
882 BOMAG 008 918 12
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
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.
F000 539
Series 90 Variable Displacement Pump (PV)
Slider Block
Servo Arm
Servo Valve
Cradle Hold Down
Servo Piston
Feed Back
Cradle Bearing
Cradle
Cradle Leveler
Cradle Guide
Charge Pump
P001 413E
Series 90 PV Cross Section
Fixed Displacement Motor
The Fixed Displacement Motor (MF) is designed to

convert an input of hydraulic power into an output torque.
It operates in the reverse 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.
90000347
Series 90 Fixed Displacement Motor (MF)
5
008 918 12 BOMAG 883
Series 90 Functional Description
In the Fixed Displacement Motor the "swashplate" is

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

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

Cradle Swashplate in Full
Displacement Position
Cradle Swashplate
Cylinder Block
Electric 2-Position Control (optional) Maximum Angle
Control Piston
90000234E
Series 90 MV Cross Section
6
884 BOMAG 008 918 12
Series 90 Minor Repair Instructions
Minor Repair Instructions
Minor repairs may be performed, following the proce- items must be kept free of foreign materials and chemi-
dures in this section, without voiding the unit warranty. cals.
Although specific models are shown, these procedures
apply to all series and types of units in the Series 90 Protect all exposed sealing surfaces and open cavities
Family. from damage and foreign material.
Cleanliness is a primary means of ensuring satisfactory It is recommended that all gaskets and O-rings be
transmission life, on either new or repaired units. Clean- replaced when servicing. All gasket sealing surfaces
ing parts by using a solvent wash and air drying is must be cleaned prior to installing new gaskets. Lightly
adequate, providing clean solvent is used. As with any lubricate all O-rings with clean petroleum jelly prior to
precision equipment, the internal mechanism and related assembly.
51
008 918 12 BOMAG 885
Hydrostatic Unit Outlines for Minor Repair Reference
Charge Pressure
Relief Valve
Control Filtration Options

Control Orifice
Charge Pump Shaft Seal
Main Shaft Speed Sensor

(Auxiliary Pad)
Left Side View Right Side View

90000843E
SAE-Flange PV
Charge Pressure Charge Pressure

Relief Valve Relief Valve
Loop Flushing
Valve
Loop Flushing
Valve
Shaft Shaft
Seal Seal
(Speed Sensor) (Speed Sensor)
Left Side View Left Side View
90000844E
SAE Flange MF Cartridge Flange MF
Control Orifices
Maximum Angle Control Orifices
Charge Pressure Displacement Limiter
Relief Valve Charge Pressure Maximum Angle
Relief Valve Displacement Limiter
Loop Flushing Loop Flushing
Valve Valve
Shaft Shaft
Seal Seal
Control Control
Minimum Angle
Minimum Angle Displacement Limiter
Displacement Limiter
Left Side View Left Side View

90000845E
Cartridge Flange MV SAE Flange MV
52
886 BOMAG 008 918 12
Pump and Motor Minor Repair
Pump / Fitting Torques

Description Torque
If any plugs or fittings are removed from the pump or 7/16-20 O-ring 20 Nm
motor during servicing, they should be torqued as indi- 9/16 inch Hex Wrench (15 lbf•ft)
cated in the accompanying table. 7/16-20 O-ring 12 Nm
3/16 inch Internal Hex Wrench (9 lbf•ft)
Always install new O-rings before reinstalling the plugs or 9/16-18 O-ring 37 Nm
fittings. 11/16 inch Hex Wrench (27 lbf•ft)
9/16-18 O-ring 23 Nm
3/4-16 O-ring 68 Nm
7/8 inch Hex Wrench (50 lbf•ft)
3/4-16 O-ring 68 Nm
7/8-14 O-ring 95 Nm
Caution 1 inch Hex Wrench (70 lbf•ft)
Plugs or fittings installed into aluminum housings 7/8-14 O-ring 68 Nm
should always be torqued to the lower values 3/8 inch Internal Hex Wrench (50 lbf•ft)
specified for internal hex plugs of the same size. 1-1/16-12 O-ring 163 Nm
S000 017E 1 1/4 inch Hex Wrench (120 lbf•ft)
1-1/16-12 O-ring 115 Nm
1-5/16-12 O-ring 190 Nm
1-1/2 inch Hex Wrench (140 lbf•ft)
1-5/16-12 O-ring 129 Nm
1-5/8-12 O-ring 224 Nm
1-7/8 inch Hex Wrench (165 lbf•ft)
T002 281E
53
008 918 12 BOMAG 887

Shaft Seal and Shaft Replacement
Lip type shaft seals are used on Series 90 pumps and

motors. These seals and/or the shafts can be replaced
without 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
90000270 90000271
Remove Screws Holding Remove Seal Carrier hex wrench (130 through 250 units). Remove the
Retainer Plate and Seal retainer plate.
Carrier
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

90000272 90000273
press out old seal.
Press Out Old Seal New Seal Installed in Carrier
6. Inspect the seal carrier, the new seal and the O-ring
Screw for any damage or nicks.
Retaining Plate
Seal Carrier 7. Using the arbor press, press the new seal into seal
Seal carrier. Be careful not to damage the seal.
Screw
Seal Carrier
(One Piece) Note: The outside diameter of the seal may be lightly
coated with a sealant (such as Loctite High
Seal
Performance Sealant #59231) prior to installa-
O-ring tion. This aids in preventing leaks caused by
damage to the seal bore in the seal carrier.
90000846E
Series 90 Shaft Seal Components
54
888 BOMAG 008 918 12
Roller Bearing
8. Inspect the sealing area on the shaft for rust, wear, Assembly Retaining Ring
or contamination. Tapered
Shaft
If the shaft is not being replaced proceed to step Splined OR Roller Bearing
Shaft
12.
OR
9. Remove shaft and roller bearing assembly from
OR
pump or motor. The bearing assembly can be trans- Straight Key
ferred to the new shaft. Shaft
90000866E
10. Remove the retaining ring that secures roller bearing Fixed Motor Shaft Configuration
assembly with a snap ring pliers. Remove the roller
bearing assembly. Roller Bearing
Assembly Retaining Ring
11. Place roller bearing assembly on new shaft and Rollen Bearing
Splined OR
secure with the retaining ring. Shaft
Tapered
12. Wrap spline or key end of shaft with plastic film to Shaft
prevent damage to the sealing lip on the seal during OR
installation.
OR
13. Prior to assembly, lubricate the O-ring on the O.D. of
Straigt Key
the seal carrier and the I.D. of the seal with clean Shaft
petroleum jelly.
90000867E
14. Assemble the seal carrier and seal over the shaft and Variable Pump Shaft Configuration
into the housing bore. Install the retainer plate (if
used).
Roller Bearing
Assembly Retaining
15. Install the screws and torque like the tables. Ring
Splined
Pumps
Shaft
Frame Size Torque Pumps
OR
030 - 042 12 Nm (9 lbf•ft) Tapered
055 - 100 16 Nm (12 lbf•ft) Shaft
130 - 250 32 Nm (24 lbf•ft)
T002 282E 90000868E
Variable Motor Shaft Configuration
Motors
Frame Size Torque Motors

030 - 100 9.5 Nm (7 lbf•ft)
130 22.5 Nm (16.6 lbf•ft)
T002 283E
Note: Torque the screws in a sequenced pattern then

recheck.
90000274 90000275
Install Seal Carrier Torque Retainer Screw
55
008 918 12 BOMAG 889
Series 90 Minor Repair

Minor Repair - Motor
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 90000338 90000339

shuttle valve spool. Late production motors use Remove Plugs Springs Remove Flushing Shuttle
a larger diameter spool. 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. 90000340 90000341
Install Flushing Shuttle Torque Plugs
Before removing the screw adjustable relief valve Spool
plug, mark the plug, lock nut, and housing so as to be
able to 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 90000342 90000343
adjustable valves, do not alter the shims or inter- Remove Shim Charge Relief Remove Screw Charge Relief
change parts with another valve. Valve Valve
71
890 BOMAG 008 918 12
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).
5. Check and adjust the charge pressure.
90000344 90000345
Shim Adjustable Charge Screw Adjustable Charge
Relief Valve Relief Valve
Defeating the Loop Flushing Valve

Lock Nut
Plug
Plug 1. Remove loop flushing valve components (these parts
O-ring
O-ring
will not be used).
Shims
Spring Spring
2. Install defeating spool into spool bore in end cap.
Poppet Poppet
Plug with O-ring
(defeat) 3. Install hex plugs provided and torque to 41 Nm
(30 lbf•ft).
4. Remove charge relief valve components (these parts

Plug with O-ring are not necessary).
(defeat)
5. Replace with the hex plug provided and torque to

Plug
41 Nm (30 lbf•ft).
O-ring Spool (defeat)
Spring
Plug with O-ring
(defeat)
Shoulder Washer
Note orientation of washers!

Shoulder OUT (toward spring). Spool
Shoulder Washer
Spring
O-ring
Plug
90000850E
Motor charge Relief Valve and Loop Flushing Valve Parts
72
008 918 12 BOMAG 891

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 Tamper-Resistant Cap
motor housing with a 6 mm internal hex wrench. Seal Lock Nut
Maximum Displacement
Limiter Screw
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.
Minimum Displacement
Caution Limiter Screw
Care should be taken in adjusting displacement Seal Lock Nut
limiters to avoid undesirable speed conditions. The
Tamper-Resistant Cap
seal lock nut must be retorqued after every
adjustment to prevent an unexpected change in SAE Flange Version shown
(cartridge Version similar)
operating conditions and to prevent external leakage
during unit operation.
S000 026E
90000851E
One full turn of the displacement limiter adjustment MV Displacement Limiters
screw will change the displacement as follows:
Approx Change in Disp per Rev of

Frame Size
Adjusting Screw
055 5.6 cm3 / Rev (0.34 in3 / Rev)
075 7.1 cm3 / Rev (0.43 in3 / Rev)
T002 295E
4. Following the final adjustment, install new tamper

resistant caps.
73
892 BOMAG 008 918 12
Variable Motor Controls
Electrohydraulic 2-Position Control (Types

NA, NB, NC, and ND)
1. Thoroughly clean external surfaces prior to removal

of the control.
2. Disconnect the external electrical signal connection.

Note: Remove BEFORE removing control.
Install AFTER installing control. 3. Remove the hex nut and solenoid from the control
Refer to "Control Orifices" Section
valve.
4. Remove the orifice check valve for the maximum

angle control cylinder, if equipped.
Hydraulic 2-Position
Control Valve
5. Remove the control valve from the motor housing.
6. Remove O-rings from the valve.
7. Install new O-rings on the control valve.

Electric 2-Position
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
90000852E nut to 5 Nm (44 lbf•in). Do not overtorque the nut.
MV Control components
10. If previously removed, reinstall the orifice check
valve. Reconnect the external signal connection.
Hydraulic 2-Position Control (Type PT)
Follow the steps above, except that in step 2 a hydraulic

signal line will be disconnected, and steps 3 and 9 are not
applicable.
1/8 in. int. hex wrench
Torque: 5.4 Nm (48 lbf•in)
Control Plugs
Remove the control plugs from the housings of earlier

9/16 in. hex wrench
Torque: 34 Nm (25 lbf•ft) production motors, if necessary. Install new O-rings,
reinstall, and torque.
7/8 in. hex wrench
Torque: 68 Nm (50 lbf•ft)
90000853E
MV Control Plugs
74
008 918 12 BOMAG 893

Variable Motor Control Orifices
Control Suply Orifice
Control Supply Orifice
Screen (pressed in)
1. Remove the control supply orifice from the motor
O-ring
housing with an 1-1/16 inch hex wrench.
Backup Washer
2. Remove the O-rings and the backup washers. Check O-ring

that the filter screen is secure in the orifice body and Backup Washer
that the screen and the orifice are not plugged.
3. Install new backup washers and O-rings onto the

orifice body. Install the orifice into the motor housing O-ring
and torque to 37 Nm (27 lbf•ft). Backup Washer Backup Washer
Caution
Screen
Do not interchange the control supply orifice with the (pressed in)
minimum displacement orifice (next section).
S000 027E Orifice Body
O-ring
Cross-section View of
Control Supply Orifice Assembly
90000854E
MV Control Supply Orifice
Minimum Displacement Cylinder Orifice or Orifice

Check Valve
Orifice Orifice / Check Valve
Assembly
1. Remove the minimum displacement cylinder drain
orifice or the orifice check valve from the motor
O-ring
housing with an 1-1/16 inch hex wrench.
Backup Washer
2. Remove the O-rings and the backup washers. Check O-ring

that the orifice is not plugged. Check that the check Backup Washer
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).
O-ring O-ring
Orifice Body Orifice Body

Caution
Do not interchange the control supply orifice (previous Backup Washer
Spring Pin
Backup Washer
section) with the minimum displacement orifice. O-ring O-ring
S000 028E Kugel
Backup Washer Backup Washer
Orifice Seat
(Spot welded)
Cross-Section View of Cross-Section View of
Orifice Assembly Orifice / Check Valve
Assembly
90000855E
MV Minimum Displacement Orifice
75
894 BOMAG 008 918 12
Maximum Displacement Cylinder Orifice Check Valve
1. Remove the seal lock nut with a 3/4 inch hex wrench.
Housing Plug Remove the maximum displacement cylinder orifice
check valve from the motor housing with a 1/4 inch
Seal Lock Nut
(seal toward housing) end wrench. Remove the O-ring. The check ball in
the valve must be free.
O-ring
2. Reinstall the check valve and torque to 15 Nm
Orifice / Check Valve Assembly
(11 lbf•ft). Install a new O-ring. Install the seal lock
nut with the seal toward the motor housing.
Seal Lock Nut
(seal toward housing)
Hold the check valve from turning while torquing
the seal lock nut to 34 Nm (25 lbf•ft).
O-ring
3. If no orifice check valve is installed, the housing plug
Orifice Body may be removed with a 9/16 inch hex wrench. Always
install a new O-ring. Reinstall the plug and torque to
Check Ball
20 Nm (15 lbf•ft).
Spring Pin
Cross-Section View of
Orifice / Check Valve
Assembly
90000856E
MV Maximum Displacement Orifice
76
008 918 12 BOMAG 895

Speed Sensor
1. Remove the speed sensor by disconnecting the

electrical connector, loosening the lock nut, and Housing Plug
Speed Sensor 1/4 in. int. hex wrench
unscrewing the speed sensor from the pump or or Torque: 23 Nm (17 lbf•ft)
motor housing.
2. Always install a new O-ring before installing the 1-1/16 in. hex wrench
sensor. After adjustment!
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 90000857E
figure. Typical Location of Speed Sensor - PV
1-1/16 in. hex wrench

After adjustment!
or
Housing Plug Speed Sensor

1/4 in. int. hex wrench
90000858E
Typical Location of Speed Sensor - MF

After adjustment!
or
Speed Sensor
Housing Plug
90000859E
Typical Location of Speed Sensor - MV
77
896 BOMAG 008 918 12
Hydraulic Power Systems
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Phone: (515) 239-6000 • Fax: (515) 239-6618 Phone: (04321) 871-0 • Fax: (04321) 871 122
SM-SPV/SMF/SMV90-E • 10/98 • 300047G • BLN-9947 Revision G • Oct. 1998

008 918 12 BOMAG 897
898 BOMAG 008 918 12

18.6 Drum reduction gear
008 918 12 BOMAG 899

900 BOMAG 008 918 12

Drum reduction gear 18.6
3ERIES#2
#OMPACT
2OLLER$RIVE
3ERVICE-ANUALAND
2EPAIR)NSTRUCTION
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902 BOMAG 008 918 12

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008 918 12 BOMAG 903

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008 918 12 BOMAG 907

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008 918 12 BOMAG 911

2EPAIR)NSTRUCTION
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008 918 12 BOMAG 913

2EPAIR)NSTRUCTION
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2EPAIR)NSTRUCTIONS
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" 2OLLER BEARING

" 0LANET GEAR

" 0LANET GEAR SUBASSEMBLY

" 2ETAINING RING

" 0LUG
" 0LUG
" 3EALING RING
" #AM
" 3PINDLE
" / RING
" / RING
" 0LUG
" 3PACER RING
" 2ETAINING RING
" !DAPTER
" / RING
" / RING
" "USHING
" 3CREW
" 3CREW
" 3CREW
# 3PACER RING
# 2ETAINING RING
# "RAKE PLATES SUBASSEMBLY
# / RING
# / RING
# "RAKE PISTON
# 3PRING
$ #LUTCH
$ 2ETAINING RING
$ 3UN GEAR
$ 3PACER RING
$ #ARRIER
$ 2ETAINING RING
$ 2OLLER BEARING
$ 0LANET GEAR
$ 0LANET GEAR
$ 0LANET GEAR SUBASSEMBLY
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$+-(03$,2EV!n
922 BOMAG 008 918 12

0ARTS,IST
0!243,)34 1UANTITY
CONTINUED )TEM $ESCRIPTION
#2 ! #2 ! #2
$ 2ETAINING RING
$ #ARRIER
$ 2OLLER BEARING
$ 2ETAINING RING
$ 0LANET GEAR
$ 2ETAINING RING
$ 3UN GEAR
$ 2ETAINING RING
$ / RING
$ #OVER
$ 3CREW

VALIDFROM*ANUARY
$+-(03$,2EV!n
008 918 12 BOMAG 923

/5202/$5#43 3AUER $ANFOSS(YDRAULIC0OWER3YSTEMS

n-ARKET,EADERS7ORLDWIDE
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924 BOMAG 008 918 12

18.7 Steering valve
008 918 12 BOMAG 925

18.7 Steering valve
926 BOMAG 008 918 12

Steering valve 18.7
Hydrostatic
Steering Unit Type
OSPB, OSPC and
OSPF
Service Manual
008 918 12 BOMAG 927

18.7 Steering valve
Hydrostatic Steering unit OSPB, OSPC and OSPF
Service Manual
Table of Contens
Table of contens
%XPLODEDVIEW/30B 3
%XPLODEDVIEW/30#/30F 4
Tools
$ISMANTLINg
$ISMANTLINGTHEPRESSURERELIEFVALVEFOR/30C
!SSEMBLINg
!SSEMBLYPATTERNFORSTANDARDBEARINg
)NSTALLATIONINSTRUCTIONFOR/ RINGROTO'LYd
!SSAMBLYOFTHEPRESSURERELIEFVALVEFOR/30C
!SSAMBLYOFTHESHOCKVALVESFOR/30#/30#,3/30#,32
-AXTIGHTENINGTORQUEANDHYDRAULICCONNECTIONs
¹3AUER $ANFOSS!LLRIGHTSRESERVED0RINTEDIN%UROPA

&RONTCOVERILLUSTRATIONS&&&
$RAWING FA
2 520L0066s2EV""s-AY
928 BOMAG 008 918 12

Steering valve 18.7
Service Manual
%XPLODED6IEW/30"
$USTSEALRING
(OUSINGSPOOLSLEEVE
"ALLMM;IN=
4HREADBUSHING
/ RINGWITHKIN RINGOR
2OTO'LYD
"EARINGASSEMBLY $ISTRIBUTORPLATE
2INGFORSPRINGS 'EARWHEEL
#ROSSPINsMM / RINGsMM;sIN=
;sIN= %NDCOVER
.EUTRALPOSITIONSPRINGS 7ASHERssMM;ssIN=
#ARDANSHAFT 3PECIALSCREW
3PACER 3CREW
/ RINGsMM .AMELABEL
;sIN= 3PACER
520L0066s2EV""s-AY 3
008 918 12 BOMAG 929
18.7 Steering valve
Service Manual
%XPLODED6IEW/30#/30&
$USTSEALRING 3PACER .AMEPLATE

(OUSINGSPOOLANDSLEEVE #ARDANSHAFT #OMPLETERELIEFVALVE
#HECKVALVEANDTHESEATSFORRELIEF 3ETOFSPRINGS 3PRINGWIRE
ANDSHOCKVALVESARELOCKTITED / RING #OMPLETESHOCKVALVE
"ALLMM;IN= $ISTRIBUTORPLATE 33 Ball 3 in
4HREADBUSHING 'EARWHEELSET 3PRING
/ RINGUSEDWITHKIN RINGITEM / RING 2OLLEDPIN
+IN RING %NDCOVER "USHING
"EARINGASSEMBLY 7ASHER "ALL
2ING 3PECIALSCREW +INRING
#ROSSPIN 3CREW / RING
4 520L0066s2EV""s-AY
930 BOMAG 008 918 12

Steering valve 18.7
Service Manual
Tools
Tools Holding tool

#ODENUMBER3*
&
'UIDERING
#ODENUMBER3*
&
!SSEMBLYTOOLFOR/ RINGANDKIN RING

2OTO'LYD
#ODENUMBER3*
#ODENUMBER3*.
&
!SSEMBLYTOOLFORLIPSEAL
#ODENUMBER3*
&
520L0066s2EV""s-AY 5
008 918 12 BOMAG 931
18.7 Steering valve
Service Manual
Tools
Tools !SSEMBLYTOOLFORCARDANSHAFT
#ODENUMBER3*
&
!SSEMBLYTOOLFORDUSTSEAL
#ODENUMBER3*
&
4ORQUEWRENCH .M
MMSOCKETSPANNER
ANDMMSOCKETS
MMSCREWDRIVER
MM;IN=SCREWDRIVER
MMRINGSPANNER
ANDMMSOCKETSPANNERS
0LASTICHAMMER
4WEEZERS
4HETOOLSARENOTAVAILABLEFROM3AUER
&
$ANFOSS
6 520L0066s2EV""s-AY
932 BOMAG 008 918 12

Steering valve 18.7
Service Manual
$ISMANTLING
Dismantling $ISMANTLESTEERINGCOLUMNFROMSTEERING
UNITANDPLACETHESTEERINGUNITINTHE
HOLDINGTOOL
3CREWOUTTHESCREWSINTHEENDCOVER
OFFPLUSONESPECIALSCREW
&
2EMOVETHEENDCOVERSIDEWAYS
&
,IFTTHEGEARWHEELSETWITHSPACERIF
lTTED OFFTHEUNIT4AKEAUTTHETWO/
RINGS
&
2EMOVETHECARDANSHAFT
&
520L0066s2EV""s-AY 7
008 918 12 BOMAG 933
18.7 Steering valve
Service Manual
$ISMANTLING
Dismantling 2EMOVEDISTRIBUTORPLATE
&
3CREWOUTTHETHREADEDBUSHOVERTHE
CHECKVALVE
&
2EMOVE/ RING
&
/30"/30",3/30"8,3

3HAKEOUTTHECHECKVALVEBALLMM
/30#,3/30#,32
3HAKEOUTTHECHECKVALVEBALLAND
SUCTIONVALVEPINSANDBALLS
/NSOMEPINSINTHE/30#THEREARE
TWOSPRINGSSEEPAGEPOS
2EPLACETHISPINSPRIORTOTHEREASSEMBLY
&
8 520L0066s2EV""s-AY
934 BOMAG 008 918 12

Steering valve 18.7
Service Manual
$ISMANTLING
Dismantling 4AKECARETOKEEPTHECROSSPININTHE
SLEEVEANDSPOOLHORIZONTAL4HEPIN
CANBESEENTHROUGHTHEOPENEND
OFTHESPOOL0RESSTHESPOOLINWARDS
ANDTHESLEEVERINGBEARINGRACES
ANDNEEDLEBEARINGWILLBEPUSHED
OUTOFTHEHOUSINGTOGETHER
&
4AKERINGBEARINGRACESANDNEEDLE
BEARINGFROMSLEEVEANDSPOOL
4HEOUTERTHIN BEARINGRACECAN
SOMETIMEShSTICKvINTHEHOUSING
THEREFORECHECKTHATITHASCOMEOUT
&
0RESSOUTTHECROSSPIN5SETHE
SPECIALSCREWFROMTHEENDCOVER
.OTENEXTPOINTPARAGRAPH
&
/30"#.AND/30##.
#. OSPF
!SMALLMARKHASBEENMADEWITH
APUMICESTONEONBOTHSPOOLAND
SLEEVECLOSETOONEOFTHESLOTSFORTHE
NEUTRALPOSITIONSPRINGSSEEDRAW m
ING
)FTHEMARKISNOTVISIBLEREMEMBER
TOLEAVEAMARKOFYOUROWNONSLEEVE
ANDSPOOLBEFORETHENEUTRALPOSITION
SPRINGSAREDISMANTLED
&OR/30&BOTHMARKSSHOULDBE
PLACEDOPPOSITEEACHOTHER &
520L0066s2EV""s-AY 9
008 918 12 BOMAG 935
18.7 Steering valve
Service Manual
$ISMANTLING
Dismantling #AREFULLYPRESSTHESPOOLOUTOFTHE
SLEEVE
&
0RESSTHENEUTRALPOSITIONSPRINGSOUT
OFTHEIRSLOTSINTHESPOOL
&
2EMOVEDUSTSEALAND/ RING+IN
RING2OTO'LYD
&
2EMOVEPLUGSFROMSHOCKVALVES
USINGAMMIHEXAGONSOCKET
spanner
&
10 520L0066s2EV""s-AY
936 BOMAG 008 918 12

Steering valve 18.7
Service Manual
$ISMANTLING
Dismantling 2EMOVESEALWASHERS OFF
&
5NSCREWTHESETTINGSCREWSUSINGA
MMIHEXAGONSOCKETSPANNER
&
3HAKEOUTTHETWOSPRINGSANDTWO
VALVEBALLSINTOYOURHAND4HEVALVE
SEATSAREBONDEDINTOTHEHOUSING
ANDCANNOTBEREMOVED
&
4HESHOCKVALVESARENOWDISMANTLED
&
520L0066s2EV""s-AY 11
008 918 12 BOMAG 937
18.7 Steering valve
Service Manual
$ISMANTLINGTHE0RESSURE2ELIEF6ALVEFOR/30#
Dismantling 3CREWOUTTHEPLUGUSINGAND
2EMOVESEALWASHERS
&
5NSCREWTHESETTINGSCREWUSINGAN
&
3HAKEOUTSPRINGANDPISTON4HE
VALVESEATISBONDEDINTOTHEHOUSING
ANDCANNOTBEREMOVED
&
4HEPRESSURERELIEFVALVEISNOW
DISMANTLED
&
12 520L0066s2EV""s-AY
938 BOMAG 008 918 12

Steering valve 18.7
Service Manual
$ISMANTLINGTHE0RESSURE2ELIEF6ALVE#ARTRIDGE
Dismantling the Pressure 3CREWOUTTHEPRESSURERELIEFVALVE

Relief Valve (Cartridge) USINGANDMMIHEXAGONSOCKET
for OSPC LS / OSPC LSR SPANNER2EMOVETHESEALRING)FTHE
VALVEISDEFECTIVEITMUSTBEREPLACED
&
4HEPRESSURERELIEFVALVEISNOW
DISMANTLED
&
4HESTEERINGUNIT/30"ISNOWCOM
PLETELYDISMANTLED
&
4HESTEERINGUNIT/30",3ISNOW
COMPLETELYDISMANTLED
&
520L0066s2EV""s-AY 13
008 918 12 BOMAG 939
18.7 Steering valve
Service Manual
$ISMANTLINGTHE0RESSURE2ELIEF6ALVE#ARTRIDGE
Dismantling the Pressure 4HESTEERINGUNIT/30#ISNOW

Relief Valve (Cartridge) COMPLETELYDISMANTLED
for OSPC LS / OSPC LSR 2EPLACETHISPINSPRIORTOTHEREAS
SEMBLY
&
4HESTEERINGUNIT/30#,3ISNOW
COMPLETELYDISMANTLED
2EPLACETHISPINSPRIORTOTHEREAS
SEMBLY
&
Cleaning Lubrication
#LEANALLPARTSCAREFULLYIN3HELLSOL+ "EFOREASSEMBLYLUBRICATEALLPARTSWITH
ORTHELIKE HYDRAULICOIL
Inspection and replacement

2EPLACEALLSEALSANDWASHERS
#HECKALLPARTSCAREFULLYANDMAKE
ANYREPLACEMENTSNECESSARY
14 520L0066s2EV""s-AY
940 BOMAG 008 918 12

Steering valve 18.7
Service Manual
!SSEMBLING
Assembling
0LACETHETWOmATNEUTRALPOSITION
SPRINGSINTHESLOT
0LACETHECURVEDSPRINGSBETWEEN
&
THEmATONESANDPRESSTHEMINTO
PLACE
!
,INEUPTHESPRINGSET
&
'UIDETHESPOOLINTOTHESLEEVE-AKE
SURETHATSPOOLANDSLEEVEFOR/30"
,3/30"8,3/30#,3/30#,32AND
OSPF are placed correctly in relation
TOEACHOTHERSEEPAGE
&
520L0066s2EV""s-AY 15
008 918 12 BOMAG 941
18.7 Steering valve
Service Manual
!SSEMBLING
Assembling !SSEMBLESPOOLANDSLEEVE
OSPB LS, OSPBX LS, OSPC LS, OSPC

LSR and OSPF
7HENASSEMBLINGSPOOLAND
SLEEVEONLYONEOFTWOPOSSIBLEWAYS
OFPOSITIONINGTHESPRINGSLOTSIS
CORRECT4HEREARETHREESLOTSINTHE
SPOOLANDTHREEHOLESINTHESLEEVEIN
THEENDOFTHESPOOLSLEEVEOPPOSITE
&
TOTHEENDWITHSPRINGSLOTS0LACE
THESLOTSANDHOLESOPPOSITEEACH
OTHERSOTHATPARTSOFTHEHOLESINTHE
SLEEVEAREVISIBLETHROUGHTHESLOTSIN
THESPOOL
OSPB CN and OSPC CN

!SSEMBLETHESPOOLSLEEVEANDMAKE
SURETHEMARKSONSPOOLANDSLEEVE
AREOPPOSITEEACHOTHERSEEDRAWING
PAGE
&
0RESSTHESPRINGSTOGETHERANDPUSH
THENEUTRALPOSITIONSPRINGSINTO
PLACEINTHESLAVE
&
,INEUPTHESPRINGSANDCENTRETHEM
&
16 520L0066s2EV""s-AY
942 BOMAG 008 918 12

Steering valve 18.7
Service Manual
!SSEMBLING
Assembling 'UIDETHERINGDOWNOVERTHESLEEVE
4HERINGSHOULDBEABLETOMOVE
FREEOFSPRINGS
&
&ITTHECROSSPININTOTHESPOOLSLEEVE
&
Fit bearing races and needle bearings

ASSHOWNONTHEDRAWINGNEXTPAGE
&
&
520L0066s2EV""s-AY 17
008 918 12 BOMAG 943
18.7 Steering valve
Service Manual
!SSEMBLY0ATTERNFOR3TANDARD"EARING
Assembling for Assembly pattern for standard bearing

Standard Bearing
/UTERBEARINGRACE
.EEDLEBEARING
3 Inner bearing race
4 Spool
3LEEVE
!
Assembly pattern for double bearing
7ASHERFORAXIALBEARING
/UTERNEEDLEBEARING
3 Outer bearing race
4 Spool
3LEEVE
)NNERNEEDLEBEARING
)NNERBEARINGRACE
!
4HEINSIDECHAMFERONTHEINNERBEARINGRACEMUSTFACETHEINNERSPOOL
18 520L0066s2EV""s-AY
944 BOMAG 008 918 12

Steering valve 18.7
Service Manual
)NSTALLATION)NSTRUCTIONFOR/ RING+IN RING2OTO'LYD
Installation 4URNTHESTEERINGUNITUNTILTHEBORE
Instructions for ISHORIZONTAL'UIDETHEOUTERPARTOF
O-ring / Kin-ring THEASSEMBLYTOOLINTOTHEBOREFOR
Roto glyd THESPOOLSLEEVE
&
'REASEO RINGANDKING RINGROTO

'LYDWITHHYDRAULICOILANDPLACE
THEMONTHETOOL
&
(OLDTHEOUTERPARTOFTHEASSEMBLY
TOOLINTHEBOTTOMOFTHESTEERING
UNITHOUSINGANDGUIDETHEINNER
PARTOFTHETOOLRIGHTTOTHEBOTTOM
&
0RESSANDTURNTHEO RINGKIN RING

INTOPOSITIONINTHEHOUSING
&
520L0066s2EV""s-AY 19
008 918 12 BOMAG 945
18.7 Steering valve
Service Manual
)NSTALLATION)NSTRUCTIONFOR/ RING+IN RING2OTO'LYD
Installation $RAWTHEINNERANDOUTERPARTSOF
Instructions for THEASSEMBLYTOOLOUTOFTHESTEERING
O-ring / Kin-ring / UNITBORELEAVINGTHEGUIDEFROMTHE
Roto Glyd INNERPARTINTHEBORE
&
20 520L0066s2EV""s-AY
946 BOMAG 008 918 12

Steering valve 18.7
Service Manual
)NSTALLATION)NSTRUCTIONFOR,IP3EAL
Installation ,UBRICATETHELIPSEALWITHHYDRAULIC
Instructions for OILANDPLACEITONTHEASSEMBLYTOOL
Lip Seal
&
'UIDETHEASSEMBLYTOOLRIGHTTOTHE
BOTTOM
&
0RESSANDTURNTHELIPSEALINTOPLACE
INTHEHOUSING
&
7ITHALIGHTTURNINGMOVEMENT
GUIDETHESPOOLANDSLEEVEINTOTHE
BORE
&ITTHESPOOLSETHOLDINGTHECROSSPIN
HORIZONTAL
&
520L0066s2EV""s-AY 21
008 918 12 BOMAG 947
18.7 Steering valve
Service Manual
Installation 4HESPOOLSETWILLPUSHOUTTHE
Instructions for ASSEMBLYTOOLGUIDE4HEO RING
Lip Seal ANDKIN RINGROTO'LYDARENOWIN
POSITION
&
4URNTHESTEARINGUNITUNTILTHEBORE
ISVERTICALAGAIN0UTTHECHECKVALVE
BALLINTOTHEHOLEINDICATEDBYTHE
ARROW
&
3CREWTHETHREADEDBUSHLIGHTLYINTO
THECHECKVALVEBORE4HETOPOFTHE
BUSHMUSTLIEJUSTBELOWTHESURFACE
OFTHEHOUSING
&
0LACEABALLINTHETWOHOLESINDICATED
BYTHEARROWS
&
22 520L0066s2EV""s-AY
948 BOMAG 008 918 12

Steering valve 18.7
Service Manual
Installation 0LACEANEWPININTHESAMETWO
Instructions for HOLES
Lip Seal
&
)NSOMECASESASPRINGHASTOBE
lTTEDSEEPAGEPOS ONTHEPIN
BEFOREITISPLACEDINTHE
HOUSING
&
'REASETHEO RINGWITHMINERALOIL
APPROXVISCOSITYMMS;353=
AT²#;²&=
&
0LACETHEDISTRIBUTORPLATESOTHATTHE
CHANNELHOLESMATCHTHEHOLESINTHE
HOUSING
&
520L0066s2EV""s-AY 23
008 918 12 BOMAG 949
18.7 Steering valve
Service Manual
Installation 'UIDETHECARDANSHAFTDOWNINTOTHE
Instructions for BORESOTHATTHESLOTISPARALLELWITH
Lip Seal THECONNECTIONmANGE
&
0LACETHECARDANSHAFTASSHOWN
SOTHATITISHELDINPOSITIONBYTHE
MOUNTINGFORK
&
'REASETHETWOO RINGSWITHMINERAL
OILAPPROXVISCOSITYMMS;353=
AT²#;²&=ANDPLACETHEMINTHE
TWOGROOVESINTHEGEARRIM&ITTHE
GEARWHEELANDRIMONTHECARDAN
SHAFT
&
Caution
&ITTHEGEARWHEELROTOR ANDCARDAN
SHAFTSOTHATATOOTHBASEINTHEROTOR
ISPOSITIONEDINRELATIONTOTHESHAFT
SLOTASSHOWN4URNTHEGEARRIMSO
THATTHESEVENTROUGHHOLESMATCH
THEHOLESINTHEHOUSING
&
24 520L0066s2EV""s-AY
950 BOMAG 008 918 12

Steering valve 18.7
Service Manual
Installation &ITTHESPACERIFANY

Instructions for
Lip Seal
&
0LACETHEENDCOVERINPOSITION
&
&ITTHESPECIALSCREWWITHWASHERAND
PLACEITINTHEHOLESHOWN
&
&ITTHESIXSCREWSWITHWASHERS
ANDINSERTTHEM
#ROSS TIGHTENALLTHESCREWSANDTHE
ROLLEDPINWITHATORQUEOF
.M; LBFIN=
4HE/30"/30",3AND/30"8,3CAN
NOWBEFUNCTIONTESTED
&
520L0066s2EV""s-AY 25
008 918 12 BOMAG 951
18.7 Steering valve
Service Manual
!SSAMBLYOFTHE0RESSURE2ELIEF6ALVEFOR/30#
Assembly of the Pressure &ITTHEPISTON

Relief Valve for OSPC
&
&ITTHESPRING
&
3CREWINTHESETTINGSCREWWITHAN
MMHEXAGONSOCKETSPANNER
-AKETHEPRESSURESETTINGONAPANEL
ORTHEVEHICLE
&
3CREWPLUGWITHDUSTSEALINTOTHE
HOUSINGUSINGANMMIHEXAGON
SOCKETSPANNER
4IGHTENINGTORQUE .M
; LBFIN=
&
26 520L0066s2EV""s-AY
952 BOMAG 008 918 12

Steering valve 18.7
Service Manual
!SSAMBLYOFTHE3HOCK6ALVESFOR/30#/30#,3/30#,32
Assambly of the Shock 0UTABALLINTHETWOHOLESINDICATED

Valves for OSPC/OSPC LS/ BYTHEARROWS
OSPC LSR
&
Place springs and valve cones over

THETWOBALLS
4HEBLUESPRINGAPPLIESTOSETTING
RANGE BAR; PSI=4HE
untreated spring applies to setting
RANGE BAR; PSI=
&
3CREWINTHETWOSETTINGSCREWSUSING
AMMIHEXAGONSOCKETSPANNER
-AKETHEPRESSURE
SETTINGONAPANELORTHEVEHICLE
&
3CREWPLUGWITHSEALRINGINTOTHE
TWOSHOCKVALVESANDTIGHTENTHEM
WITHATORQUEOF
.M;LBFIN=USING
AMMIHEXAGONSOCKETSPANNER
3TEERINGUNITTYPE/30#/30#,3OR
/30#,32ISNOWASSEMBLED
&
520L0066s2EV""s-AY 27
008 918 12 BOMAG 953
18.7 Steering valve
Service Manual
!SSAMBLYOFTHE3HOCK6ALVESFOR/30#/30#,3/30#,32
Assambly of the Shock 0LACETHEDUSTSEALRINGINTHE

Valves for OSPC/OSPC LS/ HOUSING7ITHTHE/30#/30#,3AND
OSPC LSR /30#,32THEDUSTSEALRINGMUSTBE
PLACEDONLYAFTERTHEPRESSURERELIEF
VALVEANDSHOCKVALVESHAVEBEEN
lTTED
&
&ITTHEDUSTSEALRINGINTHEHOUSING
USINGSPECIALTOOL3*
SEEPAGE ANDA
PLASTICHAMMER
&
0RESSTHEPLASTICPLUGSINTOTHE
CONNECTIONPORTS
$ONOTUSEAHAMMER
&
28 520L0066s2EV""s-AY
954 BOMAG 008 918 12

Steering valve 18.7
Service Manual
-AX4IGHTENING4ORQUEAND(YDRAULIC#ONNECTIONS
Max. Tightening Torque 4 4ANK

and Hydraulic Connec-
tions , ,EFTPORT
0 0UMP
2 2IGHTPORT
Max. tightening torque N.m [lbf.in]
Screwed With cooper With aluminium

With cutting edge With O-ring
connection washer washer
'4 ;= ;= ;=
3
' ;= ;= ;=
' ;= ;= ;=

5.& ;=
3
4 5.& ;=
-s ;= ;= ;= ;=
-s ;= ;= ;= ;=
-s ;= ;= ;= ;=
520L0066s2EV""s-AY 29
008 918 12 BOMAG 955
18.7 Steering valve
Service Manual
.OTES
30 520L0066s2EV""s-AY
956 BOMAG 008 918 12

Steering valve 18.7
Service Manual
.OTES
520L0066s2EV""s-AY 31
008 918 12 BOMAG 957
18.7 Steering valve
Our Products Sauer-Danfoss Mobile Power and Control Systems

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958 BOMAG 008 918 12
18.8 Axle
008 918 12 BOMAG 959

18.8 Axle
960 BOMAG 008 918 12

Axle 18.8
008 918 12 BOMAG 961

18.8 Axle
962 BOMAG 008 918 12

Axle 18.8
008 918 12 BOMAG

1 963
18.8 Axle
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 responsabilitaÁ per l'utilizzo di componenti non originali o accessori
non collaudati ed approvati.
AÈnderungen ohne vorherige AnkuÈndingung vorbehalten. Es wird jede Verantwortung fuÈr die Verwendung von Nichtoriginalteilen oder
nicht abgenommenem und genehmigtem ZubehoÈr 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 reÂserve le droit d'apporter des modifications aÁ sa production, sans pour cela eÃtre tenu d'en donner preÂavis. Nous
deÂclinons toute responsabiliteÂ pour l'utilisation de pieÁces non originales ou d'accessoires non testeÂs et homologueÂs.
964 BOMAG
2 008 918 12
Axle 18.8
INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX
INTRODUCTION ..........................................................5 DIFFERENTIAL UNIT

GB MAINTENANCE AND LUBRICANTS . Removal and disassembly ....................................................44
. Definition of viewpoints............................................7 . Assembly and installation .....................................................54
. Data plate ..............................................................................7 REDUCTION GEAR AND BEVEL PINION
. Maintenance points ................................................................7 . Disassembly.........................................................................68
. Maintenance intervals.............................................................8 . Installation and adjustment ...................................................74
. Adjustment and checks ..........................................................8
. Conversion tables...................................................................9 SPECIAL TOOLS ......................................................................82
. 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
INTRODUZIONE .......................................................5 GRUPPO DIFFERENZIALE

ITA . Rimozione e smontaggio.......................................................44
MANUTENZIONE E LUBRIFICANTI
. Definizione viste ..................................................7 . Assemblaggio ed installazione ..............................................54
. Targa matricola ......................................................................7 RIDUTTORE E PIGNONE CONICO
. Punti di manutenzione ............................................................7 . Smontaggio..........................................................................68
. Intervalli di manutenzione .......................................................8 . Installazione e registrazione..................................................74
. Registrazione e controlli .........................................................8 ATTREZZI SPECIALI.................................................................82
. 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
VORAUSSETZUNG .................................................5 DIFFERENTIAL

D . Abmontieren und zerlegen ....................................................44
WARTUNG UND SCHMIERSTOFFE
. Definition der Ansichten......................................7 . Montieren und installieren.....................................................54
. Kennummernschild.................................................................7 REDUZIERER UND KEGELRAD
. Wartungsstellen .....................................................................7 . Abmontieren ........................................................................68
. Wartungsintervalle..................................................................8 . Installieren und einstellen .....................................................74
. Einstellungen und Kontrollen ..................................................8 SONDERWERZZEUGE ..............................................................82
. Umrechnungstabellen.............................................................9
. Anziehdrehmomente...............................................................9
. Material zur Blockierung von Schrauben und
fuÈr 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
008 918 12 BOMAG

3 965
18.8 Axle
INDEX - INDICE - INHALTSVERZEICHNIS - INDICE - INDEX
PROLOGO................................................................ 5 GRUPO DIFERENCIAL

ESP MANTENIMIENTO Y LUBRICANTES . Remocion y desmontaje ....................................................... 44
. Definicion vistas................................................... 7 . Montaje e instalacion ........................................................... 54
. Matricula ............................................................................... 7 REDUCTOR Y PINÄON CONICO
. Puntos de manutencion.......................................................... 7 . Remocion ............................................................................ 68
. Intervalos de manutencioÁn...................................................... 8 . Instalacion y ajuste .............................................................. 74
. Ajuste y controles .................................................................. 8 HERRAMIENTAS ESPECIALES................................................. 82
. 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
INTRODUCTION ....................................................... 5 GROUPE DIFFERENTIEL

F ENTRETIEN ET LUBRIFIANTS . Depose et demontage .......................................................... 44
. DeÂfinition vues ..................................................... 7 . Assemblage et installation .................................................... 54
. Plaque d'immatriculation ........................................................ 7 REDUCTEUR ET PIGNON CONIQUE
. Points d'entretien................................................................... 7 . Depose................................................................................ 68
. Intervalle de service ............................................................... 8 . Installation et reglage ........................................................... 74
. Reglages et controles............................................................. 8 OUTILS SPECIAL ..................................................................... 82
. Tableaux de conversion ......................................................... 9
. Couples de serrage................................................................ 9
. MateÂriaux pour le blocage vis, eÂtancheÂiteÂ 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
966 BOMAG
4 008 918 12
Axle 18.8
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION
The efficiency and continued operation of mechan- martelli in plastica o rame, leve appropriate estrattori e chiavi
GB ical units depend on constant, correct maintenance specifiche, al fine di facilitare il lavoro salvaguardando nel
and also on efficient repair work, should there be a contempo le superfici lavorate e la sicurezza degli operatori.
break-down or malfunction. The instructions contained in this Prima di procedere al disassemblaggio delle parti e scaricare
manual have been based on a complete overhaul of the unit. l'olio, eÁ opportuno eseguire un'accurata pulizia del ponte,
However, it is up to the mechanic to decide whether or not it is asportando incrostazioni ed accumuli di grasso.
necessary to assemble only individual components, when
partial repair work is needed. The manual provides a quick PREMESSA: Tutti gli organi meccanici smontati, devono
and sure guide which, with the use of photographs and essere accuratamente puliti con prodotti appropriati, quindi
diagrams illustrating the various phases of the operations, ripristinati o sostituiti nel caso presentino danni, usura,
allows accurate work to be performed. incrinature, grippaggi, ecc. In particolare, verificare l'integritaÁ
All the information needed for correct disassembly, checks and di tutte quelle parti in movimento (cuscinetti, ingranaggi, coppia
assembly of each individual component is set out below. In conica, alberi) e di tenuta (anelli OR, paraolio), soggette a
order to remove the differential unit from the vehicle, the maggiori sollecitazioni ed usura. EÁ consigliabile, comunque, la
manuals provided by the vehicle manufacturer should be sostituzione degli organi di tenuta ogni qualvolta si proceda alla
consulted. In describing the following operations it is presumed revisione o riparazione dei componenti. Al momento del
that the unit has already been removed from the vehicle.
montaggio, gli anelli di tenuta devono essere lubrificati sui
IMPORTANT: In order to facilitate work and protect both bordi di tenuta. Nel caso della coppia conica, la sostituzione di
working surfaces and operators, it is advisable to use proper uno dei suoi ingranaggi comporta anche la sostituzione
equipment such as: trestles or supporting benches, plastic or dell'altro. In fase di montaggio sono da rispettare scrupolosa-
copper hammers, appropriate levers, pullers and specific mente i giochi, i precarichi e le coppie prescritte.
spanners or wrenches. Á : Il manuale fornisce le validitaÁ dei gruppi sotto forma
VALIDITA
Before going on to disassemble the parts and drain the oil, it is
di matricola. Al fine di una corretta interpretazione, le validitaÁ
best to thoroughly clean the unit, removing any encrusted or
sono indicate come:
accumulated grease.
= fino alla matricola
INTRODUCTORY REMARKS: All the disassembled mechan-
ical units should be thoroughly cleaned with appropriate = dalla matricola
products and restored or replaced if damage, wear, cracking or
seizing have occurred. Se non sono indicate validitaÁ, le operazioni di smontaggio ed
In particular, thoroughly check the condition of all moving parts assemblaggio sono comuni a tutte le versioni.
(bearings, gears, crown wheel and pinion, shafts) and sealing
parts (O-rings, oil shields) which are subject to major stress and MANUTENZIONE E RIPARAZIONE: Al fine di facilitare
wear. In any case, it is advisable to replace the seals every time interventi sui gruppi ponte differenziali e cambi di velocitaÁ la
a component is overhauled or repaired. During assembly, the SPICER CLARK-HURTH, ha ritenuto opportuno compilare
sealing rings must be lubricated on the sealing edge. In the queste istruzioni di manutenzione e riparazione. I disegni delle
case of the crown wheel and pinion, replacement of one attrezzature specifiche eventualmente necessarie per l'esecu-
component requires the replacement of the other one. During zione di interventi di manutenzione e riparazione possono
assembly, the prescribed pre-loading, backlash and torque of essere acquistati direttamente presso il costruttore; i ricambi
parts must be maintained. possono essere ordinati tramite il costruttore della macchina o
direttamente presso la DANA ITALIA S.p.A..
CLASSIFICATION: This manual classifies units according to
part numbers. For a correct interpretation, classification is
indicated as follows:
= up to the part number Die Leistung und Lebensdauer der mechanischen
D Teile haÈngt nicht nur von einer staÈndigen und
= from the part number on richtig durchgefuÈhrten Wartung sondern auch von
einem sofortigen Eingriff im StoÈrungsfall ab. Um dieses
When no classification is given, disassembly and assembly Handbuch zu erstellen sind wir von einer allgemeinen U È ber-
operations are the same for all versions. pruÈfung der Einheit ausgegangen, doch entscheidet der
Mechaniker ob die einzelnen Teile bei Reparaturen montiert
SPECIFIC EQUIPMENT AND SPARE PARTS: The drawings of werden muÈssen oder nicht. Das Handbuch ist schnell und
all specific tools required for maintenance and repair work can einfach nachzuschlagen und ermoÈglicht es anhand der Abbild-
be found at the end of this manual ; spare parts may be ordered ungen und der Zeichnungen, die die verschiedenen VorgaÈnge
either from the vehicle manufacturer or directly from the darstellen, gezielt einzugreifen. Nachstehend sind alle Infor-
Service Centers or Authorised Distributors of DANA ITALIA mationen und Hinweise aufgefuÈhrt, die zur Zerlegung, PruÈfung
S.p.A.. und Montage der Einzelteile noÈtig sind. Um die Differentia-
lachse des Fahrzeugs abzumontieren, lesen Sie bitte die
Anweisungen in den HandbuÈchern des Fahrzeugherstellers.
Die nachstehenden Beschreibungen gehen davon aus, daû die
Il rendimento e la continuitaÁ degli organi meccanici Fahrzeugachse schon abmontiert worden ist.
ITA dipendono oltre che da una costante e corretta
manutenzione, anche dal tempestivo intervento, WICHTIG: Um die Arbeit zu erleichtern und gleichzeitig die
nell'eventualitaÁ di guasti o anomalie. verarbeiteten FlaÈchen zu schuÈtzen und die Sicherheit der
Nel proporre questo manuale si eÁ considerata l'ipotesi di una Arbeiter zu gewaÈhrleisten, empfehlen wir geeignete Werk-
revisione generale del gruppo ma eÁ il meccanico a valutare la zeuge wie BoÈcke, Tisch, Gummi- oder Kupferhammer, geeig-
necessitaÁ di montare solo i singoli componenti nel caso di nete Abzieher und SchluÈssel zu verwenden.
Bevor mit der Zerlegung der Teile begonnen und das O Èl
riparazione. Il manuale eÁ una guida rapida e sicura che
consente interventi precisi, tramite le fotografie ed i disegni abgelassen wird, muû die Achse sorgfaÈltig gereinigt und
prospettici che illustrano le varie fasi delle operazioni. Di Verkrustungen und Fettablagen abgetragen werden.
seguito sono riportate tutte quelle informazioni ed avvertenze VORAUSSETZUNG: Alle abmontierten mechanischen Teile
necessarie al corretto disassemblaggio, alle relative verifiche muÈssen sorgfaÈltig mit geeigneten Reinigungsmitteln gereinigt
ed all'assemblaggio dei singoli componenti. Per la rimozione oder, wenn beschaÈdigt, verschleiût, gerissen, festgefressen
del ponte differenziale dal veicolo, eÁ necessario consultare i usw. ausgewechselt werden. Insbesondere muû der einwand-
manuali forniti dal costruttore del veicolo. Nel descrivere le freie Zustand aller beweglichen Teile (Lager, ZahnraÈder,
operazioni seguenti, si presuppone che il ponte sia giaÁ stato Kegelradpaare, Wellen) und der Dichtungen (O-Ringe, O È lab-
rimosso dal veicolo. dichtungen), die am meisten beansprucht werden und ver-
schleiûen, kontrolliert werden. Wir empfehlen auf jeden Fall die
IMPORTANTE: In tutte le operazioni, eÁ consigliabile usare Abdichtungselemente immer auszuwechseln, wenn eine U È ber-
attrezzature idonee quali cavalletti o banchi di sostegno, holung oder eine Reparatur der Teile vorgenommen wird. Bei
008 918 12 BOMAG
5 967
18.8 Axle
INTRODUCTION - INTRODUZIONE - VORAUSSETZUNG - PROLOGO - INTRODUCTION
der Montage muÈssen die RaÈnder der Dichtringe geschmiert Si no ha sido indicada validez, las operacioÂn de desmontaje y
werden. Wenn beim Kegelradpaar ein Zahnrad ausgewechselt montaje son comunes a todas las versiones.
werden muû, muû auch das andere Zahnrad ausgewechselt
werden. Bei der Montage muÈssen die vorgeschriebenen HERRAMIENTAS ESPECIFICAS Y RECAMBIOS: Los planos de
Spiele, Vorspannungen und Drehmomente strengstens ein- las herramientas especificas necesarias para la ejecucioÂn de las
gehalten werden. intervenciones de mantenimiento figuran al final del manual; los
recambios se pueden pedir al fabricante de la maÂquina o
È LTIGKEIT: Das Handbuch gibt an zu welchen Kennummern directamente al Service Center o a Distribuidores autorizados de
GU DANA ITALIA S.p.A..
die Einheiten gehoÈren. Der Einfachheit halber sind die
AngehoÈrigkeiten folgendermaûen aufgefuÈhrt:
= bis Kennummer
= ab Kennummer Le rendement et la continuiteÂ des organes meÂca-

F niques deÂpendent, non seulement d'une mainte-
Wenn keine AngehoÈrigkeit angegeben ist, verstehen sich die nance correcte et constante, mais eÂgalement de la
Arbeiten zur Zerlegung und Montage fuÈr alle AusfuÈhrungen rapiditeÂ d'intervention en cas de pannes ou d'anomalies. En
guÈltig. vous proposant ce manuel, on envisage l'hypotheÁse d'une
reÂvision geÂneÂrale du groupe, mais c'est au meÂcanicien
SPEZIFISCHE WERKZEUGE UND ERSATZTEILE: die Zeich- d'eÂvaluer la neÂcessiteÂ de monter ou non chacun des
nungen der fuÈr Wartungsarbeiten erforderlichen spezifischen composants en cas de reÂparation. Le manuel est un guide
Werkzeuge, sind am Ende des Handbuchs aufgefuÈhrt; Ersatz- rapide et suÃr consentant des interventions preÂcises, au travers
teile koÈnnen beim Fahrzeughersteller oder direkt bei der de photographies et de dessins prospectifs qui illustrent les
Kundendienststelle oder bei einem zugelassenen HaÈndler der diffeÂrentes phases des opeÂrations. Ensuite, sont reporteÂes
DANA ITALIA S.p.A. bezogen werden. toutes les informations et preÂcautions neÂcessaires pour un
deÂmontage correct et les veÂrifications et assemblage de
chaque composant. En ce qui concerne le deÂplacement du
pont d'eÂtai du veÂhicule, il est neÂcessaire consulter les manuels
El rendimiento y la duracioÂn de los oÂrganos mecaÂnicos
fournis par le constructeur du veÂhicule. En deÂcrivant les
ESP depende, ademaÂs que del constante y correcto opeÂrations suivantes, on preÂsume que le pont ait deÂjaÁ eÂteÂ
mantenimiento, tambieÂn de la intervencioÂn inmediata enleveÂ du veÂhicule.
en caso de averõÂas o anomalõÂas.
Al proponer este manual, ha sido considerada la suposicioÂn de una IMPORTANT: Pour faciliter le travail en sauvegardant en
revisioÂn general del grupo, pero es el mecaÂnico quien tiene que meÃme temps les surfaces usineÂes et la seÂcuriteÂ des opeÂra-
valorar la necesidad de montar cada uno de los componentes en teurs, il est preÂconiseÂ d'utiliser des installations approprieÂes
caso de reparacioÂn. El manual es una guõÂa raÂpida y segura que telles que des eÂtais ou banc de support, maillets en plastique
permite intervenciones precisas por medio de fotografõÂas y de ou cuivre, leviers approprieÂs, extracteurs et cleÂs speÂcifiques.
planos que muestran las distintas fases de las operaciones. A
continuacioÂn figuran todas las informaciones y advertencias Avant de proceÂder au deÂmontage des parties et vidanger
necesarias para ejecutar un montaje correcto, para las comproba- l'huile, il vaut mieux nettoyer soigneusement le pont, en
ciones y el montaje de cada uno de los componentes. Para enlevant incrustations et blocs de gras.
remover el puente diferencial del vehõÂculo hay que consultar los
manuales de los fabricantes del vehõÂculo. En la descripcioÂn de las PRELIMINAIRE: Tous les organes meÂcaniques deÂmonteÂs
operaciones siguientes se supone que el puente ya ha sido sacado doivent eÃtre soigneusement nettoyeÂs aÁ l'aide de produits
del vahõÂculo. approprieÂs et reÂpareÂs ou remplaceÂs dans le cas ouÁ ils seraient
abõÃmeÂs, useÂs, feÃleÂs, grippeÂs, etc. VeÂrifier, l'inteÂgriteÂ, en
IMPORTANTE: Para facilitar el trabajo salvaguardando al mismo particulier, de toutes les parties en mouvement (paliers,
tiempo las superficies mecanizadas y la seguridad de los
operadores, se aconseja que se usen equipos y herramientas engrenages, couple conique, arbres) et l'eÂtancheÂiteÂ des
adecuados como caballetes y bancos de soporte, martillos de bagues (bagues OR, parahuile), qui sont sujettes aÁ plus de
plaÂstico o de cobre, palancas adecuadas, extractores y llaves sollicitations et aÁ l'usure. Il est preÂconiseÂ, de toute facËon, de
especõÂficas. substituer les organes d'eÂtancheÂiteÂ, chaque fois que l'on
Antes de desmontar las partes y descargar el aceite, es effectue une reÂvision ou une reÂparation des composants. Au
conveniente que se haga una limpieza minuciosa del puente moment du montage, les bagues d'eÂtancheÂiteÂ doivent eÃtre
sacando las incrustaciones y acumulaciones de grasa. lubrifieÂes sur les bords eÂtanches. Dans le cas du couple
conique, la substitution de l'un de ses engrenages comporte
INTRODUCCION: Todos los oÂrganos mecaÂnicos desmontados eÂgalement la substitution de l'autre. En phase de montage, il
tienen que ser limpiados minuciosamente con productos adecua-
dos y restaurados o sustituidos en el caso de que presenten danÄos, faut respecter scrupuleusement les jeux, les preÂcharges et les
desgaste, rajaduras, agarrotamientos, etc. En particular, compro- couples prescrits.
bar la integridad de todas las partes en movimiento (cojinetes,
engranajes, par coÂnico, ejes) y de estanqueidad (anillos OR, VALIDITE: Le manuel fournit la validiteÂ des groupes sous
detenedor de aceite) sujetas a mayores solicitaciones y desgaste. forme de matricule. Pour une meilleure interpreÂtation, les
Se aconseja, de todas formas, que se sustituyan los oÂrganos de validiteÂs sont indiqueÂes comme:
estanqueidad cada vez que se ejecute la revisioÂn o reparacioÂn de
los componentes. = jusqu'aÁ l'immatriculation
Al volver a montar, los segmentos de compresioÂn tienen que estar
lubricados en los bordes de estanqueidad. En el caso del par = aÁ partir de l'immatriculation et apreÁs
coÂnico, la sustitucioÂn de uno de sus engranajes comporta tambieÂn
la sustitucioÂn del otro. Al montar hay que tener en cuenta Si les validiteÂs ne sont pas indiqueÂes, les opeÂrations de
escrupulosamente los juegos, las precargas y los pares descriptos.
deÂmontage et d'assemblage sont pareilles dans toutes les
VALIDEZ: El manual suministra la validez de los grupos en forma versions.
de matrõÂcula. Para poder tener una interpretacioÂn correcta, la
validez estaÂ indicada: INSTALLATIONS SPECIFIQUES ET PIECES DETACHEES:
Les dessins des installations speÂcifiques neÂcessaires pour
= hasta la matrõÂcula effectuer des interventions d'entretien sont reporteÂes aÁ la fin du
manuel, les pieÁces deÂtacheÂes peuvent eÃtre commandeÂes au
= desde la matrõÂcula en adelante constructeur de la machine ou directement aux Centres de
Services, ou Distributeurs agreÂeÂs de la SocieÂteÂ DANA ITALIA
S.p.A..
968 BOMAG
6 008 918 12
Axle
MAINTENANCE AND LUBRICANT - MANUTENZIONE E LUBRIFICANTI - WARTUNG UND SCHMIERSTOFFE
18.8
MANTENIMIENTO Y LUBRICANTES - ENTRETIEN ET LUBRIFIANTS
DEFINITION OF VIEWPOINTS - DEFINIZIONE VISTE - DEFINITION DER ANSICHTEN - DEFINICION VISTAS - DEÂFINITION VUES
LEFT SIDE RIGHT SIDE

LATO SINISTRO LATO DESTRO
LINKE SEITE RECHTE SEITE
LADO IZQUIERDO LADO DERECHO
COTE GAUCHE COTE DROITE
D1240138
DATA PLATE - TARGA MATRICOLA - KENNUMMERNSCHILD - MATRICULA - PLAQUE D'IMMATRICULATION
Type and model unit - modification index
1
Tipo e modello gruppo - indice di modifica
Typ und Modelleles Antriebes - AÈ nderungsverzeichnis
Tipo y modelo grupo - indice de modificacion
Type et modeÂle de ensemble - tableau des modifications
1 2 Serial number
2
Numero di serie
Seriennummer
3 NuÂmero de serie
Numero de serie
MFG. BY CLARK-HURTH COMPONENTS S.P.A. Lubricant
3
38062 Arco (Trento) Lubrificante
Schmieroel
MADE IN ITALY Lubricante
Lubrificant
D1240011
MAINTENANCE POINTS - PUNTI DI MANUTENZIONE - WARTUNGSSTELLEN - PUNTOS DE MANUTENCION - POINTS D'ENTRETIEN
3 1 1 1 3
2 2 2 2
2
1
Oil filling plug - Tappo di carico
EinfuÈllstopfen - Tapon de carga
Bouchon de ravitaillement
2
Oil draining plug - Tappo di scarico
1 3 Ablasstopfen - Tapon de descarga
Bouchon de vidange
2
3
Check level plug - Tappo controllo livello
È lpegelkontrolle -
Stopfen zur O
Tapon de contrl de nivel - Jauge de niveau
D1240139
008 918 12 BOMAG

7 969
18.8 Axle
MAINTENANCE INTERVALS - INTERVALLI DI MANUTENZIONE - WARTUNGSINTERVALLE - INTERVALOS DE MANUTENCIOÁN - INTERVALLE DE SERVICE
OPERATION - OPERAZIONE - FREQUENCY - PERIODICITAÁ

LUBRICANTS - LUBRIFICANTI - SCHMIERSTOFFE -
ARBEITSVORGANG - - ZEITABSTAND -
LUBRICANTES - LUBRIFIANTS
OPERACION - OPERATION FRECUENCIA - PERIODICITE
Differential monthly
Differenziale mensile
Im differential monatlich . SAE85W90 (API GL4 - MIL L-2105)
. Check levels: Diferencial cada mes With additives for oil-bath brakes
. Controllo livelli: Differentiel mensuel Con additivi per freni a bagno d'olio
. È
Olstandkontrolle: Mit Zusatzmittel fuÈr Bremsen in OÈ lbad
. Control niveles: Planetary reduction every 200 hours
Con aditivos para frenos de banÄo de aceite
. ControÃle niveaux: Riduzione epicicloidale ogni 200 ore
Avec adjuvants pour freins en bain d'huile
Planetengetrieb alle 200 Std.
ReduccioÂn epicicloidal cada 200 horas . SAE85W90 (API GL5 - MIL 2105-B)
Reduction epicycloidale toutes les 200 heures With additives for oil-bath brakes, for units pre-
Differential every 800 hours ] senting hypoid crown wheel and pinion and /or
Differenziale ogni 800 ore self-locking differential gear
Im differential alle 800 Std. Per esecuzioni con coppia conica ipoide e/o con
Diferencial cada 800 horas differenziale autobloccante, con additivi per freni
Differentiel toutes les 800 heures a bagno d'olio
Bei AusfuÈhrungen mit Kegel- und Telleradpaar
. Oil change: Planetary reduction every 1000 hours ]
und/oder Selbstsperrdifferential, mit Zusatzmit-
. Cambio olio: Riduzione epicicloidale ogni 1000 ore È lbad
È lwechsel: teln fuÈr Bremsen in O
. O Planetengetrieb alle 1000 Std.
Para ejecuciones con par coÂnico hipoide y/o con
. Cambio aceite: ReduccioÂn epicicloidal cada 1000 horas
diferencial autobloqueante con aditivos para fre-
. Vidange huile: Reduction epicycloidale toutes les 1000 heures
nos de banÄo de aceite.
Self-locking differential gear every 700 hours ] r Pour exeÂcutions avec couple conique hypoõÈde et/
Differenziale autobloccante ogni 700 ore ou diffeÂrentiel autobloquant, avec adjuvants pour
Selbstsperrdifferential alle 700 Std. freins en bain d'huile
Diferencial autobloqueante cada 700 horas
Differentiel autobloquant toutes les 700 heures
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100 horas
de trabajo - Initialement apreÁs 100 heures de travail
r When it starts sounding noisy - Anche ai primi cenni di rumorositaÁ - Auch falls ungewoÈhnliche GeraÈusche zu bemerken sind - TambieÂn al primer
indicio de ruido - MeÃme aux premiers signaux de bruit
OPERATION - OPERAZIONE - MEMBER - ORGANO - CONDITIONS - CONDIZIONI - FREQUENCY - PERIODICITAÁ - LUBRICANTS - LUBRIFICANTI -
ARBEITSVORGANG - ELEMENT - BEDINGUNG - ZEITABSTAND - SCHMIERSTOFFE -
OPERACION - OPERATION ORGANO - ORGANE CONDICIONES - CONDITIONS FRECUENCIA - PERIODICITE LUBRICANTES - LUBRIFIANTS
Normal work monthly
Lavori normali mensile
Normale Arbeit monatlich
Greasing Articulations Trabajos normales cada mes
Ingrassaggio Snodi TaÃches ordinaires mensuel
Schmieren Gelenk MOLIKOTE
Engrase RoÂtula Awkward work Weekly
Graissage Articulations Lavori gravosi Settimanale
Schwere Arbeit WoÈchentlich
Trabajos pesados Semanal
TaÃches extraordinaires Hebdomadaire
ADJUSTMENT AND CHECKS - REGISTRAZIONE E CONTROLLI - EINSTELLUNGEN UND KONTROLLEN - AJUSTE Y CONTROLES - REGLAGES ET CONTROLES
UNIT - GRUPPO - OPERATION - OPERAZIONE FREQUENCY - PERIODICITAÁ - SERVICE BRAKE CIRCUIT - CIRCUITO COMANDO FRENI -
AGGREGAT - ARBEITSVORGANG - ZEITABSTAND - BREMSKREISLAUF - CIRCUITO MANDOS FRENOS -
GRUPO - GROUPE OPERACION - OPERATION FRECUENCIA - PERIODICITE CIRCUIT DE COMMANDE DES FREINS
Negative brake Adjustment every 1000 hours ]
Freno negativo Registrazione ogni 1000 ore Only for mineral oil use e.g. ATF Dexron II. Make sure
Federspeicherbremse Einstellen alle 1000 Std. that master cylinder seals are suitable for mineral oil.
Freno negativo Ajuste cada 1000 horas Usare esclusivamente olio minerale ATF Dexron II. Ac-
Frein neÂgatif ReÂglage toutes les 1000 hours certarsi che le guarnizioni del cilindro master siano
adatte a questo olio.
Service brake Adjustment every 500 hours È l verwenden, z.B.: ATF Dexron II.
Nur mineralisches O
Freni di servizio Registrazione ogni 500 ore
Achtung: Dichtringe des Hauptbremszylinders muÈs-
Hilfsbremse Einstellen alle 500 Std. È l geeignet sein.
sen fuÈr dieses O
Frenos de ejercicio Ajuste cada 500 horas
Usar exclusivamente aceite mineral ATF Dexron II.
Freins de service ReÂglage toutes les 500 hours
Asegurarse de que las juntas del cilindro principal
Wheel nuts Tightening every 200 hours son adecuadas para este aceite.
Dadi ruota Serraggio - ogni 200 ore Utiliser exclusivement huile mineÂrale ATF Dexron II.
Radmuttern Festziehen alle 200 Std. VeÂrifier que les joints du maõÃtre-cylindre, soien compa-
Tuercas rueda Apriete cada 200 horas tibles avec cette huile.
Ecrous de roue Serrage toutes les 200 hours
] Initially after 100 working hours - Inizialmente dopo 100 ore di lavoro - Erstmals nach 100 Betriebstunden - Al principio, despueÂs de 100
horas de trabajo - Initialement apreÁs 100 heures de travail
970 BOMAG
8 008 918 12
Axle 18.8
CONVERSION TABLES - TABELLE DI CONVERSIONE - UMRECHNUNGSTABELLEN

TABLAS DE CONVERSION - TABLEAUX DE CONVERSION
Units of pressure - UnitaÁ di pressione - Druckeinheiten

Unidad de presioÂn - UniteÂs de pression: 1 Atm%1 bar%105 PA%14.4 PSi
Units of weight - UnitaÁ di peso - Gewichtseinheiten Units of torque - UnitaÁ di coppia - Drehmomenteinheiten
Unidad de peso - UniteÂs de poids Unidad de par - UniteÂs 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
TIGHTENING TORQUES - COPPIE DI SERRAGGIO - ANZIEHDREHMOMENTE

PARES DE TORSION - COUPLES DE SERRAGE
Unit - UnitaÁ di misura - Meûeinheiten - Unidad de medida - UniteÂs de mesure: Nm

TYPE OF BOLT - TIPO VITE - GEWINDE - TIPO DE TORNILLO - TYPE DE VIS
SIZE OF BOLT
MISURA VITE
SCHRAUBENMASS 8.8 10.9 12.9
TAMAN Ä O TORNILLO
MESURE VIS Normali Normali Normali Normali Normali Normali
+ Loctite 242 + Loctite 270 + Loctite 242 + Loctite 270 + Loctite 242 + 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
COARSE PITCH - PASSO GROSSO - GROûER
SCHRITT - PASO GRUESO - GROS PAS
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
FINE PITCH - PASSO FINE - KLEINER SCHRITT
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
PASO FINO - PAS FIN
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
008 918 12 BOMAG

9 971
18.8 Axle
SCREW-LOCKING, SEALING AND LUBRICATING MATERIALS - MATERIALI PER BLOCCAGGIO VITI, TENUTA E LUBRIFICAZIONE - MATERIAL ZUR
BLOCKIERUNG VON SCHRAUBEN UND FUÈR DICHTUNGEN UND SCHMIERMITTEL - MATERIALES PARA EL BLOQUEO, ESTANQUEIDAD Y LUBRICACION -
MATEÂRIAUX POUR LE BLOCAGE VIS, EÂTANCHEÂITEÂ ET LUBRIFICATION
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, fuÈr Dichtungen und Schmiermittel, die im Handbuch aufgefuÈhrt sind, sind
dieselben die auch vom Hersteller verwendet werden.
Los materiales para el bloqueo, estanqueidad y lubricacioÂn especõÂfica indicados en el manual, son los que se usan en la faÂbrica
Les mateÂriaux de blocage, d'eÂtancheÂiteÂ et de lubrification speÂcifieÂs indiqueÂs dans ce manuel sont ceux employeÂs aÁ 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 aÈhnlichen Materialien zu ersetzen, die unter
anderen Namen und Kennzeichnungen im Handel erhaÈltlich sind.
De estos materiales damos las aplicaciones tõÂpicas que los distinguen, de manera que se puedan sustituir con productos similares
comercializados por otras marcas y por tanto con otras siglas.
De ces mateÂriaux ne sont reporteÂes que les applications typiques qui les distinguent de telle sorte qu'ils puissent eÃtre substitueÂs
par des produits semblables se trouvant dans le commerce sous d'autres marques et par conseÂquent sous d'autres sigles.
DENOMINATION
DENOMINAZIONE
BEZEICHNUNG APPLICATION - APPLICAZIONE - ANWENDUNG - APLICACION - APPLICATION
DENOMINACION
DENOMINATION
. 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. FuÈr mittlere Wi-
derstandskraÈfte geeignet. Darf erst aufgetragen werden, wenn die FlaÈchen von Schmiermittel richtig sauber
Loctite 242
sind. Dazu das entsprechende Produkt verwenden.
. Producto anaeroÂbico apto para prevenir el aflojamiento de tornillos, tuerca y tapones. Usado para el frenado
de media resistencia. Tiene que ser usado soÂlo despueÂs de haber quitado todo residuo de lubricante con el
activador especõÂfico.
. Produit anareÂobic servant aÁ preÂvenir le relaÃchement des vis, eÂcrous et bouchons. UtiliseÂ pour le freinage
demi reÂsistant. Il doit eÃtre utiliseÂ apreÁs avoir enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
. 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 oÈlkompatibel ist muÈssen die geschmierten FlaÈchen nicht aktiviert
Loctite 243 werden.
. Producto alternativo al 242 que, siendo oleocompatible, no requiere la activacioÂn de superficies lubricadas.
. Produit en alternance avec le 242 lequel eÂtant oleÂocompatible ne requiert aucune activation des surfaces
lubrifieÂes.
. 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 80ëC 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, puoÁ richiedere un riscaldamento a circa 80ëC.
. Anaerobes Produkt fuÈr hohe WiderstandskraÈfte fuÈr Schrauben und Muttern geeignet. Zuerst die FlaÈche sorg-
Loctite 270
faÈltig aktivieren. Um die FlaÈchen zu saÈubern, diese auf ca. 80ëC erwaÈrmen.
. Producto anaeroÂbico apto para el frenado de alta resistencia de tornillos y tuercas. tiene que ser usado de-
spueÂs de haber quitado todo residuo de lubricante con el activador especõÂfico.
La remocioÂn de las partes, puede requerir un calentamiento a unos 80ëC.
. Produit anareÂobic apte au freinage aÁ treÁs haute reÂsistance des vis et des eÂcrous. Il doit eÃtre utiliseÂ apreÁs avoir
enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
. 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; puoÁ sigillare accoppiamenti con
gioco diametrale massimo di 0,25 mm.
. Anaerobes Produkt zum Bremsen und Siegeln von groûen Gewinden, Muttern und Stiftschrauben , sehr
Loctite 275 widerstandsfaÈhig, verschleierungsbestaÈndig, 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 anaeÂrobie adapteÂ au freinage et au scellage aÁ haute reÂsistance des parties fileteÂes, boulons et pri-
sonniers de grandes dimensions, protection anti-alteÂration et scellage de tuyauteries; il peut sceller des ac-
couplements ayant un jeu diameÂtral maximal de 0,25 mm.
972 BOMAG
10 008 918 12
Axle 18.8
DENOMINATION
DENOMINAZIONE
DENOMINACION
DENOMINATION
. 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. PuoÁ sigillare giochi tra le flange fino a 0,2 mm.
. Anaerobes Produkt zur Abdichtung von FluÈssigkeiten an Flanschen und Schrauben mit LoÈcher, die mit FluÈs-
Loctite 510
sigkeiten in Kontakt stehen. Kann ein Spiel zwischen Flanschen bis 0,2 mm abdichten.
. Producto anaeroÂbico 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 anareÂobic apte aÁ la tenue eÂtanche des fluides entre les pieÁces aÁ brides et des vis aÁ trou en contact
avec les fluides. Il peut sceller un jeu parmi les flasques jusqu'aÁ 0,2 mm.
. 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 difficoltaÁ di smontaggio per cui puoÁ richiedere, 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.
Loctite 577
Nach der Polymerisation koÈnnte das Abmontieren etwas schwierig sein weshalb groÈûere Durchmesser
zuerst erhitzt werden muÈssen.
. 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 dificultaÁde desmontaje por lo tanto puede necesitar, para
los diametros majores, un calientamiento.
. Produit anaeÂrobie collage rapide assurant l'eÂtancheÂiteÂ des filetages des raccords coniques ou cylindriques
jusqu'aÁ M80. Il doit eÃtre utiliseÂ apreÁs qu'on ait enleveÂ toute trace de lubrifiant aÁ l'aide d'un activeur speÂcial.
Une certaine difficulteÂ de deÂmontage se preÂsente apreÁs la polymeÂrisation, on peut donc avoir la neÂcessiteÂ de
devoir chauffer preÂalablement pour de plus amples diameÁtres.
. 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).
PuoÁ incollare particolari con gioco tra 0,1 e 0, 25 mm.
. Anaerober Klebstoff fuÈr groûe WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellenna-
Loctite 638
ben). Kann Einzelteil mit einem Radialspiel zwischen 0,1 mm und 0,25 mm zusammenkleben.
. Adhesivo anaeroÂbico para el encolado raÂpido de alta resistencia de juntas cilõÂndricas de metal (cubo en el eje).
Puede encolar piezas con juego entre 0,1 mm y 0,25 mm.
. AdheÂsif anaeÂrobic servant aÁ un collage rapide et hautement reÂsistant des joints cylindriques en meÂtal
(moyeu sur l'arbre). Il peut servir aÁ coller des pieÁces avec un jeu allant de 0,1 aÁ 0,25 mm.
. 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).
PuoÁ incollare particolari con gioco radiale inferiore a 0,1 mm.
. Anaerober Klebstoff fuÈr mittlere WiderstandskraÈfte fuÈr Zylinderkupplungen aus Metall geeignet (Wellenna-
Loctite 648 ben). Kann Einzelteil mit einem Radialspiel von weniger als 0,1 mm zusammenkleben.
. Adhesivo anaeroÂbico para encolado raÂpido de media resistencia juntas cilõÂndricas de metal (cubo en el eje).
Puede encolar piezas con juego radial inferior a 0,1 mm.
. AdheÂsif anaeÂrobic servant aÁ un collage rapide moyennement reÂsistant des joints cylindriques en meÂtal
(moyeu sur l'arbre).
Il peut servir aÁ coller des pieÁces avec un jeu radial infeÂrieur aÁ 0,1 mm.
. 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.
(AREXONS) . Mastice sigillante per guarnizioni elastiche a base di solvente, essicante per evaporazione.
Repositionable jointing
compound for seals Viene utilizzato per la tenuta sul diamentro esterno di anelli di tenuta per alberi rotanti con armatura metallica
Mastice per guarnizioni esterna.
riposizionabile . Klebstoff fuÈr Gummidichtung auf LoÈsemittelbasis, trocknet durch Verdampfung.
Klebstoff fuÈr verstellbare Wird am aÈuûeren Durchmesser von Dichtungsringe bei rotierenden Wellen mit Metallmantel verwendet.
Dichtungen . Pasta para juntas de sellado para juntas elaÂsticas a base de disolvente, deshidratante por evaporacioÂn.
Pasta para juntas Se utiliza para la estanqueidad en el diaÂmetro externo de segmentos de compresioÂn, para ejes giratorios con
reposicionable
armadura metaÂlica exterior.
Mastic pour garnitures aÁ
remettre en place . Mastic adheÂsif aÁ base de solvants pour garnitures eÂlastiques, seÂchant par eÂvaporation.
Il sert garder eÂtanche le diameÁtre exteÂrieur des bagues d'eÂtancheÂiteÂ des arbres rotatifs ayant une arma-
ture meÂtallique externe.
008 918 12 BOMAG

11 973
18.8 Axle
DENOMINATION
DENOMINAZIONE
DENOMINACION
DENOMINATION
. Semi-fluid adhesive material used for sealing and filling and to protect components from environmental and
physical elements. Polymerises with non-corrosive dampness.
Silicone . Materiale adesivo semifluido usato per sigillatura, riempimenti e per la protezione di componenti dagli elementi
Silicone ambientali e fisici. Polimerizza con umiditaÁ non corrosiva.
. HalbfluÈssiger Klebstoff zum Befestigen, FuÈllen und zum Schutz von Bestandteilen vor aÈuûeren Einwirkun-
Silikon
gen. Polymerisiert durch nicht korrosive Feuchtigkeit
Silicona . Material adhesivo semifluido usado para el sellado, llenado y para la proteccioÂn de componentes de elemen-
Silicone tos ambientales y fõÂsicos. Polimeriza con humedad no corrosiva.
. Produit adheÂsif semi-fluide utiliseÂ pour le scellage, remplissage et protection des eÂleÂments ambiants et phy-
siques. PolymeÂrise aÁ une humiditeÂ non corrosive.
. 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 adesivitaÁ, additivato con composti siliconici.
(TECNO LUPE/101) Applicato su viti di registrazione a foro comunicante con fluidi di tipo oleoso.
Silicone-based grease Usato quando si richiedono frequenti interventi di registrazione.
Grasso al silicone . Synthetisches Fett mit hoher Haftfestigkeit, mit silikonhaltigen Stoffen legiert.
Wird auf Stellschrauben mit Loch, die mit oÈlhaltigen FluÈssigkeiten in Kontakt stehen, angebracht.
Silikonfett Wird verwendet, wenn die Schraub oÈfters eingestellt werden muû.
Grasa a la silicona . Grasa sinteÂtica con elevado grado de adhesioÂn, aditivada con componentes silicoÂnicos.
Graisse au silicone Aplicada en tornillos de ajuste de orificio comunicante con fluidos de tipo oleoso.
Se usa cuando se requieren frecuentes intervenciones de ajuste.
. Graisse syntheÂtique ayant un degreÂ d'adheÂsiviteÂ eÂleveÂ, adjuveÂ de composeÂs au silicone.
AppliqueÂ sur les vis de reÂglage aÁ trou communiquant avec des fluides du type huileux.
UtiliseÂ quand il y a besoin de reÂglages freÂquents.
. 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.
Molikote . Schmierstoff mit MolybidaÈndisulfid; wird zum Schmieren von Gelenkstiften und gegen Ankleben und Oxy-
(DOW CORNING) dation von nicht dauergeschmierten Einzelteilen verwendet.
. Compuesto lubricante que contiene bisulfuro de molibdeno, usado para la lubricacioÂn de roÂtulas y para pre-
venir encoladuras y oxidaciones de piezas no lubricadas de manera continua.
. ComposeÂ lubrifiant contenant du bisulfure de molybdeÁne, utiliseÂ pour lubrifier les axes d'articulation et preÂ-
venir collages et oxydations des pieÁces qui ne sont pas continuellement lubrifieÂes.
. Applied to bearings, sliding parts and used to lubricate seals or parts during assembly
(Lithium-based) Grease . Applicato a cuscinetti, parti scorrevoli e per lubrificare guarnizioni o pezzi in fase di montaggio.
Grasso (al Litio) . Wird auf Lager, Gleitteilen aufgetragen und zum Schmieren von Dichtungen oder von Teilen bei der Mon-
(Lithium) Fett tage verwendet.
Grasa (al Litio) . Aplicada a cojinetes, partes deslizables o para lubricar juntas o piezas en fase de montaje.
Graisse (au Lithium) . AppliqueÂ sur les paliers, parties coulissantes et pour lubrifier les garnitures ou pieÁces pendant la phase de
montage.
974 BOMAG
12 008 918 12
Axle 18.8
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 LoÈsemittel muÈssen als SondermuÈll und auf jeden Fall laut den
GB axle should be fastened onto a trestle, while the oÈrtlich geltenden Vorschriften entsorgt werden.
other parts mentioned should rest on supporting 9- Zur Reinigung ausschlieûlich schwache LoÈsemittel wie Petroleum,
benches. Terpentin oder wasserhaltige LoÈsemittel verwenden. Auf keinen
2 - When removing one of the arms, an anti-tilting safety trestle Fall TrichloraÈthylen, tuolol- oder xylolhlatige LoÈsemittel usw.
should be placed under the other arm. verwenden.
3 - When working on an arm that is fitted on the machine, make sure 10 - Um die ArbeitsvorgaÈnge verstaÈndlich abzubilden, werden in
that the supporting trestles are correctly positioned and that the einigen Fotos die Aggregate ohne Einzelteile gezeigt, die sonst
machine is locked lengthways. bei der Arbeit nicht abmontiert werden muÈssen.
4 - Do not admit any other person inside the work area; mark off the Nur die beschriebenen Teile abmontieren.
area, hang warning signs and remove the ignition key from the 11 - Unter RECHTS und LINKS versteht man in diesem Handbuch die
machine. Seite einer Person, die zur Achse schaut und zwar dem Antrieb
5 - Use only clean, quality tools; discard all worn, damaged, low- entgegengesetzt.
quality or improvised wrenches and tools. Ensure that all 12 - Nach beendeten Arbeiten und um Rostbildungen zu vermeiden,
dynamometric wrenches have been checked and calibrated. die Teile an denen der Lack ggf. beschaÈdigt worden ist,
6 - Always wear gloves and non-slip rubber shoes when performing anstreichen.
repair work. 1 - Las operaciones descritas se refieren al eje blo-
7 - Should you stain a surface with oil, remove marks straight away. ESP queado en un caballete y a algunas partes apoyadas
8 - Dispose of all lubricants, seals, rags and solvents once work has en el banco de trabajo.
been completed. Treat them as special waste and dispose of them 2- Cuando se saca un brazo del eje, colocar debajo del otro un
according to the relative law provisions obtaining in the country caballete de seguridad antivuelco.
where the axles are being overhauled. 3- Si se trabaja con un eje montado en la maÂquina, asegurarse de
9 - Make sure that only weak solvents are used for cleaning haber colocado caballetes soporte y de haber inmovilizado
purposes; avoid using turpentine, dilutants and toluol-, xylol- longitudinalmente la maÂquina.
based or similar solvents; use light solvents such as Kerosene, 4- No permitir que personas extranÄas entren en la zona de trabajo;
mineral spirits or water-based, environment friendly solvents. delimitar esta zona, colgar carteles de aviso de hombres
10 - For the sake of clarity, the parts that do not normally need to be trabajando y sacar las llaves de arranque de la maÂquina.
removed have not been reproduced in some of the diagrams. 5- Usar soÂlo y exclusivamente herramientas limpias y de buena
11 - The terms RIGHT and LEFT in this manual refer to the position of cualidad; descartar llaves o herramientas gastadas o danÄadas, de
the operator facing the axle from the side opposite the drive. calidad mediocre o improvisadas. Asegurarse de que las llaves
12 - After repair work has been completed, accurately touch up any dinamomeÂtricas han sido controladas y calibradas.
coated part that may have been damaged. 6- Durante las operaciones de reparacioÂn, llevar siempre guantes y
calzado antideslizamiento.
1 - Le operazioni descritte sono riferite all'assale bloc- 7- Limpiar inmediatamente las zonas que pudieran estar sucias de
ITA cato su cavalletto ed alcuni particolari appoggiati su aceite.
un banco di lavoro.
8- Los lubricantes, las juntas, los trapos para la limpieza y los
2 - Quando si asporta un braccio dell'assale, sistemare sotto l'altro disolventes usados hay que eliminarlos como desechos especia-
braccio un cavalletto di sicurezza antiribaltamento. les y, de todas formas, de acuerdo con las normativas vigentes en
3 - Se si opera su un'assale montato sulla macchina, assicurarsi di el paõÂs en el que se revisan los ejes.
aver sistemato dei cavalletti di sostentamento e di aver immobi- 9- Para limpiar, utilizar soÂlo disolventes deÂbiles excluyendo en
lizzato longitudinalmente la macchina. absoluto tricloroetileno, diluyentes y disolventes a base de toluol,
4 - Non permettere che persone estranee entrino nella zona di lavoro; silol, etc.; usar soÂlo disolventes ligeros como queroseno, aguarraÂs
delimitare questa zona, appendere dei cartelli di avviso di lavori in minerales o disolventes ecoloÂgicos a base de agua.
corso ed asportare le chiavi di avviamento della macchina. 10 - Para que resulte clara la exposicioÂn y la ilustracioÂn, en las figuras
5 - Usare solo ed esclusivamente attrezzi puliti e di buona qualitaÁ; de algunos grupos faltan algunas piezas que por lo general se
scartare chiavi od attrezzi usurati o danneggiati, di bassa qualitaÁ pueden dejar montadas. Sacar soÂlo las partes descritas.
od improvvisati. Assicurarsi che le chiavi dinamometriche siano 11 - Las palabras DERECHA E IZQUIERDA usadas en el manual se
state controllate e tarate. refieren a la persona que mira el eje del lado opuesto a la toma de
6 - Durante le operazioni di riparazione, indossare sempre guanti e movimiento.
scarpe antiscivolo. 12 - Al final de las reparaciones, para evitar oxidaciones, retocar
7 - Pulire immediatamente le zone eventualmente imbrattate d'olio. cuidadosamente las partes pintadas que estuvieran danÄadas.
8 - I lubrificanti, le guarnizioni, gli eventuali stracci di pulizia ed i
solventi usati devono essere smaltiti come rifiuti speciali e 1 - Les opeÂrations deÂcrites se rapportent aÁ l'essieu
comunque secondo le normative vigenti nel Paese ove vengono F bloqueÂ sur chevalet et de quelques pieÁces poseÂes
revisionati gli assali. sur un eÂtabli de travail.
9 - Per la pulizia, usare solo solventi deboli escludendo categorica- 2- Quand on enleÁve un essieu monteÂ sur la machine, ajuster sous
mente trielina, diluenti e solventi a base di toluolo, xilolo, ecc.; l'autre bras un chevalet de seÂcuriteÂ contre tout basculement.
usare solo solventi leggeri quali cherosene, ragie minerali o 3- Si on oeuvre sur un essieu monteÂ sur la machine, s'assurer
solventi ecologici a base d'acqua. d'avoir ameÂnageÂ des chevalets de soutien et d'avoir bloqueÂ la
10 - Per chiarezza di illustrazione ed esposizione, sulle figure di alcuni machine en longueur.
gruppi mancano dei particolari che, normalmente, possono essere 4- Ne jamais permettre aÁ des eÂtrangers de peÂneÂtrer dans la zone de
lasciati montati. Rimuovere solo i particolari descritti. travail; deÂlimiter cette zone, mettre des pancartes de signalisation
11 - I termini DESTRA e SINISTRA usati nel manuale sono riferiti alla de travaux en cours et enlever les cleÂs de contact de la machine.
persona che guarda l'assale dal lato opposto alla presa di moto. 5- N'utiliser que des outils propres et de bonne qualiteÂ; eÂliminer cleÂ
12 - Al termine delle riparazioni, per evitare dannose ossidazioni, ou autres outils useÂs, abõÃmeÂs, de mauvaise qualiteÂ ou improviseÂs.
ritoccare con cura le parti verniciate eventualmente danneggiate. Veiller aÁ ce que les cleÂs dynamomeÂtriques aient eÂteÂ controÃleÂes et
calibreÂes.
1 - Die beschriebenen VorgaÈnge werden an der Achse 6- Pendant les opeÂrations de reÂparation, endosser toujours gants et
D vorgenommen, wenn diese auf einem Bock blockiert chaussures antideÂrapantes.
ist. Zur Bearbeitung der Einzelteile, werden diese 7- Nettoyer tout de suite les eÂventuelles zones souilleÂes d'huile.
auf die Werkbank gelegt. 8- Les lubrifiants, les garnitures, les eÂventuels chiffons servant au
2- Wenn eine Achse abgenommen wird, einen Sicherheitsbock unter nettoyage et les solvants utiliseÂs devront eÃtre reÂcolteÂs et traiteÂs
den zweiten Arm legen. comme rebut speÂcial conformeÂment aux lois en vigueur dans le
3- Werden Arbeiten an der Achse vorgenommen, wenn diese noch pays ouÁ les essieux sont en reÂvision.
an der Maschine montiert ist, BoÈcke zur Halterung unter die 9- Pour le nettoyage, n'utiliser que des solvants aÁ base de toluol,
Achse stellen und die Maschine der LaÈnge nach blockieren. xylol, etc.; n'utiliser que des solvants leÂgers tels que keÂroseÁne,
4- Es duÈrfen sich keine fremde Personen in der NaÈhe der Maschine essences mineÂrales, ou solvants eÂcologiques aÁ base d'eau.
waÈhrend der Arbeiten aufhalten; diesen Bereich absperren und 10 - En ce qui concerne la clarteÂ en matieÁre d'illustration et exposition,
mit Schilder kennzeichnen, die auf die laufenden Arbeiten sur les figures de certains groupes, il y a des pieÁces manquantes
hinweisen. ZuÈndschluÈssel von der Maschine abnehmen. qui normalement peuvent rester monteÂes.
5- Nur saubere Werkzeuge guter QualitaÈt verwenden; alte, beschaÈ- Enlever uniquement les pieÁces deÂcrites.
digte oder improvisierte Hilfsmittel nicht verwenden. Sicher- 11 - Les termes DROITE et GAUCHE utiliseÂs dans ce manuel se
stellen, daû die Dynamometer gepruÈft und geeicht worden sind. rapportent aÁ la personne regardant l'essieu du coÃteÂ opposeÂ aÁ celui
6- Bei Reparaturen, stets Handschuhe und rutschfeste Schuhe tragen. de la prise de mouvement.
7- Mit OÈ l beschmutzte Stellen, sofort reinigen. 12 - A la fin des opeÂrations, afin d'eÂviter un risque d'oxydation
8- Gebrauchte Schmiermittel, Dichtungen, Reinigungslappen und nuisible, retoucher soigneusement les parties vernies eÂventuelle-
ment abõÃmeÂes.
008 918 12 BOMAG
13 975
18.8 Axle
CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS
SIMBOLI KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
CONTROÃLE 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 1
Zusasmmenbauen von Baugruppen
Ensamblaje de subgrupos
Montage des sous-groupes
Remove obstruction parts T1
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 S
Attenzione, indicazione importante
Achtung, wichtiger Hinweis F1241070 F1241071
¡ Cuidado ! IndicacioÂn importante
Attention, indication importante
Check - adjust e.g. torque, dimensions, pressures, etc.
Controllare - regolare p.e. coppie, misure, pressioni ecc.
GB a bar GB b
PruÈfen - Einstellen z.B. Momente, Maûe, Drucke u.s.cs.
Controlar y ajustar, por ej. pares, medidas, presiones, etc. CHECKING WEAR Introduce tool T1 between the disks and check shim "S".
Controler, regler p.e. couples, mesures, pressions ecc. CAUTION! Perform operations on both arms. Minimum size of "S": 4.5 mm.
T=Special tool P=page Remove the oil-level plug (1).
T=Attrezzature speciali P=Pagina
T=Spezialwerkzeug P=Seite
T=Herramientas especiales P=PaÂgina
T=Outils P=Page
Note direction of installation
Rispettare direzione di montaggio
Einbaurichtung beachten
Respetar la direccioÂn de ensamblaje
Respecter direction de montage
Visual inspection
Esaminare con controllo visuale P
Kontrollieren -PruÈfen
Examinar mediante inspeccioÂn visual
Controler, examiner, controle visuel 3
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 neÂcessaire)
Renew at each reassembly 2
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 F1241072 F1241073
Entsichern-Sichern
Quitar-colocar el seguro
Enlever-mettre la securite
Lock-adhere (liquid sealant)
bar GB c GB d
Mettere la sicura, incollare (mastice liquido)
Sichern-Kleben (fluÈssige Dichtung) ADJUSTING THE BRAKES Remove screw (2) and safety plate (3).
Colocar el seguro, pegar (mastique lõÂquido) Connect an external pump to the union piece "P" of the negative
Mettre la securite, coller (mastic liquide) brake and introduce a pressure of 15 ± 30 bar to eliminate the
Guard against material damage, damage to parts pressure of the Belleville washers (11).
Evitare danni materiali, danni a pezzi
Materialschaden verhuÈten
Evitar danÄar 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 (fuÈr den Zusammenbau)
Marcar antes de desmontar (para facilitar el ensamblaje) 6
Marquer avant le demontage (pour le montage)
Filling - topping up - refilling e.g. oil, cooling water, etc.
Caricare - riempire (olio - lubrificante)
7
EinfuÈllen - AuffuÈllen - NachfuÈllen (OÈl-Schmiermittel)
Cargar - llenar (aceite lubricante)
Charger - remplir (huile - lubrifiant)
4
Drain off oil, lubricant
Scaricare olio, lubrificante
OÈl, bzw. Schmiermittel Ablassen
Descargar aceite lubricante
Vidanger, lubrifiant
Tighten
Tendere
Spannen
Tensar
Tendre
Apply pressure into hydraulic circuit
8
Inserire pressione nel circuito idraulico F1241074 F1241075
Leitung unter Druck setzen
Introducir presioÂn en el circuito hidraÂulico
Inserer pression dans le circuit hydraulique GB e GB f
To clean
Pulire Turn the brake clearance adjustment pinion (4) clockwise and as REPLACING THE BRAKING DISKS
Reinigen
Limpiar far as the limit stop. Sling the arm (6) to be removed and connect it to a hoist.
Nettoyer Release pressure and disconnect the tubes. Loosen and remove screws (7) and nuts (8).
Lubricate - grease NOTE. Remove the lower plug (5) and drain the oil.
Lubrificare - ingrassare
Schmieren - einfetten
Lubrificar - Engrasar
976 Lubrifier - Graisser BOMAG 008 918 12
14
Axle 18.8
CONTROLLO USURA Introdurre l'attrezzo T1 tra i dischi e controllare lo

ITA ATTENZIONE! Eseguire le operazioni per i due ITA spessore "S".
bracci. "S" minimo: 4,5 mm
Asportare il tappo (1) di livello olio.
VERSCHLEISS KONTROLLIEREN Werkzeug T1 zwischen den Scheiben einsetzen und

D D die StaÈrke "S" kontrollieren.
ACHTUNG! Die VorgaÈnge an beiden Armen vorneh-
men. "S" Minimum: 4,5 mm
È
OleinfuÈllstopfen (1) abnehmen.
a b
CONTROL DESGASTE Introducir la herramienta T1 entre los discos y
ESP ESP controlar el espesor "S".
ATENCION! Efectuar las operaciones por los dos
ejes. «S» minimo: 4,5 mm.
Sacar el tapon (1) de nivel aceite.
CONTROLE USURE Introduire l'outil T1 entre les disques et controÃler la

F F cale "S".
ATTENTION! Effectuer les opeÂrations aux deux bras.
Enlever le bouchon (1) du niveau d'huile. "S" minimum: 4,5 mm
REGISTRAZIONE FRENI Asportare la vite (2) e la piastrina di sicurezza (3).

ITA Collegare al raccordo "P" del freno negativo una pompa ITA
esterna ed immettere una pressione di 15v30 bar per
eliminare la pressione delle molle a tazza (11).
BREMSEN EINSTELLEN Schraube (2) und SicherheitsplaÈttchen (3) abnehmen.

D AnschluûstuÈck "P" der Federspeicherbremse an eine D
aÈuûere Pumpe anschlieûen und Druck bei 15v30 bar
einlassen, um Tellerfedern (11) zu entlasten.
c d
REGISTRACION FRENOS Sacar el tornillo (2) y la placa de securidad (3).
ESP Conectar al empalme «P» del freno negativo una ESP
pompa esterna y introducir una presion de 15v30 bar
para eliminar la presion de los muelles a taza (11).
REGLAGE DES FREINS Enlever les vis (2) et la plaquette de seÂcuriteÂ (3).
F Brancher au raccord "P" du frein neÂgatif une pompe F
externe et envoyer une pression de 15v30 bar pour
eÂliminer la pression des ressorts belleville (11).
Ruotare in senso orario il pignone (4) di regolazione SOSTITUZIONE DISCHI FRENO

ITA gioco freni fino a fondo corsa. ITA Imbragare il braccio (6) da asportare e collegarlo ad un
Rilasciare la pressione e scollegare i tubi. mezzo di sollevamento.
NOTA. Rimuovere il tappo inferiore (5) e scaricare l'olio. Allentare ed asportare le viti (7) ed i dadi (8).
Das Kegelrad (4) zur Einstellung des Bremsspiels bis BREMSSCHEIBEN AUSWECHSELN
D zum Endanschlag drehen. D Den abzunehmenden Arm (6) anschlagen und an eine
Druck ablassen und die Leitungen abtrennen. Hebezeug befestigen.
BEMERKUNG. Unteren Stopfen (5) abnehmen und das O È l. Schrauben (7) und Muttern (8) lockern und abschrauben.
e f
Girar en sentido horario el pinon (4) de regulacioÁn SUBSTITUCION DISCOS FRENOS.
ESP juego frenos hasta final carrera. ESP Atar el eje (6) de sacar y conectarlo a un medio de
Dejar la presion y desconectar los tubos. levantamiento.
NOTA. Remover el tapon inferior (5) y descargar el aceite. Aflojar y sacar los tornillos (7) y las tuercas (8).
Tourner le pignon de reÂglage du jeu des freins (4) dans Substitution des disques frein
F le sens des aiguilles d'une montre jusqu'en fin de F Elinguer le bras (6) aÁ enlever et brancher celui-ci aÁ un
course. moyen de relevage.
LibeÂrer la pression et deÂbrancher les tubes. Desserrer et enlever les vis (7), les eÂcrous (8).
REMARQUE: Enlever le bouchon infeÂrieur (5) et vidanger l'huile.
008 918 12 BOMAG

15 977
18.8 CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS Axle
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
F1241076 F1241077
GB a GB b
Remove arm (6) together with brakes and axle shafts; lay down the Loosen screws (9) in an alternate manner and remove them.
arm vertically.
11
12
10 10
F1241078 F1241079
GB c GB d
Move the cylinder (10) outwards while supporting the Belleville Remove the cylinder (10) complete with piston (12).
washers (11).
Remove the Belleville washers (11) and note down direction of
assembly.
12
13
12
14
F1241080 F1241081
bar GB e GB f
Slowly introduce low-pressure compressed air through the con- Remove O-rings (13) and (14) from the piston (12).
nection member for the negative brake, in order to extract the NOTE. The O-rings (13) and (14) must be replaced each time the
piston (12). unit is disassembled.
CAUTION! Hold the piston (12) back, as it may be suddenly ejected
and damaged.
978 BOMAG
16 008 918 12
Axle 18.8
Rimuovere il braccio (6) completo di freni e semiassi; Allentare in modo alternato le viti (9) ed asportarle.
ITA deporre il braccio in modo verticale. ITA
Den Arm (6) samt Bremsen und Halbachsen ab- Abwechselnd die Schrauben (9) lockern und ab-
D nehmen; den Arm senkrecht ablegen. D schrauben.
a b
Remover el eje (6) completo de frenos y semi-ejes; Aflojar de manera alternada los tornillos (9) y sacarlas.
ESP colocar el eje de manera vertical. ESP
Enlever le bras (6) complet de freins et demi-essieux; Desserrer les vis (9) en alternance, puis les enlever.
F deÂposer le bras en vertical. F
Spostare verso l'esterno il cilindro (10) sostenendo le Rimuovere il cilindro (10) completo di pistone (12).
ITA molle a tazza (11). ITA
Rimuovere le molle (11) ed annotare il senso di
montaggio.
Den Zylinder (10) nach auûen verstellen und dabei die Zylinder (10) samt Kolben (12) abnehmen.
D Tellerfedern (11) stuÈtzen. D
Federn (11) abnehmen und die Montagerichtung
notieren.
c d
Desplazar hacia el esterior el cilindro (10) sosteniendo Remover el cilindro (10) completo de piston (12).
ESP los muelles a taza (11). ESP
Remover los muelles (11) y anotar el sentido de
montaje.
DeÂplacer le cylindre (10) vers l'exteÂrieur en soutenant Enlever le cylindre (10) complet de piston (12).
F le ressort belleville (11). F
Enlever le ressort (11) et prendre note du sens de son
montage.
Immettere lentamente aria compressa a bassa pres- Rimuovere dal pistone (12) gli anelli OR (13) e (14).
ITA sione attraverso l'attacco per il freno negativo per ITA
NOTA. Gli anelli OR (13) e (14) devono essere
estrarre il pistone (12). sostituiti ad ogni smontaggio.
ATTENZIONE! Trattenere il pistone (12) che puoÁ essere espulso
velocemente ed essere danneggiato.
Langsam Druckluft bei Niederdruck durch den An- Kolben (12) und O-Ringe (14) und (14) abnehmen.
D schluû der Federspeicherbremse einlassen, um den D
BEMERKUNG. Die O-Ringe (13) und (14) muÈssen
Kolben (12) heraus zu druÈcken. jedesmal ausgewechselt werden, wenn das Teil zer-
ACHTUNG! Den Kolben (12) halten, da er ploÈtzlich heraus springen legt wird.
e und beschaÈdigt werden koÈnnte. f
Introducir lentamente aire comprimida a baja presioÁn Remover del piston (12) los anillos OR (13) y (14).
ESP atraves el empalme por el freno negativo para sacar el ESP
NOTA. Los anillos OR (13) y (14) deben de ser
piston (12). sobstituidos cada desmontaje.
ATENCION! Tener el piston (12) que puede ser expulso rapida-
mente y estropearse.
Envoyer lentement de l'air comprimeÂ aÁ basse pression Enlever le piston (12), les anneaux O'RING (13) et
F aÁ travers le raccord du frein neÂgatif pour extraire le F (14).
piston (12). REMARQUE. Les anneaux O'RING (13) et (14) sont aÁ
ATTENTION! Tenir le piston (12) qui pourrait eÃtre expulser substituer aÁ chaque deÂmontage.
rapidement et endommager.
008 918 12 BOMAG

17 979
18.8 CHECKING WEAR AND REPLACING THE BRAKING DISKS - CONTROLLO USURA E SOSTITUZIONE DISCHI FRENO - VERSCHLEISS Axle
KONTROLLIEREN UND BREMSSCHEIBEN AUSWECHSELN - CONTROL DEL DESGASTE Y SUSTITUCION DE LOS DISCOS DEL FRENO -
16
15
A
16
F1241082 F1241083
GB a GB b
Remove checking and guiding screws (15) from the pressure plate Remove the pressure plate (16).
(16). CAUTION! Note down the direction of assembly; flow regulator wall
NOTE. Loosen screws (15) in sequence and proportionally. "A" and oil drain holes must face the oil drain plug.
19
17
18
F1241084 F1241085
GB c GB d
Remove springs (17). Remove braking discs (18) and (19), noting down direction of
NOTE. Accurately check the condition of springs. They should not assembly.
be warped. NOTE. If disks are not to be replaced, avoid changing their
Any deformation of the springs requires spring replacement. position.
4 21
20
F1241086 F1241087
GB e GB f
Remove pinion (4) complete with O-ring (20). Unscrew and extract the braking disk clearance adjustment crown
NOTE. The O-ring must be replaced each time the unit is wheel (21).
disassembled.
980 BOMAG
18 008 918 12
Axle 18.8
Rimuovere le viti (15) di ritegno e guida dello Rimuovere lo spingidisco (16).

ITA spingidisco (16). ITA
ATTENZIONE! Annotare il senso di montaggio; la
NOTA. Allentare le viti (15) in modo sequenziale ed in parete frangiflusso "A" e gli scarichi olio, devono
uguale misura. essere rivolti verso il tappo di scarico olio.
Befestigungsschrauben (15) und die FuÈhrung der Druckplatte (16) abnehmen.

D Druckplatte (16) abnehmen. D
ACHTUNG! Montagerichtung notieren; der Strahlreg-
BEMERKUNG. Abwechselnd Schrauben (15) im È lablaûoÈffnungen muÈssen in Richtung
ler "A" und die O
gleichen Maû lockern. È
des Olablaûstopfens gerichtet sein.
a b
Remover los tornillos (15) de retencioÁn y guõÁa del Remover el empuja-disco (16).
ESP empuya-disco (16). ESP
ATENCION. Anotar el sentido de montaje; la pared
NOTA. Aflojar los tornillos (15) de manera secuencial rompe-flujo "A" y los descarge aceite, deben de ser
y en la misma mesura. dirijidos hacia el tapon de descarga aceite.
Enlever vis (15) de fixation et guide du plateau de Enlever le plateau de pression (16).
F pression (16). F
ATTENTION! Prendre noter du sens du montage; la
REMARQUE: Desserrer les vis (15) en seÂquence et en paroi brise-jet "A" et les eÂcoulements d'huile sont
eÂgale mesure. tourneÂs vers le bouchon de vidange d'huile.
Rimuovere le molle (17). Rimuovere i dischi di frenatura (18) e (19) annotando

ITA ITA l'ordine di montaggio.
NOTA. Controllare attentamente lo stato delle molle
che non devono essere deformate. NOTA. Se i dischi non devono essere sostituiti, evitare
Ogni deformazione deve portare alla sostituzione. lo scambio di posizione.
Federn (17) abnehmen. Bremsscheiben (18) und (19) abnehmen und Monta-
D D gerichtung notieren.
BEMERKUNG. Die Federn sorgfaÈltig kontrollieren; sie
duÈrfen nicht verformt sein. Sollte dies der Fall sein, BEMERKUNG. Falls die Scheiben ausgewechselt
Federn auswechseln. werden muÈssen, ihre Position nicht verwechseln.
c d
Remover los muelles (17). Remover los discos de frenadura (18) y (19) anotando
ESP ESP el orden de montaje.
NOTA. Controlar atentamente el estado de los
muelles que no deben de ser deformes. NOTA. Si los discos no deben de ser sobstituidos,
A cada deformacioÁn deben de ser cambiados. evitar el cambio de possicioÁn.
Enlever les ressorts (17). Enlever les disques de freinage (18) et (19) et prendre
F F note de l'ordre du montage.
REMARQUE. ControÃler attentivement l'eÂtat des res-
sorts, ils ne doivent pas eÃtre deÂformeÂs. REMARQUE. Si les disques doivent eÃtre substitueÂs,
Toute deÂformation veut dire substitution. eÂviter d'eÂchanger leur position.
Rimuovere il pignone (4) completo di anello OR (20). Svitare ed asportare la corona (21) di regolazione del
ITA ITA gioco dischi di frenatura.
NOTA. L'anello OR deve essere sostituito ad ogni
smontaggio.
Das Kegelrad (4) samt O-Ring (20) entfernen. Den Kranz (21) zur Einstellung des Bremsscheibens-
D D piels abnehmen.
BEMERKUNG. Den O-Ring bei jedem Zerlegen aus-
wechseln.
e f
Remover el pinon (4) completo de anillo OR (20). Destornillar y sacar la corona (21) de regulacioÁn del
ESP ESP juego discos de frenadura.
NOTA. El anillo OR debe de ser sobstituido a cada
desmontaje.
Enlever le pignon (4) complet de l'anneau O'RING DeÂvisser et enlever la couronne (21) de reÂglage du jeu
F (20). F des disques de freinage.
REMARQUE. L'anneau O-Ring est aÁ remplacer aÁ
chaque deÂmontage.
008 918 12 BOMAG

19 981
18.8 ASSEMBLING THE BRAKING UNIT - ASSEMBLAGGIO GRUPPO FRENI - ZUSAMMENBAU DES BREMSAGGREGATS - MONTAJE DE LOSAxle
GRUPOS DE FRENADO - ASSEMBLAGE DU GROUPE FREINS
22
11
13
12
10 14
9
18
18
18
15
21 17
23
16
6 19
19
7
19
4
20
1
3
5 2
24
26 8
25 D1240130
6
21 4
6 20
21
F1241133 F1241134
GB a GB b
Lubricate the threaded portion of the crown wheel (21) and screw it Replace the O-ring (20) of pinion (4).
down into the arm (6) as far as it will go. Lubricate and install the pinion in the slot provided on the arm (6),
inserting the toothing into crown wheel (21).
982 BOMAG
20 008 918 12
Axle 18.8
GB
ESP
ITA
Lubrificare la filettatura della corona (21) ed avvitarla a Sostituire l'anello OR (20) del pignone (4).
ITA fondo nel braccio (6). ITA Lubrificare il pignone e montarlo nella sede del braccio
(6) innestando la dentatura nella corona (21).
Das Gewinde des Kranzes (21) schmieren und in den O-Ring (20) des Kegelrads (4) auswechseln. Kegelrad
D Arm (6) festschrauben. D schmieren und in den Sitz des Arms (6) montieren;
dabei die ZaÈhne des Kranzes (21) einrasten.
a b
Lubrificar la rosca de la corona (21) y atornillar a Sobstituir el anillo OR (20) del pinon (4).
ESP hondo en el eje (6). ESP Lubrificar el pinon y montarlo en la sed del eje (6)
introduciendo la dentadura en la corona (21).
Lubrifier le filetage de la couronne (21), puis visser Substituer l'anneau O'RING (20) du pignon (4).
F celle-ci aÁ fond dans le bras (6). F Lubrifier le pignon, puis monter celui-ci dans le
logement du bras (6) en introduisant en meÃme temps
la denture dans la couronne (21).
008 918 12 BOMAG

21 983
19
18
B
F1241088 F1241089
GB a GB b
Lubricate the first friction disk (19) and install it on the axle shaft .
Lightly lubricate the first steel braking disk (18), then install it on the Complete the assembly, alternating steel disks and friction disks.
arm (6). CAUTION! Oval holes "B" of friction disks must be lined up.
16
17
6 A
F1241084 F1241083
GB c GB d
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.
16
15
15
F1241082 F1241090
GB e GB f
Lock the pressure plate into position (16) with screws (15). Lock screws (15) with a dynamometric wrench.
CAUTION! Tighten screws in sequence and a little at a time. Torque wrench setting: 20 ± 30 Nm.
984 BOMAG
22 008 918 12
Axle 18.8
Lubrificare leggermente il primo disco di frenatura in Lubrificare il primo disco di attrito (19) e montarlo sul
ITA acciaio (18) e montarlo nel braccio (6). ITA semiasse.
Completare il montaggio alternando dischi di acciaio e
dischi di attrito.
ATTENZIONE! I dischi di attrito devono avere il foro ovale "B"
allineato.
Die erste Bremsscheibe aus Stahl (18) etwas schmie- Die erste Reibscheibe (19) schmieren und auf die
D ren und in den Arm (6) montieren. D Halbachse montieren.
Dann die Stahlscheiben abwechselnd mit den Reibs-
cheiben montieren.
a b ACHTUNG! Die LangloÈcher "B" der Reibscheiben muÈssen ge-
fluchtet sein.
Lubrificar ligermente el primer disco de frenadura en Lubrificar el primer disco de strito (19) y montarlo
ESP acero (18) y montarlo en el eje (6). ESP 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 leÂgeÁrement le premier disque de freinage en Lubrifier le premier disque de friction (19), puis monter
F acier (18), puis monter celui-ci dans le bras (6). F 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"
aligneÂ.
Posizionare nelle sedi del braccio (6) le molle (17). Montare lo spingidisco (16).
ITA ITA
ATTENZIONE! Controllare attentamente l'orientamen-
to; il frangiflusso "A" e gli scarichi olio, devono essere
orientati verso il tappo di scarico olio del braccio.
In den Sitz des Arms (6) die Federn (17) einsetzen. Die Druckplatte (16) montieren.
D D
ACHTUNG! SorgfaÈltig die Montagerichtung kontroll-
È lablaûoÈffnungen
ieren; den Stahlregler "A" und die O
muÈssen zum Ablaûstopfen des Arms gerichtet sein.
c d
Colocar en las sedes del eje (6) los muelles (17). Montar el empuja-disco (16).
ESP ESP
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.
Mettre en place les ressorts (17) dans les logements Monter le plateau de pression (16).
F du bras (6). F
ATTENTION! ControÃler attentivement la direction; la
paroi brise-jet "A" et les eÂcoulements d'huile doivent
eÃtre dirigeÂs vers le bouchon de vidange d'huile du bras.
Fissare la posizione dello spingidisco (16) con le viti Bloccare le viti (15) con chiave dinamometrica.
ITA (15). ITA Coppia di serraggio: 20v30 Nm
ATTENZIONE! Serrare le viti in modo sequenziale ed
in piuÁ tempi.
Die Druckplatte (16) mit den Schrauben (15) be- Schrauben (15) mit dem Dynamometer blockieren.
D festigen. D Anzugsmoment: 20v30 Nm.
ACHTUNG! Die Schrauben der Reihe nach und
schrittweise festziehen.
e f
Fijar la posicioÁn del empuja-disco (16) con los tornillos Bloquear los tornillos (15) con llave dinamometrica.
ESP (15). ESP Par de serraje: 20v30 Nm.
ATENCION! Apretar los tornillos de manera secuen-
cial y en mas tiempos.
Fixer le plateau de pression (16) aÁ sa place avec les Bloquer les vis (15) aÁ l'aide de la cleÂ dynamomeÂtrique.
F vis (15). F Couple de serrage: 20v30 Nm.
ATTENTION! Serrer les vis en plusieurs temps en
ordre seÂquentiel.
008 918 12 BOMAG

23 985
14 12
12
13 10
10
F1241091 F1241092
GB a GB b
Fit O-rings (13) and (14) onto the piston (12). Using a plastic hammer, ram the piston (12) into the cylinder (10).
Lubricate the piston and the O-rings and install the unit into the NOTE. Lightly hammer all around the edge in an alternate
cylinder (10). sequence.
NOTE. Piston relief «C» must face downwards.
22 11
10
F1241079 F1241078
GB c GB d
Check the condition and the position of the O-ring (22); lubricate Position the Belleville washers (11) and engage the cylinder (10).
the O-ring and position the cylinder on the studs without fastening. NOTE. Check the sense of direction of washers (11) and relative
centring.
10 23
6
9
F1241093 F1241094
GB e GB f
Lock the cylinder (10), tightening the screws (9) with a dynamo- Check integrity and position of the arm's O-ring (23); install the
metric wrench set to a torque of 86 ± 89 Nm. complete arm (6).
NOTE. To assist axle shaft centring, slightly move the wheel hub.
986 BOMAG
24 008 918 12
Axle 18.8
Montare sul pistone (12) gli anelli OR (13) e (14). Utilizzando un mazzuolo in materiale plastico, inserire
ITA Lubrificare il pistone e gli anelli OR e montare il ITA a fondo il pistone (12) nel cilindro (10).
gruppo nel cilindro (10). NOTA. Battere leggeri colpi distribuiti in modo
NOTA. Lo scarico "C" del pistone deve essere rivolto verso il alternato su tutta la circonferenza.
basso.
Auf den Kolben (12) die O-Ringe (13) und (14) Mit einem Gummihammer den Kolben (12) in den
D montieren. D Zylinder (10) bis zum Anschlag einschlagen.
Den Kolben und die O-Ringe schmieren und das BEMERKUNG. Den Kolben abwechselnd rund um die
Aggregat in den Zylinder (10) montieren. gesamte Kreislinie leicht schlagen.
a BEMERKUNG. Die AblaûoÈffnung "C" des Kolbens muû nach unten b
gerichtet sein.
Montar sobre el piston (12) los anillos OR (13) y (14). Utilizando un martillo de materia plastica, introducir a
ESP Lubrificar el piston y los anillos OR y montar el grupo ESP fondo el piston (12) en el cilindro (10).
en los cilindros (10). NOTA. Pegar ligeros golpes distribuidos de manera
NOTA. El escargo "C" del piston debe de ser dirijido hacia el bajo. alternada sobre toda la circonferencia.
Monter sur le piston (12), les anneaux O'RING (13) et A l'aide d'un maillet en matieÁre plastique, introduire le
F (14). F piston (12) aÁ fond dans le cylindre (10).
Lubrifier le piston et les anneaux O'RING, puis monter REMARQUE. Donner de leÂgers coups reÂguliers tout
le groupe dans le cylindre (10). autour de la circonfeÂrence.
REMARQUE. L'eÂcoulement "C" du piston doit eÃtre tourneÂ vers le
bas.
Controllare lo stato ed il posizionamento dell'anello Posizionare le molle a tazza (11) e mandare in battuta
ITA OR (22); lubrificare l'anello OR e posizionare il cilindro ITA il cilindro (10).
sui prigionieri senza mandarlo in battuta. NOTA. Controllare il senso di orientamento delle molle
a tazza (11) e la loro centratura.
Den Zustand und die Position des O-Ringes (22) Tellerfedern (11) positionieren und den Zylinder (10)
D kontrollieren; den O-Ring schmieren und den Zylinder D bis zum Anschlag einsetzen.
auf die Stiftschrauben positionieren, ohne ihn bis zum BEMERKUNG. Orientierung der Tellerfedern (11) und
Anschlag ganz einzusetzen. ihre Zentrierung kontrollieren.
c d
Controlar el estado y la colocacioÁn del anillo OR (22); Colocar los muelles a taza (11) y mandar a tope el
ESP lubrificar el anillo OR y colocar el cilindro sobre los ESP cilindro (10).
prigioneros sin llevarlo a tope. NOTA. Controlar el sentido de orientamiento de los
muelles a taza (11) y su centraje.
ControÃler l'eÂtat et la position de l'anneau O'RING (22); Positionner les ressorts belleville (11) et inseÂrer aÁ fond
F lubrifier l'anneau O'RING et positionner le cylindre sur F le cylindre (10).
les prisonniers sans l'envoyer en buteÂe. REMARQUE. ControÃler l'orientation des ressorts
belleville (11) et leur centrage.
Bloccare il cilindro (10) con le viti (9) serrate con chiave Verificare l'integritaÁ ed il posizionamento dell'anello
ITA dinamometrica ad un coppia di 86v89 Nm. ITA OR (23) del braccio; installare il braccio completo (6).
NOTA. Per agevolare la centratura del semiasse,
muovere lentamente il mozzo portaruota.
Den Zylinder (10) mit den Schrauben (9) mit einem Am Arm den Zustand und die Position des O-Ringes
D Dynamometer und einem Anzugsmoment von 86v89 Nm D (23) kontrollieren; den gesamten Arm (6) installieren.
blockieren. BEMERKUNG. Um die Halbachse leichter zentrieren
zu koÈnnen, die Radhalternabe etwas bewegen.
e f
Bloquear el cilindro (10) con los tornillos (9) apretados Averiguar la integridad y la colocacioÁn del anillo OR
ESP con llave dinamometrica a un par de 86v89 Nm. ESP (23) del eje; colocar el eje completo (6).
NOTA. Para facilitar el centraje del semi-eje, mover
lentamente el cubo porta-rueda.
Bloquer le cylindre (10) avec les vis (9), serrer aÁ l'aide VeÂrifier le bon eÂtat et le positionnement de l'anneau
F de la cleÂ dynamomeÂtrique aÁ un couple de 86v89 Nm. F O'RING (23) du bras; installer le bras complet (6).
REMARQUE. Afin de rendre plus aiseÂ le centrage du
demi-essieu, bouger lentement le moyeu porte-roue.
008 918 12 BOMAG

25 987
T2
6
8
F1241095 F1241096
GB a GB b
Temporarily lock the arm (6) with nuts (8) previously coated with Check the flatness of the arms, using tool T2; then lock the arms
Loctite 242; tighten lightly to make the unit touch the main body. into their final position, using screws (7) adequately coated with
Loctite 242.
Torque wrench setting: 182 ± 202 Nm.
NOTE. Tighten using the criss-cross method.
F1241097 F1241074
bar GB c GB d
Connect an external pump to the union piece "A" of the negative Rotate the adjustment pinion (4) anticlockwise (±) to eliminate all
brake and introduce pressure to 15 ± 30 bar. existing clearance between the braking disks.
Rotate up to a torque of 8 ± 10 Nm.
+ 3
4
-- 2
D1240132
F1241073
GB e GB f
Rotate pinion (4) clockwise (+) to determine the required clearance Install safety plate (3) and lock with screw (2).
of 1 mm. Torque wrench setting: 10 ± 11 Nm.
NOTE. A turn of the adjuster produces a clearance of 0.25 mm
(1mm = 4 turns).
988 BOMAG
26 008 918 12
Axle 18.8
Fissare provvisoriamente il braccio (6) con i dadi (8) Controllare la planaritaÁ dei bracci con l'attrezzo T2 e
ITA spalmati con Loctite 242 e serrati leggermente per ITA fissarli definitivamente con le viti (7) spalmate con
frizionare il gruppo sul corpo centrale. Loctite 242.
Coppia di serraggio: 182v202 Nm
NOTA. Serrare con il metodo incrociato.
VoruÈbergehend den Arm (6) mit den mit Loctite 242 Die Ebenheit der Arme mit dem Werkzeug T2 kontroll-
D geschmierten Muttern (8) befestigen und Muttern D ieren und endguÈltig mit den mit Loctite 242 ge-
zuschrauben bis das Aggregat an dem ZentralkoÈrper schmierten Schrauben (7) befestigen.
anliegt. Anzugsmoment: 182v202 Nm
a b BEMERKUNG. Im Kreuz fest drehen.
Fijar provisoriamente el eje (6) con las tuercas (8) Controlar la planaridad de los ejes con la herramienta
ESP pasados con Loctite 242 y apretados ligermente para ESP T2 y fijarlos definitivamente con los tornillos (7) pasar
fricionar el grupo sobre el cuerpo central. con Loctite 242.
Par de serraje: 182v202 Nm
NOTA. Apretar de manera cruzada.
Fixer provisoirement le bras (6) avec les eÂcrous (8) ControÃler la planeÂiteÂ des bras aÁ l'aide de l'outil T2,
F enduits avec du Loctite 242, et serrer ceux-ci pour F puis fixer ceux-ci deÂfinitivement avec les vis (7)
frotter le groupe du corps central. enduites de Loctite 242.
Couple de serrage: 182v202 Nm.
REMARQUE. Serrer avec la meÂthode croiseÂe.
Collegare al raccordo "P" del freno negativo una pompa Ruotare in senso antiorario (±) il pignone di registro (4)
ITA esterna ed immettere una pressione di 15v30 bar. ITA per eliminare totalmente il gioco tra i dischi di frenatura.
Ruotare fino ad ottenere una coppia di 8v10 Nm.
An das AnschluûstuÈck "P" der Federspeicherbremse Gegen den Uhrzeigersinn (±) das Kegelrad (4),
D eine aÈuûere Pumpe schlieûen und Druck bei 15v30 bar D drehen, bis kein Spiel zwischen den Bremsscheiben
einlassen. mehr uÈbrig bleibt. Anzugsmoment: 8v10 Nm.
c d
Conectar al empalme "P" del freno negativo una Girar en sentido anti-horario (±) el pinon de registro (4)
ESP pompa externa y introducir presion de 15v30 bar. ESP para eliminar totalmente el juego entre discos de
frenadura.
Girar hasta obtener un par de 8v10 Nm.
Brancher au raccord "P" du frein neÂgatif une pompe Tourner le pignon de reÂglage (4) dans le sens contraire
F externe et envoyer une pression de 15v30 bar. F aux aiguilles d'une montre(-) le reÂgleur (4) pour faire
disparaõÃtre entieÁrement le jeu existant entre les
disques de freinage.
Tourner jusqu'aÁ obtenir un couple de 8v10 Nm.
Ruotare il pignone (4) in senso orario (+) per Montare la piastrina di sicurezza (3) e bloccarla con la
ITA determinare il gioco prescritto di 1 mm. ITA vite (2).
NOTA. Un giro del registro crea un gioco di 0,25 mm Coppia di serraggio: 10v11 Nm
(1 mm=4 giri).
Das Kegelrad (4) in den Uhrzeigersinn (+) drehen, bis Die Sicherheitsplatte (3) montieren und mit der
D das vorgeschriebene Spiel von 1 mm erreicht ist. D Schraube (2) blockieren.
BEMERKUNG. Eine Umdrehung gleicht einem Spiel Anzugsmoment: 10v11 Nm
von 0,25 mm (1 mm=4 Umdrehungen).
e f
Girar el pinon (4) en sentido horario (+) para Montar la plaqua de seguridad (3) y bloquearla con los
ESP determinar el juego prescrito de 1 mm. ESP tornillos 829.
NOTA. Un giro del registro crea un juego de 0,25 mm Par de serraje: 10v11 Nm
(1mm=4 giros).
Tourner le pignon (4) dans le sens des aiguilles d'une Monter la plaquette de seÂcuriteÂ (3), bloquer celle-ci aÁ
F montre (+) pour deÂfinir le jeu prescrit de 1 mm. F l'aide de la vis (2).
REMARQUE. Un tour de reÂgleur donne un jeu de 0,25 Couple de serrage: 10v11 Nm
mm (1mm=4 tours).
008 918 12 BOMAG

27 989
18.8 MECHANICAL AND MANUAL RELEASE OF THE AXLE - SBLOCCAGGIO MECCANICO MANUALE DELL'ASSALE - Axle
ACHSE MECHANISCH MANUELL ENTSICHERN - DESBLOQUEO MANUAL DE LOS AXAL -
DEBLOCAGE MECANIQUE MANUEL DE L'ESSIEU
11 16
24
25
25
26 24
D1240133
F1241098
GB a GB b
MANUAL EMERGENCY RELEASE Tighten screws (25) so as to fasten them onto the pressure plate
Loosen nuts (24) of screws (25) provided for the mechanical and (16).
manual release of the braking units, then move the nuts backwards
by approx. 8 mm.
25 26
24
25
F1241099 F1241100
GB c GB d
Using a wrench, tighten the screws (25) in an alternate sequence ADJUSTMENT AFTER MANUAL RELEASE
by 1/4 turn at a time so as to compress the Belleville washers (11) Remove screws (25) complete with nuts (24) and seals (26).
and disengage the braking disks. Replace seals (26), apply silicone-based Tecno Lupe /101 grease
IMPORTANT. Tighten max. by one turn. to the screws (25) and install all parts into the arm.
24
34 + 0,5
0
F1241101 F1241102
GB e GB f
+0.5
Adjust screws (25) to obtain a jut of 34 0 mm in relation to the arm. 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.
990 BOMAG
28 008 918 12
Axle 18.8
SBLOCCAGGIO MANUALE D'EMERGENZA Avvitare le viti (25) fino a mandarle in battuta sullo
ITA Allentare i dadi (24) delle viti (25) per lo sblocco ITA spingidisco (16).
meccanico manuale dei gruppi di frenatura e far
arretrare i dadi di circa 8 mm.
MANUELLE NOT-ENTSICHERUNG Schrauben (25) bis zum Anschlag an die Druckplatte

D Die Muttern (24) der Schrauben (25) zur mechani- D (16) zudrehen.
schen manuellen Entsicherung der Bremsaggregate
lockern und die Muttern um 8 mm zuruÈck drehen.
a b
DESBLOQUEO MANUAL DE EMERGENCIA Atornillar los tornillos (25) hasta llegar al tope sobre el
ESP Aflojar las tuercas (24) de los tornillos (25) para el ESP empuja-disco (16).
desbloqueo mecanico manual de los grupos de
frenadura y hacer pasar las tuercas de 8 mm approx.
DEBLOCAGE MANUEL D'EMERGENCE Visser les vis (25) puis les envoyer en buteÂe sur le
F Desserrer les eÂcrous (24) des vis (25) pour le F plateau de pression (16).
deÂblocage meÂcanique manuel des groupes de frei-
nage en faisant reculer les eÂcrous d'environ 8 mm.
Utilizzando una chiave, avvitare le viti (25) in modo REGOLAZIONE DOPO LO SBLOCCAGGIO MANUALE
ITA alternato di 1/4 di giro alla volta, per comprimere le ITA Rimuovere le viti (25) complete dei dadi (24) e delle
molle a tazza (11) e liberare i dischi di frenatura. guarnizioni (26).
IMPORTANTE. Avvitare per max. un giro. Sostituire le guarnizioni (26), lubrificare le viti (25) con grasso al
silicone Tecno Lupe /101 e montare il tutto nel braccio.
Mit einem SchluÈssel, die Schrauben (25) abwechselnd EINSTELLUNG NACH DER MANUELLEN ENTSICHERUNG
D jeweils um 1/4 Umdrehung zudrehen, um die Tellerfe- D Die Schrauben (25) mit den Muttern (24) und den
dern (11) einzudruÈcken und die Bremsscheiben frei- Dichtungen (26) abnehmen.
zusetzen. Die Dichtungen (26) auswechseln, die Schrauben (25) mit Silikon-
c WICHTIG. Maximal um eine Umdrehung zuschrauben. d fett Tecno Lupe/101 schmieren und das ganze Teil in den Arm
montieren.
Utilizando una llave, atornillar los tornillos (25) de REGULACION DESPUES DEL DESBLOQUEO MANUAL
ESP manera alternada de 1/4 de giro a la vez, para ESP Remover los tornillos (25) completas de guarniciones
comprimir los muelles a taza (11) y librar los discos (26).
de frenadura. Sobstituir las guarniciones (26), lubrificar los tornillos (25) con
IMPORTANTE. Atornillar por max. un giro. grasa al silicone Tecno Lupe/101 y montar todo en el eje.
A l'aide d'une cleÂ, visser les vis (25) alternativement 1/ REGLAGE FAISANT SUITE AU DEBLOCAGE MANUEL
F 4 de tour aÁ la fois, pour contraindre le ressort belleville F Enlever les vis (25) compleÁtes d'eÂcrous (24) et de
(11) et deÂgager les disques de freinage. garnitures (26).
IMPORTANT. Visser pour max. un tour. 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 Bloccare la posizione con i dadi (24).
ITA rispetto al braccio di 34+0,5
0 mm
ITA
ATTENZIONE! Mantenere la posizione delle viti (25)
quando si bloccano i dadi (24); dopo il bloccaggio,
ricontrollare la sporgenza delle viti (25).
È berstand zum Arm

Schrauben (25) einstellen, bis der U Die Position mit den Muttern (24) blockieren.
D 34+0.5
0 mm betraÈgt. D
ACHTUNG! Die Position der Schrauben (25) darf sich
beim Festziehen der Muttern (24) nicht aÈndern; nach
der Blockierung den U È berstand der Schrauben (25) nochmals
e f kontrollieren.
Regular los tornillos (25) hasta obtener una parte Bloquear la colocacioÁn con las tuercas (24).
ESP saliente respecto al eje de 34+0,5
0 mm
ESP
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).
ReÂgler les vis (25) jusqu'aÁ avoir une saillie de 34+0.5

0 mm Bloquer dans la position aÁ l'aide des eÂcrous (24).
F par rapport au bras. F
ATTENTION! Tenir les vis (25) en place quand on
bloque les eÂcrous (24); apreÁs avoir fixeÂ, controÃler la
saillie des vis (25).
008 918 12 BOMAG

29 991
18.8DISASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - SMONTAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ABMONTIEREN - DESMONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - DEMONTAGE DU REDUCTEUR
EPICICLOIDALE ET DU DEMI-ESSIEU
4
12
9 11
10
3
8 13
14
7
16
15
2
1 D1240131
1
3
2
F1241103 F1241104
GB a GB b
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).
992 BOMAG
30 008 918 12
Axle 18.8
SICHERHEIT - NORMAS CONCERNIENTES A LA SEGURIDAD - NOTES EN MATIERE DE SECURITE

NOTES ON SAFETY PRECAUTIONS - NOTE RIGUARDANTI LA SICUREZZA - BEMERKUNGEN ZUR
GB The axle shafts can only be removed once the 2 - Achse zuerst von der Maschine abmontieren und auf eine
extraction of the planetary cover has been performed. Werkbank legen.
Different procedures need to be followed depending on
the kind of repair work required: Nachstehende Beschreibung bezieht sich auf das Zerlegen an der
Werkbank, doch ist die Vorgehensweise in beiden FaÈllen dieselbe.
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 La remocioÁn de los semi-ejes puede ser efectuada solo
carried out on the bench, but the stages apply to all versions. ESP despues de la remocioÁn 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 remocioÁn efectuada al
La rimozione dei semiassi puoÁ essere eseguita solo banco, ma las fases son comunes.
ITA 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 Le deÂgagement des demi-essieux ne peut se faire
banco, ma le fasi sono comuni. F qu'apreÁs avoir enleveÂ le couvercle porte-satellites
d'une facËon diversifieÂe, en fonction du type de
reÂparations aÁ effectuer:
1 - DeÂmontage essieu monteÂ sur machine deÂposeÂe sur des baÃtis de
seÂcuriteÂ.
1 - DeÂmontage essieu deÂmonteÂ de la machine et soutenu par un
outil speÂcial (sur banc).
Les explications reporteÂes se reÂfeÁrent au deÂgagement effectueÂ au
Die Halbachse kann erst abmontiert werden, wenn der banc, mais les phases sont communes.
D Deckel des Planetenradhalters abgenommen worden
ist; auûerdem wird sie je nach Reparatur unterschied-
lich abmontiert:
1 - Mit Achse abmontieren, die an der Maschine montiert und durch
SicherheitsbloÈcke gestuÈtzt ist.
Rimuovere le viti (1) di fissaggio del coperchio Utilizzando due cacciaviti o due leve inserite nelle
ITA portasatelliti (2). ITA cave predisposte, staccare il coperchio portasatelliti
(2) dal mozzo portaruota (3).
Schrauben (1) abschrauben, die den Deckel des Zwei Schraubenzieher oder zwei Hebel in die vorge-
D Planetenradhalters (2) befestigen. D sehenen Nuten stecken und den Deckel (2) des
Planetenradhalters von den Radhalternaben (3) ab-
heben.
a b
Remover los tornillos (1) de fisaje de la tapa porta- Utilizando dos destornilladores o dos palancas inser-
ESP satelites (2). ESP tadas en las ranuras predispuestas, destacar la tapa
lleva-satelites (2) del cubo lleva-rueda (3).
Enlever les vis (1) de fixation du couvercle porte- A l'aide de deux tournevis ou de deux leviers dans les
F satellites (2). F creux preÂdisposeÂs, deÂgager le couvercle porte-satel-
lites (2) du moyeu porte-roue (3).
008 918 12 BOMAG

31 993
2 3
5
F1241105 F1241106
GB a GB b
Rotate the wheel hub (3) until one of the screw holes (1) appears at Only in case of replacement of component parts not requiring
the top. the disassembly of the crown wheel (5).
Apply a "U" piece to the screw hole; connect to a hoist and remove Countermark the position between one of the teeth of the axle shaft
the cover (2). (4) and the crown wheel (5).
F1241107 F1241108
GB c GB d
Remove the axle shaft (4). Loosen the screws (6) and remove them.
NOTE. The removal of the axle shaft allows for the substitution of
the snap ring as described in the following paragraphs.
3 5
7
F1241109 F1241110
GB e GB f
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).
994 BOMAG
32 008 918 12
Axle 18.8
Ruotare il mozzo portaruota (3) fino a portare un foro Solo se si devono sostituire dei componenti che
ITA per le viti (1) in posizione alta. ITA non richiedono lo smontaggio della corona (5).
Applicare un grillo ad "U" nel foro vite; collegare un Contrassegnare la posizione tra un dente del semias-
mezzo di sollevamento e rimuovere il coperchio (2). se (4) e la corona (5).
Nur wenn Bestandteile ausgewechselt werden

D Die Radhalternabe (3) drehen bis ein Loch fuÈr die D muÈssen, fuÈr die der Kranz (5) nicht abmontiert
Schrauben (1) in der oberen Position liegt. werden muû.
Einen U-foÈrmigen BuÈgel in das Schraubenloch stecken; ein Die Position zwischen einem Zahn der Halbachse (4) und dem
a Hebezeug anschlieûen und den Deckel (2) abnehmen. b Kranz (5) markieren.
Girar el cubo lleva-rueda (3) hasta hacer un agujero Solo si se deben de sobstituir algunos componentes
ESP para los tornillos (1) en posicioÁn alta. ESP que no comportan el desmontaje de la corona (5).
Aplicar un grillo a "U" en el agujero tornillos; conectar Senalar la colocacioÁn entre un diente del semi-eje (4) y
un medio de levantamiento y remover la tapa (2). la corona (5).
Tourner le moyeu porte-roue (3) jusqu'aÁ aÁ amener un Uniquement si on doit substituer des composants qui
F des trous pour les vis (1) en haut. F ne veulent pas le deÂmontage de la couronne (5).
Appliquer une manille en "U" dans le trou de vis; Marquer la position entre une dent du demi-essieu (4)
appliquer un moyen de relevage et enlever le couvercle (2). et la couronne (5).
Asportare il semiasse (4). Allentare le viti (6) ed asportarle.

ITA ITA
NOTA. L'asportazione del semiasse permette la
sostituzione dell'anello di tenuta come descritto di
seguito.
Die Halbachse (4) abnehmen. Schrauben (6) abschrauben.

D D
BEMERKUNG. Bei abgenommener Halbachse kann
der Dichtring, wie nachstehend beschrieben, ausge-
wechselt werden.
c d
Sacar el semi-eje (4). Aflojar los tornillos (6) y sacarlos.
ESP ESP
NOTA. Sacar el semi-eje permite la sobstitucioÁn del
anillo de tenida como descrito a seguir.
Enlever le demi-essieu (4). Desserrer les vis (6) puis les enlever.
F F
REMARQUE. Le deÂgagement du demi-essieu consent
la substitution de l'anneau d'eÂtancheÂiteÂ comme deÂcrit
par la suite.
Asportare la flangia di sicurezza (7). Avvitare parzialmente, in modo alternato ed in uguale

ITA ITA misura, cinque delle dieci viti (6).
Utilizzando un estrattore e facendo reazione sulle viti
(6) disimpegnare la corona (5) dal mozzo (3).
Sicherheitsflansch (7) abnehmen. Abwechselnd und im gleichen Maû fuÈnf von den zehn
D D Schrauben (6) zuschrauben.
Mit einem Abzieher den Kranz (5) aus der Nabe (3)
ziehen und dabei auf die Schrauben (6) wirken.
e f
Sacar la arandela de seguridad (7). Atornillar parcialmente, de manera alternada y en
ESP ESP igual mesera, cinco de las diez tornillos (6).
Utilizando un extractor y haciendo reacioÁn sobre los
tornillos (6) desempenar la corona (5) del cubo (3).
Enlever la flasque de seÂcuriteÂ (7). Visser partiellement, en alternance et de la meÃme

F F facËon cinq des dix vis (6).
A l'aide d'un extracteur, tout en faisant reÂagir les vis
(6), deÂgager la couronne (5) du moyeu (3).
008 918 12 BOMAG

33 995
3
F1241111 F1241112
GB a GB b
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).
3
9
8
10
3
F1241113 F1241114
GB c GB d
Remove the bearing (8) and the hub (3). Extract the hub (3) complete with snap ring (9) and internal bearing
(10).
14
13
11 12
F1241115 F1241116
GB e GB f
Using an extractor, remove at the same time the snap ring (11) and Remove the safety spring rings (13) of the planetary gears (14).
the centring ring (12).
NOTE. Note down the direction of assembly of snap and centring
rings.
996 BOMAG
34 008 918 12
Axle 18.8
Rimuovere le viti (6) e la corona (5). Imbragare il mozzo (3) e collegarlo ad un mezzo di
ITA ITA sollevamento; avvitare parzialmente una vite (6) e, con
un mazzuolo, smuovere il mozzo (3) ed il cuscinetto
esterno (8).
Schrauben (6) und Kranz (5) abnehmen. Nabe (3) anschlagen und an ein Hebezeug befestigen;
D D Schrauben (6) etwas zudrehen und mit einem Ham-
mer die Naben (3) und das aÈuûere Lager (8) bewegen.
a b
Remover los tornillos (6) y la corona (5). Atar el cubo (3) y conectarlo a un medio de
ESP ESP levantamiento; atornillar parcialmente un tornillo (6)
y, con un martillo, mover el cubo (3) y el cojinete
externo (8).
Enlever les vis (6) et la couronne (5). Elinguer le moyeu (3) puis relier celui-ci aÁ un moyen de
F F relevage; visser partiellement une vis (6), puis aÁ l'aide
d'un maillet, bouger le moyeu (3) et le palier externe
(8).
Rimuovere il cuscinetto (8) ed il mozzo (3). Asportare il mozzo (3) completo di anello di tenuta (9) e
ITA ITA cuscinetto interno (10).
Lager (8) und Nabe (3) abnehmen. Nabe (3) samt Dichtring (9) und inneres Lager (10)
D D abnehmen.
c d
Remover el cojinete (8) y el cubo (3). Sacar el cubo (3) completo de anillo de retencioÁn (9) y
ESP ESP cojinete interno (10).
Enlever le palier (8) et le moyeu (3). Enlever le moyeu (3) complet de bague d'eÂtancheÂiteÂ
F F (9) et de palier interne (10).
Utilizzando un estrattore, rimuovere contemporanea- Rimuovere gli anelli elastici (13) di ritegno satelliti (14).
ITA mente l'anello di tenuta (11) e l'anello centratore (12). ITA
NOTA. Annotare il senso di montaggio degli anelli di
tenuta e di centratura.
Mit einem Abzieher gleichzeitig den Dichtring (11) und Kolbenringe (13) und Planetenhalter (14) abnehmen.
D den Zentrierring (12) abnehmen. D
BEMERKUNG. Montagerichtung der Dicht- und Zen-
trierringe notieren.
e f
Utilizando un extractor, remover contemporaneamen- Remover los anillos elasticos (13) de retencioÁn
ESP te el anillo de retencioÁn (11) y el anillo centrador (12). ESP satelites (14).
NOTA. Anotar el sentido de montaje de los anillos de
retencioÁn y de centraje.
A l'aide d'un extracteur enlever en meÃme temps Enlever les anneaux ressorts (13) de fixation des
F l'anneau d'eÂtancheÂiteÂ (11) et l'anneau centreur (12). F satellites (14).
REMARQUE. Prendre note du sens de montage des
anneaux d'eÂtancheÂiteÂ et de centrage.
008 918 12 BOMAG

35 997
14
15
F1241117 F1241118
GB a GB b
Remove the planetary gears (14). Only if necessary.
NOTE. Note down direction of assembly of planetary gears. Using an extractor, remove the shim washer (15) from the planet
carrier.
9 9
3 10
F1241119 F1241120
GB c GB d
Remove the snap ring (9) from the hub (3). Remove the internal bearing (10).
NOTE. Note down direction of assembly.
CAUTION! The snap ring may not be reused.
10
8
F1241121
GB e GB f
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.
998 BOMAG
36 008 918 12
Axle 18.8
Asportare gli ingranaggi satelliti (14). Solo se necessario.

ITA ITA Utilizzando un estrattore, rimuovere dal portasatelliti la
NOTA. Annotare il senso di montaggio dei satelliti.
rondella di rasamento (15).
Planetengetriebe (14) abnehmen. Nur wenn notwendig.

D D Mit einem Abzieher vom Planetenradhalter die Zwi-
BEMERKUNG. Montagerichtung notieren.
schenlegscheibe (15) abnehmen.
a b
Sacar los engranajes satelites (14). Solo si necesario.
ESP ESP Utilizando un extractor, remover del lleva-satelites la
NOTA. Anotar el sentido de desmontaje de los
satelites. arandela de rasamiento (15).
Enlever les engrenages satellites (14). Uniquement si besoin.

F F A l'aide d'un extracteur, enlever du porte-satellite la
REMARQUE. Prendre note du sens de montage.
rondelle de rasage (15).
Rimuovere dal mozzo (3) l'anello di tenuta (9). Rimuovere il cuscinetto interno (10).
ITA ITA
NOTA. Annotare il senso di montaggio.
ATTENZIONE! L'anello di tenuta non puoÁ essere
riutilizzato.
Von der Nabe (3) den Dichtring (9) abnehmen. Das innere Lager (10) abnehmen.
D D
BEMERKUNG. Montagerichtung notieren.
ACHTUNG! Der Dichtring darf nicht wieder verwendet
werden.
c d
Remover del cubo (3) los anillos de retencioÁn (9). Remover el cojinete interior (10).
ESP ESP
NOTA. Anotar el sentido de montaje.
ATENCION! El anillo de retencioÁn no puede ser
reutilizado.
Oter du moyeu (3) l'anneau d'eÂtancheÂiteÂ (9). Enlever le palier interne (10).
F F
REMARQUE. Prendre note du sens de montage.
ATTENTION! L'anneau d'eÂtancheÂiteÂ ne peut pas eÃtre
reÂutiliseÂ.
Rimuovere le ralle esterne dei cuscinetti (8) e (10)

ITA utilizzando un cacciaspine. ITA
NOTA. Battere in modo alternato per evitare impunta-
menti e deformazioni delle ralle.
Die aÈuûeren Scheiben (8) und (10) mit einem DuÈbel

D abnehmen. D
BEMERKUNG. Abwechselnd schlagen, um ein Durch-
schlagen und Verformungen der Scheiben zu vermeiden.
e f
Remover las ranguas externas de los cojinetes (8) y
ESP (10) utilizando un extractor de clavijas. ESP
NOTA. Pegar de manera alternada para evitar
empuntamientos y deformacioÁnes de las ranguas.
Enlever les crapaudines externes des paliers (8) et

F (10) aÁ l'aide d'un chasse-clou. F
REMARQUE. Donner des coups alterneÂs pour eÂviter
talonnages et deÂformations des crapaudines.
008 918 12 BOMAG

37 999
18.8ASSEMBLY OF PLANETARY REDUCTION AND AXLE SHAFT - ASSEMBLAGGIO RIDUTTORE EPICICLOIDALE E SEMIASSE - PLANETENGE-Axle
TRIEBE UND HALBACHSE ZUSAMMENBAUEN - MONTAJE REDUCTOR EPICICLOIDAL Y SEMIEJES - ASSEMBLAGE DU REDUCTEUR
T3 10 9
3
10
F1241122 F1241123
GB a GB b
Position the wheel hub (3) under a press; lubricate the seat of the Install the bearing (10).
external bearing and, using tool T3, install the thrust block of the Apply an appropriate sealant to the outer surface of the snap ring
bearing (10). (9).
Position the snap ring (9) into the hub (3).
NOTE. Check orientation of the ring.
T4 T3
9 3
8
F1241124 F1241125
GB c GB d
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).
15
2 14
F1241126 F1241117
GB e GB f
Only if shim washer has previously been removed. Fit the planetary gear (14) onto the planetary gear cover (2).
Apply a sealant for removable seals to the outer surface of the shim CAUTION! The jointed portion of the internal ring of the bearings
washer (15) and, using a driver, fit it into the planetary gear cover must face the bottom of the pin.
(2).
1000 BOMAG
38 008 918 12
Axle 18.8
Posizionare il mozzo ruota (3) sotto una pressa; Installare il cuscinetto (10).
ITA lubrificare la sede del cuscinetto esterno e, utilizzando ITA Spalmare la superficie esterna dell'anello di tenuta (9)
l'attrezzo T3, montare la ralla del cuscinetto (10). con sigillante per guarnizioni.
Posizionare l'anello di tenuta (9) nel mozzo (3).
NOTA. Controllare l'orientamento dell'anello.
Die Radnabe (3) unter eine Presse positionieren; den Lager (10) installieren.
D Sitz des aÈuûeren Lagers schmieren und mit dem D AÈuûere FlaÈche des Dichtringes (9) mit etwas Dicht-
Werkzeug T3 die Scheibe des Lagers (10) montieren. masse schmieren.
Dichtring (9) in die Nabe (3) positionieren.
a b BEMERKUNG. Richtung des Ringes kontrollieren.
Colocar el cubo rueda (3) bajo una prensa; lubrificar la Colocar el cojinete (10).
ESP sed del cojinete externo y, utilizando la herramienta ESP Pasar la superficie externa del anillo de retencioÁn (9)
T3, montar la rangua del cojinete (10). con sigilante para guarniciones.
Colocar el anillo de retencioÁn (9) en el cubo (3).
NOTA. Controlar el orientamiento del anillo.
Positionner le moyeu roue (3) sous la presse; lubrifier Installer le palier (10).
F le logement du palier externe, puis aÁ l'aide de l'outil F Enduire la superficie externe de l'anneau d'eÂtancheÂiteÂ
T3, monter la crapaudine du palier (10). (9) avec de la colle aÁ garnitures.
Positionner l'anneau d'eÂtancheÂiteÂ (9) dans le moyeu (3).
REMARQUE. ControÃler la bonne direction de l'anneau.
Posizionare l'attrezzo T4 e pressare in sede l'anello di Capovolgere il mozzo (3), lubrificare la sede cuscinetto
ITA tenuta (9). ITA e, utilizzando l'attrezzo T3, montare la ralla del
cuscinetto (8).
Das Werkzeug T4 positionieren und den Dichtring (9) Die Nabe (3) wenden, den Lagersitz schmieren und
D in seinen Sitz druÈcken. D mit dem Werkzeug T3 die Nabe des Lagers (8)
montieren.
c d
Colocar la herramienta y apretar en sed el anillo de Volcar el cubo (3), lubrificar la sed cojinete y,
ESP retencioÁn (9). ESP utilizando la herramienta T3, montar la rangua del
cojinete (8).
Placer l'outil T4 et presser dans son logement Faire basculer le moyeu (3), lubrifier le logement du
F l'anneau d'eÂtancheÂiteÂ (9). F palier, puis aÁ l'aide de l'outil T3, monter la crapaudine
dans le palier (8).
Solo se eÁ stata rimossa. Montare sui perni del coperchio portasatelliti (2) gli
ITA Spalmare la superficie esterna della rondella di ITA ingranaggi planetari (14).
rasamento (15) con sigillante per guarnizioni removibili ATTENZIONE! La parte raccordata dell'anello interno
e, utilizzando uno spintore, montarla nel coperchio portasatelliti (2). dei cuscinetti deve essere rivolta verso il fondo del perno.
Nur wenn zuvor abgenommen. Auf die Stifte des Deckels des Planetenradhalters (2)
D AÈuûere FlaÈche der Zwischenlegscheibe (15) mit D die Planetengetriebe (14) montieren.
Dichtmasse fuÈr abnehmbare Dichtungen schmieren ACHTUNG! Das AnschluûstuÈck des inneren Lagerrin-
und mit einem StoÈûel diese Zwischenlegscheibe in den Deckel des ges muû zur unteren Seite des Stiftes gerichtet sein.
e Planetenradhalters (2) montieren. f
Solo si ha sido desplazada. Montar sobre los pernos de la tapa lleva-satelites (2)
ESP Pasar la superficie externa de la arandela de ESP los engranajes planetares (14).
rasamiento (15) con sigilante para guarnicioÁnes ATENCION! La parte empalmada del anillo interno de
removibles y, utilizando un empuje, montarla en la tapa lleva- los cojinetes debe de ser dirijida hacia el fondo de la rotula.
satelites (2).
Uniquement si elle a eÂteÂ enleveÂe. Monter sur les pivots du couvercle porte-satellites (2)
F Enduire la superficie externe de la rondelle de rasage F les engrenages planeÂtaires (14).
(15) avec de la colle pour garnitures amovibles, aÁ ATTENTION! La partie raccordeÂe de l'anneau aÁ
l'aide d'un poussoir monter celle-ci dans le couvercle porte- l'inteÂrieur du palier doit eÃtre tourneÂe vers la partie basse du pivot.
satellites (2).
008 918 12 BOMAG

39 1001
T5
13
14
11 12
F1241127 F1241128
GB a GB b
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.
3
9
3
F1241114 F1241113
GB c GB d
Grease the snap ring (9) and the hub of the arm. Install the external bearing (8).
Install the wheel hub (3). NOTE. Move the bearing to the limit stop by hammering lightly all
around the edge.
7
F1241129 F1241109
GB e GB f
Install the crown wheel (5) and, using a driver with adequate Using Tecno Lupe /101, grease the surface of the safety flange (7)
diameter, fasten it onto the hub of the arm. that touches the crown wheel.
1002 BOMAG
40 008 918 12
Axle 18.8
Fissare la posizione degli ingranaggi satelliti (14) con Lubrificare e montare sull'attrezzo T5 l'anello centra-
ITA gli anelli elastici (13). ITA tore (12) e l'anello di tenuta (11); montare gli anelli nel
braccio.
ATTENZIONE! Controllare attentamente il senso di montaggio
degli anelli.
Die Position der Planetengetriebe (14) mit den Das Werkzeug T5 schmieren und darauf den Zen-
D Kolbenringen (13) festigen. D trierring (12) und den Dichtring (11) montieren; die
Ringe in den Arm montieren.
ACHTUNG! Montagerichtung der Ringe sorgfaÈltig kontrollieren.
a b
Fijar la posicioÁn de los engranajes satelites (14) con Lubrificar y montar sobre la herramienta T5 el anillo
ESP los anillos elasticos (13). ESP central (12) y el anillo de retencioÁn (11); montar los
anillos en el eje.
ATENCION! Controlar atentamente el sentido de montaje de los
anillos.
Fixer les engrenages porte-satellites (14) aÁ leur place Lubrifier et monter sur l'outil T5 l'anneau centreur (12)
F avec les anneaux ressorts (13). F et l'anneau d'eÂtancheÂiteÂ (11); monter les anneaux
dans le bras.
ATTENTION! ControÃler attentivement le sens du montage des
anneaux.
Lubrificare con grasso l'anello di tenuta (9) ed il mozzo Montare il cuscinetto esterno (8).
ITA del braccio. ITA
NOTA. Mandare a fondo corsa il cuscinetto con
Montare il mozzo portaruota (3). leggeri colpi di mazzuolo distribuiti su tutta la
circonferenza.
Mit Fett den Dichtring (9) und die Armnabe schmieren. AÈuûeres Lager (8) montieren.
D Radhalternabe (3) montieren. D
BEMERKUNG. Das Lager bis zum Anschlag mit
leichten HammerschlaÈgen an der gesamten Kreislinie
einsetzen.
c d
Lubrificar con grasa el anillo de retencioÁn (9) y el cubo Montar el cojinete esterno (8).
ESP del eje. ESP
NOTA. Mandar a tope el cojinete con ligeros colpes de
Montar el cubo lleva-rueda (3). martillo repartidos sobre toda la circonferencia.
Lubrifier avec de la graisse l'anneau d'eÂtancheÂiteÂ (9), Monter le palier externe (8).
F le moyeu du bras. F
REMARQUE. Envoyer en buteÂe le palier avec de
Monter le moyeu porte-roue (3). leÂgers coups de maillet distribueÂs tout autour de la
circonfeÂrence.
Montare la corona (5) e, utilizzando uno spintore di Lubrificare con grasso Tecno Lupe /101 la superficie
ITA diametro adatto, mandarla in battuta sul mozzo del ITA della flangia di sicurezza (7) a contatto con la corona.
braccio.
Den Kranz (5) montieren und mit einem geeigneten Mit Fett Typ Tecno Lupe/ 101 die FlaÈche des Sicher-
D StoÈûel den Kranz bis zum Anschlag an der Armnabe D heitsflanschs (7), der am Kranz anliegt, schmieren.
einsetzen.
e f
Montar la corona (5) y, utilizando un empuje de Lubrificar con grasa Tecno Lupe/101 la superficie de
ESP diametro apto, mandarla a tope sobre el cubo del eje. ESP la brida de seguridad (7) a contacto con la corona.
Monter la couronne (5), puis aÁ l'aide d'un poussoir Lubrifier avec de la graisse Tecno Lupe/ 101 la
F d'un diameÁtre adapteÂ, envoyer celle-ci en buteÂe sur le F superficie de la flasque de seÂcuriteÂ (7) au contact de
moyeu du bras. la couronne.
008 918 12 BOMAG

41 1003
11
4
F1241130 F1241107
GB a GB b
Coat the screws (6) with Loctite 270 and screw them. Lubricate the snap ring (11), the toothed portions and the sealing
Tighten screws (6) in two stages, using the criss-cross method. surface of the axle shaft.
Initial torque wrench setting: 120 Nm Install the axle shaft (4), making sure that it is properly inserted into
Final torque wrench setting: 219 ± 242 Nm braking disks and differential unit.
3 1
2
2
16
F1241131 F1241132
GB c GB d
Fit the planetary gear cover (2) onto the wheel hub (3). Lock the planetary gear cover (2) onto the wheel hub (3) with
CAUTION! 1 - Check the condition and position of the O-ring (16). screws (1).
2 - Line up the locating release points. Screws torque wrench setting: 40 ± 0 Nm.
GB e GB f
1004 BOMAG
42 008 918 12
Axle 18.8
Spalmare le viti (6) con Loctite 270 ed avvitarle. Lubrificare l'anello di tenuta (11), le dentature e la
ITA Serrare le viti (6) in due tempi e con il metodo del ITA superficie di tenuta del semiasse.
serraggio incrociato. Montare il semiasse (4) assicurandosi che si innesti
Coppia di serraggio iniziale: 120 Nm nei dischi freni e nel differenziale.
Coppia di serraggio finale: 219v242 Nm
Die Schrauben (6) mit Loctite 270 schmieren und Dichtring (11), ZaÈhne und DichtflaÈche der Halbachse
D festschrauben. D schmieren.
Schrauben (6) im Kreuz schrittweise festziehen. Halbachse (4) montieren und darauf achten, daû sie in
Anzugsmoment zuerst: 120Nm die Bremsscheiben und in das Differential einrastet.
a Anzugsmoment am Ende: 219v242 Nm b
Pasar los tornillos (6) con Loctite 270 y atornillarlos. Lubrificar el anillo de retencioÁn (11), las dentaduras y
ESP Apretar los tornillos (6) en doss tiempos con el metodo ESP la superficie del semieje.
de torsion cruzada. Montar el semieje (4) asegurandose que se encaje en
Par de torsion inicial: 120 Nm. los discos y en el diferencial.
Par de torsion final: 219v242 Nm.
Enduire les vis (6) avec du Loctite 270 puis visser. Lubrifier l'anneau d'eÂtancheÂiteÂ (11), les dents, la
F Serrer les vis (6) en deux temps avec la meÂthode du F superficie eÂtanche des demi-essieux.
serrage croiseÂ. Monter le demi-essieu (4) en veillant aÁ ce qu'il
Couple de serrage initial: 120Nm s'enclenche bien dans les disques freins et dans le diffeÂrentiel.
Couple de serrage final: 219v242 Nm.
Montare il coperchio portasatelliti (2) sul mozzo Bloccare il coperchio portasatelliti (2) sul mozzo
ITA portaruota (3). ITA portaruota (3) con le viti (1).
ATTENZIONE! 1 - Controllare lo stato e la posizione Coppia di serraggio viti: 40v50 Nm
della guarnizione OR (16).
2 - Allineare gli scarichi di riferimento.
Den Deckel des Planetenradhalters (2) auf die Nabe Den Deckel des Planetenradhalters (2) an der Rad-
D des Radhalters (3) montieren. D halternabe (3) mit den Schrauben (1) blockieren.
ACHTUNG! 1 - Zustand und Position der O-Ringe (16) Anzugsmoment der Schrauben: 40v50 Nm
kontrollieren.
c 2 - Die Bezugsstellen bzw. AblaûoÈffnung fluchten. d
Montar la tapa lleva-satelites (2) sobre el cubo lleva- Bloquear la tapa lleva-satelietes (2) sobre el cubo
ESP rueda (3). ESP lleva-rueda (3) con los tornillos (1).
ATENCION! 1 - Controlar el estado y la posicioÁn de la Par de torsion tornillos: 40v50 Nm
guarnicioÁn OR (16).
2 - Alinear los descarges de referencia.
Monter le couvercle porte-satellite (2) sur le moyeu Bloquer le couvercle porte-satellite (2) sur le moyeu
F porte-roue (3). F porte-roue (3) aÁ l'aide des vis (1).
ATTENTION! 1 - ControÃler l'eÂtat et la position des Couple de serrage des vis: 40v50 Nm.
garnitures O'Ring (16).
2 - Aligner les points de deÂcharge de reÂfeÂrence.
ITA ITA
D D
e f
ESP ESP
F F
008 918 12 BOMAG

43 1005
18.8 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - RIMOZIONE E SMONTAGGIO GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ABNEHMEN UND ZERLEGEN - REMOCION Y DESMONTAJE GRUPO DIFERENCIAL -
DEGAGEMENT ET DEMONTAGE DU GROUPE DIFFERENTIEL
T6
T7A
F1241141 F1241142
GB a GB b
REMOVAL OF THE DIFFERENTIAL UNIT Apply tool T6 - for crown wheel side centring - with relative distance
Remove the whole arms, the cylinders, and the whole reduction pieces and lock it with two nuts.
unit. Apply centring tool T7A as well.
For details, see «CHECKING WEAR AND REPLACING THE
BRAKING DISKS» and «REMOVAL OF REDUCTION GEAR».
1 T7B
F1241143 F1241144
GB c GB d
Remove the stud screws and remove the intermediate cover (1) on Install centring tool T7B on the opposite side of the crown wheel.
the crown wheel opposite side.
2 T7B
A
4
3
5 6
F1241145 F1241146
GB e GB f
Remove centring tools T6 and T7A from crown wheel side; remove Position a stop block «A» made from tender material (aluminium,
the studs and the intermediate cover (2) on the crown wheel side. 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).
1006 BOMAG
44 008 918 12
Axle 18.8
RIMOZIONE DIFFERENZIALE Applicare l'attrezzo T6 di centraggio dal lato corona

ITA Rimuovere i bracci completi, i cilindri freni ed il ITA con i relativi distanziali e fissarlo con due dadi.
riduttore completo. Applicare anche l'attrezzo T7A di centratura.
Per i dettagli, vedere «CONTROLLO USURA E SOSTITUZIONE
DISCHI FRENO» e «RIMOZIONE RIDUTTORE».
DIFFERENTIAL ABNEHMEN Das Werkzeug T6 zur Zentrierung an der Kranzseite

D Die kompletten Arme, die Bremszylinder und den D mit den entsprechenden DistanzstuÈcken anbringen
kompletten Reduzierer abnehmen. und das Werkzeug mit zwei Muttern befestigen.
Siehe «VERSCHLEISS KONTROLLIEREN UND BREMSSCHEI- Das Werkzeug T7A zur Zentrierung anbringen.
a BEN AUSWECHSELN» und «REDUZIERER ABNEHMEN». b
REMOCION DIFERENCIAL Aplicar la herramienta T6 de centraje del lado corona
ESP Remover los ejes completos, los cilindros frenos y el ESP con los relativos distanciales y fijarla con dos tuercas.
reductor completo. Aplicar tambien la herramienta T7A de centradura.
Para los detalles, vease «CONTROL DESGASTE Y SOBSTITU-
CION DISCOS FRENOS» y «REMOCION REDUCTOR».
DEGAGEMENT DU DIFFERENTIEL Appliquer l'outil T6 de centrage du coÃteÂ couronne

F Enlever les bras entieÁrement, les cylindres freins et le F avec les entretoises correspondantes et fixer l'outil
reÂducteur tout entier. avec deux eÂcrous.
Pour de plus amples deÂtails, voir "CONTROLE DE L'USURE ET Appliquer eÂgalement l'outil de centrage T7A.
SUBSTITUTION DU DISQUE FREIN" et "DEGAGEMENT DU
REDUCTEUR".
Rimuovere le viti prigioniere e rimuovere il coperchio Montare l'attrezzo T7B di centraggio sul lato opposto
ITA intermedio (1) dal lato opposto corona. ITA corona.
Die Stiftschrauben und den Zwischendeckel (1) von Das Werkzeug T7B zur Zentrierung an der dem Kranz
D der dem Kranz entgegengesetzte Seite abnehmen. D entgegengesetzte Seite montieren.
c d
Remover los tornillos prigioneros y remover la tapa Montar la herramienta T7B de centraje sobre el lado
ESP intermedia (1) del lado opuesto corona. ESP opuesto corona.
Enlever les vis prisonnieÁres et enlever le couvercle Monter l'outil de centrage T7B du coÃteÂ opposeÂ aÁ la
F intermeÂdiaire (1) du coÃteÂ opposeÂ aÁ la couronne. F couronne.
Rimuovere gli attrezzi T6 e T7A di centraggio del lato Posizionare tra il corpo centrale (3) e la dentatura della
ITA corona; asportare i prigionieri e rimuovere il coperchio ITA corona (4) un blocchetto "A" di contrasto in materiale
intermedio (2) lato corona. tenero (alluminio ecc.).
Mantenendo in appoggio la corona (4) sul blocchetto "A",
rimuovere ed asportare le viti (5) e le rondelle elastiche (6).
Die Werkzeuge T6 und T7A zur Zentrierung an der Zwischen dem ZentralkoÈrper (3) und den ZaÈhnen des
D Kranzseite entfernen; die Stiftschrauben und den D Kranzes (4) den Block "A" aus weichem Material
Zwischendeckel (2) an der Kranzseite abnehmen. (Aluminium usw.) legen.
Den Kranz (4) am Block "A" anliegen lassen und die Schrauben (5)
e f und die Federscheiben (6) abnehmen.
Remover las herramientas T6 y T7A de centraje del Colocar entre el cuerpo central 83) y la dentadura de
ESP lado corona; sacar los prigioneros y remover la tapa ESP la corona (4) un bloque "A" de contraste de material
intermedia (2) lado corona. tierno (aluminio ect.).
Manteniendo en apoyo la corona (4) sobre el bloque "A", remover y
sacar los tornillos (5) y las arandelas elasticas (6).
Enlever les outils T6 et T7A de centrage du coÃteÂ Placer entre le corps central (3) et la denture de la
F couronne; enlever les prisonniers et deÂplacer le F couronne (4) un petit bloc "A" en mateÂriel leÂger
couvercle intermeÂdiaire (2) du coÃteÂ couronne. (aluminium etc.) de contraste.
En maintenant la couronne (4) sur le petit bloc "A", deÂvisser et
enlever les vis (5), et ensuite les rondelles eÂlastiques (6).
008 918 12 BOMAG

45 1007
7
7
F1241147 F1241148
GB a GB b
Using a driver, push the differential unit (7) or (8) towards the Extract the whole differential unit (7) or (8).
opposite side of the crown so as to disengage it from the crown (4).
T7B 3 3
4
4
F1241223 F1241174
GB c GB d
Remove tool T7B from the crown opposite side. Extract the crown (4).
B
9
9
F1241149 F1241150
GB e GB f
DISASSEMBLY OF THE DIFFERENTIAL UNIT DISASSEMBLY OF THE NO-SPIN DIFFERENTIAL UNIT
Using an extractor, remove bearings (9) from the differential unit. Insert stay "B" provided for holding into position the no-spin unit
(14) and screw tight the wing nut.
1008 BOMAG
46 008 918 12
Axle 18.8
Utilizzando uno spintore, spingere il differenziale (7) o Estrarre il gruppo differenziale (7) o (8) completo.
ITA (8) verso il lato opposto corona fino a disimpegnarlo ITA
dalla corona (4).
Mit einem StoÈûel das Differential (7) oder (8) in die dem Das komplette Differentialaggregat (7) oder (8) ab-
D Kranz entgegengesetzte Seite druÈcken und aus dem D ziehen.
Kranz (4) freisetzen.
a b
Utilizando un empuje, empujar el diferencial (7) o (8) Sacar el grupo diferencial (7) o (8) completo.
ESP hacia el lado opuesto corona hasta desempenarlo de ESP
la corona (4).
A l'aide d'un poussoir, pousser le diffeÂrentiel (7) ou (8) Extraire le groupe diffeÂrentiel (7) ou (8) tout entier.
F du coÃteÂ opposeÂ aÁ la couronne jusqu'aÁ le deÂgager de la F
couronne (4).
Rimuovere l'attrezzo T7B montato sul lato opposto Estrarre la corona (4).
ITA corona. ITA
Das Werkzeug T7B abnehmen, das an der dem Kranz Kranz (4) abziehen.
D entgegengesetzte Seite montiert ist. D
c d
Remover la herramienta T7B montado sobre el lado Extraer la corona (4).
ESP opuesto corona. ESP
DeÂplacer l'outil T7B monteÂ du coÃteÂ opposeÂ aÁ la Extraire la couronne (4).

F couronne. F
SMONTAGGIO DIFFERENZIALE SMONTAGGIO DIFFERENZIALE NO-SPIN

ITA Utilizzando un estrattore, asportare i cuscinetti (9) dal ITA Inserire il tirante "B" di trattenimento del gruppo no-
gruppo differenziale. spin (14) ed avvitare a fondo il dado ad alette.
DIFFERENTIAL ABMONTIEREN DAS NO-SPIN DIFFERENTIAL ABMONTIEREN

D Mit einem Abzieher die Lager (9) vom Differentialag- D Sie Spannstange "B" einsetzen, um das No-Spin
gregat abnehmen. Aggregat (14) festzuhalten und die FluÈgelmutter fest-
ziehen.
e f
DESMONTAJE DIFERENCIAL DESMONTAJE DIFERENCIAL NO-SPIN
ESP Utilizando un extractor, sacar los cojinetes (9) del ESP Introducir el tirante "B" de detencion del grupo no-spin
grupo diferencial. (14) y atornillar hasta el fondo la tuerca a aletas.
DEMONTAGE DU DIFFERENTIEL DEMONTAGE DU DIFFERENTIEL NO-SPIN

F A l'aide d'un extracteur, enlever les paliers (9) du F Introduire la tringle "B" de retenue du groupe no-spin
groupe diffeÂrentiel. (14), puis visser l'eÂcrou aÁ ailettes aÁ fond.
008 918 12 BOMAG

47 1009
12
10 11
12
F1241151 F1241152
GB a GB b
Remove the screws (10) and the spring washers (11) jointing the Using a plastic hammer, take the half box (12) to pieces.
differential unit half box (12). NOTE. Note down the coupling marks.
13
14
F1241153 F1241154
GB c GB d
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.
19
16
17
18
20 21
F1241155 F1241156
GB e GB f
DISASSEMBLY OF THE 45% SELF-LOCKING DIFFERENTIAL UNIT Remove the differential cover (18), any shims (19) and the friction
Remove the screws (16) and the spring washers (17) jointing the (20) complete with ring (21).
differential unit. 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.
1010 BOMAG
48 008 918 12
Axle 18.8
Rimuovere le viti (10) e le rondelle elastiche (11) di Utilizzando un mazzuolo in materiale plastico scom-
ITA unione della semiscatola differenziale (12). ITA porre la semiscatola differenziale (12).
NOTA. Annotare la marcatura di accoppiamento.
Schrauben (10) und Federscheiben (11) abnehmen, Mit einem Gummihammer das halbe Differentialge-
D die das halbe DifferentialgehaÈuse (12) zusammen D haÈuse (12) zerlegen.
halten. BEMERKUNG. Die Kupplungsmarkierung notieren.
a b
Remover los tornillos (10) y las arandelas elasticas Utilizando un martillo en material plastico decomponer
ESP (11) de union de la semi-caja diferencial (12). ESP la semicaja diferencial (12).
NOTA. Anotar la marcatura de acoplamiento.
Enlever les vis (10) et les rondelles eÂlastiques (11) A l'aide d'un maillet en matieÁre plastique deÂcomposer
F d'union de la moitieÂ du boõÃtier diffeÂrentiel (12). F la moitieÂ du boõÃtier diffeÂrentiel (12).
REMARQUE. Prendre note de la marque d'accou-
plement.
Estrarre il gruppo no-spin (13). Svitare il dado ad alette del tirante "B" e scomporre il
ITA ITA gruppo no-spin per rimuovere il distanziale (14) contro
lo scorrimento assiale dei semiassi.
Das No-Spin Aggregat (13) abziehen. Die FluÈgelmutter der Spannstange "B" abschrauben
D D und das No-Spin Aggregat zerlegen, um das Differen-
tial (14) an der Achsengleitung der Halbachsen
abnehmen zu koÈnnen.
c d
Sacar el grupo no-spin (13). Destornillar la tuerca a aletas del tirante "B" y
ESP ESP decomponer el grupo no-spin para remover el distan-
cial (14) contra el deslizamiento axial de los semi-ejes.
Extraire le groupe no-spin (13). DeÂvisser l'eÂcrou aÁ ailettes de la tringle "B" et

F F deÂcomposer le groupe no-spin pour enlever le
diffeÂrentiel (14) contre le coulisseau axial des demi-
essieux.
SMONTAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45% Rimuovere il coperchio differenziale (18), gli eventuali
ITA Rimuovere le viti (16) e le rondelle elastiche (17) di ITA spessori (19) e la frizione (20) completa dell'anello (21).
unione del corpo differenziale. 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 eÁ inferiore sostituire ambedue le frizioni.
DAS ZU 45% SELBSTHEMMENDE DIFFERENTIAL ABMONTIEREN Differentialdeckel (18) und evtl. Unterlegscheiben (19)
D Schrauben (16) und Federscheiben (17), die den D und die Kupplung (20) mit dem Ring (21) abnehmen.
DifferentialkoÈrper verbinden, abnehmen. ACHTUNG! 1 - Die Position der Kupplungsscheiben
nicht verwechseln.
e f 2 - Die GesamtstaÈrke der Kupplung muû mehr als 17,3 mm betragen;
sollte dies nicht der Fall sein, beide Kupplungen auswechseln.
DESMONTAJE DIFERENCIAL AUTOBLOQUEO AL 45% Remover la tapa diferencial (18), los eventuales
ESP Remover los tornillos (16) y las arandelas elasticas ESP espesores (19) y la fricion (20) completa del anillo (21).
(17) de union del cuerpo diferencial. 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.
DEMONTAGE DU DIFFERENTIEL AUTOBLOQUANT A 45% Enlever le couvercle diffeÂrentiel (18), les eÂventuelles
F Enlever les vis (16), les rondelles eÂlastiques (17) F cales (19) et la friction (20) compleÁte d'anneau (21).
d'union du corps diffeÂrentiel. ATTENTION! 1 - Ne pas changer la position des
disques composant la friction.
2 - ControÃler que la calage total de la friction soit supeÂrieur aÁ
17,3 mm; s'il est infeÂrieur substituer les deux frictions.
008 918 12 BOMAG

49 1011
22
25 23
24
26 24
26
F1241157 F1241158
GB a GB b
Remove the planetary gear (22). Remove the long planetary carrier journal (23) and the two short
Mark the 37 mm value on a pin-driver; using the same pin-driver, journals (24).
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).
29
28
33
32
F1241159 F1241160
GB c GB d
Extract the cross journal (27), the planet wheels (28) complete with Remove the 2nd friction (20) complete with ring (21). Also remove
shim washers (29) and the second planetary gear (22). 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.
25
23 24
1
9
F1241161 F1241162
GB e GB f
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).
1012 BOMAG
50 008 918 12
Axle 18.8
Rimuovere l'ingranaggio planetario (22). Rimuovere il perno porta satelliti lungo (23) ed i due
ITA Segnare su un cacciaspine un contrassegno a 37 mm; ITA perni corti (24).
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).
Das Planetengetriebe (20) abnehmen. An einem DuÈ- Den langen Planetenradhalterstift (23) und die beiden
D bel das Maû von 37 mm markieren; mit diesem DuÈbel D kurzen Planetenradhalterstifte (24) entfernen.
die Federstifte (25) in die Stifte (23) und (24) einsetzen.
BEMERKUNG. Die Federstifte sind in den Stiften (23) und (24)
a zentriert, wenn das markierte Maû auf der HoÈhe des Differential- b
koÈrpers (26) liegt.
Remover el engranaje planetario (22). Senalizar sobre Remover la rotula porta satelites largo (23) y las dos
ESP un extractor de clavijas un contra-segno a 37 mm; ESP rotulas cortas (24).
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 planeÂtaire (22). Marquer d'une Enlever le pivot porte-satellite long (23) et les deux
F estampille le chasse-clou aÁ 37 mm; a l'aide de ce meÃme F pivots courts (24).
chasse-clou, introduire dans les pivots (23) et (24) les
goupilles eÂlastiques (25).
REMARQUE. Les goupilles eÂlastiques sont centreÂes dans les pivots
(23) et (24) quand l'estampille atteint le bord du corps diffeÂrentiel (26).
Estrarre la crociera (27), i satelliti (28) completi delle Rimuovere la 2ã frizione (20) completa dell'anello (21).
ITA rondelle di rasamento (29) ed il 2ë ingranaggio ITA Rimuovere anche gli eventuali spessori (19).
planetario (22). 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 eÁ inferiore sostituire ambedue le frizioni.
Das Kreuz (27), die Planetengetriebe (28) samt Die 2. Kupplung (20) mit Ring (21) abnehmen.
D Zwischenlegscheiben (29) und das 2. Planetengetrie- D Eventuelle Unterlegscheiben (19) auch entfernen.
be (30) abziehen. ACHTUNG! 1 - Die Position der Kupplungsscheiben
nicht verwechseln.
c d 2 - Kontrollieren, ob die GesamtstaÈrke der Kupplung mehr als 17,3 mm
betraÈgt; anderenfalls beide Kupplungen auswechseln.
Sacar la cruceta (27), los satelites (28) completos de Remover la 2ë fricion (30) completa del anillo (21).
ESP las arandelas de rasamiento (29) y el 2ë engranaje ESP Remover tambien los eventuales espesores (19).
planetario (22). 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.
Extraire le croisillon (27), les satellites (28) complet de Enlever la 2ë friction (20) compleÁte d'anneau (21).
F rondelles de rasage (29), puis le 2ë engrenage F Enlever eÂgalement les eÂventuelles cales (19).
planeÂtaire (22). ATTENTION! 1 - Ne pas changer la position des
disques composant la friction.
2 - ControÃler que la calage total de la friction soit supeÂrieur aÁ
17,3 mm; s'il est infeÂrieur substituer les deux frictions.
Estrarre le spine elastiche (25) dai perni (23) e (24). Solo se si sostituiscono i cuscinetti
ITA ITA Rimuovere le ralle dei cuscinetti (9) dai coperchi
intermedi (1) e (2).
Die Federstifte (25) von den Stiften (23) und (24) Nur falls die Lager ausgewechselt werden.
D abziehen. D Die Scheiben von den Lagern (9) der Zwischendeckel
(1) und (2) abnehmen.
e f
Sacar las clavijas elasticas (25) de las rotulas (23) y Solo si se sobstituiyen los cojinetes
ESP (24). ESP Remover las ranguas de los cojinetes (9) de las tapas
intermedias (1) y (2).
Extraire les goupilles eÂlastiques (25) des pivots (23) et Uniquement en cas de substitution des paliers.
F (24). F Enlever les crapaudines des paliers (9) des couvercles
intermeÂdiaires (1) et (2).
008 918 12 BOMAG

51 1013
30
4 33
35 36 3 34
32
7
45 31
1
8
38
44 40
GB a GB b
6 41
39
37
46
43 47
32
42
30
GB
33 34
c GB d
31
D1240134
GB e GB f
1014 BOMAG
52 008 918 12
Axle 18.8
ITA ITA
18
20 9
29
D 25 22 D
28
a b
24 19 16
ESP 29 ESP 21 17
27
20 29
25
19 24
28
F F
22 29
21 25
23 10
11
ITA 7ITA
26 12
14
9
D D
15
c d 9
9
ESP ESP
13
F F 8
D1240135
ITA ITA
D D
e f
ESP ESP
F F
008 918 12 BOMAG

53 1015
18.8 REMOVAL AND DISASSEMBLY OF THE DIFFERENTIAL UNIT - ASSEMBLAGGIO ED INSTALLAZIONE GRUPPO DIFFERENZIALE - Axle
DIFFERENTIALAGGREGAT ZUSAMMENBAUEN UND INSTALLIEREN - MONTAJE E INSTALACION DEL GRUPO DIFERENCIAL -
ASSEMBLAGE ET INSTALLATION DU GROUPE DIFFERENTIEL
12
13
15
14
F1241154 F1241163
GB a GB b
ASSEMBLY OF THE NO-SPIN DIFFERENTIAL UNIT Fit the no-spin unit into the differential unit half box (15).
Assemble the no-spin unit (13), inserting the distance piece (14) Centre the half box (12) and fasten.
and using stay "B". CAUTION! Make sure the connection marks coincide.
10
F1241164 F1241150
GB c GB d
Fit the spring washers (11) onto the screws (10). Remove stay "B".
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.
21
20
21
20 26
17,6
19
F1241224 F1241160
GB e GB f
ASSEMBLY OF THE 45% SELF-LOCKING DIFFERENTIAL UNIT Insert in the body of the differential unit (26) any required shims
Using a depth gauge, check the shim of friction units complete with (19) and the friction (20) complete with ring (21).
rings (21). If thickness is lower than 17.6 mm, add more shims (19). CAUTION! Ring (21) must touch the planetary gear (22).
CAUTION! Shims must be placed right behind the body of the
differential unit (26).
1016 BOMAG
54 008 918 12
Axle 18.8
ASSEMBLAGGIO DIFFERENZIALE NO-SPIN Montare il gruppo no-spin nella semiscatola differen-

ITA Assemblare il gruppo no-spin (13) inserendo il distan- ITA ziale (15).
ziale (14) ed utilizzando il tirante "B". Centrare la semiscatola (12) e mandarla in battuta.
ATTENZIONE! Controllare che le marcature di accoppiamento
coincidano.
NO-SPIN DIFFERENTIAL ZUSAMMENBAUEN Das No-Spin Aggregat in das halbe Differentialge-

D Das No-Spin (13) Aggregat zusammenbauen; dazu D haÈuse (15) montieren.
das DistanzstuÈck (14) mit der Spannstange "B" Das halbe GehaÈuse (12) zentrieren und bis zum
einsetzen. Anschlag einsetzen.
a b ACHTUNG! Kontrollieren, ob die Kupplungsmarkierungen uÈberein-
stimmen.
MONTAJE DIFERENCIAL NO-SPIN Montar el grupo no-spin en la semi-caja diferencial

ESP Asemblaje el grupo no-spin (13) introduciendo el ESP (15).
diferencial (14) y utilizando el tirante "B". Centrar la semi-caja (12) y mandarla a tope.
ATENCION! Controlar que las marcaduras de acoplamiento
coincidan.
ASSEMBLAGE DU DIFFERENTIEL NO-SPIN Monter le groupe no-spin dans la moitieÂ du boõÃtier

F Assembler le groupe no-spin (13) en introduisant F diffeÂrentiel (15).
l'entretoise (14), puis aÁ l'aide de la tringle "B". Centrer la moitieÂ du boõÃtier (12) et l'envoyer en buteÂe.
ATTENTION! ControÃler que les estampilles d'accouplement
correspondent.
Infilare sulle viti (10) le rondelle elastiche (11). Rimuovere il tirante "B".
ITA Spalmare le viti (10) con Loctite 270 ed avvitarle a ITA
fondo per comporre la scatola differenziale.
Serrare le viti con il metodo incrociato ad una coppia di serraggio di
86v89 Nm.
Federscheiben (11) in die Schrauben (10) einsetzen. Spannstange "B" abnehmen.

D Die Schrauben (10) mit Loctite 270 schmieren und D
festziehen, um das DifferentialgehaÈuse zusammenzu-
bauen.
c Die Schrauben im Kreuz und mit einem Anzugsmoment von 86v89
Nm festziehen.
d
Insertar sobre tornillos (10) las arandelas elasticas Remover el tirante "B".
ESP (11). ESP
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 eÂlastiques (11). Enlever la tringle "B".
F Enduire les vis (10) avec du Loctite 270, puis visser F
celles-ci aÁ fond pour recomposer le boõÃtier diffeÂrentiel.
Serrer les vis avec la meÂthode croiseÂe aÁ un couple de serrage de
86v89 Nm.
ASSEMBLAGGIO DIFFERENZIALE AUTOBLOCCANTE AL 45% Inserire nella corpo differenziale (26) gli eventuali
ITA Controllare con un calibro di profonditaÁ lo spessore ITA spessori (19) e la frizione (20) completa dell'anello
delle frizioni complete degli anelli (21). Se lo spessore (21).
eÁ inferiore a 17,6 mm, aggiungere degli spessori (19). ATTENZIONE! L'anello (21) deve rimanere a contatto dell'ingra-
ATTENZIONE! Gli spessori devono essere posizionati a ridosso del naggio planetario (22).
corpo differenziale (26).
ZU 45% SELBSTHEMMENDE DIFFERENTIAL ZUSAMMENBAUEN In den DifferentialkoÈrper (26) eventuelle Unterleg-

D Mit Hilfe einer Tiefenlehre die StaÈrke der Kupplungen D scheiben (19) und die Kupplung (20) samt Ring (21)
mit den Ringen (21) messen. Sollte das Maû weniger einsetzen.
als 17,6 mm betragen, noch Unterlegscheiben (19) hinzufuÈgen. ACHTUNG! Der Ring (21) muû am Planetengetriebe (22) anliegen.
e ACHTUNG! Die Unterlegscheiben muÈssen am DifferentialkoÈrper f
(26) anliegen.
MONTAJE DIFERENCIAL AUTO-BLOQUEO AL 45% Introducir en el cuerpo diferencial (26) los eventuales
ESP Controlar con un calibro de profundidad el espesor de ESP espesores (19) y la fricion (20) completa del anillo (21).
las friciones completas de los anillos (21). Si el ATENCION! El anillo (33) debe quedar a contacto del
espesor es inferior a 17,6 mm, sumar de los espesorees (19). engranaje planetario (22).
ATENCION! Los espesores deben de ser colocados detraÁs del
cuerpo diferencial (26).
ASSEMBLAGE DU DIFFERENTIEL AUTOBLOQUANT A 45% Introduire le corps diffeÂrentiel (26), les eÂventuelles
F ControÃler aÁ l'aide d'un calibre de profondeur l'eÂpais- F cales (19) et la friction (20) compleÁte d'anneau (21.
seur des frictions compleÁtes d'anneaux (21). Si le ATTENTION! L'anneau (21) doit rester au contact de
calage est infeÂrieur aÁ 17,6 mm, ajouter des cales (19). l'engrenage planeÂtaire (22).
ATTENTION! Les cales doivent eÃtre placeÂes aÁ l'abri du corps
diffeÂrentiel (226).
008 918 12 BOMAG

55 1017
27
22 28
26
23
24
F1241165 F1241166
GB a GB b
Install the planetary gear (22) and three of the planet wheels (28), Install the cross journal (27), holding it into position with the long
complete with shim washers (29). journal (23).
Hold the planet wheels (28) and relative washers (29) into position Before inserting journal (23) completely, install the last planet
with pins (24). wheel (28) and the relative washer (29).
19
22
25
20
26 21
26
25,5
F1241167 F1241168
GB c GB d
Countermark a point at 25.5 mm on a pin-driver; using the same Install the second planetary gear (22) and the friction (20) complete
pin-driver, engage the journals (23) and (24) with the spring pins with ring (21) and any shims required (19).
(25). CAUTION! Ring (21) must be installed right behind the planetary
NOTE. When the countermark is lined up with the edge of the body gear (22) and the shims (19) right behind the differential cover (18).
of the differential unit (26), the journals are engaged by half.
16 17
18
26
F1241169 F1241170
GB e GB f
Position the differential cover (18). Fit the spring washers (17) onto the screws (16).
NOTE. Make sure that the assembly marks coincide. Coat the screws (16) with Loctite 270 and screws tight.
Tighten screws using the criss-cross method and a torque of
135 ± 138 Nm.
1018 BOMAG
56 008 918 12
Axle 18.8
Montare l'ingranaggio planetario (22) e tre degli Montare la crociera (27) e mantenerla in posizione con
ITA ingranaggi satelliti (28) completi di rondelle di rasa- ITA il perno lungo (23).
mento (29). Prima di inserire completamente il perno (23), montare
Mantenere in posizione gli ingranaggi satelliti (28) e le relative l'ultimo satellite (28) e la relativa rondella (29).
rondelle (29) con i perni (24).
Das Planetengetriebe (22) und drei der Planetenge- Das Kreuz (27) montieren und in der Position mit
D triebe (28) samt Zwischenlegscheiben (29) montieren. D einem langen Stift (23) festhalten.
Die Planetengetriebe (28) und die Zwischenlegschei- Bevor der Stift (23) ganz eingesetzt wird, das letzte
ben (29) mit den Stiften (24) in der Position festhalten. Planetengetriebe (28) und die Unterlegscheibe (29) montieren.
a b
Montar el engranaje planetario (22) y tres de los Montar la cruceta (27) y mantenerla en posicion con la
ESP engranajes satelites (28) completos de las arandelas ESP rotula larga (28).
de rasadura (29). Antes de insertar completamente la rotula (23), montar
Mantener en posicion los engranajes satelites (28) y las relativas el ultimo satelite (28) y la relativa arandela (29).
arandelas (29) con las rotulas (24).
Monter l'engrenage planeÂtaire (22) et trois des Monter le croisillon (27) et maintenir celui-ci aÁ sa place
F engrenages satellites (28) complets de rondelles de F aÁ l'aide du pivot long (23).
rasage (29). Avant d'introduire entieÁrement le pivot (23), monter le
Maintenir les engrenages satellites (28) et relatives rondelles (29) aÁ dernier satellite (28) et sa rondelle (29).
leur place avec les pivots (24).
Segnare sul cacciaspine un contrassegno a 25,5 mm; Montare il secondo ingranaggio planetario (22) e la
ITA utilizzando lo stesso cacciaspine impegnare i perni ITA frizione (20) completa dell'anello (21) e degli eventuali
(23) e (24) con le spine elastiche (25). spessori (19).
NOTA. Le spine impegnano metaÁ dei perni quando il contrassegno ATTENZIONE! L'anello (21) deve essere montato a ridosso
arriva a filo del corpo differenziale (26). dell'ingranaggio planetario (22) e gli eventuali spessori (19) a
ridosso del coperchio differenziale (18).
An dem DuÈbel das Maû von 25,5 mm markieren; mit Das zweite Planetengetriebe (22) und die Kupplung
D demselben DuÈbel die Stifte (23) und (24) mit den D (20) mit dem Ring (21) und eventuelle Unterlegschei-
Federstiften (25) einsetzen. ben (19) montieren.
BEMERKUNG. Die Stifte sind durch die Federstifte zur HaÈlfte ACHTUNG! Der Ring (21) muû nach der Montage am Planetenge-
c eingesetzt, wenn die Markierung auf halber HoÈhe des Differential- d triebe (22) und die eventuellen Unterlegscheiben (19) muÈssen am
koÈrpers (26) liegt. Differentialdeckel (18) anliegen.
Senalar sobre el extractor de clavijas un contra-segno Montar el segundo engranaje planetario (22) y la
ESP a 25,5 mm; utilizando el mismo extractor de clavijas ESP fricion (20) completa del anillo (21) y de los eventuales
empegnar las rotulas (23) y (24) con las clavijas espesores (19).
elasticas (25). ATENCION! El anillo (21) debe deser montado detras del
NOTA! Las clavijas empegnan midad de las rotulas cuando el engranaje planetario (22) y los eventuales espesores (19) detras
contra-segno llega al borde del cuerpo diferencial (26). de la tapa diferencial (18).
Marquer d'une estampille le chasse-clou aÁ 25,5 mm; Monter le second engrenage planeÂtaire (22), la friction
F a l'aide de ce meÃme chasse-clou, engager les pivots F (20) compleÁte d'anneau (21) et des eÂventuelles cales
(23) et (24) et les goupilles eÂlastiques (25). (19).
REMARQUE. Les goupilles arrivent aÁ la moitieÂ des pivots quand ATTENTION! L'anneau (21) est aÁ monter aÁ l'abri de l'engrenage
l'estampille atteint le bord du corps diffeÂrentiel (26). planeÂtaire (22) et les eÂventuelles cales (19) aÁ l'abri du couvercle
diffeÂrentiel (18).
Posizionare il coperchio differenziale (18). Infilare sulle viti (16) le rondelle elastiche (17).
ITA ITA Spalmare le viti (16) con Loctite 270 ed avvitarle a
NOTA. Controllare che le marcature di montaggio
coincidano. fondo.
Serrare le viti con il metodo incrociato ad una coppia di serraggio di
135v138 Nm.
Den Differentialdeckel (18) positionieren. Auf die Schrauben (16) die Federscheiben (17)
D D montieren.
BEMERKUNG. Kontrollieren, ob die Montagemarkie-
rungen uÈbereinstimmen. Die Schrauben (16) mit Loctite 270 schmieren und
festziehen. Die Schrauben im Kreuz mit einem Anzugsmoment von
e f 135v138 Nm festziehen.
Colocar la tapa diferencial (18). Introducir sobre los tornillos (16) las arandelas
ESP ESP elasticas (17).
NOTA. Colocar que las marcaduras de montaje
coincidan. 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.
Mettre le couvercle diffeÂrentiel (18) en place. Passer sur les vis (16) les rondelles eÂlastiques (17).
F F Enduire les vis (16) avec du Loctite 270 et visser
REMARQUE. ControÃler que les estampilles de mon-
tage coõÈncident. celles-ci aÁ fond.
Serrer les vis avec la meÂthode croiseÂe aÁ un couple de serrage de
135v138 Nm.
008 918 12 BOMAG

57 1019
9 9 9 9
7
8
8 7
F1241171 F1241172
GB a GB b
INSTALLATION OF THE DIFFERENTIAL UNIT Turn the unit upside down and install the second bearing (9).
Position the differential unit (7) or (8) under a press and, using a CAUTION! Pay particular attention; position a shim with adequate
driver with an adequate diameter, install the first bearing (9). diameter in order to engage the internal ring of bearing (9) without
engaging the cage.
T8
9
F1241173 F1241174
GB c GB d
Only if bearings are replaced Position the crown wheel (4) in the main body (3).
Using tool T8, insert the thrust blocks of the bearings (9) into the
intermediate covers (1) and (2).
T7B 7 8
F1241175 F1241176
GB e GB f
Fit tool T7B on the crown wheel opposite side, holding it in position Install the differential unit (7) or (8), by fitting it into the hole of tool
with two studs and two nuts. T7B.
NOTE. Engage the crown (4) onto 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.
1020 BOMAG
58 008 918 12
Axle 18.8
INSTALLAZIONE DIFFERENZIALE Capovolgere il gruppo e montare il secondo cuscinetto

ITA Posizionare il differenziale (7) o (8) sotto una pressa ed ITA (9).
utilizzando uno spintore di diametro adatto montare il ATTENZIONE! Prestare molta attenzione e posiziona-
primo cuscinetto (9). re uno spessore di diametro adatto al fine di impegnare l'anello
interno del cuscinetto (9) senza impegnare la gabbia.
DIFFERENTIAL ZUSAMMENBAUEN Das Aggregat wenden und das zweite Lager montie-
D Das Differential (7) oder (8) unter eine Presse legen D ren (9).
und mit einem geeigneten Dynamometer-StoÈûel das ACHTUNG! Den Vorgang mit groûer Sorgfalt durch-
erste Lager (9) montieren. fuÈhren und einen fuÈr die StaÈrke geeigneten Dynamometer
a b verwenden, um den Ring des inneren Lagers (9) einzusetzen,
ohne den KaÈfig einzuklemmen.
INSTALACION DIFERENCIAL Volcar el grupo y montar el segundo cojinete (9).

ESP Colocar el diferencial (7) y (8) bajo una prensa y ESP
ATENCION! Tener mucho cuidado y colocar un
utilizando un empuje de diametro adapto montar el espesor de diametro apto al fin de empegnar el anillo
primer cojinete (9). interno del cojinete (9) si empegnar la jaula.
INSTALLATION DU DIFFERENTIEL Faire basculer le groupe et monter le second palier (9).

F Mettre le diffeÂrentiel (7) ou (8) en place sous la presse, F
ATTENTION! Faire treÁs attention, mettre une cale au
aÁ l'aide d'un poussoir au diameÁtre adeÂquat, monter le diameÁtre adeÂquat afin d'engager l'anneau interne du
premier palier (9). palier (9) sans y engager la cage.
Solo se si sostituiscono i cuscinetti Posizionare la corona (4) dentro il corpo centrale (3).
ITA Utilizzando l'attrezzo T8 inserire le ralle dei cuscinetti ITA
(9) nei coperchi intermedi (1) e (2).
Nur wenn die Lager ausgewechselt werden. Den Kranz (4) in den zentralen KoÈrper (3) einsetzen.
D Mit dem Werkzeug T8 die Scheiben der Lager (9) in D
die Zwischendeckel (1) und (2) einsetzen.
c d
Solo si se sobstituyen los cojinetes Colocar la corona (4) dentro del cuerpo central (3).
ESP Utilizando la herramienta T8 Introducir las ranguas de ESP
los cojinetes (9) en las tapa intermedias (1) y (2).
Uniquement en cas de substitution des paliers Mettre la couronne (4) en place dans le corps central
F A l'aide de l'outil T8, introduire la crapaudine des F (3).
paliers (9) dans les couvercles intermeÂdiaires (1) et (2).
Montare l'attrezzo T7B sul lato opposto corona, Montare il gruppo differenziale (7) o (8) impegnandolo
ITA trattenendolo con due prigionieri e due dadi. ITA nel foro dell'attrezzo T7B.
NOTA. Impegnare la corona (4) sull'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.
Das Werkzeug T7B auf der dem Kranz entgegen- Das Differentialaggregat (7) oder (8) montieren und im
D gesetzten Seite montieren und mit zwei Stiftschrauben D Loch des Werkzeuges T7B einrasten.
und zwei Muttern festhalten. Den Kranz (4) auf das Differential (7) oder (8)
BEMERKUNG. Den Kranz (4) in das Werkzeug T7B einrasten. montieren und bis zum Anschlag am Flansch einsetzen.
e f BEMERKUNG. Die FlanschloÈcher muÈssen mit den KranzloÈchern
uÈbereinstimmen.
Montar la herramienta T7B sobre el lado opuesto Montar el grupo diferencial (7) o (8) empegnandolo en
ESP corona, deteniendo con dos prigionieros y dos ESP el agujero de la herramienta T7B.
tuercas. Montar la corona (4) sobre el diferencial (7) y (8)
NOTA. Empegnar la corona (4) sobre la herramienta T7B. mandandola a tope sobre la brida.
NOTA. Hacer coincidir los agujeros de la brida con los agujeros de
la corona.
Monter l'outil T7B du coÃteÂ opposeÂ aÁ la couronne, en le Monter le groupe diffeÂrentiel (7) ou (8) en l'engageant
F tenant aÁ l'aide de deux prisonniers et de deux eÂcrous. F dans le trou de l'outil T7B.
REMARQUE. Engager la couronne (4) sur l'outil T7B. Monter la couronne (4) sur le diffeÂrentiel (7) ou (8) puis
l'envoyer en buteÂe sur la flasque.
REMARQUE. Faire correspondre les trous de la flasque avec les
trous de la couronne.
008 918 12 BOMAG

59 1021
35
5 A
F1241177 F1241145
GB a GB b
Fit spring washers (6) onto the screws (5). Check the condition and position of the O-ring (30); lubricate the
Coat screws with Loctite 270 and screw them tight into the crown. seal and install the intermediate cover (2) on crown wheel side.
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.
2
T6
31
T7A
F1241178 F1241179
GB c GB d
Lock the intermediate cover (2) with the journals (31) tightened to a Install tool T6 on the journals (31) on the crown wheel side, placing
torque of 129 ± 143 Nm. 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).
T7B 1
30
F1241180 F1241181
GB e GB f
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.
1022 BOMAG
60 008 918 12
Axle 18.8
Montare sulle viti (5) le rondelle elastiche (6). Controllare lo stato ed il posizionamento dell'anello
ITA Spalmare le viti con Loctite 270 ed avvitarle a fondo ITA OR (30); lubrificare la guarnizione e montare il
nella corona. Posizionare il blocchetto "A" di contra- coperchio intermedio (2) lato corona.
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.
Auf die Schrauben (5) die Federscheiben (6) montieren. Den Zustand und die Position des O-Ringes (30)
D Die Schrauben mit Loctite 270 schmieren und in den D kontrollieren; die Dichtung schmieren und den Zwi-
Kranz schrauben. Den Block "A" positionieren; den schendeckel (2) an der Kranzseite montieren.
Kranz am Block anliegen lassen und die Schrauben (5) mit einem
a Anzugsmoment von 135v138 Nm festziehen. b
ACHTUNG! Die Schrauben im Kreuz festziehen.
Montar sobre los tornillos (5) las arandelas elasticas (6). Controlar el estado y la colocacion del anillo OR (30);
ESP Pasar los tornillos con Loctite 270 y atornillarlos a ESP lubrificar la guarnicion y montar la tapa intermedia (2)
fondo en la corona. Colocar el bloque "A" de contraste; lado corona.
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 eÂlastiques (6). ControÃler l'eÂtat et le positionnement de l'anneau
F Enduire les vis avec du Loctite 270, puis visser celles- F O'Ring (30); lubrifier la garniture, puis monter le
ci aÁ fond dans la couronne. Mettre le petit bloc "A" de couvercle intermeÂdiaire (2) du coÃteÂ couronne.
contraste; en maintenant la couronne poseÂe sur le petit bloc, serrer
les vis (5) aÁ un couple de 135v138 Nm.
ATTENTION! Serrer les vis avec la meÂthode croiseÂe.
Bloccare il coperchio intermedio (2) con i prigionieri Montare l'attrezzo T6 sui prigionieri (31) lato corona,
ITA (31) serrati ad una coppia di 129v143 Nm. ITA 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).
Den Zwischendeckel (2) mit den Stiftschrauben (31) Das Werkzeug T6 an den Stiftschrauben (31) an der
D blockieren und mit einem Anzugsmoment von D Kranzseite montieren und dabei DistanzstuÈcke einsetzen
129v143 Nm festziehen. und mit zwei Muttern befestigen. In das Werkzeug T6 das Werkzeug
T7A zur Zentrierung und Halterung des Differentials einsetzen.
c d BEMERKUNG. Sicherstellen, daû das Differential fest im Zwischen-
deckel (2) sitzt.
Bloquear la tapa intermedia(2) con los prigioneros (31) Montar la herramienta T6 sobre los prigioneros (31)
ESP apretados a un par de 129v143 Nm. ESP 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).
Bloquer le couvercle intermeÂdiaire (2) aÁ l'aide des Monter l'outil T6 sur les prisonniers (31) coÃteÂ cou-
F prisonniers (31) serreÂs aÁ un couple de 129v143 Nm. F ronne, en y intercalant des entretoises, puis bloquer
celui-ci avec deux eÂcrous. Introduire dans l'outil T6,
l'outil T7A de centrage et de support du diffeÂrentiel.
REMARQUE. S'assurer que le diffeÂrentiel soit engageÂ aÁ fond dans
le couvercle intermeÂdiaire (2).
Rimuovere l'attrezzo T7B del lato opposto corona. Controllare lo stato ed il posizionamento dell'anello
ITA ITA 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.
Werkzeug T7B an der dem Kranz entgegengesetzten Den Zustand und die Position des O-Ringes (30)
D Seite abnehmen. D kontrollieren; die Dichtung schmieren und den Zwi-
schendeckel (1) an der dem Kranz entgegengesetzten
Seite montieren. Den Zwischendeckel (1) mit den Stiftschrauben
e f (31) und einem Anzugsmoment von 129v143 Nm befestigen und
die Werkzeuge T6 und T7A entfernen.
Remover la herramienta T7B del lado opuesto corona. Controlar el estado y la colocacion del anillo OR (30);
ESP ESP 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.
Enlever l'outil T7B du coÃteÂ opposeÂ aÁ la couronne. ControÃler l'eÂtat et le positionnement de l'anneau
F F O'Ring (30); lubrifier la garniture, puis monter le
couvercle intermeÂdiaire (1) du coÃteÂ opposeÂ aÁ la
couronne.
Fixer le couvercle intermeÂdiaire (1) aÁ l'aide des prisonniers (31)
serreÂs aÁ un couple de 129v143 Nm, enlever les outils T6 et T7A.
008 918 12 BOMAG

61 1023
1 32
32 T9
34
33 F1241182 F1241183
GB a GB b
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.
37 3
36
35
F1241184 F1241185
GB c GB d
Remove the spring ring (35) and extract the cap (36) to allow Coat the surface of the main body (3) with Loctite 510 and install
checking of the clearance between pinion and crown to take place. the reduction gear (37) complete with pinion.
NOTE. Make sure that a continuous layer of sealant runs around
the locking holes.
38 32
T9
F1241186 F1241183
GB e GB f
Coat screws (38) with Loctite 242 and screw tight. Tighten screws Screw ring nut (32) on crown wheel side until clearance between
(38), using the criss-cross method and a tightening torque of pinion and crown equals zero, then unscrew by 1/4 turn approx.
129 ± 143 Nm.
1024 BOMAG
62 008 918 12
Axle 18.8
Asportare le viti (33) e rimuovere le linguette di Utilizzando la chiave T9 rimuovere le ghiere (32) di
ITA sicurezza (34). ITA registrazione ed asportare ogni traccia di frenafiletti.
Riavvitare le ghiere dopo averle spalmate con
Loctite 242.
Die Schraube (33) abschrauben und den Sicherheits- Mit einem SchluÈssel T9, die Nutmuttern (32) zur
D keil (34) abnehmen. D Einstellung entfernen und jede alle uÈberschuÈssigen
Reste der SchraubensicherungsloÈsung sorgfaÈltig ent-
fernen.
a b Nutmuttern mit Loctite 242 schmieren und wieder festschrauben.
Sacar los tornillos (33) y remover les lengues de Utilizando la llave T9, remover las virolas (32) de
ESP seguridad (34). ESP registracion y sacar cada senal de frenaroscas.
Restornillas las virolas despues de haberias pasadas
con Loctite 242.
Enlever le vis (33), puis deÂplacer le languettes de A l'aide de la cleÂ T9, enlever les eÂcrous annulaires (32)
F seÂcuriteÂ (34). F de reÂglage et toute trace de l'agent d'arreÃt de vis.
Enduire les eÂcrous annulaires avec Loctite 242 et
visser.
Asportare l'anello elastico (35) e rimuovere il tappo Spalmare la superficie del corpo centrale (3) con
ITA (36) per poter controllare il gioco tra pignone e corona. ITA Loctite 510 ed installare il riduttore (37) completo di
pignone.
NOTA. Assicurarsi che il sigillante crei un velo continuo attorno ai
fori di fissaggio.
Den Kolbenring (35) abnehmen und den Stopfen (363) Die FlaÈche des ZentralkoÈrpers (3) mit Loctite 510
D entfernen, um das Spiel zwischen Kegelrad und Kranz D schmieren und den Reduzierer (37) samt Kegelrad
kontrollieren zu koÈnnen. installieren.
BEMERKUNG. Sicherstellen, daû die Dichtmasse einen gleich-
c d maÈûigen Film um die BefestigungsloÈcher herum bildet.
Sacar el anillo elastico (35) y remover la tapa (36) para Pasar la superficie del cuerpo central (3) con Loctite
ESP poder controlar el juego entre pignon y corona. ESP 510 y instalar el reductor (37) completo de pignon.
NOTA. Asegurarse que el sigilante cree una pelicula
continua alrededor a los agujeros de fisaje.
Enlever l'anneau eÂlastique (35), enlever le bouchon Enduire la superficie du corps central (3) avec du
F (36) pour controÃler le jeu existant entre pignon et F Loctite 510, installer le reÂducteur (37) complet de
couronne. 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. Avvitare la ghiera (32) lato corona fino ad azzerare i
ITA Serrare le viti (38) con il metodo incrociato ad una ITA giochi tra pignone e corona e poi svitare per circa 1/4
coppia di serraggio di 129v143 Nm. di giro.
Die Schrauben (38) mit Loctite 242 schmieren und Nutmuttern (32) an der Kranzseite zuschrauben bis
D festziehen. Die Schrauben (38) im Kreuz mit einem D zwischen Rad und Kranz kein Spiel mehr uÈbrig bleibt;
Anzugsmoment von 129v143 Nm festziehen. danach um 1/4 Umdrehung aufschrauben.
e f
Pasar los tornillos (38) con Loctite 242 y atornillas a Atornillar las virolas (32) lado corona hasta acerar los
ESP fondo. ESP juegos entre el pinion y corona y despues destornillar
Apretar los tornillos (38) con el metodo cruzado y un por cerca 1/4 de giro.
par de torsion de 129v143 Nm.
Enduire les vis (38) avec du Loctite 242, puis visser Visser l'eÂcrou annulaire (32) du coÃteÂ couronne jusqu'aÁ
F celles-ci aÁ fond. F annuler le jeux entre pignon et couronne, puis
Serrer les vis (38) avec la meÂthode croiseÂe aÁ un couple deÂvisser 1/4 de tour.
de serrage de 129v143 Nm.
008 918 12 BOMAG

63 1025
T3
F1241187 F1241188
GB a GB b
Allow pinion to turn a few times in both directions to allow bearings Introduce a comparator with rotary key "C" through the rear cap
to set. Pre-load the bearings through the ring nut on crown opposite hole (43).
side to increase pinion torque up to a value of 140 ± 210 Ncm Position comparator on the centre of one of the crown teeth (4), pre-
checked by means of a torque meter. set it to 1 mm and reset it to zero.
CAUTION! If bearings are old, check static torque. If new, check Manually move the crown (4) in both directions to check the
continuous torque. existing clearance between pinion and crown.
RATIO - RAPPORTO CLEARANCE - GIOCO - SPIEL

VERHAÈ LTNIS JUEGO - JEU 32
RAPORTE - RAPPORT MIN. MAX.
T9
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 uÈberschreiten.
La diferencia entre el juego Min y Max determinada sobre la entera
circonferencia no debe de superar el valor de 0,09 mm.
La diffeÂrence de jeu entre MIN et MAX releveÂe sur toute la
circonfeÂrence ne doit pas aller au-delaÁ de la valeur de 0,09 mm.
F1241183
GB c GB d
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.
36
34
33
F1241189 F1241190
GB e GB f
Install safety tabs (41) and lock them with screws (40). Using a driver, fit the cap (36) and position it in its seat with the
Screws tightening torque: 10 ± 11 Nm. snap ring (35).
1026 BOMAG
64 008 918 12
Axle 18.8
Far compiere al pignone alcuni giri nei due sensi per Posizionare, attraverso il foro per il tappo posteriore
ITA assestare i cuscinetti. Precaricare i cuscinetti tramite la ITA (43), un comparatore a tasto orientabile "C".
ghiera lato opposto corona, per incrementare la coppia di Posizionarlo sul centro di un dente della corona (4),
rotazione pignone fino a 140v210 Ncm controllati con un torsiometro. precaricarlo di circa 1 mm ed azzerarlo.
ATTENZIONE! Con cuscinetti usati, controllare la coppia di spunto; Muovere manualmente nei due sensi la corona (4) per controllare il
con cuscinetti nuovi, controllare la coppia di rotazione continua. gioco esistente tra pignone e corona.
Das Kegelrad um einige Umdrehungen in beide Richtungen Durch das Loch des hinteren Stopfens (43) eine
D drehen, um das Lager in die richtige Position zu bringen. Die D Meûuhr mit schwenkbarer Taste "C" einsetzen.
Lager durch die Nutmutter an der dem Kranz entgegengesetzte Seite Die Meûuhr auf die Mitte eines Zahnes des Kranzes (4)
vorbelasten, um das Gegenmoment des Kegelrads bis auf 140v210 Ncm positionieren und um 1mm vorbelasten; danach zuruÈckstellen.
a zu erhoÈhen. Den Wert mit einem Drehungsmesser kontrollieren.
ACHTUNG! Bei gebrauchten Lagern, das Anlaufdrehmoment kontrollieren; b Von Hand in beide Richtungen den Kranz (4) bewegen, um das
Spiel zwischen Kegelrad und Kranz zu kontrollieren.
bei neuen Lagern, das kontinuierliche Gegenmoment kontrollieren.
Hacer efectuar al pignon algunos giros en los dos sentidos Colocar, atraves el agujero para la tapa posterior (43),
ESP para ordenar los cojinetes. Precargar los cojinetes a ESP un comparador a tecla orientable "C".
traves de las virolas lado opuesto corona, para crecer el par de rotacion Colocarlo sobre el centro de un diente de la corona (4),
pignon hasta 140v210 Ncm controlados con un torsiometro. precargarlo de 1 mm aprox y azerarlo.
ATENCION! Con cojinetes usados, controlar el par de principio; con Mover manualmente en los dos sentidos la corona (4) para
cojinetes nuevos, controlar el par de rotacion continua. controlar el juego esistente entre pignon y corona.
Faire tourner le pignon plusieurs fois dans les deux sens Placer aÁ travers le trou servant au bouchon arrieÁre
F pour ajuster les paliers. PreÂcharger les paliers au moyen de F (43), un comparateur aÁ touche orientable "C".
l'eÂcrou annulaire, du coÃteÂ opposeÂ aÁ la couronne, pour augmenter le couple Positionner celui-ci au centre d'une des dents de la
de rotation du pignon jusqu'aÁ 140v210 Ncm controÃleÂs par un torsiomeÁtre. couronne (4), preÂcharger celui-ci d'environ 1 mm et mettre aÁ zeÂro.
ATTENTION! Avec des paliers usageÂs, controÃler le couple de pointe; avec DeÂplacer manuellement la couronne (4) dans les deux sens pour
des paliers neufs, controÃler le couple de rotation continu. controÃler le jeu existant entre pignon et couronne.
Contrassegnare la posizione delle ghiere (32) rispetto i

ITA ITA 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.
Die Position der Nutmuttern (32) im VerhaÈltnis zu den

D D Zwischendeckeln markieren.
Mit dem SchluÈûel T9, das Spiel zwischen Rad und
Kranz einstellen, in dem eine Nutmutter (32) gelockert und die
c d entgegengesetzte festgezogen wird.
Normales Spiel: siehe Tabelle.
Contrasenalr la colocacion de las virolas (32) respecto

ESP ESP 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'eÂcrou annulaire (32) par

F F rapport aux couvercles intermeÂdiaires.
A l'aide de la cleÂ T9, reÂgler le jeu entre pignon et
couronne en deÂvissant l'eÂcrou annulaire (32) et en vissant l'eÂcrou
annulaire opposeÂ de la meÃme mesure.
Jeu normal: voir tableau.
Montare le linguette di sicurezza (41) e fissarle con le Con uno spintore, montare il tappo (36) ed assicurarlo
ITA viti (40). ITA in sede con l'anello elastico (35).
Coppia di serraggio viti: 10v11 Nm
Den Sicherheitskeil (41) montieren und mit den Mit einem StoÈûel den Stopfen (36) montieren und in
D Schrauben (40) befestigen. D seinem Sitz mit dem Kolbenring (35) befestigen.
Anzugsmoment der Schrauben: 10v11 Nm
e f
Montar las lenguetas de seguridad (41) y fijarlas con Con un empujador, montar la tapa (36) y asegurarlo en
ESP los tornillos (40). ESP sed con el anillo elastico (36).
Par de serraje tornillos: 10v11 Nm
Monter les languettes de seÂcuriteÂ (41), fixer celles-ci aÁ A l'aide d'un poussoir, monter le bouchon (36), ajuster
F l'aide des vis (40). F celui-ci dans son logement avec l'anneau eÂlastique
Couple de serrage des vis: 10v11 Nm. (35).
008 918 12 BOMAG

65 1027
37
36
40
F1241190 F1241192
GB a GB b
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.
41 44
40
46
47
42 43
F1241193 F1241194
GB c GB d
Lock the cover (40), using the snap washers (43) and the screws Install the breath union piece (44) with the relative sealing washers
(42) and (41) adequately tightened to a torque of 82 ± 91 Nm. (45) and plugs (47) and (46); tighten to a torque of 35 ± 50 Nm.
Tighten screws (42) and (41) with a tightening torque of 82 ± 91 Nm.
GB e GB f
Complete assembly of the axle by installing, in the following order,
brake cylinders and complete arms.
For details, see «ASSEMBLING THE BRAKING UNITS».
1028 BOMAG
66 008 918 12
Axle 18.8
Utilizzando uno spintore ed un mazzuolo in materiale Spalmare la superficie del corpo riduttore (37) con
ITA plastico, montare l'ingranaggio conduttore (39). ITA Loctite 510 ed installare il coperchio (40).
NOTA. Assicurarsi che il sigillante crei un velo
continuo attorno ai fori di fissaggio.
Mit einem StoÈûel und einem Gummihammer das Die FlaÈche des KoÈrpers des Reduzierers (37) mit
D Getriebe (39) montieren. D Loctite 510 schmieren und den Deckel (40) installie-
ren.
BEMERKUNG. Sicherstellen, daû die Dichtmasse einen gleich-
a b maÈûigen Film um die BefestigungsloÈcher herum bildet.
Utilizando un empujador y un martillo en material Pasar la superficie del cuerpo reductor (37) con Loctite
ESP plastico, montar el engranaje conductor (39). ESP 510 y instalar la tapa (40).
NOTA. Asegurarse que el sigilante cree una pelicula
continua alrededor de los agujeros de fisaje.
A l'aide d'un poussoir et d'un maillet en matieÁre Enduire la superficie du corps reÂducteur (37) avec du
F plastique, monter l'engrenage conducteur (39). F 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 Montare il raccordo di sfiato (44) con le relative rosette
ITA elastiche (43) e le viti (42) e (41) serrate con una ITA di tenuta (45) ed i tappi (47) e (46); serrarli con una
coppia di 82v91 Nm. coppia di 35v50 Nm.
Den Deckel (40) mit den Federscheiben (42) und (41) Das abgezogene VerbindungsstuÈck (44) mit den
D und den Schrauben (42) und (41) bei einem Anzu- D Dichtscheiben (45) und den Stopfen (47) und (46)
gsmoment von 82v91 Nm blockieren. montieren; Anzugsmoment 35v50 Nm.
c d
Bloquear la tapa (40) utilizando las arandelas elasti- Montar el recorde de escape (441) con las relativas
ESP cas (43) y los tornillos (42) y (41) apretadas con un par ESP rosas de tenida (45) y las tapas (47) y (46); apretarlos
de 82v91 Nm. con un par de 35v50 Nm.
Bloquer le couvercle (40) aÁ l'aide des rondelles Monter le raccord d'eÂvent (44), les relatives rosettes
F eÂlastiques (43) et des vis (42) et (41) serreÂes aÁ un F d'eÂtancheÂiteÂ (45) et les bouchons (47) et (46), serrer
couple de 82v91 Nm. ceux-ci aÁ un couple de 35v50 Nm.
Completare l'assemblaggio dell'assale installando

ITA nell'ordine i cilindri freni ed i bracci completi. ITA
Per i dettagli, vedere «ASSEMBLAGGIO GRUPPI
FRENO».
Die Achse fertig zusammenbauen und der Reihe nach

D die Bremszylinder und die kompletten Arme installie- D
ren.
Siehe «ZUSAMMENBAU DER BREMSAGGREGATE».
e f
Completar el asemblaje del axial instalando en el
ESP orden los cilindros frenos y los ejes completos. ESP
Para los detalles, vease «ASEMBLAJE GRUPOS
FRENOS».
Achever l'assemblage de l'essieu en y installant dans

F l'ordre les cylindres freins et les bras complets. F
Pour de plus amples deÂtails voir "ASSEMBLAGE DU
GROUPE FREIN".
008 918 12 BOMAG

67 1029
18.8DISASSEMBLY OF REDUCTION GEAR AND BEVEL PINION - SMONTAGGIO RIDUTTORE E PIGNONE CONICO - REDUZIERER UND KEGELRADAxle
ABMONTIEREN - REMOCION REDUCTOR Y PINÄON CONICO - DEMONTAGE DU REDUCTEUR ET PIGNON CONIQUE
1 7
6 5
F1241141 F1241195
GB a GB b
Remove the whole arms and the differential unit. Loosen and remove screws (1) and (2) and the washers (3) locking
For details, see «CHECKING WEAR AND REPLACING THE the cover (4), the plugs (5) and (6) for oil fill and oil drain, and the
BRAKING DISKS» and «REMOVAL OF DIFFERENTIAL UNIT». bleed union piece (7).
NOTE. Leave two screws (2) in position for safety.
4
13 A
11
4 12
F1241196 F1241197
GB c GB d
Using a plastic hammer, remove the cover (4) and move it away. Place a block of tender material (aluminium, etc.) between the
NOTE. If operations on the differential unit need to be performed, reduction body (11) and the gear (12) of the pinion.
remove the complete reduction gear unit (screws (9) and (10)). Loosen and remove the pinion locking nut (13).
14
12
15
14
F1241198 F1241199
GB e GB f
Remove the gear of the pinion (12) and the driving gear (14) Take the driving gear to pieces (14), extracting the bearing (15).
complete with bearing (15). NOTE. If necessary, use an extractor.
NOTE. To remove the gear (14), use a lever.
1030 BOMAG
68 008 918 12
Axle 18.8
Rimuovere i bracci completi ed il differenziale. Allentare ed asportare le viti (1) e (2) e le rondelle (3) di
ITA Per i dettagli, vedere «CONTROLLO USURA E ITA ritegno coperchio (4), i tappi (5) e (6) di carico e scarico
SOSTITUZIONE DISCHI FRENO» e «RIMOZIONE olio ed il raccordo di sfiato (7).
GRUPPO DIFFERENZIALE». NOTA. Lasciare in posizione per sicurezza due viti (2) contrappo-
ste.
Die kompletten Arme und das Differential abnehmen. Schrauben (1) und (2) abschrauben und die Unter-
D Siehe «VERSCHLEISS KONTROLLIEREN UND D legscheiben (3) zur Halterung des Deckels (4), die
BREMSSCHEIBEN AUSWECHSELN» und «DIFFE- OÈ leinfuÈll- und Ablaûstopfen (5) und (6) sowie das
RENTIALAGGREGAT ABNEHMEN». EndluÈftungsstuÈck (7) abnehmen.
a b BEMERKUNG. Die entgegengesetzten Schrauben (2) zur Sicher-
heit zuruÈck lassen.
Remover los ejes completos y el duferencial. Aflojar y sacar los tornillos (1) y (2) y las arandelas (3)
ESP Para los detalles, vease «CONTROL DESGASTE Y ESP de retencion tapa (4), los tapones (5) y (6) de carga y
SOBSTITUCION DISCOS FRENOS» y «REMOCION descarga aceite y el recorde de escape (7).
GRUPO DIFERENCIAL». NOTA. Dejar en posicion de seguridad dos tornillos (2) contra-
puestas.
Enlever les bras complets et le diffeÂrentiel. Desserrer et enlever les vis (1) et (2), les rondelles (3)
F Pour de plus amples deÂtails, voir "CONTROLE F de fixation du couvercle (4), les bouchons (5) et (6) de
USURE ET SUBSTITUTION DES DISQUES FREIN" remplissage et vidange d'huile et le raccord d'eÂvent (7).
et "DEPOSE DU GROUPE DIFFERENTIEL". REMARQUE. Pour plus de suÃreteÂ, garder deux vis (2) super-
poseÂes.
Utilizzando un mazzuolo in materiale plastico, rimuo- Sistemare tra il corpo riduttore (11) e l'ingranaggio (12)
ITA vere il coperchio (4) ed asportarlo. ITA del pignone un blocchetto "A" di materiale tenero
NOTA. Se si deve intervenire sul gruppo differenziale, (alluminio, ecc.).
rimuovere il gruppo riduttore completo (viti (9) e (10)). Allentare ed asportare il dado (13) di ritegno pignone.
Mit einem Gummihammer den Deckel (4) ausrasten Zwischen dem ReduziererkoÈrper (11) und dem Getrie-
D und abnehmen. D be (12) des Kegelrads einen Block aus weichen
BEMERKUNG. Soll am Differentialaggregat gearbeitet Material einsetzen (Aluminium usw.)
werden, das komplette Reduzieraggregat abnehmen (Schrauben Mutter (13) zur Halterung des Kegelrads abschrauben.
c (9) und (10)). d
Utilizando un martillo en material plastico, remover la Colocar entre el cuerpo reductor (11) y el engranaje
ESP tapa (4) y sacarla. ESP (12) del pinon un bloquete "A" de material tierno
NOTA. Si se debe intervenir sobre el grupo diferen- (aluminio, ect.).
cial, remover el grupo reductor completo (tornillos (9) y (10)). Aflojar y sacar la tuerca (13) de retencion pinon.
A l'aide d'un maillet en matieÁre plastique, deÂplacer le Ajuster, entre le corps reÂducteur (11) et l'engrenage
F couvercle (4) et puis l'enlever. F (12) du pignon, un petit bloc "A" en mateÂriel leÂger
REMARQUE. S'il faut intervenir sur le groupe diffeÂ- (aluminium etc.).
rentiel, enlever le groupe reÂducteur complet (vis (9) et (10)). Desserrer et enlever l'eÂcrou (13) de fixation pignon.
Rimuovere l'ingranaggio del pignone (12) e l'ingra- Scomporre l'ingranaggio conduttore (14) estraendo il
ITA naggio conduttore (14) completo di cuscinetto (15). ITA cuscinetto (15).
NOTA. Per rimuovere l'ingranaggio (14), utilizzare una NOTA. Se necessario, usare un estrattore.
leva.
Das Getriebe (12) des Kegelrads und das Getriebe Das Getriebe (14) zerlegen; dazu das Lager (15)
D (14) samt Lager (15) entfernen. D abziehen.
BEMERKUNG. Um das Getriebe (14) abnehmen zu BEMERKUNG. Wenn noÈtig, einen Abzieher verwen-
koÈnnen, einen Hebel verwenden. den.
e f
Remover el engranaje del pinon (12) y el engranaje Descomponer el engranaje conductor (14) sacando el
ESP conductor (14) completo de cojinete (15). ESP cojinete (15).
NOTA. Para remover el engranaje (14), utilizar una NOTA. Si necesario, usar un extractor.
palanca.
DeÂplacer l'engrenage du pignon (12) et l'engrenage DeÂcomposer l'engrenage conducteur (14) en deÂga-
F conducteur (14) complet de palier (15). F geant le palier (15).
REMARQUE. Pour deÂplacer l'engrenage (14), utiliser REMARQUE. Si besoin, utiliser un extracteur.
un levier.
008 918 12 BOMAG

69 1031
11
10
F1241200 F1241201
GB a GB b
Loosen all screws (9) and (10) and remove the upper check screws Connect the whole reduction gear body (11) to a hoist and remove
(9) of the reduction gear body. the screws (10) previously left in place for safety.
NOTE. Leave the two lower screws (10) in position for safety. Using a plastic hammer, pull away the whole reduction gear body
(11).
11 16
17
17
19
16 20
17
F1241202 F1241203
GB c GB d
Position the reduction gear body (11) under a press and, using a Remove distance piece (20) and shims (19) from the pinion(16).
driver, extract the pinion (16) complete with internal bearing (17), Position the pinion under a press and remove the internal bearing
shims (19) and distance piece (20). (17).
21
22 17
11 F1241204
GB e GB f
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).
1032 BOMAG
70 008 918 12
Axle 18.8
Allentare tutte le viti (9) e (10) ed asportare le viti (9) Collegare il corpo riduttore completo (11) ad un mezzo
ITA superiori di ritegno del corpo riduttore. ITA di sollevamento ed asportare le viti (10) lasciate in
NOTA. Lasciare in sede le due viti (10) inferiori per sede per sicurezza.
sicurezza. Utilizzando un mazzuolo in materiale plastico, rimuovere il corpo
riduttore (11) completo.
Alle Schrauben (9) und (10) lockern und die oberen Den kompletten ReduziererkoÈrper (11) an ein Hebe-
D Schrauben (9) zur Halterung des ReduziererkoÈrpers D zeug befestigen und die zuvor zur Sicherheit zuruÈck-
abnehmen. gelassenen Schrauben (10) abschrauben.
BEMERKUNG. Die beiden unteren Schrauben (10) zur Sicherheit Mit einem Gummihammer, den kompletten ReduziererkoÈrper (11)
a zuruÈck lassen. b abnehmen.
Aflojar todos los tornillos (9) y (10) y sacar los tornillos Conectar el cuerpo reductor completo (11) a un medio
ESP (9) superiores de retencion del cuerpo reductor. ESP de elevacion y sacar los tornillos (10) dejadas en su
NOTA. Dejar en su lugar los dos tornillos (10) lugar para seguridad.
inferiores para seguridad. Utilizando un martillo en material plastico, remover el cuerpo
reductor (11) completo.
Desserrer toutes les vis (9) et (10), enlever les vis Brancher le corps reÂducteur complet (11) aÁ un moyen
F supeÂrieures (9) de fixation du corps reÂducteur. F de relevage, puis enlever les vis laisseÂe (10) dans leur
REMARQUE. Garder les deux vis infeÂrieures (10) dans sieÁge pour plus de seÂcuriteÂ.
leur sieÁge pour plus de seÂcuriteÂ. A l'aide d'un maillet en matieÁre plastique, enlever le corps
reÂducteur (11) complet.
Posizionare il corpo riduttore (11) sotto una pressa e, Rimuovere dal pignone (16) il distanziale (20) e gli
ITA utilizzando uno spintore, estrarre il pignone (16) ITA spessori (19).
completo di cuscinetto interno (17), spessori (19) ed Posizionare il pignone sotto una pressa e rimuovere il
il distanziale (20). cuscinetto interno (17).
Den ReduziererkoÈrper (11) unter eine Presse legen Vom Kegelrad (16) das DistanzstuÈck (20) und die
D und mit einem StoÈûel das Kegelrad (16) samt dem D Unterlegscheiben (19) abnehmen.
inneren Lager (17), den Unterlegscheiben (19) und Das Kegelrad unter eine Presse legen und das innere
dem DistanzstuÈck (20) abziehen. Lager (17) abnehmen.
c d
Colocar el cuerpo reductor (11) debajo de una prensa Remover del pinon (16) el distancial (20) y los
ESP y, utilizando un empujador (16) completo de cojinete ESP espesores (19).
interno (17), espesores (19) y el distancial (20). Colocar el pinon bajo una prensa y remover el cojinete
interno (17).
Placer le corps reÂducteur (11) sous une presse, aÁ Enlever du pignon (16) l'entretoise (20) et les cales
F l'aide d'un poussoir extraire le pignon (16) complet de F (19).
palier interne (17), cales (19) et entretoise (20). Placer le pignon sous une presse et enlever le palier
interne (17).
Con un estrattore, rimuovere dal corpo riduttore (11) le

ITA ralle dei cuscinetti (17) e (21) e l'anello di tenuta (22). ITA
NOTA. Annotare il senso di montaggio dell'anello di
tenuta (22).
Mit einem Abzieher vom ReduziererkoÈrper (11) die

D Scheiben der Lager (17) und (21) und den Dichtring D
(22) entfernen.
BEMERKUNG. Montagerichtung des Dichtringes (22) notieren.
e f
Con un extractor, remover del cuerpo reductor (11) las
ESP ranguas de los cojinetes (17) y (21) y el anillo de ESP
retencion (22).
NOTA. Anotar el sentido de desmontaje del anillo de retencion
(22).
A l'aide d'un extracteur, enlever le corps reÂducteur

F (11), les crapaudines des paliers (17) et (21) et F
l'anneau d'eÂtancheÂiteÂ (22).
REMARQUE. Prendre note du sens de montage de l'anneau
d'eÂtancheÂiteÂ (22).
008 918 12 BOMAG

71 1033
23
16
17
18
19
20
GB a GB b
7
11
9
8 15
14
4
1
13
22 5
21 12
6
GB c GB d
10 2
3
D1240136
GB e GB f
1034 BOMAG
72 008 918 12
Axle 18.8
CAUTION! 1 - If disassembly has only been carried ATENCION! 1 - Si el desmontaje ha sido efectuado
GB out to replace the snap ring (22), position the new ring ESP solo para la sobstitucion del anillo de retencion (22),
and reassemble the unit, respecting the tightening proceder al alojamiento del nuevo anillo y remontar el
torques specified in the following section and using the specified grupo respectando los pares de serraje indicadas en el paragrafo
locking and sealing products. siguiente y utilizando los productos de bloqueo y tenida prescritos.
2 - If disassembly is performed to replace either crown wheel and 2 - Si el desmontaje viene efectuado para la sobstitucion del par
pinion, bearings, or planetary gears, take the unit to pieces and find conico, de los cojinetes o de los engranajes satelites, proceder a la
shims and clearances as specified in the sections relative to the descomposicion y a la busqueda de los espesores y de los juegos
removal, disassembly, assembly and installation of the differential como indicados en los paragrafos concernientes la remocion, el
unit and bevel pinion. desmontaje, el asemblaje y la instalacion del diferencial y del pinon
conico.
ATTENZIONE! 1 - Se lo smontaggio eÁ stato eseguito ATTENTION! 1 - Si le deÂmontage n'est effectueÂ que

ITA solo per la sostituzione dell'anello di tenuta (22), F pour substituer l'anneau d'eÂtancheÂiteÂ (22), positionner
procedere al posizionamento del nuovo anello e le nouvel anneau et remonter le groupe en respectant
rimontare il gruppo rispettando le coppie di serraggio indicate nel les couples de serrage indiqueÂs dans le paragraphe suivant aÁ l'aide
paragrafo seguente ed utilizzando i prodotti di bloccaggio e tenuta des produits de blocage et d'eÂtancheÂiteÂ prescrits.
prescritti. 2 - Si le montage est effectueÂ pour substituer le couple conique des
2 - Se lo smontaggio viene eseguito per la sostituzione della coppia paliers et des engrenages satellites, passer aÁ la deÂcomposition et aÁ
conica, dei cuscinetti o degli ingranaggi satelliti, procedere alla la recherche des cales et des jeux comme indiqueÂ dans les
scomposizione ed alla ricerca degli spessori e dei giochi come paragraphes concernant la deÂpose, le deÂmontage, l'assemblage et
indicato nei paragrafi riguardanti la rimozione, lo smontaggio, l'installation du diffeÂrentiel et du pignon conique.
l'assemblaggio e l'installazione del differenziale e del pignone
conico.
ACHTUNG! 1 - Falls das Teil zum Auswechseln des

D 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 StaÈrken und Spiele einhalten.
008 918 12 BOMAG

73 1035
18.8 INSTALLATION AND ADJUSTMENT OF BEVEL PINION - INSTALLAZIONE E REGISTRAZIONE PIGNONE CONICO - INSTALLATION UNDAxle
EINSTELLUNG DES KEGELRADS - INSTALACION Y AJUSTE DEL PINÄON CONICO - INSTALLATION ET REGLAGE DU PIGNON CONIQUE
MEASURE (42.35)
MISURA (42,35)
MAß (42,35) St
MESURA (42,35)
MESURE (42,35) B
MARK
CONTRASSEGNO
C C
B KENNZEICHEN
CONTRASENALACION
11
MARQUAGE
17
F1241205 F1241206
GB a GB b
Mark the thrust block and the internal bearing (17) on a faceplate, Lay two 20 mm gauged blocks "C" on the face of the reduction gear
allow the bearing to set by rotating them in both directions and by body (11). With depth gauge "B" (set to zero at the previous point),
applying a vertical thrust. With a centesimal, digital depth gauge measure space between the "C" blocks and the striking surface of
"B", check overall thickness of bearing (e.g.: 42.35 mm) and set the internal bearing (17). The size obtained (e.g.: 0.81 mm) is the
gauge to zero again. theoretical shim "St" (18) to be inserted under the thrust block of
bearing (17).
DIFFERENTIAL AXIS
ASSE DIFFERENZIALE
DIFFERENTIALACHSE
EJE DEFERENCIAL S
ESSIEU DIFFERENTIEL
Y
X
+ --
DEVIATION "X"
SCOSTAMENTI "X"
ABWEICHUNG "X" S = St + (± X)
DESPLAZAMIENTOS "X"
ECARTS "X"
D1240137
F1241225
GB c GB d
On the bar-hold of pinion (16), check the value "X" (in brackets) To calculate final thickness "S", add the negative value of "X" to
relative to the deviation from the theoretical centre distance. "St" or, alternatively, subtract the positive value of "X".
NOTE. "Y" is the number of pinion/crown coupling. 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.
22
T10
21
22
F1241227 F1241207
GB e GB f
Using a driver, mount the sealing ring (22) in the reduction unit (11). Place the reduction gear body (11) under a press and, using tool
NOTES. 1 - Carefully check the direction of assembly. T10, insert the thrust block of external bearing (21).
2 - Lubricate the outer surface of the sealing ring. CAUTION! Insert the thrust block of the bearing that is not
countermarked.
1036 BOMAG
74 008 918 12
Axle 18.8
Contrassegnare la ralla ed il cuscinetto (17) interno su Appoggiare sul piano di appoggio del corpo riduttore
ITA un piano di riscontro, assestare il cuscinetto con delle ITA (11) due blocchetti calibrati da 20 mm "C". Con il
rotazioni parziali nei due sensi ed esercitando una calibro di profonditaÁ "B" (azzerato nella fase precedente), rilevare la
spinta verticale. Con un calibro di profonditaÁ digitale centesimale misura tra i blocchetti "C" ed il piano di battuta del cuscinetto
"B", rilevare lo spessore totale del cuscinetto (es 42,35 mm) ed interno (17). La misura risultante (es. 0,81 mm) eÁ lo spessore "St"
azzerare il calibro. (18) teorico da inserire sotto la ralla del cuscinetto (17).
Die Scheibe und das innere Lager (17) an einer Auf eine AuflageflaÈche des ReduziererkoÈrpers (11) zwei
D BezugsflaÈche markieren, das Lager durch hin und her D kalibrierte BloÈcke zu 20 mm "C" legen. Mit einer Tiefen-
Drehen und einem senkrechten Druck richtig ein- lehre "B" (zuvor zuruÈckgestellt) das Maû zwischen den BloÈcken "C" und
setzen. Mit einer digitalen hundertteiligen Tiefenlehre "B" die der AnschlagflaÈche des inneren Lagers (17) messen. Das ermittelte Maû
a GesamtstaÈrke des Lagers messen (z.B. 42,35 mm) und die Lehre
zuruÈckstellen.
b (z.B. 0,81 mm) entspricht der theoretischen Unterlegscheibe "St" (18),
die unter die Scheibe des Lagers (17) gelegt werden muû.
Senalar la rangua t el cojinete (17) interno sobre una Colocar sobre la superficie de apoyo del cuerpo reductor
ESP superficie de rescontre, ordenar el cojinete con unas ESP (11) dos bloques calibrados de 20 mm "C". Con el calibre
rotaciones parciales en los dos sentidos y ejercitando de profundidad "B" (azerando en la fase precediente),
un empuje vertical. Con un calibre de profundidad digital centesimal relevar la mesura entre los bloquetes "C" y la superficie del tope del
"B", relevar el espesor total del cojinete (es.:42,35 mm) y azerar el cojinete interno (17). La mesura resultante (es.: 0,81 mm) es el
calibre. espesor "St" (18) teorico de introducir bajo la rangua del cojinete (17).
Estampiller la crapaudine et le palier (17) interne sur DeÂposer sur un plan d'appui du corps reÂducteur (11),
F un marbre de controÃle, ajuster les paliers par des F deux petits blocs calibreÂs aÁ 20 mm "C". A l'aide du
rotations partielles dans les deux sens tout en calibre de profondeur "B" (mis aÁ zeÂro preÂceÂdemment),
poussant verticalement. A l'aide d'un calibre de profondeur relever la mesure existante entre les petits blocs "C" et le plan de
numeÂrique centeÂsimal "B", relever le calage total des paliers (ex. buteÂe du palier interne (17). La mesure reÂsultante (ex. 0,81 mm) est
42,35 mm), mettre le calibre aÁ zeÂro. le calage "St" (18) aÁ introduire sous la crapaudine du palier (17).
Controllare sul codolo del pignone (16) il valore "X" Per calcolare lo spessore "S" definitivo, aggiungere a
ITA (racchiuso tra parentesi) dello scostamento rispetto ITA "St", il valore "X" negativo oppure sottrarre il valore
l'interasse teorico. "X" positivo.
NOTA. Il numero "Y" eÁ il numero di accoppiamento pignone- Es.: Scostamento X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm
corona. Scostamento X=(+0,12 mm): S=St ± X=0,81 ± 0,12=0,69 mm
ATTENZIONE! Arrotondare al valore piuÁ prossimo dei 0,05 mm.
Den Wert "X" der Gleitung am Kegelradschaft (16) (in Um die endguÈltige StaÈrke "S" auszurechnen, "St" und
D Klammern angegeben) im VerhaÈltnis zum theoreti- D "X" addieren, wenn "X" neÂgatif ist oder "X" von "St"
schen Achsenabstand kontrollieren. abziehen, falls "X" postif ist.
BEMERKUNG. Die Zahl "Y" entspricht dem Kegelrad-Kranz- Beispiel: Abweichung X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm
c Kopplungsgrad. d 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 naÈchsten liegt.
Controlar sobre al espigon del pinon (16) el valor "X" Para calcolar el espesor "S" definitivo, adicionar a
ESP (serrado entre parantesis) del desplazamiento respec- ESP "St", el valor "X" negativo o detraer el valor "X"
to al intereje teorico. positivo.
NOTA. El numero "Y" y el numero de acoplamiento pinon-corona. 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.
ControÃler sur la queue du pignon (16) la valeur "X" Pour calculer l'eÂpaisseur "S" deÂfinitif, additionner aÁ
F (entre parentheÁses) de l'eÂcart par rapport aÁ l'entraxe F "St" la valeur "X" neÂgative ou soustraire la valeur "X"
theÂorique. positive.
REMARQUE. Le numeÂro "Y" est le numeÂro de l'accouplement Ex. Ecart X=(± 0,13 mm): S=St+X=0,81+0,13=0,94 mm
pignon-couronne. Ecart X=(+0,12 mm): S=St ± X ± 0,81 ± 0,12=0,69 mm
ATTENTION! Arrondir aÁ la valeur plus proche aÁ 0,05 mm.
Utilizzando uno spintore, montare nel corpo riduttore Sistemare il corpo riduttore (11) sotto una pressa e,
ITA (11) l'anello di tenuta (22). ITA utilizzando l'attrezzo T10 inserire la ralla del cusci-
NOTE. 1 - Controllare attentamente il senso di netto esterno (21).
montaggio. ATTENZIONE! Inserire la ralla del cuscinetto non contrassegnato.
2 - Lubrificare la superficie esterna dell'anello di tenuta.
Mit einem StoÈûel den Dichtring (22) in den Reduzierer- Den ReduziererkoÈrper (11) unter eine Presse legen
D koÈrper (11). D und mit dem Werkzeug T10 die Scheibe des aÈuûeren
BEMERKUNG. 1 - SorgfaÈltig die Montagerichtung des Lagers (21) einsetzen.
Dichtrings kontrollieren. ACHTUNG! Die Scheibe des nicht gekennzeichneten Lagers
e È
2 - Auûere FlaÈche des Dichtrings schmieren. f einsetzen.
Utilizando un espesor, montar en el cuerpo reductor Colocar el cuerpo reductor (11) debajo de una prenso
ESP (11) el anillo de retencion (22). ESP y, utilizando la herramienta T10 insertar la rangua del
NOTA. 1 - Controlar atentamente el sentido de cojinete esterno (21).
montaje. ATENCION! Introducir la rangua del cojinete no segnalado.
2 - Lubrificar la superficie exterior del anillo de retencion.
A l'aide d'un poussoir, monter dans le corps reÂducteur Ajuster le corps reÂducteur (11) sous la presse, aÁ l'aide
F (11) l'anneau d'eÂtancheÂiteÂ (22). F de l'outil T10 introduire la crapaudine du palier
NOTE. 1 - ControÃ ler attentivement le sens de externe (21).
montage. ATTENTION! Introduire la crapaudine du palier non estampilleÂe.
2 - Lubrifier la surface externe de l'anneau d'eÂtancheÂiteÂ.
008 918 12 BOMAG

75 1037
17 T11
18
21
20
17
F1241208 F1241209
GB a GB b
Turn the reduction gear body (11) upside down and insert shim "S"; Fit tool T12 onto tool T11. Then, install bearings (17) and (21) so
then, with tool T10, insert the thrust block of the internal bearing that they are opposed to each other and spaced by the distance
(17). piece (20).
CAUTION! Insert the thrust block of the countermarked bearing. Position the depth comparator in one of the four radial holes; pre-
set the comparator to 3 ± 4 mm, then set it to zero.
T11
21
17
T11
F1241210 F1241211
GB c GB d
Remove the bearings from tool T11 and fit them in the thrust blocks Install tool T11 and tighten it manually to obtain a safe rolling
of the reduction gear body. torque.
CAUTION! Check that the countermarked bearing is fitted in the NOTE. During tightening, perform a few rotations to set the
centring hub of the body of the reduction gear and in the bearings.
countermarked thrust block too.
H + 0,13 ÷ 0,15 = S1
19 S1
F1241212 F1241221
GB e GB f
Introduce the previously reset comparator, in one of the four radial The deviation found is to be added to a fixed value of 0.13(0.15
holes and measure. The deviation from zero indicates the nominal mm. in order to: obtain shim "S1" (to be inserted between internal
value "H" relative to the shims that are to be inserted. 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
1038 BOMAG
76 008 918 12
Axle 18.8
Capovolgere il corpo riduttore (11) ed inserire lo Montare sull'attrezzo T11 l'attrezzo T12. Quindi mon-
ITA spessore "S" e con l'attrezzo T10 la ralla del ITA tare i cuscinetti (17) e (21) contrapposti ed intervallati
cuscinetto interno (17). con il distanziale (20).
ATTENZIONE! Inserire la ralla del cuscinetto contrassegnato. Posizionare un comparatore di profonditaÁ in uno dei quattro fori
radiali; precaricare il comparatore di 3v4 mm ed azzerarlo.
Den RedurziererkoÈrper (11) wenden und die Unter- Auf das Werkzeug T11 das Werkzeug T12 montieren.
D legscheibe "S" einsetzen; mit dem Werkzeug T10 die D Dann die entgegengesetzten Lager (17) und (21)
Scheibe des inneren Lagers (17) einsetzen. montieren und dazwischen das DistanzstuÈck (20)
ACHTUNG! Die Scheibe des gekennzeichneten Lagers einsetzen. legen.
a b Eine Meûuhr in eines der vier RadialloÈcher positionieren; die
Meûuhr auf 3v4 mm vorbelasten und dann zuruÈckstellen.
Volcar el cuerpo reductor (11) y introducir el espesor Montar sobre la herramienta T11 la herramienta T12.
ESP "S" y con la herramienta T10 la rangua del cojinete ESP Entonces colocar los cojinetes (17) y (12) contra-
interno (17). puestos y intervalados con el distancial (20).
ATENCION! Introducir la rangua del cojinete segnalado. Colocar un comparador de profundidad en uno de los cuatro
agujeros radiales, precargar el comparador de 3-4 mm y acerarlo.
Faire basculer le corps reÂducteur (11), introduire la Monter sur l'outil T11, l'outil T12. Ensuite monter les
F cale "S", et aÁ l'aide de l'outil T10 la crapaudine du F paliers (17) et (21) en les superposant et intercalant
palier interne (17). avec l'entretoise (20).
ATTENTION! Introduire la crapaudine du palier estampilleÂ. Placer un comparateur de profondeur dans l'un des quatre trous
radiaux; preÂcharger le comparateur aÁ 3v4 mm, puis le mettre aÁ
zeÂro.
Rimuovere i cuscinetti dall'attrezzo T11 e montarli Montare l'attrezzo T11 e serrarlo manualmente fino ad
ITA nelle ralle del corpo riduttore. ITA avere una sicura coppia di rotolamento.
ATTENZIONE! Controllare che il cuscinetto contras- NOTA. Durante il serraggio, eseguire alcune rotazioni
segnato sia montato nel mozzo di centratura del corpo riduttore e per assestare i cuscinetti.
quindi nella ralla contrassegnata.
Die Lager vom Werkzeug T11 abnehmen und in den Das Werkzeug T11 montieren und von Hand fest-
D Scheiben des ReduziererkoÈrpers montieren. D ziehen bis ein sicheres Gegenmoment erreicht ist.
ACHTUNG! Kontrollieren, ob das markierte Lager in BEMERKUNG. Beim Festziehen einige Umdrehungen
den Zentriernaben des ReduziererkoÈrpers und folglich in der vornehmen, um die Lager richtig in ihren Sitz zu bringen.
c markierten Scheibe montiert ist. d
Remover los cojinetes de la herramienta T11 y Montar la herramienta T11 y apretarla manualmente
ESP montarlos en las ranguas del cuerpo reductor. ESP hasta obtener una segura pareja de rotacion.
ATENCION! Controlar que el cojinete segnalado sea NOTA. Durante la torsion, efectuar algunas rotaciones
colocado en el cubo central del cuerpo reductor y por lo tanto en la para ordenar los cojinetes.
rangua segnalada.
Oter les paliers de l'outil T11, puis monter ces Monter l'outil T11 et serrer celui-ci aÁ la main jusqu'aÁ
F derniers dans les crapaudines du corps reÂducteur. F obtenir un couple de roulement assureÂ.
ATTENTION! ControÃler que le palier estampilleÂ soit REMARQUE. En serrant, effectuer quelques tours de
monteÂ dans le moyeu de centrage du corps reÂducteur, donc, dans rotation pour ajuster les paliers.
la crapaudine estampilleÂe.
Introdurre in uno dei fori radiali il comparatore Lo scostamento rilevato eÁ da sommare ad una misura
ITA azzerato precedentemente ed eseguire la lettura. ITA fissa di 0,13v0,15 mm, per ottenere lo spessore "S1"
Lo scostamento rispetto lo zero, indica il valore (19) da inserire tra cuscinetto interno (17) e distanziale (20) e
nominale "H" degli spessori da inserire. 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.
In eines der RadialloÈcher die zuvor zuruÈckgestellte Die ermittelte Abweichung muû mit einem Festmaû von 0,3 (0,15
D Meûuhr einsetzen und das Maû ablesen. D mm zusammengerechnet werden, um die Unterlegscheibe "S1"
Die Abweichung im VerhaÈltnis zur Null, gibt den (19) zu ermitteln, die zwischen dem inneren Lager (17) und das DistanzstuÈck (20)
Nennwert "H" der einzulegenden Unterlegscheiben an. gelegt werden muû und um die Vorbelastung der Lager festlegen zu koÈnnen.
e f ACHTUNG! Die Messungen sehr sorgfaÈltig vornehmen, da ein Unter-
schied von 0,01 mm das Gegenmoment um 20v40 Ncm veraÈndert.
Introducir en uno de los agujeros radiales el compa- El desplazamiento relevado es de sumarse a una
ESP rador acerado precedentemente y efectuar la lectura. ESP mesura fija de 0,13-0,15 mm, para obtener el espesor
El desplazamiento respecto a lo cero, indica el valor "S1" (19) de introducir entre cojinete interno (17) y distancial (20) y
nominal "H" de los espesores de introducir. 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.
Introduire dans l'un des trous radiaux le comparateur L'eÂcart releveÂ est aÁ additionner aÁ la mesure fixe 0,13v0,15 mm
F mis aÁ zeÂro preÂceÂdemment et en faire la lecture. F pour obtenir la cale "S1" (19) aÁ introduire entre le palier interne
L'eÂcart par rapport au zeÂro, indique la valeur nominale (17) et l'entretoise (20) et deÂfinir la preÂcharge eÂtablie pour les paliers.
"H" des cales aÁ introduire. ATTENTION! Effectuer soigneusement les mesurages parce qu'une diffeÂ-
rence de 0,01 mm ameÁne une variation du couple de rotation de 20v40 Ncm.
008 918 12 BOMAG

77 1039
16
16 11
17
F1241213 F1241214
GB a GB b
With the help of the press, install the internal, countermarked Fit the pinion (16), the shims (19), the distance piece (20) and the
bearing (17) onto the pinion (16). external bearing (21) into the body of the reduction gear (11) and
CAUTION! Lubricate pinion with oil. assemble the unit with a press.
CAUTION! Lubricate pinion with oil.
23
11
15
12
13
F1241215 F1241216
GB c GB d
Fit the reduction gear (11) into the main body (23) without Fit the gear (12) of the pinion; coat the nut (13) with Loctite 242 and
differential unit; lock temporarily with the two lower screws (9). hand-screw it.
Fit the bearing (15) of the motion in gear and lock it.
12
11
F1241217
GB e GB f
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.
1040 BOMAG
78 008 918 12
Axle 18.8
Con la pressa, montare il cuscinetto interno e Montare nel corpo riduttore (11) il pignone (16), gli
ITA contrassegnato (17) sul pignone (16). ITA spessori (19), il distanziale (20) ed il cuscinetto esterno
ATTENZIONE! Lubrificare il pignone con olio. (21) ed assemblare il gruppo con la pressa.
ATTENZIONE! Lubrificare il pignone con olio.
Mit einer Presse, das innere und markierte Lager (17) In den ReduziererkoÈrper (11) das Kegelrad (16), die
D auf das Kegelrad (16) montieren. D Unterlegscheiben (19), das DistanzstuÈck (20) und das
ACHTUNG! Rad mit O È l schmieren. aÈuûere Lager (21) montieren und das Aggregat mit der
Presse zusammenbauen.
a b ACHTUNG! Rad mit O È l schmieren.
Con la prensa, montar el cojinete interno y segnalado Montar en el cuerpo reductor (11) el pinon (16) los
ESP (17) sobre el pinon (16). ESP espesores (19), el distancial (20) y el cojinete esterno
ATENCION! Lubrificar el pinon con aceite. (21) y asemblar el grupo con la prensa.
ATENCION! Lubrificar el pinon con aceite.
A l'aide de la presse, monter le palier interne Monter dans le corps reÂducteur (11), le pignon (16), les
F estampilleÂ (17) sur le pignon (16). F cales (19), l'entretoise (20) et le palier externe (21),
ATTENTION! Lubrifier le pignon avec de l'huile. assembler le groupe aÁ l'aide de la presse.
ATTENTION! Lubrifier le pignon avec de l'huile.
Montare il corpo riduttore (11) sul corpo centrale (23) Montare l'ingranaggio (12) del pignone; spalmare il
ITA privo di differenziale e fissarlo provvisoriamente con le ITA dado (13) con Loctite 242 ed avvitarlo manualmente.
due viti inferiori (9).
Montare il cuscinetto (15) dell'ingranaggio di entrata del moto e
mandarlo in battuta.
Den ReduziererkoÈrper (11) auf den zentralen KoÈrper Das Getriebe (12) des Kegelrads montieren; Mutter
D (23) ohne Differential montieren und voruÈbergehend D (13) mit Loctite 242 schmieren und von Hand
mit den zwei unteren Schrauben (9) befestigen. zuschrauben.
Das Lager (15) des Einganggetriebes montieren und bis zum
c Anschlag einsetzen. d
Montar el cuerpo reductor (11) sobre el cuerpo central Asemblar el engranaje (12) del pinon, pasar la tuerca
ESP (23) sin el diferencial y fijarlo provisoriamente con los ESP (13) con Loctite 242 y atornillarla manualmente.
dos tornillos inferiores (9).
Asemblar el cojinete (15) del engranaje de entrada del movimiento
y mandarlo a tope.
Monter le corps reÂducteur (11) sur le corps central (23) Monter l'engrenage (12) du pignon; enduire l'eÂcrou
F sans diffeÂrentiel et fixer provisoirement ce dernier F (13) avec du Loctite 242 et visser celui-ci aÁ la main.
avec les deux vis infeÂrieures (9).
Monter le palier (15) de l'engrenage d'acceÁs au mouvement, puis
l'envoyer en buteÂe.
Sistemare tra il corpo riduttore (11) e l'ingranaggio (12)

ITA del pignone il blocchetto "A" usato per lo smontaggio ITA
e serrare il dado (13) alla coppia minima di 500 Nm,
utilizzando una chiave a bussola ed una chiave dinamometrica.
Zwischen dem ReduziererkoÈrper (11) und dem Getrie-

D be (12) des Kegelrads den Block «A» legen, der zum D
Abmontieren verwendet wurde, und Mutter (13) mit
einem Anzugsmoment von mindestens 500 Nm mit einem
e InbuûschluÈssel und einem Dynamometer festziehen. f
Colocar entre el cuerpo reductor (11) y el engranaje
ESP (12) del pinon el bloquete "A" usado para el ESP
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 reÂducteur (11) et l'engrenage

F (12) du pignon, le petit bloc "A" utiliseÂ au deÂmontage, F
serrer l'eÂcrou (13) au couple minimum de 500 Nm aÁ
l'aide d'une cleÂ aÁ pipe et d'une cleÂ dynamomeÂtrique.
008 918 12 BOMAG

79 1041
T13
F1241217
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.
11
F1241226
GB b
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».
1042 BOMAG
80 008 918 12
Axle 18.8
Far compiere al pignone alcuni giri nei due sensi per Das Kegelrad um einige Umdrehungen in beide
ITA assestare i cuscinetti. D Richtungen drehen, um die Lager richtig einzusetzen.
Applicare sul pignone (16) il codolo T13 e con un Am Kegelrad (16) den Schaft T13 anbringen und mit
torsiometro, controllare la coppia di rotazione del pignone. einem Drehungsmesser das Gegenmoment des Ke-
Coppia di rotazione: 140v150 Ncm gelrads kontrollieren.
ATTENZIONE! Se la coppia supera il valore massimo bisogna Gegenmoment: 140v150 Ncm.
aumentare lo spessore "S1" (19) tra cuscinetto (17) e distanziale ACHTUNG! Falls der Wert den Maximalwert uÈberschreitet, braucht
(20). es eine groÈûere Unterlegscheibe "S1" (19) zwischen Lager (17) und
Se la coppia di rotazione non raggiunge il valore stabilito, DistanzstuÈck (20).
aumentare la coppia di serraggio del dado (13) in piuÁ tempi fino a Falls das Gegenmoment den festgelegten Wert nicht erreicht, das
raggiungere il valore massimo ammesso di 700 Nm. Anzugsmoment der Mutter (13) schrittweise erhoÈhen, bis der
ATTENZIONE! Se la coppia di rotazione non raggiunge il valore maximal zulaÈssige Wert von 700 Nm erreicht worden ist.
minimo, eÁ necessario diminuire lo spessore "S1" (19). ACHTUNG! Falls das Gegenmoment den Mindestwert nicht
ATTENZIONE! Al fine di poter calcolare gli incrementi o la erreicht, muû die Unterlegscheibe "S1" (19) kleiner sein.
diminuzione dello spessore "S1", eÁ necessario considerare che la ACHTUNG! Um das hoÈhere oder niedrigere Maû der Unter-
variazione dello spessore (19) di 0,01 mm, fa variare la coppia di legscheibe "S1" ausrechnen zu koÈnnen, darauf achten, daû ein
rotazione del pignone (16) di 20v40 Ncm. Unterschied von 0,01 mm der Unterlegscheibe (19) das Gegen-
moment des Kegelrads (16) um 20v40 Ncm aÈndert.
a
Hacer efectuar al pinon algunos giros en los dos Faire faire quelques tours au pignon dans les deux
ESP sentidos para ordenar los cojinetes. F sens de manieÁre aÁ ajuster les paliers.
Aplicar sobre el pinon (16) el codolo T13 y con un Appliquer sur le pignon (16), la queue T13, puis aÁ
torsiometro, controlar el par de rotacion del pinon. l'aide d'un torsiomeÁtre, controÃler le couple de rotation du pignon.
Par de rotacion: 140v150 Ncm. Couple de rotation: 140v150 Ncm.
ATENCION! Si el par supera el valor maximo hay que augmentar el ATTENTION! Si le couple de rotation deÂpasse la valeur maximum,
espesor "S1" (19) entre cojinete (17) y distancial (20). augmenter la cale "S1" (19) entre le palier (17) et l'entretoise (20).
Si el par de rotacion no llega al valor establecido, augmentar el par Si le couple de rotation n'atteint pas la valeur eÂtablie, augmenter le
de torsion de la tuerca (13) en mas tiempos hasta llegar al valor couple de serrage de l'eÂcrou (13), en plusieurs temps, jusqu'aÁ
maximo admitido de 700 Nm. atteindre la valeur maximum admise de 700 Nm.
ATENCION! Si el par de rotacion no llega al valor minimo, es ATTENTION! Si le couple de rotation n'atteint pas la valeur
necesario disminuir el espesor "S1" (19). minimum, diminuer la cale "S1" (19).
ATENCION! Al fin de poder calcular los encrementos o la ATTENTION! Pour pouvoir calculer les augmentations et les
disminuciones del espesor "S1", es necesario considerar que la diminutions de la cale "S1", tenir compte que la diffeÂrence de
variacion del espesor (19) de 0,01 mm, hacer cambiar el par de 0,01 de la cale (19) fait varier le couple de rotation du pignon (16) de
rotacion del pinon (16) de 20v40 Ncm. 20v40 Ncm.
Rimuovere il corpo riduttore completo (11) e procedere

ITA con il montaggio del differenziale e dei bracci.
Per i dettagli, vedere «ASSEMBLAGGIO ED INSTAL-
LAZIONE GRUPPO DIFFERENZIALE - ASSEMBLAGGIO GRUP-
PO FRENO».
Den kompletten ReduziererkoÈrper (11) abnehmen und

D das Differential und die Arme montieren.
Siehe «ZUSAMMENBAU UND INSTALLATION DES
DIFFERENTIALAGGREGATS - ZUSAMMENBAU DES BREMSAG-
b GREGATS».
Remover el cuerpo reductor completo (11) y proceder

ESP 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 reÂducteur complet (11) et aller de

F l'avant avec le montage du diffeÂrentiel et des bras.
Pour de plus amples deÂtails, voir "ASSEMBLAGE ET
INSTALLATION DU GROUPE DIFFERENTIEL - ASSEMBLAGE
DU GROUPE FREIN".
008 918 12 BOMAG

81 1043
18.8 SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
Axle
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL
4.3 T1 T2
45°
20
25
1
=
32
32
200
=
90
= =
50
160
110
120± 0.1
120± 0.1
32
32
25
1
840
45°
10 4.5 930
2313 D1240046 2305 D1240043
T3 Ø40
T4
Ø40
32
3 x45°
3 x45°
150
150
190
195
0
R1
10
0
R1
8
17 13
40
25
32
45
32
32
3 x45°
32
Ø153
32
125
Ø154
20°
Ø178 Ø178
Ø189
Ø184
Ø200
1502 D1240120 1742 D1240121
T5
295
136 10 150
65 3 x45°
27.5
20
3 x15°
-- 0.05
-- 0.4
-- 0.6
-- 0.3
-- 0.4
-- 0.1
Ø80
Ø61
Ø35
Ø25
Ø45
Ø63
Ø46
R1
32 32
0
32
32
107.5 ---- 0.2

0.3
1501 D1240122
1044 BOMAG
82 008 918 12
Axle 18.8
75 Ø290
T6
5 Ø271
12
Ø20
Ø16
A Sez. B - B
1° 30'
° 2
32 17
°
17
32
7°
° 30' 17° 30' 1
3x15°
B
Ø150 H 7
Ø150 Hn 67
Ø318
B
43.60
° 17
82.13
113.48
17
134.91
°
17
°
Ø22
Ø16
17
21° 30'
Ø26
Ø22
Ø15
53.14
32
32
12 A
90.26
68 12
119.50
80 82
139.29
Sez. A - A n°2 pezzi
1545 D1240124
119.50 T7
190
53.14
Ø20
Ø16
9
Ø25
32 32
20
0 0 2 x30°
R1 R1 32 1° 30'
° 2
17
°
134.91
17
T7B
82.13
7°
17° 30' 7° 30' 1
Ø161.5 ±0.1
Ø264 ---- 0.15

0.25
Ø185 ---- 0.08
0.12
Ø262 ---- 0.15

0.25
Ø250
Ø172
Ø320
43.60
17°
113.49
32
°
17
17°
R5
'
21° 30
15°
15°
Ø16
5 x15° 90.26
16 20 138.29
110
32
Ø290 ±0.15
143
153
70
T7A 30 30
3 x15° 32
PROFILO HURT 45.5 x 40.5
A
Ø24
R5
Ø150 ---- 0.08
0.12
2
Ø140
Ø30
Ø38
0
R1 0
R1
Ø25 gH 67
Ø24
Ø23,9
40 74
1.2 h 11
200 200
Particolare A 400
1769 D1240125
008 918 12 BOMAG

83 1045
18.8 SPECIAL TOOLS - ATTREZZI SPECIALI - SONDERWERZZEUGE
Axle
HERRAMIENTAS ESPECIALES - OUTILS SPECIAL
T8 T9
5 - +0
.5
-0
Ø9
Ø25
13 ± 0..2
Ø102 +-- 0.2
Ø120
0
3 x45°
160
192
Sez. A-A
0
R1
22 10
0.8 600
Ø40
0.8
Es Ch 22
␣]
15 20
30
Ø]
Ø129
Ø16
] Bearing ref. 32017 DIN720 Acciaio Fe 42
] Ref. cuscinetto 32017 DIN720
] Lager Ref. 32017 DIN720
] Ref. cojinete 32017 DIN720
] ReÂf. palier 32017 DIN720
Acciaio Fe 42
0355 D1240123
Ø85.5
T10
490
Ø40
Ø25
R1
30
0
3 x45°
78
R2
48
40
10
22
150
A A
188
135
Acciaio 18 Ni Cr Mo 5
Cementazione 0.6÷0.8
Temprato HRC 60÷63
0
R1
35.5
32
1.5
40
8
32
30
3
4.5
32
32
20°
Ø23.9 ±-- 00.05
Ø104
H7
Ø25 g7
Ø109
Ø30
32
-- 0.1
Ø40.5-- 0.15
Ø80
Ø92
1487/B D1240126 1495 D1240128
1046 BOMAG
84 008 918 12
Axle 18.8
T11 Ø49.8
T12
Ø41.5
4 x45°
15
93
M14 x1
40 300
Ø110 2323 D1240127
Ø65
T13
M14 x1
Ch
22
Ø20
20
M14 x1
61 –– 0.01
0.02
R5
3/4"
4"
41
1/
30
25 25
50
Ø20
Ø9
Ø41.2 +-- 0.03
0 14
195
95
25
45
35
Ø11
60
10
Ø80
10
50
Ø6.5 25
Ø35
2312 D1240075 0870 D1240129
008 918 12 BOMAG

85 1047
18.8 Axle
1048 BOMAG 008 918 12

18.9 Diesel engine
008 918 12 BOMAG 1049

18.9 Diesel engine
1050 BOMAG 008 918 12

Diesel engine 18.9
Werkstatthandbuch
Workshop Manual
Manuel d’Atelier
Manual de Taller BFM 1012/1013
80312 4018
Gegenüber Darstellungen und Angaben dieses Werkstatthandbuches sind

technische Änderungen, die zur Verbesserung der Motoren notwendig werden,
vorbehalten. Nachdruck und Vervielfältigung jeglicher Art, auch auszugsweise,
bedarf unserer schriftlichen Genehmigung.
In view of continuous design improvements or changes, the technical spe-

cifications and the illustrations shown in this Workshop Manual are subject to
alteration. Reprinting and reproduction, in part or in whole, are subject to our
written approval.
Sous réserve de modifications techniques nécessaires à l’amélioration des

moteurs présentés par des illustrations et des indications référencées dans ce
Manuel d’Atelier. Réimpression et reproduction même partielle, quelle qu’en
soit la nature, interdites sans l’autorisation écrite de nos service.
Nos reservamos el derecho de introducir modificaciones técnicas necesarias

para el mejoramiento de motores, aunque difieran de las ilustraciones y datos
contenidos en este Manual de Taller. La reimpresión del presente libro o
cualquiera forma de reproducción, aunque sea parcial, requiere nuestra
autorización por escrito.
008 918 12 BOMAG 1051

18.9 Diesel engine
Hinsichtlich Copyright-Fragen bzw. Copyright-Lizenzvereinbarungen

wenden Sie sich bitte an:
VS-DI, Herr Sonntag
Tel.: 0221 822-3053
EMail: sonntag.j@deutz.com
Deutz AG
Service Information Systems
Ottostraße 1
D - 51149 Köln
Tel.: + 49 (0) 221-8 22-0
Fax: + 49 (0) 221-8 22-58 50
http://www.deutz.com
Printed in Germany
Alle Rechte vorbehalten
Best.-Nr. 0312 4018

© 2001
1052 BOMAG 008 918 12
Diesel engine 18.9
VORWORT
Die sachgerechte Ausführung von Reparatur- und Einstellarbeiten ist Voraussetzung für einen
zuverlässigen Motorbetrieb.
In diesem Werkstatthandbuch sind die zweckmäßigen Arbeitsabläufe für anfallende Reparatur-

und Einstellarbeiten an Motor und Motorbauteilen beschrieben. Dabei wird vorausgesetzt, daß die
Arbeiten von qualifiziertem Fachpersonal durchgeführt werden.
Bei der Gestaltung des Werkstatthandbuches wurden im Sinne einer schnellen Erfassung der
Inhalte zusätzlich zu den knapp gehaltenen beschreibenden Texten Bildzeichen gesetzt, die den
jeweils behandelten Arbeitsgang visualisieren.
Betriebs- und Wartungshinweise sind der entsprechenden Betriebsanleitung zu entnehmen.
Zur Ersatzteilbestellung ist die jeweilige Ersatzteilliste zugrunde zu legen.
Das vorliegende Werkstatthandbuch unterliegt keinem Änderungsdienst. Änderungen werden

jeweils bei Neuauflage eingearbeitet.
Beachten Sie bei Reparaturen die Hinweise unserer Technischen Rundschreiben.
Allgemeine Hinweise:
- Lesen und beachten Sie die Informationen dieses Werkstatthandbuches. Sie

vermeiden Unfälle und verfügen über einen funktionstüchtigen und einsatzbereiten
Motor.
- Stellen Sie sicher, daß dieses Werkstatthandbuch jedem an Reparatur- oder

Einstellarbeiten Beteiligten zur Verfügung steht und daß der Inhalt verstanden wird.
- Die Nichtbeachtung dieser Reparaturanleitung kann zu Funktionsstörungen und

Motorschäden sowie Verletzungen von Personen führen, für die vom Hersteller
keine Haftung übernommen wird.
- Die einschlägigen Unfallverhütungsvorschriften sowie die sonstigen allgemeinen

anerkannten sicherheitstechnischen und arbeitsmedizinischen Regeln sind einzu-
halten.
- Voraussetzung für die fachgerechte Reparatur ist die Verfügbarkeit aller erforderli-
chen Ausrüstungen, Hand- und Spezialwerkzeuge sowie deren einwandfreier Zu-
stand.
- Höchste Wirtschaftlichkeit, Zuverlässigkeit und lange Lebensdauer ist nur bei

Verwendung von Original Teilen der DEUTZ AG sichergestellt.
- Motorteile wie Federn, Klammern, elastische Halteringe etc. beinhalten bei unsach-
gemäßer Behandlung erhöhte Verletzungsgefahr.
- Die Instandsetzung des Motors muß der bestimmungsgemäßen Verwendung -

definiert durch den Gerätehersteller - entsprechen. Bei Umbauten dürfen nur von der
DEUTZ AG für den jeweiligen Verwendungszweck freigegebene Teile eingesetzt
werden.
008 918 12 BOMAG 1053

18.9 Diesel engine
FOREWORD
Reliable engine operation is dependent on properly executed repairs as well as adjustment work.
This Workshop Manual describes the appropriate operations for any repair and adjustment work
on the engine and engine components. It is presumed that this work will be carried out by qualified
personnel.
This operation manual has been designed for quick and easy understanding. Therefore the concise
text passages are accompanied by pictographs to illustrate the relevant operation.
The Workshop Manual has been laid out to ensure quick comprehension of the contents, i. e
illustrations have been placed adjacent to the brief text passages to clearly show the working
operations.
Aspects of operation and maintenance are dealt with in the respective Operation Manual.
For spare parts orders the respective spare parts catalogue should be referred to.
This Workshop Manual is not subject to engineering change service and is valid until next
issue.
Therefore please refer to the information in our Technical Circulars when carrying out repairs.
General information:
- Please read carefully and observe the instructions given in this Workshop Manual
to avoid accidents and ensure that your engine always functions properly and
reliably.
- Make sure that this Workshop Manual is readily available for all those carrying out
repairs or adjustments and that the contents are well understood.
- Non-compliance with these repair instructions may result in malfunction and engine
damage as well as personal injuries for which the manufacturer shall not accept any
liability.
- The accident prevention regulations and all other generally recognized regulations
on safety and occupational medicine are to be observed.
- A prerequisite for successful repair is that all required equipment, hand and special
tools are available and in perfect working order.
- Optimal operation economy, reliability and durability of the engine can only be
ensured when genuine parts of DEUTZ AG are used.
- Engine components such as springs, clamps, snap rings, etc. may cause injury if not
handled with care.
- Engine repairs must be carried out in accordance with intended use as defined by
the equipment manufacturer. For conversions, only parts approved by DEUTZ AG
for a specific purpose should be used.
1054 BOMAG 008 918 12

Diesel engine 18.9
PRÉFACE
Un fonctionnement fiable du moteur suppose l’exécution en bonne et due forme des travaux de
réparation et de réglage.
Le présent Manuel d’atelier décrit la suite des travaux de réparation et de réglage à effectuer sur
le moteur et ses éléments. Cela suppose que les travaux sont réalisés par un personnel spécialisé
et qualifié.
En vue d’une compréhension rapide du contenu, le manuel d’atelier comporte, en plus des textes
brefs, des symboles visualisant l’opération à réaliser.
Le manuel d'atelier a été conçu de manière à assurer une rapide compréhension des textes concis
agrémentés d'illustrations et de symboles visualisant l'opération à effectuer.
Les indications relatives au service et à l’entretien figurent dans les instructions de service
correspondantes.
Pour la commande de pièces de rechange, il convient de se baser sur la liste des pièces de rechange
correspondante.
Le présent manuel d’atelier n’est soumis à aucun service de modifications. Les modifications
seront incorporées à chaque réédition du Manuel.
Pour les réparations, veuillez respecter les indications de nos circulaires techniques.
Remarques générales:
- Veuillez lire attentivement les informations du présent Manuel d’ Atelier et en tenir

compte. Vous éviterez ainsi des accidents et disposerez en même temps d’ un
moteur fonctionnel et en parfait état de marche.
- Assurez-vous que chaque personne chargée des travaux de réparation et de mise

au point dispose bien de ce Manuel d’ Atelier et en comprenne bien le contenu.
- Le non-respect de ces instructions de réparation peut entraîner des pannes, avaries

de moteur et accidents de personnes, pour lesquels le constructeur ne peut en aucun
cas assumer la responsabilité.
- Il convient de respecter les consignes générales de sécurité et de prévention des

accidents en vigueur.
- La condition préalable de la bonne exécution des réparations est la mise à disposition

de tous les équipements, outillages manuels et spéciaux requis, en parfait état de
fonctionnement.
- Seule l’utilisation de pièces de rechange d’origine DEUTZ AG garantit une rentabilité

et fiabilité optimales ainsi qu’une longue durée de vie.
- Les éléments du moteur notamment les ressorts, attaches, bagues élastiques etc.,
peuvent entraîner, en cas de non-respect des prescriptions, des blessures graves.
- La remise en état du moteur doit répondre à son utilisation propre, définie par le
constructeur de l’engin. En cas de modification, seules les pièces autorisées par
DEUTZ AG dans le cas de l’application concernée, peuvent être utilisées.
008 918 12 BOMAG 1055

18.9 Diesel engine
PROLOGO
Una ejecución competente de trabajos de reparación y ajuste es requisito fundamental para un
funcionamiento seguro del motor.
En el presente manual para talleres han sido descritos los ciclos convenientes de trabajo para
reparaciones y ajustes del motor y de sus componentes. Se presupone, no obstante, que los
trabajos serán realizados por personal técnico especializado.
Con el fin de simplificar la comprensión del contenido del manual para talleres, se han agregado
símbolos significativos a los textos explicatorios, visualizando así el trabajo a realizar.
Para la rápida comprensión del contenido de los textos breves desciptivos se han introducido en
el manual de taller símbolos que visualizan la operación a realizar.
Informaciones con respecto al manejo y al servicio de entretenimiento del motor, se encuentran

en el Manual de Instrucciones de Servicio correspondiente.
Para pedidos de repuestos servirá de base el respectivo catálogo de repuestos.
El presente manual para talleres no está sujeto a un servicio continuado de modificaciones e

innovaciones. Cada nueva edición incluye todas las modificaciones del caso.
Al efectuar reparaciones, aconsejamos asimismo tomar en cuenta las advertencias pertinentes de

nuestras circulares técnicas.
Advertencias generales:
- Le recomendamos la detenida lectura y observancia de las informaciones con-

tenidas en este Manual de taller. Así evitará accidentes y dispondrá de un motor
que funciona perfectamente.
- Haga lo necesario para que este Manual esté a disposición de toda persona que
participe en trabajos de reparación y ajuste, y cuide de que sí comprenda el
contenido.
- Al no tenerse en cuenta estas instrucciones de reparación, podrán surgir

perturbaciones en el funcionamiento y averías en el motor así como lesiones de
personas para las cuales el fabricante no asume responsabilidad alguna.
- Se cumplirán las normas aplicables para la prevención de accidentes así como todas
las demás normas de seguridad y medicina laboral generalmente aceptadas.
- Es condición para la correcta reparación que estén disponibles todos los requeridos
equipos, herramientas manuales y especiales en perfecto estado.
- Máxima rentabilidad, fiabilidad y larga duración quedan garantizadas únicamente al

emplearse repuestos originales de DEUTZ AG.
- Piezas del motor, tales como resortes, garras, aros de sujeción elásticos, etc. ,
aumentan en caso de tratamiento incorrecto el peligro de lesiones.
- El reacondicionado del motor deberá corresponder al empleo previsto definido por

el fabricante del equipo. En caso de transformaciones, se deberán emplear
únicamente piezas admitidas por DEUTZ AG para el respectivo uso previsto.
1056 BOMAG 008 918 12

Inhalts-Verzeichnis
Diesel engine 18.9
Table of Contents
Sommaire
Indice
Technische Daten / Bildzeichenerklärung

Specification data / Key to symbols
Caractéristiques techniques / Légende des symbols
Datos técnicos / Leyenda de símbolos
Prüfen und Einstellen

Checking and adjusting
Contrôle et réglage
Verificación y ajustes
Bauteile instand setzen

Repair of components
Mise en état des composants
Reparación de componentes
Demontage und Montage, Motor komplett

Disassembly and reassembly of complete engine
Démontage et montage moteur complet
Despiece y ensamblado conjunto de motor
Werkzeuge
Tools
Outils
Herramientas
008 918 12 BOMAG 1057 5

18.9 Diesel engine
1058 BOMAG 008 918 12

Diesel engine 18.9
Technische Daten
Specification data
Caractéristiques techniques
Datos técnicos BFM 1012/1013
Hinweis zum Gebrauch des Werkstatthandbuches

In diesem Werkstatthandbuch sind alle technischen Daten, Einstellwerte und
Anziehvorschriften den Stellen zugeordnet, wo sie bei Servicearbeiten, De- und
Montage am Motor benötigt werden.
Notes for the user of this Workshop Manual

In this Workshop Manual all specification data, adjustment values and
tightening specifications are allocated to those parts where they are needed for
service work, disassembly and reassembly on the engine.
Remarque quant à l’utilisazion du Manuel d’atelier

Dans le présent Manuel d’atelier, toutes les caractéristiques techniques, valeurs
de réglage et préconisations de serrage nécessaires se trouvent dans les
chapitres correspondant aux travaux de service après-vente et montage et
démontage du moteur.
Indicación para el uso del manual de taller

En este manual de taller se indican todos los datos técnicos, valores de ajuste y
prescripciones de apriete en los puntos donde son requeridos para la realización
de trabajos de servicio, desmontaje y montaje en el motor.
008 918 12 BOMAG 1059

18.9 Diesel engine
1060 BOMAG 008 918 12

Diesel engine 18.9
008 918 12 BOMAG 1061

18.9 Diesel engine
1062 BOMAG 008 918 12

Technische Daten
Diesel engine 18.9
Specification data
Datos técnicos
Werkstatthandbuch BFM 1012/E, BFM 1013/E
008 918 12 BOMAG 1063

Technische Daten
18.9
Specification data Diesel engine
Datos técnicos
Deutsch English Français Español
Motorgewicht Engine weight Poids du moteur Peso del motor

nach DIN 70020 - A acc. to DIN 70020 - A selon DIN 70020 - A según DIN 70020 -A
1 ca. kg approx. kg approx. kg aprox. kg
Gesamthubvolumen Engine swept volume Cylindrée totale Cilindrada total
cm3 cm3 cm3 cm3
Bohrung Bore Alésage Calibre
mm mm mm mm
Hub Stroke Course Carrera
mm mm mm mm
Drehrichtung Direction of rotation Sens de rotation Sentido de giro
Nenndrehzahl Rated speed Régime nominal Régimen nominal
max. 1/min max. rpm maxi tr/mn máx. r/min
niedrigste Minimum Ralenti extrême Régimen mín.

Leerlaufdrehzahl idle speed en vacío
1/min rpm tr/mn r/min
Arbeitsweise Working cycle Principe de fonction- Sistema de trabajo

nement
1.00.02
1064 BOMAG 008 918 12
Technische Daten
Diesel engine Specification data18.9
Datos técnicos
BF4M 1012 BF4M 1012 E BF6M 1012 BF6M 1012 E

BF4M 1013 BF4M 1013 E BF6M 1013 BF6M 1013 E
inklusive Kühlsystem ohne Kühlsystem inklusive Kühlsystem ohne Kühlsystem

incl. cooling system without cooling system incl. cooling system without cooling system
y compris circuit de réfroid. sans circuit de réfroid. y compris circuit de réfroid. sans circuit de réfroid.
incl. sistema de refrige. sin sistema de refrige. incl. sistema de refrige. sin sistema de refrige.
1
380 BFM 1012 330 BFM 1012 E 490 BFM 1012 435 BFM 1012 E
480 BFM 1013 430 BFM 1013 E 625 BFM 1013 570 BFM 1013 E
3192 BFM 1012/ E 4788 BFM 1012/ E

4764 BFM 1013/ E 7146 BFM 1013/ E
94 BFM 1012/ E
108 BFM 1013/ E
115 BFM 1012/ E

130 BFM 1013/ E
auf Schwungrad gesehen links

When facing flywheel counter-clockwise
Vu sur volant à gauche
Mirándose sobre el volante,a la izquierda
2500 BFM 1012/ E

2300 BFM 1013/ E
650
Viertakt - Diesel
Four-stroke diesel
Diesel 4 temps
Diesel a 4 tiempos
1.00.03
008 918 12 BOMAG 1065
Technische Daten
18.9
Datos técnicos
Verbrennungs- Combustion Principe de Sistema de

verfahren system combustion combustión
1
Verdichtungs- Compression Taux de Relación de

verhältnis ratio compression compresión
Kompressionsdruck Compression pressure Compression Pressión de

compresión
bar bar bars
bar
Zündfolge Fiing order Ordre d'allumage Orden de

encendido
Abmessungen des Dimensions of Dimensions du Dimensiones del

Motors mit engine incl. moteur avec carter motor con
Anschlußgehäuse standard adapter d'adaption standard caja de adaptación
(normal) housing (normal)
größte Länge Max. length Longueur HT Longitud max.
mm mm mm mm
größte Breite Max. width Largeur HT Anchura máx.
mm mm mm mm
größte Höhe Max. height Hauteur HT Altura máx.
mm mm mm mm
1.00.04
1066 BOMAG 008 918 12
Technische Daten
Diesel engine 18.9
Specification data
Datos técnicos
BF4M 1012 BF4M 1012 E BF6M 1012 BF6M 1012 E

BF4M 1013 BF4M 1013 E BF6M 1013 BF6M 1013 E
Direkteinspritzung
Direct injection
Injection directe 1
Inyectión directa
17,5 BFM 1012/ E

17,6 BFM 1013/ E
28 - 33 BFM 1012/ E
30 - 38 BFM 1013/ E
1-3-4-2 1-5-3-6-2-4
874 BFM 1012 775 BFM 1012 E 1120 BFM 1012 1003 BFM 1012 E
945 BFM 1013 862 BFM 1013 E 1239 BFM 1013 1146 BFM 1013 E
678 BFM 1012 540 BFM 1012 E 678 BFM 1012 540 BFM 1012 E
685 BFM 1013 616 BFM 1013 E 760 BFM 1013 622 BFM 1013 E
743 BFM 1012 742 BFM 1012 E 834 BFM 1012 827 BFM 1012 E
818 BFM 1013 844 BFM 1013 E 868 BFM 1013 852 BFM 1013 E
1.00.05
008 918 12 BOMAG 1067
Technische Daten
18.9
Datos técnicos
Steuerzeiten ohne Valve timing without valve Calage distribution sans Cotas de reglaje sin
Stößel- und Ventilspiel clearance adjusted jeu aux culbuteurs juegos de válvulas y
réglé de empujadores
1
Einlaß öffnet Inlet opens Admission ouvre Admisión abre

vor OT before TDC avant PMH a.PMS
Grad degrees degrés grados
Einlaß schließt Inlet closes Admission ferme Admisión cierra

nach UT after BDC après PMB t.PMI
Auslaß öffnet Exhaust opens Echappement ouvre Escape abre

vor UT before BDC avant PMB a.PMI
Auslaß schließt Exhaust closes Echappement ferme Escape cierra

nach OT after TDC après PMH t.PMS
Absteuerventil Pressurestat Clapet régulateur Válvula reguladora

final final
bar bar bars bar
Schmieröldruck in Lube oil pressure at low Pression d'huile au bas Presión de aceite a
niedrigem Leerlauf idling ralent marcha lenta en vacío
Temperatur ca. 120° C Temperature approx. température ca. 120° C Temperatura aprox. 120° C
Öl SAE 15W/40 120° C oil SAE 15W/40 huile SAE 15W/40 aceite SAE 15W/40
Minimum bar min. bar mini bars mín. bar
1.00.06
1068 BOMAG 008 918 12
Technische Daten
Diesel engine 18.9
Specification data
Datos técnicos
BF4M 1012 BF4M 1012 E BF6M 1012 BF6M 1012 E

BF4M 1013 BF4M 1013 E BF6M 1013 BF6M 1013 E
46 BFM 1012/ E
46,5 BFM 1013/ E
56 BFM 1012/ E
55,5 BFM 1013/ E
96 BFM 1012/ E
100,5 BFM 1013/ E
50 BFM 1012/ E
51,5 BFM 1013/ E
6 ± 0,75 10 ± 1
0,8
1.00.07
008 918 12 BOMAG 1069
Technische Daten
18.9
Datos técnicos
1070 BOMAG 008 918 12

Diesel engine 18.9
008 918 12 BOMAG 1071

Ventilspieleinstellschema
18.9
Schematic for valve clearance adjustment Diesel engine
Schéma de réglage des soupapes
Esquema para el ajuste de holgura de válvulas
English Français Español
Crankshaft position 1 Position de l’arbre à cames 1 Posición del cigüeñal 1
Kurbelwellenstellung 11 Kurbelwellenstellung 2 1 1 Turn engine until valves of cylinder

No. 1 overlap.
Virer le moteur jusqu'au chevau- Gírese el motor, hasta que las válvulas
chement des soupapes au cylindre 1. del cilindro N° 1 coincidan en su
posición momentánea.
Motor bis zum Erreichen der Ventilüber- Motor um eine volle Umdrehung (360°)
Not ready for adjustment. non réglable no ajustable
schneidung am Zyl. Nr. 1 durchdrehen. weiterdrehen.
Crankshaft position 2: Position de l’arbre à cames 2 Posición del cigüeñal 2
nicht einstellbar einstellbar Turn engine further by one complete Tourner le moteur d’un tour complet Continuese girando el motor por una
revolution (360°). (360°) rotación completa (360°)
Ready for adjustment. réglable ajustable
1.00.09 1.00.09
1072 BOMAG 008 918 12
Reihenfolge beim Anziehen der Zylinderkopfschrauben
Tightening
Diesel orderengine
for cylinder head bolts 18.9
Ordre à respecter lors du serrage d’approche et définitif des vis de cul.
Sucesión de los trabajos al apretar los tornillos de culata
1 1
Krümmerseite, Manifold side, Krümmerseite, Manifold side,
Coté coudes, Lado codo Coté coudes, Lado codo
14 6 4 12 14 6 4 12
18 10 2 8 16 18 10 2 8 16
4-Zylinder 4-Zylinder
4-cylinder 4-cylinder
4-cylindres 4-cylindres
4 cilindros 4 cilindros
17 9 1 7 15 17 9 1 7 15
13 5 3 11 13 5 3 11
Krümmerseite, Manifold side, Krümmerseite, Manifold side,

Coté coudes, Lado codo Coté coudes, Lado codo
22 14 6 4 12 20 22 14 6 4 12 20
26 18 10 2 8 16 24 26 18 10 2 8 16 24
6-Zylinder 6-Zylinder
6-cylinder 6-cylinder
6-cylindres 6-cylindres
6 cilindros 6 cilindros
25 17 9 1 7 15 23 25 17 9 1 7 15 23
21 13 5 3 11 19 21 13 5 3 11 19
1.00.11 1.00.11
008 918 12 BOMAG 1073
18.9 Diesel engine
Bildzeichenerklärung
Bildzeichenerklärung Bildzeichenerklärung
Zerlegen Personenschäden verhüten Zerlegen Personenschäden verhüten
von Baugruppen Hinweis auf Gefahrenstelle von Baugruppen Hinweis auf Gefahrenstelle
1 1
Zusammenbauen Materialschaden verhüten Zusammenbauen Materialschaden verhüten
zu einer Baugruppe Teilbeschädigung zu einer Baugruppe Teilbeschädigung
Abbauen - Ausbauen Unterbauen - Abstützen - Abbauen - Ausbauen Unterbauen - Abstützen -

Abfangen Abfangen
behindernder Teile behindernder Teile
Einbauen - Anbauen Einölen Einbauen - Anbauen Einölen
Teile, die beim Ab-/ Ausbau hinderten Teile, die beim Ab-/ Ausbau hinderten
Achtung, wichtiger Hinweis Einfetten Achtung, wichtiger Hinweis Einfetten
Prüfen - Einstellen Markieren Prüfen - Einstellen Markieren

vor dem Zerlegen, beachten beim vor dem Zerlegen, beachten beim
z. B. Drehmomente, Maße, Drücke usw. Zusammenbau z. B. Drehmomente, Maße, Drücke usw. Zusammenbau
Spezialwerkzeug Wuchten Spezialwerkzeug Wuchten
Ausgleichen von Unwuchten Ausgleichen von Unwuchten
Einbaurichtung beachten Einfüllen - Auffüllen - Nachfüllen Einbaurichtung beachten Einfüllen - Auffüllen - Nachfüllen
z. B. Öl, Kühlwasser usw. z. B. Öl, Kühlwasser usw.
Kontrollieren - Prüfen Ablassen Kontrollieren - Prüfen Ablassen
Sichtprüfung z. B. Öl, Kühlwasser usw. Sichtprüfung z. B. Öl, Kühlwasser usw.
Bedingt wiederverwendbar Lösen Bedingt wiederverwendbar Lösen
Bei Bedarf auswechseln z. B. Lockern einer Spanneinrichtung Bei Bedarf auswechseln z. B. Lockern einer Spanneinrichtung
Beim Zusammenbau immer Spannen Beim Zusammenbau immer Spannen

erneuern erneuern
z. B. Anziehen einer Spanneinrichtung z. B. Anziehen einer Spanneinrichtung
Entsichern - Sichern Entlüften Entsichern - Sichern Entlüften
z. B. Splint, Sicherungsblech usw. z. B. Splint, Sicherungsblech usw.
Sichern - Kleben Spanabhebende Bearbeitung Sichern - Kleben Spanabhebende Bearbeitung
z. B. Dichtmittel flüssig z. B. Dichtmittel flüssig
1.00.21 1.00.21
1074 BOMAG 008 918 12
Diesel engine 18.9
Key to Symbols
Key to Symbols Key to Symbols

Disassembly Guard against personal injury Disassembly Guard against personal injury
of assembly groups Indication of hazard of assembly groups Indication of hazard

1 1
Reassemble Guard against material damage Reassemble Guard against material damage
to form assembly group Damage to parts to form assembly group Damage to parts
Remove Prop up - Support - Hold Remove Prop up - Support - Hold
obstructing parts obstructing parts
Reinstall - Remount Oil Reinstall - Remount Oil
parts which had obstructed disassembly parts which had obstructed disassembly
Attention! Important notice! Grease Attention! Important notice! Grease
Check - Adjust Mark Check - Adjust Mark

before disassembly, observe marks when before disassembly, observe marks when
e.g. torque, dimensions, pressures, etc. reassembling e.g. torque, dimensions, pressures, etc. reassembling
Special tool Balance Special tool Balance
Eliminate any imbalance Eliminate any imbalance
Note direction of installation Filling - Topping up - Refilling Note direction of installation Filling - Topping up - Refilling
e. g. oil, cooling water, etc. e. g. oil, cooling water, etc.
Visual inspection Drain off Visual inspection Drain off
e. g. oil cooling water, etc. e. g. oil cooling water, etc.
Possibly still serviceable Loosen - Release Possibly still serviceable Loosen - Release
Renew if necessary e. g. loosening a clamping device Renew if necessary e. g. loosening a clamping device
Renew at each reassembly Tighten - Clamp Renew at each reassembly Tighten - Clamp
e. g. tightening a clamping device e. g. tightening a clamping device
Unlock - Lock Vent Unlock - Lock Vent
e. g. splint pin, locking plate, etc. e. g. splint pin, locking plate, etc.
Lock - Adhere Machining process Lock - Adhere Machining process
e.g. with liquid sealant e.g. with liquid sealant
1.00.21 1.00.21
008 918 12 BOMAG 1075
18.9 Diesel engine
Légende des symboles
Légende des symboles Légende des symboles

Déassemblage Prévention aux accidents profession Déassemblage Prévention aux accidents profession
d'un ensemble constructif attirer l’attention sur un risque eventuel d'un ensemble constructif attirer l’attention sur un risque eventuel
d’accident
1 1 d’accident
Assemblage Prévention à la détérioration de Assemblage Prévention à la détérioration de

matériels matériels
des composants d’un ensemble constructif Risque d’endommager des piéces des composants d’un ensemble constructif Risque d’endommager des piéces
Démontage Monter sur tréteaux - freiner par Démontage Monter sur tréteaux - freiner par
sabots - immobiliser par un moyen sabots - immobiliser par un moyen
d’éléments entravant l’accés quelconque d’éléments entravant l’accés quelconque
Remontage - Remise en place Huiler Remontage - Remise en place Huiler
d’éléments qui entravaient l’accés d’éléments qui entravaient l’accés
Remarque importante! Graisser Remarque importante! Graisser
employer lubrificant plastique employer lubrificant plastique
Utilisation impérative Repérage en cours de démontage Utilisation impérative Repérage en cours de démontage
p.ex.: couple-moteur, cotes, pressions etc. perment un remontage correct! p.ex.: couple-moteur, cotes, pressions etc. perment un remontage correct!
Utilisation impérative Equilibrer Utilisation impérative Equilibrer
d’un outil specialise éliminer le balourd d’un outil specialise éliminer le balourd
Respecter l’ordre de montage Premier garnissage - remplissage - Respecter l’ordre de montage Premier garnissage - remplissage -
garnissage d’appoint garnissage d’appoint
p. ex.: Huile eau de refroidissement etc. p. ex.: Huile eau de refroidissement etc.
Vérification - Contrôle Vidanger - soutirer Vérification - Contrôle Vidanger - soutirer
à vue p. ex.: Huile eau de refroidissement etc. à vue p. ex.: Huile eau de refroidissement etc.
Réutilisation sous certaines Desserrer Réutilisation sous certaines Desserrer

conditions conditions
à remplacer, si besoin est p. ex.: desserrage d’un dispositiv à remplacer, si besoin est p. ex.: desserrage d’un dispositiv
A remplacer systématiquement Serrer A remplacer systématiquement Serrer
lors de remontage p. ex.: serrage entre un dispositif lors de remontage p. ex.: serrage entre un dispositif
Arracher la goupille - goupiller Faire la purge d’air Arracher la goupille - goupiller Faire la purge d’air
freiner par tôle-arrétoir freiner par tôle-arrétoir
Freiner - coller Usinage par enlèvement de copeaux Freiner - coller Usinage par enlèvement de copeaux
p. ex.: avec páte hermétique, ou frein liquide p. ex.: avec páte hermétique, ou frein liquide
1.00.21 1.00.21
1076 BOMAG 008 918 12
Diesel engine 18.9
Leyenda de símbolos
Leyenda de símbolos Leyenda de símbolos

Desarmar Evitar accidentes Desarmar Evitar accidentes
grupos de construcción indica puntos peligro grupos de construcción indica puntos peligro
1 1
Rearmar Evitar daños materiales Rearmar Evitar daños materiales
un grupo de construcción avería de piezas un grupo de construcción avería de piezas
Desmontar Calzar - Apoyar Desmontar Calzar - Apoyar
partes que puedan estorbar partes que puedan estorbar
Montar - Incorporar Aceitar Montar - Incorporar Aceitar
partes que puedan estorbar en el desmontaje partes que puedan estorbar en el desmontaje
!Atención! Indicación importante Engrasar !Atención! Indicación importante Engrasar
Verificar - Graduar - Ajustar Marcar Verificar - Graduar - Ajustar Marcar

antes del desmontaje - controlar la antes del desmontaje - controlar la
(p. ej. pares, medidas, presiones) marcación en el remontaje (p. ej. pares, medidas, presiones) marcación en el remontaje
Herramienta especial Equilibar Herramienta especial Equilibar
Eliminar desequilibros o excentricidades Eliminar desequilibros o excentricidades
Observar la dirección de montaje Llenar - Rellenar - Completar Observar la dirección de montaje Llenar - Rellenar - Completar
p. ej. aceite, agua refrigerante, etc. p. ej. aceite, agua refrigerante, etc.
Control - Examen Evacuar - Vaciar Control - Examen Evacuar - Vaciar
verificatión visual p. ej. aceite, agua refrigerante, etc. verificatión visual p. ej. aceite, agua refrigerante, etc.
Re - utilización condicional Soltar Re - utilización condicional Soltar
sustituir en caso necesario p. ej. un sistema de fijación o tensado sustituir en caso necesario p. ej. un sistema de fijación o tensado
Sustituir en cada montaje Tensar - Apretar Sustituir en cada montaje Tensar - Apretar
p. ej. un sistema de fijación o tensado p. ej. un sistema de fijación o tensado
Desafianzar - Afianzar (mecánicamente) Purgar el aire Desafianzar - Afianzar (mecánicamente) Purgar el aire
(p. ej. pasador de aletas, chapa de seguridad, (p. ej. pasador de aletas, chapa de seguridad,
etc). etc).
Afianzar - Pegar Mecanización con arranque de Afianzar - Pegar Mecanización con arranque de
virutas virutas
p. ej. con medio liquido p. ej. con medio liquido
1.00.21 1.00.21
008 918 12 BOMAG 1077
18.9 Diesel engine
Checking and adjusting
Verificación y ajustes BFM 1012/1013
1078 BOMAG 008 918 12

Diesel engine 18.9
008 918 12 BOMAG 1079

Inhalts-Verzeichnis Prüfen und Einstellen
18.9Table of Contents Checking andengine
Diesel adjusting
Sommaire Contrôle et réglage
Indice Verificación y ajustes
Deutsch Werkstatthandbuch BFM 1012/E, BFM 1013/E
2. Prüfen und Einstellen Seite
Ventilspiel _______________________________________ 2.00.01 - 2.00.02

Kompressionsdruck _______________________________________ 2.00.03 - 2.00.04
-
English
2. Checking and adjusting Page
Valve clearance _______________________________________ 2.00.01 - 2.00.02

Compression pressure _______________________________________ 2.00.03 - 2.00.04 2
-
Français
2. Contrôle et réglage Page
Jeu aux soupapes _______________________________________ 2.00.01 - 2.00.02

Taux de compression _______________________________________ 2.00.03 - 2.00.04
-
Español
2. Verificación y ajustes Pagina
Juego de válvulas _______________________________________ 2.00.01 - 2.00.02

Presión de compresión _______________________________________ 2.00.03 - 2.00.04
-
1080 BOMAG 008 918 12

Prüfen und Einstellen Ventilspiel
Checking
Dieseland adjusting
engine 18.9
Valve clearance
Contrôle et réglage Jeu de soupapes
Verificación y ajustes Holgura de válvulas
Special tool required: Outillage usuel: Herramienta especial:
Turning gear 100 320 Dispositif vireur 100 320 Dispositivo de viraje 100 320
Turning gear 100 330 Dispositif vireur 100 330 Dispositivo de viraje 100 330
The standard valve clearance can be Le réglage standard du jeu aux El ajuste del juego estándar de válvulas
adjusted: soupapes est possible: es posible:
with engine cold or warm after cooling Sur moteur froid ou chaud après une Con el motor frío o, según el caso,
down for at least 0.5 h. période de refroidissement d’au moins caliente después de transcurrir por lo
Oil temperature ≤ 80°C. 30 mi-nutes. Température de l’huile ≤ menos media hora para su
80°C. enfriamiento. Temperatura del aceite:
≤ 80°C.
Note: The valve clearance is to be Nota: à chaque changement du joint Nota: Cada vez que se cambia la junta
increased by 0.1 mm at every de culasse augmenter le jeu aux de la culata, debe aumentarse el
cylinder head gasket renewal. culbuteurs de 0,1 mm. juego por 0,1 mm.
The standard valve clearance is Après 50-150 heures de marche Tras 50-150 horas de servicio
2 to be adjusted after completion procéder au réglage standard se ajustará el juego estándar.
of 50-150 hours of operation. des culbuteurs.
Cylinder head cover and crankcase Le cache-culbuteurs et l’évent de La tapa de culatas y la ventilación del
breather have been removed carter ont été déposés. cárter del cigüeñal están
desmontadas.
1. Turn engine until valves of cyl. 1. Virer le moteur jusqu’à ce que les 1. Girar el cigüeñal hasta que se
No. 1 overlap. soupapes soient en bascule, crucen las válvulas en el cilindro 1.
cyl. no. 1.
See specification data for valve Schéma de réglage du jeu aux Para el esquema de ajuste del juego
clearance adjustment schematic. culbuteurs voir caractéristiques de válvulas, véanse los Datos
techniques. Técnicos.
1.1 If the engine is not freely accessible 1.1 Si la poulie à gorge du moteur 1.1 Si el motor no ofrece un libre
at the V-belt pulley, turning gear nést pas bien accessible, utiliser, acceso a la polea acanalada, es
100 320 may be used with the après avoir déposé la pompe posible utilizar el dispositivo de
hydraulic pump removed. hydraulique, le dispositif vireur viraje 100 320, una vez
100 320. desmontada la bomba hidráulica.
Note: Valves overlapping means: Nota: le chevauchement des Nota: Cruce de válvulas significa:
Exhaust valve about to close. soupapes signifie: La válvula de escape aún no
Inlet valve about to open. soupaped’échappement n’est está cerrada y la de admisión
Neither pushrod can be turned pas encore fermée et soupape comienza a abrirse. En este
in this position. d’admission commence à momento, no es posible girar
s’ouvrir. Les deux tiges de las dos varillas de empuje.
culbuteurs ne peuvent plus
tourner.
2.00.01
008 918 12 BOMAG 1081
Ventilspiel Prüfen und Einstellen
18.9Valve clearance Checking andengine
Diesel adjusting
Jeu de soupapes Contrôle et réglage
Holgura de válvulas Verificación y ajustes
Spezialwerkzeug:
Durchdrehvorrichtung ____________ 100 320

Durchdrehvorrichtung ____________ 100 330
Die Standard-Ventilspieleinstellung ist möglich:
Am kalten- oder am warmen Motor nach einer

Abkühlzeit von mindestens 0,5 h.
Öltemperatur ≤ 80° C
Hinweis: Bei jedem Zylinderkopf-Dichtungs-

wechsel ist das Ventilspiel um 0,1 mm
zu erhöhen.
9
Nach 50-150 Bh ist das Standard-
Ventilspiel einzustellen. 7 Neues Bild 38-2-3
2
mit Durvchdreh-
Zylinderkopfhaube und vorrichtung
Kurbelgehäuseentlüftung ist abgebaut.
1. Motor durchdrehen bis zum Erreichen der

Ventilüberschneidung, Zyl. Nr. 1
Ventilspieleinstellschema siehe Techn. Daten 9

7 Änderung von 38-2-1
1.1 Ist der Motor an der Keilriemenscheibe nicht 100 320
frei zugänglich, kann bei abgebauter Hydrau-
likpumpe die Durchdrehvorrichtung 100 320
verwendet werden.
Hinweis: Ventilüberschneidung bedeutet:

Auslaßventil ist noch nicht geschlos-
sen, Einlaßventil beginnt zu öffnen.
9
Dabei sind beide Stoßstangen nicht
drehbar.
5
2.00.01
1082 BOMAG 008 918 12
Prüfen und Einstellen Ventilspiel
Checking
Dieseland adjusting
engine 18.9
Valve clearance
Contrôle et réglage Jeu de soupapes
Verificación y ajustes Holgura de válvulas
Werkstatthandbuch BFM 1012/E, BFM 1013/E Deutsch
2. Ventilspieleinstellung am entsprechenden
Neues Bild mit Schraubendreher 6 Zylinder mit Fühlerlehrenblatt einstellen.
Änderung von 28-2-4
5 Hinweis: Ventilspiel Einlaß: _______ 0,3 mm
Ventilspiel Außlaß: _______ 0,5 mm
3. Kontermutter mit einem Drehmoment von

20 ± 2 Nm festdrehen. Einstellung nochmals
mit Fühlerlehrenblatt überprüfen.
4. Dichtung aufsetzen.
2
2 0
5. Zylinderkopfhaube und Abdeckblech montie-

4 ren. Schrauben mit einem Drehmoment von
9 ± 1 Nm festdrehen.
6. Kurbelgehäuseentlüftung anbauen.
4 Schrauben mit einem Drehmoment von
2.00.02
008 918 12 BOMAG 1083
Ventilspiel Prüfen und Einstellen
18.9
Valve clearance Checking andengine
Diesel adjusting
Jeu de soupapes Contrôle et réglage
Holgura de válvulas Verificación y ajustes
2. Adjust valve clearance on respec- 2. Régler le jeu aux soupapes au 2. Ajustar el juego de válvulas en el
tive cylinder with feeler gauge. cylindre correspondant avec une cilindro correspondiente con la
jauge d’épaisseur. galga de espesores.
Note: Inlet valve clearance: 0.3 mm Nota: Jeu soupape ADM: 0,3 mm Nota: Juego de válvulas
Exhaust valve Jeu soupape ECH: 0,5 mm - admisión: 0,3 mm
clearancee: 0.5 mm - escape: 0,5 mm
3. Tighten locknut with a torque of 3. Serrer le contre-écrou au couple de 3. Apretar la contratuerca con un par
20 ± 2 Nm. Recheck the adjust- 20 ± 2 Nm. Effectuer un nouveau de 20 ± 2 Nm. Comprobar
ment with feeler gauge. contrôle du serrage avec une jauge nuevamente el ajuste efectuado,
d’épaisseur. con la galga de espesores.
4. Position gasket in place. 4. Mettre en place le joint. 4. Poner la junta en su sitio.
5. Fit cylinder head cover and cover 5. Monter le cache-culbuteurs et la 5. Montar la tapa de culata y la chapa
plate. Tighten bolts with a torque of tôle de recouvrement. Serrer de recubrimiento. Apretar los
9 ± 1 Nm. les vis au couple de 9 ± 1 Nm. tornillos con un par de 9 ± 1 Nm.
6. Fit crankcase breather. Tighten 6. Monter l’évent de carter. Serrer les 6. Montar el sistema de ventilación
bolts with a torque of 9 ± 1 Nm. vis au couple de 9 ± 1 Nm. del cárter. Apretar los tornillos con
un par de 9 ± 1 Nm.
2.00.02
1084 BOMAG 008 918 12
Prüfen und Einstellen Kompressionsdruck
Checking
Dieseland adjusting
engine 18.9
Compression pressure
Contrôle et réglage Taux de compression
Verificación y ajustes Presión de compresión
Commercial tools required: Outillage usuel: Herramientas corrientes en el

comercio:
Compression tester 8005 Compressiomètre 8005 Compresímetro 8005

Torx tool kit 8189 Jeu d’outils Torx 8189 Juego de herramientas Torx 8189
Special tool required: Outil spécial: Herramienta especial:
Connector 100 110 Pièce de raccordement 100 110 Pieza de empalme 100 110
Injectors have been removed, valve Les injecteurs ont été déposés et le Los inyectores están desmontados y
clearance has been checked. jeu aux soupapes contrôlé. el juego de válvulas controlado.
1. Insert connector with new special 1. Mettre en place la pièce de 1. Introducir la pieza de empalme con
2 seal. raccordement avec un joint spécial una junta especial nueva.
neuf.
2. Fit clamping pad. Tighten bolt. 2. Placer la griffe de serrage et serrer 2. Colocar la garra de sujeción.
le boulon. Apretar el tornillo.
3. If necessary, screw on adapter for 3. Si nécessaire mettre en place 3. De ser necesario, enroscar el
connector. l’adaptateur de la pièce de adaptador de la pieza de empalme.
raccordement.
2.00.03
008 918 12 BOMAG 1085
Kompressionsdruck Prüfen und Einstellen
18.9Compression pressure Checking andengine
Diesel adjusting
Taux de compression Contrôle et réglage
Presión de compresión Verificación y ajustes
Handelsübliche Werkzeuge:
Kompressionsdruckprüfer ____________ 8005

Torx-Werkzeugsatz _________________ 8189
Spezialwerkzeug:
Anschlußstück __________________ 100 110
Einspritzventile sind ausgebaut, Ventilspiel ist

kontrolliert
4
1. Anschlußstück mit Dichtung der Einspritzdüse
einsetzen 7 2
0
2. Spannpratze aufsetzen. Schraube fest-

drehen. 4
3. Falls notwendig Adapter für Anschlußstück

aufschrauben.
4
2.00.03
1086 BOMAG 008 918 12
Prüfen und Einstellen Kompressionsdruck
Checking
Dieseland adjusting
engine Compression pressure18.9
Contrôle et réglage Taux de compression
Verificación y ajustes Presión de compresión
4. Kompressionsdruckprüfer anschließen.
4 Motor mit Starter durchdrehen.
Kompressionsdruck: BFM 1012 28-33 bar
6 BFM 1013 30-38 bar
Der gemessene Kompressionsdruck ist

abhängig von der Anlaßdrehzahl während des
Meßvorganges und der Höhenlage des Motor-
aufstellortes.
9 Grenzwerte sind daher nicht genau festlegbar.
Empfohlen wird die Kompressionsdruck-
2 5 messung nur als Vergleichsmessung aller

Zylinder eines Motors untereinander anzusehen.
Sind mehr als 15% Abweichung ermittelt
worden, sollte durch die Demontage der
betroffenen Zylindereinheit die Ursache
ermittelt werden.
Hinweis: Einspritzventile mit neuen Spezial-

dichtungen einsetzen. Spannpratzen
aufsetzen und Schrauben lose ein-
schrauben.
Neue Einspritzleitungen anbauen.
Überwurfmuttern fingerfest auf-
schrauben.
Die Dichtkonen müssen exakt aufein-
andersitzen.
Ein Nachbiegen ist nicht zulässig.
Die Einspritzleitungen dürfen nicht
2x verwendet werden.
Schrauben der Spannpratzen mit
einem Drehmoment von 16 + 5 Nm
festdrehen. Überwurfmuttern der
Einspritzleitungen an den Einspritz-
pumpen und Einspritzventilen mit
einem Drehmoment von ca. 5 Nm
vorspannen. Danach die Überwurf-
muttern mit einem Drehmoment von
25 + 3,5 Nm festdrehen.
Leckölleitungen sind grundsätzlich
zu erneuern.
Zylinderkopfhaube mit einem Dreh-
moment von 9 ± 1 Nm festdrehen.
2.00.04
008 918 12 BOMAG 1087
Kompressionsdruck Prüfen und Einstellen
18.9
Compression pressure Checking andengine
Diesel adjusting
Taux de compression Contrôle et réglage
Presión de compresión Verificación y ajustes
4. Connect compression tester. Turn 4. Brancher le compressiomètre. 4. Conectar el compresímetro. Girar el

engine with starter. motor con ayuda del arrancador.
Compression pressure: Pression de compression: Presión de compresión:
BFM 1012 28-33 bar BFM 1012 28-33 bars BFM 1012 28-33 bar
BFM 1013 30-38 bar BFM 1013 30-38 bars BFM 1013 30-38 bar
The measured compression pressure Le taux de compression mesuré El valor de compresión medido
is dependent on the starting speed dépend de la vitesse de démarrage depende de la velocidad de arranque
during the measuring process and also pendant le relevé des mesures, et du durante la medición y de la altitud del
on the altitude of the engine site. niveau du lieu d’implantation du lugar de instalación del motor.
Therefore it is difficult to specify moteur. Por tanto, no es posible fijar valores
precise limit values. It is recommended Des valeurs limites précises ne límite exactos. La medición de
to use the compression pressure peuvent donc pas être fixées. Il est compresión se aconseja solamente
measurement only for comparison of conseillé de considérer la mesure du como una medida de comparación 2
compression pressures of all cylinders taux de compression uniquement entre todos los cilindros de un mismo
in one engine. If a difference in comme mesure comparative pour tous motor, Si se verifican diferencias
pressure in excess of 15% is deter- les cylindres d’un moteur. En cas superiores al 15%, es conveniente
mined, the cylinder unit concerned d’écart supérieur à 15%, la cause buscar la causa, desmontando la
should be dismantled to establish the pourra être déterminée en démontant unidad de cilindro afectada.
cause. l’unité cylindre concernée.
Note: Fit injectors with new special Nota: Utiliser des injecteurs avec de Nota: Montar los inyectores provistos
seals. Position clamping pads nouveaux joints spéciaux. Placer de juntas especiales nuevas.
and start bolts. les griffes de serrage et serrer Colocar las patas de sujeción y
Fit new injection lines. Screw on les vis sans serrer. enroscar los tornillos, dejándo-
cap nuts fingertight. Monter des conduites d’injection los sueltos.
The sealing cones must match neuves. Montar tuberías de inyección
precisely. Serrer les écrous-raccords mo- nuevas. Enroscar las tuercas de
Rebending is not permissible. dérément à la main. empalme con la mano.
The injection lines may not be Les cônes d´étanchéité doivent Los conos de obturación deben
used twice. parfaitement correspondre. quedar asentados uno exacta-
Tighten bolts of clamping pads Un recintrage n’est pas auto- mente sobre el otro.
with a torque of 16 + 5 Nm. risé. Ne jamais utiliser deux Es inadmisible corregir el cur-
Preload cap nuts of injection fois les conduites d’injection. vado. La tuberías de inyección
lines on injection pumps and Bloquer les vis des griffes de no deben ser empleadas dos
injectors with a torque of serrage au couple de 16 + 5 Nm. veces.
approx. 5 Nm. Thereafter tighten Préserrer les écrous-raccords Apretar los tornillos de las patas de
cap nuts with a torque of 25 + des conduites d’injection et injec- sujeción con un par de 16 + 5 Nm.
3.5 Nm. teurs au couple d’environ 5 Nm. Apretar las tuercas de empalme
Leakage fuel lines must always Ensuite bloquer les écrous-rac- de las tuberías de inyección en
be renewed. cords au couple de 25 + 3,5 Nm. las bombas de inyección e in-
Tighten cylinder head cover with Toujours renouveller les con- yectores inicialmente con un par
a torque of 9 ± 1 Nm. duites de retour des fuites. de aprox. 5 Nm y, luego, con un
Bloquer le cache-culasse au par de 25 + 3,5 Nm.
couple de 9 ± 1 Nm. Las tuberías de combustible
sobrante han de sustituirse
siempre por otras nuevas.
Apretar la tapa de culatas con un
par de 9 ± 1 Nm.
2.00.04
1088 BOMAG 008 918 12
Checking
Dieseland adjusting
engine 18.9
Verificación y ajustes
008 918 12 BOMAG 1089

18.9 Diesel engine
Reparación de componentes BFM 1012/1013
1090 BOMAG 008 918 12

Diesel engine 18.9
06 07
19 11
08
38
27
10 39
83
01 38
15
17
05
83 05
33
01
72
01
008 918 12 BOMAG 1091

18.9 Diesel engine
1092 BOMAG 008 918 12

Diesel engine 18.9
008 918 12 BOMAG 1093

Hydraulikpumpe mit Befestigungsflansch Bauteile instand setzen
18.9Hydraulic pump with fastening flange Repair of components
Diesel engine
Pompe hydraulique avec bride de fixation Mise en état des composants
Bomba hidráulica con brida de fijación Reparación de componentes
1094 BOMAG 008 918 12

Bauteile instand setzen Hydraulikpumpe mit Besfestigungsflansch
Diesel engine Hydraulic pump with fastening flange18.9
Mise en état des composants Pompe hydraulique avec bride de fixation
Reparación de componentes Bomba hidráulica con brida de fijación
5. Neue Dichtung und Befestigungsflansch

2 auf Hydraulikpumpe auflegen.
6. Zahnrad montieren.
2 Hinweis: Auf Vorhandensein der Paßfeder
5 achten.
7. Mutter mit einem Drehmoment von 80 Nm

2 festdrehen.
3
6
3.83.118
008 918 12 BOMAG 1095
Hydraulikpumpe mit Befestigungsflansch Bauteile instand setzen
18.9
Hydraulic pump with fastening flange Repair of components
Diesel engine
Pompe hydraulique avec bride de fixation Mise en état des composants
Bomba hidráulica con brida de fijación Reparación de componentes
5. Place new gasket together with 5. Placer un joint neuf et la bride de 5. Colocar una junta nueva y la brida
fastening flange on hydraulic fixation sur la pompe hydraulique. de fijación sobre la bomba
pump. hidráulica.
6. Mount gear. 6. Monter le pignon. 6. Montar la rueda dentada.
Note: Make sure that key is inserted. Nota: veiller à la présence de la Nota: Las lengüetas de ajuste deben
clavette. estar en su sitio.
7. Tighten nut with a torque of 7. Serrer l’écrou au couple de 7. Apretar la tuerca con un par de
80 Nm. 80 Nm. 80 Nm.
3.83.118
1096 BOMAG 008 918 12
Diesel engine 18.9
Reparación de componentes
008 918 12 BOMAG 1097

18.9 Diesel engine
Despiece y ensamblado conjunto de moteur
BFM 1012/1013
1098 BOMAG 008 918 12

Diesel engine 18.9
008 918 12 BOMAG 1099

Inhalts-Verzeichnis Demontage und Montage, Motor komplett
18.9Table of Contents Disassembly and reassembly ofDiesel
complete engine
engine
Sommaire Démontage et montage moteur complet
Indice Despiece y ensamblado conjunto de motor
Deutsch
4. Demontage und Montage, Motor komplett Seite
Motor zerlegen ___________________________________ 4.00.01 - 4.00.16

Motor zusammenbauen:
Ölspritzdüsen ___________________________________ 4.00.17
Stößel/Nockenwelle ___________________________________ 4.00.18
Kurbelwellenlagerung ___________________________________ 4.00.18 - 4.00.21
Massenausgleichswellen BFM 1012 ___________________________________ 4.00.22 - 4.00.27
Antriebsrad/Regler ___________________________________ 4.00.27
Regelstange ___________________________________ 4.00.27 - 4.00.28
Räderkastendeckel ___________________________________ 4.00.28 - 4.00.29
Vorderer Deckel ___________________________________ 4.00.29 - 4.00.30
Kolben mit Pleuel ___________________________________ 4.00.30 - 4.00.31
Einspritzpumpe einbauen ___________________________________ 4.00.32 - 4.00.40
Schwungrad/Keilriemenscheibe ___________________________________ 4.00.41
Zylinderkopf ___________________________________ 4.00.42 - 4.00.47
Abstellmagnet ___________________________________ 4.00.47
Einspritzventil/Einspritzleitungen ___________________________________ 4.00.48 - 4.00.49
Luftansaugrohr/Abgassammelrohr ___________________________________ 4.00.49 - 4.00.50
Zylinderkopfhaube ___________________________________ 4.00.50 - 4.00.51
Schmierölkühler ___________________________________ 4.00.51 - 4.00.52
Kühlmittelpumpe ___________________________________ 4.00.52 - 4.00.54
Kraftstoffpumpe ___________________________________ 4.00.54
Ölsaugrohr/Ölwanne ___________________________________ 4.00.54 - 4.00.56
Regler ___________________________________ 4.00.57 - 4.00.58
Kabelbaum ___________________________________ 4.00.59
Anschlußgehäuse ___________________________________ 4.00.60
Starter ___________________________________ 4.00.61
Entlüftungsleitung ___________________________________ 4.00.61 - 4.00.62
Öldruckschalter ___________________________________ 4.00.62 - 4.00.63
Kurbelgehäuseentlüftung ___________________________________ 4.00.63
Abgasturbolader ___________________________________ 4.00.64 - 4.00.65
Ölrücklaufrohr/Druckölleitung ___________________________________ 4.00.65 - 4.00.68
Ansaugkrümmer ___________________________________ 4.00.68 - 4.00.70
Ladeluftkrümmer BFM 1013 ___________________________________ 4.00.70 - 4.00.71
Ölmeßstab ___________________________________ 4.00.71
Generator ___________________________________ 4.00.72
Keilriemen spannen ___________________________________ 4.00.72 - 4.00.74
Motoraufhängung/Aufstellfüße ___________________________________ 4.00.74
Bauteile für integrierte Kühlung ab - und anbauen BFM 1012:

Bauteile abbauen ___________________________________ 4.00.75 - 4.00.82
Bauteile anbauen ___________________________________ 4.00.83 - 4.00.94
Austausch der Wellendichtringe am kompletten Motor: 4

Räderkastendeckel Schwungradseite ___________________________________ 4.00.95 - 4.00.96
Vorderer Deckel ___________________________________ 4.00.96 - 4.00.97
Nebenabtriebe ab- und anbauen:

Luftpresser ab- und anbauen ___________________________________ 4.00.99 - 4.00.100
Lenkhilfspumpe ab- und anbauen ___________________________________ 4.00.101 - 4.00.102
Hydraulikpumpe ab- und anbauen ___________________________________ 4.00.103
Hydraulikpumpe mit Konsole ab- und anbauen ___________________________ 4.00.105 - 4.00.107
Austausch der Einspritzpumpen im Servicefall __________________________ 4.00.109 - 4.00.112
1100 BOMAG 008 918 12

Demontage und Montage, Motor komplett Inhalts-Verzeichnis
Diesel engine Table of Contents 18.9
Démontage et montage moteur complet Sommaire
Despiece y ensamblado conjunto de motor Indice
English
4. Disassembly and reassembly of complete engine Page
Dismantling engine ___________________________________ 4.00.01 - 4.00.16

Reassembling engine:
Oil spray nozzles ___________________________________ 4.00.17
Tappets/camshaft ___________________________________ 4.00.18
Crankshaft bearings ___________________________________ 4.00.18 - 4.00.21
Mass balancing shafts BFM 1012 ___________________________________ 4.00.22 - 4.00.27
Drive gear/governor ___________________________________ 4.00.27
Control rod ___________________________________ 4.00.27 - 4.00.28
Timing chest cover ___________________________________ 4.00.28 - 4.00.29
Front cover ___________________________________ 4.00.29 - 4.00.30
Piston with connecting rod ___________________________________ 4.00.30 - 4.00.31
Installing injection pump ___________________________________ 4.00.32 - 4.00.40
Flywheel/V-belt pulley ___________________________________ 4.00.41
Cylinder head ___________________________________ 4.00.42 - 4.00.47
Shutdown solenoid ___________________________________ 4.00.47
Injector/injection lines ___________________________________ 4.00.48 - 4.00.49
Air intake/exhaust manifold ___________________________________ 4.00.49 - 4.00.50
Cylinder head cover ___________________________________ 4.00.50 - 4.00.51
Lube oil cooler ___________________________________ 4.00.51 - 4.00.52
Coolant pump ___________________________________ 4.00.52 - 4.00.54
Fuel pump ___________________________________ 4.00.54
Oil suction pipe/oil pan ___________________________________ 4.00.54 - 4.00.56
Governor ___________________________________ 4.00.57 - 4.00.58
Cable harness ___________________________________ 4.00.59
Adapter housing ___________________________________ 4.00.60
Starter ___________________________________ 4.00.61
Breather pipe ___________________________________ 4.00.61 - 4.00.62
Öil pressure switch ___________________________________ 4.00.62 - 4.00.63
Crankcase breather ___________________________________ 4.00.63
Exhaust turbocharger ___________________________________ 4.00.64 - 4.00.65
Oil return pipe/pressure oil pipe ___________________________________ 4.00.65 - 4.00.68
Intake elbow ___________________________________ 4.00.68 - 4.00.70
Charge air elbow BFM 1013 ___________________________________ 4.00.70 - 4.00.71
Oil dipstick ___________________________________ 4.00.71
Alternator ___________________________________ 4.00.72
Tensioning V-belt ___________________________________ 4.00.72 - 4.00.74
Engine mounting/mounting feet ___________________________________ 4.00.74
Removing and refitting components for integrated cooling system, BFM 1012:
Removing components ___________________________________ 4.00.75 - 4.00.82
Refitting components ___________________________________ 4.00.83 - 4.00.94
4 Replacing shaft seals on complete engine

Timing chest cover flywheel end ___________________________________ 4.00.95 - 4.00.96
Front cover ___________________________________ 4.00.96 - 4.00.97
Removing and refitting PTOs:

Removing and refitting air compressor _________________________________ 4.00.99 - 4.00.100
Removing and refitting power steering pump ____________________________ 4.00.101 - 4.00.102
Removing and refitting hydraulic pump _________________________________ 4.00.103
Removing and refitting hydraulic pump together with bracket _______________ 4.00.105 - 4.00.107
Replacing injection pumps in case of service ___________________________ 4.00.109 - 4.00.112
008 918 12 BOMAG 1101

Inhalts-Verzeichnis Demontage und Montage, Motor komplett
18.9Table of Contents Disassembly and reassembly ofDiesel
complete engine
engine
Sommaire Démontage et montage moteur complet
Indice Despiece y ensamblado conjunto de motor
Français
4. Démontage et montage moteur complet Page
Démontage du moteur ___________________________________ 4.00.01 - 4.00.16

Montage du moteur:
Injecteurs ___________________________________ 4.00.17
Poussoir/arbre à cames ___________________________________ 4.00.18
Logement du vilebrequin ___________________________________ 4.00.18 - 4.00.21
Arbre à masses d’équilibrage BFM 1012 _______________________________ 4.00.22 - 4.00.27
Pignon d’entraînement / régulateur ___________________________________ 4.00.27
Crémaillère ___________________________________ 4.00.27 - 4.00.28
Couvercle de carter de distribution ___________________________________ 4.00.28 - 4.00.29
Couvercle avant ___________________________________ 4.00.29 - 4.00.30
Piston-bielle ___________________________________ 4.00.30 - 4.00.31
Montage de la pompe d’injection ___________________________________ 4.00.32 - 4.00.40
Volant-moteur / poulie à gorge ___________________________________ 4.00.41
Culasse ___________________________________ 4.00.42 - 4.00.47
l’électroaimant d’arrêt ___________________________________ 4.00.47
Injecteur / tuyauteries d’injection ___________________________________ 4.00.48 - 4.00.49
Collecteur d’admission / collecteur d’échappement ________________________ 4.00.49 - 4.00.50
Cache-culbuteurs ___________________________________ 4.00.50 - 4.00.51
Radiateur à huile ___________________________________ 4.00.51 - 4.00.52
Pompe à eau ___________________________________ 4.00.52 - 4.00.54
Pompe à combustible ___________________________________ 4.00.54
Tube d’aspiration d’huile / carter d’huile ________________________________ 4.00.54 - 4.00.56
Régulateur ___________________________________ 4.00.57 - 4.00.58
Faisceau de câbles ___________________________________ 4.00.59
Carter d’adaptation ___________________________________ 4.00.60
Démarreur ___________________________________ 4.00.61
Conduite de dégazage ___________________________________ 4.00.61 - 4.00.62
Manocontact de pression d'huile ___________________________________ 4.00.62 - 4.00.63
Event de carter ___________________________________ 4.00.63
Turbocompresseur ___________________________________ 4.00.64 - 4.00.65
Tube de retour d’huile / tube de refoulement d’huile _______________________ 4.00.65 - 4.00.68
Tubulure d’aspiration ___________________________________ 4.00.68 - 4.00.70
Tubulure d’air de sualimentation BFM 1013 _____________________________ 4.00.70 - 4.00.71
Jauge d’huile ___________________________________ 4.00.71
Alternateur ___________________________________ 4.00.72
Tension de la courroie ___________________________________ 4.00.72 - 4.00.74
Suspension moteur/pieds ___________________________________ 4.00.74
Démontage et montage des composants du refroidissement intégré BFM 1012:

Démontage des composants ___________________________________ 4.00.75 - 4.00.82
Montage des composants ___________________________________ 4.00.83 - 4.00.94
Changement des joints d’arbre sur moteur complet : 4

Couvercle de carter de distribution côté volant moteur ____________________ 4.00.95 - 4.00.96
Couvercle AV ___________________________________ 4.00.96 - 4.00.97
Montage et démontage des équipements auxiliaires :

Montage et démontage compresseur __________________________________ 4.00.99 - 4.00.100
Montage et démontage pompe auxiliaire de direction ______________________ 4.00.101 - 4.00.102
Montage et démontage pompe hydraulique ______________________________ 4.00.103
Montage et démontage pompe hydraulique avec console ___________________ 4.00.105 - 4.00.107
Changement de pompes d’injection en SAV ____________________________ 4.00.109 - 4.00.112
1102 BOMAG 008 918 12

Demontage und Montage, Motor komplett Inhalts-Verzeichnis
Diesel engine Table of Contents 18.9
Démontage et montage moteur complet Sommaire
Despiece y ensamblado conjunto de motor Indice
Español
4. Despiece y ensamblado, conjunto de motor Pàgina
Desarmado del motor ___________________________________ 4.00.01 - 4.00.16

Rearmado del motor:
Toberas de refrigeración de pistón ___________________________________ 4.0017
Empujadores / árbol de levas ___________________________________ 4.00.18
Apoyos del cigüeñal ___________________________________ 4.00.18 - 4.00.21
Arboles compensadores de masa BFM 1012 _____________________________ 4.00.22 - 4.00.27
Rueda de accionamiento / regulador ___________________________________ 4.00.27
Barra cremallera ___________________________________ 4.00.27 - 4.00.28
Tapa del cárter de la distribución ___________________________________ 4.00.28 - 4.00.29
Tapa delantera ___________________________________ 4.00.29 - 4.00.30
Pistón con biela ___________________________________ 4.00.30 - 4.00.31
Montaje de bombas de inyección ___________________________________ 4.00.32 - 4.00.40
Volante / polea acanalada ___________________________________ 4.00.41
Culata ___________________________________ 4.00.42 - 4.00.47
solenoide de parada ___________________________________ 4.00.47
Inyector / tuberías de inyección ___________________________________ 4.00.48 - 4.00.49
Colector de admisión / colector de escape ______________________________ 4.00.49 - 4.00.50
Tapa de culata ___________________________________ 4.00.50 - 4.00.51
Refrigerador de aceite lubricante ___________________________________ 4.00.51 - 4.00.52
Bomba de líquido refrigerante ___________________________________ 4.00.52 - 4.00.54
Bomba de combustible ___________________________________ 4.00.54
Tubo de aspiración de aceite / cárter de aceite ___________________________ 4.00.54 - 4.00.56
Regulador ___________________________________ 4.00.57 - 4.00.58
Mazo de cables ___________________________________ 4.00.59
Cárter de adaptación ___________________________________ 4.00.60
Arrancador ___________________________________ 4.00.61
Tubería de ventilación ___________________________________ 4.00.61 - 4.00.62
Interrupteur de presiónde aceite ___________________________________ 4.00.62 - 4.00.63
Ventilación del cárter del cigüeñal ___________________________________ 4.00.63
Turbocompresor ___________________________________ 4.00.64 - 4.00.65
Tubo de retorno de aceite / tubería de aceite a presión _____________________ 4.00.65 - 4.00.68
Codo de aspiración ___________________________________ 4.00.68 - 4.00.70
Codo de aire de sobrealimentación BFM 1013 ____________________________ 4.00.70 - 4.00.71
Varilla de medición de nivel de aceite __________________________________ 4.00.71
Alternador ___________________________________ 4.00.72
Tensado de correas trapezoidales ___________________________________ 4.00.72 - 4.00.74
Suspensión del motor / patas de colocación _____________________________ 4.00.74
Desmontaje y remontaje de componentes de la refrigeración integrada - BFM 1012:

Desmontaje de componentes ___________________________________ 4.00.75 - 4.00.82
Remontaje de componentes ___________________________________ 4.00.83 - 4.00.94
4 Cambio de los retenes en el motor completo:

Tapa del cárter de la distribución, lado volante ___________________________ 4.00.95 - 4.00.96
Tapa delantera ___________________________________ 4.00.96 - 4.00.97
Desmontaje y remontaje de accionamientos secundarios:

Desmontaje y remontaje del compresor de aire ___________________________ 4.00.99 - 4.00.100
Desmontaje y remontaje de la servobomba de dirección ____________________ 4.00.101 - 4.00.102
Desmontaje y remontaje de la bomba hidráulica __________________________ 4.00.103
Desmontaje y remontaje de la bomba hidráulica y consola __________________ 4.00.105 - 4.00.107
Cambio de las bombas de inyección en el caso de servicio ________________ 4.00.109 - 4.00.112
008 918 12 BOMAG 1103

18.9 Disassembly and reassembly ofDiesel
complete engine
engine
1104 BOMAG 008 918 12

Diesel engine 18.9
Dismantling engine Démontage du moteur Desarmado del motor
Commercial tools required: Outillage usuel : Herramientas comerciales:
Torx tool kit 8189 Jeu dóutils Torx 8189 Juego de herramientas Torx 8189
Torx socket wrench E 14 8113 Clé à douilles Torx E 14 8113 Llave de vaso Torx E 14 8113
Spring clamp pliers 9090 Pince de serrage pour ressorts 9090 Alicates para pinzas elásticas 9090
Spring clamp pliers 9088 Pince de serrage pour ressorts 9088 Alicates para pinzas elásticas 9088
Auxiliary tool for glow Outil pour accouplement de câble de Herramienta auxiliar para
plug cable coupler 9115 bougie de préchauffage 9115 acoplamientos de cables de bujías de
Cobra clamp pliers 8011 Pince de serrage Cobra 8011 incandescencia 9115
Alicates Cobra 8011
Special tools required: Outillage spécial: Herramientas especiales:
Engine assembly stand Chevalet de montage de moteur Caballete de montaje para motor
BFM 1012 6067 BFM 1012 6067 BFM 1012 6067
BFM 1013 6066 BFM 1013 6066 BFM 1013 6066
Angled clamping plate BFM 1012 Support dáblocage BFM 1012 pour Soportes de fijación BFM 1012
for external cooling system 6067/118 refroidissement externe 6067/118 para refrigeración externa 6067/118
Angled clamping plate BFM 1012 Support dáblocage BFM 1012 pour Soportes de fijación BFM 1012
for integrated cooling system 6067/119 refroidissement intégré 6067/119 para refrigeración integrada 6067/119
Angled clamping plate Equerre dáblocage Angulares de fijación
BFM 1013 6066/158 BFM 1013 6066/158 BFM 1013 6066/158
Extractor for injector 110 030 Extracteur dínjecteur 110 030 Extractor para inyector 110 030
Special device for Dispositif spécial Dispositivo especial para
extractor 150 800 déxtracteur 150 800 dispositivo de extracción 150 800
filter cartridges 170 050 Cartouches de filtre 170 050 Cartuchos filtrantes 170 050
The repair procedure outlined in this Les travaux de réparation indiqués ne Los trabajos de reparación descritos
chapter refers to the standard tiennent pas compte de la diversité des en este capítulo se refieren al volumen
specification, i.e. components for volumes de livraison des clients, c’est- de suministro estándar, o sea, no se
customizing the engine are not shown. à-dire que les pièces annexes muestran los componentes adosados
différentes du modèle standard ne sont que difieren del mismo.
pas présentées dans le présent
Manuel.
1. Mount angled clamping plate. 1. Monter le dispositif d’ablocage. 1. Montar los soportes de fijación.
Illustration shows BFM 1012. Illustration BFM 1012 Representado BFM 1012.
BFM 1012 BFM 1012 BFM 1012

4
2. Clamp engine in swivelling 2. Aligner le moteur sur le chevalet de 2. Alinear el motor en el caballete de
assembly stand and align. Tighten montage pivotable. montaje orientable. Apretar los
bolts. tornillos.
Drain and catch remaining Vidanger les restes d’huile ou Evacuar el aceite o los restos del
oil and coolant and dispose of de réfrigérant et les récupérer mismo y el refrigerante, recogerlos
in accordance with anti- selon la réglementation y eliminarlos en forma
pollution regulations. antipollution. reglamentaria.
4.00.01
008 918 12 BOMAG 1105
complete engine
engine
Motor zerlegen
Torx-Werkzeugsatz ________________ 8189

Torx-Steckschlüssel E14 ____________ 8113
Federklemmenzange _______________ 9090
Federklemmenzange _______________ 9088
Hilfswerkzeug für Glühkerzen-
Kabelkupplung ____________________ 9115
Cobraklemmenzange _______________ 8011
Spezialwerkzeuge:
Motor-Montagebock BFM 1012 _______ 6067

BFM 1013 _______ 6066
Aufspannhalter BFM 1012
für externe Kühlung _____________ 6067/118
Aufspannhalter BFM 1012
für integrierte Kühlung ___________ 6067/119
Aufspannwinkel BFM 1013 _______ 6066/158
Auszieher für Einspritzventil _______ 110 030
Spezialvorrichtung für
Ausziehvorrichtung ______________ 150 800
Filterpatronen __________________ 170 050
Bei dem gezeigten Reparaturablauf sind unter-

schiedliche Kundenumfänge nicht berücksich-
s
tigt, d.h., von der Standard-Ausführung
abweichende Anbauteile werden nicht gezeigt. 7
1. Aufspannhalter anbauen.
Darstellung BFM 1012.
BFM 1012
2. Motor im schwenkbaren Montageblock

s 4
ausrichten. Schrauben festdrehen.
Öl bzw. Restöl und Kühlmittel ablassen,
7
auffangen und vorschriftsmäßig entsor-
gen. ü
4.00.01
1106 BOMAG 008 918 12
Diesel engine 18.9
BFM 1013
s 2.1 Motor in doppelseitigen schwenkbaren
7 Montagebock aufnehmen und ausrichten.

Schrauben festdrehen.
ü Öl bzw. Restöl und Kühlmittel ablassen,

auffangen und vorschriftsmäßig entsor-
gen.
Bei Teildemontage und Drehen des Motors

3 um 180° ist das Druckregelventil zu
entfernen.
Restöl und Kühlmittel auffangen und
vorschriftsmäßig entsorgen.
3. Generator abbauen.
3
4. Kraftstoffpumpe lösen. Keilriemen abneh-
4 3 men.
4.00.02
008 918 12 BOMAG 1107
complete engine
engine
BFM 1013 BFM 1013 BFM 1013
2.1 Clamp engine in double-sided 2.1 Monter puis aligner le moteur sur 2.1 Alojar el motor en el caballete de
swivelling assembly stand and le double chevalet de montage. montaje bilateral orientable y
align.Tighten bolts. Bloquer les vis. alinearlo. Apretar los tornillos.
Drain and catch remaining oil Vidanger les restes d’huile ou de Evacuar el aceite o los restos del
and coolant and dispose of in réfrigérant et les récupérer selon mismo y el refrigerante,
accordance with anti-pollution la réglementation antipollution. recogerlos y eliminarlos en forma
regulations. reglamentaria.
In case of parts assembly and En cas de montage partiel et s’il En caso de despiece parcial y
turning of engine by 180° the faut virer le moteur de 180° retirer volteo del motor por 180°, hay que
pressure control valve is to be la vanne de régulation de retirar la válvula reguladora de
removed. pression. presión.
Catch any remaining oil Récupérer l’huile Recoger y eliminar en forma
and coolant and dispose of in restante et le liquide de reglamentaria los restos de aceite
accordance with anti-pollution refroidissement. y el líquido refrigerante.
regulations.
3. Remove alternator. 3. Déposer l’alternateur. 3. Desmontar el alternador.
4. Loosen fuel pump. Remove V-belt. 4. Desserrer la pompe à combustible. 4. Aflojar la bomba de combustible.
Retirer la courroie trapézoïdale. Quitar la correa trapezoidal.
4
4.00.02
1108 BOMAG 008 918 12
Diesel engine 18.9
5. Remove bracket. 5. Déposer la console. 5. Desmontar la consola.
6. Remove coolant pipe. 6. Déposer le tube de liquide de 6. Desmontar el tubo de líquido

refroidissement. refrigerante.
7. Remove breather pipe using special 7. Retirer le tube de purge avec une 7. Desmontar el tubo de ventilación,
spring clamp pliers. pince à crampon spéciale. utilizando las tenazas especiales
para pinzas elásticas.
8. Remove intake hose. 8. Déposer le flexible d’aspiration. 8. Desmontar la manguera de

aspiración.
4
Note: Cover up opening of exhaust Nota: boucher orifice du Nota: Cerrar la boca del
turbo charger. turbocompresseur. turbocompresor.
4.00.03
008 918 12 BOMAG 1109
complete engine
engine
5. Konsole abbauen.
3
6. Kühlmittelrohr abbauen.
3
7. Entlüftungsleitung mit spez. Federklem-

menzange abbauen. 3
8. Ansaugschlauch abbauen.
Hinweis: Öffnung von Abgasturbolader

3 4
verschließen.
5
4.00.03
1110 BOMAG 008 918 12
Diesel engine 18.9
9. Öldruckleitung und Ölrücklaufleitung

3 BFM 1012 abbauen.
10. Abgasturbolader BFM 1012 abbauen.

3 Schadhaften Abgasturbolader austau-
schen.
10.1 Öldruckleitung, Ölrücklaufleitung,

3 Ladeluftkrümmer und Abgasturbolader
BFM 1013 abbauen.
0 Schadhaften Abgasturbolader austau-
schen.
11. Steckstück herausziehen.
4 3
4.00.04
008 918 12 BOMAG 1111
complete engine
engine
9. Remove BFM 1012 oil pressure 9. Déposer la conduite de pression 9. En BFM 1012, desmontar la tubería
pipe and oil return pipe. d’huile du BFM 1012. de presión de aceite y la tubería de
retorno de aceite.
10. Remove BFM 1012 exhaust 10. Déposer le turbocompresseur du 10. En BFM 1012, desmontar el
turbocharger. Replace damaged BFM 1012. Remplacer le turbocompresor.
turbocharger. turbocompresseur endommagé. Si está defectuoso, sustituirlo por
otro nuevo.
10.1 Remove BFM 1013 oil pressure _ 10.1 Déposer la conduite de 10.1 En BFM 1013, desmontar la
pipe, oil return pipe, charge air refoulement d’huile, la conduite tubería de presión de aceite, la
elbow and exhaust turbocharger. de retour d’huile, la tubulure d’air tubería de retorno de aceite, el
Replace damaged turbocharger. de suralimentation et le turbo- codo de aire de sobrealimentación
compresseur d’échappement du y el turbocompresor.
BFM 1013. Remplacer tout Si el turbocompresor está
turbocompresseur endommagé. defectuoso, sustituirlo por otro
nuevo.
11. Pull out plug-in element 11. Retirer l’élément enfichable. 11. Retirar la pieza de enchufe.
4.00.04
1112 BOMAG 008 918 12
Diesel engine 18.9
12. Remove pressure control valve 12. Déposer la vanne de régulation de 12. Desmontar la válvula reguladora de
together with hose. pression et le flexible. presión en conjunto con la
manguera.
13. Remove air pipe to manifold 13. Déposer la conduite dáir du 13. Desmontar la tubería de aire que va
presssure compensator (LDA) and correcteur de débit (LDA) et la al tope de plena carga dependiente
breather pipe. conduite de purge. de la presión de sobrealimentación
(LDA), y la tubería de ventilación.
14. Remove starter. 14. Déposer le démarreur. 14. Desmontar el arrancador.
15. Remove lifting lugs. 15. Déposer les oeillets de 15. Desmontar las argollas de
manutention. transporte.
4
4.00.05
008 918 12 BOMAG 1113
complete engine
engine
12. Druckregelventil mit Schlauch abbauen.

3
13. Luftleitung zum LDA und Entlüftungs-

leitung abbauen. 3
14. Starter abbauen.

3
15. Transportösen abbauen.

3 4
4.00.05
1114 BOMAG 008 918 12
Diesel engine 18.9
16. Drehzahlregler abbauen.

3
17. Kraftstoff-und Ölfilter mit Spezialvor-

3 richtung abbauen.
Restöl und Kraftstoff vorschriftsmäßig
7 entsorgen.
18. Öleinfüllstutzen falls vorhanden

3 abbauen.
19. Kraftstoffleitungen abbauen.
4 3 Hinweis: Cobraklemmenzange benutzen.

5
4.00.06
008 918 12 BOMAG 1115
complete engine
engine
16. Remove governor. 16. Déposer le régulateur de vitesse. 16. Desmontar el regulador de
velocidad.
17. Remove fuel and oil filter using 17. Déposer le filtre à combustible et le 17. Sirviéndose del dispositivo
special device for filter cartridges. filtre à huile avec une pince especial, desmontar el filtro de
Dispose of remaining oil and fuel spéciale. combustible y el filtro de aceite.
in accordance with anti-pollution Eliminer les restes d’huile ou de Eliminar el aceite restante y
regulations. réfrigérant selon la combustible en forma
réglementation antipollution. reglamentaria.
18. Remove oil filler neck if any. 18. Déposer la tubulure de remplissage 18. Desmontar la tubuladura de llenado
si le moteur en est doté d’un. de aceite, si existe.
19. Remove fuel lines. 19. Déposer les tuyauteries de 19. Desmontar las tuberías de
combustible. combustible.
4
Note: Use Cobra clamp pliers. Nota: utiliser la pince de serrage Nota: Utilizar los alicates Cobra.
Cobra.
4.00.06
1116 BOMAG 008 918 12
Diesel engine 18.9
20. Remove fuel pump with clamping 20. Déposer la pompe à combustible 20. Desmontar la bomba de
plate. avec la griffe de serrage. combustible en conjunto con la
corredera.
21. Remove lube oil cooler. Remove 21. Déposer le radiateur à huile. Si le 21. Desmontar el refrigerador de aceite
also retainer for cable connector if moteur en a un, déposer le collier lubricante.
any. de liaison des câbles. Desmontar también el soporte para
el conectador de cables, si lo hay.
22. Remove coolant pump together 22. Déposer la pompe à réfrigérant 22. Desmontar la bomba de líquido
with thermostat housing. avec le boîtier du thermostat. refrigerante en conjunto con la caja
del termostato.
23. Disconnect glow plug cable coupler 23. Si le moteur en a un, désolidariser 23. Si existe, separar el acoplamiento
if any. For such purpose introduce le coupleur de câbles des bougies de cables de las bujías de
4 auxiliary tool carefully into rubber de préchauffage. Pour ce faire incandescencia. Para ello,
grommet without turning it in any introduire avec précaution l’outil introducir cuidadosamente, sin
way and disconnect cable. auxiliaire dans la douille en movimiento giratorio, la
caoutchouc sans tourner puis herramienta auxiliar en el manguito
séparer le câble. de goma y separar los cables.
4.00.07
008 918 12 BOMAG 1117
complete engine
engine
20. Kraftstoffpumpe mit Spannlasche ab-

bauen.
3
21. Schmierölkühler abbauen.

Falls vorhanden, Halter für Kabelverbinder
mit abbauen.
3
22. Kühlmittelpumpe mit Thermostatgehäuse

abbauen. 3
23. Falls vorhanden, Glühkerzen-Kabel-

kupplung trennen. Hierzu Hilfswerkzeug
vorsichtig ohne Drehbewegung in die
3 4
Gummitülle einführen und Kabel trennen.
r
4.00.07
1118 BOMAG 008 918 12
Diesel engine 18.9
24. Zylinderkopfhaube abbauen.

3 Falls vorhanden, Verkabelung mitabbauen.
25. Leckölleitung mit Überströmventil

3 abbauen.
26. Abstellmagnet ausbauen.

3
27. Einspritzleitungen mit Dichtgummis ab-

4 3 bauen.
5 Hinweis: Öffnungen verschließen.
4.00.08
008 918 12 BOMAG 1119
complete engine
engine
24. Remove cylinder head cover. 24. Déposer la culasse.Si le moteur est 24. Desmontar la tapa de culata.
Remove cabling as well if any. équipé d’un câblage, le déposer. Retirar también los cables, si
existen.
25. Remove backleakage pipe together 25. Déposer le tuyau de retour des 25. Desmontar la tubería de
with overflow valve. fuites avec la soupape de décharge. combustible sobrante en conjunto
con la válvula de rebose.
26. Remove shutdown solenoid. 26. Déposer l’électroaimant d’arrêt. 26. Desmontar el solenoide de parada.
26. Remove injection lines complete 27. Déposer les tuyauteries d’injection 27. Desmontar las tuberías deinyección
with sealing rubber. avec les caoutchoucs d’étanchéité. con las piezas obturantes de goma.
4
Note: Cover up openings. Nota: obturer les orifices. Nota: Cerrar las aberturas.
4.00.08
1120 BOMAG 008 918 12
Diesel engine 18.9
28. Remove injectors. 28. Déposer les injecteurs. 28. Desmontar los inyectores.
Note: If sticking, use disassembly tool Nota: en cas de blocage utiliser Nota: En caso de asiento fijo, utilizar
No. 150 800 with extractor dispositif No. 150 800 avec el dispositivo de extracción
No. 110 030. extracteur No. 110 030. No. 150 800 con el extractor
No.110 030.
29. Remove glow plugs if any. 29. Si le moteur est équipé de bougies 29. Desmontar las bujías de
de préchauffage, les déposer. incandescencia, si las hay.
30. Remove rocker arm brackets. 30. Déposer les supports de 30. Desmontar los soportes de
culbuteurs. balancines.
31. Take out pushrods. 31. Retirer les tiges de culbuteurs. 31. Sacar las varillas de empuje.
4.00.09
008 918 12 BOMAG 1121
complete engine
engine
28. Einspritzventile ausbauen.
Hinweis: Bei Festsitz Ausziehvorrichtung

3
Nr.150 800 mit Auszieher Nr.110 030
verwenden. 5
29. Falls vorhanden, Glühkerzen ausbauen.

3
30. Kipphebelböcke abbauen.

3
31. Stoßstangen herausnehmen.

3 4
4.00.09
1122 BOMAG 008 918 12
Diesel engine 18.9
32. Ladeluftleitung abbauen.

3
33. Abgassammelrohr abbauen.

3
34. Zylinderkopf abbauen. Dichtung entfernen.

3 Hinweis: Torx E14 / E18 verwenden.
5
35. Einspritzpumpen ausbauen.
4 3 Hinweis: Auf Ausgleichsscheiben achten.

5
4.00.10
008 918 12 BOMAG 1123
complete engine
engine
32. Remove charge air pipe. 32. Déposer la conduite d’air de 32. Desmontar el conducto de aire de
suralimentation. sobrealimentación.
33. Remove exhaust manifold. 33. Déposer le collecteur 33. Desmontar el colector de escape.
d’échappement.
34. Remove cylinder head. Take off 34. Déposer la culasse. Oter le joint. 34. Desmontar la culata. Retirar la
gasket. junta.
Note: Use E14/E18 Torx tool. Nota: utiliser l’outil Torx E14/E18. Nota: Utilizar la herramienta
Torx E14 / E18.
35. Remove injection pumps. 35. Déposer les pompes d’injection. 35. Desmontar las bombas de i
nyección.
4
Note: Watch out for shims. Nota: veiller aux rondelles de Nota: Prestar atención a las arandelas
compensation. de reglaje.
4.00.10
1124 BOMAG 008 918 12
Diesel engine 18.9
36. Take out roller tappets together 36. Retirer le poussoir à galets avec les 36. Retirar los empujadores de rodillo
with shims. rondelles de compensation. con las arandelas de reglaje.
37. Pull out oil dipstick. 37. Retirer la jauge d’huile. 37. Sacar la varilla de medición del
nivel de aceite.
38. Remove cover plate. 38. Déposer la tôle de recouvrement. 38. Desmontar la chapa de
Turn engine by 180°. Virer le moteur de 180°. recubrimiento.
Girar el motor por 180°.
Note: Catch any escaping oil and Nota: récupérer l’huile qui s’écoule en Nota: Recoger el aceite que sale,
dispose of in accordance with respectant la réglementation eliminándolo en forma
anti-pollution regulations. antipolution. reglamentaria.
39. Turn engine by 90°. Remove 39. Virer le moteur de 90°. Déposer le 39. Girar el motor por 90°. Desmontar
adapter housing. carter d’adaptation. el cárter de adaptación.
4
Note: Use Torx tools E20 and E14. Nota: utiliser Torx E20 et E14. Nota: Utilizar las herramientas
Torx E20 y E14.
4.00.11
008 918 12 BOMAG 1125
complete engine
engine
36. Rollenstößel mit Ausgleichscheiben

herausnehmen.
3
37. Ölmeßstab herausziehen.

3
38. Abdeckblech abbauen.

Motor um 180° drehen. 3
Hinweis: Auslaufendes Öl auffangen und vor-
schriftsmäßig entsorgen.
5
39. Motor um 90° drehen. Anschlußgehäuse

abbauen. 3 4
Hinweis: Torx E20 und E14 verwenden.
5
4.00.11
1126 BOMAG 008 918 12
Diesel engine 18.9
40. Motor um 90° drehen. Ölwanne abbauen.

3 Hinweis: Einbaulage des Ölsumpfs markieren.
41. Ölansaugrohr abbauen.

3
42. Kolben mit Pleuel ausbauen.

3
43. Keilriemenscheibe abbauen.
4 3 Hinweis: Torx E20 verwenden.

5
4.00.12
008 918 12 BOMAG 1127
complete engine
engine
40. Turn engine by 90°. Remove oil 40. Virer le moteur de 90°. Déposer le 40. Girar el motor por 90°. Desmontar
pan. carter d’huile. el cárter de aceite.
Note: Mark installation position of oil Nota: repérer le sens de montage du Nota: Marcar la posición de montaje
sump. carter d’huile. del sumidero de aceite.
41. Remove oil suction pipe. 41. Déposer le tube d’aspiration 41. Desmontar el tubo de aspiración de
d’huile. aceite.
42. Remove piston complete with 42. Déposer l’ensemble piston-bielle. 42. Desmontar el pistón con la biela.
connecting rod.
43. Remove V-belt pulley. 43. Déposer la poulie à gorge. 43. Desmontar la polea acanalada.
Note: Use Torx tool E20. Nota: utiliser Torx E20. Nota: Utilizar la herramienta 4
Torx E20.
4.00.12
1128 BOMAG 008 918 12
Diesel engine 18.9
44. Remove front cover. 44. Déposer le couvercle avant. 44. Desmontar la tapa delantera.
45. Remove flywheel. 45. Déposer le volant moteur. 45. Desmontar el volante.
46. Remove timing chest cover. 46. Déposer le couvercle du carter de 46. Desmontar la tapa del cárter de la
distribution. distribución.
47. Remove main bearing caps. 47. Déposer le chapeau de palier de 47. Desmontar las tapas de los
vilebrequin. cojinetes de apoyo.
4
4.00.13
008 918 12 BOMAG 1129
complete engine
engine
44. Vorderen Deckel abbauen.

3
45. Schwungrad abbauen.

3
46. Räderkastendeckel abbauen.

3
47. Hauptlagerdeckel ausbauen.

3 4
4.00.13
1130 BOMAG 008 918 12
Diesel engine 18.9
48. Kurbelwelle herausnehmen.

3
49. Anlaufringe und Lagerschalenhälften

3 herausnehmen.
50. Falls vorhanden, Antriebsräder für Aus-

3 gleichswellen ausbauen.
51. Falls vorhanden, Anlaufscheiben für
4 3 Ausgleichswellen abbauen.
4.00.14
008 918 12 BOMAG 1131
complete engine
engine
48. Lift out crankshaft. 48. Extraire le vilebrequin. 48. Retirar el cigüeñal.
49. Take out thrust rings and bearing 49. Retirer les flasques de butée et les 49. Sacar las arandelas de tope y los
shell halves. demi-coussinets. semicojinetes.
50. Remove drive gears for balancing 50. Retirer les pignons d’entraînement 50. Desmontar las ruedas de
shafts if any. des arbres à masse d’équilibrage si accionamiento de los árboles
le moteur en est équipé. compensadores de masa, si
existen.
51. Remove thrust washers for 51. Selon l’équipement du moteur 51. Desmontar las arandelas de tope de
balancing shafts if any. déposer les flasques de butée des los árboles compensadores, si
arbres à masse d’équilibrage. existen. 4
4.00.14
1132 BOMAG 008 918 12
Diesel engine 18.9
52. Take out balancing shafts if any. 52. Selon l’équipement du moteur 52. Extraer los árboles
retirer les arbres à masses compensadores, si existen.
d’équilibrage.
53. Remove drive gear for governor. 53. Dépose le pignon d’entraînement 53. Desmontar la rueda de
du régulateur de vitesse. accionamiento del regulador de
velocidad.
54. Take out camshaft. 54. Retirer l’arbre à cames. 54. Extraer el árbol de levas.
55. Remove guide sleeve. Take out 55. Déposer la douille de guidage et 55. Desmontar el manguito de guía.
control rod. retirer la crémaillère. Sacar la barra cremallera.
4
4.00.15
008 918 12 BOMAG 1133
complete engine
engine
52. Falls vorhanden, Ausgleichswellen heraus-

nehmen.
3
53. Antriebsrad für Drehzahlregler ausbauen.

3
54. Nockenwelle herausnehmen.

3
55. Führungsbuchse abbauen. Regelstange

herausnehmen. 3 4
4.00.15
1134 BOMAG 008 918 12
Diesel engine 18.9
56. Stößel herausnehmen.

3
57. Ölspritzdüsen herausdrücken.

3 Ölkanäle auf freien Durchlaß prüfen.
4.00.16
008 918 12 BOMAG 1135
complete engine
engine
56. Take out tappets. 56. Retirer les poussoirs. 56. Retirar los empujadores.
57. Press out oil spray nozzles. 57. Extraire les gicleurs d’huile. Vérifier 57. Sacar a presión las toberas de
Check oil ducts for free passage. le libre passage des canalisations refrigeración de pistón. Comprobar
d’huile. si los conductos de aceite están
despejados.
4.00.16
1136 BOMAG 008 918 12
Diesel engine 18.9
Reassembling engine Démontage et montage moteur Rearmado del motor

complet
Commercial tools required: Outillage usuel : Herramientas usuales en el comercio:
Torx tool set _______________ 8189 Jeu dóutils Torx ____________ 8189 Juego de herramientas Torx ___ 8189
Torx socket wrench E14 ______ 8113 Clé à douille Torx E14 ________ 8113 Llave de vaso Torx E14 _______ 8113
Hose clamp pliers ___________ 9090 Pince pour tuyaux souples ____ 9090 Alicates para pinzas
Hose clamp pliers __________ 9088 Pince pour tuyaux souples ____ 9088 elásticas ___________________ 9090
V-belt tension gauge _________ 8115 Appareil de mesure de tension de Alicates para pinzas
Serrated wrench for trapézoïdale ________________ 8115 elásticas ___________________ 9088
turning I.P. ________________ 8117 Clé à douille (polygomale) Verificador de tensión para
Cobra clamp pliers ___________ 8011 pour pompe dínjection _______ 8117 correas trapezoidal __________ 8115
Pince de serrage Cobra _______ 8011 Llave (estrella) de giro
para bomba de inyección ______ 8117
Alicates Cobra ______________ 8011
Special tools required: Outillage spécial : Herramientas especiales:
Dial gauge M2T __________ 100 400 Comparateur M2T ________ 100 400 Comparador M2T ________ 100 400
Measuring device ________ 100 750 Appareil de mesure _______ 100 750 Dispositivo de medición ___ 100 750
Measuring device Dispositif de montage Dispositivo de medición
BFM 1012 ______________ 100 780 BFM 1012 ______________ 100 780 BFM 1012 ______________ 101 780
100 860 100 860 100 860
BFM 1013 ______________ 100 840 BFM 1013 ______________ 100 840 BFM 1013 ______________ 101 840
Measuring device/locking device Appareil de mesure / appareil à bloquer Dispositivo de medición/bloqueo
for control rod ___________ 100 800 pour crémaillère _________ 100 800 para cremallera __________ 100 800
Adjusting pin for mass Pige de réglage pour arbres Perno de ajuste para ejes
balancing shafts BFM 1012 _ 100 810 équilibreurs BFM 1012 ____ 100 810 compensadores de
Graduated disc __________ 101 020 Echelle graduée __________ 101 020 masas, BFM 1012 ________ 100 810
Adapter for graduated disc _ 101 030 Adaptateur pour échelle Disco graduado __________ 101 020
Pointer _________________ 101 300 graduée _________________ 101 030 Adaptador para disco
Piston ring compressor Index graduée ___________ 101 300 graduado _______________ 101 030
BFM 1012 ______________ 130 630 Sangle à comprimer les segments de Indicador _______________ 101 300
BFM 1013 ______________ 130 640 piston Compresor de aros de pistón
BFM 1012 ______________ 130 630 BFM 1012 ______________ 130 630
BFM 1013 ______________ 130 640 BFM 1013 ______________ 130 640
Oil spray nozzles Gicleurs de refroidissement Toberas de refrigeración de pistón
4 1. Press in oil spray nozzles as far as 1. Insérer les gicleurs jusqu’en 1. Introducir a presión hasta el tope
they will go. position de butée. las toberas de refrigeración de
pistón.
4.00.17
008 918 12 BOMAG 1137
complete engine
engine
Motor zusammenbauen
Torx-Werkzeugsatz ________________ 8189

Schlauchklemmenzange ____________ 9090
Schlauchklemmenzange ____________ 9088
Keilriemenspannungsmeßgerät _______ 8115
Verdrehschlüssel (Vielzahn)
für E.-Pumpe _____________________ 8117
Cobraklemmenzange _______________ 8011
Spezialwerkzeuge:
Meßuhr M2T ___________________ 100 400

Meßgerät ______________________ 100 750
Meßvorrichtung
BFM 1012 _____________________ 100 780
100 860
BFM 1013 _____________________ 100 840
Meßgerät / Blockiergerät
für Regelstange _________________ 100 800
Einstellbolzen für
MAG Wellen BFM 1012 ___________ 100 810
Gradscheibe ____________________ 101 020
Adapter für Gradscheibe __________ 101 030
Zeiger ________________________ 101 300
Kolbenringspannband
BFM 1012 _____________________ 130 630
BFM 1013 _____________________ 130 640
Ölspritzdüsen
1. Ölspritzdüsen bis Anlage eindrücken.

4 4
4.00.17
1138 BOMAG 008 918 12
Diesel engine 18.9
Stößel/Nockenwelle
4 2. Stößel einsetzen.
3. Nockenwelle einsetzen.
4
z
Kurbelwellenlagerung
6 4. Innenmeßgerät einstellen.
BFM 1012 auf 36 mm

BFM 1013 auf 38 mm
5. Paßlagerbreite der Kurbelwelle messen und
4 6 notieren. Maß “a”

Zapfenbreite normal:
BFM 1012 _____________ 36 + 0,04 mm
BFM 1013 ____________ 38 + 0,06 mm
Grenzmaß für Übermaßstufe:
BFM 1012 ____________ 36,4 + 0,04mm
BFM 1013 ____________ 38,4 + 0,06mm
4.00.18
008 918 12 BOMAG 1139
complete engine
engine
Tappets/camshaft Poussoir/arbre à cames Empujadores / árbol de levas
2. Insert tappets. 2. Mettre en place le poussoir. 2. Introducir los empujadores
3. Introduce camshaft. 3. Mettre en place l’arbre à cames. 3. Introducir el árbol de levas.
Crankshaft bearings Paliers de vilebrequin Apoyos del cigüeñal
4. Set internal gauge: 4. Régler l’appareil de mesure selon le 4. Ajustar el micrómetro de interiores.
moteur:
BFM 1012 to 36 mm BFM 1012 à 36 mm. BFM 1012 a 36 mm

BFM 1013 to 38 mm BFM 1013 à 38 mm. BFM 1013 a 38 mm
5. Gauge width of crankshaft thrust 5. Mesurer la largeur des portées du 5. Medir el ancho de muñón del
bearing journal and record. palier de butée du vilebrequin et la cojinete de empuje del cigüeñal y
Dimension „a“ noter. Cote „a“. registrarlo. Medida „a“. 4
Standard journal width: Largeur normale du tourillon : Ancho de muñón normal:
BFM 1012 _______ 36 + 0.04 mm BFM 1012 _______ 36 + 0,04 mm BFM 1012 _______ 36 + 0,04 mm
BFM 1013 _______ 38 + 0.06 mm BFM 1013 _______ 38 + 0,06 mm BFM 1013 _______ 38 + 0,06 mm
Limit for oversize: Cote limite de réparation: Límite de sobremedida:

BFM 1012 _____ 36.4 + 0.04 mm BFM 1012 _____ 36,4 + 0,04 mm BFM 1012 _____ 36,4 + 0,04 mm
BFM 1012 _____ 38.4 + 0.06 mm BFM 1013 _____ 38,4 + 0,06 mm BFM 1013 _____ 38,4 + 0,06 mm
4.00.18
1140 BOMAG 008 918 12
Diesel engine 18.9
6. Insert bearing shells. 6. Mettre en place les coussinets. 6. Colocar los semicojinetes.
7. Insert bearing shells in main 7. Placer les coussinets dans le 7. Colocar los semicojinetes en las
bearing caps. chapeau de palier de vilebrequin. tapas de los cojinetes de apoyo.
8. Place half thrust rings on thrust 8. Adapter les demi-flasques de butée 8. Colocar las medias arandelas de
bearing cap, gauge and record au chapeau du palier de butée, en tope en la tapa de cojinete de
width. Dimension „b“ mesurer la largeur et la noter. Cote empuje, medir el ancho y
„b“. registrarlo. Medida „b“.
9. Determine end float. 9. Calculer le jeu axial. 9. Determinar el juego axial.
4 Example BFM 1012: Exemple BFM 1012: EjemploBFM 1012:

Dimension a = 36.04 mm cote a = 36,04 mm medida a = 36,04 mm
Dimension b = 35.90 mm cote b = 35,90 mm medida b = 35,90 mm
Dimension a - dimension b cote a - cote b = jeu axial medida a - medida b = juego axial
= end float = 0.14 mm = 0,14 mm = 0,14 mm
Permissible end float for: Jeu axial admis pour Juego axial admisible para:
BFM 1012 = 0.10 - 0.30 mm BFM 1012 = 0,10 - 0,30 mm BFM 1012 = 0,10 - 0,30 mm
BFM 1013 = 0.10 - 0.30 mm BFM 1013 = 0,10 - 0,30 mm BFM 1013 = 0,10 - 0,30 mm
4.00.19
008 918 12 BOMAG 1141
complete engine
engine
6. Lagerschalen einsetzen.
4
8
7. Lagerschalen in Hauptlagerdeckel einset-

zen. 4
8
8. Anlaufringhälften an Paßlagerdeckel
anlegen, Breite messen und notieren.
Maß “b”
4
8
6
9. Axialspiel ermitteln.
Beispiel BFM 1012: 4

Maß a = 36,04 mm
Maß b = 35,90 mm
Maß a - Maß b = Axialspiel
= 0,14 mm
Zulässiges Axialspiel für:

BFM 1012 = 0,10 - 0,30 mm
BFM 1013 = 0,10 - 0,30 mm
4.00.19
1142 BOMAG 008 918 12
Diesel engine 18.9
10. Kurbelwelle vor Einbau markieren.

i
11. Nockenwelle markieren und positionieren.

i
12. Kurbelwelle einsetzen.

4 Beim Einbau müssen die Markierungen in
Überdeckung stehen.
i
z
13. Anlaufringhälften ohne Führungsnase
4 4 einsetzen.
5 Hinweis: Anlaufringe müssen mit der Lauf-

schichtseite zum Wangenspiegel der
8 Kurbelwelle weisen.
4.00.20
008 918 12 BOMAG 1143
complete engine
engine
10. Mark crankshaft prior to 10. Avant de le monter repérer le 10. Marcar el cigüeñal antes de
installation. vilebrequin. proceder a su montaje.
11. Mark camshaft and place in 11. Repérer l’arbre à cames et le 11. Marcar el árbol de levas y
position. positionner. posicionarlo.
12. Introduce crankshaft. 12. Mettre en place le vilebrequin. 12. Introducir el cigüeñal.
Marks must be in line. Au montage il faut que les repères Las marcas deben corresponderse
coïncident. en el montaje.
13. Insert half thrust rings without lug. 13. Mettre en place les demi-flasques 13. Poner las medias arandelas de tope
de butée sans taquet de guidage. sin talón de guía en su sitio.
4
Note: Running layer of thrust rings Nota: les flasques de butée avec leur Nota: La capa de roce de las
must face towards crankweb. face de roulement doivent être arandelas debe indicar hacia la
orientées vers la joue du cara lateral de las manivelas del
vilebrequin. cigüeñal.
4.00.20
1144 BOMAG 008 918 12
Diesel engine 18.9
14. Stick half thrust rings with lug to 14. Avec un peu de graisse coller sur le 14. Pegar, mediante grasa, las medias
thrust bearing cap using some chapeau de palier de butée les arandelas de tope con talón de guía
grease. demi-flasques de butée avec le contra la tapa del cojinete de
taquet de guidage. empuje.
Note: Running layer of thrust rings Nota: le chapeau de palier no. 1 estdu Nota: La capa de roce de las
must face towards crankweb. côté du volant moteur. Les arandelas debe indicar hacia la
bossages doivent être orientés cara lateral de las manivelas del
vers le volant moteur. cigüeñal.
15. Mount thrust bearing cap. 15. Mettre en place le chapeau de 15. Montar la tapa del cojinete de
palier de butée. empuje.
Note: Bearing cap No. 1 at flywheel Nota: le chapeau de palier no. 1 est Nota: La tapa de cojinete No. 1 se
end. Bosses must face towards orienté côté volant moteur. encuentra en el lado de volante.
flywheel on BFM 1012. Sur le BFM 1012 les bossages En BFM 1012, los salientes
doivent être orientés vers le deben indicar hacia el volante.
volant moteur.
16. Mount main bearing caps, paying 16. Monter le chapeau de palier de 16. Montar las tapas de los cojinetes
attention to the numbering. vilebrequin selon la numérotation. de apoyo, teniendo en cuenta la
numeración.
17. Tighten main bearing bolts 17. Serrer les vis de palier principal 17. Apretar los tornillos de los
according to specification. selon les préconisations de cojinetes de apoyo según
4 serrage. prescripción.
Initial tightening torque Valeur de préserrage Apriete inicial
BFM 1012: ___________ 30 Nm BFM 1012: ___________ 30 Nm BFM 1012: ___________ 30 Nm
BFM 1013: ___________ 50 Nm BFM 1013: ___________ 50 Nm BFM 1013: ___________ 50 Nm
1st tightening angle ______ 60° 1er serrage à l’angle _____ 60° 1er reapriete ___________ 60°
2nd tightening angle _____ 60° 2ème serrage à l’angle ___ 60° 2o reapriete ____________ 60°
Note: Bolts may be used 3x if Nota: après preuve à l’appui les vis Nota: Si es comprobable, se pueden
evidence can be provided peuvent être utilisées 3 fois. utilizar los tornillos tres veces.
concerning their use.
4.00.21
008 918 12 BOMAG 1145
complete engine
engine
14. Anlaufringhälften mit Führungsnase am

Paßlagerdeckel mit etwas Fett ankleben.
4
Hinweis: Anlaufringe müssen mit der Lauf-
schichtseite zum Wangenspiegel der u
Kurbelwelle weisen.
5
8
15. Paßlagerdeckel aufbauen
Hinweis: Lagerdeckel Nr. 1 ist schwungrad-

4
seitig.
Bei BFM 1012 müssen die Butzen 8
5
zum Schwungrad weisen.
16. Hauptlagerdeckel entsprechend der

Numerierung montieren. 4
9
17. Hauptlagerschrauben nach Anziehvor-

schrift festdrehen. 4 4
Vorspannwert
BFM 1012 ___________________ 30 Nm 6
BFM 1013 ___________________ 50 Nm
1. Nachspannwert ________________ 60° 5
2. Nachspannwert ________________ 60°
Hinweis: Schrauben können bei Nachweisbar-

keit 3x verwendet werden.
4.00.21
1146 BOMAG 008 918 12
Diesel engine 18.9
Massenausgleichswellen BFM 1012

3 (falls vorhanden)
Motor um 180° drehen.
18. Verschlußschrauben herausdrehen.
19. Massenausgleichswelle einbauen.

4 Hinweis: Die Gewichtslage muß zur Ölwannen-
z dichtfläche weisen.
20. Einstellbolzen für Massenausgleichswelle

4 in das Kurbelgehäuse bis zum Anschlag
einschrauben.
7 Hinweis: Bohrung der Massenausgleichswelle
5
muß mit der Bohrung im Kurbelwel-
lengehäuse in Überdeckung stehen.
21. Anlaufscheibe anbauen und zur Wellen-
4 4 achse ausrichten.
4.00.22
008 918 12 BOMAG 1147
complete engine
engine
Mass balancing shafts BFM 1012 Arbres à masse d’équilibrage Arboles compensadores de masa -
(if any) BFM 1012 BFM 1012
(selon l’équipement du moteur) (si existen)
Turn engine by 180°. Virer le moteur de 180°. Girar el motor por 180°
18. Turn out screw plugs. 18. Dévisser et sortir les vis filetées. 18. Desenroscar los tapones de cierre.
19. Introduce mass balancing shaft. 19. Monter l’arbre à masses 19. Introducir uno de los árboles
d’équilibrage. compensadores de masa.
Note: The weights must be positioned Nota: les poids doivent être orientés Nota: Las masas deben estar
towards oil pan sealing surface. vers le plan d’étanchéité du orientadas hacia la superficie de
carter d’huile. cierre del cárter de aceite.
20. Screw adjusting pin for mass 20. Visser la pige de réglage de l’arbre 20. Enroscar el perno de ajuste del
balancing shaft into crankcase as à masses d’équilibrage dans le bloc árbol compensador de masa en el
far as it will go. moteur jusqu’en position de butée. bloque motor hasta que haga tope.
Note: Bore of mass balancing shaft Nota: l’alésage de l’arbre à masses Nota: El orificio existente en el árbol
must be in line with bore in d’équilibrage doit correspondre compensador de masa debe
crankcase. à l’alésage du bloc moteur. coincidir con el del bloque
motor.
21. Fit thrust washer and align relative 21. Monter la flasque de butée en 21. Montar la arandela de tope y
to shaft axis. l’orientant vers l’axe de l’arbre. alinearla con el eje del árbol.
4
4.00.22
1148 BOMAG 008 918 12
Diesel engine 18.9
22. Tighten bolt with a torque of 22. Serrer la vis au couple de 29 Nm. 22. Apretar el tornillo con un par de
29 Nm. 29 Nm.
23. Turn crankshaft and bring cyl. 1 to 23. Mettre le vilebrequin cyl. 1 en 23. Girando el cigüeñal, poner el cil. 1
TDC. TDC position is reached when position de PMH. Le PMH est en PMS.Se ha alcanzado el PMS,
the crankshaft marking coincides atteint quand le repère sur le cuando la marca puesta en el
with the centerline of crankshaft vilebrequin se trouve à cigüeñal se encuentra en la línea
and camshaft. l’intersection entre les points milieu que une los centros del cigüeñal y
du vilebrequin et de l’arbre à árbol de levas.
cames.
24. Position idler gear and press down 24. Mettre en place le pignon 24. Instalar la rueda intermedia y
lightly until it meshes with the intermédiaire et l’enfoncer forzarla ligeramente hasta que
crankshaft gear. légèrement dans l’engrènement du engrane en la rueda dentada del
pignon du vilebrequin. cigüeñal.
25. Mark opposite teeth. 25. Repérer les dents se trouvant en 25. Marcar los dientes que se
regard les unes des autres. enfrenten.
4
4.00.23
008 918 12 BOMAG 1149
complete engine
engine
22. Schraube mit einem Drehmoment von

29 Nm festdrehen.
4
6
23. Kurbelwelle Zyl. 1 auf OT stellen.

OT ist dann erreicht, wenn die Markierung
auf der Kurbelwelle in Verbindungslinie
4
der Mittelpunkte von Kurbelwelle und
Nockenwelle liegt.
9
24. Zwischenrad einsetzen und leicht in den

Eingriff des Zahnrades der Kurbelwelle
drücken.
4
25. Die gegenüberliegenden Zähne markieren.

i 4
4.00.23
1150 BOMAG 008 918 12
Diesel engine 18.9
26. Kurbelwelle im Uhrzeigersinn drehen, bis

9 3 Zähne übergesprungen sind.
27. Kurbelwelle entgegen dem Uhrzeigersinn

9 drehen, bis Bohrungen in Überdeckung
stehen.
28. Lagerzapfen einsetzen.

4 Hinweis: Durch leichtes Hin- und Herdrehen
z der Kurbelwelle prüfen, ob Lager-
zapfen in der Bohrung zentriert ist.
29. Schraube einsetzen und mit einem
4 4 Drehmoment von 29 Nm festdrehen.
4.00.24
008 918 12 BOMAG 1151
complete engine
engine
26. Turn crankshaft in clockwise 26. Virer le vilebrequin dans le sens 26. Girar el cigüeñal en sentido horario
direction until 3 teeth have horaire jusqu’à ce que 3 dents hasta que hayan engranado 3
engaged. sautent. dientes.
27. Turn crankshaft in anti-clockwise 27. Virer le vilebrequin dans le sens 27. Girar el cigüeñal en sentido
direction until bores are in line. antihoraire jusqu’à ce que les contrario al de las agujas del reloj
alésages correspondent. hasta que coincidan los orificios.
28. Insert bearing journal. 28. Mettre en place le tourillon. 28. Introducir el muñón de soporte.
Note: Check whether bearing journal Nota: déplacer légèrement par un Nota: Imprimiendo al cigüeñal un
is centered in bore by slightly mouvement de va-et-vient le ligero movimiento giratorio de
turning crankshaft back and vilebrequin pour vérifier si le vaivén, comprobar si el muñón
forth. tourillon est bien centré dans queda centrado en el orificio.
l’alésage.
29. Insert bolt and tighten with a 29. Placer la vis et la serrer au couple 29. Meter el tornillo y apretarlo con
torque of 29 Nm. de 29 Nm. 29 Nm.
4
4.00.24
1152 BOMAG 008 918 12
Diesel engine 18.9
30. Introduce 2nd mass balancing 30. Monter le 2ème arbre à masses 30. Introducir el segundo árbol
shaft. d’équilibrage. compensador de masa.
Note: The weights must be positioned Nota: les poids doivent être orientés Nota: Las masas deben estar
towards oil pan sealing surface. vers le plan de joint du carter orientadas hacia la superficie de
d’huile. cierre del cárter de aceite.
31. Screw adjusting pin for mass 31. Visser la pige de réglage de l’arbre 31. Enroscar el perno de ajuste del
balancing shaft into crankcase as à masses d’équilibrage dans le bloc árbol compensador de masa en el
far as it will go. moteur jusqu’en position de butée. bloque motor hasta el tope .
Note: Bore of mass balancing shaft Nota: l’alésage de l’arbre à masses Nota: El orificio existente en el árbol
must be in line with bore in d’équilibrage doit correspondre compensador de masa debe
crankcase. à l’alésage du bloc moteur. coincidir con el del bloque
motor.
32. Fit thrust washer and align relative 32. Monter la flasque de butée en 32. Colocar la arandela de tope y
to shaft axis. l’orientant vers l’axe de l’arbre. alinearla con el eje del árbol.
33. Tighten bolt with a torque of 33. Serrer la vis au couple de 29 Nm. 33. Apretar el tornillo con un par de
29 Nm. 29 Nm.
4
4.00.25
008 918 12 BOMAG 1153
complete engine
engine
30. 2. Massenausgleichswelle einbauen.
Hinweis: Die Gewichtslage muß zur Ölwannen-

4
dichtfläche weisen.
z
5
31. Einstellbolzen für Massenausgleichswelle

in das Kurbelgehäuse bis zum Anschlag
einschrauben.
4
Hinweis: Bohrung der Massenausgleichswelle 7
5
muß mit der Bohrung im Kurbel-
gehäuse in Überdeckung stehen.
32. Anlaufscheibe anbauen und zur

Wellenachse ausrichten. 4
9

29 Nm festdrehen. 4 4
6
4.00.25
1154 BOMAG 008 918 12
Diesel engine 18.9
34. Zwischenrad so einsetzen, daß Bohrungen

4 in Überdeckung stehen.
35. Lagerzapfen einsetzen.

4
z
36. Schraube einsetzen und mit einem

4 Drehmoment von 29 Nm festdrehen.
37. Beide Einstellbolzen entfernen.
4 3
4.00.26
008 918 12 BOMAG 1155
complete engine
engine
34. Insert idler gear so that bores are in 34. Placer le pignon intermédiaire de 34. Instalar la rueda intermedia,
line. manière à ce que les alésages teniendo en cuenta que coincidan
correspondent. los orificios.
35. Insert bearing journal. 35. Mettre en place le tourillon. 35. Introducir el muñón de soporte.
36. Insert bolt and tighten with a 36. Placer la vis et serrer au couple de 36. Meter el tornillo y apretarlo con un
torque of 29 Nm. 29 Nm. par de 29 Nm.
37. Remove both adjusting pins. 37. Oter les deux piges de calage. 37. Retirar ambos pernos de ajuste.
4.00.26
1156 BOMAG 008 918 12
Diesel engine 18.9
38. Cover up bores with new Cu seals. 38. Obturer les alésages avec des 38. Cerrar los orificios con anillos de
bagues d’étanchéité Cu neuves. cobre nuevos.
Drive gear/governor Pignon d’entraînement/régulateur Rueda de accionamiento/regulador
39. Insert governor drive gear 39. Mettre en place le pignon 39. Instalar la rueda de accionamiento
complete with bearing journal. d’entraînement du régulateur avec del regulador con el muñón de
le tourillon. soporte.
40. Insert bolt and tighten with a 40. Placer la vis et la serrer au couple 40. Meter el tornillo y apretarlo con un
torque of 21 Nm. de 21 Nm. par de 21 Nm.
Control rod Crémaillère Barra cremallera
4 41. Fit control rod complete with guide 41. Monter la crémaillère avec la 41. Instalar la barra cremallera con el
sleeve. douille de guidage. manguito de guía puesto.
4.00.27
008 918 12 BOMAG 1157
complete engine
engine
38. Bohrungen mit neuen Cu-Dichtringen

verschließen.
4
ß
Antriebsrad/Regler
39. Antriebsrad für Regler mit Lagerzapfen

4
einsetzen.
z
40. Schraube einsetzen und mit einem Dreh-

moment von 21 Nm festdrehen. 4
6
Regelstange
41. Regelstange mit Führungsbuchse

4 4
einbauen.
4.00.27
1158 BOMAG 008 918 12
Diesel engine 18.9
42. Schraube mit Sicherungmittel Deutz

4 DW 71 einsetzen und mit einem
Drehmoment von 10 + 2 Nm festdrehen.
w
6
Räderkastendeckel
4 43. Dichtfläche des Räderkastendeckels mit
w Dichtmittel Deutz DW 67 bestreichen.
BFM 1012
BFM 1013
4
w
4
44. Räderkastendeckel anbauen. Schrauben
beidrehen und Räderkastendeckel zur
4 Ölwannendichtfläche ausrichten.
9
4.00.28
008 918 12 BOMAG 1159
complete engine
engine
42. Apply Deutz DW 71 locking 42. Monter la vis à la pâte de frein 42. Meter el tornillo con sellante
compound to bolt and tighten with DEUTZ DW 71 et la serrer au Deutz DW 71 y apretarlo con un
a torque of 10 + 2 Nm. couple de 10 + 2 Nm. par de 10 + 2 Nm.
Timing chest cover Couvercle de carter de distribution Tapa del cárter de la distribución
43. Apply Deutz DW 67 sealing 43. Enduire le produit Deutz DW 67 la 43. Aplicar sellante Deutz DW 67 a la
compound to sealing surface of surface d'étanchéité du couvercle superficie de cierre de la tapa del
timing chest cover. de la distribution. cárter de la distribución.
BFM 1012 BFM 1012 BFM 1012
BFM 1013 BFM 1013 BFM 1013
44. Mount timing chest cover. Start 44. Monter le couvercle de la 44. Montar la tapa en el cárter de la
bolts and align timing chest cover distribution. Server les vis à la main distribución. Apretar con la mano
relative to oil pan sealing surface. et aligner le couvercle de la los tornillos hasta que se apoyen y 4
distribution par rapport au plan alinear la tapa con respecto a la
d'appui du carter d'huile. superficie de cierre del cárter de
aceite.
4.00.28
1160 BOMAG 008 918 12
Diesel engine 18.9
45. Tighten bolts with a torque of 45. Serrer les vis au couple de 45. Apretar los tornillos con un par de
21 ± 2 Nm. 21 ± 2 Nm. 21 ± 2 Nm.
Front cover Couvercle avant Tapa delantera
46. Lightly oil rotors in front cover. 46. Huiler légèrement les rotors du 46. Untar con un poco de aceite los
couvercle avant. rotores en la tapa delantera.
47. Stick gasket to front cover using 47. Coller le joint du couvercle avant 47. Pegar con un poco de grasa la
some grease. avec un peu de graisse. junta en la tapa delantera.
Turn engine by 180°. Oil pan sealing Virer le moteur de 180°. Le plan de Girar el motor por 180°. La superficie
surface must point downward. joint du carter d’huile doit être dirigé de cierre del cárter de aceite tiene que
4 vers le bas. indicar hacia abajo.
48. Position rotor relative crankshaft. 48. Positionner le rotor par rapport au 48. Posicionar el rotor con respecto al
vilebrequin. cigüeñal.
4.00.29
008 918 12 BOMAG 1161
complete engine
engine
45. Schrauben mit einem Drehmoment von

4
6
Vorderer Deckel
46. Rotoren im vorderen Deckel leicht ölen.

4
z
47. Dichtung für vorderen Deckel mit etwas

Fett ankleben. 4
u
ß
Motor 180° drehen. Ölwannnendichtfläche

muß nach unten weisen. 4 4
48. Rotor zur Kurbelwelle positionieren.
9
4.00.29
1162 BOMAG 008 918 12
Diesel engine 18.9
49. Vorderen Deckel anbauen, Deckel nach

4 oben drücken und zur Ölwannendichtfläche
ausrichten. Schrauben leicht andrehen.
50. Schrauben für vorderen Deckel mit einem

4 Drehmoment von 21 ± 2 Nm festdrehen.
Kolben mit Pleuel

4 51. Pleuellagerschalen in Pleuelstange
8 einbauen.
52. Kolbenringstöße 90-120° zueinander
4 9 versetzt anordnen.
4.00.30
008 918 12 BOMAG 1163
complete engine
engine
49. Mount front cover, press cover 49. Monter le couvercle avant, le serrer 49. Montar la tapa delantera,
upward and align relative to oil pan vers le haut et l'aligner par rapport presionarla hacia arriba y alinearla
sealing surface. Start bolts. au plan de joint du carter d’huile. con respecto a la superficie de
Serrer les vis modérément. cierre del cárter de aceite. Enroscar
los tornillos con la mano hasta que
se apoyen.
50. Tighten bolts for front cover with a 50. Serrer les vis du couvercle avant au 50. Apretar los tornillos para la tapa
torque of 21 ± 2 Nm. couple de 21 ± 2 Nm. delantera con un par de 21 ± 2 Nm.
Piston complete with connecting rod Ensemble piston-bielle Conjunto pistón-biela
51. Insert bearing shells in connecting 51. Monter les coussinets dans la 51. Insertar los coijnetes en la biela.
rod. bielle.
52. Piston ring gaps must be staggered 52. Tiercer les coupes de segment de 52. Cuidar de que los cortes de los
by 90-120°. 90-120°. aros de pistón estén desplazados
entre sí por 90-120°. 4
4.00.30
1164 BOMAG 008 918 12
Diesel engine 18.9
53. Introduce piston complete with 53. Insérer le piston complet et la bielle 53. Introducir el pistón completo con la
connecting rod into crankcase with dans le bloc moteur. biela en el bloque de motor.
integrated cylinder liners.
Note: Flywheel symbol must point Nota: le symbole du volant doit être Nota: El símbolo del volante tiene que
towards flywheel. orienté vers le volant. indicar hacia el volante.
54. Press connecting rod against 54. Enfoncer la bielle en exerçant une 54. Presionando la biela contra su
crankpin. Fit pertinent big end pression contre le maneton. muñequilla, montar la tapa de biela
bearing cap. Monter le chapeau de bielle correspondiente.
correspondant.
55. Tighten new conrod bolts in 55. Serrer les vis de bielle neuves 55. Apretar los tornillos de biela
accordance with specification. selon les consignes de serrage. nuevos, según prescripción.
Initial tightening torque ___ 30 Nm Serrage d'approche ______ 30 Nm Apriete inicial: __________ 30 Nm
1st tightening angle ________ 60° 1. Serrage à l’angle ________ 60° 1er ángulo de reapriete ______ 60°
2nd tightening angle 2. Serrage à l’angle 2o ángulo de reapriete
BFM 1012 _____________ 30° BFM 1012 _____________ 30° BFM 1012 _____________ 30°
BFM 1013 _____________ 60° BFM 1013 _____________ 60° BFM 1013 _____________ 60°
56. Check that connecting rods can be 56. Contrôler les bielles: elles doivent 56. Comprobar las bielas para ver si
easily moved back and forth on the se déplacer légèrement au niveau pueden moverse fácilmente sobre
4 crankpin. du maneton. sus muñequilla.
Note: Turn engine by 180°. Nota: virer le moteur de 180°. Nota: Girar el motor por 180°.
4.00.31
008 918 12 BOMAG 1165
complete engine
engine
53. Kolben komplett mit Pleuel in das

Zylinderkurbelgehäuse einschieben. 4
Hinweis: Schwungradsymbol muß zum
Schwungrad weisen. z
7
5
54. Pleuelstange gegen den Hubzapfen

drücken. Dazugehörigen Pleuellagerdeckel
montieren.
4
z
9
55. Neue Pleuelschrauben nach Anziehvor-

schrift festdrehen. 4
Vorspannwert ________________ 30 Nm
1. Nachspannwinkel _____________ 60° 6
ß
2. Nachspannwinkel
BFM 1012 ___________________ 30°
BFM 1013 ___________________ 60°
56. Pleuelstangen kontrollieren, ob sie sich

auf dem Hubzapfen leicht verschieben
lassen.
9 4
Hinweis: Motor um 180° drehen. 5
4.00.31
1166 BOMAG 008 918 12
Diesel engine 18.9
Einspritzpumpen einbauen
4 Regelstangenweg messen ohne Einspritz-
7 pumpen
57. Feststellvorrichtung für Regelstange an-

bauen.
58. Von Vorrichtung bis zur Stopstellung der

6 Regelstange messen.
58.1 Von Vorrichtung bis zur Startstellung der

6 Regelstange messen.
9 Differenz zur Stopstellung ergibt Regel-

stangenweg.
Beispiel:
Stopstellung = 30,7 mm
Startstellung = 13,4 mm
Regelstangenweg = 17,3 mm
Sollmaß = 17,0 mm - 17,5 mm
59. Vorrichtung drehen. Regelstange mit
4 s Rändel-Feststellschraube von Hand in

Stopstellung drücken.
4.00.32
008 918 12 BOMAG 1167
complete engine
engine
Installing injection pumps Monter les pompes d’injection Montaje de las bombas de inyección
Gauging control rod travel without Mesurer le déplacement de la Determinación del recorrido de la
injection pumps installed crémaillère sans pompes d’injection. cremallera sin las bombas de
inyección
57. Fit control rod locking device. 57. Monter le dispositif de fixation de la 57. Montar el dispositivo de bloqueo de
crémaillère. la cremallera.
58. Gauge from locking device to stop 58. Mesurer la distance entre le 58. Medir la distancia entre el
position of control rod. dispositif et la position stop de la dispositivo y la cremallera en
crémaillère. posición de parada.
58.1 Gauge from locking device tostart 58.1 Mesurer la distance entre le 58.1 Medir la distancia entre el
position of control rod. dispositif et la position de dispositivo y la cremallera en
démarrage de la crémaillère. posición de arranque.
Difference between start and stop La différence par rapport à la La diferencia entre ambos valores
positions equals control rod travel. position de stop est le déplacement es el recorrido de la cremallera.
de la crémaillère.
Example: Exemple: Ejemplo:
stop position = 30.7 mm position stop = 30,7 mm Posición de parada = 30,7 mm
start position = 13.4 mm position démarrage = 13,4 mm Posición de arranque = 13,4 mm
control rod travel = 17.3 mm déplacement crémaillère =17,3 mm Recorrido de
Specified dimension = 17.0 mm Valeur de consigne = 17,0 mm la cremallera = 17,3 mm
- 17.5 mm -17,5 mm Valor prescrito = 17,0 mm
-17,5 mm
59. Turn locking device. Press control 59. Tourner le dispositif. A la main 59. Girar el dispositivo. Apretando el
rod in stop position by hand with enfoncer la crémaillère avec la vis tornillo de bloqueo, forzar la
knurled-head setscrew. d’immobilisation en position de cremallera para que se sitúe en la 4
stop. posición de parada.
4.00.32
1168 BOMAG 008 918 12
Diesel engine 18.9
60. Fit graduated disc to flywheel 60. Monter le disque gradué sur la 60. Fijar el disco graduado a la brida
flange. bride du volant moteur. del volante.
61. Fit pointer. 61. Monter l’index gradué. 61. Montar el indicador.
Determining TDC of piston pertaining Calculer le PMH du piston de la Determinación del PMS de com-
to injection pump to be timed. pompe d’injection à caler. presión del pistón que corresponda a
la bomba de inyección a ajustar.
62. Position TDC measuring bar 62. Mettre en place la barre de mesure 62. Colocar la regleta de medición del
together with spacing washers. du PMH avec des plaquettes PMS con las plaquitas
Turn crankshaft in direction of d’écartement. Virer le vilebrequin distanciadoras. Girar el cigüeñal en
engine rotation until pointer of dial dans le sens de rotation du moteur el sentido de giro normal del motor
gauge has reached its reversal jusqu’à ce que l’index du hasta que la aguja del comparador
point. comparateur atteigne son point haya alcanzado su punto de
Set dial gauge to „0“. d’inversion. inversión.
Régler le comparateur sur „0“. Ajustar el comparador a „0“.
63. Turn crankshaft by about 90° in 63. Virer le vilebrequin de 90° environ 63. Girar el cigüeñal unos 90° en
direction of engine rotation. dans le sens opposé au sens de sentido contrario al del motor y a
4 Thereafter turn again in opposite rotation du moteur. Ensuite virer à continuación otra vez en el sentido
direction of engine rotation until nouveau dans le sens de rotation de giro normal del mismo hasta
8 mm before TDC (reversal point of du moteur jusqu’à 8 mm avant le 8 mm delante del PMS (punto de
dial gauge). PMH (point d’inversion du inversión del comparador).
Set graduated disc to „0“. comparateur). Ajustar el disco graduado a „0“.
Régler le disque gradué sur „0“.
4.00.33
008 918 12 BOMAG 1169
complete engine
engine
60. Gradscheibe an Schwungradflansch

anbauen.
4
7
61. Zeiger anbauen.

4
7
Zünd O.T. des Kolbens ermitteln, der zur

einzustellenden Einspritzpumpe gehört. 4
62. O.T.-Meßbalken mit Abstandsplättchen
auflegen. Kurbelwelle in Motordreh- 6
7
richtung drehen bis der Zeiger der Meßuhr
seinen Umkehrpunkt erreicht hat.
Meßuhr auf "0" stellen.
63. Kurbelwelle ca. 90° entgegen der Motor-

drehrichtung drehen. Danach wieder in
Motordrehrichtung bis 8 mm vor O.T.
6 4
(Umkehrpunkt der Meßuhr) drehen.
Gradscheibe auf “0” stellen.
4.00.33
1170 BOMAG 008 918 12
Diesel engine 18.9
64. Kurbelwelle ca. 90° in Motordrehrichtung

6 drehen. Danach wieder entgegen der
Motordrehrichtung bis 8 mm vor O.T.
(Umkehrpunkt der Meßuhr) drehen.
Ermittelten Wert ablesen.
Beispiel: 50°
65. Ermittelten Wert halbieren. Halbierter

9 Wert ist O.T.
0°+ 50°
Beispiel: = 25° IST
2
Kurbelwelle auf halbierten Wert drehen.
66. Kurbelwelle jetzt nicht mehr verdrehen.

a 2 Rändelschrauben lösen und Gradscheibe
auf "0" stellen.
6
67. Rollenstößel einsetzen
4 4
z
4.00.34
008 918 12 BOMAG 1171
complete engine
engine
64.Turn crankshaft by about 90° in 64. Virer le vilebrequin de 90° environ 64. Girar el cigüeñal aprox. 90° en
direction of engine rotation. dans le sens opposé au sens de sentido de giro normal del motor y
Thereafter turn again in opposite rotation du moteur. Ensuite virer à a continuación de nuevo en sentido
direction of engine rotation until nouveau dans le sens de rotation contrario al mismo hasta 8 mm
8 mm before TDC (reversal point of du moteur jusqu’à 8 mm avant le delante del PMS (punto de
dial gauge). Read off determined PMH (point d’inversion du inversión del comprador). Tomar
value. comparateur). Lire la valeur lectura del valor determinado.
Example: 50° obtenue. Ejemplo: 50°
Exemple : 50°
65. Halve the value determined. The 65. Diviser la valeur calculée par deux. 65. Dividir el valor determinado por
halved value equals TDC. La valeur divisée par deux est le dos. El valor dividido por dos es el
PMH. PMS.
Example: 0°+50° = 25° ACTUAL Exemple: 0°+50° = 25° REEL Ejemplo: 0°+50° = 25° REAL
2 value 2 2
Turn crankshaft until halved value Virer le vilebrequin d’après cette Girar el árbol de manlvela al valor
is reached. valeur divisée par deux. dividido en dos.
66. Stop turning crankshaft. Loosen 2 66. Ne plus virer le vilebrequin. 66. A partir de ahora, no debe
knurled-head screws and set Desserrer les 2 vis moletées puis cambiarse la posición del cigüeñal.
graduated disc to „0“. régler le disque gradué sur 0. Soltar 2 tornillos de cabeza
moleteada y poner el disco
graduado en „0“.
67. Insert roller tappet. 67. Mettre en place le poussoir à galet. 67. Introducir el empujador de rodillo.
4.00.34
1172 BOMAG 008 918 12
Diesel engine 18.9
Determining commencement of Calcul du début d’injection sur la Determinación del comienzo de

delivery with Bosch injection pump pompe d’injection Bosch alimentación - bomba de inyección
Bosch
The commencement of delivery and Le début d’injection et depuis juillet El comienzo de alimentación y, desde
since about 07.96 also the type of 1996 le type de l’arbre à cames sont aprox. julio de 1996, también el tipo
camshaft are stamped on the rating indiqués sur la plaque signalétique. del árbol de levas figuran en la placa
plate. de fabricante.
68. Set dial gauge of measuring device 68. Régler le comparateur dans le 68. Ajustar el comparador del
under preload to 0. dispositif de mesure à la valeur 0. dispositivo de medición con
precarga a „0“.
Set value: Cote de réglage: Medida de ajuste:
BFM 1012 115 mm (100 780) BFM 1012 115 mm (100 780) BFM 1012 115 mm (100 780)
126 mm (100 860) 126 mm (100 860) 126 mm (100 860)
BFM 1013 150 mm (100 840) BFM 1013 150 mm (100 840) BFM 1013 150 mm (100 840)
69. Position roller tappet of the 69. Régler le poussoir à galet de la 69. El empujador de rodillo de labomba
injection pump to be timed on pompe d’injection à tarer sur le de inyección a ajustar debe
base circle. For that purpose turn cercle de base. Pour cela virer le encontrarse sobre el círculo base.
crankshaft by about 180° opposite vilebrequin d’environ 180° dans le Para ello, girar el cigüeñal aprox.
to direction of engine rotation. sens opposé au sens de rotation du 180° en sentido contrario al de giro
moteur. normal del motor.
70. Insert measuring device carefully. 70. Mettre en place le dispositif de 70. Introducir el dispositivo de
mesure avec la plus grande medición cuidadosamente.
précaution.
71. Measure dimension „L“, and enter 71. Mesurer le cote „L“ puis incrire 71. Medir el valor „L“ y registrarlo en la
in table 1, chapter 1. cette valeur dans le tableau, voir tabla, ver capítulo 1.
4 chap. 1.
BFM 1012 116.26 mm BFM 1012 116,26 mm BFM 1012 116,26 mm
126.57 mm 126,57 mm 126,57 mm
BFM 1013 152.22 mm BFM 1013 152,22 mm BFM 1013 152,22 mm
4.00.35
008 918 12 BOMAG 1173
complete engine
engine
Förderbeginn ermitteln Bosch-

Einspritzpumpe
9
Der Förderbeginn und seit ca. 07.96 auch der
Nockenwellentyp, sind auf dem Firmenschild 6
angegeben.
68. Meßuhr in Meßvorrichtung mit Vor-

7
spannung auf 0 stellen.
Einstellmaß:
BFM 1012 115 mm (100 780)
126 mm (100 860)
BFM 1013 150 mm (100 840)
69. Rollenstößel der zur einzustellenden

Einspritzpumpe auf Grundkreis stellen.
Hierzu Kurbelwelle ca. 180° entgegen der
9
Motordrehrichtung drehen.
70. Meßvorrichtung vorsichtig einsetzen.

4
r
71. Maß “L” messen und in Tabelle, siehe

Kapitel 1, eintragen. 6 4
Beispiel:
BFM 1012 116,26 mm
126,57 mm
BFM 1013 152,22 mm
"L"
4.00.35
1174 BOMAG 008 918 12
Diesel engine 18.9
72. Meßuhr über den Außenring auf Zeiger-

6 Nullstellung drehen.
5 Hinweis: Bei der Vorhubeinstellung darf die

Drehrichtung nicht mehr verändert
werden.
73. Kurbelwelle in Motordrehrichtung drehen

9 bis Meßuhr auf Vorhubmaß anzeigt.
Siehe Tabelle 1.
6 Beispiel BFM 1012: Förderbeginn 9°

Nockenwelle Typ C
Vorhub 4,63 mm
Beispiel BFM 1013: Förderbeginn 10°
Nockenwelle Typ A
Vorhub 5,31 mm
74. Förderbeginn IST ablesen und in Tabelle,

9 siehe Kapitel 1, eintragen.
Beispiel: BFM 1012 8°
BFM 1013 10°
75. Maß “A” = Kennzahl für Einspritzpumpen-

4 9 länge ablesen und in Tabelle, siehe Kapitel 1,
eintragen.
Beispiel: BFM 1012 53
BFM 1013 133
4.00.36
008 918 12 BOMAG 1175
complete engine
engine
72. Set pointer of dial gauge to 0 with 72. Virer le comparateur au niveau de 72. Poner la aguja del comparador
outer ring. la bague extérieure en position 0. mediante el anillo exterior en
posición „0“.
Note: The direction of rotation must Nota: pour le réglage de la précourse Nota: Para el ajuste de la carrera
not be changed anymore when ne plus modifier le sens de previa, ya no se debe modificar
the pre-stroke position has rotation. el sentido de giro.
been reached.
73. Turn crankshaft in direction of 73. Virer le vilebrequin dans le sens 73. Girar el cigüeñal en el sentido de
engine rotation until dial gauge de rotation jusqu’à ce que le giro normal del motor hasta que el
indicates pre-stroke dimension, comparateur indique la cote de comparador marque el valor de la
see table 1. précourse. Voir tableau 1. carrera previa. Ver tabla 1.
Example BFM 1012: Exemple BFM 1012: Ejemplo: BFM 1012:

Comencement of delivery 9° début d’injection 9° comienzo de alimentación 9°
Camshaft type C arbre à cames type C árbol de levas, tipo C
Pre-stroke 4.63 mm précourse 4,63 mm carrera previa 4,63 mm
Example BFM 1013: Exemple BFM 1013: Ejemplo: BFM 1013:
Commencement of delivery 10° début d’injection 10° comienzo de alimentación 10°
Camshaft type A arbre à cames type A árbol de levas, tipo A
Pre-stroke 5.31 mm précourse 5,31 mm carrera previa 5,31 mm
74. Read off ACTUAL commencement 74. Lire début d’injection VALEUR 74. Leer el comienzo de alimentación
of delivery and enter in table, REELLE et l’inscrire sur le tableau, REAL y registrarlo en la tabla, ver
chapter 1. voir chap. 1. capítulo 1.
BFM 1012 8° BFM 1012 8° BFM 1012 8°
BFM 1013 10° BFM 1013 10° BFM 1013 10°
75. Read off dimension „A“ = code for 75. Lire cote „A“ = indice de longueur 75. Leer el valor „A“ = índice de l
injection pump length and enter in de pompe d’injection et inscrire la ongitud de la bomba de inyección y
table, chapter 1. valeur sur le tableau, voir chap. 1. registrarlo en la tabla, vercapítulo1. 4
BFM 1012 53 BFM 1012 53 BFM 1012 53
BFM 1013 133 BFM 1013 133 BFM 1013 133
4.00.36
1176 BOMAG 008 918 12
Diesel engine 18.9
76. Remove measuring device. 76. Déposer l’appareil de mesure. 76. Desmontar el aparato de medición.
Determine shims. Calculer l’épaisseur de la rondelle Determinar la arandela de reglaje.
See chapter 1. de compensation. Voir chap. 1. Ver capítulo 1.
77. Position selected shim on roller 77. Placer la rondelle de compensation 77. Colocar la arandela de reglaje
tappet. calculée sur le poussoir à galet. determinada sobre el empujador de
rodillo.
Note: The measuring procedures Nota: effectuer le relevé des mesures Nota: Las operaciones de medicióndel
under items 62-77 is to be indiquées aux points 62 à 77 punto 62 al punto 77 han de
carried out for each injection pour chaque pompe d’injection. repetirse para cada bomba de
pump. inyección.
Injection pump Pompe d’injection Bomba de inyección
78. Turn injection pump linkage lever 78. Virer le levier de la pompe 78. Girar la palanca de dirección de la
to approx. middle position. d’injection approximativement en bomba de inyección
position milieu. aproximadamente a la posición
intermedia.
Note: The assembly procedure under Nota: effectuer l'opération de Nota: Realizar La operación de
items 78-84 is to be carried out montage du position 78 à 84 montaje, puntos 78 - 84, para
for each injection pump. pour n' importe quelle pompe cada bomba de inyección.
d'injection.
79. Position roller tappet of relevant 79. Placer le poussoir à galet du 79. Colocar el empujador del cilindro
cylinder on base circle. Lightly oil cylindre concerné sur le cercle de correspondiente sobre el círculo
4 receiving bore in crankcase and O- base. Huiler légèrement les joints base. Untar con un poco de aceite
seals of injection pump. Carefully toriques de la pompe d’injection et el taladro de alojamiento en el
introduce injection pump linkage l’alésage de positionement du bloc bloque motor y los anillos tóricos
lever into control rod. moteur. Insérer avec précaution le de la bomba de inyección.
levier de direction de la pompe Introducir cuidadosamente la
d’injection sur la crémaillère. palanca de dirección de bomba de
inyección en la cremallera.
4.00.37
008 918 12 BOMAG 1177
complete engine
engine
76. Meßgerät abbauen.

Ausgleichsscheiben ermitteln.
Siehe Kapitel 1.
3
9
77. Ermittelte Ausgleichsscheibe auf

Rollenstößel auflegen. 4
Hinweis: Der Meßvorgang von Pos. 62 - 77 ist
für jede Einspritzpumpe durchzufüh- 5
ren.
Einspritzpumpe
78. Einspritzpumpenlenkhebel auf ca. Mittel-

9
stellung drehen .
6
Hinweis: Der Montagevorgang von Pos. 78 -
84 ist für jede Einspritzpumpe 5
durchzuführen.
79. Rollenstößel des jeweiligen Zylinders auf

Grundkreis stellen.
Aufnahmebohrung im Kurbelgehäuse und
4 4
Runddichtringe der Einspritzpumpe leicht
einölen.
9
Einspritzpumpenlenkhebel vorsichtig in die
Regelstange einführen. z
4.00.37
1178 BOMAG 008 918 12
Diesel engine 18.9
80. Flansch auflegen.

4 Hinweis: Anfasung muß zum Einspritzpum-
5 penkörper weisen.
81. Schrauben leicht einölen und mit einem

4 Drehmoment von 5 Nm gleichmäßig fest-
drehen.
z
6
82. Schrauben wieder 60° lösen.

3
6
83. Einspritzpumpe mit Verdrehschlüssel
4 4 gegen Uhrzeigersinn vorsichtig bis zum

fühlbaren Anschlag drehen.
6
4.00.38
008 918 12 BOMAG 1179
complete engine
engine
80. Position flange. 80. Mettre en place la bride. 80. Colocar la brida.
Note: Chamfer must face injection Nota: le chanfreinage doit être Nota: El biselado debe indicar hacia el
pump body. orienté vers le corps de la cuerpo de la bomba inyectora.
pompe d’injection.
81. Lightly oil bolts and tighten 81. Huiler modérément les vis et les 81. Untar con un poco de aceite los
uniformly with a torque of 5 Nm. serrer uniformément au couple de tornillos y apretarlos
5 Nm. uniformemente con un par de
5 Nm.
82. Loosen bolts again by 60°. 82. Desserrer à nouveau les vis de 60°. 82. Volver a aflojar los tornillos 60°.
83. Turn injection pump with wrench 83. Serrer avec précaution la pompe 83. Sirviéndose de la Ilave de giro,
carefully counter-clockwise until d’injection dans le sens antihoraire girar la bomba de inyección
tangible stop. jusqu’en position de butée sensible. cuidadosamente en el sentido anti- 4
horario hasta el tope perceptible.
4.00.38
1180 BOMAG 008 918 12
Diesel engine 18.9
84. Tighten bolts by 60° and then 84. Serrer à nouveau lesvis à 60° et par 84. Apretar los tornillos de nuevo con
alternately with a torque of passes successives au couple de 60° y apretarlos en escalones con
7 Nm, 10 Nm and 30 Nm. 7 Nm, 10 Nm et 30 Nm. un par de 7 Nm, 10 Nm y 30 Nm.
Note: Start with the outer bolt, remote Nota: commencer á chaque fois par la Nota: Comenzar siempre con el
of the flywheel (see arrow). vis extérieure la plus éloignée tornillo exterior, más alejado del
du volant moteur (voir flèche). volante (ver la flecha).
Gauging control rod travel with Mesurer le déplacement de la Determinación del recorrido de la
injection pumps installed crémaillère avec les pompes cremallera con las bombas de
d’injection inyección montadas.
85. Undo setscrew from locking device. 85. Dévisser et extraire la vis 85. Desenroscar del dispositivo el
Turn locking device. d’immobilisation du dispositif. Virer tornillo de bloqueo. Girar el
le dispositif. dispositivo.
86. Gauge from locking device to stop 86. Mesurer la distance entre le 86. Medir la distancia entre el
position of control rod. dispositif et la position stop de la dispositivo y la cremallera en
crémaillère. posición de parada.
86.1 Gauge from locking device to 86.1 Mesurer la distance entre le 86.1 Medir la distancia entre el
start position of control rod. dispositif et la position dispositivo y la cremallera en
démarrage de la crémaillère. posición de arranque.
Difference between stop and start La différence par rapport à la position La diferencia entre ambos valores da el
positions equals control rod travel. stop donne la course de la crémaillère. recorrido de la cremallera.
4
Example: Exemple : Ejemplo:
stop position = 30.5 mm position stop = 30,5 mm Posición de parada = 30,5 mm
start position = 13.4 mm position démarrage = 13,4 mm Posición de arranque = 13,4 mm
control rod travel = 17.1 mm déplacement de la Recorrido de la cremallera = 17,1 mm
crémaillère = 17,1 mm
Min. control rod travel 16.8 mm Déplacement de la Recorrido mínimo de la
crémaillère 16,8 mm cremallera 16,8 mm
4.00.39
008 918 12 BOMAG 1181
complete engine
engine
84. Schrauben wieder 60° festdrehen und in

Stufen mit einem Drehmoment von 7 Nm,
10 Nm und 30 Nm festdrehen.
4
Hinweis: Mit der jeweils außenliegenden, vom 6
5
Schwungrad entfernteren Schraube
beginnen. (siehe Pfeil)
Regelstangenweg messen mit Einspritz-

pumpen 3
85. Feststellschraube aus Vorrichtung heraus-
schrauben. Vorrichtung drehen.
86. Von Vorrichtung bis zur Stopstellung der

Regelstange messen. 6
86.1 Von Vorrichtung bis zur Startstellung der

Regelstange messen. 6 4
Differenz zur Stopstellung ergibt Regel-
stangenweg.
9
Beispiel: Stopstellung = 30,5 mm
Startstellung = 13,4 mm
Regelstangenweg = 17,1 mm
Regelstangenweg mindestens 16,8 mm
4.00.39
1182 BOMAG 008 918 12
Diesel engine 18.9
87. Feststellvorrichtung, Zeiger und Grad-

3 scheibe abbauen.
Leichtgängigkeit der Regelstange prüfen

9 88. Beim langsamen Hineinschieben der
Regelstange darf kein ungleichmäßiger
Widerstand auftreten.
Nach dem Loslassen muß die Regelstange
durch die Feder aus jeder Position in die
Ausgangslage zurückgedrückt werden.
Regelstangenweg messen für Regleran-

6 passung
89. Regelstangenweg (Rückstandsmaß) vom

Räderkastendeckel bis zur Stopstellung
messen.
Dieses ermittelte Maß ist bei Regleraus-

tausch oder Reglerreparatur unbedingt
anzugeben.
4.00.40
008 918 12 BOMAG 1183
complete engine
engine
87. Remove locking device, pointer and 87. Déposer le dispositif 87. Desmontar el dispositivo de
graduated disc. d’immobilisation, l’index et le bloqueo, el indicador y el disco
disque gradué. graduado.
Checking ease of movement of Contrôle du libre coulissement de la Comprobar el fácil movimiento de la

control rod crémaillère cremallera
88. When slowly introducing the 88. Lors de l'introduction lente de la 88. Introciendo lentamente la
control rod, there must not occur crémaillère, aucune résistance cremallera no se deberá percibir
any unequal resistance. irrégulière ne doit se produire. ninguna resistencia desigual.
After detaching the control rod, the Après avoir relâché la crémaillère Al soltar la cremallera deberá volver
spring must press it from any doit pouvoir revenir, grâce au a su posición de partida desde
position back into its original ressort, dans sa position de départ cualquier posición, por fuerza del
position â partir de n'importe quelle resorte.
position.
Gauging control rod travel for Mesurer la course de la crémaillère Determinación del recorrido de la
governor adjustment par ajustement du régulateur cremallera para la adaptación del
regulador
89. Gauge control rod travel from 89. Mesurer la cource de la crémaillère
surface of timing chest cover to (côte de retrait) du couvercle de la 89. Medir el recorrido (medida de
stop position. distribution à la position stop. retroceso) de la tapa del cárter de
It is mandatory to indicate the Toujours indiquer cette cote lors la distribución a la posición de
dimension determined when d'un changement ou d'une parada.
replacing or repairing the governor. réparation du régulateur. El valor determinado de esta
manera, tendrá que ser indicado,
imprescindiblemente, para la
reparación o sustitución del
regulador.
4.00.40
1184 BOMAG 008 918 12
Diesel engine 18.9
Flywheel/V-belt pulley Volant moteur/poulie à gorge Volante / polea acanalada
90. Position flywheel, using a selfmade 90. Mettre en place le volant moteur en 90. Colocar el volante en su sitio,
guide mandrel. Secure bolts utilisant un mandrin de guidage de utilizando un mandril de guía de
fingertight. fabrication locale. Serrer les vis à la confección propia. Apretar los
main. tornillos a mano.
91. Retain flywheel. Tighten bolts 91. Maintenir le volant moteur. Serrer 91. Retener el volante. Apretar los
according to specification. les vis selon les consignes de Tornillos según prescripción.
serrage. Apriete inicial:
Initial tightening torque Valeur de préserrage tornillos 30 - 45 mm long
Bolts 30 - 45 mm long 20-30 Nm Vis 30 - 45 mm de long 20-30 Nm ________________ 20-30 Nm
Bolts 50 - 85 mm long 30-40 Nm Vis 50 - 85 mm de long 30-40 Nm tornillos 50 - 85 mm long
1st tightening angle 1er serrage à l’angle ________________ 30-40 Nm
bolts 30 - 85 mm long ______ 60° vis 30 - 85 mm de long _____ 60° 1er ángulo de reapriete
2nd tightening angle 2e serrage à l’angle tornillos 30 - 85 mm long ___ 60°
bolts 30 mm long __________ 30° vis 30 mm de long _________ 30° 2o ángulo de reapriete
bolts 35-85 mm long _______ 60° vis 35 - 85 mm de long _____ 60° tornillos 30 mm long _______ 30°
tornillos 35 - 85 mm long ___ 60°
Note: Bolts may be used 5x if Nota: les vis peuvent être utilisées, Nota: Los tornillos son reutilizables
evidence can be furnished selon la pratique, 5 fois au hasta 5 veces, siempre que
concerning their use. maximum. esto se pueda comprobar.
92. Fit V-belt pulley and retain against 92. Monter la poulie et maintenir le 92. Montar la polea acanlada, retenerla
flywheel. Tighten bolts according to volant moteur. Serrer les vis selon en el volante y apretar los tornillos
specifications. les consignes de serrage. según prescripción.
Initial tightening torque 40-50 Nm Valeur de préserrage _ 40 - 50 Nm Apriete inicial: _______ 40-50 Nm
1st tightening angle 1er serrage à l'angle 1er ángulo de reapriete:
bolts 60 mm long __________ 60° vis 60 mm de long _________ 60° tornillos 60 mm long _______ 60°
2nd tightening angle 2e serrage à l'angle 2° ángulo de reapriete:

Note: Use Torx socket wrench E20. Nota: utiliser la clé à douille Torx E20. Nota: Utilizar la llave de vaso Torx
4 Bolts may be used max. 5x if Les vis peuvent être utilisées, E20. Los tornillos son
evidence can be furnished selon la pratique, 5 fois au reutilizables hasta 5 veces,
concerning their use. maximum. siempre que esto se pueda
comprobar.
4.00.41
008 918 12 BOMAG 1185
complete engine
engine
Schwungrad/Keilriemenscheibe
90. Schwungrad unter Verwendung eines

4
selbstgefertigten Führungsdornes
aufsetzen. Schrauben handfest anziehen.
91. Schwungrad gegenhalten. Schrauben nach

Anziehvorschrift festdrehen. 4
Vorspannwert:
Schrauben 30 - 45 mm lang __ 20-30 Nm
Schrauben 50 - 85 mm lang __ 30-40 Nm
6
1. Nachspannwinkel
Schrauben 30 - 85 mm lang _______ 60°
5
2. Nachspannwinkel
Schrauben 30 mm lang ___________ 30°
Schrauben 35 - 85 mm lang _______ 60°
Hinweis: Schrauben können bei Nachweis-

barkeit max. 5x wiederverwendet
werden.
4
92. Keilriemenscheibe anbauen und am
Schwungrad gegenhalten. Schrauben nach
Anziehvorschrift festdrehen.
6
Vorspannwert: ______________ 40-50 Nm
1. Nachspannwinkel
5
Schrauben 60 mm lang ____________ 60°
2. Nachspannwinkel
Hinweis: Torx-Steckschlüssel E20 verwenden.
Schrauben können bei Nachweis-
barkeit max. 5x wiederverwendet 4
werden.
4.00.41
1186 BOMAG 008 918 12
Diesel engine 18.9
Zylinderkopf
4 93. Zylinderkopfdichtung bestimmen.
7 94. Abstandsplättchen auf die Dichtfläche des
6
Zylinderkurbelgehäuse legen und Meßuhr
auf “0” stellen.
95. Meßuhr an den Meßstellen auf den Kolben

4 setzen und den größten Kolbenüberstand
ermitteln.
6 Hinweis: Alle Kolben müssen vermessen
5
werden.
96. Meßpunkte beachten.

9
90
BFM 1012 90 mm
BFM 1013 95 mm
4.00.42
008 918 12 BOMAG 1187
complete engine
engine
Cylinder head Culasse Culata
93. Determine cylinder head gasket. 93. Définir le joint de culasse. 93. Determinar junta de culata.
94.Place spacers on sealing surface of 94. Placer les plaquettes d’écartement 94. Poner las plaquitas distanciadoras
crankcase with integrated liners sur le plan de joint du bloc moteur sobre la superficie de cierre del
and set dial gauge to „0“. et régler le comparateur sur „0“. bloque motor y ajustar el
comparador a „0“.
95. Position dial gauge on piston at 95. Placer le comparateur aux points 95. Colocar el comparador sobre el
gauge points and determine max. de mesure sur le piston et calculer pistón en los puntos de medición y
piston projection. la plus grande cote d dépassement. determinar el saliente máximo del
pistón.
Note: All pistons must be gauged. Nota: le relevé des mesures doit être Nota: Este valor deberá determinarse
fait sur tous les pistons. para todos los pistones.
96. Watch gauge points. 96. Veiller aux points de mesure. 96. Observar los puntos de medición.
BFM 1012 90 mm BFM 1012 90 mm BFM 1012 90 mm

BFM 1013 95 mm BFM 1013 95 mm BFM 1013 95 mm
4.00.42
1188 BOMAG 008 918 12
Diesel engine 18.9
97. Compare max. value with table and 97. Comparer à l’aide du tableau la 97. Comparar el valor máximo con la
determine appropriate cylinder valeur la plus élevée puis définir le tabla y definir la junta de culata
head gasket. joint de culasse correspondant. correspondiente.
BFM 1012 BFM 1012 BFM 1012
Piston Marking of Cote de Caractéristique Saliente de pistón Marcación de la

projection cylinder head gasket dépassement joint culasse junta de culata
piston
0.43 - < 0.64 mm 1 hole 0,43 - < 0,64 mm 1 trou 0,43 - < 0,64 mm 1 agujero
0.64 - < 0.74 mm 2 holes 0,64 - < 0,74 mm 2 trous 0,64 - < 0,74 mm 2 agujeros
0.74 - 0.85 mm 3 holes 0,74 - 0,85 mm 3 trous 0,74 - 0,85 mm 3 agujeros
BFM 1013 BFM 1013 BFM 1013
Piston Marking of Cote de Caractéristique Saliente de pistón Marcación de la

projection cylinder head gasket dépassement joint culasse junta de culata
piston
0.28 - < 0.54 mm 1 hole 0,28 - < 0,54 mm 1 trou 0,28 - < 0,54 mm 1 agujero
0.54 - < 0.64 mm 2 holes 0,54 - < 0,64 mm 2 trous 0,54 - < 0,64 mm 2 agujeros
0.64 - 0.75 mm 3 holes 0,64 - 0,75 mm 3 trous 0,64 - 0,75 mm 3 agujeros
98. Position cylinder head gasket. 98. Placer le joint de culasse. 98. Colocar la junta de culata.
Note: Sealing surfaces for cylinder Nota: les plans de joint du joint de Nota: Las superficies de cierre para la
head gasket must be clean and culasse doivent être propres et junta de culata deben estar
free of oil. Watch out for dowel sans huile. Veiller aux douilles limpias y exentas de aceite.
sleeves. d’ajustage. Prestar atención a los
casquillos de ajuste.
4.00.43
008 918 12 BOMAG 1189
complete engine
engine
97. Größten Wert mit der Tabelle vergleichen

und entsprechende Zylinderkopfdichtung
ermitteln.
9
BFM 1012
Kolbenüberstand Kennzeichnung der

Zylinderkopfdichtung
0,43 - < 0,64 mm 1 Loch

0,64 - < 0,74 mm 2 Löcher
0,74 - 0,85 mm 3 Löcher
BFM 1013
Kolbenüberstand Kennzeichnung der

9
Zylinderkopfdichtung
0,28 - < 0,54 mm 1 Loch

0,54 - < 0,64 mm 2 Löcher
0,64 - 0,75 mm 3 Löcher
98. Zylinderkopfdichtung auflegen.
Hinweis: Dichtflächen für Zylinderkopfdich-

4
tung müssen sauber und ölfrei sein.
Auf Paßhülsen achten.
8
5
4.00.43
1190 BOMAG 008 918 12
Diesel engine 18.9
Zylinderkopf mit Ventiltrieb BFM 1012

4 99. Zylinderkopf aufsetzen. Kurze Zylinderkopf-
z schrauben leicht einölen und beidrehen.
5
Hinweis: Zylinderkopfschrauben können
bei Nachweisbarkeit max. 5x
verwendet werden.
100. Stoßstangen einsetzen.

4
101. Kipphebelbock montieren und zu den

4 Stoßstangen/Ventilen ausrichten.
102. Lange Zylinderkopfschrauben leicht
4 4 einölen und beidrehen. M8 Schraube

einsetzen und beidrehen.
z Hinweis: Zylinderkopfschrauben können
5 bei Nachweisbarkeit max. 5x

verwendet werden.
4.00.44
008 918 12 BOMAG 1191
complete engine
engine
Cylinder head with valve gear Culasse et culbuterie du BFM 1012 Culata con accionamiento de
BFM 1012 válvulas, BFM 1012
99. Position cylinder head. Lightly oil 99. Mettre en place la culasse. Huiler 99. Colocar la culata. Untar con un
and start short cylinder head bolts. légèrement les vis de culasse et les poco de aceite los tornillos de
serrer modérément. culata cortos y apretarlos hasta que
se apoyen.
Note: Cylinder head bolts may be Nota: réutiliser les vis de culasse au Nota: Los tornillos de culata son
reused max. 5x if evidenced can moins 5 fois. reutilizables hasta 5 veces,
be furnished concerning their siempre que esto se pueda
use. comprobar.
100. Insert pushrods. 100. Mettre en place les tiges de 100. Introducir las varillas de empuje.
culbuteurs.
101. Fit rocker arm bracket and align 101. Monter le support des 101. Montar el soporte de balancines
relative to pushrods/valves. culbuteurs et l’aligner par y alinearlo con respecto a las
rapport aux tiges de culbuteurs/ varillas de empuje / válvulas.
soupapes.
102. Lightly oil and start long 102. Huiler légèrement les vis de 102. Untar con un poco de aceite los
cylinder head bolts. Insert and culasse longues et les serrer tornillos de culata largos y
start M8 bolt. modérément. Placer une vis M8 apretarlo hasta que se apoyen. 4
et serrer à la main. Meter el tornillo M8 y apretarlo
hasta que se apoye.
Note: Cylinder head bolts may be Nota: réutiliser les vis de culasse au Nota: Si es comprobable, se pueden
reused max. 5x if evidenced can moins 5 fois. utilizar los tornillos a lo sumo
be furnished concerning their 5 veces.
use.
4.00.44
1192 BOMAG 008 918 12
Diesel engine 18.9
103. Tighten M8 bolt with a torque 103. Serrer la vis M8 au couple de 103. Apretar el tornillo M8 con un
of 21 Nm. 21Nm. par de 21 Nm.
104. Tighten cylinder head bolts 104. Serrer les vis de culasse selon 104. Apretar los tornillos de culata
according to specification. les préconisations de serrage: según prescripción.
Initial tightening torque: Valeur préserrage Apriete inicial:

1st stage ____________ 30 Nm 1ère phase __________ 30 Nm 1ª fase _____________ 30 Nm
2nd stage ___________ 80 Nm 2ème phase _________ 80 Nm 2ª fase _____________ 80 Nm
Tightening angle: _____________ 90° Serrage définiti: ______________ 90° Reapriete: _____________ 90°
Note: Observe tightening order for Nota: tenir compte de l’ordre de Nota: Observar el orden de sucesión
cylinder head bolts. See serrage des vis de culasse. Voir al apretar los tornillos de culata.
Specification Data. caractéristiques techniques. Ver Datos técnicos.
Note: Adjust valve clearance - see Nota: pour le réglage du jeu aux Nota: Ajustar el juego de válvulas, ver
chapter 2. soupapes voir chapitre 2. capítulo 2.
Cylinder head with valve gear Culasse et culbuterie BFM 1013 Culata con accionamiento de
BFM 1013 válvulas, BFM 1013
4
105. Position cylinder head. Lightly 105. Mettre la culasse en place. 105. Colocar la culata. Untar con un
oil and start cylinder head bolts. Huiler légèrement les vis de poco de aceite los tornillos de
culasse et les serrer à la main. culata cortos y apretarlos hasta
que se apoyen.
Note: Cylinder head bolts may beused Nota: les vis de culasse sont Nota: Los tornillos de culata son
max. 5x if evidence can be réutilisables au moins 5 fois. reutilizables hasta 5 veces,
furnished concerning their use. siempre que esto se pueda
comprobar.
4.00.45
008 918 12 BOMAG 1193
complete engine
engine
103. M8 Schraube mit einem Drehmoment von

21 Nm festdrehen.
4
6
104. Zylinderkopfschrauben nach Anziehvor-

schrift festdrehen. 4
Vorspannwert:
1. Stufe ____________________ 30 Nm 6
5
2. Stufe ____________________ 80 Nm
Nachspannen: __________________ 90°
Hinweis: Reihenfolge beim Anziehen der

Zylinderkopfschrauben beachten.
Siehe Techn. Daten.
Hinweis: Ventilspiel einstellen siehe Kapitel 2.
Zylinderkopf mit Ventiltrieb BFM 1013
105. Zylinderkopf aufsetzen. Zylinderkopf-

4 4
schrauben leicht einölen und beidrehen.
z
5
Hinweis: Zylinderkopfschrauben können bei
Nachweisbarkeit max. 5x verwendet
werden.
4.00.45
1194 BOMAG 008 918 12
Diesel engine 18.9
106. Zylinderkopfschrauben nach Anziehvor-

4 schrift festdrehen.
6 Vorspannwert:
1. Stufe ____________________ 50 Nm
5
2. Stufe ___________________ 130 Nm
Nachspannen: __________________ 90°
Hinweis: Reihenfolge beim Anziehen der

Zylinderkopfschrauben beachten.
Siehe Techn. Daten.
107. Stoßstangen einsetzen.

4
108. Kipphebelbock montieren und zu den

4 Stoßstangen/Ventilen ausrichten.
4 4 21 Nm festdrehen.
6 Hinweis: Ventilspiel einstellen, siehe Kapitel 2.
4.00.46
008 918 12 BOMAG 1195
complete engine
engine
106. Tighten cylinder head bolts 106. Serrer les vis de culasse selon 106. Apretar los tornillos de culata
according to specification. les préconisations de serrage. según prescripción.
Initial tightening torque: Valeur préserrage: Apriete inicial:

1st stage ___________ 50 Nm 1ère phase __________ 50 Nm 1ª fase _____________ 50 Nm
2nd stage _________ 130 Nm 2ème phase ________ 130 Nm 2ª fase ___________ 130 Nm
Tightening angle: ________ 90° Serrage définitif ________ 90° Reapriete: _____________ 90°
Note: Observe tightening order for Nota: tenir compte de l’ordre de Nota: Observar el orden de sucesión
cylinder head bolts. See serrage des vis de culasse. Voir al apretar los tornillos de culata.
Specification Data. caractéristiques techniques. Ver Datos técnicos.
107. Insert pusrods. 107. Introduire les tiges de culbuteurs. 107. Introducir las varillas de empuje.
108. Fit rocker arm bracket and align 108. Monter le support des culbuteurs 108. Montar el soporte de balancines y
towards pushrods/valves. et l’aligner par rapport aux tiges alinearlo con respecto a las
de culbuteurs/soupapes. varillas de empuje / válvulas.
109. Tighten bolt with a torque of 109. Serrer la vis M8 au couple de 109. Apretar el tornillo con un par de
21 Nm. 21 Nm. 21 Nm.
4
Note: Adjust valve clearance, see Nota: pour le réglage du jeu aux Nota: Ajustar el juego de válvulas, ver
chapter 2. soupapes voir chapitre 2. capítulo 2.
4.00.46
1196 BOMAG 008 918 12
Diesel engine 18.9
110. Fit pencil-type glow plugs or 110. Monter les bougies de 110. Montar las piezas de cierre o
blanking parts. préchauffage ou les éléments de bujías de espiga de
fermeture. incandescencia.
111. Tighten pencil-type glow plugs or 111. Serrer les bougies de 111. Apretar las piezas de cierre o
blanking parts with a torque of préchauffage ou les éléments de bujías de espiga de
20 ± 2 Nm. fermeture au couple de incandescencia con un par de
20 ± 2 Nm. 20 ± 2 Nm.
Shutdown solenoid Electroaimant d'arrêt Solenoide de parada
112. Press control rod into stop posi- 112. Pousser et maintenir la crémail- 112. Empujar la barra cremallera en la
tion and hold in place. Fit shut- lère en position de stop. Monter posición de parada, reteniéndola.
down solenoid with new O-seal. électroaimant d’arrêt avec un Montar el solenoide de parada
joint torique neuf. con un anillo tórico nuevo.
Note: Lightly oil O-seal. Nota: huiler légèrement le joint Nota: Untar con un poco de aceite el
torique. anillo tórico.
113. Tighten bolts with a torque 113. Serrer les vis au couple 113. Apretar los tornillos con un par
of 21 Nm. de 21 Nm. de 21 Nm.
4
4.00.47
008 918 12 BOMAG 1197
complete engine
engine
110. Glühstiftkerzen oder Verschlußteile

einbauen.
4
111. Glühstiftkerzen oder Verschlußteile mit

einem Drehmoment von 20 ± 2 Nm
festdrehen.
4
6
Abstellmagnet
112. Regelstange in Stop-Stellung drücken und

4
festhalten. Abstellmagnet mit neuem Rund-
dichtring einbauen.
ß
Hinweis: Runddichtring leicht einölen. 5

6
4.00.47
1198 BOMAG 008 918 12
Diesel engine 18.9
Einspritzventil/Einspritzleitungen
4 114. Neue Dichtung mit etwas Fett auf das
ß Einspritzventil aufschieben und Einspritz-

ventil einsetzen.
u Hinweis: Leckölanschluß muß zur Abgasseite

weisen.
5
115. Spannpratzen aufsetzen. Schraube lose ein-

4 schrauben.
116. Neue Einspritzleitung mit Dichtgummi an-

4 bauen. Überwurfmuttern fingerfest auf-
schrauben.
38-4-193 ß Hinweis: Bei Montage der Einspritzleitungen
5
müssen die Dichtkonen exakt aufein-
andersitzen.
Ein Nachbiegen ist nicht zulässig.
Die Einspritzleitungen dürfen nicht
2x verwendet werden.
117.Schraube der Spannpratzen mit einem Dreh-
4 4 moment von 16 + 5 Nm festdrehen.
4.00.48
008 918 12 BOMAG 1199
complete engine
engine
Injector/injection lines Injecteur/conduites d’injection Inyector/tuberías de inyección
114. Slide new seal over injector using 114. Insérer avec un peu de graisse un 114. Colocar la junta nueva con un
some grease and insert injector. joint neuf sur l’injecteur et mettre poco de grasa sobre el inyector
en place l’injecteur. e instalar éste.
Note: leakage fuel line connection Nota: le raccordement de la conduite Nota: El racor de combustible
must face the exhaust side. de retour des fuites doit être sobrante debe indicar hacia el
orienté dans le sens lado de escape.
échappement.
115. Position clamping pads. Start 115. Placer les griffes de serage et 115. Colocar las patas de sujeción.
bolt. visser boulon sans serrer. Enroscar el tornillo, dejándolo
suelto.
116. Fit new injection line with sealing 116. Monter une conduite d’injection 116. Montar la tubería de inyección
rubber. Screw on cap nuts finger- neuve avec un caoutchouc d’étan- nueva con una junta de goma.
tight. chéité. Serrer les écrous-raccords Enroscar las tuercas de empalme
modérément à la main. con la mano.
Note: When fitting the injection lines, Nota: au montage des conduites Nota: Al montar las tuberías de
the sealing cones must match d’injection les cônes inyección, se deberá cuidar de
pecisely. d’étanchéité doivent que los conos de obturación
Rebending is not permissible. parfaitement correspondre. queden asentados unos
The injection lines must not Un recintrage n’est pas exactamente sobre los otros.
be used twice. autorisé. Ne jamais utiliser Es inadmisible corregir el
deux fois les conduites curvado. La tuberías de
d’injection. inyección no deben ser
empleadas dos veces.
117. Tighten bolt of clamping pads 117. Visser le boulon des griffes de 117. Apretar el tornillo de las patas de
with a torque of 16 + 5 Nm. serrage au couple de 16 + 5 Nm. sujeción con un par de 16 + 5 Nm.
4
4.00.48
1200 BOMAG 008 918 12
Diesel engine 18.9
118. Preload cap nuts of injection line 118. Préserrer les écrous-raccords de 118. Apretar las tuercas de empalmede
on injection pump and injector la conduite d’injection de la pom- las tuberías de inyección en la
with a torque of approx. 5 Nm. pe d’injection et de l’injecteur au bomba de inyección e inyector
Thereafter tighten cap nuts with couple d’environ 5 Nm. Ensuite inicialmente con un par de aprox.
a torque of 25 + 3.5 Nm. bloquer les écrous-raccords au 5 Nm y, luego, con un par de
couple de 25 + 3,5 Nm. 25 + 3,5 Nm.
119. Fit leakage fuel line and 119. Monter la conduite de retour des 119. Montar la tubería de combustible
introduce through sealing rubber. fuites et la faire passer à travers sobrante y hacarla pasar a través
les caouchoucs d’étanchéité. de las piezas obturantes de goma.
Note: Leaage fuel lines must always Nota: Il faut en principe renouveler les Nota: Las tuberías de combustible
be replaced. conduites de retour d’huile de sobrante deberán ser
fuite. sustituidas siempre por otras
nuevas.
120. Fit overflow valve with new Cu 120. Monter la soupape de décharge 120. Montar la válvula de rebose
seals and leakage fuel line.Tighten avec des joints Cu neufs et la provista de juntas de cobre
overflow valve with a torque of conduite de retour des fuites. nuevas y la tubería de
30 Nm. Serrer la soupape de décharge combustible sobrante. Apretar la
au couple de 30 Nm. válvula de rebose con un par de
30 Nm.
Air intake/exhaust manifold Collecteur d’admission/collecteur Colector de admisión / colector de

d’échappement escape
4
121. Mount air intake manifold with 121. Monter le collecteur d’admission 121. Montar el colector de admisión
new gaskets. avec des joints neufs. con juntas nuevas.
4.00.49
008 918 12 BOMAG 1201
complete engine
engine
118. Überwurfmuttern der Einspritzleitung an Ein-

spritzpumpe und Einspritzventil mit einem
Drehmoment von ca. 5 Nm vorspannen.
4
Danach die Überwurfmuttern mit einem
Drehmoment von 25 + 3,5 Nm festdrehen. 6
119. Leckölleitung anbauen und durch Dicht-

gummis einführen.
4
Hinweis: Leckölleitungen sind grundsätzlich
zu erneuern. 5
ß
120. Überströmventil mit neuen Cu-Dichtun-

gen und Leckölleitung anbauen.
Überströmventil mit einem Drehmoment
4
von 30 Nm festdrehen.
ß
6
Luftansaugrohr/Abgassammelrohr
121. Luftansaugrohr mit neuen Dichtungen

4 4
anbauen.
ß
4.00.49
1202 BOMAG 008 918 12
Diesel engine 18.9
122. Schrauben für Ladeluftleitung mit einem

123. Abgassammelrohr mit neuen Dichtungen

4 anbauen.
Die Umbördelung der Dichtung muß zum
ß Zylinderkopf weisen.
8
Hinweis: Stiftschrauben mit Deutz S1
Never Seize-Paste einstreichen.
124. Muttern für Abgassammelrohr mit einem

4 Drehmoment von 25 ± 2,5 Nm festdre-
hen.
6
Zylinderkopfhaube
4 4 125. Dichtung aufsetzen.

0
4.00.50
008 918 12 BOMAG 1203
complete engine
engine
122. Tighten bolts for charge air pipe 122. Serrer les vis de la conduite d’air 122. Apretar los tornillos de la tubería
with a torque of 11 ± 1 Nm. de suralimentation au couple de de aire de sobrealimentación con
11 ± 1 Nm. un par de 11 ± 1 Nm.
123. Mount exhaust manifold with new 123. Monter le collecteur 123. Montar el colector de escape con
gaskets. d’échappement avec des joints juntas nuevas.
The gasket bead must point neufs. El bordeado de la juntadebe
towards the cylinder head. Le bord rabattu du joint doit être indicar a la culata.
orienté vers la culasse.
Note: Apply Deutz S1 Never Seize Nota: enduire les goujons filetés de Nota: Aplicar a los espárragos pasta
paste to studs. pâte Deutz S1 Never Seize. Deutz S1 Never Seize.
124. Tighten nuts for exhaust manifold 124. Serrer les écrous du collecteur 124. Apretar las tuercas del colector de
with a torque of 25 ± 2.5 Nm. d’échappement au couple de escape con un par de
25 ± 2,5 Nm. 25 ± 2,5 Nm.
Cylinder head cover Culasse Tapa de culata
125. Position gasket. 125. Mettre en place le joint. 125. Colocar la junta. 4
4.00.50
1204 BOMAG 008 918 12
Diesel engine 18.9
126. Fit cylinder head cover together 126. Monter la vis de culasse avec la 126. Montar la tapa de culata con
with cover plate and cable tôle de recouvrement et le chapa de recubrimiento y mazo
harness. Tighten bolts with a faisceau de câbles. Serrer les vis de cables. Apretar los tornillos
torque of 9 ± 1 Nm. au couple de 9 ± 1 Nm. con un par de 9 ± 1 Nm.
Lube oil cooler Radiateur à huile Refrigerador de aceite lubricante
127. Mount lube oil cooler with new 127. Monter le radiateur avec un 127. Montar el refrigerador de aceite
gasket. joint neuf. lubricante con una junta nueva.
128. Tighten bolts with a torque of 128. Serrer les vis au couple de 128. Apretar los tornillos con un par
21 ± 2 Nm. 21 ± 2 Nm. de 21 ± 2 Nm.
Note: Fit retainer for cable connector Nota: selon l’équipement du moteur Nota: Si lo hay, montar también el
as well if any. monter le support de liaison soporte para la conexión de
des câbles. cables.
129. Fit both screw plugs with new 129. Monter les deux tubulures à 129. Instalar ambos enchufes con
Cu seals. visser avec un joint Cu neufs. una junta de cobre nuevas.
4
4.00.51
008 918 12 BOMAG 1205
complete engine
engine
126. Zylinderkopfhaube mit Abdeckblech und

Kabelbaum montieren. Schrauben mit
einem Drehmoment von 9 ± 1 Nm fest-
4
drehen.
6
Schmierölkühler
127. Schmierölkühler mit neuer Dichtung

4
anbauen.
ß

21 ± 2 Nm festdrehen. 4
Hinweis: Falls vorhanden, Halter für Kabel-
verbindung mitanbauen. 6
5
129. Beide Einschraubstutzen mit neuer Cu-

Dichtung anbauen. 4 4
ß
4.00.51
1206 BOMAG 008 918 12
Diesel engine 18.9
130. Muttern mit einem Drehmoment von

4 50 ± 5 Nm festdrehen.
131. Kraftstoffilterdichtung leicht einölen.

4 Kraftstoffilterpatrone handfest andrehen.
132. Ölfilterdichtung leicht einölen.

4 Ölfilterpatrone handfest andrehen.
Kühlmittelpumpe
4 4 133. Steckstück.
ß Neue Runddichtringe aufziehen.
5
Hinweis: Runddichtringe mit Montagegleitmit-
tel AP25N bestreichen.
4.00.52
008 918 12 BOMAG 1207
complete engine
engine
130. Tighten nut with a torque of 130. Serrer les écrous au couple de 130. Apretar la tuerca con un par de
50 ± 5 Nm. 50 ± 5 Nm. 50 ± 5 Nm.
131. Lightly oil fuel filter gasket. 131. Huiler légèrement le joint du filtre 131. Untar con un poco de aceite la
Secure fuel filter cartridge à combustible. Serrer la junta del filtro de combustible.
fingertight. cartouche filtrante à la main. Apretar el cartucho filtrante con la
mano.
132. Lightly oil oil filter gasket. Secure 132. Huiler légèrment le joint du filtre à 132. Untar con un poco de aceite la
oil filter cartridge fingertight. huile. Serrer la cartouche filtrante junta del filtro de aceite. Apretar el
à la main. cartucho filtrante con la mano.
Coolant pump Pompe à réfrigérant Bomba de líquido refrigerante
133. Plug-in element 133. Pièce d'insertion. Monter les 133. Pieza de enchufe. 4
Slide on O-seals. joints toriques neufs. Colocar anillos tóricos nuevos.
Note: Apply lubricant AP25N to Nota: enduire le joint torique de Nota: Aplicar lubricante de montaje
O-seals. lubrifiant de montage AP25N. AP25N a los anillos tóricos.
4.00.52
1208 BOMAG 008 918 12
Diesel engine 18.9
134. Press plug-in element into 134. Insérer l’élément enfichable dans 134. Introducir a presión la pieza de
thermostat housing and coolant le boîtier du thermostat et la enchufe en la caja del termostato
pump. pompe à réfrigérant. y en la bomba de líquido
refrigerante.
135. Insert new O-seals into 135. Monter le joint toique neuf dans 135. Montar un anillo tórico nuevo en
thermostat housing. le carter du thermostat. la caja del termostato.
Note: Apply lubricant AP25N to Nota: enduire le joint torique de Nota: Aplicar lubricante de montaje
O-seals. lubrifiant de montage AP25N. AP25N a los anillos tóricos.
136. Mount preassembled coolant 136. Monter la pompe à réfrigérant 136. Montar la bomba de líquido
pump with new gasket. préassemblée avec un joint neuf. refrigerante premontada, con una
junta nueva.
137. Tighten bolts alternately with a 137. Serrer alternativement les vis au 137. Apretar alternativamente los
torque of 21 ± 2 Nm. couple de 21 ± 2 Nm. tornillos con un par de
4 21 ± 2 Nm.
4.00.53
008 918 12 BOMAG 1209
complete engine
engine
134. Steckstück in Thermostatgehäuse und

Kühlmittelpumpe eindrücken.
4
135. Neuen Runddichtring in Thermostatge-

häuse einsetzen. 4
Hinweis: Runddichtring mit Montagemittel
AP25N bestreichen. ß
5
136. Vormontierte Kühlmittelpumpe mit neuer

Dichtung anbauen. 4
ß
137. Schrauben wechselseitig mit einem Dreh-

moment von 21 ± 2 Nm festdrehen. 4 4
6
4.00.53
1210 BOMAG 008 918 12
Diesel engine 18.9
138. Kühlmitteltemperaturgeber mit neuer

4 Dichtung und Isolierschlauch, falls vor-
handen, mit einem Drehmoment von
ß 18 ± 2 Nm festdrehen.
Kraftstoffpumpe
4 139. Kraftstoffpumpe anbauen
5 Hinweis: Schrauben leicht andrehen.
140. Kraftstoffleitungen mit neuen Cu-Dichtun-

4 gen anbauen.
Cobraklemmenzange benutzen.
ß Hinweis: Achtung - Gewinde für Anschluß der
5
Zulaufleitung an der Kraftstoffpumpe
ist M16x1,5.
Ölansaugrohr/Ölwanne
4 4 141. Motor 180° drehen. Ölansaugrohr mit

ß neuer Dichtung anbauen.
5 Hinweis: Halter mitanbauen. Schrauben nicht

festdrehen.
4.00.54
008 918 12 BOMAG 1211
complete engine
engine
138. Fit coolant temperature sensor 138. Serrer au couple de 18 ± 2 Nm 138. Apretar con un par de 18 ± 2 Nm
with new seal and insulating hose, le capteur de produit refrigérant el transmisor de temperatura de
if any, and tighten with a avec un joint neuf et un tuyau refrigerante con una junta nueva
torque of 18 ± 2 Nm. isolant , si le moteur en est y, si existe, manguera aislante.
équipé d'un.
Fuel pump Pompe à combustible Bomba de combustible
139. Fit fuel pump. 139. Monter la pompe à combustible. 139. Montar la bomba de combustible.
Note: Start bolts. Nota: serrer légèrement les vis. Nota: Apretar ligeramente a mano los
tornillos.
140. Fit fuel lines with new Cu seals. 140. Monter les tuyauteries de 140. Montar las tuberías de
Use Cobra clamp pliers. combustible avec des joint Cu combustible con juntas de cobre
neufs. Utiliser la pince de serrage nuevas. Utilizar los alicates Cobra.
Cobra.
Note: Attention - thread for feed line Nota: attention - filetage du raccord Nota: Atención - la rosca para la
connection on fuel pump is de la conduite d’arrivée à la unión la tubería de entrada a la
M16x1.5. pompe à combustible est bomba de combustible es
M16x1,5. M16x1,5.
Oil suction pipe/oil pan Tube d’aspiration d’huile/carter Tubo de aspiración de aceite/cárter
d’huile de aceite
4
141. Turn engine by 180°. Fit oil 141. Virer le moteur de 180°. Monter le 141. Girar el motor por 180°. Montar el
suction pipe with new gasket. tube d’aspiration d’huile en tubo de aspiración de aceite con
utilisant un joint neuf. una junta nueva.
Note: Fit retainer as well. Do not Nota: monter le dispositif de Nota: Montar también el soporte. No
tighten bolts. maintien.Ne pas serrer les vis à apretar los tornillos.
fond.
4.00.54
1212 BOMAG 008 918 12
Diesel engine 18.9
142. Order of tightening. 142. Ordre de serrage. 142. Orden de sucesión a seguir para
el apriete:
1. Bolts of oval flange 1. Vis de la bride ovale 1. Tornillos de la brida ovalada.

2. Retainer of oil suction pipe 2. Serrer le support de maintien 2. Soporte del tubo de aspiración
with a torque of 21 ± 2 Nm. du tube d’aspiration d’huile au de aceite, apretar con un par de
couple de 21 ± 2 Nm. 21 ± 2 Nm.
143. Cut off projecting gasket. 143. Sectionner la partie du joint qui 143. Cortar lo que sobresale de la
dépasse. junta.
144. Fill up joints of oil pan sealing 144. Remplir les joints du plan de joint 144. Tapar las juntas de la superficie
surface with Deutz DW 47. du carter d’huile de Deutz DW 47. de cierre del cárter de aceite con
Deutz DW 47.
145. Position new gasket on 145. Placer un joint neuf sur le bloc 145. Colocar una junta nueva sobre el
crankcase. moteur. bloque motor.
4
4.00.55
008 918 12 BOMAG 1213
complete engine
engine
142. Reihenfolge beim Festdrehen.
1. Schrauben des Ovalflansches

4
2. Halter des Ölansaugrohres
mit einem Drehmoment von 21 ± 2 Nm 6
festdrehen.
143. Überstehende Dichtung abschneiden.

9
144. Fugen der Ölwannendichtfläche mit Deutz

DW 47 auffüllen. 4
w
145. Neue Dichtung auf das Kurbelgehäuse

auflegen. 4 4
ß
4.00.55
1214 BOMAG 008 918 12
Diesel engine 18.9
146. Bei Dichtung für Blechölwanne alle

w Aussparungen mit Deutz DW 74 auffüllen.
147. Bei Blechölwanne:

4 Ölwanne anbauen.
5 Hinweis: Markierte Einbaulage beachten.
148. Bei Gußölwanne:

4 Ölwanne anbauen und zum Räderkasten-
deckel ausrichten.
9
149. Schrauben gleichmäßig/wechselseitig mit
4 4 einem Drehmoment von 21 ± 2 Nm bei

Blechölwanne oder
6 29 ± 2 Nm bei Gußölwanne festdrehen.
4.00.56
008 918 12 BOMAG 1215
complete engine
engine
146. Fill up all recesses in the gasket 146. En présence du joint du carter 146. Si el cárter es de chapa:
for the sheet metal oil pan with d’huile en tôle remplir tous les Rellenar todas las escotaduras de
Deutz DW 74. évidements de Deutz DW 74. la junta con Deutz DW 74.
147. With sheet metal oil pan: 147. En présence d’un carter d’huile en 147. Si el cárter es de chapa:
Mount oil pan. tôle : monter le carter d’huile. Montar el cárter.
Note: Watch marked installation Nota: veiller au sens de montage Nota: Observar la posición marcada
position. indiqué. para el montaje.
148. With cast oil pan: 148. En présence d’un carter d’huile en 148. Si el cárter es de fundición:
Mount oil pan and align relative to fonte: Montar el cárter y alinearlo con
timing chest cover. Monter le carter et l’aligner respecto a la tapa del cárter de la
par rapport au couvercle du carter distribución.
de distribution.
149. Tighten bolts uniformly/alternately 149. Serrer uniformément l’une après 149. Apretar uniforme/alternativamente
with a torque of 21 ± 2 Nm with l’autre les vis au couple de os tornillos con un par de
sheet metal oil pan or with 21 ± 2 Nm pour le carter d’huile 21 ± 2 Nm en el caso del cárter de 4
29 ± 2 Nm with cast oil pan. en tôle ou au couple de 29 ± 2Nm chapa o de 29 ± 2 Nm en el
pour le carter d’huile en fonte. caso del cárter de fundición.
4.00.56
1216 BOMAG 008 918 12
Diesel engine 18.9
Governor Régulateur Regulador
150. Apply sealing compound 150. Enduire de pâte d’étanchéité 150. Aplicar sellante Deutz DW 48 al
Deutz DW 48 to governor. Deutz DW 48 le régulateur. regulador.
Sealing string dia.: 1.5 + 0.5 mm Epaisseur du fil d’étanchéité: Espesor del filo sellante:
ø 1,5 + 0,5 mm ø 1,5 + 0,5 mm
Note: Sealing surface must be free of Nota: le plan de joint doit être exempt Nota: La superficie de cierre debe
oil and grease. d’huile et de graisse. estar exenta de aceite y de
grasa.
151. Turn engine by 180°, mount 15.1 Virer le moteur de 180° et monter le 151. Girar el motor 180°. Montar el
governor. régulateur. regulador.
152. Tighten bolts in the order 152. Serrer les vis au couple de 152. Apretar los tornillos con un par
1-2-3-4-5 with a torque of 17 ± 1,5 Nm dans l’ordre 1-2-3-4-5. de 17 ± 1,5 Nm en el orden de
17 ± 1.5 Nm. sucesión 1-2-3-4-5.
153. Fit new O-seal to cover and 153. Monter le joint torique neuf sur le 153. Montar un anillo tórico nuevo
grease lightly. couvercle de fermeture et le sobre la tapa de cierre y
4 graisser légèrement. engrasarlo ligeramente.
4.00.57
008 918 12 BOMAG 1217
complete engine
engine
Regler
150. Dichtmittel Deutz DW 48 auf Regler

4
auftragen.
Dichtfadenstärke ø 1,5 + 0,5 mm w
Hinweis: Dichtfläche muß öl- und fettfrei sein. 5 47
,5
21 R
R
151. Motor um 180° drehen. Regler anbauen.

4
152. Schrauben in der Reihenfolge 1-2-3-4-5

mit einem Drehmoment von 17 ± 1,5 Nm
festdrehen.
4
6
3 1
4
5 2
153. Neuen Runddichtring auf Verschluß-

deckel montieren und leicht einfetten. 4 4
ß
u
4.00.57
1218 BOMAG 008 918 12
Diesel engine 18.9
154. Verschlußdeckel montieren.

4 Hinweis: Auf Abstandshülsen achten.

156. Halteplatte an Regler anbauen.

4
4
4
6
4.00.58
008 918 12 BOMAG 1219
complete engine
engine
154. Fit cover. 154. Monter le couvercle de fermeture. 154. Montar la tapa de cierre.
Note: Watch out for spacer sleeves. Nota: veiller aux douilles Nota: Prestar atención a los
d’écartement. casquillos distanciadores.
21 ± 2 Nm. 21 ± 2 Nm. 21 ± 2 Nm.
156. Fit retaining plate to governor. 156. Monter plaque d’appui sur 156. Montar la placa de soporte en el
régulateur. regulador.
21 ± 2 Nm. 21 ± 2 Nm. 21 ± 2 Nm.
4
4.00.58
1220 BOMAG 008 918 12
Diesel engine 18.9
Cable harness Faisceau de câbles Mazo de cables
158. Fit cable lug to governor. 158. Monter cosse de câble sur le 158. Montar el terminal de cable en el
régulateur. regulador.
159. Fit cable lug to shutdown 159. Monter cosse de câble sur 159. Montar el terminal de cable en el
solenoid. l’électroaimant d’arrêt. solenoide de parada.
160. Put together glow plug cable 160. Assembler coupleurs de câble de 160. Unir las dos partes de los
couplers. bougie de préchauffage. acoplamientos de cables de las
bujías de incandescencia.
4.00.59
008 918 12 BOMAG 1221
complete engine
engine
Kabelbaum
158. Kabelschuh an Regler anbauen.

4
159. Kabelschuh an Abstellmagnet anbauen.

4
160. Glühkerzen-Kabelkupplungen zusammen-

stecken. 4
4 4
4.00.59
1222 BOMAG 008 918 12
Diesel engine 18.9
Anschlußgehäuse
4 (Darstellung BFM 1012)
5 161. Motor 90° drehen. Anschlußgehäuse

anbauen.
Hinweis: Auf Vorhandensein der Zentrierhül-

sen achten.
162. Schrauben nach Anziehvorschrift

4 festdrehen.
Schrauben M 12 = 99 ± 10 Nm
6 Schrauben M 16 = 243 ± 25 Nm
5
Hinweis: Torx Werkzeug verwenden.
E 14 lange Ausführung
E 20 lange Ausführung
163. Abdeckblech anbauen.

4
4.00.60
008 918 12 BOMAG 1223
complete engine
engine
Adapter housing Carter d’adaptation Cárter de adaptación

(BFM 1012 shown here) (Illustration BFM 1012) (Representado BFM 1012)
161. Turn engine by 90°. Mount 161. Virer le moteur de 90° puis monter 161. Voltear el motor 90°. Montar el
adapter housing. le carter d’adaptation. cárter de adaptación.
Note: Make sure that centering sleeve Nota: veiller à la présence des Nota: Los casquillos de centraje
are fitted. douilles de centrage. deben estar en su sitio.
162. Tighten bolts according to 162. Serrer les vis selon les 162. Apretar los tornillos según
specification. préconisations de serrage : prescripción:
M 12 = 99 ± 10 Nm Vis M 12 = 99 ± 10 Nm tornillos M 12 = 99 ± 10 Nm
M 16 = 243 ± 25 Nm Vis M 16 = 243 ± 25 Nm tornillos M 16 = 243 ± 25 Nm
Note: Use Torx tool. Nota: utiliser les outils Torx Nota: Utilizar las herramientas
E 14 long version E 14 modèle long Torx.
E 20 long version E 20 modèle long E 14 - tipo largo
E 20 - tipo largo
163. Mount cover plate. 163. Monter la tôle de recouvrement. 163. Montar la chapa de
recubrimiento.
4.00.60
1224 BOMAG 008 918 12
Diesel engine 18.9
Starter Démarreur Arrancador
164. Mount starter. Tighten bolts with 164. Monter le démarreur. Serrer les vis 164. Montar el arrancador. Apretar los
a torque of 70 Nm. au couple de 70 Nm. tornillos con un par de 70 Nm.
Note: Tighten collar nut, if any, with a Nota: selon l’équipement du Nota: Apretar la tuerca de collarín, si
torque of 40 Nm. moteurserrer l’écrou à embase existe, con un par de 40 Nm.
au couple de 40 Nm.
165. Fit cable and fastening clips. 165. Monter le câble et les colliers de 165. Montar el cable y las abrazaderas
fixation. de fijación.
Breather pipe Conduite de dégazage Tubería de ventilación
166. Fit breather pipe with new Cu 166. Monter la conduite de dégazage 166. Unir la tubería de ventilación con
seals. avec des joints d'étanchiété Cu anillos de junta de cobre nuevos.
neufs.
167. Tighten bolts for breather pipe 167. Serrer la vis de la conduite de 167. Apretar el tornillo para la tubería
with a torque of 11 ± 1 Nm. degazage au couple de de ventilación con un par de
4 11 ± 1 Nm. 11 ± 1 Nm.
4.00.61
008 918 12 BOMAG 1225
complete engine
engine
Starter
164. Starter anbauen. Schrauben mit einem

4
Drehmoment von 70 Nm festdrehen.
6
5
Hinweis: Falls vorhanden, Bundmutter mit
einem Drehmoment von 40 Nm fest-
drehen.
165. Kabel und Befestigungsschellen anbauen.

4
Entlüftungsleitung
166. Entlüftungsleitung mit neuen Cu-Dicht-

4
ringen anbauen.
ß
167. Schraube für Entlüftungsleitung mit

festziehen.
4 4
6
4.00.61
1226 BOMAG 008 918 12
Diesel engine 18.9
168. Luftleitung zum LDA anbauen.

4
169. Transportösen anbauen. Schrauben mit

4 einem Drehmoment von 47 ± 4 Nm
festdrehen.
6
170. Kabelschuh an Kühlmitteltemperaturgeber

4 anbauen.
38-4-206
Öldruckschalter
4 4 171. Öldruckschalter mit neuem Cu- Dichtring

ß anbauen und mit einem Drehmoment von
4.00.62
008 918 12 BOMAG 1227
complete engine
engine
168. Fit air pipe to manifolf pressure 168. Monter la conduite d'air du 168. Unir la tubería de aire al tope de
compensator (LDA) correcteur de débit (LDA). plena carga dependiente de la
presión de
sobrealimentación(LDA).
169. Fit lifting lugs. Tighten bolts with 169. Monter les oeillets de manutention 169. Montar las argollas de transporte.
a torque of 47 ± 4 Nm. et serrer les vis au couple de Apretar los tornillos con un par de
47 ± 4 Nm. 47 ± 4 Nm.
170. Fit cable lug to coolant 170. Monter la cosse de câble sur la 170. Montar el terminal de cable en el
temperature sensor. sonde de température de transmissor de temperatura del
réfrigérant. liquido refrigerante.
Oil pressure switch Manocontact de pression d'huile Interruptor de presión de aceite
171. Fit oil pressure switch with new 171. Monter le manocontact de 171. Montar el interruptor de presión 4
Cu seal and tighten with a torque pression d'huile avec un joint de aceite con un anillo de junta de
of 18 ± 2 Nm. d'étanchéité Cu neuf et serrer au cobre nuevo y apretar con un par
couple de 18 ± 2 Nm. de 18 ± 2 Nm.
4.00.62
1228 BOMAG 008 918 12
Diesel engine 18.9
172. Fit cable lug to oil pressure 172. Monter la cosse de câble sur le 172. Montar el terminal de cable en el
switch. manocontact de pression d’huile. interruptor de presión de asceite.
Crankcase breather Event de carter Ventilación del cárter

173. Assemble crankcase breather. 173. Compléter l’assemblage de l’évent 173. Completar la ventilación del
de carter. cárter.
Order of parts assembly: Suite du montage: Orden del montaje:
1 Seal 1 Joint 1 Junta
2 Pressure control valve 2 Soupape de régulation de 2 Válvula reguladora de presión
3 Rubber sleeve pression 3 Manguito de goma
3 Manchon en caoutchouc
Note: Pay attention to positioning aids Nota: veiller aux points de Nota: Prestar atención a las ayudas
on pressure control valve and positionnement sur la soupape de posicionamiento existentes
rubber sleeve. Slide on rubber de régulation de pression et de en la válvula reguladora de
sleeve as far as it will go. manchon en caoutchouc. presión y en el mangito de
Insérer le manchon en goma, Colocar éste hasta el
caoutchouc jusqu'en position tope.
de butèe.
174. Press rubber sleeve as far as it 174. Enfoncer le manchon en 174. Introducir a presión el manguito
will go into timing chest bore. Fit caoutchouc dans l'alésage de la de goma hasta el tope en el
pressure control valve to cylinder distribution puis monter la taladro existente en el cárter de la
head. soupape de régulation de distribución. Montar la válvula
pression sur la culasse. reguladora de presión en la
culata.
Note: Lightly grease receiving bore in Nota: huiler légèrement l'alésage de Nota: Lubricar con un poco de grasa
cylinder head. positionement dans la culasse. el taladro de alojamiento en la
culata.
8,5 ± 1 Nm. 8,5 ± 1 Nm. 8,5 ± 1 Nm.
4
4.00.63
008 918 12 BOMAG 1229
complete engine
engine
172. Kabelschuh an Öldruckschalter

anbauen.
4
Kurbelgehäuseentlüftung
173. Kurbelgehäuseentlüftung komplettieren.

4
Folge der Einzelmontage: 0
5
1 Dichtung
2 Druckregelventil
3 Gummimuffe
Hinweis: Auf Positionierhilfen an Druckregel-

ventil und Gummimuffe achten.
Gummimuffe bis Anschlag aufschie-
ben.
174. Gummimuffe bis zum Anschlag in die

Räderkastenbohrung eindrücken. Druck-
4
regelventil an Zylinderkopf anbauen.
5
38-4-209
Hinweis: Aufnahmebohrung im Zylinderkopf

leicht einfetten.

8,5 ± 1 Nm festdrehen. 4 4
6
4.00.63
1230 BOMAG 008 918 12
Diesel engine 18.9
Kühlmittelrohr
38-4-210
4 176. Kühlmittelrohr mit Dichtmittel Deutz DW
w 67 anbauen. Schrauben mit einem

Drehmoment von 21 ± 2 Nm festdrehen.
Abgasturbolader BFM 1012

4 Schwungradseite
ß 177. Zwischenstück
u
Neue Runddichtringe aufziehen und
fetten.
178. Zwischenstück bis Anschlag eindrücken.

4
179. Abgasturbolader mit neuer Dichtung

4 4 anbauen.
ß Hinweis: Stiftschrauben mit Deutz S1 Never

Seize Paste einstreichen.
4.00.64
008 918 12 BOMAG 1231
complete engine
engine
Coolant pipe Conduite de réfrigérant Tubo de líquido refrigerante
176. Mount coolant pipe with sealing 176. Monter la conduite de réfrigérant 176. Montar el tubo de líquido
compound Deutz DW 67. Tighten avec de la pâte d’étanchéité refrigerante con sellante
bolts with a torque of 21 ± 2 Nm. Deutz DW 67. Serrer les vis au Deutz DW 67. Apretar Los
couple de 21 ± 2 Nm. tornillos con un par de
21 ± 2 Nm.
Exhaust turbocharger BFM 1012 Turbocompresseur sur échappement Turbocompresor, BFM 1012
Flywheel end BFM 1012. Côté volant moteur Lado del volante
177. Adapter 177. Pièce intermédiaire 177. Pieza intermedia
Slide on new O-seals and grease. Monter des joints toriques neufs et Colocar los anillos tóricos nuevos
les graisser. y engrasarlos.
178. Press in adapter as far as it will 178. Introduire la pièce intermédiaire 178. Introducir a presión la pieza
go. jusqu’en position de butée. intermedia hasta el tope.
179. Mount exhaust turbocharger with 179. Monter le turbocompresseur avec 179. Montar el turbocompresor con
new gasket. un joint neuf. una junta nueva.
4
Note: Apply Deutz S1 Never Seize Nota: enduire les goujons filetés de Nota: Aplicar a los espárragos pasta
paste to studs. pâte d’étanchéité Deutz S1 Deutz S1 Never Seize.
Never Seize.
4.00.64
1232 BOMAG 008 918 12
Diesel engine 18.9
180. Tighten nuts with a torque of 180. Serrer les écrous au couple de 180. Apretar las tuercas con un par de
21 ± 2 Nm. 21 ± 2 Nm. 21 ± 2 Nm.
Exhaust turbocharger BFM 1013 Turbocompresseur sur échappement Turbocompresor, BFM 1013
Central arrangement BFM 1013 Posición intermedia
Position milieu
181. Mount exhaust turbocharger with 181. Monter le turbocompresseur avec 181. Montar el turbocompresor con
new gasket. un joint neuf. una junta nueva.
Note: Apply Deutz S1 Never Seize Nota: enduire les goujons filetés de Nota: Aplicar a los tornillos pasta
paste to bolts. pâte d’étanchéité Deutz S1. Deutz S1 Never Seize.
182. Tighten bolts according to 182. Serrer les vis selon les 182. Apretar los tornillos según
specification. préconisations de serrage prescripción.
Bolts M8 21 ± 2 Nm vis M8 21 ± 2 Nm Tornillos M8 21 ± 2 Nm
or ou o
Bolts M10 40.5 ± 4 Nm vis M10 40,5 ± 4 Nm tornillos M10 40,5 ± 4 Nm
Oil return pipe/pressure oil pipe Tube de retour d’huile/conduite Tubo de retorno de aceite/tubería de
BFM 1012 d’huile sous pression BFM 1012 aceite a presión, BFM 1012
4
183. Slide on new O-seals and grease. 183. Monter un joint torique neuf et 183. Colocar anillos tóricos nuevos y
le graisser. engrasarlos.
4.00.65
008 918 12 BOMAG 1233
complete engine
engine
180. Muttern mit einem Drehmoment von

21 ± 2 Nm festdrehen. 4
6
Abgasturbolader BFM 1013

Mittig 4
181. Abgasturbolader mit neuer Dichtung
anbauen. ß 30-4-211
Hinweis: Schrauben mit Deutz S1 Never Seize 5

Paste einstreichen.
182. Schrauben nach Anziehvorschrift fest-

drehen.
Schrauben M8 21 ± 2 Nm
4
oder
Schrauben M10 40,5 ± 4 Nm 6
38-4-212
Ölrücklaufrohr/Druckölleitung BFM 1012
183. Neue Runddichtringe aufziehen und

4 4
fetten.
ß
u
4.00.65
1234 BOMAG 008 918 12
Diesel engine 18.9
184. Einschraubstutzen mit neuem Cu-Dicht-

4 ring und einem Drehmoment von
6
ß
185. Ölrücklaufleitung anbauen. Halter fest-

4 schrauben.
186. Druckölleitung anbauen:

4 Hohlschrauben mit neuen Cu-Dichtringen
ß anbauen und mit einem Drehmoment von
Pos. 1 29 ± 3 Nm
6
Pos. 2 39 ± 4 Nm
festdrehen.
5 Hinweis: Abgasturbolader durch einen

Spritzer Öl in die Ölzulaufbohrung
vorölen.
Druckölleitung/Ölrücklaufrohr BFM 1013
4 4 187. Druckölleitung mit neuer Dichtung

ß anbauen.
5 Hinweis: Abgasturbolader durch einen

Spritzer Öl in die Ölzulaufbohrung
vorölen.
4.00.66
008 918 12 BOMAG 1235
complete engine
engine
184. Tighten screw plug with new Cu 184. Serrer la tubulure avec un joint 184. Apretar el enchufe roscado,
seal and a torque of 40 ± 2 Nm. d'étanchéité Cu neuf et au provisto de un anillo de junta de
couple de 40 ± 2 Nm. cobre nuevo, con un par de
40 ± 2 Nm.
185. Mount oil return pipe. Tighten 185. Monter la conduite de retour d’huile 185. Montar la tubería de de retorno de
retainer. et serrer le support. aceite. Atornillar el sujetador.
186. Mount pressure oil pipe: 186. Monter la conduite de refoulement 186. Montar la tubería de aceite a
d’huile . presión:
Fit banjo bolts with new Cu seals Serrer les vis creuses avec des Enroscar los tornillos racor,
and tighten with a torque of joints d'étanchéité neufs et au provistos de anillos de junta de
item 1 29 ± 3 Nm couple de cobre nuevos, y apretarlos con un
item 2 39 ± 4 Nm. Pos. 1 29 ± 3 Nm par de
Pos. 2 39 ± 4 Nm. 29 ± 3 Nm = pos. 1
39 ± 4 Nm = pos. 2.
Note: Pre-lubricate turbocharger by Nota: huiler le turbocompresseur en Nota: Preaceitar el turbocompresor
spraying a drip of oil into the oil injectant un peu d'huile dans proyectando una gota de aceite
supply bore. l'alésage d'arrivée. al interior del taladro de
alimentación de aceite.
Pressure oil pipe/oil return pipe Conduite de refoulement d’huile/ Tubería de aceite a presión/tubo de
BFM 1013 tuyau de retour d’huile BFM 1013 retorno de aceite BFM 1013
4
187. Mount pressure oil pipe with new 187. Monter la conduite de refoulement 187. Montar la tubería de aceite a
gasket. d’huile avec un joint neuf. presión con una junta nueva.
Note: Pre-lubricatel turbocharger by Nota: huiler le turbocompresseur en Nota: Montar la tubería de aceite a
spraying a drip of oil into the oil injectant un peu d'huile dans presión con una junta nueva.
supply bore. l'alésage d'arrivée d'huile.
4.00.66
1236 BOMAG 008 918 12
Diesel engine 18.9
21 ± 2 Nm. 21 ± 2 Nm. 21 ± 2 Nm.
189. Fit banjo bolt with new Cu seals 189. Monter la vis creuse avec des 189. Montar el tornillo racor con
and tighten with a torque of joints d'étanchéite Cu neufs et anillos de junta de cobre nuevos y
39 ± 3 Nm. serrer au couple de 39 ± 3 Nm. apretar con un par de 39 ± 3 Nm.
190. Slide on new O-seals and apply 190. Monter les joints toriques neufs et 190. Colocar anillos tóricos nuevos y
dehydrated lubricant. les enduire d’un produit de untarlos con lubricante de
montage anhydre. montaje exento de agua.
191. Mount oil return pipe with new 191. Monter tube de retour avec joint 191. Acoplar el tubo de retorno
gasket. neuf. provisto de una junta nueva.
4
Note: Apply dehydrated lubricant to Nota: enduire alésage de logement du Nota: Aplicar al alojamiento en el
receiving bore in crankcase. bloc moteur d’un produit de bloque motor lubricante de
montage anhydre. montaje exento de agua.
4.00.67
008 918 12 BOMAG 1237
complete engine
engine

4
6
189. Hohlschraube mit neuen Cu-Dichtringen

anbauen und mit einem Drehmoment von
4
ß
6
190. Neue Runddichtringe aufziehen und mit

wasserfreiem Montagemittel einstreichen.
4
ß
191. Rücklaufrohr mit neuer Dichtung an-

bauen. 4 4
Hinweis: Aufnahmebohrung im Kurbelge-
häuse mit wasserfreiem Montage-
ß
mittel einstreichen.
5
4.00.67
1238 BOMAG 008 918 12
Diesel engine 18.9

193. Haltebügel anbauen. Schraube mit einem

Ansaugkrümmer BFM 1012

4 194. Ansaugkrümmer (Schlauch) mit
Schlauchschelle befestigen.
195. Winkelstutzen mit Schlauchschelle ein-
4 4 setzen.
5 Hinweis: Schlauchschelle noch nicht

festdrehen.
4.00.68
008 918 12 BOMAG 1239
complete engine
engine
21 ± 2 Nm. 21 ± 2 Nm. 21 ± 2 Nm.
193. Fit clamping yoke. Tighten bolt 193. Monter l’étrier de fixation etserrer 193. Montar el estribo de sujeción.
with a torque of 21 ± 2 Nm. la vis au couple de 21 ± 2 Nm. Apretar el tornillo con un par de
21 ± 2 Nm.
Intake elbow BFM 1012 Tubulure d’aspiration BFM 1012 Codo de aspiración, BFM 1012
194. Fasten intake elbow (hose) with 194. Fixer la tubulure d’aspiration 194. Fijar el codo de aspiración
hose clip. (flexible) à l’aide d’un collier. (manguera) mediante abrazadera.
195. Insert elbow nipple with hose clip. 195. Placer le raccord en équerre avec le 195. Colocar la tubuladura acodada
collier de serrage. con abrazadera.
4
Note: Do not tighten hose clip yet. Nota: ne pas encore serrer le Nota: La abrazadera todavía no debe
collier. apretarse.
4.00.68
1240 BOMAG 008 918 12
Diesel engine 18.9
196. Mount breather hose and fasten. 196. Monter flexible de purge et le 196. Montar la manguera de purga de
Tighten hose clip. fixer. Serrer collier de fixation. aire y fijarla. Apretar la
abrazadera.
Intake elblow BFM 1013 Tubulure d’aspiration BFM 1013 Codo de aspiración, BFM 1013
197. Mount intake elbow (hose). 197. Fixer la tubulure d’aspiration 197. Montar el codo de aspiración de
(flexible). aire (manguera).
Note: Do not tighten hose clip yet. Nota: ne pas encore bloquer le Nota: La abrazadera todavía no debe
collier de fixation. apretarse.
198. Mount breather pipe with retainer 198. Monter conduite de purge avec 198. Montar sin tensiones la tubería de
free of stress. support sans tension. purga de aire con soporte.
199. Fit spring-loaded clamp. 199. Monter les colliers à ressort. 199. Instalar las pinzas elástica.
4 Note: Use spring clamp pliers. Nota: utiliser la pince à crampon Nota: Utilizar los tornillos para pinzas
élastique. elásticas.
4.00.69
008 918 12 BOMAG 1241
complete engine
engine
196. Entlüftungsschlauch montieren und

befestigen. Schlauchschelle festdrehen.
4
Ansaugkrümmer BFM 1013
197. Ansaugkrümmer (Schlauch) anbauen.

4
Hinweis: Schlauchschelle noch nicht fest- 5
drehen.
198. Entlüftungsleitung mit Halter span-

nungsfrei anbauen. 4
199. Federklemmen montieren.
Hinweis: Federklemmenzange benutzen.

4 4
5
4.00.69
1242 BOMAG 008 918 12
Diesel engine 18.9
200. Federklemme montieren.

4 Hinweis: Federklemmenzange benutzen.
201. Schlauchschelle festdrehen.

4
Ladeluftkrümmer BFM 1013

4 202. Steckstück eindrücken.
5 Hinweis: Dichtprofil und Aufnahmebohrung
mit Montagemittel einstreichen.
203. Ladeluftkrümmer mit neuer Dichtung
4 4 anbauen.
4.00.70
008 918 12 BOMAG 1243
complete engine
engine
200. Fit spring-loaded clamp. 200. Monter crampon à ressort. 200. Instalar la pinza elástica.
Note: Use spring clamp pliers. Nota: utiliser la pince à crampon à Nota: Utilizar las tenazas especiales
ressort. para pinzas.
201. Secure hose clip. 201. Serrer le collier de fixation. 201. Apretar la abrazadera de
manguera.
Charge air elbow BFM 1013 Conduite d’air de suralimentation Codo de aire de sobrealimentación,
BFM 1013 BFM 1013
202. Press in plug-in element. 202. Introduire le manchon. 202. Introducir a presión la pieza de
enchufe.
Note: Apply lubricant to sealing Nota: enduire d’un produit de Nota: Aplicar lubricante de montaje al
section and receiving bore. montage le profilé d’étanchéité perfil de cierre y al alojamiento.
et l’alésage du logement.
203. Mount charge air elbow with new 203. Monter la conduite d’air de 203. Montar el codo de aire de
seal. suralimentation avec un joint sobrealimentación provisto de
neuf. una junta nueva. 4
4.00.70
1244 BOMAG 008 918 12
Diesel engine 18.9
22 ± 2 Nm. 22 ± 2 Nm. 22 ± 2 Nm.
205. Fit oil filler neck, if any, complete 205. Selon l’équipement du moteur 205. Si existe, montar la tubuladura de
with new seal and tighten with a serrer la tubulure de remplissage llenado de aceite con una junta
torque of 21 ± 2 Nm. d’huile au couple de 21 ± 2 Nm en nueva y apretar con un par de
utilisant un joint neuf. 21 ± 2 Nm.
Oil dipstick Jauge d’huile Varilla de medición del nivel de

aceite
206. Slide on new O-seal. 206. Monter un joint torique neuf. 206. Colocar un anillo tórico nuevo.
207. Press in oil dipstick as far as it 207. Insérer la jauge d’huile jusqu’en 207. Presionar adentro la varilla de
will go. position d’appui. medición hasta que haga tope.
4
4.00.71
008 918 12 BOMAG 1245
complete engine
engine

4
6
205. Falls vorhanden, Öleinfüllstutzen mit

neuer Dichtung anbauen und mit einem
4
ß
6
Ölmeßstab
206. Neuen Runddichtring aufziehen.

4
ß
207. Ölmeßstab bis Anlage eindrücken.

4 4
4.00.71
1246 BOMAG 008 918 12
Diesel engine 18.9
Generator
4 208. Konsole anbauen. Schrauben mit einem
209. Generator anbauen. Sechskantschraube

4 leicht andrehen.
210. Spannlasche mit Abstandsbuchsen an-

4 bauen. Sechskantschrauben leicht an-
drehen.
Keilriemen spannen
4 4 211. Keilriemen auflegen.
4.00.72
008 918 12 BOMAG 1247
complete engine
engine
Alternator Alternateur Alternador
208. Fit alternator bracket. Tighten 208. Monter la console et serrer les vis 208. Montar la consola. Apretar los
bolts with a torque of au couple de 21 ± 2 Nm. tornillos con un par de
21 ± 2 Nm. 21 ± 2 Nm.
209. Mount alternator. Start hex. bolt. 209. Monter l’alternateur. Serrer 209. Montar el alternador. Apretar el
modérément la vis six pans. tornillo hexagonal ligeramente
con la mano.
210. Fit clamping plate together with 210. Monter la griffe de serrage avec 210. Montar la corredera con los
spacer bushes. Start hex. bolts. des douilles d’écartement. Serrer casquillos distanciadores. Apretar
légèrement les vis six pans. los tornillos hexagonales
ligeramente con la mano.
ensado de correas trapezoidales
Tensioning V-belt Tendre la courroie trapézoïdale Tensar la correa trapezoidal
211. Position V-belt. 211. Monter la courroie trapézoïdale. 211. Colocar la correa trapezoidal. 4
4.00.72
1248 BOMAG 008 918 12
Diesel engine 18.9
212. Tension V-belt. Tighten bolts with 212. Tendre la courroie trapézoïdale et 212. Tensar la correa trapezoidal.
a torque of 21 ± 2 Nm. serrer les vis au couple de Apretar los tornillos con un par de
21 ± 2 Nm. 21 ± 2 Nm.
213. Check V-belt tension with belt 213. Contrôler la tension de la courroie 213. Comprobar la tensión de la correa
tension gauge. trapézoïdale à l’aide d'un utilizando un verificador de
tensiomètre. tensión.
Belt back width 10 mm Largeur du dos de la courroie Ancho de correa 10 mm
Initial assembly ____ 450 ± 50 N 10 mm Primer montaje ____ 450 ± 50 N
Check value after 15 min.of Première monte ____ 450 ± 50 N Control tras una marcha
operation under load 300 ± 50 N Contrôle après 15 min de marche de 15 min. bajo carga 300 ± 50 N
When reusing belt __ 300 ± 50 N Sous charge ______ 300 ± 50 N Para reutilización ___ 300 ± 50 N
Après réutilisation __ 300 ± 50 N
Belt back width 13 mm Ancho de correa 13 mm
Initial assembly ____ 550 ± 50 N Largeur du dos de la courroie Primer montaje ____ 550 ± 50 N
Check value after 15 min.of 13 mm Control tras una marcha
operation under load 400 ± 50 N Première monte ____ 550 ± 50 N de 15 min. bajo carga 400 ± 50 N
When reusing belt __ 400 ± 50 N Contrôle après 15 min de marche Para reutilización ___ 400 ± 50 N
Sous charge ______ 400 ± 50 N
Après réutilisation __ 400 ± 50 N
214. Position V-belt. 214. Monter la courroie. 214. Colocar la correa trapezoidal.
215. Tension V-belt. Tighten bolts with 215.Tendre la courroie trapézoïdale et 215. Tensar la correa trapezoidal.
a torque of 30 Nm. serrer les vis au couple de 30 Nm. Apretar los tornillos con un par de
4 30 Nm.
4.00.73
008 918 12 BOMAG 1249
complete engine
engine
212. Keilriemen spannen. Schrauben mit einem

s
4
6
213. Keilriemenspannung mit einem

Spannungsmeßgerät prüfen. s
Riemenrückenbreite 10 mm
Erstmontage _____________ 450 ± 50 N 6
Kontrolle nach 15 Min. Lauf
unter Last _______________ 300 ± 50 N
Bei Wiederverwendung _____ 300 ± 50 N
Erstmontage _____________ 550 ± 50 N
unter Last _______________ 400 ± 50 N
214. Keilriemen auflegen. 4
215. Keilriemen spannen. Schrauben mit einem

Drehmoment von 30 Nm festdrehen. s 4
4
6
4.00.73
1250 BOMAG 008 918 12
Diesel engine 18.9

s Spannungsmeßgerät prüfen.
6 Erstmontage _____________ 450 ± 50 N

unter Last ______________ 300 ± 50 N
Bei Wiederverwendung ____ 300 ± 50 N
217. Nach dem Riemenspannen sind die

4 übrigen Schrauben festzudrehen und die
Kabel anzuklemmen.
3
Motor von Montagebock abbauen.
Motoraufhängung/Aufstellfüße
4 218. Motoraufhängung anbauen. Schrauben
6 mit einem Drehmoment von 260 Nm
festdrehen.
219. Aufstellfüße anbauen. Schrauben mit
4 4 einem Drehmoment von 95 Nm

festdrehen.
6
4.00.74
008 918 12 BOMAG 1251
complete engine
engine
216. Check V-belt tension with belt 216. Vérifier la tension de courroie avec 216. Comprobar la tensión de la correa
tension gauge. un appareil de mesure. trapezoidal mediante un
verificador de tensión.
Initial assembly ___ 450 ± 50 N Première monte ___ 450 ± 50 N Primer montaje ___ 450 ± 50 N
Check value after 15 min. of Contrôle après une marche de Control tras 15 minutos
operation under load 300 ± 50 N 15 min de marcha bajo carga
When reusing belt __ 300 ± 50 N sous charge ______ 300 ± 50 N _______________ 300 ± 50 N
Pour réutilisation __ 300 ± 50 N Para reutilización __ 300 ± 50 N
217. After tensioning of belt tighten 217. Après avoir tendu la courroie 217. Una vez tensadas las correas, se
remaining bolts and connect serrer les autres vis et brancher apretarán los demás tornillos y se
cables. les câbles. conectarán los cables.
Remove engine from assembly Déposer le moteur du chevalet de Desmontar el motor del caballete
stand. montage. de montaje.
Engine mounting/mounting feet Suspension moteur / pieds Suspensión del motor / patas de
colocación
218. Fit engine mounting. Tighten bolts 218. Monter la suspension du moteur. 218. Montar la suspensión del motor.
with a torque of 260 Nm. Serrer les vis au couple de Apretar los tornillos con un par de
serrage de 260 Nm. 260 Nm.
219. Fit mounting feet. Tighten bolts 219. Monter les pieds du moteur. Serrer 219. Montar las patas de colocación.
with a torque of 95 Nm. les vis au couple de 95 Nm. Apretar los tornillos con un par de
95 Nm. 4
4.00.74
1252 BOMAG 008 918 12
Diesel engine 18.9
Removing and refitting components Montage et démontage des éléments Desmontaje y remontaje de
for integrated cooling system - du refroidissement intégré du - componentes de la refrigeración
BFM 1012 BFM 1012 integrada - BFM 1012
The components may differ from the Selon le volume de livraison du moteur Los componentes adosados pueden
illustrations shown here, depending on les pièces auxiliaires peuvent être diferir de los indicados en estas
the engine scope of supply. différentes des croquis. ilustraciones, según el volumen de
suministro del motor.
Drain and catch coolant and oil. Vidanger et récupérer le liquide de Dejar salir y recoger el líquido
refroidissement usagé ou l’huile usée. refrigerante y aceite.
Removing components Dépose des composants Desmontaje de elementos
1. Loosen tension pulley, take off 1. Desserrer le galet tendeur et retirer 1. Soltar la polea tensora, quitar la
V-belt. la courroie. correa trapezoidal.
2. Remove tension pulley together 2. Déposer la galet tendeur et la 2. Desmontar la polea tensora con
with bracket. console. consola.
3. Remove air guide ring. 3. Déposer le diffuseur d'air. 3. Desmontar el aro guía de aire.
4.00.75
008 918 12 BOMAG 1253
complete engine
engine
Bauteile für integrierte Kühlung ab- und

anbauen - BFM 1012
Je nach Lieferumfang des Motors können die

Anbauteile von den gezeigten Abbildungen
abweichen.
Kühlflüssigkeit bzw. Öl ablassen und auffan-

gen.
Bauteile abbauen
1. Spannrolle lösen, Keilriemen abnehmen.

3
2. Spannrolle mit Konsole abbauen.

3
3. Lufttrichter abbauen.
3 4
4.00.75
1254 BOMAG 008 918 12
Diesel engine 18.9
4. Generator und Kraftstoffpumpe lösen.

3 Keilriemen abnehmen. Generator und
Kraftstoffpumpe abbauen.
5. Keilriemenscheibe am Schwungrad gegen-

3 halten. Keilriemenscheibe und Schwin-
gungsdämpfer abbauen.
6. Entlüftungsleitung abbauen.
3
7. Schaulochblech abbauen.
4 3
4.00.76
008 918 12 BOMAG 1255
complete engine
engine
4. Loosen alternator and fuel pump, 4. Desserrer l'alternateur et la pompe 4. Soltar el alternador y la bomba de
take of V-belt. Remove alternator de combustible. Retirer la courroie combustible. Quitar la correa
and fuel pump. trapézoïdale. Déposer l'alternateur trapezoidal. Desmontar el
et la pompe de combustible. alternador y la bomba de
combustible.
5. Retain V-belt pulley against 5. Maintenir la poulie à gorge du 5. Retener la polea acanalada en el
flywheel. Remove V-belt pulley and volant moteur. Déposer la poulie et volante. Desmontar la polea
vibration damper. l'amortisseur de vibrations. acanalada y el amortiguador de
vibraciones.
6. Remove breather pipe. 6. Déposer la conduite de purge. 6. Desmontar la tubería de purga de

aire.
7. Remove inspection hole plate. 7. Déposer la tôle à trou de regard. 7. Desmontar la chapa de la abertura
de inspección.
4
4.00.76
1256 BOMAG 008 918 12
Diesel engine 18.9
8. Remove top cover plate. 8. Déposer la tôle de recouvrement 8. Desmontar la chapa de

supérieure. recubrimiento superior.
9. Remove central cover plate. 9. Déposer la tôle de recouvrement du 9. Desmontar la chapa de

milieu. recubrimiento intermedia.
10. Remove bottom cover plate. 10.Déposer la tôle de recouvrement 10. Desmontar la chapa de
inférieure. recubrimiento inferior.
11. Remove retainer from radiator. 11. Déposer le support du 11. Desmontar los soportes del
refoidisseur à liquide. refrigerador de líquido.
4
4.00.77
008 918 12 BOMAG 1257
complete engine
engine
8. Abdeckblech oben abbauen.

3
9. Abdeckblech mitte abbauen.

3
10. Abdeckblech unten abbauen.

3
11. Halter vom Flüssigkeitskühler abbauen.

3 4
4.00.77
1258 BOMAG 008 918 12
Diesel engine 18.9
12. Flüssigkeitskühler abbauen.

3 Hinweis: Auslaufendes Restkühlmittel auffan-
5 gen.
13. Halter abbauen.

3
14. Verkabelung Niveauschalter Kühlmittel

3 abbauen.
15. Kabel von Starter und Anschlussbolzen
4 3 abbauen.
4.00.78
008 918 12 BOMAG 1259
complete engine
engine
12. Remove radiator. 12. Déposer le radiateur. 12. Desmontar el refrigerador de

líquido.
Note: Catch any escaping coolant that Nota: récupérer le réfrigérant qui Nota: Recoger los restos de
has remained in the radiator. s’écoule. refrigerante.
13. Remove retainer. 13. Déposer le support. 13. Desmontar los sujetadores.
14. Remove cabling from coolant level 14. Déposer le câblage d'interrupteur 14. Desmontar el cable del interruptor
switch. du niveau du réfrigérateur. de nivel de refrigerante.
15. Remove cables from starter and 15. Déposer le câble du démarreur et le 15. Desmontar el cable del arrancador
terminal stud. boulon de fixation. y bulón de conexión.
4
4.00.78
1260 BOMAG 008 918 12
Diesel engine 18.9
16. Remove cover plate. 16. Déposer la tôle d’extrémité. 16. Desmontar la chapa final.
17. Remove oil pressure pipe. 17. Déposer la conduite de refoulement 17. Desmontar la tubería de presión de
d'huile. aceite.
18. Remove oil return pipe. 18. Déposer le tuyau de retour d'huile. 18. Desmontar el tubo de retorno de
aceite.
19. Remove cover plate. 19. Déposer la tôle de recouvrement. 19. Desmontar la chapa de
recubrimiento.
4
4.00.79
008 918 12 BOMAG 1261
complete engine
engine
16. Abschlußblech abbauen.

3
17. Öldruckleitung abbauen.

3
18. Ölrücklaufrohr abbauen.

3
19. Abdeckblech abbauen.

3 4
4.00.79
1262 BOMAG 008 918 12
Diesel engine 18.9
20. Schrauben für Flansch herausschrauben.

3 Hinweis: Auf Position der Sicherungsscheibe
5 achten.
21. Kühlmittelleitung abbauen.

3
22. Kühlmittelleitung abbauen.

3
23. Klemmprofil abnehmen.
4 3
4.00.80
008 918 12 BOMAG 1263
complete engine
engine
20. Unscrew bolts for flange. 20. Dévisser et retirer les vis de la 20. Desenroscar los tornillos para la
bride. brida.
Note: Pay attention to position of Nota: veiller au bon positionnement Nota: Prestar atención a la posición
locking washer. de la rondelle d'arrêt. de la arandela de seguridad.
21. Remove coolant pipe. 21. Déposer la conduite de réfrigérant. 21. Desmontar la tubería de
refrigerante.
22. Remove coolant pipe. 22. Déposer la conduite de réfrigérant. 22. Desmontar la tubería de
refrigerante.
23. Take off clamping section. 23. Retirer le profilé de serrage. 23. Quitar el perfil de apriete.
4.00.80
1264 BOMAG 008 918 12
Diesel engine 18.9
24. Remove coolant compensating 24. Déposer la conduite de compensation 24. Desmontar la tubería de
pipe. de réfrigérant. compensación de refrigerante.
25. Remove complete blower. 25. Déposer entièrement la soufflante de 25. Desmontar por completo la turbina
refroidissement. de refrigeración.
Note: Catch any escaping coolant. Nota: récupérer le réfrigérant qui Nota: Recoger el refrigerante quesale.
s’écoule.
26. Detach cable connections. 26. Désolidariser les connexions des 26. Separar las conexiones de cables.
câbles.
27. Remove cable harness. 27. Déposer le faisceau des câbles. 27. Desmontar el mazo de cables.
4.00.81
008 918 12 BOMAG 1265
complete engine
engine
24. Kühlmittel-Ausgleichsleitung abbauen.

3
25. Kühlgebläse komplett abbauen.
Hinweis: Auslaufendes Kühlmittel auffangen.

3
5
26. Kabelverbindungen trennen.

3
27. Kabelbaum abbauen.

3 4
4.00.81
1266 BOMAG 008 918 12
Diesel engine 18.9
28. Kühlmitteltemperaturgeber ausbauen.

3
29. Öldruckschalter ausbauen.

3 Alle Bauteile sichtprüfen. Schadhafte
9 Bauteile austauschen.
4.00.82
008 918 12 BOMAG 1267
complete engine
engine
28. Remove coolant temperature 28. Déposer l’interrupteur de température 28. Desmontar el transmisor de
sensor. de réfrigérant. temperatura de refrigerante.
29. Remove oil pressure switch. 29 .Déposer le manostat de pressio 29. Desmontar el interruptor de
d’huile. presión de aceite.
Inspect all components, replace if Contrôler visuellement tous les Examinar visualmente todos los
damaged. composants. Remplacer ceux qui componentes y sustituir los que
sont détériorés. estén defe.
4.00.82
1268 BOMAG 008 918 12
Diesel engine 18.9
Refitting components: Repose des éléments: Montaje de los componentes:
Oil pressure switch/ Manocontact de pression d’huile/ Interruptor de presión de aceite/

Coolant temperature sensor capteur de température de réfrigérant transmisor de temperatura de
refrigerante
30. Fit oil pressure switch with new Cu 30. Monter l’interrupteur de pression 30. Montar el interruptor de presión de
seal and tighten with a torque of d’huile avec une bague neuve Cu aceite con un anillo de cobre nuevo
18 ± 2 Nm. puis serrer au couple de y apretar con un par de 18 ± 2 Nm.
18 ± 2 Nm.
31. Fit coolant temperature sensor with 31. Monter l’interrupteur de 31. Montar el transmisor de
new Cu seal and tighten with a température de réfrigérant avec une temperatura de refrigerante con un
torque of 18 ± 2 Nm. bague Cu neuve et serrer au couple anillo de cobre nuevo y apretar con
de 18 ± 2 Nm. un par de 18 ± 2 Nm.
Cable harness Faisceau de câbles Mazo de cables
32. Fit cable harness. 32. Monter le faisceau de câbles. 32. Montar el mazo de cables.
33. Tighten fastening bolts with a 33. Serrer les vis de fixation au couple 33. Apretar los tornillos de fijación con
torque of 21 ± 2 Nm. de 21 ± 2 Nm. un par de 21 ± 2 Nm.
4
4.00.83
008 918 12 BOMAG 1269
complete engine
engine
Bauteile anbauen:
Öldruckschalter/
4
Kühlmitteltemperaturgeber
ß 38-4-167
6
30. Öldruckschalter mit neuem Cu-Ring
anbauen und mit einem Drehmoment von
31. Kühlmitteltemperaturgeber mit neuem

Cu-Ring anbauen und mit einem
4
ß 38-4-168
Kabelbaum
32. Kabelbaum anbauen.

4
33. Befestigungsschrauben mit einem Dreh-

moment von 21 ± 2 Nm festdrehen. 4 4
6
4.00.83
1270 BOMAG 008 918 12
Diesel engine 18.9
34. Kabelbaum verlegen und mit Haltebänder

4 befestigen.
Kühlgebläseträger
4 35. Kühlgebläseträger kompl. mit Keilriemenan-
6 schlag anbauen und mit einm Drehmoment

von 21 ± 2 Nm festdrehen.
36. Kühlmittelausgleichsleitung mit neuen

4 Cu-Ringen anbauen.
37. Neue Runddichtringe aufziehen.
4 4 Hinweis: Runddichtringe mit Montage-

ß gleitmittel AP 25 N bestreichen.
4.00.84
008 918 12 BOMAG 1271
complete engine
engine
34. Lay cable harness and fasten with 34. Poser la faisceau de câbles et fixer 34. Colocar el mazo de cables y fijarlo
holding straps. à l'aide de colliers. con cintas de sujeción.
Blower carrier Support de soufflante de Soporte de la turbina de refrigeración

refroidissement
35. Fit blower carrier complete with V- 35. Monter entièrement le support de 35. Montar el soporte de la turbina de
belt stop and secure with a torque soufflante et la butée de courroie, refrigeración completo con el tope
of 21 ± 2 Nm. puis serrer au couple de de correa trapezoidal y apretar con
21 ± 2 Nm. un par de 21 ± 2 Nm.
36. Fit coolant compensating pipe with 36. Monter la conduite de 36. Montar la tubería de compensación
new Cu seals. compensation de réfrigérant avec de refrigerante con anillos de cobre
des bagues Cu neuves. nuevos.
37. Slide on new O-seals. 37. Monter des joints toriques neufs. 37. Colocar anillos tóricos nuevos.
Note: Apply lubricant AP 25N to O- Nota: enduire les joints toriques de Nota: Aplicar lubricante de montaje 4
seals. lubrifiant de montage type AP 25N a los anillos tóricos.
AP 25N.
4.00.84
1272 BOMAG 008 918 12
Diesel engine 18.9
38. Insert coolant. Tighteen bolts with 38. Placer un tube de réfrigérant. Serrer 38. Colocar el tubo de refrigerante.
a torque of 28 Nm. les vis au couple de 28 Nm. Apretar los tornillos con un par de
28 Nm.
Vibration damper/V-belt pulley Amortisseur de vibrations/poulie à Amortiguador de vibraciones/polea

gorge acanalada
39. Fit V-belt pulley and vibration 39. Déposer la poulie à gorge et 39. Montar la polea acanalada y el
damper. l'amortisseur de vibrations. amortiguador de vibraciones.
40. Fit V-belt pulley and retain against 40. Monter la poulie à gorge et la 40. Montar la polea acanalada y retener
flywheel. Tighten bolts according to maintenir au niveau du volant. en el volante. Apretar los tornillos
specification. Serrer les vis selon le serrage según prescripción.
d'approche.
Initial tightening torque: __ 40-50 Nm Valeur de préserrage _____ 40-50 Nm Apriete inicial: __________ 40-50 Nm
1st tightening angle 1er serrage à l'angle 1er ángulo de reapriete:
bolts 60 mm long ____________ 60° Vis 60 mm de long ___________ 60° tornillos 60 mm long __________ 60°
2nd tightening angle 2e serrage à l'angle 2° ángulo de reapriete:

Note: Use Torx socket wrench E20. Nota: utiliser la clé à douile Torx E20. Nota: Utilizar la llave de vaso Torx
Bolts may be used max. 5x if Les vis peuvent être utilisées E20. Los tornillos son
evidence can be furnished selon la pratique, 5 fois au reutilizables hasta 5 veces,
4 concerning their use. maximum. siempre que esto se pueda
comprobar.
41. Fit fuel pump loosely. 41. Reposer la pompe à l'huile sans 41. Montar la bomba de combustible,
serrer. dejándola todavía suelta.
4.00.85
008 918 12 BOMAG 1273
complete engine
engine
38. Kühlmittelrohr einsetzen. Schraube mit

einem Drehmoment von 28 Nm festdre-
hen.
4
6
Schwingungsdämpfer/Keilriemenscheibe
39. Keilriemenscheibe mit Schwingungs-

4
dämpfer anbauen.
40. Keilriemenscheibe anbauen und am

Schwungrad gegenhalten. Schrauben nach
Anziehvorschrift festdrehen.
4
Vorspannwert: ____________ 40-50 Nm
1. Nachspannwinkel
6
Schrauben 80 mm lang ____________ 60° 5
2. Nachspannwinkel
Hinweis: Torx Steckschlüssel E20 verwenden.
Schrauben können bei Nachweisbar-
keit max. 5x verwendet werden.
41. Kraftstoffpumpe lose anbauen.
4 4
4.00.85
1274 BOMAG 008 918 12
Diesel engine 18.9
42. Keilriemen auflegen und spannen.

s
6

s Spannungsmeßgerät prüfen.
6 Erstmontage ______________ 450 ± 50 N
Kontrolle nach 15 min. Lauf
unter Last ________________ 300 ± 50 N
Bei Wiederverwendung ______ 300 ± 50 N
Erstmontage ______________ 550 ± 50 N
Kontrolle nach 15 min. Lauf
unter Last ________________ 400 ± 50 N
44. Generatorkonsole anbauen und mit einem

4 Drehmoment von 60 Nm festdrehen.
38-4-221
6
4
45. Generator anbauen. Schrauben leicht
andrehen.
4
38-4-222
4.00.86
008 918 12 BOMAG 1275
complete engine
engine
42. Position V-Belt in place and 42. Placer la courroie trapézoïdale et 42. Colocar la correa trapezoidal y
tension. Tighten bolts with a torque tendre. Serrer les vis au couple de tensarla. Apretar los tornillos de
of 21 ± 2 Nm. 21 ± 2 Nm. fijación con un par de 21 ± 2 Nm.
tension gauge. trapézoïdale à l'aide d'un utilizando un verificador de tensión.
tensiomètre.
Belt back width 10 mm Largeur du dos de la courroie Ancho de correa 10 mm
Initial assembly _____ 450 ± 50 N 10 mm Primer montaje _____ 450 ± 50 N
Check value after 15 min.of Première monte _____ 450 ± 50 N Control tras una marcha
operation under load _ 300 ± 50 N Contrôle après 15 min. de marche 15 min. bajo carga ___ 300 ± 50 N
When reusing belt ___ 300 ± 50 N Sous charge ________ 300 ± 50 N Para reutilización ____ 300 ± 50 N
Après réutilisation ___ 300 ± 50 N
Belt back width 13 mm Ancho de correa 13 mm
Initial assembly 550 ± 50 N Largeur du dos de la couronne Primer montaje _____ 550 ± 50 N
Check value after 15 min.of 13 mm Control tras una marcha
operation under load 400 ± 50 N Première monte _____ 550 ± 50 N 15 min. bajo carga ___ 400 ± 50 N
When reusing belt __ 400 ± 50 N Contrôle après 15 min. de marche Para reutilización ____ 400 ± 50 N
Sous charge ________ 400 ± 50 N
Après réutilisation ___ 400 ± 50 N
44. Fit alternator bracket and secure 44. Monter la console de lálternateur 44. Montar la consola del alternator y
within a torque of 60 Nm. et serrer au couple 60 Nm. apretar con un par de 60 Nm.
45. Mount alternator. Start bolts. 45. Monter l'alternateur et serrer les vis 45. Montar el alternador. Enroscar los
modérément. tornillos con la mano hasta que se
apoyen con su cabeza. 4
4.00.86
1276 BOMAG 008 918 12
Diesel engine 18.9
46. Position V-belt in place and 46. Placer la courroie trapézoïdale et 46. Colocar la correa trapezoidal y
tension. Tighten bolts with a torque tendre. Serrer les vis au couple de tensarla. Apretar los tornillos con
of 31 Nm. Turn belt drive 2-3 31 Nm. Virer l'entraînement de un par de 31 Nm. Darle a la polea
revolutions. courroie de 2 à 3 tours. acanalada 2 a 3 vueltas.
tension gauge. trapézoïdale à l'aide d'un utilizando un verificador de tensión.
tensiomètre.
Initial assembly _____ 450 ± 50 N Première monte _____ 450 ± 50 N Premer montaje _____ 450 ± 50 N
Check value after 15 min.of Contrôle après 15 min. Controle tras una marcha
operation under load _ 300 ± 50 N Marche sous charge _ 300 ± 50 N de 15 min. bajo carga 300 ± 50 N
When reusing belt ___ 300 ± 50 N Après réutilisation ___ 300 ± 50 N para reutilización ____ 300 ± 50 N
48. Fit air guide ring. Tighten bolts and 48. Monter le diffuseur d'air. Serrer les 48. Montar el aro guía de aire. Apretar
nuts with a torque of 11 Nm. vis et les écrous au couple de los tornillos y tuercas con un par
11 Nm. de 11 Nm.
49. Fit tension pulley together with 49. Monter le galet tendeur et la 49. Montar la polea tensora con
bracket and secure with a torque of console et serrer au couple de consola y apretar con un par de
4 29 Nm. 29 Nm. 29 Nm.
4.00.87
008 918 12 BOMAG 1277
complete engine
engine
46. Keilriemen auflegen und spannen.

Schrauben mit einem Drehmoment von
31 Nm festdrehen.
4
Riementrieb 2-3 Umdrehungen durchdre-
hen. s
6
47. Keilriemenspannung mit Spannungsmeß-

gerät prüfen. s
Erstmontage ______________ 450 ± 50 N
Kontrolle nach 15 min. 6
Lauf unter Last ___________ 300 ± 50 N
48. Luftrichter anbauen. Schrauben und

Muttern mit einem Drehmoment von
11 Nm festdrehen.
4
6
49. Spannrolle mit Konsole anbauen und mit

einem Drehmoment von 29 Nm fest-
drehen.
4 4
6
4.00.87
1278 BOMAG 008 918 12
Diesel engine 18.9
49.1 Keilriemen auflegen und spannen.

29 Nm festdrehen.
s
6
50. Keilriemenspannung mit Spannungs-

s meßgerät prüfen.
6 Erstmontage ______________ 450 ± 50 N

Kontrolle nach 15 min.
Lauf unter Last ____________ 300 ± 50 N
51. Kabel anbauen.

4
i
9
52. Kabel für Kühlmitteltemperaturgeber
4 4 anbauen.
4.00.88
008 918 12 BOMAG 1279
complete engine
engine
49.1 Position V-belt in place and 49.1 Placer la courroie trapézoîdale et 49.1 Colocar la correa trapezoidal y
tension. Tighten bolts with a tendre. Serrer les vis au couple tensarla. Apretar los tornillos con
torque of 29 Nm. de 29 Nm. un par de 29 Nm.
tension gauge. trapézoîdale à l'aide d'un utilizando un verificador de
tensionmètre. tensión.
Initial assembly ____ 450 ± 50 N Première monte _____ 450 ± 50 N Primer montaje _____ 450 ± 50 N
Check value after 15 min.of Contrôle après 15 min. Control tras 15 minutos
operation under load 300 ± 50 N Marche sous charge _ 300 ± 50 N de marcha bajo carga _ 300 ± 50 N
When reusing belt __ 300 ± 50 N Après réutilisation ___ 300 ± 50 N Para reutilización ____ 300 ± 50 N
51. Fit cable. 51. Monter le câble. 51. Montar el cable.
52. Fit cable for coolant temperature 52. Monter le câble du capteur de 52. Montar el cable para el transmisor
sensor. température du réfrigérant. de temperatura de refrigerante.
4
4.00.88
4.00.89
1280 BOMAG 008 918 12
Diesel engine 18.9
Coolant pipe Tuyau de réfrigérent Tubo de refrigerante
53. Slide on new O-seals. 53. Monter des joints toriques neufs. 53. Colocar anillos tóricos nuevos.
Note: Apply lubricant AP 25 N to Nota: enduire les joints toriques de Nota: Aplicar deslizante de montaje
O-seals lubrifiant de montage AP 25 N. AP 25 N a los anillos tóricos.
54. Preassemle coolant pipe with 54. Préassembler le tuyau de 54. Preensamblar el tubo de
flange. réfrigérant avec la bride. refrigerante con la brida.
55. Apply sealing compound DEUTZ 55. Enduire la plan de joint de la bride à 55. Aplicar a la superficie de cierre de
DW 67 to flange sealing surface. Fit l'aide d'unproduit d'étanchéité la brida pasta sellante
coolant pipe. DEUTZ DW 67. Monter le tuyau de DEUTZ DW 67. Montar el tubo de
réfrigérant. refrigerante.
56. Tighten bolts with a torque of 56. Serrer les vis au couple de 28 Nm. 56. Apretar los tornillos con un par de
28 Nm. 28 Nm.
4
Note: Pay attention to correct position Nota: veiller au bon positionnement Nota: Pretar atención a la correcta
of locking washer. de la rondelle d'arrêt. posición de la arandela de
seguridad.
4.00.89
008 918 12 BOMAG 1281
complete engine
engine
Kühlmittelrohr
53. Neue Runddichtringe aufziehen.

4
Hinweis: Runddichtringe mit Montagegleit- ß
5
mittel AP 25 N bestreichen.
54. Kühlmittelrohr mit Flansch vormontieren.

4
55. Dichtfläche des Flansches mit Dichtmasse

DEUTZ DW 67 bestreichen. Kühlmittelrohr
anbauen.
4
w

Hinweis: Auf richtige Position der Sicher-
ungsscheibe achten. 6
5
4.00.89
1282 BOMAG 008 918 12
Diesel engine 18.9
Verblechung
4 57. Abdeckblech anbauen.
Ölrücklaufrohr/Druckölleitung
4 58. Neue Runddichtringe aufziehen und fetten.
ß
u
59. Einschraubstutzen mit neuem Cu-Dichtring

4 mit einem Drehmoment von 40 ± 2 Nm
festdrehen.
6
ß
4
60. Ölrücklaufleitung und Halter anbauen.
Schraube mit einem Drehmoment von
6
4.00.90
008 918 12 BOMAG 1283
complete engine
engine
Panelling Tôle Chapas
57. Fit cover plate. 57. Monter la tôle de recouvrement. 57. Montar la chapa de recubrimiento.
Oil return pipe/pressure oil pipe Tuyau de retour d'huile/conduite de Tubo de retorno de aceite/tubería de
refoulement d'huile aceite a presión
58. Slide on new O-seals and grease. 58. Monter les joint toriques neufs et 58. Colocar anillos tóricos nuevos y
graisser. engrasarlos con grasa.
59. Tighten screw plug with new Cu 59. Serrer les tubulures à visser avec 59. Apretar los enchufes roscados,
seal with a torque of 40 ± 2 Nm. un joint d'étanchiété au couple de provistos de un anillo de junta de
40 ± 2 Nm. cobre nuevo, con un par de
40 ± 2 Nm.
60. Fit oil return pipe and retainer. 60. Monter le tuyau de retour d'huile et 60. Montar la tubería de retorno de
Tighten bolt with a torque of le support. Serrer la vis au couple aceite y los sujetadores. Apretar los
22 ± 2 Nm. de 22 ± 2 Nm. tornillos de fijación con par de 4
22 ± 2 Nm.
4.00.90
1284 BOMAG 008 918 12
Diesel engine 18.9
61. Fit pressure oil pipe. Tighten banjo 61. Monter la conduite de refoulement 61. Montar la tubería de aceite a
bolts with new Cu seals and with a d'huile. Serrer les vis creuses avec presión:
torque of des joints d'étanchéité Cu neufs. Enroscar los tornillos racor,
item 1 29 ± 3 Nm Pos. 1 29 ± 3 Nm provistos de anillos de junta de
item 2 39 ± 4 Nm. Pos. 2 39 ± 4 Nm. cobre nuevos, y apretarlos con un
par de
29 ± 3 Nm = pos. 1
39 ± 4 Nm = pos. 2.
62. Fit cover plate. 62. Monter la tôle d’extrémité. 62. Montar la chapa final.
63. Fit cable to starter and terminal 63. Monter le câble sur le démarreur et 63. Unir el cable al arrancador y bulón
stud. le boulon de fixation. de conexión.
Tighening specifications: Consigne de serrage: Prescripción de apriete:

Hex. nut on terminal stud Ecrou hexagonal sur le boulon de Tuerca hexagonal en el bulón de
35 ± 4 Nm fixation 35 ± 4 Nm conexión 35 ± 4 Nm
Hex. nut on starter (terminal 30) Ecrou hexagonal sur le démarreur Tuerca hexagonal en el arrancador
28 ± 2 Nm (borne 30) 28 ± 2 Nm (borne 30) 28 ± 2 Nm.
64. Introduce cable harness through 64. Introduire le faisceau de câble par 64. Hacer pasar el mazo de cables a
cover plate. Fit rubber grommet. la tôle de recouvrement. Monter le través de la chapa de
4 passe-câble. recubrimiento. Montar el
pasacables.
4.00.91
008 918 12 BOMAG 1285
complete engine
engine
61. Druckölleitung anbauen:
Hohlschrauben mit neuen Cu-Dichtringen

4
und mit einem Drehmoment von
Pos. 1 29 ± 3 Nm
Pos. 2 39 ± 4 Nm
festdrehen.
62. Abschlußblech anbauen.

4
63. Kabel an Starter und Anschlußbolzen an-

bauen. 4
Anziehvorschrift:
Sechskantmutter am Anschlußbolzen
6
35 ± 4 Nm
Sechskantmutter am Starter (Klemme 30)
28 ± 2 Nm
64. Kabelbaum durch Abdeckblech durchführen.

Gummitülle montieren 4 4
9
4.00.91
1286 BOMAG 008 918 12
Diesel engine 18.9
65. Niveauschalter mit neuer Gummimuffe

4 einbauen.
Schraube mit einem Drehmoment von
ß 28 Nm festdrehen.
66. Verkabelung mit Haltebinder und Halter

4 anbauen.
38-4-226 6 9 Nm festdrehen.
67. Klemmprofil anbauen.

4
Flüssigkeitskühler
4 4 68. Neue Runddichtringe für Flüssigkeits-

ß kühler einsetzen.
4.00.92
008 918 12 BOMAG 1287
complete engine
engine
65. Install level switch with new rubber 65. Monter l'interrupteur du niveau 65. Instalar el interruptor de nivel con
sleeve. Tighten bolt with a torque of avec le manchon en caoutchouc un manguito de goma nuevo.
28 Nm. neuf. Serrer la vis au couple de Apretar el tornillo con un par de
28 Nm. 28 Nm.
66. Fit cabling with fixing strap and 66. Monter le câblage avec le collier de 66. Montar los cables con atacables y
holder. Tighten bolts with a torque fixation et le support. Serrer les vis sujetadores.
of 9 Nm. au couple de 9 Nm. Apretar los tornillos con un par de
9 Nm.
67. Fit clamping section. 67. Monter le profilé de serrage. 67. Colocar anillos tóricos nuevos para
el refrigerador de líquido.
Radiator Refroidisseur à liquide Refrigerador de líquido
68. Insert new O-seals for radiator. 68. Placer les joints toriques neufs 68. Colocar anillos tóricos nuevos para 4
dans le refroidisseur de liquide. el refrigerador de líquido.
4.00.92
1288 BOMAG 008 918 12
Diesel engine 18.9
69. Fit retainer for radiator. 69. Monter le support du refroidisseur 69. Montar los soportes para el
Tighten bolts with a torque of à liquide. Serrer les vis au couple refrigerador.
21 Nm. de 21 Nm. Apretar los tornillos con un par de
21 Nm.
70. Mount radiator. Tighten bolts with 70. Monter le refroidisseur à liquide. 70. Montar el refrigerador. Apretar los
a torque of 9 ± 1 Nm. Serrer les vis au couple de tornillos de fijación con un par de
9 ± 1 Nm. 9 ± 1 Nm.
71. Fit cover plate. 71. Monter la tôle de recouvrement. 71. Montar la chapa de rccubrimiento.
4
4.00.93
008 918 12 BOMAG 1289
complete engine
engine
69. Halter für Flüssigkeitskühler anbauen.

21 Nm festdrehen.
4
6
70. Flüssigkeitskühler anbauen. Schrauben mit

festdrehen.
4
6

4

4 4
4.00.93
1290 BOMAG 008 918 12
Diesel engine 18.9

4 Hinweis: Schrauben noch nicht festdrehen.
74. Entlüftungsleitung mit neuen Cu-Ringen

4 anbauen. Halter gemeinsam mit Abdeck-
blech festdrehen.
4
75. Schaulochblech anbauen.
4 4
7
4.00.94
008 918 12 BOMAG 1291
complete engine
engine
Note: Do not tighten bolts yet. Nota: ne pas encore serrer les vis. Nota: Los tornillos todavia no deben
appretarse.
74. Fit breather pipe with new Cu seals. 74. Monter la conduite de dégazage 74. Montar la tubería de ventilación con
Tighten retainer together with cover avec des joints Cu neufs. Serrer le anillos de cobre nuevos. Apretar el
plate. support avec la tôle de sujetador junto con la chapa de
recouvrement. recubrimiento.
75. Fit inspection hole cover plate. 75. Monter la tôle-regard. 75. Montar la chapa de la abuerta de
inspección.
4.00.94
1292 BOMAG 008 918 12
Diesel engine 18.9
Replacing shaft seals on complete Remplacement des joints d’arbre sur Cambio de los retenes en el motor
engine moteur complet completo
Special tools required: Outillage spécial : Herramientas especiales:
Extractor for Extracteur de Dispositivo de extracción

shaft seals ______________ 142 710 joints d’arbre ___________ 142 710 para retenes _____________ 142 710
Assembly tool, rear Dispositif de montage AR Dispositivo de montaje, atrás
BFM 1012 _________ 142 890 BFM 1012 ___________ 142 890 BFM 1012 ___________ 142 890
BFM 1013 _________ 142 910 BFM 1013 ___________ 142 910 BFM 1013 ___________ 142 910
Assembly tool, front Dispositif de montage AV Dispositivo de montaje, delante
BFM 1012 _________ 142 900 BFM 1012 ___________ 142 900 BFM 1012 ___________ 142 900
BFM 1013 _________ 142 920 BFM 1013 ___________ 142 920 BFM 1013 ___________ 142 920
- Timing chest cover flywheel end - - Couvercle de carter de distribution - Tapa del cárter de la distribución,
côté volant moteur - lado de volante -
Flywheel has been removed. Le volant moteur a été déposé. El volante está desmontado.
1. Press extractor into shaft seal. 1. Insérer le crochet extracteur dans le 1. Introducir a presión el gancho
joint d’arbre. extractor en el retén.
2. Lift shaft seal with extractor out of 2. A l’aide de l’extracteur retirer le 2. Haciendo palanquilla con el
timing chest cover. joint d’arbre du couvercle du carter dispositivo de extracción, sacar el
de distribution. retén de su alojamiento en la tapa
del cárter de la distribución.
3. Fit guide sleeve. 3. Monter la douille de guidage. 3. Montar la consola.
4.00.95
008 918 12 BOMAG 1293
complete engine
engine
Austausch der Wellendichtringe am komplet-

ten Motor
4
Spezialwerkzeuge:
6
Ausziehvorrichtung für
Wellendichtringe ________________ 142 710
Montagevorrichtung hinten
BFM 1012 ________ 142 890
BFM 1013 ________ 142 910
Montagevorrichtung vorne
BFM 1012 ________ 142 900
BFM 1013 ________ 142 920
- Räderkastendeckel Schwungradseite -
Schwungrad ist abgebaut.

4
1. Abziehhaken in den Wellendichtring 7
eindrücken.
2. Wellendichtring mit Ausziehvorrichtung aus

dem Räderkastendeckel hebeln. 3
7
3. Führungsbuchse anbauen.
4 4
7
4.00.95
1294 BOMAG 008 918 12

Diesel engine 18.9
0 ± 0,5 4. Einbautiefe beachten.
1 4 Pos.1 Einbautiefe Erstmontage
6 Pos. 2 Maximale Einbautiefe
2 3 ± 0,5
10-4-307
4.1 Dichtlippen einölen. Wellendichtring mit

4 Eindrückvorrichtung montieren.
Dichtlippe weist zur Kurbelwelle.
z
7
8
- Vorderer Deckel -
4 Keilriemenscheibe ist abgebaut.
7 1. Abziehhaken in den Wellendichtring
eindrücken.
2. Wellendichtring mit Ausziehhaken aus

4 3 dem vorderen Deckel hebeln.
4.00.96
008 918 12 BOMAG 1295
complete engine
engine
4. Pay attention to the installation 4. Tenir compte de la profondeur de 4. Observar la profundidad de

depth. montage montaje.
Item 1 installation depth initial Rep. 1 Profondeur de montage Pos. 1 Profundidad de montaje
assembly première monte primer montaje
Item 2 maximum installation depth Rep. 1 Profondeur de montage Pos. 1 Profundidad máxima de
maximale montaje
4.1 Oil sealing lips. Fit shaft seal with 4.1 Huiler les lèvres d’étanchéité. 4.1 Aceitar los labios obturantes.
assembly tool. Sealing lip faces Monter le joint d’arbre à l’aide du Montar el retén mediante el
crankshaft. dispositif d’insertion. La lèvre dispositivo de montaje a presión.
d’étanchéité est dirigée vers le El labio indica hacia el cigüeñal.
vilebrequin.
- Front cover - - Couvercle AV - - Tapa delantera -
V-belt pulley has been removed. La poulie à gorge a été déposée. La polea acanalada está desmontada.
1. Press extractor into shaft seal. 1. Introduire le crochet extracteur 1. Introducir a presión el gancho
dans le joint d’arbre. extractor en el retén.
2. Lift shaft seal with extractor out of 2. A l’aide du crochet extracteur 2. Haciendo palanquilla con el
front cover. dégager et retirer le joint d’arbre dispositivo extractor, sacar el retén
du couvercle avant. de la tapa delantera. 4
4.00.96
1296 BOMAG 008 918 12
Diesel engine 18.9
3. Fit guide sleeve. 3. Monter la douille de guidage. 3. Montar el manguito de guía.
4. Pay attention to the installation 4. Tenir compte de la profondeur de 4. Observar la profundidad de

depth. montage montaje.
Item 1 installation depth initial Rep. 1 Profondeur de montage Pos. 1 Profundidad de montaje
assembly première monte primer montaje
Item 2 maximum installation depth Rep. 1 Profondeur de montage Pos. 1 Profundidad máxima de
maximale montaje
4.1 Oil sealing lips. Fit shaft seal with 4.1 Huiler les lèvres d’étanchéité. 4.1 Aceitar los labios de obturantes.
assembly tool. Sealing lip faces Monter le joint d’arbre à l’aide du Montar el retén mediante el
crankshaft. dispositif d’insertion. La lèvre dispositivo correspondiente.
d’étanchéité est dirigée vers le El labio indica hacia el cigüeñal.
vilebrequin.
4.00.97
008 918 12 BOMAG 1297
complete engine
engine
3. Führungsbuchse anbauen.
4
7
4. Einbautiefe beachten.
Pos.1 Einbautiefe Erstmontage

4 1 5
Pos. 2 Maximale Einbautiefe
6
8
2
10-4.311
4.1 Dichtlippen einölen. Wellendichtring mit

Eindrückvorrichtung montieren.
Dichtlippe weist zur Kurbelwelle.
4
z
7
8
4.00.97
1298 BOMAG 008 918 12
Diesel engine 18.9
008 918 12 BOMAG 1299

complete engine
engine
1300 BOMAG 008 918 12

Diesel engine 18.9
Removing and refitting air Pose et dépose du compresseur à air Desmontaje y remontaje del
compressor compresor de aire.
1. Remove air compressor and oil 1. Déposer le compresseur à air et les 1. Desmontar el compresor de aire y
pressure pipes. conduites de refoulement d’huile. las tuberías de presión de aceite.
Note: Inspect all single parts and Nota: contrôler visuellement toutes Nota: Examinar visualmente todas las
replace if necessary. les pièces, les changer le cas piezas y reemplazarlas según
échéant. necesidad.
2. Fit new O-seal. 2. Monter un joint torique neuf. 2. Montar un aro tórico nuevo.
3. Fit oil pressure pipe together with 3. Monter la conduite de refoulement 3. Montar la tubería de presión de
new Cu seals prior to mounting air d’huile avec des joints neufs en Cu aceite con juntas de cobre nuevas
compressor. avant de mettre en place le antes de adosar el compresor.
compresseur à air.
Note: Do not yet tighten banjo bolt. Nota: ne pas encore serrer la vis Nota: El tornillo racor todavía no debe
creuse. apretarse.
4. Mount air compressor. 4. Monter le compresseur. Monter les 4. Montar el compresor de aire.
Insert bolts with locking compound vis avec de la pâte de sécurité Meter los tornillos con sellante
4 Deutz DW 72 and tighten with a Deutz DW 72 puis serrer au couple DEUTZ DW 72 y apretar con un par
torque of 61 ± 6 Nm. de 61 ± 6 Nm. de 61 ± 6 Nm.
4.00.99
008 918 12 BOMAG 1301
complete engine
engine
Luftpresser ab- und anbauen.
1. Luftpresser und Öldruckleitungen abbauen.

3
Hinweis: Alle Teile sichtprüfen, ggf. austau- 5
schen.
2. Neuen Runddichtring montieren.

4
ß
3. Öldruckleitung mit neuen Cu-Dichtungen

vor Luftpresseranbau montieren.
4
Hinweis: Noch nicht festdrehen.
ß
5
4. Luftpresser anbauen.
Schrauben mit Sicherungsmittel Deutz DW
72 einsetzen und mit einem Drehmoment
4 4
von 61 ± 6 Nm festdrehen.
w
6
4.00.99
1302 BOMAG 008 918 12
Diesel engine 18.9
5. Zweite Öldruckleitung mit neuen Cu-

4 Dichtungen anbauen.
6. Öldruckleitungen am Kurbelgehäuse und

4 Luftpresser festdrehen.
4.00.100
008 918 12 BOMAG 1303
complete engine
engine
5. Fit 2nd oil pressure pipe with new 5. Monter la 2éme conduite de 5. Montar la segunda tubería de
Cu seals. refoulement d´heule avec des joints presión de aceite con juntas de
en Cu neufs. cobre nuevas.
6. Secure oil pressure pipes on 6. Serrer les conduites du 6. Apretar la tuberías de presión de
crankcase and air compressor. refoulement d´huile et le aceite en el bloque motor y en el
compresseur á air. compresor de aire
4.00.100
1304 BOMAG 008 918 12
Diesel engine 18.9
Removing and refitting power Pose et dépose de la pompe direction Desmontaje y remontaje de la
steering pump auxiliaire servobomba de dirección.
1. Fit power steering pump. Take off 1. Dé poser la pompe de direction 1. Desmontar la servobomba de
driver disc. auxiliare. Retirer le disque dirección. Retirar el disco
déntraînement. arrastrador.
Note: Inspect all single parts and Nota: contrôler visuellement toutes Nota: Examinar visualmente todas las
replace if necesarry. les piéces, les changer le cas piezas y reemplazarlas según
échéant, necesidad.
2. Fit driver disc. 2. Monter le disque déntraînement. 2. Instalar el disco arrastrador.
3. Fit new O-seal and apply dehydated 3. Monter un joint torique neuf et 3. Montar un anillo tórico nuevo y
lubricant. lénduire de lubrifiant anhydre. untarlo con lubricante exento de
agua.
4. Fit power steering pump and make 4. Monter la pompe de direction 4. Montar la servobomba de
sure that drivers engage in driver auxiliare. Veiller á ce que les tocs dirección, prestando anteción a que
4 disc. soient bien en prise dans les los arrastradores entren en el disco
disques déntraînemement. arrastrador.
4.00.101
008 918 12 BOMAG 1305
complete engine
engine
Lenkhilfspumpe ab- und anbauen.
1. Lenkhilfspumpe abbauen. Mitnehmer-

3
scheibe abnehmen.
5
Hinweis: Alle Teile sichtprüfen, ggf. austau-
schen.
2. Mitnehmerscheibe einbauen.
4
3. Neuen Runddichtring montieren und mit

wasserfreiem Schmiermittel bestreichen. 4
ß
4. Lenkhilfspumpe anbauen. Darauf achten, daß die

Mitnehmer in die Mitnehmerscheibe greifen.
4 4
9
4.00.101
1306 BOMAG 008 918 12
Diesel engine 18.9

4 43,5 ± 4 Nm festdrehen.
6 Hinweis: Auf Spezialscheiben achten.
4.00.102
008 918 12 BOMAG 1307
complete engine
engine
43.5 ± 4 Nm. 43.5 ± 4 Nm. 43,5 ± 4 Nm.
Note: Watch out for special washers. Nota: veiller aux cales spêciales. Nota: Tener en cuenta las arandelas
especiales.
4.00.102
1308 BOMAG 008 918 12
Diesel engine 18.9
Removing and refitting hydraulic Pose et dépose de la pompe Desmontaje y remontaje de la bomba
pump hydraulique hidráulica.
1. Unscrew bolts from hydraulic 1. Dévisser puis retirer les vis de la 1. Desenroscar los tornillos de la
pump. pompe hydraulique. bomba hidráulica.
2. Unscrew bolts from guide flange. 2. Devisser puis retirer les vis de la 2. Desenroscar los tornillos de la
Remove hydraulic pump complete bride de guidage. brida de guía.
with guide flange. Retirer entiérement la pompe Retirar la bomba hidráulica
hydraulique avec la bride de completamente con la brida de
guidage. guía.
Note: Inspect all single parts and Nota: enduire visuellement toutesles Nota: Examinar visualmente todas las
replace if necessary. piéces, les changer le cas piezas y reemplazarlas según
échéant. necesidad.
3. Mount preassembled hydraulic 3. Monter la pompe hydraulique 3. Montar la bomba hidráulica

pump together with guide flange. préassemblée avec la bride de premontada, con la brida de guía.
Tighten guide flange bolts with a guidage. Apretar los tornillos de la brida de
torque of 21 ± 2 Nm. Serrer les vis de la bride de guidage guía con un par de 21 ± 2 Nm.
au couple de 21 ± 2 Nm.
Note: Apply dehydrated lubricant to Nota: enduire el joint torique et Nota: Aplicar lubricante exento de
seal/receiving bore. lálésager du legement de agua al anillo tórico/
lubrifiant anhydre. alojamiento.
4. Move gasket into installation 4. Insérer el joint en position de 4. Colocar la junta en su posición de
position. Tighten hydraulic pump montage. Serrer les vis de la montaje. Apretar los tornillos de la
4 bolts with a torque of 50 ± 10 Nm. pompe hyfraulique au couple de bomba hidráulica con un par de
50 ± 10 Nm. 50 ± 10 Nm.
4.00.103
008 918 12 BOMAG 1309
complete engine
engine
Hydraulikpumpe ab- und anbauen.
1. Schrauben von Hydraulikpumpe heraus-

3
schrauben.
2. Schrauben von Führungsflansch heraus-

schrauben.
Hydraulikpumpe komplett mit Führungs-
3
flansch abnehmen.
5
schen.
3. Vormontierte Hydraulikpumpe mit

Führungsflansch anbauen.
Schrauben von Führungsflansch mit einem
4
6
5
Hinweis: Runddichtring/Aufnahmebohrung
mit wasserfreiem Schmiermittel be-
streichen.
4. Dichtung in Einbaulage schieben. Schrau-

ben von Hydraulikpumpe mit einem Dreh-
moment von 50 ± 10 Nm festdrehen.
4 4
6
4.00.103
1310 BOMAG 008 918 12
Diesel engine 18.9
008 918 12 BOMAG 1311

complete engine
engine
1312 BOMAG 008 918 12

Diesel engine 18.9
Removing and refitting hydraulic Poset et dépose de la pompe Desmontaje y remontaje de la bomba
pump together with bracket hydraulique hidráulica y consola
1. Remove oil pressure pipe 1. Monter conduite de refoulement 1. Desmontar la tubería de presión de
d´huile. aceite.
2. Remove hydraulic pump. 2. Déposer la pompe hydraulique. 2. Desmontar la bomba hidráulica.
3. Remove bracket. 3. Déposer la console. 3. Desmontar la consola.
Note: Inspect all single parts and Nota: effectuer un contrôle visuel de Nota: Inspeccionar todas las piezas
replace if necessary. Renew toutes les pièces, au besoin les visualmente, sustituyéndolas en
gaskets. Check bore in hollow remplacer. Renouveller les caso necesario. Renovar las
shaft and drive shaft for free joints. Contrôler le libre juntas. Comprobar los taladros
passage. passage de l'alésage de l'arbre en el eje hueco y eje arrastrador
creux d'entraînement. para ver si están despejados.
4. Fit preassembled bracket. 4. Monter la console préassemblée. 4. Montar la consola premontada.
4 Note: Lightly oil O-seal/bore. Nota: huiler légérement le joint Nota: Untar con un poco de aceite el
torique/lálésage. anillo tórico/alojamiento.
4.00.105
008 918 12 BOMAG 1313
complete engine
engine
Hydraulikpumpe mit Konsole ab- und

anbauen
3
1. Öldruckleitung abbauen.
2. Hydraulikpumpe abbauen.
3
3. Konsole abbauen.

3
schen. Dichtungen erneuern.
Bohrung in Hohl- und Mitnehmer- 5
welle auf freien Durchgang prüfen.
4. Vormontierte Konsole anbauen.
Hinweis: Runddichtring/Bohrung leicht ein-

4 4
ölen.
5
4.00.105
1314 BOMAG 008 918 12
Diesel engine 18.9
5. Neuen Runddichtring auf Befestigungs-

4 flansch auflegen.
6. Befestigungsflansch anbauen.
4 Schrauben nach Anziehvorschrift fest-
drehen.
6 Schrauben M 8 = 21 ± 2 Nm
Schrauben M 10 = 40,5 ± 4 Nm
5 Hinweis: Schrauben M10 sind mikrover-

kapselt. Eine Wiederverwendung ist
nicht zulässig.
7. Führungshülse einsetzen.
4 Hinweis: Auf Sicherungsring in der Mitte der
5 Führungshülse achten.
8. Neue Dichtung auflegen. Hydraulikpumpe
4 4 anbauen.
4.00.106
008 918 12 BOMAG 1315
complete engine
engine
5. Position new O-seal on fastening 5. Placer un joint torique neuf sur la 5. Colocar un anillo tórico nuevo
flange. bride de fixation. sobre la brida de fijación.
6. Fit fastening flange. Tighten bolts 6. Monter la bride de fixation. 6. Montar la brida de fijación.
according to specification. Serrer les vis selon les préconisations Apretar los tornillos según
de serrage prescripción.
Bolts M 8 = 21 ± 2 Nm vis M 8 = 21 ± 2 Nm Tornillos M8 = 21 ± 2 Nm
Bolts M 10= 40.5 ± 4 Nm vis M 10 = 40,5 ± 4 Nm Tornillos M10 = 40,5 ± 4 Nm
Note: Bolts M10 are micro- Nota: les vis M10 sont dotées d'une Nota: Los tornillos M10 tienen un
encapsulated. Their re-use is microcapsule. recubrimiento sellante. Es
not permissible. inadmisible volver a utilizarlos.
7. Insert guide bush. 7. Mettre en place la douille de guidage. 7. Introducir el manguito de guía.
Note: Watch out for circlip in the Nota: veiller à ce que le circlip soit au Nota: Prestar atención al anillo de
middle of guide bush. milieu de la douille de guidage. retención en medio del
manguito de guía.
8. Position new gasket. Mount 8. Placer un joint neuf puis monter la 8. Colocar una junta nueva. Montar la
hydraulic pump. pompe. bomba hidráulica.
4
4.00.106
1316 BOMAG 008 918 12
Diesel engine 18.9
9. Tighten bolts with a torque of 9. Serrer les vis au couple de 9. Apretar los tornillos de fijación con
50 ± 10 Nm. 50 ± 10 Nm. un par de 50 ± 10 Nm.
10. Fit oil pressure pipe with new Cu 10. Monter la conduite du refoulement 10. Montar la tubería de presión de
seals. d’huile avec des joints Cu neufs. aceite con juntas de cobre nuevas.
4.00.107
008 918 12 BOMAG 1317
complete engine
engine

4
6
10. Öldruckleitung mit neuen Cu-Dichtungen

anbauen. 4
ß
4.00.107
1318 BOMAG 008 918 12
Diesel engine 18.9
008 918 12 BOMAG 1319

18.9 and reassembly of complete engine
Disassembly Diesel engine
1320 BOMAG 008 918 12

Diesel engine 18.9
Replacing injection pump in case of Remplacement de la pompe Cambio de las bombas de inyección
service d’injection en SAV en el caso de servicio
This repair method only refers to the La présente méthode de réparation ne Este método de reparación sólo está
replacement of injection pumps. If concerne que le remplacement des pensado para el cambio de las bombas
other components are to be replaced pompes d’injection. En cas de de inyección. Si adicionalmente han de
as well, e.g. roller tappets, governor, remplacement supplémentaire d’autres cambiarse otras piezas, como el
etc., proceed according to chapter 4 pièces comme p. ex. les poussoirs à empujador de rodillo, regulador, etc.,
„Installing injection pump“. galet, le régulateur etc. procéder se procederá como se indica en el
comme au chapitre 4 „montage capítulo 4 „Montaje de bombas de
pompes d’injection“. inyección“.
Special tool required: Outillage spécial: Herramientas especiales:

Press-on device for Dispositif de montage de Dispositivo de presión para
control rod ______________ 100 830 crémaillère ______________ 100 830 la cremallera ____________ 100 830
Extracting device _________ 150 800 Extrateur _______________ 150 800 Dispositivo de extracción ___ 150 800
Extractor for injector ______ 110 030 Extrateur pour injecteur ____ 110 030 Extractor para inyector ____ 110 030
1. Remove crankcase breather and 1. Déposer l’évent de carter et le cache- 1. Desmontar la ventilación del cárter
cylinder head cover. culbuteurs. y la tapa de culata.
2. Pull off cable plug. 2. Retirer le contacteur de câble. 2. Sacar el enchufe de cable.
Remove shutdown solenoid or Déposer l’électroaimant d’arrêt ou Desmontar el solenoide de parada
screw plug. le bouchon de fermeture. o el tapón de cierre.
3. Press control rod with shutdown 3. A l’aide du levier d’arrêt pousser la 3. Presionar la barra cremallera
4 lever into stop position. Insert crémaillère en position de stop. mediante la palanca de parada en
press-on device and screw on. Monter l’outil de montage et serrer. posición de parada. Introducir el
dispositivo de presión y atornillarlo.
4.00.109
008 918 12 BOMAG 1321
complete engine
engine
Austausch der Einspritzpumpe im Servicefall
Diese Reparaturmethode ist nur für den Aus-

tausch der Einspritzpumpen gedacht. Sollten
zusätzlich noch andere Teile getauscht werden,
z.B. Rollenstößel, Regler etc., ist wie in Kapitel
4 „Einspritzpumpen Einbau“ zu verfahren.
Spezialwerkzeug:
Andrückvorrichtung für
Regelstange ____________________ 100 830
Ausziehvorrichtung ______________ 150 800
Auszieher für Einspritzventil _______ 110 030
1. Kurbelgehäuseentlüftung und Zylinderkopf-

haube abbauen.
3
2. Kabelstecker abziehen.
Abstellmagnet oder Verschlußstopfen aus-
bauen.
3
3. Regelstange mittels Abstellhebel in Stop-

stellung drücken. Andrückvorrichtung ein-
setzen und verschrauben.
4 4
7
4.00.109
1322 BOMAG 008 918 12
Diesel engine 18.9
4. Regelstange mit Rändel-Feststellschraube

s in Stopstellung drücken.
5 Hinweis: Rändel-Feststellschraube von Hand

festdrehen.
5. Zylinder der auszubauenden Einspritzpum-

Zünd OT 6 pe auf Zünd-O.T. stellen.
Kurbelwelle ca. 120° entgegen der Motor-
5 drehrichtung drehen.
Hinweis: Darstellung Blickrichtung auf

Schwungrad.
120
6. Einspritzleitung und Einspritzpumpe

3 abbauen.
7. Ausgleichsscheibe mit Stabmagnet vorsich-
4 3 tig herausnehmen.
5 Hinweis: Neue Ausgleichsscheibe ermitteln,

siehe für BFM 1012 Seite 1.00.15
für BFM 1013 Seite 1.00.17
4.00.110
008 918 12 BOMAG 1323
complete engine
engine
4. Press control rod with knurled- 4. A l’aide de la vis de blocage 4. Presionar la cremallera en posición
head setscrew into stop position. moletée amener la crémaillère en de parada con ayuda del tornillo de
position de stop. cabeza moleteada, de bloqueo.
Note: Tighten knurled-head setscrew Nota: serrer la vis de blocage moletée Nota: Apretar con la mano el tornillo
by hand. à la main. de cabeza moleteada, de
bloqueo.
5. Move cylinder of injection pump to 5. Placer le cylindre de la pompe 5. Poner el cilindro que corresponda a
be removed to firing TDC. d’injection à déposer en position la bomba de inyección a
Turn crankshaft about 120°against d’allumage PMH. desmontar, en el PMS de
direction of engine rotation. Virer le vilebrequin d’environ 120° compresión.
dans le sens opposé au sens de Girar el cigüeñal aprox. 120° en
rotation du moteur. sentido opuesto al de giro normal
del motor.
Note: Flywheel is faced on the Nota: illustration observateur Nota: Representado con dirección de
illustration at the left. regardant le volant moteur. la mirada al volante.
6. Remove injection line and 6. Déposer la conduite d'injection et la 6. Desmontar la tubería de inyección y
injection pump. pompe d'injection. la bomba de inyección.
7. Carefully take out shim using bar 7. Retirer avec précaution la rondelle 7. Retirar la arandela de reglaje
magnet. d’épaisseur à l’aide d’une barre cuidadosamente mediante el imán
magnétique. de barra. 4
Note: Determine new shim, see Nota: calcul de l’épaisseur de la Nota: Determinar la arandela de
page 1.00.15 for BFM 1012, rondelle, voir page reglaje nueva:
page 1.00.17 for BFM 1013. 1.00.15 pour le BFM 1012 para BFM 1012 ver pág. 1.00.15
et page para BFM 1013 ver pág. 1.00.17
1.00.17 pour le BFM 1013
4.00.110
1324 BOMAG 008 918 12
Diesel engine 18.9
8. Position new shim previously 8. Placer la rondelle d’épaisseur 8. Colocar la arandela de reglaje
determined on roller tappet. nouvellement calculée sur le determinada sobre el empujador de
poussoir à galet. rodillo.
Note: See page 4.00.37 items Nota: montage pompe d’injection Nota: Para el montaje de la bomba de
78 - 84 for installation of voir page 4.00.37 à partir inyección, ver la pág. 4.00.37 a
injection pump. des pts 78 - 84. partir del punto 78 - 84.
9. Remove injector. 9. Déposer l’injecteur. 9. Desmontar el inyector.
Note: If jammed, use extracting Nota: si les pièces sont bloquées Nota: Si está fijo, utilizar el dispositivo
device No. 150 800 together utiliser d’extraction de extracción
with extractor No. 110 030. No. 150 800 avec l’extracteur No. 150 800 con extractor
No. 110 030. No. 110 030.
See page 4.00.48 from items 114 Monter l’injecteur et la con- Montar el inyector y la tubería de
for fitting injector and injection duite voir page 4.00.48 pt. 114. inyección,
line. ver pág. 4.00.48, a partir del punto
114.
10. Turn back knurled-head setscrew. 10. Dévisser la vis de blocage moletée 10. Girar hacia atrás el tornillo de
Remove press-on device. puis déposer l’outil de montage. cabeza moleteada, de bloqueo.
Desmontar el dispositivo de
presión.
Note: Check whether control rod Nota: vérifier si la crémaillère Nota: Comprobar la facilidad de
moves easily from stop to start coulisse librement de la movimiento de la cremallera
position. For this purpose position stop à la position de entre la posición de parada y la
actuate shutdown lever of démarrage. Pour cela actionner de arranque, lo que se hace
governor. le levier d’arrêt du régulateur. accionando la palanca de
parada del regulador.
11. Press control rod with shutdown 11. A l’aide du levier d’arrêt pousser la 11. Sirviéndose de la palanca de
lever into stop position. Fit crémaillère en position de stop. parada, llevar la cremallera a la
4 shutdown solenoid with new Monter l’électroaimant d’arrêt avec posición de parada.
O- seal. un joint torique neuf. Incorporar el solenoide de parada
con un anillo tórico nuevo.
Note: Lightly oil O-seal. Nota: huiler légèrement le joint Nota: Untar con un poco de aceite el
torique. anillo tórico.
4.00.111
008 918 12 BOMAG 1325
complete engine
engine
8. Neu ermittelte Ausgleichscheibe auf Rollen-

stößel auflegen.
4
Hinweis: Einspritzpumpen - Einbau, siehe
Seite 4.00.37 ab Pos. 78 - 84. 5
9. Einspritzventil ausbauen.
Hinweis: Bei Festsitz Ausziehvorrichtung

3
Nr. 150 800 mit Auszieher
Nr. 110 030 verwenden. 5
Einspritzventil und Einspritzleitung anbauen,
siehe Seite 4.00.48 ab Pos. 114
10. Rändel-Feststellschraube zurückdrehen.

Andrückvorrichtung abbauen. a
Hinweis: Prüfen ob Regelstange von Stop-
stellung zur Startstellung leichtgän- 3
5
gig ist. Hierzu Abstellhebel des
Reglers betätigen.
11. Regelstange mittels Abstellhebel in Stop-

stellung drücken.
Abstellmagnet mit neuem Runddichtring
4 4
einbauen.
ß
Hinweis: Runddichtring leicht einölen.
5
4.00.111
1326 BOMAG 008 918 12
Diesel engine 18.9

4 21 Nm festdrehen. Kabelstecker montieren.
13. Zylinderkopfhaube montieren. Schrauben

4 mit einem Drehmoment von 9 ± 1 Nm
festdrehen.
6 Hinweis: Bei Bedarf Dichtung erneuern.
4
14. Runddichtring leicht einölen. Kurbelgehäu-
seentlüftung anbauen. Schrauben mit
einem Drehmoment von 9 ± 1 Nm fest-
z drehen.
6 Hinweis: Bei Bedarf Runddichtring erneuern.
4.00.112
008 918 12 BOMAG 1327
complete engine
engine
12. Tighten bolts with a torque of 12. Serrer les vis au couple de 21 Nm. 12. Apretar los tornillos de fijación con
21 Nm. Fit cable plug. Monter les fiches de câble. un par de 21 Nm. Montar el
enchufe de cable.
13. Fit cylinder head cover. Tighten 13. Monter le cache-culbuteurs et 13. Montar la tapa de culata. Apretar
bolts with a torque of 9 ± 1 Nm. serrer les vis au couple de los tornillos de fijación con un par
9 ± 1 Nm. de 9 ± 1 Nm.
Note: Renew gasket if necessary. Nota: au besoin renouveller le joint. Nota: De ser necesario, sustituir la
junta por otra nueva.
14. Lightly oil O-seal. Fit crankcase 14. Huiler légèrement le joint torique. 14. Untar con un poco de aceite el
breather. Tighten bolts with a Monter l’évent de carter et serrer anillo tórico. Montar la ventilación
torque of 9 ± 1 Nm. les vis au couple de 9 ± 1 Nm. del cárter.
Note: Renew O-seal if necessary. Nota: au besoin renouveller le joint Nota: De ser necesario, sustituir el
torique. anillo tórico por otro nuevo.
4.00.112
1328 BOMAG 008 918 12
Diesel engine 18.9
008 918 12 BOMAG 1329

18.9 Diesel engine
Werkzeuge
Tools
Outils
Herramientas BFM 1012/1013
1330 BOMAG 008 918 12

Diesel engine 18.9
008 918 12 BOMAG 1331

Handelsübliche Werkzeuge
18.9 Commercial
Diesel enginetools
Outils usuels
Herramientas comerciales
BFM 1012
BFM 1013
Deutsch English Français Español No. Werkstatthandbuch BFM 1012/1013
Druckpumpe für Kühlmitteldichtheitsprüfung 8002 ● ●
Pressure Pump for coolant leakage
Pompe refoulante pour contrôle de l'étanchéité

du liquide de refroidisseur
Bomba de presión para pruebas de

estanqueidad sistema de liquido refrigerante
Verschlußdeckel
Kompressionsdruckprüfer 8005 ● ●
Compression tester
Compressiomètre
Compresímetro
Düsenprüfgerät 8008 ● ●
Nozzle tester
Banc déssais dínjecteurs
Comprobador para inyectors
Cobraklemmenzange 8011 ● ●
Cobra clamp pliers
Pince à colier Cobra
Alicates Cobra
5.00.01
1332 BOMAG 008 918 12 5
Commercial tools
Diesel engine 18.9
Outils usuels
BFM 1012
BFM 1013
Werkstatthandbuch BFM 1012/1013 No. Deutsch English Français Español
● ● 8012 Stecknuß SW 15, lange Ausführung für

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

(Cap nut)
Douille de 15 modèle long pour injecteur (écrou-

raccord)
Dado de vaso de 15, tipo largo, para inyectores

(tuerca de unión)
● ● 8112 Schraubendrehereinsatz
Screw driver socket
Embout de tournevis
Punta recambiable de destornillador
● ● 8113 Torx-Steckschlüssel-Einsätze,
lange Ausführung
● 8116 Torx sockets long version
● ● 8114 Embouts de clé à douille Torx, modèle long
Llaves de caja Torx, tipo largo
● ● 8115 Keilriemenspannungsmeßgerät
V-belt tension gauge
Appareil de vérification de la tension de la

courroie trapézoïdale
Verificador de tensión para correas

trapezoidales
5.00.02
5 008 918 12 BOMAG 1333
18.9 Commercial
Diesel enginetools
Outils usuels
BFM 1012
BFM 1013
Verdrehschlüssel (Vielzahn) für Einspritzpumpe 8117 ● ●
Serrated wrench for turning injection pump
Clé polygonale pour pompe dínjection
Llave de estrella para giro de bombas de inyección
Torx-Werkzeugsatz 8189 ● ●
Torx tool kit
Jeu d’outils Torx
Juego de herramientas TorxTorx-Werkzeugsatz
Ventilfedermontagehebel 9017 ● ●
Valve spring assembly lever
Levier de montage pour ressort de soupape
Palanca de montaje para muelles de válvula
Federklemmenzange 9088 ● ●
Spring clamp pliers
Pince à crampon élastique
Tenazas para pinzas elásticas.
5.00.03
1334 BOMAG 008 918 12 5
Commercial tools
Diesel engine 18.9
Outils usuels
BFM 1012
BFM 1013
● ● 9090 Federklemmenzange
Spring clamp pliers
Pince à crampon élastique
Tenazas para pinzas elásticas
● ● 9115 Hilfswerkzeug für Glühkerzen-Kabelkupplung
Auxiliary tool for glow plug cable coupler
Outil auxilaire pour racords de câbles de

bougies de préchauffage
Herramienta auxiliar para acoplamiento de cables

de bujías de incandescencia
5.00.04
5 008 918 12 BOMAG 1335
18.9 Diesel engine
1336 BOMAG 008 918 12

Spezialwerkzeuge
Diesel engine 18.9
Special tools
Outils spéciaux
Herramientas especiales
BFM 1012
BFM 1013
Anschlußstück für Kompressionsdruckprüfer 100 110 ● ●
Connector for compression tester
Raccord pour compressiomètre
Pieza de empalme para el compresímetro
Durchdrehvorrichtung 100 320
Turning gear
Dispositif vireur
Dispositivo de viraje
Durchdrehvorrichtung 100 330
Turning gear
Dispositif vireur
Dispositivo de viraje
Meßuhr M2T mit Feststellring 100 400 ● ●
Dial gauge M2T with locking ring
Comparateur M2T avec bague d’immobilisation
Comparador M2T con anillo de fijación
5.00.05
008 918 12 BOMAG 1337 5
Spezialwerkzeuge
18.9
Special tools Diesel engine
Outils spéciaux
BFM 1012
BFM 1013
● ● 100 750 Meßbalken mit Abstandsblättchen zum Messen

des OT und des Kolbenüberstandes
Measuring bar with spacers for gauging TDC

and piston projection
Barre de mesure avec plaquettes d’écartement

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

para la medición del PMS y saliente de pistón
● 100 780 Meßvorrichtung für Grundkreismessung

" Einspritzpumpe und Förderbeginn "
● 100 860 Measuring device for base circle measurement

„injection pump and commencement of
delivery“
● 100 840 Dispositif de mesure du cercle de base „pompe
d’injection et début d’injection“
Dispositivo para la medición del círculo

base „bomba de inyección y comienzo de
alimentación“
● ● 100 800 Meßgerät zum Messen und Blockieren der

Regelstange
Measuring device for measuring and locking

control rod
Appareil de mesure et de blocage de la crémaillère
Dispositivo para la medición y bloqueo de la

barra cremallera
● 100 810 Einstellbolzen für MAG-Wellen.
Adjusting pin for mass balancing shafts
Pige de calage pour arbres à masses d’équilibrage

(MAG)
Pernos de ajuste para ejes compensadores de

masa „MAG“.
5.00.06
5 1338 BOMAG 008 918 12
Spezialwerkzeuge
Diesel engine 18.9
Special tools
Outils spéciaux
BFM 1012
BFM 1013
Andrückvorrichtung für Regelstange 100 830 ● ●
Press-on device for control rod
Dispositif de montage de crémaillère
Dispositivo de presión para la cremallera
Gradscheibe 360° mit Befestigung an der 101 020 ● ●

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

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

moteur pour PMH et point de calage du début
d’injection
Disco graduado 360° con los elementos de

fijación al volante para el ajuste del PMS y
comienzo de alimentación (FB)
Adapter für Gradscheibe 101 030 ● ●
Adapter for graduated disc
Adaptateur pour disque gradué
Adaptador para el disco graduado
Auszieher für Einspritzventil in Verbindung mit 110 030 ● ●

150 800
Extractor for injectors, to be used with tool

150 800
Extrcteur pour injecteur, à utiliser avec

150 800
Extractor para inyectores, en combinación

con herramienta 150 800
5.00.07
008 918 12 BOMAG 1339 5
Spezialwerkzeuge
18.9
Outils spéciaux
BFM 1012
BFM 1013
● ● 110 110 Halter für Einspritzventil SW11
Dolly for injector a/flats 11
Dispositif d’immobilisation d’injecteur SW 11
Dispositivo de montaje de para inyectores, de 11
● 110 470 Montagewerkzeug für Regelstangen-Buchsen
● 110 480 Assembly tool for control rod sleeves
Outil de montage pour bague de crémaillère
Herramienta de montaje para manguitos de la

barra cremallera
● ● 120 900 Aufspannbock für Zylinderkopf
Swivelling clamping stand for cylinder head
Chevalet d’ablocage pour culasse
Soporte de fijación para culatas
● ● 120 910 Aufspannplatte für 120 900
Clamping plate for 120 900
Plaque d’ablocage pour 120 900
Placa de fijación para 120 900
5.00.08
5 1340 BOMAG 008 918 12
Spezialwerkzeuge
Diesel engine 18.9
Special tools
Outils spéciaux
BFM 1012
BFM 1013
Kolbenring-Auflegezange 130 300 ● ●
Piston ring pliers
Pince à monter les segments de piston
Alicates para colocar aros de pistón
Kolbenringspannband 130 630 ●
Piston ring compressor 130 640 ●
Collier à comprimer les segments de piston
Fleje compresor de aros de pistón
Montagewerkzeug für Kolbenbolzenbuchse 131 070 ●
Assembly tool for small end bush 131 090 ●
Outil de montage de bague de pied de bielle
Dispositivo de montaje para casquillos de pie de

biela
Demontagewerkzeug für Kolbenbolzen- 131 080 ●

sicherungsring
Disassembly tool for piston pin circlip
Appareil de démontage de circlip d’axe de piston
Dispositivo de desmontaje para el anillo de

retención de bulones de pistón
5.00.09
008 918 12 BOMAG 1341 5
Spezialwerkzeuge
18.9
Outils spéciaux
BFM 1012
BFM 1013
● ● 142 710 Demontagewerkzeug (Haken) für Kurbelwellen-

dichtringe vorn und hinten
Puller (hook) for front and rear crankshaft

seals
Outil de démontage (crochet) de joint d’étanchéité

de vilebrequin AV et AR
Dispositivo de desmontaje (ganchos) para los

retenes delantero y trasero del cigüeñal
● 142 890 Montagewerkzeug für Kurbelwellendichtring

hinten
● 142 910 Assembly tool for rear crankshaft seal
Outil de montage de joint d’étanchéité de

vilebrequin AR
Dispositivo de montaje para el retén trasero del

cigüeñal
● 142 900 Montagewerkzeug für Kurbelwellendichtring

vorn
● 142 920 Assembly tool for front crankshaft seal
Outil de montage de joint d’étanchéité de

vilebrequin AV
Dispositivo de montaje para el retén delantero del

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

d’équilibrage
Herramienta de montaje para casquillos de

compensación de masa „MAG“
5.00.10
5 1342 BOMAG 008 918 12
Spezialwerkzeuge
Diesel engine 18.9
Special tools
Outils spéciaux
BFM 1012
BFM 1013
Montagewerkzeug für Nockenwellen-Buchsen 143 790 ●
Assembly tool for camshaft sleeves 143 810 ●
Outil de montage de douilles d’arbre à cames
Herramienta de montaje para casquillos de árbol

de levas
Montagewerkzeug für Zylinderlaufbuchse 150 100 ●
Assembly tool for cylinder liner
Outil de montage pour chemise
Herramienta de montaje para camisas de

cilindro
Montagewerkzeug für Druckregelventil 150 110 ●
Assembly tool for pressure control valve
Outil de montage pour soupape de régulation

de pression
Herramienta de montaje para la válvula

reguladora de presión
Ausziehvorrichtung 150 800 ● ●
Extractor
Extracteur
Dispositivo de extracción
5.00.11
008 918 12 BOMAG 1343 5
Spezialwerkzeuge
18.9
Outils spéciaux
BFM 1012
BFM 1013
● ● 170 050 Spezialvorrichtung zum Abschrauben der

Filterpatrone
Special device for screwing off filter cartridge
Dispositif spécial pour dévisser les cartouches

filtrantes
Herramienta especial para desenroscar cartuchos

filtrantes
● ● 170 090 Montagewerkzeug für Kühlmittelthermostat
Assembly tool for coolant thermostat
Outil de montage de thermostat à réfrigérant
Dispositivo de montaje para el termostato de

líquido refrigerante
● ● 170 630 Gegenhalter für Zahnrad Luftpresser
Dolly for air compressor gear
Dispositif de maintien pour pignon de

compresseur dáir
Dispositivo de retención para la rueda dentada

del compressor de aire
● 6066 Motormontagebock für doppelseitige Auf-

spannung
Engine assembly stand for double-sided

chucking
Chevalet de montage moteur avec double

ablocage
Cabellete de montaje para fijación bilateral del

motor
5.00.12
5 1344 BOMAG 008 918 12
Spezialwerkzeuge
Diesel engine 18.9
Special tools
Outils spéciaux
BFM 1012
BFM 1013
1 Satz Aufspannwinkel für doppelseitige 6066/158 ●

Aufspannung
1 Set of angled clamping plates for double-

sidet chucking
1 jeu d´équerre de fixation pour double

ablocage
1 juego de angulares para fijación bilateral
Motormontagebock für einseitige Aufspannung 6067 ●
Engine assembly stand for one-sidet chucking
Chevalet de montage moteur pour simple

ablocage
Caballete de montaje para fijación unilateral del

motor
1 Satz Aufspannwinkel für Motor mit externer 6067/118 ●

Kühlung
1 Set of angled clamping plates for engine with

external cooling system.
1 jeu d’équerre de fixation pour moteur à

refroidissement externe
1 juego de angulares de fijación para el motor con

refrigeración externa
1 Satz Aufspannwinkel für Motor mit integrieter 6067/119 ●

Kühlung.
1 Set of angled clamping plates for for engine

with integrated cooling system
1 jeu d’équerre de fixation pour moteur à

refroidissement intégré
1 juego de angulares de fijación para el motor con

refrigeración integrada
5.00.13
008 918 12 BOMAG 1345 5
18.9 Diesel engine
1346 BOMAG 008 918 12

19 Circuit diagrams
008 918 12 BOMAG 1347

1348 BOMAG 008 918 12
19.1 Hydraulic diagram 581 202 01
008 918 12 BOMAG 1349

1350 BOMAG 008 918 12

Hydraulic diagram 581 202 01 19.1
BW 218 D-40
008 918 12 BOMAG 1351

1352 BOMAG 008 918 12

008 918 12 BOMAG 1353

1354 BOMAG 008 918 12

Hydraulic diagram 581 202 06 19.2
008 918 12 BOMAG 1355

1356 BOMAG 008 918 12

19.3 Wiring diagram 582 702 41
008 918 12 BOMAG 1357

S/N Wiring diagram 582 702 41
S/N 101 583 271 001 ⇔ 101 583 271 219 BW 177 D-4
S/N 101 583 091 294 ⇔ 101 583 091 561 BW 211 D-4
S/N 101 583 101 034 ⇔ 101 583 101 051 BW 211 PD-4
S/N 101 583 081 397 ⇔ 101 583 081 943 BW 213 D-4
S/N 101 583 131 001 ⇔ 101 583 131 001 BW 213 PD-4
S/N 101 583 421 001 ⇔ 101 583 421 008 BW 214 D-4
S/N 101 583 391 001 ⇔ 101 583 391 022 BW 216 D-40
S/N 101 583 401 001 ⇔ 101 583 401 008 BW 216 DH-40
1358 BOMAG 008 918 12

Inhaltsverzeichnis: BW 177..219 D−4/D−40
008 918 12
table of contents: BW 177..219 D−4/D−40
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
001 582 702 41 Stromlaufplan Circuit Diagram
002 582 702 41 Versorgung, Starten, Motordrehzahl supply, starting unit, engine−speed
003 582 702 41 Motor−Heizflansch, Signalhorn, Kraftstoffvorwärmung engine heating−flange cont., warning horn, fuel pre−heater
004 582 702 41 Bremse, Rückfahrwarneinr., brake, back up alarm,
005 582 702 41 Überwachung monitoring
Wiring diagram 582 702 41
006 582 702 41 Anzeigen indicators

007 582 702 41 Fahrstufen, Sitzkontaktsch., Vibration speed−ranges, seat−switch, vibr.
008 582 702 41 ZA Messtechnik option measurement equipm.
009 582 702 41 BOMAG Compaction Management BCM, GPS BOMAG Compaction Management BCM, GPS
010 582 702 41 ZA Beleuchtung und StvZO opt. illumination and StvZO
011 582 702 41 ZA Kabine, Beleuchtung, Radio, Tachograph opt. cabin, headlights, radio, tachograph
012 582 702 41 ZA Kabinenheizung, Klimaanlage, Zusatzheizung opt. cabin−heater, air conditioning, add. heater
013 582 702 41 Diebstahlschutzsystem D−4, D−40, DHC−4, DH−40 anti − theft system
101 582 702 41 Bauteilliste component listing
BOMAG
06.12.2007
001 001
Vogt Stromlaufplan 582 702 41
06.12.2007
19.3
1359
circuit diagram 001
Seis
30
1360
8:1
F48:2 K30
3:2 11:2
15:54
19.3
2:10 K11 30
X1
X1:15E 2:10
X1:9
17E
X1:10
87 87a
F13 1 1
F105
30A
2 20A
X1:15A 2 K11/87 3:1
X1
X36:B
X36:A
X37:A
17A X1
S00 30 27E X1:30E
30
F158:2 3:2 K35 1
2:16 F14 1 F39
F159:2 15A 15A
4qmm
3:2 Startschalter 87a 87 2 2
starting switch 15 54 58 19 17 50a
X1 X1 X1:30A
15:54 27A
2:13 80 K32:86
X1 11:2
79 S120 11 23
30 F14:2
B+ 7:9
2:10 K114
nur ohne Sitzkontaktschalter
without switch seat−contact
X37:B 2:14 S01:21

X1:3 X1:4 7:9
V01
3:2 87a 87
switch engine speed

12 24
Schalter Motordrehzl
125mA
2 1 K11:86 X1:151
4:5
8:5
main fuse
K61 86 1 21 11 31 ?
Nur bei BW 177D−4

only at BW 177 D−4
fuse Glow plug 1

fuse glow plug 2
30
Hauptsicherung
R10 K61 30 K05 S01
86
Sicherung Heizflansch
fuse heating−flange
82 OHM 4:3
Sicherung Glühwendelkerze 1
Sicherung Glühwendelkerzw 2
85 2 2:6 22 12 32 ?
87 87a K35
F48 2 2 2 F00 2 87 87a K05/87A NOT−AUS
F158 F159 3:2 Emerg.−Stop
85
125A 50A 50A 125A X1:53
BOMAG
1 1 1 1 5:6 X1:152
K61/85
8:2 X1 X1 1 X1 X1 30
Y01 X1:60 K22
X1 D+ MESX 7 8 58 59
1 211...219D−4/40 5:2
2
177...213 D−40 USA
X1 2x2.5qmm 87 87a
2:6
G03 + G01 +
65 X38:A 2
nur bei Klimaanlage

B+ X1
X1
B+
− − D+ 81 V47 54
only acc.to air conditioning

G02
125mA
1
3.8A
30 50 45 AW
nur bei BW 219D−4 und D−40 USA Version, sonst Option

86
only at BW 219 D−4 and D−40 USA version, otherwise option

AUX
86 86 86 + HW 1
K09 Y13
B− W K114 Y120
1 K36 K11 M
S30 M01 70A/1A − 2
85
85 85 85
−
Y139 1 Y01 1 X1 X1 X1
X1:55 X1:56
2 W 6:2 62 63 55
option
Option
X1:66 X1:168 2 2
31 31 3:1
2:8 4:4 12:7 2:18 2:16 2:14

BW 177D−4
Batterie Batterie Generator Starter Startmehrmenge Hubmagnet Drehzahl Kraftstoffabschaltug

battery battery generator
starter start boost fuel sol. engine speed fuel shut off
Trennschalter Batterie Minusangleichung
break switch battery boost−fuel
06.12.2007
1 1
008 918 12
Vogt Versorgung, Starten, Motordrehzahl 582 702 41
06.12.2007
Seis supply, starting unit, engine−speed 002
2:20 K11/87 K11/87 4:1
2:3 F159:2
2:3 F158:2 X1 X1
37E 28E
2:14 K05/87A 1 1
008 918 12
F124 F23
K11:86 X1 25A 10A
2:10 2 2
52 X1 X1
2:2 F48:2 37A 28A
1
R26
220K−OHM
X1:155
13 23
2 7 5 1 15 TK 50 30 S03
14 24
A13
L A13
30(3) R 31 H X1 X1
K14 3 4 6 X1 97 98
30
Anbau im Motorbereich
assembled in engine−area
3:5 75 X1 X1
87(4) K14.1
101 102
Glühzeit Steuergerät
Modul Heizflanschsteuerung
modul heating−flange−control
3:9 87
X1
Taster Signalhorn
78
modul−glowing−control
X1:217
push but. warning horn
BOMAG
1 86
K14 K14.1
GLÜH
2
2
V21
V22
X67:1
4.2A
4.2A
1
1
85
5:12
2
Anbau im Motorbereich
assembled in engine−area
1 B11 1 B11 1
R79
Relais Heizflansch
relais heating−flange
1
Nur bei BW 219 D−4 und D−40 USA Version, sonst Option
only at BW 219 D−4 and D−40 USA version, otherwise option
167A
2 2 2
1 1 1 X67:2
B113
R19 2 R02 R78
Nur bei BW 177 D−4

only at BW 177 D−4
Option Winterpaket
option winter package
nicht bei D−40/BW211D−4 ohne SN1
not at D−40/BW211D−4 ohne SN1
2 50A 2 50A 2
X1 X1 X1 X1 X1
57 64 57 X1:218 99 100
2:20 31 31 4:1
3:2 3:12
Sensor Kühlmitteltemperatur Glühwendelkerze 1 Kraftstoffvorwärmung Signalhorn Signalhorn
sensor collant temperature glow plug 1 fuel pre−heater warning horn warning horn
Heizflansch Glühwendelkerze 2
heating−flange glow plug 2
06.12.2007
1 1
Vogt Motor−Heizflansch, Signalhorn, Kraftstoffvorwärmung
06.12.2007
19.3
1361
Seis engine heating−flange cont., warning horn, fuel pre−heater 003
K11/87
1362
3:20 K11/87 5:1
X1
29E
19.3
1
F25
10A
2
X1
29A
X1:156
F25:2
7:2
X12 X13
1 1
geöffnet in 0
Position (Bremse ein)
BR/BN 30 BR/BN
30
B13 K48 B14 K26
4:2 4:6
87a 87 87a 87
BL/BU SW/BK BL/BU SW/BK
30
K36
2:7
Initiator Farhebel"0
87a 87
Initiator Vorw. und Null

X12 3 X12 2 X13 3 X13 2
BOMAG
K48:87A 5:6 X1:147 K26/87A 7:9
proximity switch forwards and "0"−position

11
proximity switch travel lever "0"−position

K48/86 S01
7:9 2:18
X1:148 12
X1:150 X1
X1:153 114
8:2
300mA
X1:113 BRAKE MESX
2.5A
125mA
86 86 Y04 86 X9 1
K48 K05 1 K26
H14+
2 −
85 85 85 X9
2
125mA
125mA
X1:149 X1
X1:117 129 X1:117
3:20 31 31 5:1
4:3 2:11 4:8
Magnetventil Bremse Rückfahrwarnsummer

solenoid valve brake buzzer back up alarm
06.12.2007
1 1
008 918 12
Vogt Bremse, Rückfahrwarneinr., 582 702 41
06.12.2007
Seis brake, back up alarm, 004
4:20 K11/87 K11/87 7:1
X1:31E
1
F24
10A
008 918 12
2
Sammelanzeige
X1:31A monitoring module
3 Vorglühen
A15 GLÜH
F24:2 6:1 3:7
Warnbl.
14 BL−W
10:16
X1 15/54 Blinker rechts
26 FUEL 12 BL−R
HOURS 10:16
86 OUT2 Blinker links
24 13 BL−L Zentralstecker Sammelanzeige (Ansicht von hinten)
10:16
OUT1 Sitz mainplug monitoring module (view from backside)
23 9 A68/6
7:9
Bel.
5 22
10:5
BEL 25 21
3 5
1 10 4 17 16 8 11 15
D+
1 7
GND
Bremse
7:9
7:9
8 13
Luftfilter
Tankanzeige
Motoröldruck
Öltemperatur
14 19
X5:1−26
Hydraulikölfilter
Wasserabscheider
D+
X1 X1 X1
B06:1
69 87 76 20 26
Kühlmittelfüllstand
21 25
X1 X1 X1 X1
6:6
110 71 X1:77 X1:72 111 112
X1 X1 X1 X1 X1
106 67 X1:74 73 X1:68 107 108
K61/85
B30:2
BOMAG
X1
109 2:7
SITZ
7:9
X1:61
X1 X1
105
90 K48:87A X8 1 X8 2
4:3
X10
2 X21:1
Sensor
X1 or B21 3 B03 3 2 1 B06 1 B55 B124
89 +
86 R03
K22 P P _t P Q
+ bl 4 4 B30 2 −
P
H07
85 X10 X21:2
3 X1:117 X1:57
X1:82 X1:117
4:20 31 31 6:1
2:18 nicht bei D−40

not at D−40 nicht bei D−40/BW177 D−4
not at D−40/BW177 D−4
Warnsummer Störung Tankgeber Luftfilter Motoröldruck Sensor Wasserabschei

buzzer failure sender fuel
air cleaner engine oil pressure sens. water separator
Hydraulikölfilter Öltemperatur Kühlmittelstand
hydraulik oil cleaner oil temperature coolant stock level
06.12.2007
1 1 582 702 41
Vogt Überwachung
06.12.2007
19.3
1363
Seis monitoring 005
1364
5:4 F24:2
19.3
X1:225
X1
X1:187 92
br
15/54
Lern
Test
OUT+
P04
Modul Geschw. A05
X22:1
X1:191 modul speedometer
speedometer
Voltmeter
volt meter
Drehzahlmesser
RPM meter
Hydrauliköltemperatur
hydraulic oil temperature
Kühlmitteltemperatur
collant temperature
gg −
X1:189
in
+
Geschwindigkeitsanz.
+ + + + br X1
OUT−
+ ws X22:4
93
P05
P12 V P03 n P02 P14 B16
− G − G − G − bei BW177 sw − X22:3 −
Frequenzanzeige
frequency meter
bei BW213 bl
sw ZA Geschwindigkeitsanzeige
X1:192 option speedometer
bei BW177 bl
bei BW213 sw
Aufnehmer Vibration
transducer vibration
X1:171
X22:2
+
in X1:188
15/54
OUT+
OUT−
bl B60 dir. X1:173 DIR MESX 8:2
X1:70 X1:227 X1:226 A06 Elektronik
transducer speed SPEED MESX 8:2
W
2:6 − 1 3 4 − X1:172
SPEED TAC
11:6
BOMAG
X1:223
1 BW 177−179 D−4/40 −−−−
B30:2
BW 177−179 DHC−4/DH−40 −−−−
R04 X1:174
2 BW 211−216 D−4/40 PIN 1: −
BW 213−214 DHC−4/DH−40 PIN 1: − BEL ANZ
5:8
10:5
BW 216 DHC−4 PIN 3: +
1 1 1 1
BW 219 D−4 PIN 3: +
E03 E04 E73 E22
P03:E1 2 P04:E1 2 P07:E1 2 PXX:E1 2
X1:82 X1:228 X1:190
5:20 31 31 7:1
Hydrauliköltemperatur Sensor Achse Beleuchtung Anzeigen

hydr.oil temp. sender axle illumination indicators
ZA Frequenzanzeige
Option option frequency meter nur bei ZA Messtechnik, Geschw.−Anzeige und Tachograph
option only at opt. measurement−equ., speedometer and tachograph
06.12.2007
1 1
008 918 12
Vogt Anzeigen 582 702 41
06.12.2007
Seis indicators 006
5:20 K11/87 K11/87 10:1
D+ X1:32E
5:6
5:10 B06:1 F03 1
15A 2
008 918 12
K48/86
4:3 X1:32A
2:20 F14:2 Nur mit Sitzkontaktschalter

only with switch seat−contact
nur D−40/BW177D−4 Standard D−Maschinen/D−40 USA

only D−40/BW177D−4 Standard D−maschines/D−40 USA
Fahren
Öldruck
D+
F25:2 1 12 13 14 30 56
4:8
K04
31
A68 Modul Sitzschalter/Vibration
module seatswitch/vibration
S 56b
modul vibration
Modul Vibration
13 4 6 9 11 15 5
S42 1234 2
S42
1 5 7 3 S01:21
14 2:20 X1:158 X1:157
Fahrstufensch.
switch speed ranges K26/87A
switch speed ranges

Nur ohne Sitzkontaktschalter
without switch seat−contact
4:8 X14 X11
Schalter Fahrstufen
2
1
B 1 X1:159
V09 X1 14
S13
88
23 13
3 S35
A68/6 S58
5:12 13
X1:143 X1:144 X1:162 X1:143 SITZ 4

5:3 24 14
BOMAG
2
1
V05 X1:161 X1:160
V02 V03
2 1 1 2
GA MESX
8:2
KA MESX
Taster Vibration
pushbutton vibration
X1:141 X1:137 X1:142 X1:141 8:2

X1:116 X1:115
switch seat−contact
Sitzkontaktschalter
1.23A
1.23A
1.23A
X6 X7
Y31 Y30 Y30 Y31 X14 X11 1 1
1 1 1 1 Y07 Y08
3.33A
3.33A
A 2
11:7 KA
11:6 GA
a b
2 2 2 2
X6 X7
2 2
X1:124 X1:138 X1:124 X1:124
X1:149
X1:154
X1:149
X1:149
31
X1:118
6:20 31 8:1
Schalter Vibration klein/groß

nur BW216+219D−4 switch vibration small/big ampl.
only BW216+219D−4
Stufenumsch. hinten Stufenumschaltung vorn Stufenumschaltung hinten Vibration vorne groß
switching axle switching drum switching axle vibration big ampl.
Vibration vorne klein
Stufenumschaltung vorn
switching drum vibration small ampl.
06.12.2007
1 1 582 702 41
Vogt Fahrstufen, Sitzkontaktsch., Vibration
06.12.2007
19.3
1365
Seis speed−ranges, seat−switch, vibr. 007
Beschleunigungssensoren Beschleunigungssensoren Drucker Anzeige BMFSA Display Messtechnik BOP
1366
acc. sensor front acc. sensor rear printer Display BMFSA display measurem. BOP
GND
30
19.3
2:20 30 10:1
Pot 30
K11/87
10:20 Pot 15
F146:1 9:2 X2:66 X2:70 X2:47 X2:48 X2:49

X1:145 X42:1 X42:2 X42:3
X2:71
X46:B X46:A X46:E
X1:33E X1:35E 31
+ −
1 1 S01
F148 F146 2:18 X2:56 X2:53 X2:60 X2:57
10A 15A
2 2 32
X48:2 X48:1 X49:2 X49:1 P33
X1:33A X1:35A X1:146
X4:C
X4:E
X4:D
P16
B62 B62 F1 F2
+/sw
+/sw
nur bei BEM
only at BEM
F148:2 X1:34E −/gg −/gg

9:2
CAN+ CAN−
nur bei BTM+/BTM prof
only at BTM+/BTM prof
F84 1 X46:D X46:F

10A 15g/bl 15g/bl
X74:3
X74:5
X74:4
2 X42:4 X42:5
X2:57 X1:34A P11
20g/br
20g/br
nur bei BTM prof
X48:3 X48:4 X49:3 X49:4
only at BTM prof

X74:1 X74:2
X2:50 X2:51
X2:54 X2:55 X2:58 X2:59 X4:A X4:B R20
1 2
60OHM
X2:64 X2:65
Pot. 15
Leistung
Elektronik
AGND MESX
Aufn. vorne 15g

Aufn. vorne 20g
Aufn. hinten 15g
Aufn. hinten 20g
CAN1+
CAN1−
RxD TxD
BOMAG
X44:1
X44:7
X44:5
X44:4
X44:31
X44:56
X44:57
X44:59
X44:60
X44:30
X44:58
X44:29
X44:27
X44:26
X44:28
X44:54
A83
Messtechnik−Rechner
X44:38
X44:15
X44:35
X44:14
X44:36
X44:37
X44:41
X44:25
X44:53
X44:33
measurement calc. unit

X44:3
X44:55
X44:65
X44:66
X44:67
X44:68
GA MESX CAN3+ CAN3−

7:17
GPS
GND
GND
EVIB
7:17 KA MESX CAN3− 9:2

SPEED MESX X1:85
6:17
DIR MESX X2:49 X2:52 + CAN3+
6:17 BEL MESX STVZO 9:2
10:7 X2:79 P07 E
VIB
4:5 BRAKE MESX BEL MESX 10:4 X44:25 9:2 −
D+ MESX
2:7 Anschluß ohne StvZO Bel. X2:63 X2:66 X1:82
connection without StvZO
31 31 9:1
7:20
EVIB−Meter
EVIB−meter
nur bei BEM
only at BEM
06.12.2007
1 1
008 918 12
Vogt ZA Messtechnik 582 702 41
06.12.2007
Seis option measurement equipm. 008
8:18 CAN3−
8:18 CAN3+
8:2 F148:2
X44:25
008 918 12
8:10
8:4 F146:1
X2 80E
1 CAN3+ R92 CAN3−
F150 1 2
5A
2 60 OHM
X2 80A
X2 X2 X2 X2 X2
43 44 70 61 62
X4 X4 X4 X4 X4
H J G N M
X75:7 X75:2
X78:1
X78:2
X78:3
X78:4
X71:12 X72:A X73:A
A93 30 A87
X71:6 X72:B X73:B USB−CAN Schnittst.
15 USB−CAN Interface BCM
X71:5
TxD2 X76:1
X71:8
BOMAG
RxD2
X71:10 X72:E X70:3
TxD1
X71:3 X72:D X70:2
RxD1
X71:7 X72:C X70:5
GND
GPS Empfänger StarFire P15

X73:C X76:2
GPS Receiver StarFire
BCM 05
nur bei BCM
only at BCM
X4:F
nur bei StarFire GPS X2:63

only at StarFire GPS
8:20 31 31 10:1
06.12.2007
1 1 582 702 41
Vogt BOMAG Compaction Management BCM, GPS
06.12.2007
19.3
1367
Seis BOMAG Compaction Management BCM, GPS 009
K11/87
1368
7:20 K11/87 8:2
8:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
19.3
F11 F18 F07 F08

15A 10A 15A 15A
30
X1:18A K06 X1:19A X1:25A
X1:26A
10:4 X1:305
X1:83
X1:301
Schalter StvZO 87 87a
switch, StvZO
13 23
012 31 11 23 Anschluß Arbeitsschein− L0R
werfer ohne StvZO L0R Schalter Blinker
S37
connection working head X1:21E X1:22E switch indicator
lights without StvZO 5 4 14 24
S15 F22 F19
32 12 24 15A 15A
Anschluß Arbeitsscheinwerfer
X1:21A E X1:22A D bei Kabine
Connection head lights
X1:306
X1:307
X3:4 X3:5 with cabin 30 49L 49R

STV1
X1:302
11:17 A02
STV2
11:17
X1:23E X1:24E
K16 30 31 82 L R
10:9 F09 F10
15A 15A
87 87a X1:23A X1:24A
BL−L X1:91
BEL ANZ 5:12
6:19 BEL MESX STVZO BL−R
5:12
8:8
X1:96
5:4
13 BEL
BOMAG
S53 14
X1:308
X1:304
X1:303
13 23
switch, working head lights

Schalter Arbeitsbeleuchtung
01
X1:84 S14
X1:311
X1:313
BEL MESX Warnblinkschalter 14 24

8:8 switch, hazard light
Arbeitsscheinwerfer hinten links

working head lights, rear lh.
Arbeitsscheinwerfer hinten rechts
working head lights, rear rh.
Arbeitsscheinwerfer vorne links
working head lights, front lh.
Arbeitsscheinwerfer vorne rechts
working head lights, front rh.
X61:3 X1:320
X59:5 X1:310
X60:3 X1:319
X59:3 X1:312
X58:5 X1:309
X58:3
X61:1 X1:322
lights without StvZO

X60:1 X1:321
X59:2 X1:314
X58:2
BL−W
Anschluß Arbeitsschein−
werfer ohne StvZO
connection working head
5:12
0,125A
E16 1 E17 1 E13 1 E12 1 E14 1 E15 1 E27 1 E28 1 E23 1 E25 1 E08 1 E09 1 E10 1 E11 1
0,125A
+
2 2 86 2 2 2 2 86 2 2 2 2 H06 2 2 2 2
K06 K16
4,6A
4,6A
4,6A
4,6A
−
X61:2
X59:6
X58:6
X60:2
85 85
X3:1
X1:315 X58:6
X1:316 X59:6
X1:315 X58:6
X1:316 X59:6
4,6A
4,6A
0,42A
0,42A
0,42A
0,42A
1,75A
1,75A
1,75A
1,75A
X1:323 X60:4
X1:324 X61:4
X1:315
X1:316
X1:323
X1:324
9:20 11:1
31
10:10 Schlußleuchte links 10:2 Bel. Warnbinkschalter 31
Scheinwerfer links tail light, LH illumination, switch hazard light
head light LH Parkleuchte links Blinkleuchte VL Blinkleuchte HR
Anschluß Arbeitsscheinwerfer
Scheinwerfer rechts parking light, LH bei ROPS/SD Aufbau indicator front, LH indicator rear, RH
head light RH Parkleuchte rechts Blinkleuchte HL
parking light, RH Connection head lights indicator rear, LH
acc.to ROPS/SD
Schlußleuchte rechts Blinkleuchte VR
tail light, RH indicator front, RH
06.12.2007
1 1
008 918 12
Vogt ZA Beleuchtung und StvZO 582 702 41
06.12.2007
Seis opt. illumination and StvZO 010
F42:H 12:14 F41:5 12:14
X3:6
2:11 K30 2:11 K32:87 12:2
X3:7
K32:86 K32 30 STV2
X3:8 10:13
2:20 11:2 STV1
008 918 12
10:13
87 87a E F
G H A B C
X3:3
F143 F42 F43 F44 F130 F41 F144
15A 10A 15A 15A 10A 10A 15A
7 8 1 2 3
5 6
F42 12:8
F130 11:9 F130 F130 12:7
11:14
A12
15
1,75A
0,83A
K141 30 1 B51 + 30 01W 7 2 01W 7 2 1 S163 5 1 S38 5
+ + + B51
01 01 E72
11:16 E29 E70
− − − − 1
87 87a 2 2 2 1
31 S21 5 4 S20 5 4
Radio
radio
Steckdose Fahrerst.
3,8A
3,8A
1 Tachographenmodul
socket operator platform

E71 1 module, tachograph
XS
+ R80 A2+A3
X3:17
4,6A
4,6A
4,6A
4,6A
2 4 6 A1 XS
Nachtleuchte
− 6:17 P09 +
indicator
X55:1
X56:1
X55:3
X56:3
12V 2 1
X55:4
X56:4
night illumination
SPEED TAC A16 1 B3 E27 1 E28 1 E23 1 E25
Kontrolleuchte
Innenleuchte
inside light, cabin
socket cabin
−
12V
Steckdose Kabine
+ 7,8,9 2 B4 2 2 2 2
A01 5 3 C3
A5+A6
S45 TK −
Heizung Heckscheibe
4 1
heating rear screen
BOMAG
A51
Schalter Innenleuche
switches interior lights
3
5A
86 S86 + 3 2 5 + + S158 I 15 +
K32 E32
M05 M M04 M K141
M M
31
X3:16
X3:15
− −
3 min
85 − M07 − M06 4
KA
GA
2,9A
ZA
Nur bei Geländer/Rops/SD

4,7A
X55:2 X56:2 option

Abfallverzögert
only at hand−rail/Rops/sun−roof
7:17
7:16
12:11
Relais Kabine Türkontaktschalter Frequenzmodul Tachograph KABINE 31
relais cabin door switch module, frequency tachograph Schalter Nachtleuchte
switch, night illumination
X3:1
X3:2
Schalterbel.
switch illum.
10:20 31 31 12:1
11:6 Wascher hinten Wascher vorn 11:2 Arbeitsscheinwerfer vorn

washer rear washer front working head lights, front
Wischer hinten Wischer vorne Arbeitsscheinwerfer hinten Rundumkennleuchte

windscreen wiper, rear windscreen wiper, rear working head lights, rear rotary beacon
06.12.2007
1 1 582 702 41
Vogt ZA Kabine, Beleuchtung, Radio, Tachograph
06.12.2007
19.3
1369
Seis opt. cabin, headlights, radio, tachograph 011
1370
11:20 K32:87
Potential 15 aus Kabine
11:19 F41:5
F42:H
11:4
19.3
F31 D F40 A F15 B

BOX2 BOX2
20A 20A 5A
4 11:17 F130 1 2
Potential 15 aus Kabine
F42
11:9 Potential 30 aus Kabine
2.5qmm
Bedienteil Kabinenheizung/Klimaanlage
1 2 3 12 11 13 14 16
X53:B X53:C control−unit cab−heater /air conditioning X54:4 X54:3 X54:2
0123 4 3 2 5 7 11 3 10 1
S44 A72
Steuergerät
control unit
6 11 12 1 Regel aus = 0,4A
S28
Schalter Kabinenlüfter
E30 Kleine Stufe = 0,67A
switch blower cabin X54:6 X54:11 X54:12 X54:1 Zusatzheizung mittleter Stufe = 1,0A
add. heater große Stufe = 1.9A
heater timer
X3:13 Power Stufe = 2,8A

Schaltuhr Heizung
Anlaufstrom beim Start = 8,3A

30 2 6 8 9 4 12
K09
X3:14
X53:L
X53:H
X53:M
2:8
87 87a X1:167 5 9 10 6 8 7 4 15
2.5qmm
X1:169 X18:1
X3:9
X3:11
X3:10
X3:12
X19:1
B131
B103 1 1 F97 1
_t 3A
BOMAG
_t 2 2
2
Thermofühler Klimaanlage
inline fuse
X19:2 Inline Sicherung
X20:1 X18:2
X17:1 X1:163
temperature sensor air conditioning
X17:3 X1:166
X17:2 X1:165
Thermofühler Heizung
temperature sensor heating unit
B104 4
P
HP X69:1 X77:1
1A
LP 3
ge rt or ge rt or +
Y138 1 1
X1:170 M17
X20:4
X20:3
V06 Y14
Überwachung Kühlmitteldruck
monitoring coolant pressure
M09 M M09 M M
Kabinenlüfter 2 2 2
br br −
X20:2 V04
X69:2 X77:2
1
Option
option
Y15 1
X17:4 X1:168
2 11:19
3,5A
X1:164 KABINE 31
X1:154
11:20 31 31 13:1
Kabinenlüfter Klimakompressor Magnetventil Heizung Kraftstoffpumpe

cab ventilator air conditioning compr. solenoid valve, heating unit fuel pump heating unit
Frischluft Lüfter
blower fresch air
06.12.2007
1 1
008 918 12
Seis ZA Kabinenheizung, Klimaanlage, Zusatzheizung 582 702 41
06.12.2007
Seis opt. cabin−heater, air conditioning, add. heater 012
A67 1 2 3
Keyboard
008 918 12
keyboard
4 5 6
7 8 9
ANN 0 VAL
A66
Steuereinheit
control unit
BOMAG
ZA
option
06.12.2007
1 1 582 702 41
Vogt Diebstahlschutzsystem D−4, D−40, DHC−4, DH−40
06.12.2007
19.3
1371
Seis MV014 anti − theft system 013
Name Bl. Pf. Benennung title TYP
19.3 A02
A05
A06
010
006
006
17
17
10
Blinkgeber
Elektronik Geschwindigkeitsanzeige
Elektronik Frequenzanzeige vorne
flasher
Electronic system, speedometer Wiring diagramMODUL
electronic frequency−meter, front
582 702 41
MODUL
A12 011 5 Radio Radio
A13 003 4 Steuergeraet Heizung Control unit, heating
A13 003 9 Steuergeraet Heizung Control unit, heating
A15 005 9 Ueberwachungsmodul monitoring module
A16 011 7 Elektronik Tachograph Electronic system, tachograph
A51 011 6 Platine Frequenzanzeige Circuit board,frequenzy meter
A66 013 9 Elektronik Steuereinheit Electronic control unit
A67 013 15 Eingabeeinheit Keyboard
A68 007 10 Modul Sitzkontakt Modul seat contact MAX. 0,12A
A72 012 11 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A83 008 6 Elektronik Messtechnik electronic measurement−equipment
Seis
07.12.2007
Vogt
07.12.2007
A87 009 18 USB−CAN Schnittstelle BCM USB−CAN Interface BCM

A93 009 7 GPS Antenne GPS antenna
B03 005 8 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B06 005 10 Druckschalter Motoroel Pressure switch, engine oil
B11 003 16 Signalhorn Warning horn MAX.5A
B11 003 18 Signalhorn Warning horn MAX.5A
B13 004 2 Naeherungsinitiator Fahrhebel links Proximity switch, travel lever, lh.
B14 004 6 Naeherungsinitiator Fahrhebel rechts Proximity switch, travel lever, rh.
B16 006 9 Aufnehmer Vibrationsfrequenz vorne Transducer, vibration frequency, front
B21 005 7 Differenzdruckschalter Hydr.−Oelfilter Pressure diff. switch, hydr. oil filter
B30 005 9 Temperaturschalter Motoroel Temperature switch, engine oil
B51 011 5 Lautsprecher Radio Speaker radio
B51 011 6 Lautsprecher Radio Speaker radio
B55 005 11 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B60 006 14 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 008 12 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 008 8 Beschleunigungsaufnehmer Acceleration sensor
B62 008 10 Beschleunigungsaufnehmer Acceleration sensor
B103 012 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning
B104 012 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B113 003 4 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B124 005 12 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B131 012 10 Temperaturschalter Heizung Temperature switch, heating
E03 006 16 Beleuchtung Drehzahlmesser Illumination, rpm meter

E04 006 17 Beleuchtung Geschwindigkeitsanzeige Illumination, speedometer
E08 010 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
E09 010 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
component listing
E10 010 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 010 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
Bauteilliste
E12 010 7 Parkleuchte links Parking light, lh. MAX. 0,42A

E13 010 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 010 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 010 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
E16 010 2 Scheinwerfer links Head light, lh. MAX. 4,6A
E17 010 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
E22 006 19 Beleuchtung Temperaturanzeige Hydr.−oel Illumination, temp. gauge, hydraulic oil
E23 010 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 011 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 010 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 011 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 010 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 011 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 010 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 011 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 011 4 Innenleuchte Kabine Inside light, cabin 1,75A
E30 012 15 Heizgeraet Heating unit
E32 011 19 Kennleuchte Warning light 5A
E70 011 15 Nachtleuchte Night lamp 0,83A
E71 011 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 011 16 Beleuchtung Bedienschalter illum. Switches
E73 006 18 Beleuchtung, Evib−Meter Illumination, Evib−meter
F00 002 4 Hauptsicherung Batterie Fuse, main, battery 125A

F03 007 18 Sicherung Vibration Fuse, vibration MAX. 1,23A
F07 010 15 Sicherung Warnblinker Fuse, hazard light 15A
F08 010 18 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 010 6 Sicherung Park− u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 010 8 Sicherung Park− u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 010 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 002 10 Sicherung Startschalter Fuse, starter switch 30A
F14 002 18 Sicherung Hubmagnet Motor Fuse, shut off solenoid, engine 15A
F15 012 19 Sicherung Heizgeraet Fuse, heating unit BOX2
F18 010 5 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
F19 010 12 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 30A
F22 010 10 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 30A
F23 003 16 Sicherung Signalhorn Fuse, warning horn 10A
1
F24 005 3 Sicherung Ueberwachungsmodul Fuse, monitoring module 10A

F25 004 2 Sicherung Magnetv. Fahren u. Bremse Fuse, sol. valve, travel and brake 10A
F31 012 3 Sicherung Kabinenluefter Fuse, cabin ventilator
F39 002 19 Hauptsicherung Kabine Main fuse, cab 15A
F40 012 15 Sicherung Kabinenheizung Fuse, heating unit cab BOX2
7
F41 011 19 Sicherung Rundumkennleuchte Fuse, rotary beacon

F42 011 4 Sicherung Kabineninnenleuchte Fuse, inside light cab
F43 011 10 Sicherung Wischermotor hinten Fuse, wipermotor rear
F44 011 13 Sicherung Wischermotor vorn Fuse, wipermotor front
582 702 41
F48 002 2 Sicherung Gluehanlage Fuse, glow plug system 125A

F68 002 6 Sicherung Potential 30 Fuse, potential 30 5A
F84 008 5 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
F97 012 13 Sicherung Frischluftluefter fuse, blower fresh air 3A
FM4 008 11 Platinensicherung Multifuse
101
F105 002 16 Sicherung Motordrehzahl Fuse, motor speed 20A

F124 003 14 Sicherung Kraftstoffvorwärmung Fuse, fuel pre−heating 25A
1372 F130 011 15 Sicherung Nachtleuchte BOMAG
Fuse, night lamp 008 918 12
F143
F146
011
F144 011
008
2
20
4
Sicherung Heckscheibenheizung
Sicherung Kabinensteckdose
Sicherung Steuerung MESX (Potential 30)
fuse rear screen heating unit
Fuse cabin−socket
Fuse Controller (Pot. 30)
19.3
F148 008 2 Sicherung Steuerung MESX (Potential 15) Fuse Controller (Pot. 15)
F150 009 14 Sicherung GPS Receiver Fuse, GPS receiver 5A
F158 002 3 Sicherung Gluehkerze 1 fuse glow plug 1 50A
F159 002 3 Sicherung Glühkerze 2 fuse glow plug 2 50A
G01 002 4 Batterie Battery 103A

G02 002 5 Generator Generator
G03 002 2 Batterie Battery 103A
H06 010 15 Meldeleuchte Warnblinker Indicator light, hazard light

H07 005 3 Warnsummer Betriebsstoerung Warning buzzer, breakdown MAX. 0,12A
Seis
07.12.2007
Vogt
07.12.2007
H14 004 8 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer MAX. 0,12A
K04 007 18 Schrittrelais Vibration Toggle relay, vibration MAX. 1,23A

K05 004 3 Relais Startstrom Relay, starting current BOSCHW
K06 010 4 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 8 Relais Klimageraet Relay, air conditioning BOSCHW
K11 002 10 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHW
K14 003 5 Relais Vorgluehen Relay, glow plug system BOSCHL
K16 010 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K22 005 2 Relais Hubmagnet Motor Relay, shut off solenoid, engine BOSCHW
K26 004 6 Relais Rueckfahrwarneinrichtung Relay, back up alarm BOSCHW
K32 011 2 Relais Kabine Relay, cabin BOSCHW
K35 002 16 Relais Selbsthaltung Relay, holding contact BOSCHW
K36 002 7 Relais Bremskontrolle Relay, brake control BOSCHW
K48 004 2 Relais Fahrhebel 0−Stellung Relay, travel lever 0−position BOSCHW
K61 002 6 Relais Ladekontrolle Relay, charge control BOSCHW
K114 002 14 Relais Motordrehzahl Relay, engine rpm BOSCHW
K14.1 003 9 BOSCHL
K141 011 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW
M01 002 10 Starter Starter

M04 011 13 Scheibenwischermotor vorne Windscreen wiper motor, front 4,7A
M05 011 10 Scheibenwischermotor hinten Windscreen wiper motor, rear 2,9A
M06 011 14 Scheibenwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 011 11 Scheibenwaschermotor hinten Windscreen washer motor, rear MAX. 3,8A
M09 012 3 Kabinenluefter Cabin ventilator
M09 012 4 Kabinenluefter Cabin ventilator
M17 012 13 Zusatzluefter Additional blower
component listing
P02 006 5 Temperaturanzeige Hydraulikoel Temperature gauge, hydraulic oil

P03 006 3 Drehzahlmesser Rpm meter
Bauteilliste
P04 006 19 Geschwindigkeitsanzeige Speedometer

P05 006 11 Frequenzanzeige vorne Frequency meter, front
P07 008 15 Omegameter Omegameter
P09 011 8 Frequenz− und Geschwindigkeitsanzeige Frequency− and Speedometer
P11 008 14 Drucker Printer
P12 006 2 Voltmeter Volt meter
P14 006 6 Anzeige Kuehlmitteltemperatur Temperature gauge, coolant
P15 009 18 BCM 03 Bildschirm BCM 03 terminal
P16 008 16 Diagnose, Variomatic Diagnostics, varimatic
P33 008 18 Opus 21 Opus 21
R02 003 10 Gluehkerze Glow plug 50A

R03 005 5 Geber Tankanzeige Sender, level gauge
R04 006 4 Geber Hydraulikoeltemperatur Sender, hydraulic oil temp.
R10 002 7 Parallelwiderstand Parallel resistor 82 OHM
R19 003 2 Heizflansch heater flange 167A
R20 008 17 Widerstand Resistor 60OHM
R26 003 9 Widerstand Resistor 220K−OHM
R78 003 12 Glühkerze Vorglühen glow plug, pre−glowing 50A
R79 003 14 Kraftstoffvorwärmung fuel pre−heater 250W
R80 011 2 Heizung Heckscheibe heating rear screen
R92 009 18 Abschlußwiderstand (1) CAN 3 termination resistor (1) CAN 3 60 OHM
S00 002 10 Startschalter Starter switch

S01 002 18 Schalter NOT AUS Switch, emergency off
S03 003 16 Taster Signalhorn Push button, warning horn
S13 007 13 Vibrationsschalter Fahrhebel rechts Switch, vibration, travel lever, rh.
S14 010 15 Warnblinkschalter Switch, hazard light
S15 010 4 Beleuchtungsschalter StVZO Switch, lighting StVZO
S20 011 13 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 011 10 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S28 012 19 Schalter Kabinenheizung Switch, cabin heating
S30 002 4 Batterietrennschalter Switch, battery disconnect
S35 007 15 Vibrationsschalter klein/gross Switch, vibration low/high
S37 010 18 Schalter Blinker Switch, indicator
S38 011 19 Schalter Kennleuchte Switch, warning light
S42 007 3 Stufenumschalter schnell−langsam Speed range selector, fast−slow
2
S42 007 7 Stufenumschalter schnell−langsam Speed range selector, fast−slow

S44 012 3 Schalter Kabinenluefter Switch, cabin ventilator
S45 011 4 Schalter Kabineninnenleuchte Switch, cabin inside light
S53 010 4 Schalter Arbeitsbeleuchtung Switch, working lights
S58 007 13 Schalter Aetherstartanlage Push button, ether starting unit
7
S86 011 4 Schalter Tuer, links Switch door, lh.

S120 002 14 Schalter Motordrehzahl Switch, engine speed
S158 011 15 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 011 16 Schalter Heckscheibenheizung switch rear screen heating unit
582 702 41
V01 002 6 Diode Diode 4UF004

V02 007 6 Diode Diode MAX. 1,23A
V04 012 8 Diode Diode FE5B
102

V06 012 9 Diode Diode
008 918
V09 12 007 10 Diode BOMAG
Diode MAX. 0,12A 1373
19.3 V21
V22
V47
003 17 Diode
003 19 Diode
002 15 Diode (A7)
Diode
Diode
Diode (A7)
FE5B
X1:1 002 6 WAGO,E−Kasten WAGO,E−BOX

X1:2 010 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
Seis
07.12.2007
Vogt
07.12.2007

X1:69 005 6 WAGO,E−KASTEN WAGO, E−box
component listing

Bauteilliste

3

7

582 702 41

103

1374 X1:147 004 5 WAGO,E−Kasten BOMAG
WAGO,E−BOX 008 918 12
X1:148
X1:149
004
X1:149 004
007
2
1
12
WAGO,E−Kasten
WAGO,E−Kasten
WAGO,E−Kasten
WAGO,E−BOX
WAGO,E−BOX
WAGO,E−BOX
19.3
Seis
07.12.2007
Vogt
07.12.2007

X1:15A 002 10 WAGO,E−Kasten WAGO,E−BOX
X1:15E 002 10 WAGO,E−Kasten WAGO,E−BOX
X1:16A 002 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:16E 002 6 WAGO ZENTRALELEKTRIK WAGO E−BOX
component listing

Bauteilliste

4

7

582 702 41

104

008 918
X1:32012 010 8 WAGO ZENTRALELEKTRIK BOMAG
WAGO E−BOX 1375
19.3 X1:321
X1:322
X1:323
010
010
010
18
19
6
WAGO ZENTRALELEKTRIK
WAGO E−BOX
WAGO E−BOX
WAGO E−BOX
Seis
07.12.2007
Vogt
07.12.2007

X2:43 009 14 WAGO−MESSTECHNIK Wago−measurement equip.
component listing

Bauteilliste

X2:80A 009 14 WAGO−MESSTECHNIK Wago−measurement equip.
X2:80E 009 14 WAGO−MESSTECHNIK Wago−measurement equip.
X3:1 010 11 STECKER ROPS/SD conn. ROPS/SR
X3:1 011 10 STECKER KABINE/ROPS conn. cabin/ROPS
X4:A 008 14 KABINENST. MESST. con. measurem.equipm.
X4:B 008 14 KABINENST. MESST. con. measurem.equipm.
X4:C 008 14 KABINENST. MESST. con. measurem.equipm.
X4:D 008 14 KABINENST. MESST. con. measurem.equipm.
X4:E 008 15 KABINENST. MESST. con. measurem.equipm.
X4:F 009 15 KABINENST. MESST. con. measurem.equipm.
X4:G 009 15 KABINENST. MESST. con. measurem.equipm.
X4:H 009 14 KABINENST. MESST. con. measurem.equipm.
X4:J 009 15 KABINENST. MESST. con. measurem.equipm.
X4:M 009 18 KABINENST. MESST. con. measurem.equipm.
X4:N 009 17 KABINENST. MESST. con. measurem.equipm.
5
X6:1 007 14 DEUTSCH DEUTSCH connector

7

XS 011 1 Steckdose Socket
582 702 41
XS 011 20 Steckdose Socket

X10:2 005 5 AMP SUPERSEAL AMP connector
X10:3 005 5 AMP SUPERSEAL AMP connector
105

1376 X12:3 004 1 DEUTSCH BOMAG
DEUTSCH connector 008 918 12
X13:1
X13:3
004
X13:2 004
004
6
6
6
DEUTSCH
DEUTSCH
DEUTSCH
DEUTSCH connector
DEUTSCH connector
DEUTSCH connector
19.3
X14:A 007 13 DEUTSCH DEUTSCH connector
X14:B 007 13 DEUTSCH DEUTSCH connector
X17:1 012 3 STECKER LÜFTER HKL conn. blower
X18:1 012 10 STECKER THERMOFÜHLER conn. sender temp.
X18:2 012 10 STECKER THERMOFÜHLER conn. sender temp.
X19:1 012 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X19:2 012 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X20:1 012 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
Seis
07.12.2007
Vogt
07.12.2007

X21:1 005 11 STECKER KÜHLMITTEL connector coolant sensor
X21:2 005 11 STECKER KÜHLMITTEL connector coolant sensor
X22:1 006 9 ST. VIBRATIONSAUFNEHM connector vibration sensor
X36:A 002 4 EINSPEISUNG SCHALTKAS supply e−box
X36:B 002 4 EINSPEISUNG SCHALTKAS supply e−box
X37:A 002 10 ST. ZÜNDSCHLOß E−KAST connector ignition switch
X37:B 002 11 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X38:A 002 11 ST.STARTER E−KASTEN connector starter e−box
X42:1 008 18 STECKER ADAPTER BOP conector adapter BOP
X44:1 008 13 MESX STECKER MESX Stecker
component listing

Bauteilliste

X46:A 008 19 STECKER BOP Connector BOP
X46:B 008 18 STECKER BOP Connector BOP
X46:D 008 18 STECKER BOP Connector BOP
X46:E 008 19 STECKER BOP Connector BOP
X46:F 008 18 STECKER BOP Connector BOP
X47:A 008 11 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:B 008 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:C 008 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X48:1 008 8 STECKER AUFN. VORNE conn. sender front
X49:1 008 10 STECKER AUFN. HINTEN conn. sender rear
6

X53:B 012 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:C 012 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:H 012 4 STECKER LÜFTERSCHALTE conn. blowerswitch
7
X53:L 012 3 STECKER LÜFTERSCHALTE conn. blowerswitch

X53:M 012 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X54:1 012 11 STECKER HEIZSTEUERUNG conn. heating controller
582 702 41

106
X55:1 011 11 STECKER WISCHER HINTE connector wiper rear

X55:2 011 10 STECKER WISCHER HINTE connector wiper rear
008 918
X55:3 12 011 10 STECKER WISCHER HINTE BOMAG
connector wiper rear 1377
19.3 X55:4
X56:1
X56:2
011
011
011
10
14
13
STECKER WISCHER HINTE
STECKER WISCHER VORNE
STECKER WISCHER VORNE
connector wiper rear
conn. wiper front
conn. wiper front
X56:3 011 13 STECKER WISCHER VORNE conn. wiper front
X56:4 011 13 STECKER WISCHER VORNE conn. wiper front
X58:2 010 17 STECKER STVZO VL Con. STVZO FL
X59:2 010 19 STECKER STVZO VR Con. STVZO FR
Seis
07.12.2007
Vogt
07.12.2007

X60:1 010 18 STECKER STVZO HL Con. STVZO BL
X61:1 010 19 STECKER STVZO HR Con. STVZO BR
X65:1 013 5 KEYBOARD Keyboard
X67:1 003 14 STECKER KRAFTSTOFFHEI connector fuel pre−heater
X67:2 003 14 STECKER KRAFTSTOFFHEI connector fuel pre−heater
X69:1 012 13 STECKER FRISCHLUFT LÜ connector fresh air blower
X69:2 012 13 STECKER FRISCHLUFT LÜ connector fresh air blower
X70:2 009 16 SUB−D STECKER SUB−D Connector
component listing
X71:3 009 9 STECKER GPS ANTENNE connector GPS Receiver

Bauteilliste

X72:A 009 12 STECKER ANSCHL. GPS Connector GPS
X72:B 009 12 STECKER ANSCHL. GPS Connector GPS
X72:C 009 12 STECKER ANSCHL. GPS Connector GPS
X72:D 009 12 STECKER ANSCHL. GPS Connector GPS
X72:E 009 12 STECKER ANSCHL. GPS Connector GPS
X73:A 009 13 STECKER VERS. GPS Connector Supply GPS
X73:B 009 13 STECKER VERS. GPS Connector Supply GPS
X73:C 009 13 STECKER VERS. GPS Connector Supply GPS
X74:1 008 14 STECKER DRUCKER con. printer
X75:2 009 18 SUB D STECKER BCM INT SUB D Connector BCM
X75:7 009 17 SUB D STECKER BCM INT SUB D Connector BCM
X76:1 009 16 STECKER VERS. BCM con. Power−sup. BCM
X76:2 009 16 STECKER VERS. BCM con. Power−sup. BCM
X77:1 012 15 STECKER PUMPE STANDHE Conn. pump add. heater
X77:2 012 15 STECKER PUMPE STANDHE Conn. pump add. heater
X78:1 009 10 STECKER RTK−MODUL GPS Connector RTK−module GPS
Y01 002 13 Magnetventil Startmehrmenge Solenoid valve, start boost fuel

Y01 002 14 Magnetventil Startmehrmenge Solenoid valve, start boost fuel
Y04 004 5 Magnetventil Bremse Solenoid valve, brake MAX. 1,8A
Y07 007 14 D*Prop. Ventil Vibration groß E*prop. Valve vibration high MAX. 2,5A
Y08 007 16 D*Prop. Ventil Vibration groß E*prop. Valve vibration high MAX. 2,5A
Y13 002 18 Hubmagnet Motor Shut off solenoid, engine MAX. 3.8A
Y14 012 15 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 012 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
7
Y30 007 4 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front MAX. 1,67A
Y30 007 6 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front MAX. 1,67A
Y31 007 3 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
Y31 007 8 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear MAX. 1,23A
Y120 002 16 Magnetventil Motordrehzahl hoch Solenoid valve, rpm engine high
7
Y138 012 10 Magnetveentil Heizung Solenoid valve, heating unit 3,5A

Y139 002 12 Magnetventil Minusangleichung solenoid−valve boost−fuel
582 702 41
107
1378 BOMAG 008 918 12

X1
008 918 12
X38
X37
X36
X1
X1
BOMAG
Nur bei StvzO
only acc. To StvZO illumination
A02 R10 K05
K11 K16 K06
K36 K22
Nur bei Klimaanlage

K09 K35
only acc. to aircond.
K48
K61
A68 K114
K26
Nur wenn Sitzkontakt angebaut

only acc. if seatswitch is assembled
Nur wenn kein Sitzkontakt angebaut Gez.: 06.12.2007 Seite: 1 von: 2
only acc. if no seatswitch is assembled Name: Vogt Übersicht Schaltkasten BW 177...219 D-4/D-40 page: 1 from: 2
582 702 41
19.3
1379
K04
Gepr.: 06.12.2007 Ers. f.: Blatt Nr.: 201
Name: Seis
overview e-box BW 177...219 D-4/D-40 Replaces: Sheet No.: 201
Nur bei VM8
only acc. To VM8
1380
F1 F2 CAN 1
19.3
X2
BOMAG
CAN 1 OPUS 21
A83
Messtechnik Steuerung
CAN 3 BCM
008 918 12
Gez.: 06.12.2007 Seite: 2 von: 2
Name: Vogt Übersicht Schaltkasten-Tür BW 177...219 D-4/D-40 page: 2 from: 2
582 702 41
Name: Seis
overview e-box door BW 177...219 D-4/D-40 Replaces: Sheet No.: 201
Wiring diagram 582 702 41 19.3
WAGO smart DESIGNER 5.0
4,0 mm
1 057 564 17
2 057 564 21
3 2 x 057 564 25 "L" + 793-501
5 057 564 25 "L" + 057 564 20 + 793-501
6 057 564 25 "L" + 793-501
7 057 564 22
8 057 564 23 "L" + 057 564 19 + 793-501
9 057 564 23 "L" + 793-501
10 057 564 23 "L" + 057 564 19 + 793-501
11 057 564 23 "L" + 793-501
12 057 564 36 "R" + 2 x 057 564 19 + 793-501
13 3 x 057 564 36 "R" + 057 564 19 + 793-501
16 057 564 36 "R" + 793-501
17 057 564 36 "R" + 057 564 19 + 793-501
18 057 564 36 "R" + 793-501
239,0 mm
19 057 564 36 "R" + 057 564 19 + 793-501
270,0 mm
20 057 564 36 "R" + 793-501
21 8 x 057 564 36 "R" + 057 564 19 + 793-501
29 4 x 057 564 36 "R" + 793-501
33 057 564 35
34 057 564 17
27,0 mm
Optional1 : Projektgruppe : Walzenzüge -4 Klemmenleisten Zeichnungsnummer : 582 702 41

Artikelnummer :
Optional2 : Projekt : D-4/40 Artikelnummer lang :
Zeichnung : gezeichnet: : Vogt
Optional3 : Plan : geprüft: : Seis
Ort :
Optional4 :
Tragschiene : X1 - Absicherung D-4/40* Lieferadresse :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Optional7 : Größe der Bohrung : 5.20 x 25.00 [mm]
Copyright WAGO. Technische Änderungen vorbehalten.

07.12.2007 11:08:09 Seite 1
008 918 12 BOMAG 1381

4,0 mm
239,0 mm
270,0 mm
27,0 mm

Artikelnummer :
Ort :
Optional4 :
Tragschiene : X1 - Absicherung D-4/40* Lieferadresse :

07.12.2007 11:08:13 Seite 2
1382 BOMAG 008 918 12

20,0 mm
1 057 564 17
2 057 565 40 "R" + 793-501 + 057 565 36
3 3 x 057 565 40 "R" + 793-501
6 3 x 057 565 39 "R" + 793-501
9 057 565 37
10 4 x 057 565 38 "R" + 793-501
14 057 565 37
15 3 x 057 565 38 "R" + 793-501
18 057 565 37
400,0 mm
19 3 x 057 565 40 "R" + 793-501
370,0 mm
22 057 565 35 "R" + 793-501
23 057 565 37
24 5 x 057 565 40 "R" + 793-501
29 057 565 37
30 2 x 057 565 38 "R" + 793-501
32 2 x 057 565 39 "R" + 793-501
34 057 565 37
35 4 x 057 565 38 "R" + 793-501
39 057 565 37
40 4 x 057 565 40 "R" + 793-501

Artikelnummer :
Ort :
Optional4 :
Tragschiene : X1 - Kabelbäume D-4/40 Lieferadresse :

07.12.2007 11:08:33 Seite 1
008 918 12 BOMAG 1383

44 057 565 39 "R" + 793-501
45 057 565 35 "R" + 793-501
46 057 565 37
47 2 x 057 565 40 "R" + 793-501
49 057 565 37
50 057 565 40 "R" + 793-501
51 057 565 38 "R" + 793-501
52 057 565 37
53 4 x 057 565 40 "R" + 793-501
57 057 565 39 "R" + 793-501
58 057 565 37
59 4 x 057 565 40 "R" + 793-501
63 057 565 37
64 057 565 40 "R" + 793-501
65 057 565 35 "R" + 793-501
370,0 mm
66 057 565 37
400,0 mm
67 057 565 40 "R" + 793-501
68 057 565 35 "R" + 793-501
69 057 565 37
70 057 565 38 "R" + 793-501
71 2 x 057 565 40 "R" + 793-501
73 057 565 38 "R" + 793-501
74 057 565 37
75 4 x 057 565 40 "R" + 793-501
79 057 565 37
80 057 565 40 "R" + 793-501
81 057 565 39 "R" + 793-501
82 057 565 37
83 057 565 40 "R" + 793-501
84 2 x 057 565 38 "R" + 793-501
86 057 565 39 "R" + 793-501
87 057 565 37
88 057 564 17
10,0 mm

Artikelnummer :
Ort :
Optional4 :

07.12.2007 11:08:33 Seite 2
1384 BOMAG 008 918 12

20,0 mm
400,0 mm
370,0 mm

Artikelnummer :
Ort :
Optional4 :

07.12.2007 11:08:38 Seite 3
008 918 12 BOMAG 1385

370,0 mm
400,0 mm
10,0 mm

Artikelnummer :
Ort :
Optional4 :

07.12.2007 11:08:38 Seite 4
1386 BOMAG 008 918 12

129,5 mm
240,0 mm
1 057 564 17
2 2 x 057 565 40 "R" + 793-501
4 057 565 37
5 057 565 40 "R" + 793-501 + 057 565 36
6 057 565 40 "R" + 793-501
7 057 565 39 "R" + 793-501
8 057 565 37
9 057 565 38 "R" + 793-501
10 2 x 057 565 40 "R" + 793-501
12 057 565 38 "R" + 793-501
109,5 mm
13 057 565 37
14 2 x 057 565 40 "R" + 793-501
16 057 565 39 "R" + 793-501
17 057 565 37
18 057 565 40 "R" + 793-501
19 057 565 38 "R" + 793-501
20 057 565 40 "R" + 793-501
21 057 565 37
22 057 564 21
23 057 564 25 "L" + 793-501
24 057 564 36 "R" + 793-501
25 057 564 35
26 057 564 17
1,0 mm

Artikelnummer :
Optional2 : Projekt : Messtechnik D-4/40, DHC-4, DH-40 Artikelnummer lang :
Ort :
Optional4 :
Tragschiene : X2 - Messtechnik Lieferadresse :

07.12.2007 11:16:10 Seite 1
008 918 12 BOMAG 1387

129,5 mm
240,0 mm
109,5 mm
1,0 mm

Artikelnummer :
Optional2 : Projekt : Messtechnik D-4/40, DHC-4, DH-40 Artikelnummer lang :
Ort :
Optional4 :
Tragschiene : X2 - Messtechnik Lieferadresse :

07.12.2007 11:16:13 Seite 2
1388 BOMAG 008 918 12

12,0 mm
1 057 564 17
2 4 x 057 565 40 "R" + 793-501
6 057 565 37
7 057 565 40 "R" + 793-501 + 057 565 36
8 057 565 40 "R" + 793-501
74,0 mm
100,0 mm
9 4 x 057 565 38 "R" + 793-501
13 2 x 057 565 39 "R" + 793-501
15 057 565 37
16 057 564 17
14,0 mm

Artikelnummer :
Optional2 : Projekt : E2 Beleuchtung StvZO Beleuchtung Artikelnummer lang :
Ort :
Optional4 :
Tragschiene : X1 - Option E2 StvZO Beleuchtung Lieferadresse :

10.12.2007 08:55:25 Seite 1
008 918 12 BOMAG 1389

12,0 mm
74,0 mm
100,0 mm
14,0 mm

Artikelnummer :
Optional2 : Projekt : E2 Beleuchtung StvZO Beleuchtung Artikelnummer lang :
Ort :
Optional4 :
Tragschiene : X1 - Option E2 StvZO Beleuchtung Lieferadresse :

10.12.2007 08:55:27 Seite 2
1390 BOMAG 008 918 12

X71 X72
X70 X73
X74 X75 X77
X55
X56 X76 X53 X54
008 918 12
X5
X21
X39 X11 X12
X59 X40 X13
X58 X42
X20
X69 X46 X14
X18 X77
X6 X7
X17
X22 X19 X4 X3
X67 X8
X48 X49 X10

X36 X60
X37 X1 X61
X38 X2
X9
X44
BOMAG
X71
X61
X72
X77 X9
X21
X73 X74 X70
X59
X75 X76
X67 X8
X42 X11 X12
X10
X46 X13
X56
X53
X20
X18
X5 X17 X14
X19 X55 X6 X7
X54
X69 X39
X40
X58 X77
X4 X3
X36 X1
X37 X44 X2
X38 X60
X48 X49
X22
Gez.: 06.12.2007 Seite: 1 von: 1

Name: Vogt Steckerübersicht BW 177...219 D-4/D-40 page: 1 from: 1
582 702 41
19.3
1391
Name: Seis Connector overview BW 177...219 D-4/D-40 Replaces: Sheet No.: 301
1392 BOMAG 008 918 12

008 918 12 BOMAG 1393

19.4 Wiring diagram 9
1394 BOMAG 008 918 12

S/N Wiring diagram 9
008 918 12 BOMAG 1395

S/N 101 582 421 940 ⇔ 101 582 421 .... BW 211 D-40
S/N 101 582 432 399 ⇔ 101 582 432 .... BW 211 D-40
S/N 101 582 441 209 ⇔ 101 582 441 .... BW 211 D-40
S/N 101 582 471 053 ⇔ 101 582 471 .... BW 211 PD-40
S/N 101 582 481 239 ⇔ 101 582 481 .... BW 211 PD-40
S/N 101 582 491 019 ⇔ 101 582 491 .... BW 211 PD-40
S/N 101 583 081 944 ⇔ 101 583 081 .... BW 213 D-4
S/N 101 583 091 562 ⇔ 101 583 091 .... BW 211 D-4
S/N 101 583 101 052 ⇔ 101 583 101 .... BW 211 PD-4
S/N 101 583 131 002 ⇔ 101 583 131 .... BW 213 PD-4
S/N 101 583 391 023 ⇔ 101 583 391 .... BW 216 D-40
S/N 101 583 401 009 ⇔ 101 583 401 .... BW 216 DH-40
S/N 101 583 411 001 ⇔ 101 583 411 .... BW 218 D-40
S/N 101 583 421 009 ⇔ 101 583 421 .... BW 214 D-4
S/N 101 583 451 001 ⇔ 101 583 451 .... BW 211 DE-40
S/N 101 583 481 095 ⇔ 101 583 481 .... BW 211 D-40
S/N 101 583 491 000 ⇔ 101 583 491 .... BW 211 D-40
S/N 101 583 501 000 ⇔ 101 583 501 .... BW 211 PD-40
1396 BOMAG 008 918 12

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SM Bomag BW218 4d

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Service - Manual

BW 216 D-40 / PD-40

Single drum roller

008 918 12 BOMAG 3

6.22 Service the battery 119

4 BOMAG 008 918 12

10.14 Adjust the parking brake 316

008 918 12 BOMAG 5

13.18 Trouble shooting, refrigerant circuit diagram 419

6 BOMAG 008 918 12

008 918 12 BOMAG 7

This manual addresses the professionally qualified

Use only genuine BOMAG spare parts.

These safety regulations must be read and ap-

8 BOMAG 008 918 12

l Use protective clothes like hard hat, safety boots

008 918 12 BOMAG 9

10 BOMAG 008 918 12

008 918 12 BOMAG 11

Engine air conditioning system. The development of heat

12 BOMAG 008 918 12

Special safety regulations

008 918 12 BOMAG 13

14 BOMAG 008 918 12

008 918 12 BOMAG 15

Generator Starter motor

16 BOMAG 008 918 12

008 918 12 BOMAG 17

Air conditioning system l Damaged or leaking parts of the air conditioning

18 BOMAG 008 918 12

008 918 12 BOMAG 19

20 BOMAG 008 918 12

008 918 12 BOMAG 21

22 BOMAG 008 918 12

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

Fig. 8 Identification of nuts

Strength class of Strength class of associated

Nuts for screw joints without specified load factor

008 918 12 BOMAG 23

Identification in clock system Identification of UNF-threads

Fig. 9 Identification of nuts in clock system

Studs and brake rods

24 BOMAG 008 918 12

008 918 12 BOMAG 25

The values specified in the table apply for screws:

Tightening torques for screws with metric unified thread*

Tightening torques for screws with metric unified fine thread*

26 BOMAG 008 918 12

Tightening torques for wheel nuts (fine thread) * **

008 918 12 BOMAG 27

The values specified in the table apply for screws:

28 BOMAG 008 918 12

008 918 12 BOMAG 29

30 BOMAG 008 918 12

008 918 12 BOMAG 31

2.1 Technical data

* BW 216 D-40 BW 216 PD-40

32 BOMAG 008 918 12

008 918 12 BOMAG 33

34 BOMAG 008 918 12

Additional engine data

Drum reduction gear

Drum drive motor

008 918 12 BOMAG 35